1998 TOYOTA LAND CRUISER clock

ABS Antilock Brake System
A/C Air Conditioner
assy assembly
ECT Electronic Controlled Transmission
ECU Electronic Control Unit
e.g. Exempli Gratia (for Example)
Ex. Except
4WD Four Wheel Drive Vehicles
in. inch
LH Left-hand
LHD Left-hand Drive
MIG Metal Inert Gas
M/Y Model Year
PPS Progressive Power Steering
RH Right-hand
RHD Right-hand Drive
SRS Supplemental Restraint System
SSM Special Service Materials
w/ with
w/o without
5. ECU (ELECTRONIC CONTROL UNIT)
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.

Before starting electric welding operations, disconnect the negative (-) terminal cable from the battery.
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all
equipped with memory function, it is not possible to make a record of the memory contents. So when the
operation is finished, it will be necessary to explain this fact to the customer, and request the customer to
adjust the features and reset the memory.

Do not expose the ECUs to ambient temperatures above 80°C (176°F).
NOTICE: If it is possible the ambient temperature may reach 80° (176°F) or more, remove the ECUs
from the vehicle before starting work.

Be careful not to drop the ECUs and not to apply physical shocks to them.
ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual.
INTRODUCTIONIN-9

HANDLING PRECAUTIONS ON RELATED COMPONENTS
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
The TOYOTA LAND CRUISER is equipped with an SRS (Supplemental Restraint System), such as the driver
airbag and front passenger airbag and seat belt pretensioners. Failure to carry out service operations in the
correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing, pos-
sibly leading to a serious accident. Further, if a mistake is made in servicing the supplemental restraint system,
it is possible the SRS may fail to operate when required. Before servicing (including removal or installation of
parts, inspection or replacement), be sure to read the following items carefully, then follow the correct proce-
dure described in this manual.

Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic
trouble codes become the most important source of information when troubleshooting.
When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes
before disconnecting the battery.

Work must be started after 90 seconds from the time the ignition switch is turned to the ºLOCKº position
and the negative (-) terminal cable is disconnected from the battery.
(The supplemental restraint system is equipped with a back-up power source so that if work is started
within 90 seconds of disconnecting the negative (-) terminal cable from the battery, the SRS may
deploy.)
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by the
audio memory system.
Then when work is finished, reset the clock and audio systems as before.
To avoid erasing the memory of each memory system, never use a back-up power supply from outside
the vehicle.

Even in cases of a minor collision where the SRS does not deploy, the passenger's airbag assembly,
the steering wheel pad and seat belt pretensioners should be inspected.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs.

Never disassemble and repair the airbag sensor assembly, steering wheel pad in order to reuse it.

If the airbag sensor assembly, steering wheel pad have been dropped, or if there are cracks, dents or
other defects in the case, bracket or connector, replace them with new ones.

Do not expose the airbag sensor assembly, steering wheel pad directly to hot air or flames.

Use a volt/ohmmeter with high impedance (10 k
/V minimum) for troubleshooting of the electrical cir-
cuit.

Information labels are attached to the periphery of the SRS components. Follow the instructions on the
notices.

After work on the supplemental restraint system is completed, check the SRS warning light.

Before repairing the body, remove the SRS parts if, during repair, shocks are likely to be applied to the
sensors due to vibrations of the body or direct tapping with tools or other parts.

Do not expose the SRS parts directly to hot air or flames.
NOTICE:
1) The maximum ambient temperature tolerance is 120
°C (248°F) for the front airbag sensor, 105°C
(221
°F) for the center airbag sensor assembly and 93°C (200°F) for the steering wheel pad, and
front passenger airbag assembly. If it is possible that the ambient temperature may reach or ex-
ceed the temperature limit, remove the sensors and the steering wheel pad from the vehicle or
protect them with a hot insulation material before staring work.
2) Prior to welding, remove adjacent SRS parts form the vehicle or protect them with fire-proof cov-
ers.

