1996 TOYOTA LAND CRUISER Workshop Manual

EM−104
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
(c) Position the piston rings so that the ring ends are as shown.
NOTICE:
Do not align the ring ends.
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting rod cap.
(b) Install the bearings in the connecting rod and connecting rod cap.
4. INSTALL CYLINDER BLOCK ORIFICE
5. INSTALL OIL NOZZLES AND CHECK VALVES
(a) Align the pin of the oil nozzle with the pin hole of the cylin-
der block.
(b) Install the oil nozzle with the check valve. Install the 6 oil nozzles and check valves.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
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P03813
P05520A16079
−
ENGINE MECHANICAL CYLINDER BLOCK
EM−105
1996 LAND CRUISER (RM451U)
6. INSTALL MAIN BEARINGS
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 7 upper bearings.
(b) Align the bearing claw with the claw groove of the main bearing cap, and push in the 7 lower bearings.
HINT:
A number is marked on each main bearing cap to indicate the
installation position.
7. INSTALL UPPER THRUST WASHERS
Install the 2 thrust washers under the No.4 journal position of
the cylinder block with the oil grooves facing outward.
8. PLACE CRANKSHAFT ON CYLINDER BLOCK
9. INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS
(a) Place the main bearing caps and lower thrust washers on
the cylinder block.
(1) Install the 2 thrust washers on the No.4 bearing cap
with the grooves facing outward.
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EM−106
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
(2) Install the 7 main bearing caps in their proper loca-
tions.
HINT:
Each bearing cap has a number and front mark.
(b) Install the main bearing cap bolts.
HINT:
The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any of the main bearing cap bolts is broken or deformed,
replace it.
(1) Apply a light coat of engine oil on the threads and
under the heads of the main bearings cap bolts.
(2) Install and uniformly tighten the 14 bolts of the main
bearing caps, in several passes, in the sequence
shown.
Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)
If any one of the main bearing cap bolts does not meet the
torque specification, replace the main bearing cap bolt.
(3) Mark the front of the main bearing cap bolt withpaint.
(4) Retighten the main bearing cap bolts by 90 ° in the
numerical order shown above.
(5) Check that the painted mark is now at a 90° angle
to the front.
(c) Check that the crankshaft turns smoothly.
(d) Check that the crankshaft thrust clearance (See page EM−83 ).
10. INSTALL PISTON AND CONNECTING ROD AS- SEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
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ENGINE MECHANICAL CYLINDER BLOCK
EM−107
1996 LAND CRUISER (RM451U)
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
11. INSTALL CONNECTING ROD CAP
(a) Place the connecting rod cap on the connecting rod. (1) Match the numbered connecting rod cap with theconnecting rod.
(2) Install the connecting rod cap with the front mark facing for ward.
(b) Install the connecting rod cap nuts.
HINT:
The connecting rod cap nuts are tightened in 2 progres-
sive steps (steps (b) and (d)).
If any connecting rod bolt is broken or deformed, replace
it.
(1) Apply a light coat of engine oil on the threads and under the nuts of the connecting rod cap.
(2) Install and alternately tighten the nuts of the con-
necting rod cap in several passes.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
If any one of the connecting rod cap nuts does not meet the
torque specification, replace the connecting rod bolt and cap
nut as a set.
(3) Mark the front of the connecting rod cap nut and bolt
with paint.
(4) Retighten the connecting rod cap nuts 90 ° as
shown.
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P04615
EM−108
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
(5) Check that the painted mark on the nut is at 90 °
angle in relation to the mark on the bolt.
(c) Check that the crankshaft turns smoothly.
(d) Check that the connecting rod thrust clearance (See page
EM−83 ).
12. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the retainer
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non −residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the retainer as shown in the illustra-
tion.
