Toyota Pick-ups/Land Cruiser/4Runner 1989-1996

Engine

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REMOVAL & INSTALLATION




CAUTION
Please refer to General Information & Maintenance before discharging the compressor or disconnecting air conditioning lines. Damage to the air conditioning system or personal injury could result. Consult your local laws concerning refrigerant discharge and recycling. In many areas it may be illegal for anyone but a certified technician to service the A/C system. Always use an approved recovery station when discharging the air conditioning system.

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, i.e. "disconnect the exhaust system'' or "remove the radiator.'' In most instances, a detailed removal procedure can be found elsewhere in this guide.

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. Be absolutely sure to tag and wire or hose before it is disconnected, so that you can be assured of proper reconnection during installation.

22R Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine undercover or splash shield.
  4.  

Apply a lubricant onto any nuts or bolts that will be removed. Allow the lubricant to sit for a short while. This will aid in removal of tight and frozen nuts and bolts.

  1. Disconnect the windshield washer hose. Scribe matchmarks around the hinges, then remove the hood.
  2.  
  3. Drain the engine oil. Drain the engine coolant from the radiator and the cylinder block.
  4.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant may be reused unless it is contaminated or several years old.

  1. Drain the automatic transmission fluid on models so equipped.
  2.  
  3. Disconnect the air cleaner hoses and then remove the air cleaner.
  4.  
  5. Remove the fan coupling with the fan.
  6.  
  7. Disconnect the two heater hoses at the engine.
  8.  
  9. Remove the radiator with the shroud attached.
  10.  
  11. Disconnect the accelerator cable at the carburetor.
  12.  
  13. Tag and disconnect the following wires:

    Vacuum switching valve (VSV) wire at the evaporative emissions (EVAP) canister
     
    Vacuum switching (VSV) valve wire at the air conditioning compressor
     
    Vacuum switch wire
     
    HAC wire (ex. Calif.)
     
    Cold mixture heater wire
     
    Fuel cut solenoid wire
     
    Water temperature sender gauge wire
     
    Electronic air control (EACV) valve wire (Calif.)
     
    Starter wire
     
    Oil pressure switch wire
     

  14.  
  15. Disconnect the following parts:

    Brake booster hose
     
    Main fuel line at the fuel inlet pipe
     
    Fuel return line at the fuel return pipe
     
    Charcoal canister hose
     
    HAC from the bracket (except Calif.)
     
    Vacuum switch, Electronic Bleed Air Control Valve (EBCV) Calif. and Vacuum Switching Valve (VSV) with its bracket
     

  16.  
  17. Remove the drive belt.
  18.  
  19. Remove the power steering pump from its bracket (if equipped). Move the pump to one side without disconnecting the hoses. Use a piece of stiff wire to support it. Disconnect the ground strap from the bracket.
  20.  
  21. On models with air conditioning, loosen the drive belt and remove the air conditioning compressor. Position it out of the way with the refrigerant lines still attached. Use several pieces of stiff wire to support the compressor.
  22.  
  23. Disconnect the engine ground straps at the rear and right side of the engine.
  24.  
  25. On trucks with a manual transmission, remove the shift lever from inside the truck.
  26.  
  27. On models with automatic transmission, remove the shift lever retainer.
  28.  
  29. Remove the rear driveshaft.
  30.  
  31. On vehicles with automatic transmissions, disconnect the manual shift linkage at the neutral start switch. On 4WD models with automatic transmission, disconnect the transfer shift linkage at the cross-shaft.
  32.  
  33. Remove the cross-shaft from the body.
  34.  
  35. Disconnect the speedometer cable. Be sure not to lose the felt dust protector and washers.
  36.  
  37. On 4WD models, remove the transfer case undercover.
  38.  
  39. On 4WD models, remove the stabilizer bar.
  40.  
  41. On 4WD models, remove the front driveshaft.
  42.  
  43. Remove the No. 1 frame crossmember.
  44.  
  45. Disconnect the oxygen sensor wiring. Disconnect the exhaust pipe at the manifold; remove the clamp from the clutch housing. Remove the exhaust pipe from the catalytic converter.
  46.  
  47. On models with manual transmission, remove the clutch release (slave) cylinder and its bracket from the transmission.
  48.  
  49. Remove the No. 1 front floor heat insulator and the brake tube heat insulator (4WD only).
  50.  
  51. On 2WD models, remove the four rear engine mount bolts. Raise the transmission slightly with a floor jack and then remove the four support member mounting bolts.
  52.  
  53. On 4WD models, remove the four rear engine mount bolts, raise the transmission slightly with a floor jack and then remove the four bolts from the side member and remove the No. 2 frame crossmember.
  54.  
  55. Attach an engine hoist chain to the lifting brackets on the engine. Remove the engine mount nuts and bolts and slowly lift the engine/transmission out of the truck.
  56.  
  57. Remove the starter. If automatic transmission, remove the oil cooler lines from the transmission. Remove the two stiffener brackets and the exhaust pipe bracket from the engine.
  58.  
  59. Remove the transmission.
  60.  
  61. If manual transmission, remove the clutch cover (pressure plate) and clutch disc.
  62.  
  63. Mount the engine on an engine stand, making sure the retaining bolts are tight. If an engine stand is not available, support the engine in an upright position with blocks. Never leave an engine hanging from a lift or hoist.
  64.  

To install:
  1. Install the clutch and pressure plate onto the engine. Tighten the bolts correctly.
  2.  
  3. Install the transmission onto the engine.
  4.  
  5. Slowly lower the engine assembly into the engine compartment.
  6.  
  7. On 4WD models, use a floor jack to raise the transmission onto the crossmember. Always use a piece of wood between the jack and the transmission pan.
  8.  
  9. Align the holes in the engine mounts and the frame, install the bolts and then remove the engine hoist chain.
  10.  
  11. On 2WD models, raise the transmission slightly and align the rear engine mount with the support member. Tighten the bolts to 9 ft. lbs. (13 Nm). Lower the transmission until it rests on the extension housing and then tighten the bracket mounting bolts to 19 ft. lbs. (25 Nm).
  12.  
  13. On 4WD models, raise the transmission slightly and tighten the No. 2 frame crossmember-to-side frame bolts to 70 ft. lbs. (95 Nm). Lower the transmission and tighten the four rear engine mount bolts to 9 ft. lbs. (13 Nm).
  14.  
  15. On 4WD models, install the brake tube and front floor heat insulators.
  16.  
  17. Install the clutch release (slave) cylinder and its bracket to the manual transmission. Tighten the bracket bolts to 29 ft. lbs. (39 Nm) and the cylinder bolts to 9 ft. lbs. (13 Nm).
  18.  
  19. Reconnect the exhaust pipe to the catalytic converter and to the exhaust manifold. Install the clamps. Install the wiring to the oxygen sensor.
  20.  
  21. Install the No. 1 frame crossmember.
  22.  
  23. On 4WD models, install the front driveshaft, stabilizer bar and the transfer case undercover.
  24.  
  25. Connect the speedometer cable.
  26.  
  27. On 4WD models with automatic transmission, install the cross-shaft to the body. Connect the transfer shift linkage.
  28.  
  29. Connect the manual shift linkage to the neutral start switch (automatic transmission only).
  30.  
  31. Install the rear driveshaft.
  32.  
  33. Install the shift lever (manual transmission) or the shift lever retainer (automatic)
  34.  
  35. Connect the engine ground straps.
  36.  
  37. Install the air conditioning compressor.
  38.  
  39. Install the power steering pump and connect the ground strap to the bracket.
  40.  
  41. Connect all parts removed earlier:
  42.  



Brake booster hose
 
Main fuel line at the fuel inlet pipe
 
Fuel return line at the fuel return pipe
 
Charcoal canister hose
 
HAC from the bracket (ex. Calif.)
 
Vacuum switch, Electronic Bleed Air Control Valve (EBCV) Calif. and Vacuum Switching Valve (VSV) with its bracket
 

  1. Connect all wires removed earlier:
  2.  



Vacuum Switching Valve (VSV) wire at the evaporative emissions (EVAP) canister
 
Vacuum Switching Valve (VSV) wire at the air conditioning compressor
 
Vacuum switch wire
 
HAC wire (ex. Calif.)
 
Cold mixture heater wire
 
Fuel cut solenoid wire
 
Water temperature sender gauge wire
 
EACV wire (Calif.)
 
