Toyota Tacoma 2002-06

Engine

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Removal & Installation



1gr-FE Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly disable the SRS system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable. Disconnect the positive battery cable.
  8.  
  9. Disconnect the windshield washer hose. Matchmark and remove the hood.
  10.  
  11. Drain the engine coolant. Remove the battery. Remove the battery tray. Drain the engine oil.
  12.  
  13. Remove the radiator support to frame seal, left side.
  14.  
  15. Remove the fan shroud. Remove the radiator hoses. Remove the radiator.
  16.  
  17. Remove the V bank cover.
  18.  
  19. Remove the transmission. If equipped with manual transmission, remove the clutch cover and clutch.
  20.  
  21. Remove the fan pulley. Remove the vane pump assembly. Remove the alternator.
  22.  
  23. Separate the air conditioning compressor from the engine and position it to the side.
  24.  
  25. Disconnect the heater hoses from the heater core. Disconnect the fuel line hoses. Remove the intake air surge tank.
  26.  
  27. To separate the main engine wire harness, remove the glove box door. Remove the instrument panel finish panel subassembly, lower right side. Disconnect the ECM connectors. Disconnect the connectors from the ECU, if equipped with 4WD. Pull the harness into the engine compartment. Disconnect the front differential connector, if equipped with 4WD. Disconnect the three connectors from the engine compartment relay block. Separate the engine wire from the engine compartment relay block.
  28.  
  29. Disconnect the ground cable from the cylinder head.
  30.  
  31. Remove the front exhaust pipe assembly.
  32.  
  33. Install engine hanger, tool 12281-31070 and 12282-31050 and retainer bolts 90119-08177. Attach a suitable engine lifting fixture.
  34.  
  35. Remove the engine retaining bolts and mounts.
    NOTE
    Check to be sure nothing will interfere with the removal of the engine. Check to be sure all required wires, hoses and connectors are disconnected.



    Click image to see an enlarged view

    Fig. Engine retaining bolt locations-4.0L engine

  36.  
  37. Remove the engine from the vehicle.
  38.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Tighten the four mounting insulator bolts to 28 ft. lbs.
  4.  
  5. If equipped with automatic transmission, perform the automatic transmission initialization procedure listed below.
    NOTE
    Perform the automatic transmission initialization procedure when replacing the automatic transmission, engine or ECM.

  6.  
  7. On the A340E automatic transmission, initialization is completed by connecting and disconnecting the negative battery cable.
  8.  
  9. On the A750E automatic transmission, initialization is performed using the intelligent tester tool.
  10.  
  11. Turn the ignition switch OFF.
  12.  
  13. Connect the intelligent tester tool together with the controller area network vehicle interface module (CAN VIN) to the DLC3.
  14.  
  15. Turn the ignition switch to the ON position.
  16.  
  17. Push the intelligent tester tool main switch to the ON position.
  18.  
  19. Select the items, DIAGNOSIS/ENHANCED OBD II.
  20.  
  21. Perform the reset memory procedure from the ENGINE menu.
    NOTE
    After performing the reset memory, be sure to perform the roadtest procedure. For roadtest procedure information, refer to the intelligent tester instruction manual.

  22.  
  23. Be sure to fill the cooling system with the proper grade and type engine coolant.
  24.  
  25. Be sure to fill the engine with the proper grade and type engine oil.
  26.  
  27. Check ignition timing. Check idle speed.
  28.  
  29. Start the engine and check for leaks, correct as required.
  30.  

2RZ-FE Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Turn the ignition switch OFF .
  6.  
  7. Remove or disconnect the following:

    Battery cables; negative cable first
     
    Hood by matchmarking the hood hinges
     
    Engine undercover
     

  8.  
  9. Drain the engine oil, transmission oil and cooling system.
  10.  
  11. Remove or disconnect the following:

    Radiator
     
    Drive belts
     
    Loosen the lockbolt and adjusting bolt to the idler pulley, if equipped with power steering
     
    Loosen the idler pulley nut and adjusting bolt, if equipped with air conditioning
     
    Fan (with fan clutch), water pump pulley and fan shroud
     
    Accelerator cable from the throttle body, if equipped with a manual transaxle
     
    Accelerator and throttle cables from the throttle body, if equipped with an automatic transaxle
     
