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 1890 of 3115
P20634
P20635
Protrusion
- ENGINE MECHANICALTIMING BELT
EM-21
1594 Author: Date:
2004 LAND CRUISER (RM1071U)
(b) Hold the tensioner with both hands, and push the push
rod strongly to check that it doesn't move.
If the push rod moves, replace the tensioner.
NOTICE:
Never hold the tensioner push rod facing downward.
(c) Measure the protrusion of the push rod from the housing
end.
Protrusion:
10.5 - 11.5 mm (0.413 - 0.453 in.)
If the protrusion is not as specified, replace the tensioner.
4. INSPECT WATER PUMP
(See page CO-7)
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 1892 of 3115

A04448
A04449
SST
A08660
A04340
SST
- ENGINE MECHANICALTIMING BELT
EM-23
1596 Author: Date:
2004 LAND CRUISER (RM1071U)
5. INSTALL TIMING BELT GUIDE
Install the belt guide, facing the cup side outward.
6. INSTALL NO.1 TIMING BELT COVER
Install the timing belt cover with the 4 bolts.
7. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the crank-
shaft pulley.
(b) Using SST and a hammer, tap in the crankshaft pulley.
SST 09223-4601 1
8. INSTALL DRIVE BELT TENSIONER
Install the belt tensioner with the bolt and the 2 nuts.
Torque: 16 N´m (160 kgf´cm, 12 ft´lbf)
HINT:
Use a bolt of 106 mm (4.18 in.) in length.
9. INSTALL GENERATOR
(See page CH-16)
10. CHECK CRANKSHAFT PULLEY POSITION
Check that the timing mark of the crankshaft pulley is aligned
with the timing mark º0º of the No.1 timing belt cover.
11. INSTALL RH, LH CAMSHAFT TIMING PULLEYS
(a) Align the camshaft knock pin with the knock pin grove of
the timing pulley, and slide on the timing pulley.
(b) Using SST, install the pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 108 N´m (1,100 kgf´cm, 80 ft´lbf)
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.
Page 1894 of 3115
A08597Turn
A04335
A09156
SST
A04455
- ENGINE MECHANICALTIMING BELT
EM-25
1598 Author: Date:
2004 LAND CRUISER (RM1071U)
16. CHECK VALVE TIMING
(a) Temporarily install the crankshaft pulley bolt.
(b) Slowly turn the crankshaft pulley 2 revolutions from TDC
to TDC.
NOTICE:
Always turn the crankshaft pulley clockwise.
(c) Check that each pulley aligns with the timing marks as
shown in the illustration.
If the timing marks do not align, remove the timing belt and rein-
stall it.
17. TIGHTEN CRANKSHAFT PULLEY BOLT
Using SST, install the pulley bolt.
SST 09213-7001 1 (90105-70020),
09330-00021
Torque: 245 N´m (2,500 kgf´cm, 181 ft´lbf)
18. INSTALL FAN BRACKET
Install the fan bracket with the 2 bolts and the 2 nuts.
Torque:
12 mm head
16 N´m (160 kgf´cm, 12 ft´lbf)
14 mm head
32 N´m (330 kgf´cm, 24 ft´lbf)
HINT:
Bolt Length:
106 mm (4.17 in.) for 12 mm head (A)
114 mm (4.49 in.) for 14 mm head (B)
19. INSTALL A/C COMPRESSOR
(See page EM-81)
Page 1895 of 3115

A04330
A04329
A04331
EM-26
- ENGINE MECHANICALTIMING BELT
1599 Author: Date:
2004 LAND CRUISER (RM1071U)
20. INSTALL NO.2 TIMING BELT COVER
Install the No.2 timing belt cover with the 2 bolts.
Torque: 16 N´m (160 kgf´cm, 12 ft´lbf)
21. INSTALL RH NO.3 TIMING BELT COVER
(a) Fit the RH No.3 timing belt cover, matching it with the fan
bracket.
(b) Install the RH No.3 timing belt cover with the 3 bolts and
nut.
Torque: 7.5 N´m (80 kgf´cm, 66 in.´lbf)
22. INSTALL LH NO.3 TIMING BELT COVER
(a) Install the oil cooler pipe and the bolt.
(b) Run the camshaft position sensor wire through the LH
No.3 timing belt cover hole.
(c) Fit the LH No.3 timing belt cover, matching it with the fan
bracket.
(d) Install the LH No.3 timing belt cover with the 4 bolts and
the nut.
Torque: 7.5 N´m (80 kgf´cm, 66 in.´lbf)
(e) Install the wire grommet to the LH No.3 timing belt cover.
(f) Install the sensor connector to the connector bracket.
(g) Connect the sensor connector.
(h) Install the sensor wire to the wire clamp on the LH No.3
timing belt cover.
(i) Install the engine wire to the 2 wire clamps on the LH No.3
timing belt cover.
23. INSTALL DRIVE BELT IDLER PULLEY
Install the idler pulley and the cover plate with the bolt.
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
24. INSTALL RADIATOR ASSEMBLY
(See page CO-19)
Page 1896 of 3115
A02247
- ENGINE MECHANICALTIMING BELT
EM-27
1600 Author: Date:
2004 LAND CRUISER (RM1071U)
25. INSTALL FAN PULLEY, FAN, FLUID COUPLING
AND DRIVE BELT
(a) Temporarily install the fan pulley, the fan, fluid coupling
assembly with the 4 nuts.
(b) Install the generator drive belt.
(See page CH-16)
(c) Tighten the 4 nuts holding the fluid coupling to the fan
bracket.
Torque: 21 N´m (215 kgf´cm, 16 ft´lbf)
26. INSTALL AIR CLEANER AND INTAKE AIR
CONNECTOR ASSEMBLY
27. INSTALL V-BANK COVER
28. FILL WITH ENGINE COOLANT
29. START ENGINE AND CHECK FOR LEAKS
30. RECHECK ENGINE COOLANT LEVEL
31. INSTALL BATTERY CLAMP COVER
32. INSTALL ENGINE UNDER COVER
33. INSTALL OIL PAN PROTECTOR