Starter wire
 
Oil pressure switch wire
 

  1. Connect the accelerator cable to the carburetor, don't forget the tension spring.
  2.  
  3. Install the fan pulley, belt guide, fluid coupling and alternator drive belt.
  4.  
  5. Install the air conditioning compressor belt and adjust it correctly.
  6.  
  7. Install the power steering pump and belt; adjust the belt correctly. Tighten the pump pulley locknut to 32 ft. lbs. (43 Nm).
  8.  
  9. Install the radiator and shroud. Install the radiator hoses.
  10.  
  11. Connect the two heater hoses and install the air cleaner. Connect the air cleaner hoses.
  12.  
  13. Refill the engine with oil and the radiator with coolant.
  14.  
  15. Install the engine undercover.
  16.  
  17. Install the battery.
  18.  
  19. Install the hood.
  20.  
  21. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  22.  
  23. With the coil wire disconnected from the distributor, crank the engine with the ignition key for 5-10 seconds. This should pre-oil at least the lower part of the engine.
  24.  
  25. Reconnect the coil wire. Start the engine, allowing it to warm up. Check carefully for leaks.
  26.  
  27. Check and adjust the engine specifications as necessary.
  28.  
  29. Road test the vehicle. Recheck and top fluid levels as needed.
  30.  

22R-E Engine

See Figures 1, 2, 3 and 4

  1. Disconnect the windshield washer hose. Scribe matchmarks around the hinges then remove the hood.
  2.  

Apply a lubricant onto any nuts or bolts that will be removed. Allow the lubricant to sit for a short while. This will aid in the removal of tight and frozen nuts and bolts.

  1. Relieve the fuel pressure.
  2.  
  3. Disable the air bag system.
  4.  


CAUTION
Fuel injected engine systems remain under pressure after the engine has been turned OFF. Properly relieve the fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine undercover.
  4.  
  5. Drain the engine oil. Drain the engine coolant from the radiator and the cylinder block.
  6.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize you exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Drain the automatic transmission fluid on models so equipped.
  2.  
  3. Remove the air cleaner case and the intake air hose.
  4.  
  5. Remove the radiator and shroud.
  6.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant may be reused unless it is contaminated or several years old.

  1. Loosen the power steering pulley locknut and remove the power steering belt.
  2.  
  3. If equipped with air conditioning, remove the compressor belt.
  4.  
  5. Remove the alternator drive belt, fluid coupling for the fan and the fan pulley.
  6.  
  7. Disconnect the following wires and connectors:
  8.  



Ground strap from the left fender apron
 
Alternator connector and wire
 
Igniter
 
Alternator wires
 
Coil wire from distributor
 
Ground strap at rear of engine
 
Electronic Control Unit (ECU)
 
Starter relay connector (manual transmission only)
 
The check connector
 
Air conditioning compressor connector
 

  1. Disconnect and label these hoses: air hoses from the fuel filter and air pipe, brake booster hose, charcoal canister hose and cruise control vacuum hose if so equipped.
  2.  
  3. Disconnect the accelerator cable, throttle cable for the automatic transmission (if so equipped) and the cruise control cable if so equipped.
  4.  
  5. Remove the power steering pump from its bracket (if equipped).
  6.  
  7. Disconnect the ground strap from the bracket.
  8.  
  9. On models with air conditioning, remove the air conditioning compressor. Position it out of the way with the refrigerant lines still attached.
  10.  
  11. Disconnect the engine ground straps at the rear and right side of the engine.
  12.  
  13. On trucks with a manual transmission, remove the shift lever from inside the truck.
  14.  
  15. Remove the rear driveshaft.
  16.  
  17. On models with automatic transmission, disconnect the manual shift linkage at the neutral start switch.
  18.  
  19. On 4WD models with automatic transmission, disconnect the transfer shift linkage at the cross-shaft.
  20.  
  21. Remove the cross-shaft assembly from the body.
  22.  
  23. Disconnect the speedometer cable. Be sure not to lose the felt dust protector and washers.
  24.  
  25. Remove the transfer case undercover (4WD only).
  26.  
  27. Remove the stabilizer bar (4WD only).
  28.  
  29. Remove the front driveshaft (4WD only).
  30.  
  31. Remove the No. 1 frame crossmember.
  32.  
  33. Disconnect the oxygen sensor wiring. Disconnect the exhaust pipe at the manifold; remove the clamp from the clutch housing. Remove the exhaust pipe from the catalytic converter.
  34.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the bolts securing the front exhaust pipe to the engine and manifold

  1. On models with manual transmission, remove the clutch release (slave) cylinder and its bracket from the transmission.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: On manual transmissions, remove the bolts securing the slave cylinder

  1. Remove the No. 1 front floor heat insulator and the brake tube heat insulator (4WD only).
  2.  
  3. On 2WD models, remove the four rear engine mount bolts. Raise the transmission slightly with a floor jack and then remove the support member mounting bolts.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: On 2WD models, remove the four rear engine mount bolts first, then the remaining support member bolts

  1. On 4WD models, remove the four rear engine mount bolts, raise the transmission slightly with a floor jack and then remove the four bolts from the side member and remove the No. 2 frame crossmember.
  2.  



Click image to see an enlarged view

Fig. Fig. 4: On 4WD models, remove these frame crossmember bolts

  1. Attach an engine hoist chain to the lifting brackets on the engine. Remove the engine mount nuts and bolts and slowly lift the engine/transmission out of the truck.
  2.  
  3. Remove the starter. If automatic transmission, remove the oil cooler lines from the transmission. Remove the two stiffener brackets and the exhaust pipe bracket from the engine.
  4.  
  5. Remove the transmission.
  6.  
  7. If manual transmission, remove the clutch cover (pressure plate) and clutch disc.
  8.  
  9. Mount the engine on an engine stand, making sure the retaining bolts are tight. If an engine stand is not available, support the engine in an upright position with blocks. Never leave an engine hanging from a lift or hoist.
  10.  

To install:
  1. Slowly lower the engine assembly into the engine compartment.
  2.  
  3. Raise the transmission onto the crossmember with a floor jack.
  4.  
  5. Align the holes in the engine mounts and the frame, install the bolts and then remove the engine hoist chain.
  6.  
  7. On 2WD models, raise the transmission slightly and align the rear engine mount with the support member and tighten the bolts to 9 ft. lbs. (13 Nm). Lower the transmission until it rests on the extension housing and then tighten the bracket mounting bolts to 19 ft. lbs. (25 Nm).
  8.  
  9. On 4WD models, Raise the transmission slightly and tighten the No. 2 frame crossmember-to-side frame bolts to 70 ft. lbs. (95 Nm). Lower the transmission and tighten the four rear engine mount bolts to 9 ft. lbs. (13 Nm).
  10.  
  11. On 4WD models, install the brake tube and front floor heat insulators.
  12.  
  13. Install the clutch release (slave) cylinder and its bracket to the manual transmission. Tighten the bracket bolts to 29 ft. lbs. (39 Nm) and the cylinder bolts to 9 ft. lbs. (13 Nm).
  14.  
  15. Reconnect the exhaust pipe.
  16.  
  17. Install the No. 1 frame crossmember.
  18.  
  19. On 4WD models, install the front driveshaft, stabilizer bar and the transfer case undercover.
  20.  
  21. Connect the speedometer cable.
  22.  
  23. Connect the transfer shift linkage on 4WD models with automatic transmission.
  24.  
  25. Connect the manual shift linkage to the neutral start switch (automatic transmission only).
  26.  
  27. Install the rear driveshaft.
  28.  
  29. Install the shift lever (manual transmission only).
  30.  
  31. Connect the engine ground straps.
  32.  
  33. Install the air conditioning compressor.
  34.  
  35. Install the power steering pump and connect the ground strap.
  36.  
  37. Connect the accelerator cable, throttle cable for the automatic transmission (if so equipped) and the cruise control cable if removed.
  38.  
  39. Connect the hoses to the charcoal canister, the brake booster, the cruise control if so equipped and the air hoses to the fuel filter and air pipe.
  40.  
  41. Attach the wires and connectors:
  42.  



