1996 TOYOTA LAND CRUISER Drive

EM1EB−01
−
ENGINE MECHANICAL TIMING CHAIN
EM−19
1996 LAND CRUISER (RM451U)
INSTALLATION
1. SET CRANKSHAFT
Turn the crankshaft until the set key on crankshaft facing down-
ward.
2. INSTALL PUMP DRIVE SHAFT GEAR
3. INSTALL OIL PUMP DRIVE SHAFT GEAR
(a) Apply a light coat of engine oil on the shaft portion of the
gear.
(b) Install the gear.
4. INSTALL CRANKSHAFT ROTOR
5. INSTALL OIL JET
Install the oil jet with the bolt. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
6. INSTALL CHAIN TENSIONER SLIPPER AND VIBRA- TION DAMPER
(a) Install the damper with the 2 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Using a 10 mm hexagon wrench, install the slipper with the bolt.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

EM−22
−
ENGINE MECHANICAL TIMING CHAIN
1996 LAND CRUISER (RM451U)
(d) Engage the gear of the oil pump drive rotor with the gear
of the oil pump drive gear, and install the oil pump.
(e) Install the oil pump and drive belt adjusting bar with the 9 bolts and 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
HINT:
Each bolt length is indicated in the illustration.
Bolt A: 30 mm (1.18 in.)
Bolt B: 50 mm (1.97 in.)
Bolt C: 60 mm (2.38 in.)
(f) Remove the cord from the chain.
10. INSTALL DRIVE BELT IDLER PULLEY
Install the pulley with the bolt. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
11. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.
(b) Using SST, install and torque the pulley bolt.
SST 09213−58012, 09330 −00021
Torque: 412 N·m (4,200 kgf·cm, 304 ft·lbf)
12. INSTALL NO. 1 OIL PAN (See page LU−12)
13. INSTALL NO. 2 OIL PAN (See page LU−12)
14. INSTALL BOLTS HOLDING NO. 1 OIL PAN TO TRANS-
MISSION HOUSING
Install the 6 bolts. Torque: 72 N·m (730 kgf·cm, 53 ft·lbf)
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

−
ENGINE MECHANICAL TIMING CHAIN
EM−23
1996 LAND CRUISER (RM451U)
15. INSTALL OIL LEVEL SENSOR
(a) Install a new gasket to the level sensor.
(b) Install the level sensor with the 4 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
16. CONNECT OIL COOLER PIPE BRACKET TO NO. 1 OIL
PA N
17. INSTALL CYLINDER HEAD (See page EM−54 )
NOTICE:
However, for the installation of the camshaft timing gear
and timing chain, follow the below procedure. Align the
blight link of the timing chain and camshaft timing gear
mark, and install them to the camshaft.
18. INSTALL WATER PUMP
Install a new gasket and water pump with the 4 bolts and 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
19. INSTALL RADIATOR PIPE
(a) Connect the No.2 radiator hose to the water inlet.
(b) Install the 2 nuts holding the radiator pipe to the No.1 oil
pan.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
20. INSTALL A/C COMPRESSOR AND BRACKET
(a) Install the A/C compressor bracket with the 5 bolts.
Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
(b) Install the A/C compressor with the 4 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Install and adjust the drive belt (See page CH−2).
21. INSTALL RADIATOR (See page CO−16 )
22. FILL ENGINE WITH OIL
23. INSTALL ENGINE UNDER COVER
24. START ENGINE AND CHECK FOR LEAKS
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

P08374A16075
1 Dot Mark
EM−32
−
ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
30. REMOVE CYLINDER HEAD COVER
Remove the 13 bolts, cylinder head cover and gasket.
31. REMOVE SPARK PLUGS
32. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley and align its groove with the ”0”
mark on the timing chain cover.
(b) Check that the timing marks (1 and 2 dots) of the camshaft
drive and driven gears are in straight line on the cylinder
head surface as shown in the illustration.
If not, turn the crankshaft 1 revolution (360° ) and align the
marks as above.
33. REMOVE CHAIN TENSIONER
Remove the 2 nuts, chain tensioner and gasket.
34. REMOVE CAMSHAFT TIMING GEAR
(a) Remove the semi−circular plug.
(b) Place the matchmarks on the camshaft timing gear and timing chain.
(c) Hold the intake camshaft with a wrench, remove the bolt and distributor gear.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

