Toyota Land Cruiser 100/Amazon, Lexus LX 470

since 1997 release

Repair and operation of the car



Toyota Land Cruiser, Amazon, Lexus LX470
+ Identification numbers of the car
+ Governing bodies and methods of safe operation of the car
+ Settings and routine maintenance of the car
- Engine
   + Typical procedures of service of engines
   + Procedures of service of the petrol engine
   - Procedures of service of the diesel engine
      Removal, installation, dismantling and assembly of a head of cylinders
      Removal and installation of the inlet pipeline and final collector
      Removal, check of a state and installation of a belt of the GRM drive
      Removal and installation of cogwheels of the GRM drive
      Replacement of a forward epiploon of a bent shaft and epiploons of the camshaft and TNVD
      Replacement of a back epiploon of a bent shaft
      Removal and installation of camshafts and pushers of valves
      Removal and installation of the pallet of a case of the engine
      Removal, check of a state and installation of the oil pump
      Removal and installation of the oil cooler
      Removal and installation of a driving disk
+ Cooling systems of the engine, heating of salon and air conditioning
+ A power supply system and production of the fulfilled gases
+ Engine electric equipment
+ Control systems of the engine and decrease in toxicity of the fulfilled gases
+ Gear shifting box
+ Transmission line
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment





Removal, installation, dismantling and assembly of a head of cylinders

Removal

Components of installation of a head of cylinders of models with the EGR system

1 — Perepuskny a water hose
2 — the Branch pipe
3 — Laying
4 — the Clip
5 — the Vacuum hose
6 — a turbocompressor Arm
7 — the Turbocompressor and a final collector
8 — the Termozashchitny screen
9 — an EGR system valve Arm
10 — Assembly of an inlet branch pipe
11 — Laying
12 — the Termozashchitny screen of an inlet branch pipe
13 — Laying

14 — the Clip
15 — the Fuel tube of high pressure
16 — the Tube of return of fuel from a nozzle No. 3
17 — the Vacuum hose
18 — the Termozashchitny screen of the inlet pipeline
19 — the Vacuum hose
20 — the Clip
21 — Laying
22 — the Socket of the sensor of position of the accelerator pedal
23 — the Drive of a butterfly valve
24 — the Sealing washer
25 — the Inlet pipeline
26 — Laying

Components of installation of a head of cylinders of models without the EGR system

1 — Perepuskny a water hose
2 — the Branch pipe
3 — Laying
4 — the Clip
5 — the Vacuum hose
6 — a turbocompressor Arm
7 — the Termozashchitny screen
8 — Laying
9 — the Vacuum hose
10 — Assembly of a turbocompressor and final collector
11 — the Inlet branch pipe
12 — Laying
13 — the Heater on an admission
14 — the Termozashchitny screen of an inlet branch pipe

15 — Laying
16 — the Vacuum hose
17 — the Clip
18 — the Fuel tube of high pressure
19 — the Clip
20 — the Tube of return of fuel from a nozzle No. 3
21 — the Termozashchitny screen of the inlet pipeline
22 — the Clip
23 — Laying
24 — the Inlet pipeline
25 — the Sealing washer
26 — the Drive of a butterfly valve
27 — the Socket of the sensor of position of the accelerator pedal (model with AT)

Components of installation of the camshaft

1 — the Sealing washer
2 — the Cover of a gear belt
3 — the Coupler
4 — Natyazhitel of a gear belt
5 — the Tension roller
6 — the Washer
7 — a camshaft Pulley No. 1
8 — a camshaft Epiploon
9 — the camshaft epiploon Case
10 — camshaft bearing Inserts
11 — a pulley Spline
12 — a camshaft bearing Cover
13 — Laying
14 — the Sealing ring
15 — the Cover of a head of cylinders
16 — the Tube of return of fuel from a nozzle No. 1

17,18 — Laying
19 — the Nozzle
20 — Consolidation of the holder of a nozzle
21 — the Camshaft
22 — the Segment stopper
23 — the Persistent half ring
24 — the Sealing ring
25 — a nozzle Saddle
26 — the Back eye of the engine
27 — the Head of cylinders
28 — Perepuskny a water hose (from TNVD)
29 — Laying of a head of cylinders
30 — the Gear belt
31 — Laying
32 — the Insulator