    Actuator cover and cruise control cable from the actuator, if equipped with cruise control
     
    Air cleaner cap, Mass Air Flow (MAF) and resonator
     
    Air cleaner case
     
    Intake air connector
     
    Air conditioning compressor and bracket, if equipped with air conditioning
     
    Alternator wires from the alternator
     
    Heater hoses at the cowl panel
     
    Brake booster vacuum hose
     
    EVAP hose
     
    Vacuum hose, if equipped with 4WD with Automatic Disconnecting Differential (ADD)
     
    Both power steering hoses, if equipped with power steering
     
    Fuel return hose
     
    Fuel inlet hose
     

  12.  
  13. Remove the power steering pump as follows:

    Nut and power steering pulley
     
    Both bolts and the power steering pump
     

  14.  
  15. Disconnect the Engine Control Module (ECM) wiring from the ECM as follows:

    Right front door scuff plate
     
    Cowl panel side trim by removing the clip
     
    4 ECM electrical connectors.
     

  16.  
  17. Detach the engine wiring harness and connectors as follows:

    Igniter connector
     
    Ground strap from the cowl top panel
     
    Both engine wiring harness clamps
     
    Engine wiring harness retainer to the cowl panel nuts and pull out the engine wiring harness from the vehicle
     

  18.  
  19. Disconnect the front exhaust pipe from the exhaust manifold and catalytic converter.
  20.  
  21. If equipped with manual transmission, remove the shift lever assembly as follows:

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

  22.  
  23. Remove or disconnect the following:

    Driveshaft
     
    Speedometer cable from the transmission
     
    Clutch release cylinder, if equipped with manual transmission
     
    Cross-shaft, if equipped with automatic transmission
     
    Wires at the starter
     

  24.  
  25. Position a jack and wooden block under the transmission and remove the rear engine mounting bracket.
  26.  
  27. Attach an engine hoist to the engine hangers.
  28.  
  29. Remove or disconnect the following:

    Nuts and bolts from the engine mounts
     
    Engine/transmission assembly
     

  30.  

To install:

  1. Install or connect the following:

    Engine/transmission assembly, by keeping the engine level, while aligning the engine mounts
     
    Engine mount fasteners but do not fully tighten them
     

  2.  
  3. Position a jack and wooden block under the transmission.
  4.  
  5. Install the rear engine mounting bracket. Tighten the frame bolts to 43 ft. lbs. (58 Nm) and the mount bolts to 13 ft. lbs. (18 Nm).
  6.  
  7. Remove the jack and engine hoist.
  8.  
  9. Install or connect the following:

    Tighten the engine mounts to 28 ft. lbs. (38 Nm).
     
    Starter wires to the starter
     
    Clutch release cylinder, if equipped with manual transmission
     
    Cross-shaft, if equipped with automatic transmission
     
    Speedometer to the transmission
     
    Driveshaft
     

  10.  
  11. If equipped with manual transmission, install the shift lever assembly as follows:

    Baffle and shift lever assembly with the 6 bolts
     
    Shift lever boot with the 4 screws
     
    Shift lever knob
     
    Front exhaust pipe to the exhaust manifold
     
    All wires and connectors
     
    Cowl side trim and clip
     
    Front door scuff plate
     
    Alternator wires to the alternator
     

  12.  
  13. Install the power steering pump as follows:

    Power steering pump to the bracket with the 2 bolts. Tighten the bolts to 43 ft. lbs. (58 Nm).
     
    Power steering pulley with the nut. Tighten the nut to 32 ft. lbs. (43 Nm).
     

  14.  
  15. Install or connect the following:

    All hoses
     
    Compressor, if equipped with air conditioning
     
    Intake air connector. Tighten the 2 bolts to 13 ft. lbs. (18 Nm).
     
    Water pump pulley, fan shroud, fan (with fan clutch) and alternator drive belt.
     
