Toyota 4Runner 2001-06

Engine

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NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Removal & Installation




NOTE
If your vehicle is equipped with air conditioning, refer to the information regarding the implications of servicing your A/C system yourself. Only an MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as -disconnect the exhaust system- or -remove the radiator.- In most instances, a detailed removal procedure can be found elsewhere in this manual.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible additions to any repair procedure.

Always tag any wire or hose and the components they came from before disconnecting them, so that you can be assured of proper reconnection during installation.

1gr-FE Engine
  1. Relieve the fuel pressure. For additional information, please refer the following topic(s): Fuel System, Relieving Fuel System Pressure.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the transmission assembly. For additional information, please refer the following topic(s): Automatic Transmission, Automatic Transmission Assembly.
  8.  
  9. Remove the battery.
  10.  
  11. Remove the hood.
  12.  
  13. Remove the engine appearance cover.
  14.  
  15. Remove the ventilation hose.
  16.  
  17. Remove the air intake assembly.

    Click image to see an enlarged view

    Fig. Remove the hose clamps and mounting bolts to remove the air intake assembly-4.0L (1GR-FE) Engine

  18.  
  19. Remove the upper radiator support seal by removing the 11 clips.
  20.  
  21. Remove the radiator.
  22.  
  23. Unfasten the hose clamp, and remove the oil cooler hoses from the fan shroud.
  24.  
  25. Remove the fan shroud.
  26.  
  27. Loosen the four fluid coupling bolts for the engine fan.
  28.  
  29. Remove the accessory drive belt.
  30.  
  31. Remove the fan with fluid coupling.
  32.  
  33. Remove the fan pulley.
  34.  
  35. Disconnect the power steering oil pressure switch, remove the mounting bolts for the power steering pump and hang the pump securely using mechanic-s wire or the equivalent.
  36.  
  37. Remove the alternator.
  38.  
  39. Separate the A/C compressor as follows:
    1. Remove the bolt and separate the suction hose.
    2.  
    3. Disconnect the A/C compressor electrical connector.
    4.  
    5. Remove the mounting bolts and separate the A/C compressor from the drive belt tensioner.
    6.  

  40.  
  41. Disconnect the fuel supply and return hoses.
  42.  
  43. Disconnect the heater hoses.
  44.  
  45. Remove the upper intake manifold (air surge tank) as follows:
    1. Disconnect the 2 water by-pass hoses.
    2.  
    3. Disconnect the fuel vapor feed hose.
    4.  
    5. Disconnect the ventilation hose.
    6.  
    7. Disconnect the 2 VSV connectors.
    8.  
    9. Disconnect the throttle body w/ motor connector.
    10.  
    11. Separate the three wire harness clamps and hose clamp.
    12.  
    13. Remove the two bolts and throttle body bracket.
    14.  
    15. Remove the bolt and oil baffle plate.
    16.  
    17. Remove the four bolts and two surge tank stays.
    18.  
    19. Remove upper intake manifold and gasket.

      Click image to see an enlarged view

      Fig. Location of the upper intake manifold (air surge tank) mounting bolts-4.0L (1GR-FE) Engine

    20.  

  46.  
  47. Separate the engine wiring harness as follows:
    1. Remove the right side front door scuff plate.
    2.  
    3. Remove the right side cowl side trim board.
    4.  
    5. Remove the glove compartment door.
    6.  
    7. Disconnect each connector for the Electronic Control Module (ECM), four wheel drive control ECU (if equipped) and instrument panel wire before pull out the engine wire into the engine room.
    8.  
    9. Disconnect the front differential connector.
    10.  
    11. Disconnect the ground cable from the cylinder block.
    12.  

  48.  
  49. Install two engine hangers to the block.

    Click image to see an enlarged view

    Fig. Attach the engine chain hoist to the engine hangers-4.0L (1GR-FE) Engine

  50.  
  51. Attach the engine chain hoist and hang the engine with the chain block.
  52.  
  53. Remove the engine mounting bolts and nuts and separate the engine mounting brackets from the frame brackets.
  54.  
  55. Carefully lift the engine out of the vehicle.
    NOTE
    Make sure the engine is clear of all wiring and hoses.

  56.  

