Page 870 of 1399
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ENGINE MECHANICAL CYLINDER BLOCK
EM−85
1996 LAND CRUISER (RM451U)
14. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Check the matchmarks on the connecting rod cap and
connecting rod to ensure correct reassembly.
(b) Remove the connecting rod cap nuts.
(c) Using a plastic− faced hammer, lightly tap the connecting
rod bolts and lift off the connecting rod cap.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
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Page 872 of 1399
P04620
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ENGINE MECHANICAL CYLINDER BLOCK
EM−87
1996 LAND CRUISER (RM451U)
Standard sized bearing center wall thickness:
Mark ”2”1.744 − 1.747 mm (0.0687 − 0.0688 in.)
Mark ”3”1.747 − 1.750 mm (0.0688 − 0.0689 in.)
Mark ”4”1.750 − 1.753 mm (0.0689 − 0.0690 in.)
Mark ”5”1.753 − 1.756 mm (0.0690 − 0.0691 in.)
Mark ”6”1.756 − 1.759 mm (0.0691 − 0.0693 in.)
(k) Completely remove the Plastigage.
15. R E M O V E P I S TO N A N D C O N N E C T I N G R O D A S-
SEMBLIES
(a) Using a ridge reamer, remove the all carbon from the top of the cylinder.
(b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
HINT:
Keep the bearings, connecting rod and cap together.
Arrange the piston and connecting rod assemblies in cor-
rect order.
16. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver. Standard thrust clearance:
0.020 − 0.220 mm (0.0008 − 0.0087 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set. Thrust washer thickness:
STD2.440 − 2.490 mm (0.0961 − 0.0980 in.)
O/S 0.1252.503 − 2.553 mm (0.0985 − 0.1005 in.)
O/S 0.2502.565 − 2.615 mm (0.1010 − 0.1030 in.)
17. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the main bearing cap bolts
in several passes, in the sequence shown.
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Page 875 of 1399
P04628
EM−90
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ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
19. REMOVE CHECK VALVES AND OIL NOZZLES
Remove the 6 check valves and oil nozzles.
20. REMOVE CYLINDER BLOCK ORIFICE
21. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
22. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
HINT:
Arrange the rings in correct order only.
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Page 879 of 1399
EM−94
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ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
3. INSPECT BEARING OF OIL PUMP DRIVE SHAFT
GEAR
Check the bearing for pitting and scratches.
If the bearing is damaged, replace the cylinder block.
4. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.
(c) Using solvent and a brush, thoroughly clean the piston.
NOTICE:
Do not use a wire brush.
5. INSPECT PISTON AND CONNECTING ROD
(a) Inspect the piston oil clearance.
HINT:
There are 3 sizes of the standard piston diameter , marked ”1”,
”2” and ”3”. The mark is stamped on the piston top.
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Page 881 of 1399
P04002
125 mm
EM7639
P03829
EM−96
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ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
(c) Inspect the piston ring end gap.
(1) Insert the piston ring into the cylinder bore.
(2) Using a piston, push the piston ring a little beyondthe bottom of the ring travel, 125 mm (4.92 in.) from
the top of the cylinder block.
(3) Using a feeler gauge, measure the end gap.
Standard end gap:
No. 10.300 − 0.520 mm (0.0118 − 0.0205 in.)
No. 20.450 − 0.670 mm (0.0177 − 0.0264 in.)
Oil (Side rail)0.150 − 0.520 mm (0.0059 − 0.0205 in.)
Maximum end gap:
No. 11.12 mm (0.0441 in.)
No. 21.17 mm (0.0461 in.)
Oil (Side rail)1.12 mm (0.0441 in.)
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, rebore all the 6 cylinders or replace the cylinder block.
(d) Inspect the piston pin fit.
At 80 − 90°C (176 − 194°F), you should be able to push
the piston pin into the piston pin hole with your thumb.
(e) Using a rod aligner and feeler gauge, check the connect- ing rod alignment.
(1) Check for out−of−alignment.
Maximum out−of−alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If out− of−alignment is greater than maximum, replace the con-
necting rod assembly.
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P03828
P03868
EM0227
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ENGINE MECHANICAL CYLINDER BLOCK
EM−97
1996 LAND CRUISER (RM451U)
(2) Check for twist
Maximum twist:
0.15 mm (0.0059 in. ) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
(f) Inspect the piston pin oil clearance. (1) Using a caliper gauge, measure the inside diameter
of the connecting rod bushing.
Bushing inside diameter:
26.008 − 26.020 mm (1.0239 − 1.0244 in.)
(2) Using a micrometer, measure the piston pin diame-
ter.
Piston pin diameter:
26.000 − 26.012 mm (1.0236 − 1.0241 in.)
(3) Subtract the piston pin diameter measurement from
the bushing inside diameter measurement.
Standard oil clearance:
0.004 − 0.012 mm (0.0002 − 0.0005 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)
If the oil clearance is greater than maximum, replace the bush-
ing. If necessary, replace the piston and piston pin as a set (See
page EM−99 ).
(g) Inspect the connecting rod bolts. Install the cap nut to the connecting rod bolt. Check that
the cap nut can be turned easily by hand to the end of the
thread.
If the cap nut cannot be turned easily, measure the outside di-
ameter of the connecting rod bolt with vernier calipers. Standard outside diameter:
8.40 − 8.60 mm (0.3307 − 0.3386 in.)
Minimum outside diameter: 8.00 mm (0.3150 in.)
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Page 883 of 1399
EM−98
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ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
HINT:
If the location of this area cannot be judged by visual inspection,
measure the outer diameter at the location shown in the illustra-
tion.
If the outside diameter is less than minimum, replace the con-
necting rod bolt and nut as a set.
6. INSPECT CRANKSHAFT
(a) Inspect for circle runout. (1) Place the crankshaft on V−blocks.
(2) Using a dial indicator, measure the circle runout atthe center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
(b) Inspect the main journals and crank pins. (1) Using a micrometer, measure the diameter of each
main journal and crank pin.
Main journal diameter:
STD68.982 − 69.000 mm (2.7158 − 2.7165 in.)
U/S 0.2568.745 − 68.755 mm (2.7065 − 2.7069 in.)
Crank pin diameter:
STD56.982 − 57.000 mm (2.2434 − 2.2441 in.)
U/S 0.2556.745 − 56.755 mm (2.2341 − 2.2344 in.)
If the diameter is not as specified, check the oil clearance (See
page EM−83 ). If necessary, grind or replace the crankshaft.
(2) Check each main journal and crank pin for taper and out−of−round as shown.
Maximum taper and out−of−round:
0.02 mm (0.0008 in.)
If the taper and out −of− round is greater than maximum, replace
the crankshaft.
7. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the fin-
ished undersized diameter. Install new main journal and/or
crankshaft pin undersized bearings.
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Page 884 of 1399
EM1EI−02
P03827
P03867
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ENGINE MECHANICAL CYLINDER BLOCK
EM−99
1996 LAND CRUISER (RM451U)
REPLACEMENT
1. REPLACE CONNECTING ROD BUSHING
(a) Using SST and a press, press out the bushing.
SST 09950 −60010 (09951 −00280), 09950 −70010
(09951 −07100)
(b) Align the oil holes of a new bushing and the connecting rod.
(c) Using SST and a press, press in the bushing. SST 09950 −60010 (09951 −00280), 09950 −70010
(09951 −07100)
(d) Using a pin hole grinder, hone the bushing to obtain the standard specified cliarance (See page EM−92) between
the bushing and piston pin.
(e) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, and push it into the connect-
ing rod with your thumb.
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