    Drive belt, if equipped with air conditioning
     
    Power steering drive belt
     
    Accelerator cable to the throttle body, if equipped with manual transmission
     
    Accelerator and throttle cables to the throttle body, if equipped with automatic transmission
     
    Air cleaner case
     
    MAF meter, resonator and air cleaner cap
     
    Radiator with the support tabs through the radiator service holes. Tighten the bolts to 108 inch lbs. (13 Nm).
     
    Lower radiator hose to the radiator
     
    Oil cooler hoses to the radiator, if equipped with an automatic transmission
     
    No. 2 fan shroud.
     
    Radiator reservoir hose to the radiator
     
    Upper radiator hose to the radiator
     
    Air pipe
     
    Radiator grille to the vehicle with the 11 clips
     
    Both fillers
     
    Clearance lights to the grille with the 4 bolts and 2 clips
     
    Both battery cables
     

  16.  
  17. Fill the engine oil, engine coolant and transmission oil.
  18.  
  19. Start the engine and check for leaks.
  20.  
  21. Check ignition timing.
  22.  
  23. Install or connect the following:

    Engine undercover
     
    Hood
     

  24.  
  25. Roadtest the vehicle and check all fluids.
  26.  

2TR-FE Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly disable the SRS system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable. Disconnect the positive battery cable.
  8.  
  9. Matchmark and remove the hood.
  10.  
  11. On 4WD and PreRunner, remove the number one engine cover.
  12.  
  13. On 4WD and PreRunner (regular cab) remove the number two engine cover.
  14.  
  15. Drain the engine coolant. Remove the battery. Remove the battery tray. Drain the engine oil.
  16.  
  17. Remove the radiator support to frame seal, left side.
  18.  
  19. Remove the fan shroud. Remove the air cleaner cap sub assembly. Remove the air cleaner filter element subassembly. Remove the air cleaner case.
  20.  
  21. Separate the vane pump. Remove the radiator hoses. Separate the air conditioning compressor from the engine and position it to the side.
  22.  
  23. Disconnect the heater hoses from the heater core.
  24.  
  25. Disconnect the fuel line hoses. Separate the fuel vapor feed hose assembly. Disconnect the number one air injection hose.
  26.  
  27. Disconnect all engine wiring harnesses and connectors in the engine compartment.
    NOTE
    Disconnect the connector from the ECM, then pull the engine wire harness to the compartment side. Do not forcibly pull the wire harness to the engine compartment side.

  28.  
  29. Remove the exhaust pipe assembly. Remove the front exhaust pipe assembly.
  30.  
  31. Remove the transmission.
  32.  
  33. Install engine hanger, tool 12281-75040 and retainer bolts 91552-A1020. Attach a suitable engine lifting fixture.
  34.  
  35. Remove the engine retaining bolts and mounts.
    NOTE
    Check to be sure nothing will interfere with the removal of the engine. Check to be sure all required wires, hoses and connectors are disconnected.



    Click image to see an enlarged view

    Fig. Engine retaining bolt locations-2.7L (2TR-FE) engine

  36.  
  37. Remove the engine from the vehicle.
  38.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Tighten the four mounting insulator bolts to 28 ft. lbs.
  4.  
  5. Be sure to fill the cooling system with the proper grade and type engine coolant.
  6.  
  7. Be sure to fill the engine with the proper grade and type engine oil.
  8.  
  9. Check ignition timing. Check idle speed.
  10.  
  11. Start the engine and check for leaks, correct as required.
  12.  

3RZ-FE Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Turn the ignition switch OFF .
  6.  
  7. Remove or disconnect the following:

    Battery cables; negative cable first
     
    Hood
     
    Engine undercover
     

  8.  
  9. Drain the engine oil, transmission oil and cooling system.
  10.  
  11. Remove or disconnect the following:

    Radiator
     
    Idler pulley and drive belt, if equipped with power steering
     
    Idler pulley nut/bolt and drive belt, if equipped with air conditioning
     
    Alternator drive belt, fan (with fan clutch), water pump pulley and fan shroud
     
    Accelerator cable from the throttle body, if equipped with a manual transaxle
     
    Accelerator and throttle cables from the throttle body, if equipped with a automatic transaxle
     
    Actuator cover and the cruise control cable from the actuator, if equipped with cruise control
     