To install:

  1. Lower the engine into the engine compartment.
  2.  
  3. Attach the engine mounting brackets to the frame brackets.
  4.  
  5. Install the engine mounting brackets bolts through the frame brackets and tighten the nuts to 28 ft. lbs. (38 Nm).
  6.  
  7. Remove the engine hangers from the block.
  8.  
  9. Install the engine wiring harness as follows:
    1. Install the ground cable to the cylinder block and tighten to 9 ft. lbs. (13 Nm).
    2.  
    3. Connect the front differential connector.
    4.  
    5. Insert the engine wire to the vehicle room, and install the grommet.
    6.  
    7. Connect each connector for the ECM, four wheel drive control ECU (if equipped with 4WD) and instrument panel wire.
    8.  
    9. Install the glove compartment door.
    10.  
    11. Install the right side cowl side trim board.
    12.  
    13. Install the right side front door scuff plate.
    14.  

  10.  
  11. Install the upper intake manifold (air surge tank) as follows:
    1. Install a new gasket to the manifold.
    2.  
    3. Install the manifold and tighten the mounting bolts and nuts to 21 ft. lbs. (28 Nm).
    4.  
    5. Install the manifold supports and tighten the bolts to 15 ft. lbs. (21 Nm).
    6.  
    7. Install the oil baffle plate and tighten the bolt to 80 inch lbs. (9 Nm).
    8.  
    9. Install the throttle body bracket and tighten the bolts to 15 ft. lbs. (21 Nm).
    10.  
    11. Install the 3 wire harness clamps and hose clamp.
    12.  
    13. Connect the throttle body w/ motor connector.
    14.  
    15. Connect the two VSV connectors.
    16.  
    17. Connect the ventilation hose.
    18.  
    19. Connect the fuel vapor feed hose.
    20.  
    21. Connect the 2 water by-pass hoses.
    22.  

  12.  
  13. Connect the heater hoses.
  14.  
  15. Connect the fuel supply and return hoses.
  16.  
  17. Install the A/C compressor and tighten the mounting bolts to 18 ft. lbs. (25 Nm) and connect the electrical connector.
  18.  
  19. Install the alternator.
  20.  
  21. Install the power steering pump.
  22.  
  23. Install the fan pulley.
  24.  
  25. Install the fan with the fluid coupling, but do not tighten the bolts.
  26.  
  27. Install the accessory drive belt.
  28.  
  29. Fully tighten the fan mounting bolts to 15 ft. lbs. (21 Nm).
  30.  
  31. Install the fan shroud and connect the oil cooler hoses.
  32.  
  33. Install the radiator.
  34.  
  35. Install the upper radiator support seal.
  36.  
  37. Install the air intake assembly.
  38.  
  39. Connect the ventilation hose.
  40.  
  41. Install the hood.
  42.  
  43. Install the battery.
  44.  
  45. Install the transmission.
  46.  
  47. Refill the engine cooling system to the correct level.
  48.  
  49. Refill the engine oil to the correct level.
  50.  
  51. Start the engine and check for leaks.
  52.  
  53. Install the engine appearance cover.
  54.  
  55. Recheck the engine oil and coolant levels.
  56.  

2RZ-FE And 3RZ-FE Engines
2wd
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercover
     

  6.  
  7. Drain the engine coolant.
  8.  
  9. Drain the engine oil and the transmission oil.
  10.  
  11. Remove or disconnect the following:

    Hood
     
    Radiator
     
    Drive belt for the alternator and the water pump pulley
     
    Accelerator cable from the throttle body
     
    Actuator cover and the cruise control cable from the actuator, if equipped with cruise control
     

  12.  
  13. Remove or disconnect the air cleaner assembly, as follows:

    Intake Air Temperature (IAT) sensor and the Mass Air Flow (MAF) meter connectors
     
    3 wire clamps and the engine wiring harness
     
    Air cleaner hose clamp, loosen it
     
    MAF meter, resonator and the air cleaner assembly
     

  14.  
  15. Install or connect the following:

    Air conditioning compressor, if equipped with air conditioning
     
    Alternator connector
     
    Heater hoses
     

  16.  
  17. Disconnect the following hoses:

    Brake booster vacuum hose
     
    Evaporative Emissions (EVAP) hose
     
    2 air hoses for the power steering idle-up
     
    Fuel return hose
     
    Fuel inlet hose
     

  18.  
  19. Remove the power steering pump from the engine.
  20.  
  21. Disconnect the engine wiring harness, as follows:

    Glove box door
     
    Finish No. 2 panel, lower it
     
    4 ECM connectors
     
    2 cassette connectors and the 2 wire clamps from the lower finish panel
     
    Igniter
     
    Ground strap from the cowl top panel
     
    2 engine wiring harness clamps.
     
