Toyota Tundra 2001-06

Engine

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

Removal & Installation



3.4L Engines
2-Wheel Drive
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Hood
     
    Battery
     
    Engine under covers
     

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

    Radiator
     
    Fan with the fluid coupling and fan pulleys
     
    Air cleaner cap
     
    Air cleaner case and filter
     

  10.  
  11. Disconnect the following hoses:

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

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

    Ground strap, by removing the bolt
     
    Starter wires
     

  14.  
  15. Remove or disconnect the following:

    Alternator connector and wire
     
    Throttle cable, if equipped with an automatic transmission
     
    Cruise control cable, if equipped with cruise control
     

  16.  
  17. Disconnect the engine wiring harness, as follows:

    Glove box door
     
    Lower the finish No. 2 panel
     
    Heater to register duct
     
    3 Engine Control Module (ECM) connectors
     
    2 cassette connectors and the 2 wire clamps from the lower finish panel
     
    Engine wiring harness clamp
     

  18.  
  19. Remove or disconnect the following:

    Igniter connector
     
    Ground strap
     
    2 engine wiring harness retainer-to-cowl panel nuts and pull out the engine wiring harness
     

  20.  
  21. If equipped with a manual transmission, remove or disconnect the following:

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

  22.  
  23. Remove or disconnect the following:

    Driveshaft from the transmission
     
    Speedometer cable
     

  24.  


NOTE
Do not lose the felt protector and washers.



Front exhaust pipe
 
Clutch release cylinder, if equipped with a manual transmission
 
Nut and the control cable
 

  1. Place a jack under the transmission.
  2.  
  3. Remove or disconnect the following:

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

  4.  
  5. If necessary, install a No. 2 engine hanger with 2 bolts. Tighten the 2 bolts to 30 ft. lbs. (40 Nm).
  6.  
  7. Attach the engine hoist chain to the 2 engine hangers.
  8.  
  9. Remove or disconnect the following:

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

  10.  

To install:

  1. Install or connect the following:

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

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

    Air conditioning wire with the bolt, if equipped with air conditioning
     
    Transmission mounting bracket. Tighten the frame bolts to 43 ft. lbs. (58 Nm) and the mounting insulator bolts to 13 ft. lbs. (18 Nm).
     
    Tighten the engine mounting nuts and bolts to 28 ft. lbs. (38 Nm).
     
    Control cable
     
    Clutch release cylinder, if equipped with a manual transmission. Torque the bolts to 9 ft. lbs. (12 Nm).
     

  6.  
  7. Install or connect the following:

    Front exhaust pipe
     
    Speedometer cable
     
    Driveshaft
     

  8.  
  9. If equipped with a manual transmission, install or connect the following:

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

  10.  
  11. Install or connect the following:

    All engine wiring harness, hoses and cables
     
    Fan with the fluid coupling and fan pulleys. Tighten the nuts to 48 inch lbs. (5.4 Nm).
     
    Air cleaner case and air filter
     
    Radiator
     

  12.  
  13. Install or connect the following hoses:

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

  14.  
  15. Fill the engine with oil.
  16.  
  17. Fill the engine and radiator with coolant.
  18.  
  19. Install or connect the following:

    Engine undercover
     
    Battery
     
    Hood
     

  20.  
  21. Start the engine and check for leaks.
  22.  
  23. Make any necessary adjustments and road test the vehicle.
  24.  

