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.
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.