Page 1813 of 3115
EM0L8-03
A04861
A04876
60°C
A04882A04886A05182
Front Mark
(2 Cavities) Front
Mark
(1 Cavity)
Outside Mark LH Piston
RH Piston
Outside Mark
A04860
- ENGINE MECHANICALCYLINDER BLOCK
EM-107
1680 Author: Date:
2004 LAND CRUISER (RM1071U)
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets, O-rings and oil seals with new parts.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Using a small screwdriver, install a new snap ring on one
side of the piston pin hole.
(b) Gradually heat the piston to about 60°C (140°F).
(c) Coat the piston pin with engine oil.
(d) Position the piston front mark to the outside mark on the
connecting rod as shown in the diagram.
NOTICE:
The installation directions of the piston and connecting rod
are different for the LH and RH banks. The LH piston is
marked with ºLHº and º2Lº, the RH piston with ºRHº and
º2Rº.
(e) Align the piston pin holes of the piston and connecting
rod, and push in the piston pin with your thumb.
(f) Using a small screwdriver, install a new snap ring on the
other side of the piston pin hole.
Page 1814 of 3115
A04213
No.1
No.2Code Mark
1R
Code Mark
2R
A04871A04870A05183
Lower
Side
Rail
Front
Mark
(1 Cavity)
Upper Side Rail
No.1 CompressionExpander LH PistonNo.2 Compression
Lower
Side
Rail
Front
Mark
(2 Cavities)
Upper Side RailNo.1 Compression No.2 Compression RH Piston
Expander
45° 45° 45° 45°
60°
60°
60°
60°
EM6484
A04846
Upper
Lower
22.5 mm19.5 mm No.1 and No.5 Others
EM-108
- ENGINE MECHANICALCYLINDER BLOCK
1681 Author: Date:
2004 LAND CRUISER (RM1071U)
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and the 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code mark:
No.11R
No.22R
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the ring ends
.
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or the connecting cap.
(b) Install the bearings in the connecting rod and the con-
necting rod cap.
4. INSTALL MAIN BEARINGS
HINT:
Main bearings come in widths of 19.5 mm (0.768 in.) and
22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bear-
ings in the No.1 and No.5 cylinder block journal positions
with the main bearing cap. Install the 19.5 mm (0.768 in.)
bearings in the other positions.
Upper bearings have an oil groove and an oil holes; lower
bearings do not.
Page 1815 of 3115
A04216
A04214
Mark
1, 2, 3, 4, or 5
A04215
A04217
A05091
- ENGINE MECHANICALCYLINDER BLOCK
EM-109
1682 Author: Date:
2004 LAND CRUISER (RM1071U)
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 5 upper bearings.
(b) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 5 lower bearings.
HINT:
A number is marked on each main bearing cap to indicate the
installation position.
5. INSTALL UPPER THRUST WASHERS
Install the 2 thrust washers under the No.3 journal position of
the cylinder block with the oil grooves facing outward.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK
7. PLACE MAIN BEARING CAPS AND LOWER THRUST
WASHERS ON CYLINDER BLOCK
(a) Install the 2 thrust washers on the No.3 bearing cap with
the grooves facing outward.
(b) Install the 5 main bearing caps in their proper locations.
8. INSTALL MAIN BEARING CAP BOLTS
HINT:
The main bearing cap bolts are tightened in 2 steps (steps
(b) and (d)).
If any one of the main bearing cap bolts is broken or de-
formed, replace it.
Page 1816 of 3115
A05095
1
248
6
3
5
9
7
10
A05094
Front
Painted
Mark90° 90°
A04854A04883A04884A05177
Front Mark
(1 Cavity)
Front
LH
Piston
RH
PistonFront
Front Mark
(2 Cavities)
EM-1 10
- ENGINE MECHANICALCYLINDER BLOCK
1683 Author: Date:
2004 LAND CRUISER (RM1071U)
(a) Apply a light coat of engine oil on the threads and under
the main bearing cap bolts.
(b) Install and evenly tighten the 10 main bearing cap bolts
a little at a time for several times as in the sequence
shown.
Torque: 27 N´m (275 kgf´cm, 20 ft´lbf)
If any one of the main bearing cap bolts does not meet the
torque specification, replace the main bearing cap bolt.
(c) Mark the front of the main bearing cap bolt with paint.
(d) Retighten the main bearing cap bolts by 90° in the numer-
ical order shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
9. CHECK CRANKSHAFT THRUST CLEARANCE
(See page EM-88)
10. INSTALL PISTON AND CONNECTING ROD
ASSEMBLES
Using a piston ring compressor, push the correctly numbered
piston and connecting rod assemblies into each cylinder with
the front mark of the piston facing forward.
NOTICE:
The shape of the piston varies for the LH and RH banks. The
LH piston is marked with ºLHº and º2Rº, the RH piston with
ºRHº and º2Rº.
Page 1817 of 3115
A05106
A05107A05108A05174
Front
Outside Mark
(Protrusion)
RH Bank LH Bank
Front
Outside Mark
(Protrusion)
A05101
A05099
Painted
Mark Front90°
90°
- ENGINE MECHANICALCYLINDER BLOCK
EM-1 11
1684 Author: Date:
2004 LAND CRUISER (RM1071U)
11. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Align the pin groove of the connecting rod cap with the
pins of the connecting rod, and install the connecting rod
cap.
(c) Check that the outside mark of the connecting rod cap is
facing in correct direction.
12. INSTALL CONNECTING ROD CAP BOLTS
HINT:
The connecting rod cap bolts are tightened in 2 steps
(steps (b) and (d)).