    2 engine wiring harness retainer-to-cowl panel nuts and the engine wiring harness
     

  22.  
  23. Install or connect the following:

    Heated Oxygen (HO 2 S) sensor
     
    Front exhaust pipe
     

  24.  
  25. Remove the shift lever assembly for a manual transmission, as follows:
  26.  
  27. Remove or disconnect the following:

    Shift lever knob
     
    4 screws and the shift lever boot
     
    6 bolts, the shift lever assembly and baffle
     

  28.  
  29. Remove or disconnect the following:

    Driveshaft
     
    Speedometer cable
     
    Clutch release cylinder, if equipped with a manual transmission
     
    Cross-shaft, if equipped with an automatic transmission
     
    Starter wire
     

  30.  
  31. Place a jack under the transmission and remove the engine rear mounting bracket.
  32.  
  33. Install a rear engine hanger in the correct direction.
  34.  
  35. Attach the engine hoist chain to the 2 engine hangers.

    Click image to see an enlarged view

    Fig. Be sure to support the engine before removing the right and left engine mounts-4Runner 2-wheel drive with 2.7L engine

  36.  
  37. Remove or disconnect the following:

    Engine front mounting insulators-to-frame bolts/nuts
     
    Engine/transmission assembly
     
    Engine
     

  38.  

To install:

  1. Install or connect the following:
    NOTE
    Keep the engine level and align the right and left mounting and body mountings.



    Transmission to the engine
     
    Chain hoist to the engine hangers
     
    Engine/transmission assembly into the engine compartment
     



    Right and left mounting insulators to the body mountings and temporarily install the bolts/nuts
     

  2.  
  3. Raise the transmission onto the frame
  4.  
  5. Remove the chain hoist.
  6.  
  7. Remove the bolt and the rear engine hanger.

    Click image to see an enlarged view

    Fig. Bolt tightening pattern for the engine rear mounting bracket-4Runner 2-wheel drive with 2.7L engine

  8.  
  9. Install the engine rear mounting bracket and tighten to:

    Bolt A: 13 ft. lbs. (19 Nm)
     
    Bolt B: 19 ft. lbs. (26 Nm)
     

  10.  
  11. Install or connect the following:

    Tighten the left and right engine mounting insulator bolts and nuts to 28 ft. lbs. (38 Nm).
     
    Starter wire
     
    Clutch release cylinder, for a manual transmission. Tighten the clutch line bolt to 29 ft. lbs. (39 Nm) and the clutch release cylinder bolts to 108 inch lbs. (13 Nm).
     
    Cross-shaft, for an automatic transmission. Tighten the bolt to 29 ft. lbs. (39 Nm) and the nut to 13 ft. lbs. (18 Nm).
     
    Speedometer cable
     
    Driveshaft
     
    Shift lever assembly, for a manual transmission
     

  12.  
  13. Install the front exhaust pipe, as follows:

    New gaskets and the front exhaust pipe assembly. Tighten the 3 new nuts to 46 ft. lbs. (62 Nm).
     
    Support bracket. Tighten the bolts to 29 ft. lbs. (39 Nm).
     
    3-way catalytic converter with a new gasket to the tail pipe. Tighten to 29 ft. lbs. (39 Nm).
     
    HO 2 S sensor
     
    Engine wiring harness
     
    Power steering pump
     
    All hoses previously removed
     
    Alternator wire
     
    Air conditioning compressor, if removed. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    Intake air connector. Tighten the bolts to 13 ft. lbs. (18 Nm).
     
    Air cleaner assembly
     
    Throttle cable to the throttle body
     
    Cruise control cable to the actuator and the actuator cover, if disconnected
     
    Drive belt for the alternator and water pump pulley
     
    Radiator
     
    Negative battery cable
     

  14.  
  15. Refill the engine oil, coolant and transmission oil.
  16.  
  17. Start the engine and check for leaks.
  18.  
  19. Check the ignition timing.
  20.  
  21. Install or connect the following:

    Engine undercover
     
    Hood
     

  22.  
  23. Road test the vehicle and recheck the fluid levels.
  24.  

