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EM1E7−01
EM−54
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL CYLINDER HEAD AND INTAKE MANIFOLD ASSEMBLY
(a) Place the cylinder head on the cylinder head. (1) Apply seal packing to the 2 locations as shown.
Seal packing: Part No. 08826−00080 or equivalent
NOTICE:
Do not apply too much seal packing
(2) Place a new cylinder head gasket in position on the
cylinder block.
NOTICE:
Be careful of the installation direction. (3) Place the cylinder head in position on the cylinderhead gasket.
(b) Install the cylinder head bolts.
HINT:
The cylinder head bolts are tightened in 3 progressive
steps (steps (b), (d) and (e)).
If any cylinder head bolt is broken or deformed, replace
it.
(1) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(2) Install and uniformly tighten the 14 cylinder head
bolts and plate washers in several passes, in the se-
quence shown.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
If any of the cylinder head bolts does not meet the torque speci-
fication, replace the cylinder head bolt.
(3) Mark the front of the cylinder head bolt head withpaint.
(4) Retighten the cylinder head bolts by 90 ° in the nu-
merical order shown.
(5) Retighten the cylinder head bolts by an additional 90°.
(6) Check that the painted mark is now facing rearward.
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P22567A16077
2 Dot Marks
EM−56
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(a) Install the intake camshaft.
(1) Apply engine oil to the thrust portion of the intakecamshaft.
(2) Lightly place the intake camshaft on top of the cylin-
der head as shown in the illustration so that the No.
1 and No. 4 cylinder cam lobes face downward.
(3) Lightly push the camshaft towards the front without
applying excessive force.
(4) Place the No. 2 and No. 5 bearing caps in their prop-
er location.
(5) Temporarily tighten these bearing cap bolts uni- formly and alternately in several passes until the
bearing caps are snug with the cylinder head.
(6) Place the No. 3, No. 4, No. 6 and No. 7 bearing caps
in their proper location.
(7) Temporarily tighten these bearing cap bolts, alter- nately tightening the left and right bolts uniformly.
(8) Place the No. 1 bearing cap in its proper location. When doing this, check that there is no gap be-
tween the cylinder head and the contact surface of
bearing cap.
(9) Temporarily tighten the bearing cap bolts, alternate-
ly tightening the left and right bolts uniformly.
(10) Uniformly tighten the 14 bearing cap bolts in several
passes.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(b) Install the exhaust camshaft. (1) Set the timing mark (2 dot marks) of the camshaftdrive gear at approx. 35 ° angle by turning the hexa-
gon wrench head portion of the intake camshaft
with a wrench.
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ENGINE MECHANICAL CYLINDER HEAD
EM−57
1996 LAND CRUISER (RM451U)
(2) Apply engine oil to thrust portion of the exhaust
camshaft.
(3) Engage the exhaust camshaft gear to the intake
camshaft gear by matching the timing marks (two
dot marks) on each gear.
(4) Roll down the exhaust camshaft onto the bearing journals while engaging gears with each other.
(5) Lightly push the intake camshaft towards the front without applying excessive force.
(6) Install the No. 4 and No. 6 bearing caps in their proper location.
(7) Temporarily tighten the bearing cap bolts uniformly and alternately in several passes until the bearing
caps are snug with the cylinder head.
(8) Place the No. 2, No. 3, No. 5 and No. 7 bearing caps
in their proper location.
(9) Temporarily tighten these bearing cap bolts, alter- nately tightening the left and right bolts uniformly.
(10) Place the No. 1 bearing cap in its proper location. When doing this, check that there is no gap be-
tween the cylinder head and the contact surface of
bearing cap.
(11) Temporarily tighten the bearing cap bolts, alternate-
ly tightening the left and right bolts uniformly.
(12) Uniformly tighten the 14 bearing cap bolts in several
passes.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(13) Bring the service bolt installed in the driven sub −
gear upward by turning the hexagon wrench head
portion of the camshaft with a wrench.
(14) Remove the service bolt.
(15) Check that the intake and exhaust camshafts turn smoothly.
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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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EM1ED−02
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ENGINE MECHANICAL ENGINE UNIT
EM−69
1996 LAND CRUISER (RM451U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. DRAIN ENGINE OIL
3. REMOVE HOOD
4. REMOVE BATTERY AND BATTERY TRAY
(a) Disconnect the battery cables.
(b) Remove the nuts, hold−down clamp and battery.
(c) Remove the bolt and disconnect the ground strap.
(d) Remove the 5 bolts and battery tray.
5. REMOVE RADIATOR GRILLE
Remove the 5 screws, clip and radiator grille.