 PERFORMANCE ORDER

1. Components of installation of a head of cylinders are given on illustrations above.
2. Merge cooling liquid, remove air ducts and fuel tubes of high pressure.
3. On models with the EGR system:
   a. Disconnect three vacuum hoses from a vacuum tube on the inlet pipeline;
b. Disconnect a vacuum hose from three clips on a cover of a gear belt, and also a returnable fuel hose (address an accompanying illustration);
   c. Turn out two bolts and remove the EGR system valve;


   d. Give two nuts of fastening of the adapter of the EGR valve to a final collector;

   e. Give two bolts and two nuts of fastening of a branch pipe of the inlet pipeline (address an accompanying illustration);
   f. Disconnect an inlet branch pipe from an air hose and remove assembly of a branch pipe with two laying and the screen.
4. On models without the EGR system:
   a. Remove an inlet branch pipe and a heater of air;
   b. Disconnect a vacuum hose from a vacuum tube on the inlet pipeline;
   c. Turn out a bolt and disconnect the weight plug from a head of cylinders;
   d. Give two nuts of fastening of the adapter of the EGR valve to a final collector;
   e. Give two bolts and two nuts of fastening of a branch pipe of the inlet pipeline;
  f. Disconnect an inlet branch pipe from an air hose and remove assembly of a branch pipe with two laying and the screen.
5. Remove fuel tubes of high pressure.
6. On models with the EGR system disconnect three vacuum hoses from TNVD (address an accompanying illustration).
7. On models without the EGR system:


   a. Disconnect two vacuum hoses from TNVD;

   b. Disconnect a vacuum hose from two clips on a cover of a gear belt (address an accompanying illustration);
   c. Give 8 nuts, remove 8 washers, the inlet pipeline and two laying (address an accompanying illustration).
8. Remove a branch pipe of removal of cooling liquid (address an accompanying illustration).
9. Remove nozzles.
10. Give fixture and remove the thermofilter (address an accompanying illustration).
11. Remove a final collector with a turbocompressor (address an accompanying illustration).
12a. Separate parts of a final collector (address an accompanying illustration).
12b. Remove spring rings (address an accompanying illustration).
13. Uncover a head of cylinders.
14. Turn out four bolts of fastening of a back cover of a belt to a head of cylinders and uncover (address an accompanying illustration).
15. Remove the camshaft (cm. an illustration at the beginning of the Section). For this purpose:
 a. Turn out 7 bolts "And" (address an accompanying illustration);
   b. Evenly weaken and remove 14 remained bolts in several approaches and in the established sequence;
   c. Remove 7 covers of bearings, 12 yokes, 6 clamping holders of nozzles, assembly of an axis of yokes, and 7 top inserts of bearings.

You hold the removed details complete with an axis of yokes, and inserts – inserted into a bearing cover;

   d. Remove the camshaft, its persistent plate and 7 lower inserts of bearings.

Arrange inserts of bearings and a cover as installation.

16. In stages and in the established sequence (address an accompanying illustration) turn out fixing bolts, remove a head of cylinders and lay it on wooden whetstones.
17. If the head is not removed, accurately hook it the screw-driver in the place specified on an accompanying illustration.

Dismantling

Components of assembly of a head of cylinders are presented on an accompanying illustration.

Components of assembly of a head of cylinders

1 — the Head of cylinders
2 — the Valve
3 — the Directing valve plug
4 — the Lever of valves
5 — Crackers
6 — the Top plate of a spring
7 — the Valvate spring
8 — the Lower plate of a spring
9 — the Oil scraper cap
10 — the ECT Sensor
11 — the Yoke

12 — a nozzle Clip
13 — a camshaft bearing Cover
14 — the Bolt of fastening of a cover of the bearing
15 — the Axis of yokes
16 — the Forward part of a final collector
17 — the Back part of a final collector
18 — the Ring
19 — Laying
20 — the Sealing ring
21 — the Ring
22 — the Turbocompressor


 PERFORMANCE ORDER

1. Take out pushers of valves and lay pushers as installation.
2. Remove forward and back lifting eyes of the engine.
3. Remove the ECT sensor.
4. Remove levers of the drive of valves and arrange them as installation (address an accompanying illustration).
5. Remove valves. For this purpose:
   and. Squeeze a stripper a spring and remove 2 crackers;
   b. Remove a plate springs, a spring and its saddle; arrange details of each set as installation;
   c. Remove oil scraper caps.