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

    Hood
     
    Battery
     
    Engine under covers
     

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

    Radiator
     
    Fan with the fluid coupling and fan pulleys
     
    Air cleaner cap
     
    Air cleaner case and filter
     

  10.  
  11. Disconnect the following hoses:

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

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

    Ground strap, by removing the bolt
     
    Starter wires
     

  14.  
  15. Remove or disconnect the following:

    Alternator connector and wire
     
    Throttle cable, if equipped with an automatic transmission
     
    Cruise control cable, if equipped with cruise control
     

  16.  
  17. Disconnect the engine wiring harness, as follows:

    Glove box door
     
    Lower the finish No. 2 panel
     
    Heater to register duct
     
    3 Engine Control Module (ECM) connectors
     
    2 cassette connectors and the 2 wire clamps from the lower finish panel
     
    Engine wiring harness clamp
     

  18.  
  19. Remove or disconnect the following:

    Igniter connector
     
    Ground strap
     
    2 engine wiring harness retainer-to-cowl panel nuts and pull out the engine wiring harness
     

  20.  
  21. If equipped with a manual transmission, remove or disconnect the following:

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

  22.  
  23. Remove or disconnect the following:
    NOTE
    Do not lose the felt protector and washers.



    Driveshaft from the transmission
     
    Speedometer cable
     



    Front exhaust pipe
     
    Clutch release cylinder, if equipped with a manual transmission
     
    Nut and the control cable
     

  24.  
  25. Place a jack under the transmission.
  26.  
  27. Remove or disconnect the following:

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

  28.  
  29. If necessary, install a No. 2 engine hanger with 2 bolts. Tighten the 2 bolts to 30 ft. lbs. (40 Nm).
  30.  
  31. Attach the engine hoist chain to the 2 engine hangers.
  32.  
  33. Remove or disconnect the following:

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

  34.  

To install:

  1. Install or connect the following:

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

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

    Air conditioning wire with the bolt, if equipped with air conditioning
     
    Transmission mounting bracket. Tighten the frame bolts to 43 ft. lbs. (58 Nm) and the mounting insulator bolts to 13 ft. lbs. (18 Nm).
     
    Tighten the engine mounting nuts and bolts to 28 ft. lbs. (38 Nm).
     
    Control cable
     
    Clutch release cylinder, if equipped with a manual transmission. Torque the bolts to 9 ft. lbs. (12 Nm).
     

  6.  
  7. Install or connect the following:

    Front exhaust pipe
     
    Speedometer cable
     
    Driveshaft
     

  8.  
  9. If equipped with a manual transmission, install or connect the following:

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

  10.  
  11. Install or connect the following:

    All engine wiring harness, hoses and cables
     
    Fan with the fluid coupling and fan pulleys. Tighten the nuts to 48 inch lbs. (5.4 Nm).
     
    Air cleaner case and air filter
     
    Radiator
     

  12.  
  13. Install or connect the following hoses:

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

  14.  
  15. Fill the engine with oil.
  16.  
  17. Fill the engine and radiator with coolant.
  18.  
  19. Install or connect the following:

    Engine undercover
     
    Battery
     
    Hood
     

  20.  
  21. Start the engine and check for leaks.
  22.  
  23. Make any necessary adjustments and road test the vehicle.
  24.  

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

    Transmission
     
    Hood
     

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

    Battery
     
    Engine undercovers
     

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

    Radiator
     
    Fan with the fluid coupling and fan pulleys
     
    Air cleaner cap
     
    Mass Air Flow (MAF) meter and the resonator
     
    Cruise control cable, if equipped with cruise control
     
    Throttle cable, if equipped with an automatic transmission
     

  14.  
  15. Disconnect the following hoses:

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

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

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

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

    Glove box door
     
    Lower the finish No. 2 panel
     
    3 Engine Control Module (ECM) connectors
     
    2 cassette connectors and the 2 wire clamps from the lower finish panel
     
    Igniter connector
     
    Ground strap
     
    Engine wiring harness clamp
     

  22.  
  23. Remove or disconnect the following:

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

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

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

  30.  

To install:

  1. Install or connect the following:

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

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

    Air conditioning wire with the bolt and the compressor bracket, if equipped with air conditioning
     
    Tighten the engine mounting nuts and bolts to 28 ft. lbs. (38 Nm).
     