4wd
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Transmission
     
    Engine undercover
     

  6.  
  7. Drain the engine coolant.
  8.  
  9. Drain the engine oil.
  10.  
  11. Remove or disconnect the following:

    Hood
     
    Radiator
     
    Drive belt for the alternator and the water pump pulley
     
    Accelerator cable from the throttle body
     
    Actuator cover and the cruise control cable from the actuator, if equipped with cruise control
     
    Air cleaner assembly
     
    Intake air connector
     
    Air conditioning compressor, if equipped with air conditioning
     
    Alternator connector
     
    Heater hoses
     

  12.  
  13. Disconnect the following hoses:

    Brake booster vacuum hose
     
    Evaporative Emissions (EVAP) hose
     
    2 air hoses for the power steering idle-up
     
    With Automatic Disconnecting Differential (ADD) Vacuum hose
     
    Fuel return hose
     
    Fuel inlet hose
     

  14.  
  15. Remove the power steering pump from the engine.
  16.  
  17. Disconnect the engine wiring harness, as follows:
  18.  
  19. Remove or disconnect the following:

    Glove box door
     
    Lower the finish No. 2 panel
     
    Engine Control Module (ECM) connectors
     
    2 cassette connectors and the 2 wire clamps from the lower finish panel
     
    Vacuum Switching Valve (VSV) connector for the EVAP and clamp
     
    Igniter
     
    Ground strap from the cowl top panel
     
    2 engine wiring harness clamps
     
    2 engine wiring harness retainer-to-cowl panel nuts and the engine wiring harness
     

  20.  
  21. Install a rear engine hanger in the correct direction.
  22.  
  23. Attach the engine hoist chain to the 2 engine hangers.
  24.  
  25. Remove or disconnect the following:

    Engine front mounting insulators-to-frame bolts and nuts
     
    Engine, making sure that the engine is clear of all wiring and hoses
     
    Engine
     

  26.  

To install:

  1. Attach a chain hoist to the engine hangers.
  2.  
  3. Install or connect the following:
    NOTE
    Keep the engine level and align the right and left mounting and body mountings



    Engine into the engine compartment
     



    Right and left mounting insulators to the body mountings and temporarily install the bolts and nuts
     

  4.  
  5. Remove the chain hoist.
  6.  
  7. Remove the bolt and the rear engine hanger.
  8.  
  9. Install or connect the following:

    Tighten the right and left engine mounting insulator bolts/nuts to 28 ft. lbs. (38 Nm).
     
    Engine wiring harness
     
    Alternator wire
     
    Power steering pump
     
    All hoses
     
    Air conditioning compressor. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    Intake air connector. Tighten the bolts to 13 ft. lbs. (18 Nm).
     
    Air cleaner assembly
     
    Throttle cable to the throttle body
     
    Cruise control cable to the actuator and the actuator cover, if removed
     
    Radiator
     
    Hood
     

  10.  
  11. Fill with engine with oil and the coolant system with coolant.
  12.  
  13. Install or connect the following:

    Transmission
     
    Engine undercover
     
    Negative battery cable
     

  14.  
  15. Fill the transmission fluid.
  16.  
  17. Check the ignition timing.
  18.  
  19. Test drive the vehicle and check for leaks.
  20.  
  21. Recheck fluid levels.
  22.  

2UZ-FE Engine
  1. Relieve the fuel pressure. For additional information, please refer the following topic(s): Fuel System, Relieving Fuel System Pressure.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the transmission assembly. For additional information, please refer the following topic(s): Automatic Transmission, Automatic Transmission Assembly.
  8.  
  9. Remove the hood.
  10.  
  11. Remove the throttle body cover.
  12.  
  13. Disconnect the vacuum and ventilation hoses from the air intake assembly.
  14.  
  15. Remove the air intake assembly.
  16.  
  17. Remove the engine under covers.
  18.  
  19. Remove the radiator.
  20.  
  21. Disconnect the oil cooler hoses from the fan shroud, and remove the fan shroud with the fan.
  22.  
  23. Disconnect the fuel supply, return and vapor hoses.
  24.  
  25. Remove the accessory drive belt.
  26.  
  27. Remove the power steering pump mounting bolts and nuts, and hang the pump securely.
    NOTE
    Do not disconnect the power steering hoses.

  28.  
  29. Remove the alternator.
  30.  
  31. Remove the A/C compressor mounting bolts, and hang the compressor securely.
    NOTE
    Do not disconnect the A/C compressor lines.

  32.  
  33. Remove the fan with the fluid coupling and fan pulley.
  34.  
  35. Remove the transmission dipstick tube.
  36.  
  37. Remove the engine oil dipstick tube.
  38.  
  39. Remove the left and right exhaust manifolds as follows:
    1. Remove the exhaust manifold heat shields.
    2.  

