Page 1801 of 3115
A05095
1
2
4
8
6
3
5
97
10
A05093
A05097
Plastigage
A05095
EM-92
- ENGINE MECHANICALCYLINDER BLOCK
1665 Author: Date:
2004 LAND CRUISER (RM1071U)
23. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Evenly loosen and remove the 10 main bearing cap bolts
a little at time for several times, in the sequence shown.
(b) Using 2 screwdrivers, pry out the main bearing cap, and
remove the 5 main bearing caps, the 5 lower bearings and
the 2 lower thrust washers (No.3 main bearing cap only).
NOTICE:
Be careful not to damage the cylinder block.
HINT:
Keep the lower bearing and the main bearing cap togeth-
er.
Arrange the main bearing caps and lower thrust washers
in correct order.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearings and the upper thrust washers together
with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of plastigage across each journal.
(h) Install the main bearing caps.
(See page EM-107)
NOTICE:
Do not turn the crankshaft.
(i) Remove the main bearing caps.
(See procedure (a) and (b) above)
Page 1802 of 3115
A05098
A05089A05088A05090A05176
Number Mark
Number
Mark
Number
Mark No.1No.2 No.3No.4 No.5
No.1No.2
No.3
No.4No.5
Cylinder block (A)
Crankshaft (B)Use bearing
+
24 - 28 18 - 23 12 - 176 - 11 0 - 5 No.1, No.5:
EXAMPLE:
Cylinder block º08º + Crankshaft º06º
= Total number 14 (Use bearing º5º)3
4
5
6
7
Cylinder block (A)
Crankshaft (B)Use bearing
+
24 - 28 18 - 23 12 - 176 - 11 0 - 5
EXAMPLE:
Cylinder block º08º + Crankshaft º06º
= Total number 14 (Use bearing º3º)3
4
5 1
2 Others:
- ENGINE MECHANICALCYLINDER BLOCK
EM-93
1666 Author: Date:
2004 LAND CRUISER (RM1071U)
(j) Measure the plastigage at its widest point.
Standard clearance:
0.040 - 0.058 mm (0.0016 - 0.0023 in.)
Maximum clearance: 0.070 mm (0.0028 in.)
If the oil clearance is greater than the maximum, replace the
bearings. If necessary, replace the crankshaft.
HINT:
If using a standard bearing, replace it with the one having the
same number. If the number of the bearing cannot be deter-
mined, sum up the numbers imprinted on the cylinder block and
the crankshaft, then refer to the table below for the appropriate
bearing number. There are 5 sizes of the standard bearings. For
No.1 and No.5 position bearings, use bearings marked º3º, º4º,
º5º, º6º and º7º. For others position bearings, use bearings
marked º1º, º2º, º3º, º4º and º5º.
Reference
Cylinder block main journal bore diameter (A):
Mark º00º72.000 mm (2.8346 in.)
Mark º01º72.001 mm (2.8347 in.)
Mark º02º72.002 mm (2.8347 in.)
Mark º03º72.003 mm (2.8348 in.)
Mark º04º72.004 mm (2.8348 in.)
Mark º05º72.005 mm (2.8348 in.)
Mark º06º72.006 mm (2.8349 in.)
Mark º07º72.007 mm (2.8349 in.)
Page 1804 of 3115
A04862
A04873
A04860
A04887
- ENGINE MECHANICALCYLINDER BLOCK
EM-95
1668 Author: Date:
2004 LAND CRUISER (RM1071U)
24. REMOVE CRANKSHAFT
(a) Lift up the crankshaft.
(b) Remove the 5 upper main bearings and the 2 upper thrust
washers from the cylinder block.
HINT:
Arrange the main bearing caps, bearings and thrust washers in
correct order for installation.
25. 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.
26. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and the oil ring by hand.
HINT:
Arrange the piston rings in correct order for installation.
27. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to approx. 60°C (140°F).
Page 1808 of 3115
A04877
A04878
A04879
A04874
A04885A05180
Mark 1, 2 or 3Mark 1, 2 or 3
LH
Piston
RH
Piston
30.75 mm
- ENGINE MECHANICALCYLINDER BLOCK
EM-99
1672 Author: Date:
2004 LAND CRUISER (RM1071U)
3. 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.
4. INSPECT PISTON AND CONNECTING ROD
(a) Inspect the piston oil clearance.
HINT:
There are 3 sizes of the standard piston diameter, marked º1º,
º2º and º3º accordingly. The mark is stamped on the piston top.
(1) Using a micrometer, measure the piston diameter at
right angles to the piston pin center line, 30.75 mm
(1.2106 in.) from the piston head.
Piston diameter:
STD Mark º1º93.902 - 93.912 mm (3.6969 - 3.6973 in.)STD Mark 1
Mark º2º
93.902 - 93.912 mm (3.6969 - 3.6973 in.)
93.912 - 93.920 mm (3.6973 - 3.6976 in.)Mark 2
Mark º3º
93.912 93.920 mm (3.6973 3.6976 in.)
93.920 - 93.930 mm (3.6976 - 3.6980 in.)
O/S 0.5094.402 - 94.430 mm (3.7166 - 3.7177 in.)
