Tentatively Adjust Valve Clearance

Adjust Valves The Cars Toyota

Pull out the combustion chamber with SST [09208-48010].

Be careful not to damage the hole.

Keep combustion chambers in correct order.

Toyota Engine Valves Damaged
Fig. 3-17
Land Cruiser Engine

INSPECTION & REPAIR

Cylinder Head

1. Clean and Check the cylinder head for cracks or scoring.

2. Check cylinder head underside surface for warpage with a precision straight edge and thickness gauge.

Underside surface warpage limit

3.. Check surfaces along the indicated line for warpage.

4. Inspect the manifold mounting surface for warpage.

Manifold mounting surface warpage limit 0.2 mm (0.008 in.)

5. If the warpage exceeds the limit, either machine flat or replace cylinder head.

Valve & Guide

1. Clean and check the valves for wear, scores and bend.

Valve Stem Measurement Toyota 1dz Engine Valve ClearanceValve Stem Measurement

2. Measure valve stem clearance.

(1) Measure inside diameter of valve guide.

Guide inside diameter (for both IN. and EX.)

(2) Measure valve stem diameter.

Stem diameter

(0.3524 - 0.3531 in.) Oil clearance limit IN. 0.10 mm

3. If the oil clearance exceeds the limit, replace guides and valves. (1) Drive out valve guide from top end toward the combustion chamber with SST [09201-60011].

(2) Drive in new valve guide until its end projects from the top of the cylinder head to the specified length below.

Projected length

Fig. 3-23

I

j

o

I ¿==

■m(¡ll^fe^lfc j^t

Fig. 3-24

Margin Thickness J I

t

(3) Ream valve guide to obtain specified clearance with a sharp reamer.

4. Reface valve seating face with a valve refacer.

Valve face angle 45°

5. Check valve head margin thickness.

Margin thickness limit

Engine Valve Margin

6. Resurface valve stem tip with a valve grinder.

Stem tip resurfacing limit

Overall length

IN. 127.95 mm (5.0374 in.) EX. 127.75 mm (5.0295 in.)

Fig. 3-27
Fig 1502 Check Valve Length

Valve Seat

1. Check the position of valve contact with seat. Coat valve face with Prussian blue or red lead. Locate contact point on valve by rotating valve against seat.

Contact position Middle of valve face

2. Resurface valve seat with 45 cutter.

Valve Seat Contact

3. Correct seat position.

(1) If seat position is too high, use 45° and 75° cutters in the order indicated.

1.2-1.6 mm

Valve Springs

1. Check squareness of valve spring with a square.

Que Rbol Levas Para Dibujar Valve Spring Tension Tester

Valve Springs

1. Check squareness of valve spring with a square.

2. Measure free height of valve springs.

3. Using a spring tester, measure spring tension at the specified installed height.

Installed height

Installed tension

Limit 23.1 kg (50.9 lb) STD IN. 25.5 kg (56.2 lb) EX. 26.0 kg (57.3 lb)

Combustion Chamber

Clean and check combustion chamber for cracks and extreme damages.

Land Cruiser Valves Adjustment

Rocker Arms & Shaft

1. Check the valve contacting surface of the rocker arm for wear. Correct or replace if necessary.

2. Check rocker arm-to-shaft clearance by moving each rocker arm as shown. Little or no movement should be possible. If movement is felt, disassemble and inspect.

3. Disassemble valve rocker shaft assembly in numerical order.

Keep rocker arms in correct order.

Fig. 3-37
Fig. 3-38
Land Cruiser Valves Adjustment

4. Correct the valve contacting surface of the rocker arm with a valve refacer and oil stone, if only a light ridged wear.

5. Measure oil clearance between rocker arm to shaft.

Shaft diameter limit

18.44 mm (0.7260 in.) Rocker arm bore limit

Oil clearance

6. Assemble valve rocker shaft assembly in numerical order.

Align oil hole of the front rocker support with the shaft oil hole.

Manifold

Using a precision straight edge and thickness gauge, inspect surfaces in contact with the cylinder head for warpage, and correct or replace if warped over the specified limit.

ASSEMBLY

Assemble in numerical order.

Thoroughly clean all parts to be assembled.

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

Toyota Land Cruiser 2003 Machine Parts

3-47

3-47

1.

Combustion Chamber

10.

V Belt Adjusting Bar

2.

Valve & Compression Spring

11.

Water Outlet Housing

3.

Cylinder Head Assembly

12.

Intake Manifold

4.

Valve Push Rod

13.

Fuel Filter

5.

Valve Rocker Shaft Assembly

14.

Rear Engine Hanger

6.

Cylinder Head Cover

15.

Injection Nozzle Holder

7.

Exhaust Manifold

16.

Leakage Pipe

8.

