1996 TOYOTA LAND CRUISER engine

P08374A16075
1 Dot Mark
EM−58
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
4. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the
timing mark ”0” of the timing chain cover.
(b) Turn the camshafts so that the timing marks with 1 and 2 dots will be in straight line on the cylinder head surface as
shown in the illustration.
5. INSTALL CAMSHAFT TIMING GEAR
HINT:
Check that the matchmarks on the camshaft timing gear and
timing chain are aligned.
(a) Place the gear over the straight pin of the intake cam- shaft.
(b) Align the straight pin of distributor gear with the straight pin groove of the intake camshaft gear as shown.
(c) Hold the intake camshaft with a wrench, install and torque
the bolt.
Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)
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Front Mark
P09890
Push
P08374A16075
1 Dot Mark
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ENGINE MECHANICAL CYLINDER HEAD
EM−59
1996 LAND CRUISER (RM451U)
6. INSTALL CHAIN TENSIONER
(a) Place a new gasket so that the front mark is toward the
front side.
(b) Push the tensioner by hand until it touches the head installation surface, then install the 2 nuts.
(c) Tighten the 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
7. CHECK VALVE TIMING
(a) Turn the crankshaft pulley, and align its groove with the timing mark ”0” of the timing chain cover.
NOTICE:
Always turn the crankshaft clockwise.
(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.
8. CHECK AND ADJUST VALVE CLEARANCE (See page
EM−4)
Turn the camshaft and position the cam lobe upward and check
and adjust the valve clearance.
Valve clearance (Cold):
Intake0.15 − 0.25 mm (0.006 − 0.010 in.)
Exhaust0.25 − 0.35 mm (0.010 − 0.041 in.)
9. INSTALL SPARK PLUGS
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P03789
P08374A16075
1 Dot Mark
EM−60
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
10. INSTALL SEMI −CIRCULAR PLUG
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head installation sur- face of the semi−circular plug.
Seal packing: Part No. 08826−00080 or equivalent
(c) Install the semi −circular plug to the cylinder head.
11. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the timing mark ”0” of the timing chain cover.
(b) Check that the timing marks with 1 and 2 dots 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 mark
as above.
12. INSTALL CYLINDER HEAD COVER
(a) Install the gasket to the cylinder head cover.
(b) Install the cylinder head cover with the 13 bolts.
13. INSTALL WATER BYPASS OUTLET AND PIPE
(a) Install a new O−ring to the water bypass outlet.
(b) Install 2 new O−rings to the water bypass pipe.
(c) Apply soapy water to the O−rings.
(d) Assemble the water bypass outlet and pipe.
(e) Install the water bypass outlet and pipe with the 2 bolts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
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ENGINE MECHANICAL CYLINDER HEAD
EM−61
1996 LAND CRUISER (RM451U)
14. INSTALL HEATER PIPE
Install a new gasket, the heater pipe and ground cable with the
2 bolts and 2 nuts.
Torque:
20 N·m (200 kgf·cm, 14 ft·lbf) for bolt:
21 N·m (210 kgf·cm, 15 ft·lbf) for nut
15. INSTALL NO. 1 AND NO. 2 EXHAUST MANIFOLDS
(a) Install 2 new gaskets, No. 1 exhaust manifold and No. 2
exhaust manifold with the 13 nuts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Install the No. 1 heat insulator and No. 2 heat insulator with the 6 bolts.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
16. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe with the 4 nuts.
Torque: 63 N·m (630 kgf·cm, 46 ft·lbf)
(b) Install the No. 1 support bracket with the 2 bolts. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
(c) Connect the clamp and tighten the clamp bolt.
Torque: 19.5 N·m (195 kgf·cm, 14 ft·lbf)
(d) Connect the front exhaust pipe to the rear TWC with a new gasket, 2 bolts and 2 nuts.
Torque: 46 N·m (470 kgf·cm, 34 ft·lbf)
17. CONNECT NO. 2 WATER BYPASS PIPE
Connect the bypass pipe to the cylinder head with the 3 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
18. CONNECT ENGINE WIRE
(a) Place the engine wire on the intake manifold.
(b) Connect the connectors. (1) Connect the 3 injector connectors.