  40.  
  41. Disconnect the oxygen sensor connectors.
  42.  
  43. Remove the mounting nuts and remove the exhaust manifolds.
  44.  
  45. Disconnect the heater hoses.
  46.  
  47. Separate the engine wiring harness as follows:
    1. Remove the right side front door scuff plate.
    2.  
    3. Remove the right side cowl side trim board.
    4.  
    5. Remove the glove compartment door.
    6.  
    7. Disconnect each connector for the Electronic Control Module (ECM), four wheel drive control ECU (if equipped with 4WD) and instrument panel wire before pulling out the engine wire into the engine room.
    8.  
    9. Disconnect the three ground cables from the body.
    10.  
    11. Disconnect the engine wire No.2 from the battery terminals and engine room relay block.

      Click image to see an enlarged view

      Fig. Disconnect the engine wiring harness from the battery, relay block and body ground cables-4.7L (2UZ-FE) Engine

    12.  

  48.  
  49. Install two engine hangers to the block.
  50.  
  51. Attach the engine chain hoist and hang the engine with the chain block.
  52.  
  53. Remove the engine mounting bolts and nuts and separate the engine mounting brackets from the frame brackets.

    Click image to see an enlarged view

    Fig. Remove the engine mounting bolts after securing the engine with a chain hoist to remove-4.7L (2UZ-FE) Engine

  54.  
  55. Carefully lift the engine out of the vehicle.
    NOTE
    Make sure the engine is clear of all wiring and hoses.

  56.  

To install:

  1. Slowly lower the engine assembly into the engine compartment.
  2.  
  3. Attach the engine mounting brackets to the frame brackets.
  4.  
  5. Install the four nuts and four bolts holding the engine mounting brackets to the frame brackets. Tighten the nuts to 28 ft. lbs. (38 Nm).
  6.  
  7. Remove the engine chain hoist and engine hangers.
  8.  
  9. Install the engine wiring harness in the reverse order in which it was removed.
  10.  
  11. Connect the heater hoses.
  12.  
  13. Install the right and left exhaust manifolds. Tighten the mounting nuts to 33 ft. lbs. (44 Nm) and tighten the heat shields to 69 inch lbs. (7.8 Nm).
  14.  
  15. Install the engine oil dipstick tube. Tighten the mounting bolts to 11 ft. lbs. (15 Nm).
  16.  
  17. Install the transmission oil dipstick tube and tighten the mounting bolts to 9 ft. lbs. (12 Nm).
  18.  
  19. Install the fan pulley.
  20.  
  21. Install the fan with fluid coupling and tighten the mounting nuts to 21 ft. lbs. (29 Nm).
  22.  
  23. Install the A/C compressor and tighten the mounting bolts to 34 ft. lbs. (47 Nm) and the mounting nut to 18 ft. lbs. (25 Nm).
  24.  
  25. Install the alternator.
  26.  
  27. Install the power steering pump and tighten the mounting bolts and nut to 32 ft. lbs. (43 Nm).
  28.  
  29. Install the accessory drive belt.
  30.  
  31. Connect the fuel supply, return and vapor feed hoses.
  32.  
  33. Install the fan shroud into the engine compartment. Tighten mounting bolts 44 inch lbs. (5 Nm). Connect the oil cooler hoses to the fan shroud.
  34.  
  35. Install the radiator.
  36.  
  37. Install the engine under covers.
  38.  
  39. Install the air intake assembly. Tighten the mounting bolts to 9 ft. lbs. (12 Nm).
  40.  
  41. Attach the vacuum and ventilation hoses to the air intake.
  42.  
  43. Install the throttle body cover, tighten the nuts to 66 inch lbs. (7.5 Nm).
  44.  
  45. Install the hood.
  46.  
  47. Install the transmission assembly.
  48.  
  49. Refill the engine cooling system to the correct level.
  50.  
  51. Refill the engine oil to the correct level.
  52.  
  53. Start the engine and check for leaks.
  54.  
  55. Recheck the engine oil and coolant levels.
  56.  

5vz-FE Engine
  1. Raise and safely support the vehicle.
  2.  
  3. Relieve the fuel pressure. For additional information, please refer the following topic(s): Fuel System, Relieving Fuel System Pressure.
  4.  
  5. Remove the engine under cover.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Drain the engine oil.
  10.  
  11. Remove the hood.
  12.  
  13. Remove the radiator.
  14.  
  15. Remove the fan with the fluid coupling and the fan pulleys.
  16.  
  17. Remove the air intake assembly.
  18.  
  19. Disconnect the accelerator cable from the throttle body.
  20.  
  21. Disconnect the following hoses:

    Heater hoses
     
    Evaporative emissions (EVAP) hose
     
    CCV hose
     
    Fuel return and supply hoses
     

  22.  
  23. Disconnect the starter wire and connector as follows:
    1. Remove the bolt that retains the ground strap.
    2.  
    3. Disconnect the positive battery cable.
    4.  
    5. Disconnect the starter wires and connectors.
    6.  