Front Engine Hanger

17.

Injection Pipe

9.

Heater Hose Union

18.

Match the combustion chamber knock pin with the cylinder head notch, and drive in the combustion chamber.

Valve Spring Protrusion

Check combustion chamber protrusion.

Combustion chamber protrusion 0-0.10 mm (0 - 0.0039 in.)

Check combustion chamber protrusion.

Combustion chamber protrusion 0-0.10 mm (0 - 0.0039 in.)

-Install oil seal before assembling the valve spring.

A new oil seal should be used whenever valve is disassembled.

Compress the valve spring with SST[09202 -43011] and insert the spring retainer locks.

Toyota Sst 09202

After installing the springs, lightly tap the stem ends and allow the springs to settle down snugly.

Cylinder_

Head

Cylinder_

Head

.Cylinder Block

0Put cylinder head gasket on the cylinder block, aligning the bolt holes as shown.

Clean the cylinder block upper surface with a scraper before installing the head gasket.

Front

Front

Tighten cylinder head bolts little by little in two or three steps in the specified numerical sequence.

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

Tighten cylinder head bolts to specified torque.

Torque

Tighten valve rocker support bolts little by little in three or four steps in the specified numerical sequence.

Tighten valve rocker support bolts to specified torque.

Torque

Adjusting Clearance Valves Toyota
Tentatively, adjust valve clearance. 1. Set No. 1 cylinder to TDC/Compression.

2. Adjust valve clearances indicated by arrows.

Valve clearance

3. Rotate crankshaft one turn in normal direction.

4. Adjust remaining valves indicated by arrows.

Valve clearance

Valve Clearance Adjustment Toyota

Install exhaust manifold.

Torque

Heater Hose Lancruiser Picture

Apply liquid sealer on the threads of the heater hose union, and assemble so that the union faces upward.

Adjust the "V" belt tension.

Deflection at 10 kg (22 lb) force

B engine 10 - 13 mm (0.4 - 0.5 in.) 2B engine 8-11 mm (0.3 - 0.4 in.)

Apply liquid sealer on the threads of the heater hose union, and assemble so that the union faces upward.

Adjust the "V" belt tension.

Deflection at 10 kg (22 lb) force

B engine 10 - 13 mm (0.4 - 0.5 in.) 2B engine 8-11 mm (0.3 - 0.4 in.)

Toyota Engine

Install intake manifold.

Torque

How Rewind Engine With Magnet Wire

Connect and adjust the overinjection magnet connecting wire with the magnet core end surface positioned as shown.

Upward

Upward

Note the orientation of the nozzle seat gasket as shown.

Tighten nozzle holder with SST [09260-46011 ]

Torque

TIMING GEAR

DISASSEMBLY

Disassemble in numerical order.

Pulley Crankshaft Engine
F'9- 3-66 Fig. 3-71 Fig. 3-64

1.

Oil Pan

7.

Crankshaft Pulley

2.

Push Rod Cover

8.

Timing Gear Cover

3.

Valve Lifter

9.

Automatic Timer

4.

Cooling Fan

10.

Idle Gear & Shaft

5.

Fan Pulley

11.

Camshaft & Timing Gear

6.

V Belt

12.

Crankshaft Timing Gear

Timing Belt Engine Toyota Valve

^^ Keep valve lifters in correct order.

723456U

Toyota 09213 31021
Pull out the crankshaft pulley with SST[09213 -31021].
Sst Gear Case

Remove the automatic timer from the timing gear cover after heating the cover to about 60°C (140°F).

For disassembly and assembly of the automatic timer, refer to "FUEL SYSTEM" section.

Install the automatic timer to the injection pump spline shaft, and measure the timing gear backlashes. Back lash

Camshaft, Timer to idle gear

(0.0024 - 0.0035 in.) Crankshaft to idle gear

Measure idle gear thrust clearance.

Thrust clearance

Pull out camshaft using care not to damage the camshaft bearings.

Pull out crankshaft timing gear with SST[09213 -60015].

ENGINE SERVICE -TimingGear 3-25

n fi fi

INSPECTION & REPAIR Valve Lifter

Inspect lifters and lifter bores for wear or damage.

Oil clearance

Timing Gears

Inspect gears for cracks, wear and chipped teeth. If damaged, replace both timing gears.

Camshaft

1. Inspect camshaft for straightness, damage or wear.

2. Measure the run out.

3. Measure camshaft thrust clearance.

Thrust clearance

Cam Wear Crankshaft Journal
Fig. 3-78

Replace thrust plate if the thrust clearance exceeds the limit.

(1) Using a press and a spacer, press out the timing gear from the camshaft.

(2) Using a press, press in the timing gear.

(3) Tighten retaining bolt.

