Land Cruiser Cylinder Liner Install

Bearing No.

Fig. 3-109

Fig. 3-109

INSPECTION & REPAIR

Cylinder Block 8c Liner

1. Clean and check cylinder block for cracks or scores.

2. Using a precision straight edge and thickness gauge, inspect the cylinder block topside surface for warpage.

Topside surface warpage limit

Fig. 3-111

Fig. 3-111

Check Cylinder

3. Inspect for warpage at the indicated lines shown in left.

4. Visually inspect cylinders for vertical scratches.

If there are deep scratches, the cylinder liner must be rebored.

When reboring cylinder, rebore all cylinders to the same size.

Fig. 3-113

Fig. 3-113

Fig. 3-114

Fig. 3-115

5. Measure cylinder bores at top, middle and bottom as shown. If the bore exceeds the limit, it must be rebored.

Standard Bore

a rk

Size

B Engine

2B Engine

3

95.02 - 95.03 mm (3.7409 -3.7413 in.)

98.02 - 98.03 mm (3.8590 - 3.8594 in.)

The bore marks are stamped on cylinder block topside surface as shown.

The bore marks are stamped on cylinder block topside surface as shown.

Fig. 3-115

Zmogus Voras Spalvinimas

Fig. 3-116

6. If the wear is less than 0.3 mm (0.012 in.), machine piston ring ridge at the top of bore with a ridge reamer.

If this step is not performed prior to removing pistons the piston ring lands will be damaged.

Fig. 3-116

O/S Piston

O/S Piston

7. Use oversize pistons when cylinder liners are rebored.

Oversize piston diameter, O/S 1.00 B engine 95.88 - 95.91 mm

Fig. 3-117

Fig. 3-118

Fig. 3-117

Fig. 3-118

8. Use following equation to determine reboring finished diameter.

Where B: Reboring finished diameter P: O/S piston diameter C: Piston clearance 0.11 -0.13 mm (0.0043 - 0.0051 in.) H: Honing allowance Less than 0.02 mm

9. Replace cylinder liner if the bore damage is excessive, or if the bore is worn so much that 0/S 1.00 piston cannot be used.

(1) Press out cylinder liner with SST [09218-56010].

Fig. 3-119

Fig. 3-119

(2) Select the liner having the same mark with the cylinder block, "A" or "B".

Fig. 3-120

(3) Lubricate outside surface of the liner with engine oil before installing.

Fig. 3-121

Fig. 3-121

(4) Press in the liner with SST[09218 -56010].

Pressing force

After pressing in the liner, rebore and hone the liner bore to fit STD piston.

Fig. 3-122

Fig. 3-122

Press Fit Potrusion

10. Measure protrusion of cylinder liner above cylinder block topside surface at four positions.

Protrusion 0.01 - 0.10 mm

Fig. 3-123

Fig. 3-123

1. Adjust protrusion of cylinder liner with cylinder liner shims.

Cylinder liner shim thickness

1. Adjust protrusion of cylinder liner with cylinder liner shims.

Cylinder liner shim thickness

Piston Land Hole

Piston Pin & Connecting Rod

1. Check pin fit by rocking pistion at right angle to pin.

If any movement is felt, replace piston and pin.

3. Remove piston pin with SST [09221 -46010].

Fig. 3-127

Fig. 3-127

Fig. 3-128

Fig. 3-128

4. Check piston pin fitness.

Heat piston to about 60°C (140°F), and coat pin with engine oil. It should then be possible to push the pin into the piston hole with thumb pressure.

5. Measure oil clearance between bushing and piston pin.

Oil clearance

Fig. 3-129

Fig. 3-129

6. Replace bushing with SST[09222-66010]. - Note -

Align the bushing oil hole with the connecting rod oil hole.

Fig. 3-130

Fig. 3-130

7. After installing the bushing, finish bushing bore with a pin hole grinder.

Fig. 3-131

Fig. 3-131

8. The fitting between bushing and pin should be such that the pin, when coated with engine oil, can be pushed in with the thumb at normal temperature.

Fig. 3-132

Crankpin Bearing

1. Check bearings for flaking or scoring. If damaged, replace.

Fig. 3-133

Fig. 3-133

2. Measure crankpin diameter.

If wear is excessive, crankshaft must be reground or replaced.

