Page 1878 of 3115
EM0L9-07
- ENGINE MECHANICALENGINE UNIT
EM-77
1650 Author: Date:
2004 LAND CRUISER (RM1071U)
REMOVAL
1. REMOVE HOOD
2. REMOVE ENGINE UNDER COVERS
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. REMOVE V-BANK COVER
6. REMOVE BATTERY
7. REMOVE AIR CLEANER CAP AND INTAKE AIR CON-
NECTOR PIPE ASSEMBLY
8. REMOVE RADIATOR RESERVOIR
(a) Disconnect the clamp on the wire from the reservoir.
(b) Disconnect the reservoir hose from the radiator.
(c) Remove the 2 bolts, the reservoir and the grommet.
9. REMOVE RADIATOR AND FAN SHROUD
(a) Disconnect the upper radiator hose from the front water
bypass joint.
(b) Remove the 2 nuts, and disconnect the 2 clamps on the
A/C discharge tube from the bracket.
(c) Remove the 2 bolts, and disconnect the 2 brackets on the
wire from the radiator.
(d) Remove the 3 bolts, and disconnect the fan shroud from
the radiator.
(e) Remove the lower radiator hose.
(f) Disconnect the 2 A/T oil cooler hoses from the radiator.
(g) Remove the 2 bolts, the 2 nuts, the 2 support collars and
the radiator.
(h) Remove the fan shroud.
10. REMOVE GENERATOR DRIVE BELT, FAN, FLUID
COUPLING AND FAN PULLEY
(a) Loosen the 4 nuts holding the fluid coupling to the fan
bracket.
(b) Remove the generator drive belt. (See page CH-7)
(c) Remove the 4 nuts, the fan, the fluid coupling assembly
and the fan pulley.
11. DISCONNECT ENGINE WIRE FROM CABIN
(a) Remove the glove compartment door.
(b) Remove the lower No.2 panel.
(c) Disconnect the 3 connectors from the ECM.
(d) Remove the 3 screws, and disconnect ECM from the
body bracket.
(e) Disconnect the 3 wire harness connectors.
12. DISCONNECT HOSES, WIRES, CONNECTORS,
CLAMPS, GROMMET AND CABLES
(a) Disconnect the 2 PS air hoses from the hose clamp on the
No.3 RH timing belt cover.
(b) Disconnect the generator wire.
(c) Disconnect the generator connector.
(d) Disconnect the hose clamp for PS air hose.
(e) Disconnect the PS air hose from upper intake manifold.
Page 1880 of 3115
A05126
A05125
A05172
Lift
Down
- ENGINE MECHANICALENGINE UNIT
EM-79
1652 Author: Date:
2004 LAND CRUISER (RM1071U)
18. DISCONNECT PS PUMP FROM ENGINE
Remove the 3 bolts, and disconnect the PS pump from the en-
gine.
HINT:
Suspend the PS pump securely.
19. REMOVE ENGINE AND TRANSMISSION ASSEMBLY
FROM VEHICLE
(a) Attach the engine chain hoist to the engine hangers.
(b) Remove the 2 nuts and the 4 bolts holding the engine
mounting brackets to the frame brackets.
(c) Remove the 3 bolts and the transfer case protector.
(d) Remove the 8 bolts, the 2 nuts and the frame crossmem-
ber.
(e) Lift the engine and take out from the vehicle slowly and
carefully.
HINT:
Make sure the engine is clear of all wiring, hoses and cables.
(f) Place the engine and transmission assembly onto a
stand.
20. DISCONNECT ENGINE WIRE FROM TRANSMISSION
(a) Disconnect the 5 connectors.
(b) Disconnect the 2 wire clamps.
21. REMOVE OIL COOLER PIPES FOR TRANSMISSION
(a) Remove the 3 bolts and the 3 stays.
(b) Loosen the 2 union nuts, and remove the 2 oil cooler
pipes.
Page 1884 of 3115
EM0KT-10
A07061
TOYOTA Hand-Held Tester
DLC3
A05511
A05512
SSTTC
E1
A04459
- ENGINE MECHANICALIGNITION TIMING
EM-9
1582 Author: Date:
2004 LAND CRUISER (RM1071U)
IGNITION TIMING
INSPECTION
1. REMOVE BATTERY CLAMP COVER
2. REMOVE INTAKE AIR CONNECTOR
3. REMOVE V-BANK COVER
4. WARM UP ENGINE
Allow the engine to warm up to the normal operating tempera-
ture.