  24.  
  25. Disconnect the alternator harness.
  26.  
  27. Disconnect the engine wire from the cabin area as follows:
    1. Remove the glove compartment door.
    2.  
    3. Remove the lower finish No.2 panel.
    4.  
    5. Disconnect the 5 Electronic Control Module (ECM) connectors.
    6.  
    7. Disconnect the 2 cassette connectors (cowl wire x engine wire) and 2 wire clamps from the lower finish panel.
    8.  
    9. Disconnect the engine wire clamp.
    10.  
    11. Disconnect the igniter connector.
    12.  
    13. Disconnect the ground strap.
    14.  
    15. Disconnect the VSV connector for the EVAP.
    16.  
    17. Disconnect the VSV connector for the CCV and clamp.
    18.  
    19. Remove the bolt and wire bracket.
    20.  
    21. Remove the 2 nuts holding the engine wire retainer to the cowl panel, and pull out the engine wire from the cabin.
    22.  

  28.  
  29. Remove the driveshaft.
  30.  
  31. Disconnect the speedometer cable.
    NOTE
    Do not lose the felt protector and washers from the speedometer cable.

  32.  
  33. Remove the front exhaust pipe as follows:
    1. Disconnect the heated oxygen sensor.
    2.  
    3. Remove the two bolts and retainer holding the front pipe to the catalytic converter.
    4.  
    5. Remove the three bolts and the support bracket.
    6.  
    7. Loosen and remove the three nuts holding the front pipe and gaskets.

      Click image to see an enlarged view

      Fig. Remove the bolts securing the front exhaust pipe to the manifold, support bracket and catalytic converter-3.4L (5VZ-FE) Engine

    8.  

  34.  
  35. Support the transmission with a suitable jack.
  36.  
  37. Remove the 8 bolts holding the rear engine mounting bracket to the mounting insulator and crossmember.
  38.  
  39. If equipped with A/C, remove the bolt and disconnect the A/C compressor wire clamp.
  40.  
  41. Attach an engine hoist chain to the two engine hangers.

    Click image to see an enlarged view

    Fig. Attach the engine hoist chain to the engine hangers

  42.  
  43. Remove the four bolts and nuts holding the engine front mounting insulators to the frame.
  44.  
  45. Carefully lift the engine with transmission out of the vehicle
    NOTE
    Make sure the engine is clear of all wiring and hoses.

  46.  

To install:

  1. Lower the engine and transmission assembly into the engine compartment.
  2.  
  3. Keeping the engine level, align the engine mountings and body mountings.
  4.  
  5. Attach the engine mounting insulators to the body mountings, and temporarily install the four bolts and nuts.
  6.  
  7. Using a suitable jack, raise the transmission onto the frame.
  8.  
  9. Remove the engine chain hoist and engine hanger.
  10.  
  11. If equipped with A/C, connect the A/C compressor wire with the bolt.
  12.  
  13. Raise the transmission slightly by raising the engine with a suitable jack with a wooden block to prevent damage to the transmission.
  14.  
  15. Install the engine rear mounting bracket to the frame and tighten the bolts to 43 ft. lbs. (58 Nm).
  16.  
  17. Lower the transmission and rest it on the extension housing.
  18.  
  19. Install the mounting bracket to the mounting insulator and tighten the bolts to 13 ft. lbs. (18 Nm).

    Click image to see an enlarged view

    Fig. Install these four bolts for the rear engine mounting bracket and four bolts for the transmission mounting insulator-3.4L (5VZ-FE) Engine

  20.  
  21. Tighten the four bolts and nuts holding the mounting insulators to the body mountings. Tighten the nuts to 28 ft. lbs. (38 Nm).

    Click image to see an enlarged view

    Fig. Install these four bolts and nuts that secure the engine mounting insulators to the frame

  22.  
  23. Attach the front exhaust pipe:
    1. Install the gaskets and attach the pipe to the engine with new mounting nuts. Tighten the nuts to 36 ft. lbs. (44 Nm).
    2.  
    3. Install the support bracket and tighten the bolts to 33 ft. lbs. (44 Nm).
    4.  
    5. Connect the exhaust pipe with a new gasket to the catalytic converter. Tighten the bolts to 35 ft. lbs. (48 Nm).
    6.  
    7. Connect the two heated oxygen sensors.
    8.  