Ground strap from the left fender apron
 
Alternator connector and wire
 
Igniter
 
Alternator wires
 
Coil wire from distributor
 
Ground strap at rear of engine
 
Electronic control unit (ECU) connectors
 
Starter relay connector (manual transmission only)
 
The check connector
 
Air conditioning compressor connector
 

  1. Install the fan pulley, belt guide, fluid coupling and alternator belt.
  2.  
  3. Install the air conditioning compressor drive belt.
  4.  
  5. Install the power steering pump belt and adjust it correctly. Tighten the pump pulley locknut to 32 ft. lbs. (43 Nm).
  6.  
  7. Install the radiator and shroud.
  8.  
  9. Install the air cleaner case and the intake duct.
  10.  
  11. Install the proper amounts of oil and coolant.
  12.  
  13. Install the undercover or splash shield below the engine.
  14.  
  15. Install the battery.
  16.  
  17. Install the hood.
  18.  
  19. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  20.  
  21. With the coil wire disconnected from the distributor, crank the engine with the ignition key for 5-10 seconds. This should pre-oil at least the lower part of the engine.
  22.  
  23. Reconnect the coil wire. Start the engine, allowing it to warm up. Check carefully for leaks.
  24.  
  25. Check and adjust the engine specifications as necessary.
  26.  
  27. Road test the vehicle. Recheck and top fluid levels as needed.
  28.  

3VZ-E Engine

See Figures 5 through 11

  1. Relieve the fuel pressure.
  2.  


CAUTION
Fuel injected engine systems remain under pressure after the engine has been turned OFF. Properly receive the fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Disconnect the windshield washer hose. Scribe matchmarks around the hinges, then remove the hood.
  2.  
  3. Disconnect the battery cables and remove the battery.
  4.  

Apply a lubricant onto any nuts or bolts that will be removed. Allow the lubricant to sit for a short while. This will aid in the removal of tight and frozen nuts and bolts.

  1. Remove the engine undercover.
  2.  
  3. Drain the engine oil. Drain the engine coolant from the radiator and the cylinder block.
  4.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant may be reused unless it is contaminated or several years old.

  1. Drain the automatic transmission fluid on models so equipped.
  2.  
  3. Disconnect the air cleaner hose and then remove the air cleaner.
  4.  
  5. Remove the cooling fan.
  6.  



Click image to see an enlarged view

Fig. Fig. 5: Hold the fan while loosening the retaining bolts

  1. Remove the radiator.
  2.  
  3. Remove all drive belts and then remove the fluid coupling and fan pulley.
  4.  
  5. Tag and disconnect the following wires and connectors:
  6.  



Left side and rear ground straps
 
Alternator connector and wire
 
Igniter
 
Oil pressure switch
 
Electronic Control Unit (ECU)
 
Vacuum Switching Valve (VSV)
 
Starter relay (manual transmission only)
 
Solenoid resistor
 
Check connector
 
Air conditioning compressor
 

  1. Tag and disconnect the following hoses:
  2.  



Air hoses at the gas filter and air pipe
 
Brake booster
 
Cruise control vacuum hose (if equipped)
 
Charcoal canister hose at the canister
 
Vacuum Switching Valve (VSV)
 
Oil cooler-(automatic transmissions)
 

  1. Disconnect the accelerator cable, throttle control cable (auto. trans.) and cruise control cable if equipped.
  2.  
  3. Unbolt the power steering pump and position it out of the way with the hydraulic lines still connected.
  4.  



Click image to see an enlarged view

Fig. Fig. 6: Remove the bolts securing the power steering pump, then position it aside

  1. Remove the air conditioning compressor if equipped. Position is out of the way with the lines still attached.
  2.  
  3. On manual transmissions, disconnect the clutch release (slave) cylinder hose.
  4.  



Click image to see an enlarged view

Fig. Fig. 7: On the manual transmissions, disconnect the slave cylinder hose from the pipe

  1. Disconnect the two heater hoses from the engine.
  2.  
  3. Disconnect and plug the fuel inlet and outlet lines.
  4.  
  5. Remove the shift levers (manual transmission only).
  6.  
  7. Remove the rear driveshaft.
  8.  
  9. Disconnect the manual shift linkage (automatic transmission only).
  10.  
  11. Disconnect the speedometer cable-don't lose the felt dust protector and washers.
  12.  
  13. Remove the transfer case undercover.
  14.  
  15. Remove the stabilizer bar.
  16.  
  17. Remove the front driveshaft.
  18.  
  19. Remove the No.1 frame crossmember.
  20.  
  21. Remove the front exhaust pipe.
  22.  



Click image to see an enlarged view

Fig. Fig. 8: Remove the bolts securing the front exhaust pipe to the manifold

  1. Remove the front floor heat insulator and the brake tube heat insulator.
  2.  
  3. Remove the four rear engine mount bolts. Raise the transmission slightly with a floor jack and remove the bolts securing the bracket and frame crossmember.
  4.  



Click image to see an enlarged view

Fig. Fig. 9: On 2WD vehicles, first remove the 4 rear engine mount bolts ...



Click image to see an enlarged view

Fig. Fig. 10: ... then remove the remaining bracket bolts



Click image to see an enlarged view

Fig. Fig. 11: On 4WD models, remove these crossmember bolts

  1. Attach an engine hoist chain to the lifting brackets on the engine. Remove the engine mount nuts and bolts and slowly lift the engine/transmission out of the truck.
  2.  
  3. Remove the starter. If automatic transmission, remove the oil cooler lines from the transmission. Remove the two stiffener brackets and the exhaust pipe bracket from the engine.
  4.  
  5. Remove the transmission.
  6.  
  7. If manual transmission, remove the clutch cover (pressure plate) and clutch disc.
  8.  
  9. Mount the engine on an engine stand, making sure the retaining bolts are tight. If an engine stand is not available, support the engine in an upright position with blocks. Never leave an engine hanging from a lift or hoist.
  10.  

To install:
  1. After connecting the transmission to the engine and installing the starter, slowly lower the engine assembly into the engine compartment.
  2.  
  3. Raise the transmission onto the crossmember with a floor jack. Be certain to use a broad piece of wood between the transmission pan and the floor jack.
  4.  
  5. Align the holes in the engine mounts and the frame, install the bolts and then remove the engine hoist chain.
  6.  
  7. For 2WD vehicles, install the rear engine mount and bracket. Install the bolts holding the bracket to the support and tighten them to 9 ft. lbs. (13 Nm). Lower the transmission, resting it on the extension housing. Install the bracket to the mount; tighten the bolts to 19 ft. lbs. (25 Nm)
  8.  
  9. On 4WD vehicles, raise the transmission slightly and tighten the No. 2 frame crossmember-to-side frame bolts to 70 ft. lbs. (95 Nm). Lower the transmission and tighten the four rear engine mount bolts to 9 ft. lbs. (13 Nm).
  10.  
  11. Install the brake tube and front floor heat insulators.
  12.  
  13. Reconnect the exhaust pipe.
  14.  
  15. Install the No. 1 frame crossmember.
  16.  
  17. Install the front driveshaft.
  18.  
  19. Install the stabilizer bar and the transfer case undercover. Connect the speedometer cable.
  20.  
  21. Connect the manual shift linkage (automatic transmission only).
  22.  
  23. Install the rear driveshaft.
  24.  
  25. Install the shift levers (manual transmission only).
  26.  
  27. Install the fuel inlet and outlet lines.
  28.  
  29. Connect the heater hoses.
  30.  
  31. Connect the clutch release (slave) cylinder hose.
  32.  
  33. Install the air conditioning compressor.
  34.  
  35. Install the power steering pump and connect the ground strap.
  36.  
  37. Connect the throttle, cruise control and accelerator cables.
  38.  
  39. Connect the hoses:
  40.  



Air hoses at the fuel filter and air pipe
 
Brake booster
 
Cruise control vacuum hose (if equipped)
 
Charcoal canister hose at the canister
 
Vacuum Switching Valve (VSV)
 

  1. Connect the wires:
  2.  



Left side and rear ground straps
 
Alternator connector and wire
 
Igniter
 
Oil pressure switch
 
Electronic Control Unit (ECU)
 
Vacuum Switching Valve (VSV)
 
Starter relay (manual transmission only)
 
Solenoid resistor
 
Check connector
 
Air conditioning compressor
 

  1. Install the fan pulley, belt guide, fluid coupling and drive belt.
  2.  
  3. Inspect and replace the air conditioning belt.
  4.  
  5. Install the power steering pump and connect the ground strap. Tighten the pump pulley locknut to 32 ft. lbs. (43 Nm).
  6.  
  7. Install the radiator and attach the shroud.
  8.  
  9. Install the air cleaner. Refill the engine with oil and the radiator with coolant.
  10.  
  11. Install the engine undercover.
  12.  
  13. Install and adjust the hood.
  14.  
  15. Install the battery.
  16.  
  17. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  18.  
  19. With the coil wire disconnected from the distributor, crank the engine with the ignition key for 5-10 seconds. This should pre-oil at least the lower part of the engine.
  20.  
  21. Reconnect the coil wire. Start the engine, allowing it to warm up. Check carefully for leaks.
  22.  
  23. Check and adjust the engine specifications as necessary.
  24.  
  25. Road test the vehicle. Recheck and top fluid levels as needed.
  26.  