    Air cleaner cap
     
    Mass Air Flow (MAF) meter and resonator
     
    Air cleaner case
     
    Intake air connector
     
    Air conditioning compressor and bracket, if equipped with air conditioning
     
    Alternator wires
     
    Heater hoses at the cowl panel
     

  12.  
  13. Disconnect the following hoses:

    Brake booster vacuum hose
     
    Evaporative Emissions (EVAP) hose
     
    Vacuum hose, if equipped with 4WD with Automatic Disconnecting Differential (ADD)
     
    Both power steering hoses, if equipped with power steering
     
    Fuel return hose
     
    Fuel inlet hose
     

  14.  
  15. Remove the power steering pump as follows:

    Nut and power steering pulley
     
    Power steering pump
     

  16.  
  17. Disconnect the Engine Control Module (ECM) wiring from the ECM as follows:

    4 screws to the right front door scuff plate
     
    Scuff plate
     
    Cowl panel side trim by removing the clip
     
    4 ECM electrical connectors
     

  18.  
  19. Detach the engine wiring harness and connectors from the vehicle as follows:

    Igniter
     
    Ground strap from the cowl top panel
     
    2 engine wiring harness clamps
     
    Engine wiring harness retainer to cowl panel nut and wiring harness
     

  20.  
  21. Disconnect the front exhaust pipe from the exhaust manifold and catalytic converter.
  22.  
  23. If equipped with manual transmission, remove the shift lever assembly as follows:
  24.  
  25. Remove or disconnect the following:

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

  26.  
  27. Remove or disconnect the following:

    Driveshaft
     
    Speedometer cable from the transmission
     
    Clutch release cylinder, if equipped with manual transmission
     
    Cross-shaft, If equipped with automatic transmission
     
    Wires at the starter
     

  28.  
  29. Position a jack and wooden block under the transmission.
  30.  
  31. Remove the rear engine mounting bracket.
  32.  
  33. Attach an engine hoist to the engine hangers.
  34.  
  35. Remove or disconnect the following:

    Nuts and bolts from the engine mounts
     
    Engine/transmission
     

  36.  

To install:

  1. Attach the engine hoist to the engine hangers.
  2.  
  3. Install or connect the following:
    NOTE
    Keep the engine level, while aligning the engine mounts.



    Engine/transmission assembly
     



    Engine mount fasteners but do not fully tighten them
     
    Position a jack and wooden block under the transmission
     
    Rear engine mounting bracket. Tighten the frame bolts to 19 ft. lbs. (26 Nm) and the mount bolts to 13 ft. lbs. (18 Nm).
     

  4.  
  5. Remove the jack and engine hoist.
  6.  
  7. Install or connect the following:

    Tighten the engine mounts to 28 ft. lbs. (38 Nm).
     
    Starter wires
     
    Clutch release cylinder, if equipped with manual transmission
     
    Cross-shaft, if equipped with automatic transmission
     
    Speedometer to the transmission
     
    Driveshaft
     

  8.  
  9. If equipped with manual transmission, install the shift lever assembly as follows:

    Baffle and shift lever assembly with the 6 bolts
     
    Shift lever boot with the 4 screws
     
    Shift lever knob
     

  10.  
  11. Install or connect the following:

    Front exhaust pipe to the exhaust manifold
     
    Engine wiring harness
     
    Cowl side trim and clip
     
    Front door scuff plate
     
    Alternator wires
     

  12.  
  13. Install the power steering pump as follows:

    Power steering pump to the bracket. Tighten the 2 bolts to 43 ft. lbs. (58 Nm).
     
    Power steering pulley. Tighten the nut to 32 ft. lbs. (43 Nm).
     

  14.  
  15. Install or connect the following:

    All hoses
     
    Heater hoses at the cowl panel
     
    Compressor, if equipped with air conditioning
     
    Intake air connector. Tighten the 2 bolts to 13 ft. lbs. (18 Nm).
     

  16.  
  17. Install the water pump pulley, fan shroud, fan (with fan clutch) and alternator drive belt as follows:

    Fan (with the fan clutch), water pump pulley and fan shroud in position
     
    Water pump pulley but do not tighten the nuts
     
    Alternator drive belt
     
    Stretch the alternator belt tight. Tighten the fan nuts to 16 ft. lbs. (21 Nm).
     