  24.  
  25. Connect the speedometer cable.
  26.  
  27. Install the driveshaft.
  28.  
  29. Connect the engine wiring harness into the cabin:
    1. Push in the engine wiring harness through the cowl panel and install the two nuts, bolt and bracket.
    2.  
    3. Connect the engine wiring harness clamp.
    4.  
    5. Connect the ground strap.
    6.  
    7. Connect the igniter connector.
    8.  
    9. Connect the VSV connector for the EVAP.
    10.  
    11. Connect the VSV connector for the CCV and clamp.
    12.  
    13. Connect the five connectors to the ECM.
    14.  
    15. Connect the two cassette connectors.
    16.  
    17. Install the ECM with the 2 bolts.
    18.  
    19. Install the lower finish No.2 panel.
    20.  
    21. Install the glove compartment door.

      Click image to see an enlarged view

      Fig. Connect the engine wire ground clamp (d), ground strap (e) and igniter connector (f)-3.4L (5VZ-FE) Engine



      Click image to see an enlarged view

      Fig. Connect the VSV connector for the EVAP (g) and VSV connector for the CCV (h)-3.4L (5VZ-FE) Engine

    22.  

  30.  
  31. Connect the alternator wires.
  32.  
  33. Connect the starter wiring:
    1. Connect the 2 starter wire clamps and connector.
    2.  
    3. Install the two nuts, and connect the positive (+) terminal cable to the battery.
    4.  
    5. Connect the ground strap with the bolt.
    6.  
    7. Connect the wire from relay block No.2 with the nut.
    8.  

  34.  
  35. Connect the following hoses:
    NOTE
    Always use a new gasket when reconnecting the fuel hoses.



    Connect the fuel return hose.
     
    Connect the fuel inlet hose
     



    Connect the EVAP hose.
     
    Connect the CCV hose.
     
    Heater hoses
     

  36.  
  37. Connect the accelerator cable to the throttle body.
  38.  
  39. Install the fan with the fluid coupling and the fan pulley.
  40.  
  41. Install the air intake assembly.
  42.  
  43. Install the radiator.
  44.  
  45. Refill the engine with oil to the correct level.
  46.  
  47. Refill the cooling system to the correct level.
  48.  
  49. Install the engine under covers.
  50.  
  51. Install the hood.
  52.  
  53. Start the engine and check for leaks.
  54.  
  55. Recheck the engine oil and coolant levels.
  56.  

2wd
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Hood
     
    Battery
     
    Engine under covers
     

  6.  
  7. Drain the engine coolant.
  8.  
  9. Drain the engine oil.

    Radiator
     
    Fan with the fluid coupling and fan pulleys
     
    Air cleaner cap
     
    Mass Air Flow (MAF) meter and the resonator
     
    Air cleaner case and filter
     

  10.  
  11. Disconnect the following hoses:

    Heater hoses
     
    Brake booster vacuum hose
     
    Evaporative Emissions (EVAP) hose
     
    Fuel return hose
     
    Fuel inlet hose
     

  12.  
  13. Detach the starter wire and connectors, as follows:

    Ground strap, by removing the bolt
     
    3 starter wire clamps and connector
     

  14.  
  15. Detach the alternator connector and wire.
  16.  
  17. Disconnect the engine wiring harness, as follows:

    Glove box door
     
    Lower the finish No. 2 panel
     
    4 ECM connectors
     
    2 cassette connectors and the 2 wire clamps from the lower finish panel
     
    Engine wiring harness clamp
     

  18.  
  19. Remove or disconnect the following:

    Igniter connector
     
    Ground strap
     
    Vacuum Switching Valve (VSV) connector for the Evaporative Emissions (EVAP)
     
    Vapor pressure sensor connector and clamp
     
    Vapor connector for the vapor pressure sensor and clamp
     
    2 engine wiring harness retainer-to-cowl panel nuts and pull out the engine wiring harness
     
    Driveshaft from the transmission
     
    Speedometer cable
     
    Front exhaust pipe
     
    Nut and the control cable
     

  20.  
  21. Place a jack under the transmission.
  22.  
  23. Remove or disconnect the following:

    Transmission rear mounting bracket by removing the 8 bolts
     
    Bolt and the air conditioning compressor wire clamp, if equipped with air conditioning
     

  24.  
  25. If necessary, install a No. 2 engine hanger with 2 bolts. Tighten the 2 bolts to 30 ft. lbs. (40 Nm).
  26.  
  27. Attach the engine hoist chain to the 2 engine hangers.
  28.  
  29. Remove or disconnect the following:

    4 engine front mounting insulators-to-frame bolts and nuts
     
    Engine and transmission
     

  30.  