5VZ-FE Engine2WD MODELS

See Figures 12 through 16

Apply a lubricant onto any nuts or bolts that will be removed. Allow the lubricant to sit for a short while. This will aid in the removal of tight and frozen nuts and bolts.

  1. Remove the hood.
  2.  
  3. Relieve the fuel pressure.
  4.  
  5. Disable the air bag system. Refer to Chassis Electrical .
  6.  


CAUTION
Work must be started only after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.

  1. Disconnect the battery and remove it from the vehicle.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the engine under covers.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Drain the engine oil.
  10.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize you exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the radiator.
  2.  
  3. Remove the power steering drive belt:
    1. Stretch the belt and loosen the fan pulley mounting bolts.
    2.  
    3. Loosen the lock, pivot and adjusting bolts. Remove the drive belt from the engine.
    4.  

  4.  
  5. If equipped with A/C, remove the A/C drive belt by loosening the idle pulley nut and adjusting bolt.
  6.  
  7. Loosen the lock, pivot and adjusting bolts, then remove the alternator belt.
  8.  
  9. Remove the fan with the fluid coupling and the fan pulleys.
  10.  
  11. Disconnect the power steering pump from the engine and set aside. Do not disconnect the lines from the pump.
  12.  
  13. If equipped with A/C, disconnect the compressor from the engine and set aside. Do not disconnect the lines from the compressor.
  14.  
  15. Remove the air cleaner lid, Mass Air Flow (MAF) meter and resonator.
  16.  
  17. Remove the air cleaner case and filter assembly.
  18.  
  19. Disconnect the following cables:
  20.  



If the vehicle has cruise control, disconnect the detent cable
 
Accelerator
 
Throttle cable on automatics
 

  1. Disconnect the heater hoses.
  2.  
  3. Disconnect the following hoses:
  4.  



Brake booster vacuum
 
Evaporative emissions (EVAP)
 
Fuel return
 
Fuel inlet
 

  1. Disconnect the starter wire and connectors as follows:
  2.  

  1. Remove the bolt retaining the ground strap.
  2.  
  3. Disconnect the positive battery cable.
  4.  
  5. Disconnect the starter wires and connectors.
  6.  

  1. Disconnect the alternator harness.
  2.  
  3. Remove the engine harness as follows:
  4.  



Click image to see an enlarged view

Fig. Fig. 12: The Electronic Control Unit (ECU) can be found behind the passenger's side kick panel

  1. Remove the four screws to the right front door scuff plate.
  2.  
  3. Remove clip retaining the cowl panel side trim.
  4.  
  5. Disconnect the Electronic Control Unit (ECU) wiring.
  6.  
  7. Detach the two connectors from the cowl wire.
  8.  
  9. Disconnect the igniter.
  10.  
  11. Detach the ground strap.
  12.  
  13. Disconnect the six engine wire clamps.
  14.  
  15. Pull the engine wire from the compartment.
  16.  



Click image to see an enlarged view

Fig. Fig. 13: Remove the clamps securing the engine wiring harness at the points shown

  1. If equipped with a manual transmission, remove the shift lever as follows:
  2.  

  1. Remove the shift lever knob.
  2.  
  3. Remove the four screws and the shift lever boot.
  4.  
  5. Remove the six bolts to retrieve the shift lever assembly and gasket.
  6.  

  1. Remove the stabilizer bar.
  2.  
  3. Remove the driveshaft from the transmission.
  4.  
  5. Disconnect the speedometer cable.
  6.  



Click image to see an enlarged view

Fig. Fig. 14: Remove the bolts securing the front exhaust pipe to the manifold, support bracket and catalytic converter

  1. 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.
    8.  

  2.  
  3. If equipped with with a manual transmission, remove the slave cylinder.
  4.  
  5. On automatic transmissions, remove the cross-shaft.
  6.  
  7. Place a jack under the transmission.
  8.  
  9. Remove the eight bolts retaining the transmission rear mounting bracket.
  10.  
  11. If equipped with A/C, remove the bolt and disconnect the wire.
  12.  
  13. Attach the engine hoist chain to the two engine hangers.
  14.  



Click image to see an enlarged view

Fig. Fig. 15: Attach the engine hoist chain to the engine hangers

  1. Remove the four bolts and nuts holding the front mounting insulators to the frame.
  2.  



Click image to see an enlarged view

Fig. Fig. 16: Remove these four bolts and nuts that secure the engine mounting insulators to the frame

  1. Lift the engine and transmission out of the vehicle.
  2.  

To install:
  1. Install the engine assembly to the vehicle. Attach the engine mounts to the body mountings, then install bolts and nuts. Do not tighten them.
  2.  
  3. Remove the engine hoist from the engine hangers.
  4.  
  5. If equipped with A/C, connect the A/C wire with the bolt.
  6.  
  7. Raise and support the transmission slightly to install the mounting bracket. Tighten the bolts to the frame to 43 ft. lbs. (58 Nm) along with the bolts to the mounting bracket insulator to 13 ft. lbs. (18 Nm).
  8.  
  9. Tighten the engine mounting nuts and bolts to 28 ft. lbs. (38 Nm).
  10.  
  11. If equipped with an automatic transmission, install the cross-shaft.
  12.  
  13. On manual transmissions, install the slave cylinder, tighten the mounting bolts to 9 ft. lbs. (12 Nm).
  14.  
  15. 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.  

  16.  
  17. Attach the speedometer cable.
  18.  
  19. Install the driveshaft.
  20.  
  21. Attach the stabilizer bar.
  22.  
  23. Install the shift lever assembly:
    1. Using a new gasket, secure the shift lever assembly with its retainers.
    2.  
    3. Install the shift lever boot.
    4.  
    5. Install the shifter lever knob.
    6.  

  24.  
  25. Connect the engine harness and wiring:
    1. Push the engine wiring into the cabin.
    2.  
    3. Connect the engine wire clamps.
    4.  
    5. Attach the ground strap.
    6.  
    7. Install and connect the igniter.
    8.  
    9. Attach the two connectors to the cowl wire.
    10.  
    11. Connect the Electronic Control Unit (ECU).
    12.  
    13. Install the scuff plate to the vehicle.
    14.  
    15. Install the cowl panel side trim.
    16.  

  26.  
  27. Connect the alternator wires.
  28.  
  29. Attach the starter wires:
    1. Install the starter clamps and connectors.
    2.  
    3. Install the nuts and attach the positive battery cable.
    4.  
    5. Install the ground strap.
    6.  

  30.  
  31. Connect the hoses:

    Fuel inlet
     
    Fuel return
     
    Evaporative emissions (EVAP)
     
    Brake booster vacuum
     

  32.  
  33. Connect the heater hoses.
  34.  
  35. Connect the following cables:

    If equipped with cruise control, attach the actuator cable with bracket
     
    Accelerator cable
     
    On A/T, connect the throttle cable
     

  36.  
  37. Install the air cleaner case and filter.
  38.  
  39. Install the Mass Air Flow (MAF) meter, resonator and air cleaner cover.
  40.  
  41. On vehicles with A/C, install the compressor.
  42.  
  43. Install the fan, fluid couplings and pulleys. Tighten to 48 inch lbs. (5 Nm).
  44.  
  45. Install the alternator and A/C drive belts.
  46.  
  47. Install the power steering pump, pulley and drive belt.
  48.  
  49. Install the radiator.
  50.  
  51. Fill the engine with oil.
  52.  
  53. Fill the cooling system.
  54.  
  55. Attach the engine splash shield.
  56.  
  57. Start the engine and check for leaks.
  58.  
  59. Top off any fluid levels.
  60.  

4WD MODELS

See Figures 12, 15 and 16

  1. Disable the air bag system.
  2.  
  3. Remove the transmission from the vehicle.
  4.  
  5. Remove the hood.
  6.  

Apply a lubricant onto any nuts or bolts that will be removed. Allow the lubricant to sit for a short while. This will aid in the removal of tight and frozen nuts and bolts.

  1. Disconnect the battery and remove it from the vehicle.
  2.  


CAUTION
Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.

  1. Raise and support the vehicle safely.
  2.  
  3. Remove the engine splash shields.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove the radiator.
  10.  
  11. Remove the Power Steering (PS) drive belt:
    1. Loosen the fan pulley mounting bolts.
    2.  
    3. Loosen the lock, pivot and adjusting bolts. Remove the drive belt.
    4.  