  6.  
  7. Install the engine wiring harness, as follows:

    Engine wiring harness clamp
     
    Ground strap
     
    Igniter connector
     
    2 cassette connectors and the 2 wire clamps from the lower finish panel
     
    3 Engine Control Module (ECM) connectors
     
    Lower the finish No. 2 panel
     
    Glove box door
     

  8.  
  9. Install or connect the following:

    Cruise control cable, if equipped with cruise control
     
    Throttle cable, if equipped with an automatic transmission
     

  10.  
  11. Connect the following hoses:

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

  12.  
  13. Install or connect the following:

    All wires, hoses and cables
     
    Fan with the fluid coupling and fan pulleys. Tighten the nuts to 48 inch lbs. (5.4 Nm).
     
    Air cleaner case and air filter
     
    MAF meter, resonator and the air cleaner cap
     
    Radiator
     

  14.  
  15. Fill the engine with oil.
  16.  
  17. Fill the engine and radiator with coolant.
  18.  
  19. Install or connect the following:

    Transmission and refill it with transmission oil
     
    Engine undercover
     
    Battery
     
    Hood
     

  20.  
  21. Start the engine, make any necessary adjustments and check for leaks.
  22.  

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

    Transmission
     
    Hood
     

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

    Battery
     
    Engine undercovers
     

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

    Radiator
     
    Fan with the fluid coupling and fan pulleys
     
    Air cleaner cap
     
    Mass Air Flow (MAF) meter and the resonator
     
    Cruise control cable, if equipped with cruise control
     
    Throttle cable, if equipped with an automatic transmission
     

  14.  
  15. Disconnect the following hoses:

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

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

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

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

    Glove box door
     
    Lower the finish No. 2 panel
     
    3 Engine Control Module (ECM) connectors
     
    2 cassette connectors and the 2 wire clamps from the lower finish panel
     
    Igniter connector
     
    Ground strap
     
    Engine wiring harness clamp
     

  22.  
  23. Remove or disconnect the following:

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

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

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

  30.  

To install:

  1. Install or connect the following:

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

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

    Air conditioning wire with the bolt and the compressor bracket, if equipped with air conditioning
     
    Tighten the engine mounting nuts and bolts to 28 ft. lbs. (38 Nm).
     

  6.  
  7. Install the engine wiring harness, as follows:

    Engine wiring harness clamp
     
    Ground strap
     
    Igniter connector
     
    2 cassette connectors and the 2 wire clamps from the lower finish panel
     
    3 Engine Control Module (ECM) connectors
     
    Lower the finish No. 2 panel
     
    Glove box door
     

  8.  
  9. Install or connect the following:

    Cruise control cable, if equipped with cruise control
     
    Throttle cable, if equipped with an automatic transmission
     

  10.  
  11. Connect the following hoses:

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

  12.  
  13. Install or connect the following:

    All wires, hoses and cables
     
    Fan with the fluid coupling and fan pulleys. Tighten the nuts to 48 inch lbs. (5.4 Nm).
     
    Air cleaner case and air filter
     
    MAF meter, resonator and the air cleaner cap
     
    Radiator
     

  14.  
  15. Fill the engine with oil.
  16.  
  17. Fill the engine and radiator with coolant.
  18.  
  19. Install or connect the following:

    Transmission and refill it with transmission oil
     
    Engine undercover
     
    Battery
     
    Hood
     

  20.  
  21. Start the engine, make any necessary adjustments and check for leaks.
  22.  