5. CONNECT TOYOTA HAND-HELD TESTER OR OBD II
SCAN TOOL
(a) Connect the TOYOTA hand-held tester or OBD II scan
tool to the DLC3.
(b) Please refer to the TOYOTA hand-held tester or OBD II
scan tool operator's manual for further details.
6. CONNECT TIMING LIGHT TO ENGINE
Connect the tester probe of a timing light to the wire of the igni-
tion coil connector for No.1 cylinder.
7. CHECK IDLE SPEED
(a) Race the engine speed at 2,500 rpm for approx. 90 se-
conds.
(b) Check the idle speed.
Idle speed:
700 ± 50 rpm
8. INSPECT IGNITION TIMING
(a) Using SST, connect terminal TC and E1 of the DLC1.
SST 09843-18020
(b) Using a timing light, check the ignition timing.
Ignition timing:
5 - 15° BTDC @ idle
(Transmission in neutral position)
(c) Remove SST from the DLC1.
SST 09843-18020
9. DISCONNECT TIMING LIGHT FROM ENGINE
10. DISCONNECT TOYOTA HAND-HELD TESTER OR
OBD II SCAN TOOL
Page 1886 of 3115
EM0KV-1 1
A09750
P/S Air HoseRadiator
Reservoir Tank
Intake Air
Connector
Radiator Assembly
EVAP HoseV-Bank Cover
Engine Under Cover No.1
N´m (kgf´cm, ft´lbf) : Specified torque Generator
Drive Belt
A/C CompressorA/C Compressor
Connector
A/T Oil Cooler Hose
Fan w/ Fluid
Coupling
Fan Pulley
49 (500, 36)
5.0 (50, 43 in.´lbf)
18 (185, 13)
Air Hose
x 8Fan Shroud Fuel Return
Hose
20 (200, 15)
A/T Oil Cooler
Hose
A/C Discharge
Tube
Clamp
BracketWireClamp
Clamp
Lower Radiator Hose
Bracket
EM-12
- ENGINE MECHANICALTIMING BELT
1585 Author: Date:
2004 LAND CRUISER (RM1071U)
TIMING BELT
COMPONENTS
Page 1887 of 3115
A04326
RH No. 3 Timing Belt Cover
No. 2 Timing
Belt Cover
LH No. 3 Timing Belt Cover Drive Belt Idler Pulley
Camshaft Position
Sensor ConnectorCover Plate
Engine Wire
16 (160, 12)
7.5 (80, 16 in.´lbf)
N´m (kgf´cm, ft´lbf) : Specified torque
Oil Cooler PipeWire Grommet
39 (400, 29)
7.5 (80, 66 in.´lbf)
A04327
Timing BeltRH Camshaft Timing Pulley
LH Camshaft Timing Belt Pulley
Timing belt Tensioner
Fan BracketDust Boot
108 (1,100, 80)
245 (2,500, 181)
16 (160, 12)
32 (330, 24)
26 (270, 19)N´m (kgf´cm, ft´lbf) : Specified torque
- ENGINE MECHANICALTIMING BELT
EM-13
1586 Author: Date:
2004 LAND CRUISER (RM1071U)
Page 1889 of 3115
EM0KX-06
EM3336
NO !
P20079
P20633
EM-20
- ENGINE MECHANICALTIMING BELT
1593 Author: Date:
2004 LAND CRUISER (RM1071U)
INSPECTION
1. INSPECT TIMING BELT
NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow the timing belt to contact with oil, water
or steam.
Do not utilize timing belt tension when installing or re-
moving the mount bolt of the camshaft timing pulley.
If there any defects as shown in the illustrations, check these
points:
(a) Premature parting
Check for proper installation.
Check the timing cover gasket for damage and
proper installation.
(b) If the belt teeth are cracked or damaged, check if either
camshaft is locked.
(c) If there is noticeable wear or cracks on the belt face,
check if there are nicks on the side of the idler pulley lock
and the water pump.
(d) Even if there is wear or damage on only one side of the
belt, check the belt guide and the alignment of each
pulley.
(e) If there is noticeable wear on the belt teeth, check timing
cover for damage and for foreign materials on the pulley
teeth.
If necessary, replace the timing belt.
2. INSPECT IDLER PULLEYS
(a) Visually check the seal portion of the idler pulley for oil
leakage.