(2) Connect the EGR gas temp. sensor connector.
(c) Connect the clamp of the No.6 injector wire to the bracket.
(d) Connect the engine wire clamp.
(e) Connect the engine wire clamp.
(f) Connect the connectors. (1) Connect the connector for the emission control
valve set assembly.
(2) Connect the 3 injector connectors.
(g) Install the bolt holding the engine wire to the intake man- ifold.
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EM−62
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(h) Connect the engine wire to the intake manifold and cylin-
der block with the 2 bolts.
(i) Connect the PNP switch connector.
(j) Connect the 2 heated oxygen sensor connectors.
(k) Connect the connectors.
(1) Connect the Knock sensor connector.
(2) Connect the oil level sensor connector.
(3) Connect the 2 connectors to tthe ransmission.
(4) Connect the starter connector.
(l) Connect the engine wire to the cylinder block with the bolt.
(m) Connect the connectors.
(1) Connect the ECT sender gauge connector.
(2) Connect the ECT cut switch connector.
(3) Connect the ECT sensor connector.
(4) Connect the knock sensor connector.
(5) Connect the crankshaft position sensor connector.
19. CONNECT FUEL INLET HOSE
Connect the fuel inlet hose to the fuel filter with 2 new gaskets
and the union bolt. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
20. INSTALL INTAKE MANIFOLD STAY
Install the intake manifold stay with the 2 bolts. Torque: 36 N·m (360 kgf·cm, 26 ft·lbf)
21. INSTALL OIL DIPSTICKS AND GUIDES FOR ENGINE AND TRANSMISSION
(a) Install a new O−ring to the dipstick guide.
(b) Apply a light coat of engine oil on the O −ring.
(c) Push in the dipstick guide into the guide hole of the oil pan.
(d) Install the dipstick guide with the 2 bolts. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
22. INSTALL THROTTLE BODY (See page SF−48)
23. INSTALL GENERATOR AND DRIVE BELTS (See page CH−19 )
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ENGINE MECHANICAL CYLINDER HEAD
EM−63
1996 LAND CRUISER (RM451U)
24. CONNECT NO. 3 WATER BYPASS HOSE
25. CONNECT RADIATOR INLET HOSE
26. CONNECT PS RESERVOIR TANK
Connect the reservoir tank with the 3 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
27. INSTALL DISTRIBUTOR (See page IG−11)
28. INSTALL NO. 2 AND NO. 3 CYLINDER HEAD COVERS
Install the head covers with the 4 bolts.
29. CONNECT HEATER VALVE AND ENGINE WIRE TO COWL PANEL
(a) Connect the heater valve with the 2 bolts.
(b) Connect the engine wire and ground strap with the 2 bolts.
30. CONNECT HEATER HOSES
31. CONNECT FUEL RETURN HOSE
32. CONNECT EVAP HOSE
33. CONNECT BRAKE BOOSTER VACUUM HOSE
34. CONNECT CONNECTOR ON INTAKE MANIFOLD TO LH FENDER APRON
35. CONNECT ENGINE GROUND STRAPS
(a) Connect the ground strap to the No. 1 engine hanger.
(b) Connect the ground strap to the air intake chamber.
36. CONNECT THROTTLE CABLE TO THROTTLE BODY
37. CONNECT ACCELERATOR CABLE TO THROTTLE
BODY
38. CONNECT CRUISE CONTROL ACTUATOR CABLE TO
THROTTLE BODY
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EM−64
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
39. INSTALL AIR CLEANER HOSE AND CAP
40. INSTALL BATTERY TRAY AND BATTERY
(a) Install the battery tray with the 5 bolts.
(b) Connect the ground strap with the bolt.
(c) Install the battery and hold−down clamp with the nuts.
(d) Connect the battery cables.
41. FILL RADIATOR WITH ENGINE COOLANT
42. START ENGINE AND CHECK FOR LEAKS
43. ADJUST IGNITION TIMING (See page EM−10)
44. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
45. RECHECK ENGINE COOLANT LEVEL
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EM1EC−01
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ENGINE MECHANICAL ENGINE UNIT
EM−65
568
Author: Date:
1996 LAND CRUISER (RM451U)
ENGINE UNIT
COMPONENTS
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