  12.  
  13. On A/C vehicles, loosen the idle pulley nut and adjusting bolt to remove the A/C drive belt.
  14.  
  15. Loosen the lock, pivot and adjusting bolts. Remove the drive belt.
  16.  
  17. Remove the fan, fluid coupling and pulleys.
  18.  
  19. Disconnect the PS pump from the engine and set aside. Do not disconnect the lines from the pump.
  20.  
  21. On A/C vehicles, disconnect the compressor from the engine and set aside. Do not disconnect the lines from the compressor.
  22.  
  23. Remove the air cleaner lid, Mass Air Flow (MAF) meter and resonator.
  24.  
  25. Remove the air cleaner assembly.
  26.  
  27. Disconnect the following cables:

    Cruise control actuator and bracket
     
    Accelerator cable
     
    On automatics, remove the throttle cable
     

  28.  
  29. Disconnect the heater hoses.
  30.  
  31. Disconnect the following hoses:

    Brake booster vacuum hose
     
    Evaporative emissions (EVAP) hose
     
    Fuel return
     
    Fuel inlet
     

  32.  
  33. Disconnect the starter wire:
    1. Remove the ground strap.
    2.  
    3. Remove the nuts and disconnect the positive battery cable.
    4.  
    5. Disconnect the three starter wire clamps.
    6.  

  34.  
  35. Disconnect the alternator harness.
  36.  
  37. Detach the engine harness:
    1. Remove the right front door scuff plate.
    2.  
    3. Remove the cowl panel side trim.
    4.  
    5. Disconnect the Electronic Control Unit (ECU).
    6.  
    7. Disconnect the wires leading to the cowl.
    8.  
    9. Remove the wiring to the igniter.
    10.  
    11. Disconnect the ground strap.
    12.  
    13. Remove the wire clamps.
    14.  
    15. Pull out the engine wire from the cabin.
    16.  

  38.  
  39. On A/C vehicles, remove the bolt and disconnect the compressor wire clamp.
  40.  
  41. Attach the engine hoist chain to the two engine hangers.
  42.  
  43. Remove the bolts and nuts holding the engine front mounting insulators to the frame.
  44.  
  45. Lift the engine out of the vehicle.
  46.  

To install:
  1. Install the engine assembly in the vehicle. Attach the engine mounts to the body mountings. Install the bolts and nuts but do not tighten them.
  2.  
  3. Remove the engine hoist chain from engine hangers.
  4.  
  5. If equipped with A/C, connect the A/C wire with the bolt.
  6.  
  7. Tighten the engine mounting nuts and bolts to 28 ft. lbs. (38 Nm).
  8.  
  9. Connect the engine harness and wiring:
    1. Push the engine wiring into the cabin.
    2.  
    3. Connect the engine wire clamps.
    4.  
    5. Attach the ground strap.
    6.  
    7. Install and connect the igniter.
    8.  
    9. Attach the two connectors to the cowl wire.
    10.  
    11. Connect the Electronic Control Unit (ECU).
    12.  
    13. Install the scuff plate to the vehicle.
    14.  
    15. Install the cowl panel side trim.
    16.  

  10.  
  11. Connect the alternator wires.
  12.  
  13. Attach the starter wires:
    1. Install the starter clamps and connectors.
    2.  
    3. Install the nuts and attach the positive battery cable.
    4.  
    5. Install the ground strap.
    6.  

  14.  
  15. Connect these hoses:

    Fuel inlet
     
    Fuel return
     
    Evaporative emissions (EVAP)
     
    Brake booster vacuum
     

  16.  
  17. Connect the heater hoses.
  18.  
  19. Connect the following cables:

    If equipped with cruise control, attach the actuator cable with bracket
     
    Accelerator cable
     
    On A/T, connect the throttle cable
     

  20.  
  21. Install the air cleaner case and filter.
  22.  
  23. Install the Mass Air Flow (MAF) meter, resonator and air cleaner cover.
  24.  
  25. Install the A/C compressor if equipped.
  26.  
  27. Install the fan, coupling and pulleys. Tighten the nuts to 48 inch lbs. (5 Nm).
  28.  
  29. Install the A/C drive belt.
  30.  
  31. Install the power steering pump, pulley and drive belt.
  32.  
  33. Install the radiator.
  34.  
  35. Fill the engine with oil.
  36.  
  37. Fill the cooling system.
  38.  
  39. Install the hood.
  40.  
  41. Attach the engine splash shield.
  42.  
  43. Install the transmission in the vehicle.
  44.  
  45. Start the engine and check for leaks.
  46.  
  47. Top off any fluid levels.
  48.  

2RZ-FE and 3RZ-FE Engines

See Figures 17 through 23

  1. Turn the ignition OFF . Disable the air bag system, if equipped.
  2.  
  3. If not already done, disconnect the battery cables, negative first.
  4.  


CAUTION
The air bag system is equipped with a back-up power source. To avoid possible air bag deployment, do not start working on the vehicle until 90 seconds has elapsed from the time the ignition switch is turned OFF and the negative battery terminal is disconnected.

  1. Matchmark the hood hinges, then remove the hood.
  2.  
  3. Relieve the fuel system pressure.
  4.  

Apply a lubricant onto any nuts or bolts that will be removed. Allow the lubricant to sit for a short while. This will aid in the removal of tight and frozen nuts and bolts.

  1. Remove the engine splash shield.
  2.  
  3. Drain the engine oil, transmission fluid and cooling system.
  4.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize you exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. To remove the radiator:
    1. Remove the parking lights from the grille.
    2.  
    3. Remove the two fillers.
    4.  
    5. Remove the grille from the vehicle.
    6.  
    7. On some California models you may need to remove the bolts retaining the air pipe.
    8.  
    9. Disconnect the upper radiator hose and the reservoir hose.
    10.  
    11. Remove the No. 2 fan shroud if equipped.
    12.  
    13. On automatics, disconnect the oil cooler hoses.
    14.  
    15. Remove the lower radiator hose.
    16.  
    17. Remove the four bolts retaining the radiator, and pull the radiator from the vehicle.
    18.  

  2.  
  3. If equipped with power steering, loosen the lock bolt and adjusting bolt to the idler pulley, then remove the drive belt.
  4.  
  5. On A/C vehicles, loosen the idler pulley nut and adjusting bolt. Remove the drive belt.
  6.  



Click image to see an enlarged view

Fig. Fig. 17: Remove the bolts securing the A/C compressor, then position it aside

  1. Remove the alternator drive belt, fan, fan clutch, water pump pulley, and fan shroud as follows:
    1. Loosen the water pump pulley mounting bolts.
    2.  
    3. Loosen the lock, pivot and adjusting bolts for the alternator and remove the alternator drive belt.
    4.  
    5. Remove the water pump pulley mount nuts.
    6.  
    7. Remove the fan (with clutch) and the water pump pulley.
    8.  

  2.  
  3. On manual transmissions, disconnect the accelerator cable from the throttle body.
  4.  
  5. On automatics, disconnect the accelerator and throttle cables from the throttle body.
  6.  
  7. For vehicles with cruise control, remove the actuator cover and disconnect the cable.
  8.  
  9. Remove the air cleaner top, Mass Air Flow (MAF) meter and resonator. Remove the air cleaner assembly.
  10.  
  11. Remove the intake air connector.
  12.  
  13. On vehicles with A/C, disconnect the compressor and bracket:
    1. Disconnect the A/C compressor wiring.
    2.  
    3. Remove the mounting bolts and mounting bracket. Do not disconnect the A/C pressure lines from the compressor. Suspend the compressor away from the engine.
    4.  
    5. Remove the compressor bracket.
    6.  

  14.  
  15. Detach the alternator wiring.
  16.  
  17. Remove the heater hoses at the cowl.
  18.  



Click image to see an enlarged view

Fig. Fig. 18: Remove the clamps shown securing the heater hoses

  1. Disconnect the following hoses:

    Brake booster vacuum
     
    Evaporative emissions (EVAP)
     
    On vehicles with power steering, disconnect the two hoses
     
    Fuel return
     
    Fuel inlet
     

  2.  



Click image to see an enlarged view

Fig. Fig. 19: A spanner wrench can be used to hold the pulley while removing the bolt

  1. Remove the power steering pump:
    1. Using special service tool 09960-10010 or an equivalent spanner wrench, remove the nut and power steering pulley.
    2.  
    3. Remove the two bolts and disconnect the power steering pump.
    4.  