To install:

  1. Install or connect the following:

    Engine
     
    Engine mounts to the body mountings. Install the bolts and nuts but do not tighten at this time.
     

  2.  
  3. Remove the engine chain hoist the No. 2 engine hanger.
  4.  
  5. Install or connect the following:

    Air conditioning wire with the bolt, if equipped with air conditioning
     
    Transmission mounting bracket. Tighten the frame bolts to 43 ft. lbs. (58 Nm) and the mounting insulator bolts to 13 ft. lbs. (18 Nm).
     
    Tighten the engine mounting nuts and bolts to 28 ft. lbs. (38 Nm).
     
    Control cable
     
    Front exhaust pipe
     
    Speedometer cable
     
    Driveshaft
     
    All engine wiring harness, hoses and cables
     
    Fan with the fluid coupling and fan pulleys. Tighten the nuts to 48 inch lbs. (5.4 Nm).
     
    Air cleaner case and air filter
     
    MAF meter, resonator and the air cleaner cap
     
    Radiator
     

  6.  
  7. Fill the engine with oil.
  8.  
  9. Fill the engine and radiator with coolant.
  10.  
  11. Install or connect the following:

    Engine under-cover
     
    Battery
     
    Hood
     

  12.  
  13. Start the engine and check for leaks.
  14.  
  15. Make any necessary adjustments and road test the vehicle.
  16.  

4wd
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Transmission
     
    Hood
     

  4.  
  5. Release the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Battery
     
    Engine undercovers
     

  8.  
  9. Drain the engine coolant.
  10.  
  11. Drain the engine oil.
  12.  
  13. Remove or disconnect the following:

    Radiator
     
    Fan with the fluid coupling and fan pulleys
     
    Air cleaner cap
     
    Mass Air Flow (MAF) meter and the resonator
     

  14.  
  15. Disconnect the following hoses:

    Heater hoses
     
    Brake booster vacuum hose
     
    Evaporative Emissions (EVAP) hose
     
    Automatic Disconnecting Differential (ADD) vacuum hose
     
    Fuel return hose
     
    Fuel inlet hose
     

  16.  
  17. Detach the starter wire and connectors, as follows:

    Ground strap, by removing the bolt
     
    3 starter wire clamps and connector
     

  18.  
  19. Detach the alternator connector and wire.
  20.  
  21. Disconnect the engine wiring harness, as follows:

    Glove box door
     
    Lower the finish No. 2 panel
     
    4 ECM connectors
     
    2 cassette connectors and the 2 wire clamps from the lower finish panel
     
    Engine wiring harness clamp
     

  22.  
  23. Disconnect the following:

    Igniter connector
     
    Ground strap
     
    Vacuum Switching Valve (VSV) connector for the EVAP
     
    Vapor pressure sensor connector and clamp
     
    Vapor connector for the vapor pressure sensor and clamp
     

  24.  
  25. Remove or disconnect the following:

    2 engine wiring harness retainer-to-cowl panel nuts and wiring harness
     
    Air conditioning compressor wire clamp, if equipped with air conditioning
     

  26.  
  27. If necessary, install a No. 2 engine hanger with 2 bolts. Tighten the 2 bolts to 30 ft. lbs. (40 Nm).
  28.  
  29. Attach the engine hoist chain to the 2 engine hangers.
  30.  
  31. Remove or disconnect the following:

    4 engine front mounting insulators-to-frame bolts and nuts
     
    Engine
     

  32.  

To install:

  1. Install or connect the following:

    Engine
     
    Engine mounts-to-body mountings. Install the bolts and nuts but do not tighten at this time.
     

  2.  
  3. Remove the engine chain hoist the No. 2 engine hanger.
  4.  
  5. Install or connect the following:

    Air conditioning wire with the bolt, if equipped with air conditioning
     
    Tighten the engine mounting nuts and bolts to 28 ft. lbs. (38 Nm).
     
    Engine wiring harness
     
    Engine wiring harness clamp
     
    All wires, hoses and cables
     
    Fan with the fluid coupling and fan pulleys. Tighten the nuts to 48 inch lbs. (5.4 Nm).
     
    Air cleaner case and air filter
     
    MAF meter, resonator and the air cleaner cap
     
    Radiator
     

  6.  
  7. Fill the engine with oil.
  8.  
  9. Fill the engine and radiator with coolant.
  10.  
  11. Install or connect the following:

    Transmission and refill it with transmission oil
     
    Engine undercover
     
    Battery
     
    Hood
     

  12.  
  13. Start the engine, make any necessary adjustments and check for leaks.
  14.  

 
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