P22143A16076
2 Dot Marks
−
ENGINE MECHANICAL CYLINDER HEAD
EM−33
1996 LAND CRUISER (RM451U)
(d) Remove the camshaft timing gear and chain from the in-
take camshaft and leave on the slipper and damper.
35. REMOVE CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being removed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
(a) Remove the exhaust camshaft. (1) Bring the service bolt hole of the driven sub −gear
upward by turning the hexagon wrench head por-
tion of the exhaust camshaft with a wrench.
(2) Secure the exhaust camshaft sub −gear to the main
gear with a service bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 − 20 mm (0.63 − 0.79 in.)
HINT:
When removing the camshaft, make sure that the torsional
spring force of the sub −gear has been eliminated by the above
operation.
(3) Set the timing mark (2 dot marks) of the camshaftdriven gear at approx. 35 ° angle by turning the
hexagon wrench head portion of the intake cam-
shaft with a wrench.
(4) Lightly push the camshaft towards the rear without applying excessive force.
(5) Loosen and remove the No. 1 bearing cap bolts, al-
ternately loosening the left and right bolts uniformly.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

P22567A16077
2 Dot Marks
EM−34
−
ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(6) Loosen and remove the No. 2, No. 3, No. 5 and No.
7 bearing cap bolts, alternately loosening the left
and right bolts uniformly in several passes, in the
sequence shown.
NOTICE:
Do not remove the No. 4 and No. 6 bearing cap bolts at this
stage. (7) Remove the 4 bearing caps.
(8) Alternately and uniformly loosen and remove theNo. 4 and No. 6 bearing cap bolts.
HINT:
As the 4 No. 4 and No. 6 bearing cap bolts are loosened,
make sure that the camshaft is lifted out straight and level.
If the camshaft is not being lifted out straight and level, re-
tighten the 4 No. 4 and No. 6 bearing cap bolts. Then re-
verse the order of above steps from (g) to (e) and repeat
steps from (c) to (h) once again.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
(9) Remove the 2 bearing caps and exhaust camshaft.
(b) Remove the intake camshaft. (1) Set the timing mark (2 dot marks) of the camshaftdrive gear at approx. 25 ° angle by turning the hexa-
gon wrench head portion of the intake camshaft
with a wrench.
HINT:
The above angle arrows the No. 1 and No. 4 cylinder cam lobes
of the intake camshaft to push their valve lifters evenly.
(2) Lightly push the intake camshaft towards the frontwithout applying excessive force.
(3) Loosen and remove the No. 1 bearing cap bolts, al-
ternately loosening the left and right bolts uniformly.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

−
ENGINE MECHANICAL CYLINDER HEAD
EM−35
1996 LAND CRUISER (RM451U)
(4) Loosen and remove the No. 3, No. 4, No. 6 and No.
7 bearing cap bolts, alternately loosening the left
and right bolts uniformly in several passes, in the
sequence shown.
NOTICE:
Do not remove the No. 2 and No. 5 bearing cap bolts at this
stage. (5) Remove the 4 bearing caps.
(6) Alternately and uniformly loosen and remove theNo. 2 and No. 5 bearing cap bolts.
HINT:
As the 4 No. 2 and No. 5 bearing cap bolts are loosened,
make sure that the camshaft is lifted out straight and level.
If the camshaft is not being lifted out straight and level, re-
tighten the 4 No. 2 and No. 5 bearing cap bolts. Then re-
verse the order of above steps from (e) to (c) and repeat
steps from (a) to (f) once again.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
(7) Remove the 2 bearing caps and exhaust camshaft.
36. DISASSEMBLE EXHAUST CAMSHAFT
(a) Mount the hexagon wrench head portion of the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Insert a service bolt (A) into the service hole of the cam-
shaft sub−gear.
(c) Using a screwdriver, turn the sub− gear clockwise, and re-
move the service bolt (B).
NOTICE:
Be careful not to damage the camshaft.
(d) Using snap ring pliers, remove the snap ring.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

EM−36
−
ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(e) Remove the wave washer (1), camshaft sub− gear (2) and
camshaft gear spring (3).
37. REMOVE CYLINDER HEAD AND INTAKE MANIFOLD ASSEMBLY
(a) Remove the 2 bolts in front of the head before the other head bolts are removed.
(b) Uniformly loosen and remove the 14 cylinder head bolts, in several passes, in the sequence shown.
NOTICE:
Cylinder head warpage or cracking could result from re-
moving bolts in incorrect order.
(c) Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on
a bench.
HINT:
If the cylinder head is difficult to lift off, pry between the cylinder
head and cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010