  2.  
  3. Disconnect the following engine wiring:

    Click image to see an enlarged view

    Fig. Fig. 20: Remove the bolts securing the engine wiring clamps

    1. Remove the igniter connection
    2.  
    3. Disconnect the ground strap from the cowl top panel.
    4.  
    5. Disconnect the two engine wire clamps.
    6.  
    7. Remove the nuts holding the engine wire retainer to the cowl panel and pull out the engine wire from the vehicles cabin.
    8.  

  4.  
  5. Disconnect the front exhaust pipe from the exhaust manifold and catalytic converter as follows:
    1. Disconnect the two heated oxygen sensors connectors.
    2.  
    3. Remove the two bolts and retainer holding the front exhaust pipe to the catalytic converter.
    4.  
    5. Loosen the clamp bolt and disconnect the clamp from the support bracket.
    6.  
    7. Remove the two bolts to release the support bracket.
    8.  
    9. Disconnect the three nuts, front exhaust pipe and gaskets from the exhaust manifold.
    10.  

  6.  
  7. On manual transmissions, remove the shift lever assembly as follows:
    1. Remove the shift lever knob.
    2.  
    3. Remove the shift lever boot.
    4.  
    5. Loosen the retaining bolts for the shift lever assembly and baffle, then remove.
    6.  

  8.  
  9. Remove the driveshaft from the vehicle.
  10.  
  11. Disconnect the speedometer cable from the transmission.
  12.  
  13. On manual transmissions, remove the slave cylinder.
  14.  



Click image to see an enlarged view

Fig. Fig. 21: On manual transmissions, the slave cylinder must be removed

  1. On automatics, remove the cross-shaft.
  2.  
  3. Disconnect the wires at the starter.
  4.  
  5. Position a jack and wooden block under the transmission, then remove the rear engine mounting bracket.
  6.  
  7. Attach a suitable engine hoist to the engine hangers.
  8.  
  9. Remove the nuts and bolts from the engine mounts.
  10.  



Click image to see an enlarged view

Fig. Fig. 22: Remove the bolts retaining the rear engine mounting bracket



Click image to see an enlarged view

Fig. Fig. 23: The left and right engine mount retainers must be removed

Make sure the engine/transmission assembly is clear of all the wiring and hoses.

  1. Carefully lift the engine/transmission out of the vehicle.
  2.  

To install:
  1. Attach the engine hoist to the engine hangers. Carefully lower the engine/transmission into the vehicle. Keep the engine level, while aligning the engine mounts.
  2.  
  3. Install the engine mount fasteners, but do not fully tighten them.
  4.  
  5. Position a jack and wooden block under the transmission, then install the rear engine mounting bracket. Tighten the bolts to the frame to 19 ft. lbs. (58 Nm) and the bolts to the mount to 13 ft. lbs (18 Nm).
  6.  
  7. Remove the jack and engine hoist. Tighten the engine mounts to 28 ft. lbs. (38 Nm).
  8.  
  9. Connect the starter wires.
  10.  
  11. On manual transmissions, install the slave cylinder.
  12.  
  13. On automatics, install the cross-shaft.
  14.  
  15. Connect the speedometer to the transmission.
  16.  
  17. Install the driveshaft.
  18.  
  19. On manual transmissions, install the shift lever assembly, shift lever boot and shift knob.
  20.  
  21. Install the front exhaust pipe to the manifold:
    1. Install the two gaskets and the front pipe to the manifold. Install the nuts and bolts, tighten the nuts to 46 ft. lbs. (62 Nm).
    2.  
    3. Install the support bracket with the two bolts. Tighten the brackets to 29 ft. lbs. (39 Nm).
    4.  
    5. Connect the clamp and tighten to 14 ft. lb.s (19 Nm).
    6.  
    7. Install a new gasket on the front pipe and attach to the catalytic converter. Tighten the bolts to 29 ft. lbs. (39 Nm).
    8.  
    9. Connect the heated oxygen sensor wiring.
    10.  

  22.  
  23. Connect the engine wire:
    1. Push the engine wire through the cowl panel. Install the nuts to hold the engine wire retainer to the cowl.
    2.  
    3. Attach the ground strap to the cowl panel.
    4.  
    5. Attach the igniter harness to the unit.
    6.  
    7. Install the two connectors to the cowl wire.
    8.  

  24.  
  25. Attach the alternator wires.
  26.  
  27. Install the power steering pump to the bracket, tighten the bolts to 43 ft. lbs. (58 Nm).
  28.  
  29. With special service tool 09960-10010 or an equivalent spanner wrench, install the power steering pulley, tighten the nut to 32 ft. lbs. (43 Nm).
  30.  
  31. Connect the following hoses:

    Brake booster vacuum
     
    Evaporative emissions (EVAP)
     
    On vehicles with power steering, connect the two hoses
     
    Fuel return
     
    Fuel inlet
     

  32.  
  33. Connect the engine heater hoses at the cowl panel.
  34.  
  35. On vehicles with A/C install the compressor:
    1. Attach the compressor bracket, tighten to 32 ft. lbs. (44 Nm).
    2.  
    3. Attach the A/C compressor to the bracket, tighten the bolts 18 ft. lbs. (25 Nm).
    4.  

  36.  
  37. Install the intake air connector, tighten the bolts to 13 ft. lbs. (18 Nm).
  38.  
  39. Install the water pump pulley, fan shroud, fan with fan clutch, and alternator drive belt:
    1. Place a fan (with the fan clutch), water pump pulley and and shroud in position.
    2.  
    3. Install the water pump pulley mounting nuts but do not tighten them at this time.
    4.  
    5. Install the alternator drive belt.
    6.  
    7. Stretch the belt tight and tighten the fan nuts to 16 ft. lbs. (21 Nm).
    8.  
    9. Adjust the drive belt for the alternator.
    10.  

  40.  
  41. If equipped with A/C, install and adjust the drive belt.
  42.  
  43. Install the adjust the power steering drive belt.
  44.  
  45. On manual transmissions, connect the accelerator cable to the throttle body.
  46.  
  47. On automatics, connect the accelerator and throttle cables to the throttle body.
  48.  
  49. Install the air cleaner case.
  50.  
  51. Install the Mass Air Flow (MAF) meter, resonator and air cleaner cap.
  52.  
  53. Install the radiator to the vehicle with the tabs on the supports through the radiator service holes. Install the bolts and tighten them to 9 ft. lbs. (12 Nm).
  54.  
  55. Connect the lower radiator hose.
  56.  
  57. On automatic transmissions, connect the oil cooler hoses.
  58.  
  59. Connect the upper radiator hose.
  60.  
  61. If removed, connect the air pipe.
  62.  
  63. Install the radiator grille.
  64.  
  65. Attach the two fillers.
  66.  
  67. Attach the parking lights to the grille.
  68.  
  69. Fill the engine oil, coolant and transmission oil.
  70.  
  71. Connect the negative battery cable, then the positive cable.
  72.  
  73. Start the engine and check for leaks.
  74.  
  75. Check the ignition timing.
  76.  
  77. Install the engine splash shield.
  78.  
  79. Install the hood.
  80.  
  81. Road test the vehicle and recheck the fluids.
  82.  

3F-E Engine

See Figures 24 through 32

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant. Drain the engine oil.
  4.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant may be reused unless it is contaminated or several years old.

  1. Scribe matchmarks around the hood hinges, then remove the hood.
  2.  
  3. Relieve the fuel pressure.
  4.  
  5. Remove the battery and its tray.
  6.  

Apply a lubricant onto any nuts or bolts that will be removed. Allow the lubricant to sit for a short while. This will aid in the removal of tight and frozen nuts and bolts.