4.0L 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.
  8.  
  9. Matchmark and remove the hood. Remove the V bank cover.
  10.  
  11. Remove the transmission.
  12.  
  13. Remove the front exhaust pipe assembly.
  14.  
  15. Drain the engine coolant. Remove the radiator.
  16.  
  17. Drain the engine oil.
  18.  
  19. Disconnect the positive battery cable. Remove the battery.
  20.  
  21. Remove the air cleaner assembly. Remove the drive belt. Remove the engine fan. Remove the fan pulley.
  22.  
  23. Remove the power steering pump. Position the unit to the side.
  24.  
  25. Remove the alternator. Remove the air conditioning compressor. Position it to the side.
  26.  
  27. Disconnect the heater hoses from the heater core. Disconnect the fuel line hoses. Remove the intake air surge tank.
  28.  
  29. To separate the main engine wire harness, remove the glove box door. Remove the instrument panel finish panel subassembly, lower right side. Remove the heater to register duct. Disconnect the ECM connectors. Disconnect the engine wire from the engine wire bracket and remove the two nuts, bolt and bracket. Pull the engine wire from the cowl panel.
  30.  
  31. Install engine hanger, tool 12281-31070 and 12282-31050 and retainer bolts 90119-08177. Attach a suitable engine lifting fixture.
  32.  
  33. 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

  34.  
  35. Remove the engine from the vehicle.
  36.  

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.
    NOTE
    On 2005-2006 vehicles perform the automatic transmission initialization procedure when replacing the automatic transmission, engine or ECM.

  10.  
  11. Turn the ignition switch OFF.
  12.  
  13. Connect the intelligent tester tool 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 road test procedure. For roadtest procedure information, refer to the intelligent tester instruction manual.

  22.  
  23. Start the engine and check for leaks, correct as required.
  24.  

4.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Battery and tray
     
    Hood
     
    Engine appearance cover
     
    Air intake pipe
     
    Engine under covers
     
    Coolant recovery tank
     
    Radiator hoses
     
    Radiator and fan shroud
     
    Accessory drive belt
     
    Cooling fan and pulley
     
    Powertrain Control Module (PCM) harness connectors and pass the wiring harness through the firewall
     
    Accelerator cable
     
    Power steering vacuum hoses
     
    Alternator harness connectors
     
    Heater hoses
     
    Engine control wiring harness and grommet at the firewall
     
    Ground cable connector
     
    Fuel lines
     
    Evaporative Emissions (EVAP) canister hoses
     
    Wire clamp at right inner fender
     
    Negative battery cable at the relay box and right inner fender
     
    Positive battery cable
     
    Center console
     
    Transmission shift lever assembly
     
    Transfer case shift lever and rod
     
    Exhaust front pipes
     
    Stabilizer bar
     
    Front and rear driveshafts
     
    A/C compressor
     
    Power steering pump
     

  10.  
  11. Attach a hoist to the engine lifting eyes.
  12.  
  13. Remove or disconnect the following:

    Transfer case skid plate
     
    Left and right motor mounts
     
    Transmission mount crossmember
     

  14.  
  15. Attach a hoist to the engine lifting eyes and raise the powertrain out of the vehicle.
  16.  

To install:

  1. Lower the powertrain into the vehicle.
  2.  
  3. Install or connect the following:

    Transmission mount crossmember. Tighten the bolts to 37 ft. lbs. (50 Nm) and the nuts to 55 ft. lbs. (74 Nm).
     
    Transfer case skid plate
     
    Left and right motor mounts. Tighten the fasteners to 22 ft. lbs. (30 Nm).
     
    Power steering pump. Tighten the bolts to 13 ft. lbs. (17 Nm).
     
    A/C compressor. Tighten the bolts to 36 ft. lbs. (49 Nm).
     
    Front driveshaft. Tighten the fasteners to 59 ft. lbs. (80 Nm).
     
    Rear driveshaft. Tighten the fasteners to 78 ft. lbs. (106 Nm).
     
    Stabilizer bar. Tighten the bracket bolts to 13 ft. lbs. (18 Nm) and the link nuts to 18 ft. lbs. (25 Nm).
     