(2) Measure the cylinder bore diameter in the thrust
directions. (See step 2 above)
(3) Subtract the piston diameter from the cylinder bore
diameter.
Page 1809 of 3115
A04211A04875A04885A05179
Cylinder Block
Front
No.2 No.4 No.6
No.8
No.1
No.5 No.7
RH Piston
No.3
:
LH PistonMark 1, 2 or 3
Mark 1, 2 or 3Mark 1, 2 or 3
A04880
EM-100
- ENGINE MECHANICALCYLINDER BLOCK
1673 Author: Date:
2004 LAND CRUISER (RM1071U)
Standard oil clearance:
0.090 - 0.111 mm (0.0035 - 0.0044 in.)
Maximum oil clearance: 0.13 mm (0.0051 in.)
If the oil clearance is greater than the maximum, replace all the
8 pistons and rebore all the 8 cylinders. (See page EM-104) If
necessary, replace the cylinder block.
HINT
Use new cylinder block:
Use a piston with the same number mark as the cylinder
diameter marked on the cylinder block.
The shape of the piston varies for the LH and the RH
banks. The LH piston is marked as ºLHº and º2Lº, and the
RH piston as ºRHº and º2Rº.
(b) Inspect the piston ring groove clearance.
Using a feeler gauge, measure the clearance between
new piston ring and the wall of the ring groove.
Ring groove clearance:
No.10.030 - 0.080 mm (0.0012 - 0.0031 in.)
No.20.030 - 0.070 mm (0.0012 - 0.0028 in.)
If the clearance is not as specified, replace the piston.
Page 1810 of 3115
A04872
105 mm
EM7639
A04048
60°C
Z14454
- ENGINE MECHANICALCYLINDER BLOCK
EM-101
1674 Author: Date:
2004 LAND CRUISER (RM1071U)
(c) Inspect the piston ring end gap.
(1) Insert the piston ring into the cylinder bore.
(2) Using a piston, push the piston ring to a little beyond
the bottom of the ring travel, 105 mm (4.13 in.) from
the top of the cylinder block.
(3) Using a feeler gauge, measure the end gap.
Standard end gap:
No.10.300 - 0.500 mm (0.0118 - 0.0197 in.)
No.20.400 - 0.650 mm (0.0157 - 0.0256 in.)
Oil (Side rail)0.130 - 0.480 mm (0.0051 - 0.0189 in.)
Maximum end gap:
No.11.10 mm (0.0433 in.)
No.21.20 mm (0.0472 in.)
Oil (Side rail)1.15 mm (0.0453 in.)
If the end gap is greater than the maximum, replace the piston
ring. If the end gap is greater than the maximum, even with a
new piston ring, rebore all the 8 cylinders (See page EM-104)
or replace the cylinder block.
(d) Inspect the piston pin fit.
At 60°C (140°F), you should be able to push the piston
pin into the piston pin hole with your thumb.
(e) Using a rod aligner and the feeler gauge, check the con-
necting rod alignment.
(1) Check for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If bend is greater than maximum, replace the connecting rod as-
sembly.
Page 1811 of 3115
Z14455
EM6525
EM0227
A04223
Tension
Portion
EM-102
- ENGINE MECHANICALCYLINDER BLOCK
1675 Author: Date:
2004 LAND CRUISER (RM1071U)
(2) Check for twist
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than the maximum, replace the connecting rod
assembly.
(f) Inspect the piston pin oil clearance.
(1) Using a caliper gauge, measure the inside diameter
of the connecting rod bushing.
Bushing inside diameter:
22.005 - 22.014 mm (0.8663 - 0.8667 in.)
(2) Using a micrometer, measure the piston pin diame-
ter.
Piston pin diameter:
21.997 - 22.009 mm (0.8660 - 0.8664 in.)
(3) Subtract the piston pin diameter from the bushing
inside diameter.
Standard oil clearance:
0.005 - 0.011 mm (0.0002 - 0.0004 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)
If the oil clearance is greater than the maximum, replace the
bushing. If necessary, replace the piston and the piston pin as
a set.
(g) Using vernier calipers, measure the tension portion of the
connecting rod bolt.
Standard diameter:
7.200 - 7.300 mm (0.2835 - 0.2874 in.)
Minimum diameter: 7.00 mm (0.2756 in.)
If the diameter is less than the minimum, replace the bolt.
Page 1812 of 3115
A05121
A05854A05122A05169
- ENGINE MECHANICALCYLINDER BLOCK
EM-103
1676 Author: Date:
2004 LAND CRUISER (RM1071U)
5. INSPECT CRANKSHAFT
(a) Inspect for circle runout.
(1) Place the crankshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.08 mm (0.0031 in.)
If the circle runout is greater than the maximum, replace the
crankshaft.
(b) Inspect the main journals and the crank pins.
(1) Using a micrometer, measure the diameter of each
main journal and crank pin.
Main journal diameter:
66.988 - 67.000 mm (2.6373 - 2.6378 in.)
Crank pin diameter:
51.982 - 52.000 mm (2.0465 - 2.0472 in.)
If the diameter is not as specified, check the oil clearance (See
page EM-88). If necessary, 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 the maximum, re-
place the crankshaft.