  1. Disconnect the accelerator and throttle cables.
  2.  
  3. Disconnect the air flow meter connector and clamp. Disconnect the ISC hose, the air pump hose, distributor hose, PCV hose, the 3 hoses from the rear of the intake chamber, and the 2 vacuum hoses from the charcoal canister. Disconnect the air intake hose clamp.
  4.  
  5. Remove the air intake hose, air flow meter and air cleaner cap. Remove the air cleaner element. Remove the three bolts and the air cleaner case.
  6.  
  7. Remove the coolant reservoir tank; remove the radiator.
  8.  
  9. Tag and detached the following wires and connectors:

    Oil pressure sensor
     
    High tension cord at the coil
     
    Neutral start switch and transfer near the starter
     
    Front differential lock
     
    Starter wire and connector
     
    Starter ground strap
     
    Oxygen sensor
     
    Alternator wire and connector
     
    Cooling fan
     

  10.  
  11. Disconnect the following hoses:

    Heater
     
    Fuel
     
    Transfer Case
     
    Brake booster
     
    Distributor
     

  12.  
  13. Remove the glove box. Unplug the four connectors from the ECU. Carefully pull the wiring harness through the firewall.
  14.  
  15. Loosen the power steering pump pulley on its shaft. Loosen the idler pulley nut and bolt; remove the drive belt. Remove the pulley mounting nut, drive pulley and woodruff key. Unbolt the power steering pump and remove it from the bracket.
  16.  
  17. At the air conditioning compressor, disconnect the wiring lead. Loosen the idler pulley and adjuster, then remove the belt. Remove the 4 compressor mounting bolts. Position the compressor out of the way with the hoses still attached. Use stiff wire to support the unit; do not allow the compressor to hang by the hoses.
  18.  
  19. Raise the vehicle, making sure it is well supported. Remove the transfer case undercover.
  20.  
  21. Remove the front and rear driveshafts.
  22.  
  23. Disconnect the speedometer cable.
  24.  
  25. Disconnect the ground strap from the body.
  26.  
  27. Detach the two vacuum hoses from the diaphragm cylinder for the transfer case.
  28.  
  29. Remove the transfer case shift lever.
    1. Remove the clip and pin, disconnect the shift rod from the transfer case.
    2.  
    3. Remove the nut, then disconnect the washers and the shift lever with the shift rod.
    4.  

  30.  
  31. Disconnect the transmission control rod.
  32.  
  33. Disconnect the exhaust pipe at the manifold.
  34.  
  35. Position a floor jack under the transmission with a broad piece of wood to protect the pan. Remove the eight bolts and two nuts that attach the frame crossmember and then remove the crossmember.
  36.  
  37. Attach an engine hoist chain to the lifting brackets on the engine. Remove the engine mount nuts and bolts, then slowly lift the engine/transmission out of the truck.
  38.  



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Fig. Fig. 24: Once disconnected, slide the harness through the cowl panel



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Fig. Fig. 25: Remove the compressor mounting bolts and position out of the way with the hoses attached.



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Fig. Fig. 26: Locations of the front and rear driveshafts bolts



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Fig. Fig. 27: Use a pair of pliers to loosen the speedometer cable fitting



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Fig. Fig. 28: Detach the two vacuum hoses from the diaphragm cylinder on the transfer case



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Fig. Fig. 29: Remove the two nuts securing the control rod on the transmission



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Fig. Fig. 30: Remove the nuts retaining the front exhaust pipe to the manifold



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Fig. Fig. 31: Remove the outer crossmember bolts first, then the inner ones



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Fig. Fig. 32: Use an engine hoist to remove the engine and transmission as an assembly

  1. Remove the oil cooler lines from the transmission.
  2.  
  3. Remove the transmission from the engine.
  4.  
  5. Mount the engine on an engine stand, making sure the retaining bolts are tight. If an engine stand is not available, support the engine in an upright position with blocks. Never leave an engine hanging from a lift or hoist.
  6.  

To install:
  1. Install the transmission and oil cooler lines to the engine. Slowly lower the engine assembly into the engine compartment.
  2.  
  3. Raise the transmission onto the crossmember with a floor jack.
  4.  
  5. Align the holes in the engine mounts and the frame, install the bolts and then remove the engine hoist chain.
  6.  
  7. Raise the transmission slightly and tighten the frame crossmember-to-chassis bolts to 29 ft. lbs. (39 Nm). Tighten the two nuts to 43 ft. lbs. (59 Nm).
  8.  
  9. Install the exhaust pipe with a new gasket and nuts. Tighten the nuts to 46 ft. lbs. (62 Nm).
  10.  
  11. Connect the speedometer cable.
  12.  
  13. Install the front and rear driveshafts. Tighten the nuts to 65 ft. lbs. (88 Nm).
  14.  
  15. Install the transfer case undercover.
  16.  
  17. Install the air conditioning compressor.
  18.  
  19. Install the power steering pump and tighten the pulley nut to 35 ft. lbs. (47 Nm).
  20.  
  21. Carefully feed the fuel injection harness through the firewall. Engage the 4 connectors to the Electronic Control Unit (ECU).
  22.  
  23. Install the glove box.
  24.  
  25. Connect the hoses removed:

    Heater
     
    Fuel
     
    Transfer Case
     
    Brake booster
     
    Air control valve
     
    Distributor
     
    Emission
     

  26.  
  27. Attach the wires and connectors removed:

    Oil pressure sensor
     
    High tension cord at the coil
     
    Neutral start switch and transfer near the starter
     
    Front differential lock
     
    Starter wire and connector
     
    Starter ground strap
     
    Oxygen sensor
     
    Alternator wire and connector
     
    Cooling fan
     
    Check connector
     
    Connector on right fender apron
     

  28.  
  29. Install the radiator and the coolant reservoir tank.
  30.  
  31. Install air cleaner case and the element. Install the air intake hose, air flow meter and air cleaner cap. Connect the hoses:

    ISC hose
     
    Air pump hose
     
    Distributor hose
     
    PCV hose
     
    3 hoses from the rear of the intake chamber
     
    2 vacuum hoses from the canister
     

  32.  
  33. Connect the accelerator and throttle cables. Be sure to adjust them.
  34.  
  35. Refill the engine with oil and the radiator with coolant.
  36.  
  37. Install the battery tray and battery.
  38.  
  39. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  40.  
  41. With the coil wire disconnected from the distributor, crank the engine with the ignition key for 5-10 seconds. This should pre-oil at least the lower part of the engine.
  42.  
  43. Reconnect the coil wire. Start the engine, allowing it to warm up. Check carefully for leaks.
  44.  
  45. Check and adjust the engine specifications as necessary.
  46.  
  47. Install the hood.
  48.  
  49. Road test the vehicle. Recheck and top fluid levels as needed.
  50.  

1FZ-FE Engine

See Figures 33 through 43

  1. Disable the air bag system.
  2.  
  3. Release the fuel pressure.
  4.  
  5. Disconnect the battery cables, negative first. Remove the battery and tray assembly.
  6.  


CAUTION
The air bag system is equipped with a back-up power source. To avoid possible air bag deployment, do not start working on the vehicle until 90 seconds has elapsed from the time the ignition switch is turned OFF and the negative battery terminal is disconnected.

  1. Raise and safely support the vehicle.
  2.  
  3. Drain the engine coolant, transmission fluid and engine oil.
  4.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize you exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Scribe the hood hinges and remove the hood.
  2.  
  3. Remove the radiator grille and radiator.
  4.  
  5. Disconnect the oil cooler hose from the oil cooler pipe.
  6.  
  7. Remove the air cleaner hose, cap and case assembly.
  8.  
  9. Disconnect the cruise control actuator cable from the throttle body.
  10.  
  11. Disconnect the accelerator actuator cable from the throttle body.
  12.  
  13. Disconnect the heater hoses.
  14.  
  15. Disconnect the ground wire and heater control valve from the cowl panel.
  16.  



Click image to see an enlarged view

Fig. Fig. 33: Remove the bolts securing the engine ground wire and heater control valve

  1. Remove the brake booster vacuum hose.
  2.  
  3. Disconnect the evaporative emissions (EVAP) hoses and fuel hoses.
  4.  


CAUTION
Fuel injected engines remain under constant pressure after the ignition has been turned OFF. Properly relieve the pressure before disconnecting any fuel lines. Failure to do so may result in personal injury.

  1. Disconnect the following wires and connectors:

    The two heated oxygen sensors
     
    DCL1 clamp
     
    Oil pressure gauge connections
     
    Alternator wire and connector
     
    Intake manifold from the fender apron connection
     
    High tension cord leading to the ignition coil
     
    Ground strap from the No. 1 engine hanger
     
    Ground strap from the air intake chamber
     
    Ground cable from the cylinder block
     

  2.  
  3. Loosen the idler pulley nut and adjusting nut to remove the A/C drive belt.
  4.  
  5. Disconnect the A/C compressor, then remove the bracket.
  6.  



Click image to see an enlarged view

Fig. Fig. 34: Remove the bolts securing the compressor, then position it aside

  1. Remove the radiator pipe as follows:
    1. Remove the two nuts retaining the radiator pipe to the No. 1 oil pan.
    2.  
    3. Disconnect the No. 2 radiator hose from the water inlet, then remove the radiator pipe.