If any one of the connecting rod cap bolts is broken or de-
formed, replace it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(b) Install and alternately tighten the 2 connecting rod cap
bolts a little at a time for several times.
Torque: 24.5 N´m (250 kgf´cm, 18 ft´lbf)
If any one of the connecting rod cap bolts does not meet the
torque specification, replace the connecting rod cap bolts.
(c) Mark the front of the connecting cap bolt with paint.
(d) Retighten the cap bolts 90° as shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
13. CHECK CONNECTING ROD THRUST CLEARANCE
(See page EM-88)
Page 1818 of 3115
A04848
Seal Width
2 - 3 mm A
BA
B
A04855
New O-Ring
P12477
Seal Packing EM-1 12
- ENGINE MECHANICALCYLINDER BLOCK
1685 Author: Date:
2004 LAND CRUISER (RM1071U)
14. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material, and be careful
not to drop any oil on the contact surfaces of the oil seal
retainer and the cylinder block.
Using a razor blade and a gasket scraper, remove
old FIPG from the seal surface.
Clean all the components to remove the redundant
FIPG completely.
Clean sealing surfaces with solvent so that any resi-
due does not remain on the seal.
(b) Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing: Part No. 08826-00080 or equivalent
Install a nozzle that is cut to a 2 - 3 mm (0.08 - 0.12
in.) opening.
Parts must be assembled within 5 minutes after the
seal packing application. Otherwise the material
must be removed and the seal packing have to be
reapplied.
Immediately remove the nozzle from the tube and
reinstall the cap.
(c) Install a new O-ring to the cylinder block.
(d) Install the oil seal retainer with the 7 bolts.
Torque: 8.0 N´m (80 kgf´cm, 71 in.´lbf)
15. INSTALL ENGINE COOLANT DRAIN UNIONS
(a) Apply seal packing to 2 or 3 threads from the end of the
drain unions.
Seal packing: Part No. 08826-00100 or equivalent
Page 1819 of 3115
A04856
FrontPort
A05110
LH Side
A05109
RH Side
A05132
Push
Wire
Clamp
New
O-Ring
- ENGINE MECHANICALCYLINDER BLOCK
EM-1 13
1686 Author: Date:
2004 LAND CRUISER (RM1071U)
(b) Install the 2 drain unions.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
HINT:
After applying the specified torque, rotate the drain union clock-
wise until the drain port is facing forward.
16. INSTALL OIL PUMP (See page LU-15)
17. INSTALL OIL STRAINER (See page LU-15)
18. INSTALL NO.1 OIL PAN (See page LU-15)
19. INSTALL OIL PAN BAFFLE PLATE
(See page LU-15)
20. INSTALL NO.2 OIL PAN (See page LU-15)
21. INSTALL WATER PUMP (See page CO-8)
22. INSTALL ENGINE MOUNTING BRACKETS
Install the mounting bracket with the 4 bolts. Install the 2 mount-
ing brackets.
Torque: 36 N´m (370 kgf´cm, 27 ft´lbf)
23. INSTALL ENGINE WIRE TO LH SIDE OF CYLINDER
BLOCK
(a) Install the bracket on the engine wire with the bolt.
(b) Install the engine wire cover with the 2 bolts.
24. INSTALL ENGINE WIRE TO RH SIDE OF CYLINDER
BLOCK
Install the 2 brackets on the engine wire with the 2 bolts.
25. INSTALL OIL COOLER PIPE BRACKET FOR A/T
Install the bracket with the bolt.
26. INSTALL KNOCK SENSORS (See page SF-55)
27. INSTALL STARTER (See page ST-17)
28. INSTALL WATER BYPASS PIPE
(a) Install a new O-ring to the water bypass pipe.
(b) Apply soapy water to the O-ring.
(c) Push the water bypass pipe end into the pipe hole of the
water pump.
(d) Install the water bypass pipe with the bolt.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
(e) Install the wire clamp to the bracket of the water bypass
pipe.
29. INSTALL CYLINDER HEADS (See page EM-59)
Page 1821 of 3115
EM0L7-05
A04874A04885A05180
Sized MarkLH
Piston
RH
Piston
Sized Mark
P20665
SST
P20666
Oil
Hole EM-104
- ENGINE MECHANICALCYLINDER BLOCK
1677 Author: Date:
2004 LAND CRUISER (RM1071U)
REPLACEMENT
1. REPLACE OVERSIZED (O/S) PISTONS FOR CYL-
INDER BORING
HINT:
Bore all the 8 cylinders to the oversized piston outside di-
ameter.
Replace all the piston rings with the ones to match the
oversized pistons.
(a) Keep 8 new O/S pistons.
O/S 0.50 piston diameter:
94.402 - 94.430 mm (3.7166 - 3.7177 in.)
HINT:
The shape of the piston varies for the LH and RH banks. The
LH piston is marked with ºLHº and º2Lº, the RH piston with ºRHº
and º2Rº.
(b) 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.
(c) Calculate the amount for each cylinder to be rebored as
follows:
Size to be rebored = P + C - H
P = Piston diameter
C = Piston clearance:
0.090 - 0.111 mm (0.0035 - 0.0044 in.)
H = Allowance for honing: 0.02 mm (0.0008 in.) or less
(d) Bore and hone the cylinders to calculated dimensions.
Maximum honing: 0.02 mm (0.0008 in.)
NOTICE:
Excess honing will destroy the finished roundness.
2. REPLACE CONNECTING ROD BUSHINGS
(a) Using SST and a press, press out the bushing.
SST 09222-30010
(b) Align the oil holes of a new bushing and the connecting
rod.
(c) Using SST and a press, press in the bushing.
SST 09222-30010