    Adjust the alternator drive belt
     

  18.  
  19. Install or connect the following:

    Adjust the drive belt, if equipped with air conditioning
     
    Adjust the power steering drive belt
     
    Accelerator cable to the throttle body, if equipped with manual transmission
     
    Accelerator and throttle cables to the throttle body, if equipped with automatic transmission
     
    Air cleaner case
     
    MAF meter, resonator and air cleaner cap
     
    Radiator with the tabs on the supports through the radiator service holes. Tighten the bolts to 108 inch lbs. (13 Nm).
     
    Lower radiator hose to the radiator
     
    Oil cooler hoses to the radiator, if equipped with automatic transmission
     
    No. 2 fan shroud
     
    Radiator reservoir hose to the radiator
     
    Upper radiator hose to the radiator
     
    Air pipe with the 2 bolts, if removed
     
    Radiator grille with the 11 clips
     
    2 fillers
     
    Clearance lights to the grille with the 4 bolts and 2 clips
     
    Negative and positive cables to the battery
     

  20.  
  21. Fill the engine oil, engine coolant and transmission oil.
  22.  
  23. Start the engine and check for leaks.
  24.  
  25. Check ignition timing.
  26.  
  27. Install or connect the following:

    Engine undercover
     
    Hood
     

  28.  
  29. Road test the vehicle and check all fluids.
  30.  

5vz-FE Engine
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 undercovers
     

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

    Radiator
     

  12.  
  13. Remove the power steering drive belt as follows:

    Stretch the belt and loosen the fan pulley mounting nuts
     
    Loosen the lockbolt, pivot bolt and adjusting bolt and remove the drive belt
     

  14.  
  15. Remove or disconnect the following:

    Air conditioning drive belt by loosening the idle pulley nut and adjusting bolt, if equipped with air conditioning
     
    Loosen the lockbolt, pivot bolt and adjusting bolt and the alternator drive belt
     
    Fan with the fluid coupling and fan pulleys
     
    Power steering pump, do not disconnect the lines from the pump
     
    Compressor, if equipped with air conditioning; do not disconnect the lines from the compressor
     
    Air cleaner cap
     
    Mass Air Flow (MAF) meter and resonator
     
    Air cleaner case and filter
     

  16.  
  17. Disconnect the following cables:

    Actuator cable with the bracket, if equipped with cruise control
     
    Accelerator cable
     
    Throttle cable, if equipped with an automatic transmission
     

  18.  
  19. Disconnect the following hoses:

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

  20.  
  21. Detach the starter wire and connectors as follows:

    Ground strap by removing the bolt
     
    Positive cable from the battery
     
    3 starter wire clamps and connector
     

  22.  
  23. Detach the alternator connector and wire.
  24.  
  25. Detach the engine wiring harness and connectors as follows:

    Right front door scuff plate.
     
    Cowl panel side trim, by removing the clip
     
    Engine Control Module (ECM)
     
    2 connectors from the cowl wire
     
    Igniter
     
    Ground strap
     
    6 engine wiring harness clamps
     
    Engine wiring harness
     

  26.  
  27. If equipped with manual transmission, remove the shift lever assembly as follows:

    Shift lever knob
     
    4 screws and the shift lever boot
     
    Shift lever assembly and gasket, by removing the 6 bolts
     

  28.  
  29. Remove or disconnect the following:

    Stabilizer bar
     
    Driveshaft from the transmission
     
    Speedometer cable
     
    Front exhaust pipe
     
    Clutch release cylinder, if equipped with a manual transmission
     
    Cross-shaft, if equipped with an automatic transmission
     

  30.  
  31. Place a jack under the transmission.
  32.  
  33. Remove or disconnect the following:

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

  34.  
  35. If necessary, install a No. 2 engine hanger with 2 bolts. Tighten the 2 bolts to 30 ft. lbs. (40 Nm).
  36.  
  37. Attach the engine hoist chain to the 2 engine hangers.
  38.  
  39. Remove or disconnect the following:

    4 bolts/nuts holding the engine front mounting insulators to the frame
     
    Engine/transmission assembly
     

  40.  