If leakage is found, replace the idler pulley.
(b) Check that the idler pulley turns smoothly.
If necessary, replace the idler pulley.
3. INSPECT TIMING BELT TENSIONER
(a) Visually check the seal portion of the tensioner for oil leak-
age.
HINT:
If there is only the faintest trace of oil on the seal on the push
rod side, the tensioner is all right.
If leakage is found, replace the tensioner.
Page 1891 of 3115
EM0KY-09
A04446
SST
Inward
A04447
A04342
EM-22
- ENGINE MECHANICALTIMING BELT
1595 Author: Date:
2004 LAND CRUISER (RM1071U)
INSTALLATION
1. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the timing pulley set key with the key groove of the
pulley.
(b) Using SST and a hammer, tap in the timing pulley, facing
the flange side inward.
SST 09223-4601 1
2. INSTALL NO.1 IDLER PULLEY AND NO.2 IDLER
PULLEY
(a) Apply adhesive 2 or 3 threads from the end of the pivot
bolt.
Adhesive:
Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a 10 mm hexagon wrench, install the plate washer
and the No.1 idler pulley with the pivot bolt.
Torque: 34.5 N´m (350 kgf´cm, 25 ft´lbf)
(c) Install the No.2 idler pulley with the bolt.
Torque: 34.5 N´m (350 kgf´cm, 25 ft´lbf)
(d) Check that the No.1 and No.2 idler pulley moves smooth-
ly.
3. TEMPORARILY INSTALL TIMING BELT
NOTICE:
The engine should be cold.
(a) Remove any oil or water on and clean the crankshaft
pulley, the oil pump pulley, the water pump pulley, the
No.1 idler pulley and the No.2 idler pulley.
NOTICE:
Only wipe the pulleys; do not use any cleansing agent.
(b) Align the installation mark on the timing belt with the tim-
ing mark of the crankshaft timing pulley.
(c) Install the timing belt on the crankshaft timing pulley, the
No.1 idler pulley and the No.2 idler pulley.
4. INSTALL TIMING BELT COVER SPACER
(a) Install the gasket to the cover spacer.
(b) Install the cover spacer.
Page 1893 of 3115
A04451
Turn
A04452
Tension
Turn
A04453
Turn
P20636
1.27 mm
Hexagon
Wrench
A04454
1.27 mm
Hexagon
Wrench
EM-24
- ENGINE MECHANICALTIMING BELT
1597 Author: Date:
2004 LAND CRUISER (RM1071U)
12. CONNECT TIMING BELT TO LH CAMSHAFT
TIMING PULLEY
(a) Remove any oil or water on the LH camshaft timing pulley,
and clean it up.
NOTICE:
Only wipe the pulleys; do not use any cleansing agent.
(b) Turn the LH camshaft timing pulley. Align the installation
mark on the timing belt with the timing mark of the cam-
shaft timing pulley, and hang the timing belt on the LH
camshaft timing pulley.
(c) Turn the LH camshaft timing pulley counterclockwise until
there is tension between the crankshaft timing pulley and
the LH camshaft timing pulley.
13. CONNECT TIMING BELT TO RH CAMSHAFT
TIMING PULLEY
(a) Remove any oil or water on the RH camshaft timing pulley
and water pump pulley, and clean them up.
NOTICE:
Only wipe the pulleys; do not use any cleansing agent.
(b) Turn the RH camshaft timing pulley. Align the installation
mark on the timing belt with the timing mark of the cam-
shaft timing pulley, and hang the timing belt on the RH
camshaft timing pulley.
14. SET TIMING BELT TENSIONER
(a) Using a press, slowly press in the push rod using 981 -
9,807 N (100 - 1,000 kgf, 220 - 2,205 lbf) of pressure.
(b) Align the holes of the push rod and the housing, pass a
1.27 mm (0.050 in.) hexagon wrench through the holes to
keep the setting position of the push rod.
(c) Release the press.
(d) Install the dust boot to the belt tensioner.
15. INSTALL TIMING BELT TENSIONER
(a) Temporarily install the belt tensioner with the 2 bolts.
(b) Alternately tighten the 2 bolts.
Torque: 26 N´m (270 kgf´cm, 19 ft´lbf)
(c) Using pliers, remove the 1.27 mm (0.050 in.) hexagon
wrench from the belt tensioner.