Assembly

 PERFORMANCE ORDER

1. Carefully clear all details and oil their rubbing surfaces fresh engine.
2. Establish lifting eyes of the engine (address an accompanying illustration).
3. Establish a segment insert, previously having applied on it sealant (address an accompanying illustration).
4. Install the valve as it should be, the return to a removal order.
5. Tap the plastic hammer a valve core end face.
6. Establish pushers of valves and adjusting washers. Make sure that pushers freely rotate by hand.
7. Install levers of valves and make sure of smoothness of their course (address an accompanying illustration).
8. Install the ECT sensor.

Installation

 PERFORMANCE ORDER

1. The interfaced surfaces of heads of cylinders and their covers have to be absolutely pure and dry. By means of a scraper remove all traces of old sealant and fragments of the destroyed laying, then wipe surfaces with the rags moistened in acetone. Presence on the interfaced surfaces of traces of oil can lead to development of leaks.
2a. Measure the size of the maximum ledge of each piston in two points, calculate arithmetic-mean value of a ledge and compare it to requirements of Specifications (address an accompanying illustration).
2b. If necessary replace the piston assembled with a rod (address an accompanying illustration).
3. Define the greatest value of a ledge of the piston and in compliance with it pick up laying of a head of cylinders, being guided by the table given below.

As spare parts only laying No. No. 1, 3 and 5 respectively 0.85 - 0.95, 0.95 - 1.05 and 1.05 - 1.15 mm thick is delivered.

Number of laying is determined by number of cuts on it (address an accompanying illustration).

Ledge поршя, mm

Number of laying

   No more than 0,225

1

   0,226 – 0,325

3

   Not less than 0,326

5

4. Install the piston of the first cylinder in the provision of VMT.
5. Lay laying of a head of cylinders on the block of cylinders, grease a carving and the lower part of heads of bolts of fastening of a head of cylinders with motive oil and tighten bolts by hand. Then tighten bolts in the established sequence with effort of 69 Nanometers then hold on them twice on the 90th hail., observing the sequence (address an accompanying illustration).

Bolts of "B" (No. No. 21, 13, 5, 4, 12, 20) have length of 133.5 mm, and bolts "And" (others) – 121.5 mm.

6a. Establish 7 lower inserts (address an accompanying illustration).

Install an insert by width in the bearing No. 1, and inserts 20 mm wide – in other bearings.

6b. Establish a persistent ring of the camshaft (address an accompanying illustration).
7. Lay the camshaft in a head of cylinders a shponochny flute up (address an accompanying illustration).
8. Establish the top inserts in covers of bearings.
9. Establish covers of bearings, yokes, clips of nozzles and an axis of yokes assembled.
10. Tighten 14 bolts of fastening of covers of bearings in a certain sequence and 7 bolts "And" (address an accompanying illustration).
11. Establish nozzles.
12. Check and if necessary adjust valvate gaps.
13. Remove old sealant from the interfaced surface of a back cover of a belt, apply new sealant and establish a cover (address an accompanying illustration).
14. Establish pulleys and a gear belt.
15a. Fill segment rubber traffic jams in the landing grooves, having made sure of their suitability (address an accompanying illustration).
15b. Grease them with sealant (address an accompanying illustration).
16. Lay laying of a cover of a head of cylinders, establish a cover with 12 new sealing washers and tighten bolts of its fastening with effort of 6.5 Nanometers.
17. Establish a back arm of the engine.
18. Collect a final collector in the sequence, the return procedure of its dismantling.
19. Establish laying, a turbocompressor and assembly of a final collector.
20. Further installation is made as it should be, the return to an order of dismantle of components. Tighten fixture with the required effort.