Seal packing: Part No. 08826−00080 or equivalent
Install a nozzle that has been cut to a 2 − 3 mm (0.08
− 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the retainer with the 4 bolts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
13. INSTALL OIL COOLER COVER AND OIL COOLER
Install a new gasket, the oil cooler cover and oil cooler with the
10 bolts and 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
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ENGINE MECHANICAL CYLINDER BLOCK
EM−109
1996 LAND CRUISER (RM451U)
14. INSTALL LH ENGINE MOUNTING BRACKET
(a) Install the bracket with the 4 bolts.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(b) Install the insulator with the nut. Torque: 72 N·m (730 kgf·cm, 43 ft·lbf)
15. INSTALL RH ENGINE MOUNTING BRACKET
(a) Install the bracket with the 4 bolts. Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(b) Install the insulator with the nut. Torque: 72 N·m (730 kgf·cm, 43 ft·lbf)
16. INSTALL PS PUMP
(a) Place a new O−ring to the pump.
(b) Install the pump with the 2 nuts.
Torque: 36 N·m (370 kgf·cm, 27 ft·lbf)
17. INSTALL KNOCK SENSORS
Using SST, install the 2 knock sensors. SST 09816−30010
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
18. INSTALL OIL FILTER UNION
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
19. INSTALL OIL FILTER (See page LU−2)
20. INSTALL TIMING CHAIN (See page EM−19)
21. INSTALL CYLINDER HEAD (See page EM−54 )
22. REMOVE ENGINE STAND
23. INSTALL DRIVE PLATE
(a) Install the front spacer, drive plate and rear plate on the crankshaft.
(b) Install and uniformly tighten the 10 drive plate bolts, in several passes, in the sequence shown.
Torque: 100 N·m (1,000 kgf·cm, 74 ft·lbf)
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EM0EE−10
EM−11 0
−
ENGINE MECHANICAL EXHAUST SYSTEM
613
Author: Date:
1996 LAND CRUISER (RM451U)
EXHAUST SYSTEM
COMPONENTS
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IG0IB−02
SPARK TEST
TRY ANOTHER IGNITERNO
OK
OK
OK
OK
OK
BAD
BAD
BAD
BAD
BAD
BADConnect securely.
Replace the cord(s).
Replace the distributor housing assembly.
Check wiring between ECM, ignition coil and
igniter, and then try another ECM.
CHECK CONNECTION OF IGNITION COIL, IGNITER AND
DISTRIBUTOR CONNECTOR
CHECK RESISTANCE OF HIGH−
TENSION CORD
(See step 8)
Maximum resistance: 25 k Ω per cord
CHECK RESISTANCE OF IGNITION COIL (See step 24)
Resistance: Cold Hot
Primary 0.36 − 0.55 Ω 0.45 − 0.65 Ω
Secondary 9.0 − 15.4 kΩ 11.4 − 18.1 kΩ
CHECK AIR GAP OF DISTRIBUTOR (See step 31)
Air gap: 0.2 − 0.4 mm (0.008 −0.016 in.)
OK
CHECK RESISTANCE OF SIGNAL GENERATOR
(PICKUP COIL) (See step 32)
Resistance: Cold Hot
G1 and G− 185 − 275 Ω 240 − 325 Ω
G2 and G− 185 − 275 Ω 240 − 325 Ω
NE and G − 185 − 275 Ω 240 − 325 Ω
CHECK IGT SIGNAL FROM ECM
(See page DI−93 ) Check
wiring between ignition switch to ignition
coil and igniter.
Replace the ignition coil.
Replace the distributor housing assembly.
BAD
OK
CHECK
POWER SUPPLY TO IGNITION COIL AND IGNITER
1. Turn ignition switch to ON.
2. Check that there is battery voltage at ignition coil positive (+)
terminal.
−
IGNITION IGNITION SYSTEM
IG−1
735
Author: Date:
1996 LAND CRUISER (RM451U)
IGNITION SYSTEM
ON−VEHICLE INSPECTION
1. CHECK THAT SPARK OCCURS
(a) Disconnect the high −tension cords (from the ignition coil)
from the distributor cap.
(b) Hold the end approx. 12.5 mm (0.50 in.) from the body ground.
(c) Check if spark occurs while engine is being cranked.
HINT:
To prevent gasoline from being injected from injectors during
this test, crank the engine for no more than 1 − 2 seconds at a
time.
If the spark does not occur, do the test as follows:
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