Crankpin diameter (STD)

Fig. 3-134

Fig. 3-134

3. Measure crankpin oil clearance.

(1) Clean crankshaft pin, connecting rod, cap and bearings.

Fig. 3-135

Fig. 3-136

(2) Lay strip of plastigage across pin.

(3) Tighten cap nuts to specified torque.

Do not turn connecting rod or crankshaft.

Fig. 3-137

Fig. 3-137

Fig. 3-138

(4) Measure plastigage at its widest point.

If clearance is not within specification, replace bearings.

Oil clearance

(0.0012 - 0.0028 in.) U/S bearing type 0.25,0.50,1.00

Fig. 3-138

Piston

1. Check piston for wear and damage, especially in the piston ring grooves and ring lands.

Fig. 3-140

Piston Size Mark

Front Mark

Parti Frutto

a r k

Piston Size

B Engine

2B Engine

2 3

94.90-94.91 mm (3.7362-3.7366 in.)

97.90-97.91 mm (3.8543-3.8547 in.)

Piston Size Mark

Front Mark

At the piston top surface there is a mark indicating the front side, and stamped codes indicating piston diameter and piston pin bore.

2. Check piston clearance.

(1) Measure piston diameter, in the thrust direction about 15 mm (0.59 in.) up from skirt bottom edge. Measurement must be made at normal temperature 20°C (68°F).

Fig. 3-139

Fig. 3-140

Fig. 3-141

Fig. 3-142

(2) Measure cylinder bore and subtract piston size.

Fig. 3-142

Fig. 3-143
Front Mark

a rk

Cylinder Size

B Engine

2B Engine

2 3

95.02 - 95.03 mm (3.7409 -3.7413 in.)

98.02 - 98.03 mm (3.8590-3.8594 in.)

Piston clearance

3 Assemble piston and connecting rod as follows.

(1) Heat piston to about 60°C (140°F) before installing piston pin.

Align front mark of the piston and mark of the connecting rod as shown.

Mark

Front Mark

Mark

Front Mark

Fig. 3-144

Fig. 3-144

(3) Install piston pin with SST[09221 -46010],

Fig. 3-145

Fig. 3-145

Fig. 3-146
Piston Ring Gap Alignment

(4) Install snap ring on both side. — Caution —

Make sure snap ring is completely in place.

Piston Ring

1. Remove piston ring with a piston ring expander.

Fig. 3-147

Fig. 3-147

Piston Grinders Fig

2. Measure piston ring end gap with the ring at the lower part of the cylinder bore Where the wear is least.

Use correct size rings to match the piston size.

Fig. 3-148

Fig. 3-148

2. Measure piston ring end gap with the ring at the lower part of the cylinder bore Where the wear is least.

Use correct size rings to match the piston size.

3. Measure end gap. End Gap

Ring

B Engine

2B Engine

No.1 No.2 Oil Ring

0.30 - 0.50 mm (0.0118 - 0.0197 in.)

0.40 - 0.60 mm (0.0157 - 0.0236 in.)

Fig. 3-149

Fig. 3-150

4. Clean ring grooves with groove cleaning tool or broken ring.

Fig. 3-150

Fig. 3-151

5. Install piston ring with the piston ring expander.

1. Always install the rings with code marks facing up.

Fig. 3-151

.Coil Joint

Ring Ends

.Coil Joint

Ring Ends

2. To assemble the oil ring and expander coil, insure that expander coil joint is at the opposite side of the ring ends.

Fig. 3-152

Fig. 3-152

6. With a thickness clearance between groove when ring surface.

gauge, measure the No.1 ring and ring is flush with piston

No.1 ring to groove clearance 0.03 - 0.07 mm (0.0012-0.0028 in.)

Fig. 3-153

Fig. 3-153

Fig. 3-154

7. Measure No.2 and oil ring groove clearance. If it exceeds specification, replace ring and/or piston.

Ring to groove clearance No.2 0.04 - 0.08 mm

Fig. 3-154

Fig. 3-155

Crankshaft & Bearing

1. Check crankshaft for run out and if it exceeds limit, replace.

Fig. 3-155

2. Measure crankshaft main journal.

If wear is excessive, crankshaft must be reground or replaced.