    Exhaust front pipes
     
    Transfer case shift lever and rod
     
    Transmission shift lever assembly
     
    Center console
     
    Positive battery cable
     
    Negative battery cable at the relay box and right inner fender
     
    Wire clamp at right inner fender
     
    EVAP canister hoses
     
    Fuel lines
     
    Ground cable connector
     
    Engine control wiring harness and grommet at the firewall
     
    Heater hoses
     
    Alternator harness connectors
     
    Power steering vacuum hoses
     
    Accelerator cable
     
    PCM harness connectors
     
    Cooling fan and pulley
     
    Accessory drive belt
     
    Radiator and fan shroud
     
    Radiator hoses
     
    Coolant recovery tank
     
    Engine under covers
     
    Air intake pipe
     
    Engine appearance cover
     
    Hood
     
    Battery and tray
     

  4.  
  5. Fill the crankcase to the correct level.
  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Battery and tray
     
    Hood
     
    Engine appearance cover
     
    Air intake pipe
     
    Engine under covers
     
    Coolant recovery tank
     
    Radiator hoses
     
    Radiator and fan shroud
     
    Accessory drive belt
     
    Cooling fan and pulley
     
    Powertrain Control Module (PCM) harness connectors and pass the wiring harness through the firewall
     
    Accelerator cable
     
    Power steering vacuum hoses
     
    Alternator harness connectors
     
    Heater hoses
     
    Engine control wiring harness and grommet at the firewall
     
    Ground cable connector
     
    Fuel lines
     
    Evaporative Emissions (EVAP) canister hoses
     
    Wire clamp at right inner fender
     
    Negative battery cable at the relay box and right inner fender
     
    Positive battery cable
     
    Center console
     
    Transmission shift lever assembly
     
    Transfer case shift lever and rod
     
    Exhaust front pipes
     
    Stabilizer bar
     
    Front and rear driveshafts
     
    A/C compressor
     
    Power steering pump
     

  10.  
  11. Attach a hoist to the engine lifting eyes.
  12.  
  13. Remove or disconnect the following:

    Transfer case skid plate
     
    Left and right motor mounts
     
    Transmission mount crossmember
     

  14.  
  15. Attach a hoist to the engine lifting eyes and raise the powertrain out of the vehicle.
  16.  

To install:

  1. Lower the powertrain into the vehicle.
  2.  
  3. Install or connect the following:

    Transmission mount crossmember. Tighten the bolts to 37 ft. lbs. (50 Nm) and the nuts to 55 ft. lbs. (74 Nm).
     
    Transfer case skid plate
     
    Left and right motor mounts. Tighten the fasteners to 22 ft. lbs. (30 Nm).
     
    Power steering pump. Tighten the bolts to 13 ft. lbs. (17 Nm).
     
    A/C compressor. Tighten the bolts to 36 ft. lbs. (49 Nm).
     
    Front driveshaft. Tighten the fasteners to 59 ft. lbs. (80 Nm).
     
    Rear driveshaft. Tighten the fasteners to 78 ft. lbs. (106 Nm).
     
    Stabilizer bar. Tighten the bracket bolts to 13 ft. lbs. (18 Nm) and the link nuts to 18 ft. lbs. (25 Nm).
     
    Exhaust front pipes
     
    Transfer case shift lever and rod
     
    Transmission shift lever assembly
     
    Center console
     
    Positive battery cable
     
    Negative battery cable at the relay box and right inner fender
     
    Wire clamp at right inner fender
     
    EVAP canister hoses
     
    Fuel lines
     
    Ground cable connector
     
    Engine control wiring harness and grommet at the firewall
     
    Heater hoses
     
    Alternator harness connectors
     
    Power steering vacuum hoses
     
    Accelerator cable
     
    PCM harness connectors
     
    Cooling fan and pulley
     
    Accessory drive belt
     
    Radiator and fan shroud
     
    Radiator hoses
     
    Coolant recovery tank
     
    Engine under covers
     
    Air intake pipe
     
    Engine appearance cover
     
    Hood
     
    Battery and tray
     

  4.  
  5. Fill the crankcase to the correct level.
  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
  10.  