6. REMOVE RADIATOR (See page CO−14 )
7. DISCONNECT OIL COOLER HOSE FROM OIL COOL- ER PIPE
8. REMOVE AIR CLEANER HOSE AND CAP
9. REMOVE AIR CLEANER CASE
10. DISCONNECT CRUISE CONTROL ACTUATOR CABLE FROM THROTTLE BODY
11. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY
12. DISCONNECT HEATER HOSES
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EM−70
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ENGINE MECHANICAL ENGINE UNIT
1996 LAND CRUISER (RM451U)
13. DISCONNECT ENGINE WIRE AND HEATER VALVE
FROM COWL PANEL
(a) Remove the 2 bolts and disconnect the engine wire and
ground strap.
(b) Remove the 2 bolts and disconnect the heater valve.
14. DISCONNECT BRAKE BOOSTER VACUUM HOSE
15. DISCONNECT EVAP HOSE
16. DISCONNECT FUEL HOSES
(a) Disconnect the fuel return hose.
(b) Remove the union bolt and 2 gaskets, and disconnect the
fuel inlet hose from the fuel filter.
17. DISCONNECT WIRES AND CONNECTORS
(a) Disconnect the 2 heated oxygen sensor connectors.
(b) Disconnect the DLC1 clamp.
(c) Disconnect the 2 oil pressure gauge connectors.
(d) Disconnect the generator wire and connector.
(e) Disconnect the connector on the intake manifold from the
fender apron.
(f) Disconnect the high−tension cord from the ignition coil.
(g) Disconnect the ground strap from the No. 1 engine hang-
er.
(h) Disconnect the ground strap from the air intake chamber.
(i) Disconnect the starter wire.
(j) Disconnect the ground cable from the cylinder block.
18. DISCONNECT A/C COMPRESSOR AND BRACKET
(a) Loosen the idler pulley nut and adjusting bolt, and remove
the drive belt.
(b) Remove the 4 mounting bolts, and disconnect the com-
pressor from the bracket.
HINT:
Put aside the compressor, and suspend it.
(c) Remove the 5 bolts and A/C compressor bracket.
19. REMOVE RADIATOR PIPE
(a) Remove the 2 nuts holding the radiator pipe to the No. 1 oil pan.
(b) Disconnect the No. 2 radiator hose from the water inlet and remove the radiator pipe.
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ENGINE MECHANICAL ENGINE UNIT
EM−73
1996 LAND CRUISER (RM451U)
(g) Disconnect the 3 connectors.
(h) Remove the 10 bolts and the transfer shift lever boot and
transmission shift lever assembly.
(i) Pull out the pin and disconnect the shift rod.
(j) Remove the 4 bolts, hose clamp and the transfer shift le- ver.
26. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the 2 nuts and 2 bolts holding the front exhaust pipe to the rear TWC.
(c) Disconnect the front exhaust pipe, and remove the gas- ket.
(d) Loosen the clamp bolt and disconnect the clamp from the
No.1 support bracket.
(e) Remove the 2 bolts and No. 1 support bracket.
(f) Remove the 4 nuts, front exhaust pipe and 2 gaskets.
27. DISCONNECT GROUND STRAP FROM HEAT INSULA-
TOR
28. PLACE JACK UNDER TRANSMISSION
Be sure to put a wooden block between the jack and the trans-
mission oil pan to prevent damage.
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EM−74
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ENGINE MECHANICAL ENGINE UNIT
1996 LAND CRUISER (RM451U)
29. REMOVE FRAME CROSSMEMBER
(a) Remove the 2 nuts holding the crossmember to the en-
gine rear mounting insulator.
(b) Remove the 8 bolts and crossmember.
30. REMOVE ENGINE WITH TRANSMISSION
(a) Attach the engine hoist chain to the 2 engine hangers.
(b) Remove the 2 nuts holding the engine front mounting in- sulators to the frame.
(c) Lift the engine with transmission out of the vehicle slowly
and carefully.
NOTICE:
Make sure that the engine is clear of all wiring and hoses.
(d) Place the engine and transmission assembly onto the stand.
31. REMOVE OIL DIPSTICK GUIDE FOR TRANSMISSION
(a) Disconnect the 2 breather hoses.
(b) Remove the 2 mounting bolts.
(c) Pull out the dipstick guide and dipstick from the transmis- sion.
(d) Remove the O−ring from the dipstick guide.
32. DISCONNECT ENGINE WIRE FROM TRANSMISSION
(a) Disconnect the PNP switch connector.
(b) Disconnect the 2 connectors from the transmission.
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