If the vehicle is damaged, visually inspect for damage to the steering wheel pad using the inspection
procedures described in section RS of the repair manual for the relevant model year.
INTRODUCTIONIN-6

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)

A02859
A02889
Service Bolt
SST
Sub Gear
Main Gear
Turn
A02890
Seal Packing
A05502
RH Cylinder Head
LH Cylinder HeadFront EM-62
- ENGINE MECHANICALCYLINDER HEAD
1635 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(c) Mount the hexagon shaped part of the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(d) Using SST, align the holes of the camshaft main gear and
sub-gear by turning camshaft sub-gear counterclock-
wise, and temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(e) Align the gear teeth of the main gear and sub-gear, and
tighten the service bolt.
7. INSTALL CAMSHAFT HOUSING PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the camshaft housing plug grooves.
Seal packing:
Part No. 08826-00080 or equivalent
(c) Install the 2 camshaft housing plugs to the cylinder heads.

A04336
Timing
MarkNo. 2 Idler Pulley Bolt
Turn
A05525
Approx. 10°
A05503
Seal Packing
Groove Seal Width
1.5 mm
- ENGINE MECHANICALCYLINDER HEAD
EM-63
1636 Author
: Date
:
2004 LAND CRUISER (RM1071U)
8. INSTALL CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being removed.
Otherwise, excessive pressure is put on the cylinder head
journal thrust, causing a burr on the journal and damage on
the camshaft. To avoid this, follow the steps below.
(a) Set the crankshaft pulley position.
Turn the crankshaft pulley clockwise or counterclockwise,
and put the timing mark of the crankshaft pulley in line with
the centers of the crankshaft pulley bolt and the idler
pulley bolt.
NOTICE:
Having the crankshaft pulley at the wrong angle can cause
the piston head and the valve head to come into contact
with each other when removing the camshaft, causing
damage on them. So always set the crankshaft pulley at the
correct angle.
(b) Install the RH camshafts.
(1) Apply MP grease to the thrust portion of the intake
and exhaust camshafts.
(2) Place the intake and exhaust camshafts.
(3) Set the timing mark (1 dot mark) of the camshaft
main gear at approx. 10° angle.
(4) Remove any old packing (FIPG) material from the
front bearing cap.
(5) Apply seal packing to the front bearing cap as
shown in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent

Install a nozzle that is cut to a 1.5 mm (0.06
in.) opening.

Parts must be assembled within 5 minutes
the seal packing application. Otherwise the
material must be removed and the packing
have to be reapplied.

Immediately remove nozzle from the tube
and reinstall cap.
NOTICE:
Do not apply seal packing to the front bearing cap grooves.

A02856Service Bolt
A02857
Align
A04470
4
6
108
1
16
12
18 2
19 20 2221
15
3
5
97
14
1713
11
A02859
A02850
SST
Service Bolt
Turn EM-40
- ENGINE MECHANICALCYLINDER HEAD
1613 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(c) Remove the LH camshafts.
(1) Move a service bolt of the sub-gear upward by turn-
ing the hexagon shaped port of the exhaust cam-
shaft with a wrench.
(2) Secure the sub-gear to the main gear with a service
bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 - 20 mm
HINT:
When removing the camshaft, make sure that the torsional
spring force of the sub-gear is eliminated by the above opera-
tion.
(3) Align the timing mark (2 dot marks) of the camshaft
drive gear by turning the hexagon wrench head por-
tion of the exhaust camshaft with a wrench.
(4) Evenly loosen and remove the 22 bearing cap bolts
a little at a time for several times as in the sequence
shown.
(5) Remove the oil feed pipe, 9 bearing caps, and cam-
shafts.
HINT:
Arrange the bearing caps in correct order for installation.
22. DISASSEMBLE EXHAUST CAMSHAFTS
(a) Mount the hexagon wrench head portion of the camshaft
in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Using SST, turn the sub-gear clockwise, and remove the
service bolt.
SST 09960-10010 (09962-01000, 09963-00500)

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.

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)