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, 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).
     
    Cross-shaft, if equipped with an automatic transmission
     
    Clutch release cylinder, if equipped with a manual transmission. Tighten the bolts to 108 inch lbs. (13 Nm).
     
    Front exhaust pipe
     
    Speedometer cable
     
    Driveshaft
     
    Stabilizer bar
     

  6.  
  7. Install the shift lever assembly, as follows:
  8.  
  9. Install or connect the following:

    New gasket and shift lever assembly with the 6 bolts
     
    Shift lever boot with the 4 screws
     
    Shift lever knob
     

  10.  
  11. Install or connect the following:

    All engine wiring harness, hoses and cables
     
    Air cleaner case and air filter
     
    MAF meter, resonator and air cleaner cap
     
    Air conditioning compressor, if equipped
     
    Remaining components
     

  12.  
  13. Fill the engine with oil.
  14.  
  15. Fill the engine and radiator with coolant.
  16.  
  17. Install the engine undercover.
  18.  
  19. Start the engine and check for leaks.
  20.  

4wd
  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:

    Transmission
     
    Hood
     
    Battery from the vehicle
     
    Engine undercovers
     

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

    Radiator
     

  12.  
  13. Remove the power steering drive belt, as follows:

    Stretch the belt and loosen the fan pulley mounting nuts
     
    Loosen the lockbolt, pivot bolt and adjusting bolt
     
    Drive belt from the engine
     

  14.  
  15. Remove or disconnect the following:

    Air conditioning drive belt by loosening the idle pulley nut and adjusting bolt, if equipped with air conditioning
     
    Alternator drive belt
     
    Fan with the fluid coupling and fan pulleys
     
    Power steering pump; do not disconnect the lines from the pump
     
    Compressor, if equipped with air conditioning. Do not disconnect the lines from the compressor.
     
    Air cleaner cap, Mass Air Flow Meter (MAF) meter and resonator
     
    Air cleaner case and filter
     

  16.  
  17. Disconnect the following cables:

    Actuator cable with the bracket, if equipped with cruise control
     
    Accelerator cable
     
    Throttle cable, if equipped with an automatic transmission
     

  18.  
  19. 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
     

  20.  
  21. Detach the starter wire and connectors as follows:
  22.  
  23. Remove or disconnect the following:

    Ground strap by removing the bolt
     

  24.  
  25. Disconnect the positive cable from the battery, as follows:

    3 starter wire clamps and connector
     
    Automatic Disconnecting Differential (ADD) indicator switch connector
     

  26.  
  27. Detach the alternator connector and wire.
  28.  
  29. Detach the engine wiring harness and connectors, as follows:

    Right front door scuff plate
     
    Cowl panel side trim, by removing the clip
     
    Engine Control Module (ECM)
     
    2 connectors from the cowl wire
     
    Igniter connector
     
    Ground strap
     
    6 engine wiring harness clamps
     
    Engine wiring harness
     

  30.  
  31. Remove or disconnect the following:

    Air conditioning compressor wire clamp, if equipped with air conditioning
     

  32.  
  33. If necessary, install a No. 2 engine hanger with 2 bolts. Tighten the 2 bolts to 30 ft. lbs. (40 Nm).
  34.  
  35. Attach the engine hoist chain to the 2 engine hangers.
  36.  
  37. Remove or disconnect the following:

    4 Engine front mounting insulators-to-frame bolts/nuts
     
    Engine
     

  38.  

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
     
    Tighten the engine mounting nuts and bolts to 28 ft. lbs. (38 Nm).
     
    All engine wiring harness, hoses and cables
     
    Air cleaner case and air filter
     
    MAF meter, resonator and air cleaner cap
     
    Air conditioning compressor, if equipped
     
    Fan with the fluid coupling and fan pulleys. Tighten the nuts to 48 inch lbs. (5.4 Nm).
     
    Alternator drive belt
     
    Adjust the air conditioning drive belt, if equipped
     
    Power steering pump, pump pulley and the drive belt
     
    Radiator
     

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

    Hood
     
    Engine undercover
     
    Transmission
     

  12.  
  13. Start the engine and check for leaks.
  14.  

 
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