Main journal diameter (STD)

Fig. 3-156

Fig. 3-156

3. Measure main journal ojl clearance. (1) Clean journal, cap and bearing.

Fig. 3-157

Fig. 3-157

(2) Lay a strip of plastigage across journal.

Fig. 3-158

Fig. 3-158

Do not turn crankshaft.

Fig. 3-159

Fig. 3-159

Fig. 3-160

(3) Tighten cap bolts to specified torque.

Torque

Do not turn crankshaft.

(4) Measure plastigage at its widest point. If clearance is not within specification, replace bearings.

Oil clearance

(0.0012-0.0028 in.) U/S bearing type 0.25, 0.50, 1.00

Camshaft Bearing

1. Remove camshaft rear expansion plug.

Fig. 3-161

Fig. 3-161

09223 56010

2. Remove camshaft bearings with SST [09210-56010].

Fig. 3-162

Fig. 3-162

09223 56010
3. Align the bearing oil holes.

Fig. 3-163

Fig. 3-163

^^ 4. Install new bearings with SST[09210 __-56010],

5. Check bearing oil clearance.

Oil clearance

Fig. 3165

Liquid serler

Fig. 3165

Liquid serler

Fig. 3-166

Fig. 3-166

Fig. 3-167

6. Install new expansion plug with liquid sealer.

Crankshaft Rear Oil Seal

1. Remove oil seal.

2. Install new oil seal with SST[09223 -56010],

ASSEMBLY

Assemble in numerical order. Fig. 3-168_

Thoroughly clean all parts to be assembled.

Apply clean engine oil to all sliding and rotating surfaces of the parts before assembly.

Land Cruiser Cooler Clean

1.

Crankshaft

8.

Oil Strainer & Pipe

2.

Piston & Connecting Rod

9.

Injection Pump

3.

Oil Filter

10.

Rear Oil Seal

4.

Oil Cooler

11.

Rear End Plate

5.

Alternator

12.

Flywheel

6.

Water Pump

13.

Input Shaft Bearing

7.

Timing Gear Case

Fig. 3-170

Face arrow mark toward the front.

Fig. 3-171

Tighten bearing cap bolts little by little in two or tree steps in the specified numerial sequence.

Fig. 3-171

Fig. 3-172

Tighten bearing caps to specified torque.

Fig. 3-172

Check for tightness of crankshaft rotation after each tightening of bearing.

Fig. 3-173

Fig. 3-173

Measure crankshaft thrust clearance.

Thrust clearance

Fig. 3-174

Fig. 3-174

Fig. 3-175

A Cover rod bolts with a hose to protect crankpins from damage.

Fig. 3-175

Sheet Metal Coil Packaging Equipment

Fig. 3-176

Position ring gap in the direction shown.

Fig. 3-176

The oil ring ends should be at the opposite side of the expander coil joint.

Fig. 3-177

Front Mark-

Front Mark

Cylinder No.

Cylinder No.

Fig. 3-178

Fig. 3-179

Assemble correctly numbered piston/rod assembly with the notch on piston and the "©" mark on connecting rod facing the front.

Fig. 3-178

Insert piston into cylinder while compressing rings with a piston ring compressor.

Use care not to break piston ring.

Fig. 3-179

Insert piston into cylinder while compressing rings with a piston ring compressor.

Use care not to break piston ring.

Fig. 3-180

Fig. 3-180

Check connecting rod thrust clearance.

Thrust clearance

Tighten connecting rod cap to specified torque.

Check for tightness of crankshaft rotation after each tightening of bearing.

Check connecting rod thrust clearance.

Thrust clearance

Fig. 3-181

Fig. 3-181

A Set the injection period line back to the former position.

Fig. 3-183

Fig. 3-184

Tighten bolts to specified torque

Apply a light coating of engine oil on the bolt threads and under head before installing.

Check flywheel for run out.

Run out limit

Fig. 3-184

Fig. 3-185

Fig. 3-185

Drive in input shaft bearing with SST[09304 -30012].
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