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 1820 of 3115
EM-1 14
- ENGINE MECHANICALCYLINDER BLOCK
1687 Author: Date:
2004 LAND CRUISER (RM1071U)
30. INSTALL TIMING BELT AND PULLEYS
(See page EM-22)
31. DISCONNECT ENGINE FROM ENGINE STAND
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
Page 1822 of 3115

P20667
P20668
A04865
A04866
SST
A04863Cut Position
- ENGINE MECHANICALCYLINDER BLOCK
EM-105
1678 Author: Date:
2004 LAND CRUISER (RM1071U)
(d) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance (See page EM-97) be-
tween the bushing and piston pin.
(e) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, and push it into the connect-
ing rod with your thumb.
3. REPLACE CRANKSHAFT FRONT OIL SEAL
HINT:
There are 2 methods ((a) and (b)) to replace the oil seal.
(a) If the oil pump is removed from the cylinder block:
(1) Using a screwdriver, pry out the oil seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the oil pump body edge.
SST 09316-6001 1 (09316-00011)
(3) Apply MP grease to the oil seal lip.
(b) If the oil pump is installed to the cylinder block:
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape up the
screwdriver tip.
Page 1823 of 3115

A04864
SST
A04868
A04867
SST
A04858Cut Position
A04859
SST
EM-106
- ENGINE MECHANICALCYLINDER BLOCK
1679 Author: Date:
2004 LAND CRUISER (RM1071U)
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the oil pump body edge.
SST 09316-6001 1 (09316-00011)
4. REPLACE CRANKSHAFT REAR OIL SEAL
HINT:
There are 2 methods ((a) and (b)) to replace the oil seal.
(a) If the rear oil seal retainer is removed from the cylinder
block:
(1) Using a screwdriver and hammer, tap out the oil
seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the rear oil seal retainer
edge.
SST 09223-56010
(3) Apply MP grease to the oil seal lip.
(b) If the rear oil seal retainer is installed to the cylinder block:
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape up the
screwdriver tip.
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223-56010
Page 1824 of 3115
EM1V7-01
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-28
- ENGINE MECHANICALCYLINDER HEAD
1601 Author: Date:
2004 LAND CRUISER (RM1071U)
CYLINDER HEAD
COMPONENTS