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

5. Measure cam height.

Cam Height (for both IN. and EX.) Limit 39.0 mm (1.535 in.) STD 39.47 - 39.56 mm (1.5539 — 1.5575 in.

6. Measure journal oil clearance.

(1) Measure camshaft journal diameter.

Journal diameter (STD) No.1 47.16-47.18 mm

(2) Measure bearing inner diameter, referring to "CYLINDER BLOCK" section.

Oil clearance

Cam Wear Crankshaft Journal

Idle Gear

Measure idle gear oil clearance.

Oil clearance Limit STD

0.3 mm (0.012 in.) 0.04 - 0.09 mm (0.0016 - 0.0035 in.)

Crankshaft Front Oil Seal

1. Check oil seal for wear or damage.

2. Replace oil seal with SST[09223-46010].

Crankshaft Front Oil Seal

1. Check oil seal for wear or damage.

2. Replace oil seal with SST[09223-46010].

ASSEMBLY

Assemble in numerical order.

Thoroughly clean all parts to be assembled.

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

Fig. 3-88

Fig. 3-97 Fig. 3-95, Fig. 3-93, Fig 3-85 Fig. 3-98,

1.

Crankshaft Timing Gear

7.

Cooling Fan & Fan Pulley

2.

Camshaft & Timing Gear

8.

V Belt

3.

Idle Gear & Shaft

9.

Valve Lifter

4.

Automatic Timer

10.

Push Rod Cover

5.

Timing Gear Cover

11.

Oil Pan

6.

Crankshaft Pulley

Drive in crankshaft timing gear with SST[09214 -60010].

Insert camshaft using care not to damage the camshaft bearings.
How Care For Torque Thrust
Tighten camshaft thrust plate.

Torque

Landcruiser Idle Pulley

A Set idle gear aligning marks "1" and "2" respectively against crankshaft gear mark "1" and camshaft gear mark "2".

Land Cruiser Mark Engine

Tighten the idle gear and shaft.

Apply a light coating of engine oil on the bolt threads and under head (thrust plate contacting surface) before installing the bolts.

Landcruiser Idle Pulley
Fig. 3-91

Align the mating marks on injection pump spline shaft and timer drive shaft when installing the automatic timer.

Coat the splines and bearing with MP grease.

Align the mating marks on injection pump spline shaft and timer drive shaft when installing the automatic timer.

Coat the splines and bearing with MP grease.

Fig. 3-92

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I W^L^

\ Align the idle gear mark "0" against the timer - * drive gear mark "0".

Heat the timing gear cover to about 60°C (140°F) before installing.
Land Cruiser Timing Gear

Tighten timing gear cover.

Torque

8 mm bolt

10 mm bolt

1.5 — 2.2 kg-m (11 -15 ft-lb) 3.0 - 4.5 kg-m (22 - 32 ft-lb)

Pulley Crankshaft Engine

0 Drive in the crankshaft pulley with SST[09214 -60010].

10 kg

10 kg

Deflection

Tighten retaining bolt.

Torque

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

Adjust "V" belt tension.

Deflection at 10 kg (22 lb) force

B engine 10 - 13 mm (0.4 - 0.5 in.) 2B engine 8 - 11 mm (0.3 - 0.4 in.)

3-32 ENGINE SERVICE - Timing Gear

A Apply liquid sealer to the cylinder block and gear cover as shown.

Install oil pan. Torque

Fig. 3-100

CYLINDER BLOCK

DISASSEMBLY

Disassemble in numerical order.

Fig. 3-100

2004 Toyota Highlander Flywheel

3-108

Fig. 3-106

3-108

1. Input Shaft Bearing

2. Flywheel

3. Rear End Plate

4. Rear Oil Seal

5. Injection Pump

6. Oil Strainer & Pipe

7. Timing Gear Case

Fig. 3-101

8. Water Pump

9. Alternator

10. Oil Cooler

11. Oil Filter

12. Piston & Connecting Rod

13. Crankshaft ig. 3-101

Remove input shaft bearing with SST[09303 -35010].

Remove input shaft bearing with SST[09303 -35010].

Fig. 3-102

Fig. 3-102

A Check the position of injection period line before removing injection pump.

Fig. 3-103

Measure connecting rod thrust clearance. If if exceeds the limit, replace connecting rod.

Thrust clearance

Land Cruiser Piston Valve

Fig. 3-105

A Keep connecting rods and bearings in correct order.

Fig. 3-105

Fig. 3-106
Toyota Land Cruiser Fj4 Engine

Measure crankshaft thrust clearance.

If it exceeds the limit, replace bearings as a set.

Thrust clearance

(0.0028 - 0.0071 in.) U/S bearing type 0.25, 0.50,1.00

Keep crankshaft bearings and caps in correct order.

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