      Click image to see an enlarged view

      Fig. Fig. 35: Disconnect the No. 2 radiator hose from the water inlet

    4.  

  2.  
  3. Remove the union bolt and the two gaskets, then disconnect the pressure hose from the power steering reservoir pump.
  4.  
  5. Disconnect the return hose from the power steering reservoir tank.
  6.  
  7. Remove the glove compartment door.
  8.  
  9. Remove the speaker panel.
  10.  
  11. Disconnect the A/C amplifier.
  12.  
  13. Disconnect the wire leading to the Electronic Control Unit (ECU) and cowl wire.
  14.  
  15. Pull the engine wire out from the cabin of the vehicle.
  16.  
  17. Remove the stabilizer bar.
  18.  
  19. Matchmark the flanges of the front and rear driveshafts, then remove the shafts.
  20.  



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Fig. Fig. 36: Always matchmark the driveshaft flanges prior to removal

  1. Remove the transfer shift lever.

    Click image to see an enlarged view

    Fig. Fig. 37: Remove this nut to release the control rod



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    Fig. Fig. 38: Remove the screws securing the shifter console, then detach the wiring



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    Fig. Fig. 39: The center console should also be removed

    1. Remove the nut retaining the transmission control rod.
    2.  
    3. Remove the shift knob.
    4.  
    5. Lift up the console slightly in order to disconnect the wire.
    6.  
    7. Remove the shifter console.
    8.  
    9. Remove the center console box.
    10.  
    11. Disconnect the wires, then remove the transfer shift lever boot and lever assembly.
    12.  
    13. Pull out the retaining pin, then disconnect the shift rod.
    14.  
    15. Remove the hose clamp, then the transfer shift lever.
    16.  

  2.  



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Fig. Fig. 40: Bolt locations for removing the shift lever assembly



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Fig. Fig. 41: Assemble the washers for the shift rod linkage as shown

  1. Remove the front exhaust pipe.
    1. Disconnect the heated oxygen sensor.
    2.  
    3. Remove the nuts and bolts holding the exhaust to the catalyst.
    4.  
    5. Loosen the clamp then disconnect the from the No. 1 support bracket.
    6.  
    7. Remove the No. 1 support bracket.
    8.  
    9. Remove the front exhaust pipe.
    10.  

  2.  
  3. Detach the ground strap from the heat insulator.
  4.  
  5. Place a jack under the transmission. Put a wooden block between the jack and the transmission oil pan to prevent damages to the pan.
  6.  
  7. Remove the frame crossmember.
  8.  
  9. Attach the engine hoist chain to the two engine hangers.
  10.  



Click image to see an enlarged view

Fig. Fig. 42: Secure the engine hoist chain to the engine as shown

  1. Remove the nuts holding the engine front mounting insulators to the frame.
  2.  
  3. Lift the engine with the transmission out of the vehicle slowly and carefully. Make certain the engine is clear of all wiring and hoses.
  4.  

To install:
  1. Attach the engine hoist chain to the engine hangers, then lower the engine and transmission into the vehicle.
  2.  
  3. Install the nuts holding the engine front mounting insulators to the frame crossmember.
  4.  
  5. Keep the engine level with a jack, then remove the chain hoist.
  6.  
  7. Install the front crossmember, then tighten the bolts to 45 ft. lbs. (61 Nm).
  8.  
  9. Tighten the nuts holding the crossmember to the engine rear mounting insulator to 54 ft. lbs. (74 Nm).
  10.  
  11. Tighten the nuts holding the engine front mounting insulators to the frame to 54 ft. lbs. (74 Nm).
  12.  
  13. Connect the ground strap to the heat insulator.
  14.  
  15. Install the front exhaust pipe, then tighten the nuts to 46 ft. lbs. (63 Nm).
    1. Install the No. 1 support bracket, then tighten the bolts to 17 ft. lbs. (24 Nm).
    2.  
    3. Connect the clamp and tighten to 14 ft. lbs. (19 Nm).
    4.  
    5. Connect the front exhaust pipe to the rear catalyst, tighten the bolts to 34 ft. lbs. (46 Nm).
    6.  

  16.  
  17. Install the transfer shift lever and hose clamp, tighten the bolts to 13 ft. lbs. (18 Nm).
  18.  



Click image to see an enlarged view

Fig. Fig. 43: The shift lever must be placed in the neutral position

  1. Connect the shift rod and install the pin.
  2.  
  3. Install the transfer shift lever boot, transmission shift lever assembly and tighten the bolts to 4 ft. lbs. (5 Nm).
  4.  
  5. Attach the connectors to the shift lever assembly.
  6.  
  7. Install the center console box.
  8.  
  9. Connect the pattern select switch.
  10.  
  11. Install the shifter console and shift lever knob.
  12.  
  13. Shift the lever into the neutral (N) position.
  14.  
  15. Fully turn the control shaft lever back and return two notches. It will now be in the neutral (N) position.
  16.  
  17. Connect the transmission control rod and tighten to 9 ft. lbs. (13 Nm).
  18.  

  1. Install the front and rear driveshafts.
    1. On the differential side, align the matchmarks on the flanges, then tighten the front shaft to 54 ft. lbs. (74 Nm), and the rear shaft to 65 ft. lbs. (88 Nm).
    2.  
    3. On the transfer side, align the matchmarks on the flanges, then tighten the front shaft to 54 ft. lbs. (74 Nm), and the rear shaft to 65 ft. lbs. (88 Nm).
    4.  

  2.  
  3. Temporarily install the stabilizer bar to the axle housing.
  4.  
  5. Connect the stabilizer bar brackets to 13 ft. lbs. (18 Nm).
  6.  
  7. Lower the vehicle so that it is resting on its suspension, tighten the bolts holding the stabilizer bar to the axle housing to 19 ft. lbs. (25 Nm).
  8.  
  9. Push the engine wire through the cowl panel and connect the wiring to the Electronic Control Unit (ECU) and the cowl wire.
  10.  
  11. Attach the A/C amplifier.
  12.  
  13. Install the speaker panel and glove compartment door.
  14.  
  15. Connect the return hose to the power steering reservoir tank.
  16.  
  17. Connect the power steering pressure hose with the union bolt and tighten to 42 ft. lbs. (56 Nm).
  18.  
  19. Install the radiator pipe as follows:
    1. Connect the No. 2 radiator hose to the water inlet.
    2.  
    3. Install the two nuts holding the radiator pipe to the No. 1 oil pan. Tighten the nuts to 15 ft. lbs. (21 Nm).
    4.  

  20.  
  21. Install the A/C bracket and tighten the bolts to 27 ft. lbs. (37 Nm).
  22.  
  23. Install the A/C compressor and tighten to bolts to 18 ft. lbs. (25 Nm).
  24.  
  25. Install and adjust the A/C drive belt.
  26.  
  27. Install the following wires and connections:
    1. Two heated oxygen sensors
    2.  
    3. DCL1 clamp
    4.  
    5. Low oil pressure gauge connectors
    6.  
    7. Alternator wires
    8.  
    9. Intake manifold from the fender apron
    10.  
    11. High tension cord from the ignition coil
    12.  
    13. Ground strap from the No. 1 engine hanger
    14.  
    15. Ground strap from the air intake chamber
    16.  
    17. Starter wire
    18.  
    19. Ground cable from the cylinder block
    20.  

  28.  
  29. Connect the fuel inlet hose to the fuel filter and tighten the union bolt to 22 ft. lbs. (39 Nm). Connect the fuel return line.
  30.  
  31. Connect the evaporative emissions (EVAP) hose and brake booster vacuum hose.
  32.  
  33. Connect the heater control valve and the engine wire to the cowl panel. Connect the engine wire and the ground strap.
  34.  
  35. Connect the heater hoses.
  36.  
  37. Connect the accelerator cable to the throttle body.
  38.  
  39. Connect the cruise control actuator cable to the throttle body.
  40.  
  41. Install the air cleaner case, the hose and the cap.
  42.  
  43. Connect the oil cooler hose to oil cooler pipe.
  44.  
  45. Install the radiator.
  46.  
  47. Install the grille.
  48.  
  49. Install the battery tray and battery. Connect the cable.
  50.  
  51. Fill the engine with oil and the transmission with proper amount and type of fluid.
  52.  
  53. Fill the cooling system with coolant.
  54.  
  55. Start the engine and check for leaks.
  56.  
  57. Check the automatic transmission fluid level.
  58.  
  59. Check the timing.
  60.  
  61. Install the hood and test drive the vehicle.
  62.  
  63. Top off any fluid levels.
  64.  

 
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