NOTE
On 2WD the transmission is removed along with the engine. On 4WD the automatic transmission must be removed before removing the 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 remove the front driveshaft assembly. Remove the automatic transmission.
  12.  
  13. Drain the cooling system. Remove the radiator.
  14.  
  15. Drain the engine oil.
  16.  
  17. Remove the air cleaner hose. Remove the air cleaner cap. Remove the air cleaner filter element subassembly. Remove the air cleaner case.
  18.  
  19. Loosen the fan assembly. Remove the drive belt. Remove the engine fan.
  20.  
  21. To separate the main engine wire harness, remove the glove box door. Remove the instrument panel finish panel subassembly. Disconnect the ECM connectors. Disconnect the two wire harness connector. Disconnect the engine wire from the engine wire bracket and remove the two nuts, bolt and bracket. Pull the engine wire from the cowl panel. Disconnect the ground strap.
  22.  
  23. Disconnect the two power steering air hoses from the hose clamp on the number three timing belt cover, right side.
  24.  
  25. Disconnect the hose clamp for the power steering air hose.
  26.  
  27. Disconnect the power steering air hose from the upper intake manifold.
  28.  
  29. Disconnect and plug the heater hoses.
  30.  
  31. Disconnect the air inlet hose from the charcoal canister.
  32.  
  33. Disconnect the EVAP hose from the VSV.
  34.  
  35. Disconnect the brake booster hose. Disconnect the alternator wiring. Disconnect the fuel lines.
  36.  
  37. Disconnect the heated oxygen sensor connectors. Remove the two bolts, three nuts, gasket, ring and front right exhaust pipe from the exhaust manifold.
  38.  
  39. Disconnect the heated oxygen sensor connectors. Remove the two bolts, three nuts, gasket, ring and front left exhaust pipe from the exhaust manifold.
  40.  
  41. Remove the driveshaft, with the center bearing assembly.
  42.  
  43. Remove the front stabilizer bar assembly.
  44.  
  45. Disconnect the power steering hoses.
  46.  
  47. Remove the transmission control cable assembly.
  48.  
  49. Remove the air conditioning compressor and position it to the side.
  50.  
  51. Remove the power steering pump and position it to the side.
  52.  
  53. Install the engine hangers and retainer bolts. Attach a suitable engine lifting fixture.
  54.  
  55. Remove the engine retaining bolts.
  56.  
  57. On 2WD, remove the eight bolts, two nuts and frame crossmember. Remove the four bolts and engine rear mounting bracket from the transmission.
  58.  
  59. Remove the engine assembly from the vehicle.
    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.

  60.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Tighten the four mounting insulator bolts to 27 ft. lbs.
  4.  
  5. On 2WD tighten the number one engine rear mounting insulator bolts to 48 ft. lbs.
  6.  
  7. On 2WD tighten the four frame crossmember bolts to 53 ft. lbs.
  8.  
  9. On 2WD tighten the four crossmember to transmission nuts to 13 ft. lbs.
  10.  
  11. Be sure to fill the cooling system with the proper grade and type engine coolant.
  12.  
  13. Be sure to fill the engine with the proper grade and type engine oil.
    NOTE
    On 2005-2006 vehicles perform the automatic transmission initialization procedure when replacing the automatic transmission, engine or ECM.

  14.  
  15. Turn the ignition switch OFF.
  16.  
  17. Connect the intelligent tester tool to the DLC3.
  18.  
  19. Turn the ignition switch to the ON position.
  20.  
  21. Push the intelligent tester tool main switch to the ON position.
  22.  
  23. Select the items, DIAGNOSIS/ENHANCED OBD II.
  24.  
  25. Perform the reset memory procedure from the ENGINE menu.
    NOTE
    After performing the reset memory, be sure to perform the road test procedure. For roadtest procedure information, refer to the intelligent tester instruction manual.

  26.  
  27. Start the engine and check for leaks, correct as required.
  28.  

 
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