In this chapter there is engine removal procedure mentioned.
The procedure to remove and install engine on Toyota tacoma.
1gr-FE Engine Replacing procedure.
2RZ-FE Engines Replacing procedure.
2TR-FE Engine Replacing Procedure.
3RZ-FE Engine Replacing Procedure.
5vz-FE Engine 2wd & 4wd engine replacing procedure.
Also required help diagrams are provided for more help.
This all details are mentioned here in this section.
Engine
REMOVAL & INSTALLATION Details are as follows:----
1gr-FE Engine
- Before servicing the vehicle, refer to the Precautions Section.
- Properly disable the SRS system.
- Properly relieve the fuel system pressure.
- Disconnect the negative battery cable. Disconnect the positive battery cable.
- Disconnect the windshield washer hose. Matchmark and remove the hood.
- Drain the engine coolant. Remove the battery. Remove the battery tray. Drain the engine oil.
- Remove the radiator support to frame seal, left side.
- Remove the fan shroud. Remove the radiator hoses. Remove the radiator.
- Remove the V bank cover.
- Remove the transmission. If equipped with manual transmission, remove the clutch cover and clutch.
- Remove the fan pulley. Remove the vane pump assembly. Remove the alternator.
- Separate the air conditioning compressor from the engine and position it to the side.
- Disconnect the heater hoses from the heater core. Disconnect the fuel line hoses. Remove the intake air surge tank.
- 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.
- Disconnect the ground cable from the cylinder head.
- Remove the front exhaust pipe assembly.
- Install engine hanger, tool 12281-31070 and 12282-31050 and retainer bolts 90119-08177. Attach a suitable engine lifting fixture.
- Remove the engine retaining bolts and mounts.
 NOTECheck to be sure nothing will interfere with the removal of the engine. Check to be sure all required wires, hoses and connectors are disconnected.
 
 
 
- Remove the engine from the vehicle.
To install:
- Installation is the reverse of the removal procedure.
- Tighten the four mounting insulator bolts to 28 ft. lbs.
- If equipped with automatic transmission, perform the automatic transmission initialization procedure listed below.
 NOTEPerform the automatic transmission initialization procedure when replacing the automatic transmission, engine or ECM.
- On the A340E automatic transmission, initialization is completed by connecting and disconnecting the negative battery cable.
- On the A750E automatic transmission, initialization is performed using the intelligent tester tool.
- Turn the ignition switch OFF.
- Connect the intelligent tester tool together with the controller area network vehicle interface module (CAN VIN) to the DLC3.
- Turn the ignition switch to the ON position.
- Push the intelligent tester tool main switch to the ON position.
- Select the items, DIAGNOSIS/ENHANCED OBD II.
- Perform the reset memory procedure from the ENGINE menu.
 NOTEAfter performing the reset memory, be sure to perform the roadtest procedure. For roadtest procedure information, refer to the intelligent tester instruction manual.
- Be sure to fill the cooling system with the proper grade and type engine coolant.
- Be sure to fill the engine with the proper grade and type engine oil.
- Check ignition timing. Check idle speed.
- Start the engine and check for leaks, correct as required.
- Before servicing the vehicle, refer to the Precautions Section.
- Properly relieve the fuel system pressure.
- Turn the ignition switch OFF .
- Remove or disconnect the following:
 
 Battery cables; negative cable first
 Hood by matchmarking the hood hinges
 Engine undercover
 
- Drain the engine oil, transmission oil and cooling system.
- 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
 
- Remove the power steering pump as follows:
 
 Nut and power steering pulley
 Both bolts and the power steering pump
 
- 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.
 
- 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
 
- Disconnect the front exhaust pipe from the exhaust manifold and catalytic converter.
- 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
 
- 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
 
- Position a jack and wooden block under the transmission and remove the rear engine mounting bracket.
- Attach an engine hoist to the engine hangers.
- Remove or disconnect the following:
 
 Nuts and bolts from the engine mounts
 Engine/transmission assembly
 
To install:
- 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
 
- Position a jack and wooden block under the transmission.
- 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).
- Remove the jack and engine hoist.
- 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
 
- 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
 
- 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).
 
- 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
 
- Fill the engine oil, engine coolant and transmission oil.
- Start the engine and check for leaks.
- Check ignition timing.
- Install or connect the following:
 
 Engine undercover
 Hood
 
- Roadtest the vehicle and check all fluids.
- Before servicing the vehicle, refer to the Precautions Section.
- Properly disable the SRS system.
- Properly relieve the fuel system pressure.
- Disconnect the negative battery cable. Disconnect the positive battery cable.
- Matchmark and remove the hood.
- On 4WD and PreRunner, remove the number one engine cover.
- On 4WD and PreRunner (regular cab) remove the number two engine cover.
- Drain the engine coolant. Remove the battery. Remove the battery tray. Drain the engine oil.
- Remove the radiator support to frame seal, left side.
- Remove the fan shroud. Remove the air cleaner cap sub assembly. Remove the air cleaner filter element subassembly. Remove the air cleaner case.
- Separate the vane pump. Remove the radiator hoses. Separate the air conditioning compressor from the engine and position it to the side.
- Disconnect the heater hoses from the heater core.
- Disconnect the fuel line hoses. Separate the fuel vapor feed hose assembly. Disconnect the number one air injection hose.
- Disconnect all engine wiring harnesses and connectors in the engine compartment.
 NOTEDisconnect 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.
- Remove the exhaust pipe assembly. Remove the front exhaust pipe assembly.
- Remove the transmission.
- Install engine hanger, tool 12281-75040 and retainer bolts 91552-A1020. Attach a suitable engine lifting fixture.
- Remove the engine retaining bolts and mounts.
 NOTECheck to be sure nothing will interfere with the removal of the engine. Check to be sure all required wires, hoses and connectors are disconnected.
 
 
 
- Remove the engine from the vehicle.
To install:
- Installation is the reverse of the removal procedure.
- Tighten the four mounting insulator bolts to 28 ft. lbs.
- Be sure to fill the cooling system with the proper grade and type engine coolant.
- Be sure to fill the engine with the proper grade and type engine oil.
- Check ignition timing. Check idle speed.
- Start the engine and check for leaks, correct as required.
- Before servicing the vehicle, refer to the Precautions Section.
- Properly relieve the fuel system pressure.
- Turn the ignition switch OFF .
- Remove or disconnect the following:
 
 Battery cables; negative cable first
 Hood
 Engine undercover
 
- Drain the engine oil, transmission oil and cooling system.
- 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
 
- 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
 
- Remove the power steering pump as follows:
 
 Nut and power steering pulley
 Power steering pump
 
- 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
 
- 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
 
- Disconnect the front exhaust pipe from the exhaust manifold and catalytic converter.
- If equipped with manual transmission, remove the shift lever assembly as follows:
- Remove or disconnect the following:
 
 Shift lever knob
 4 screws and shift lever boot
 6 bolts, shift lever assembly and baffle
 
- 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
 
- Position a jack and wooden block under the transmission.
- Remove the rear engine mounting bracket.
- Attach an engine hoist to the engine hangers.
- Remove or disconnect the following:
 
 Nuts and bolts from the engine mounts
 Engine/transmission
 
To install:
- Attach the engine hoist to the engine hangers.
- Install or connect the following:
 NOTEKeep 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).
 
- Remove the jack and engine hoist.
- 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
 
- 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
 
- 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
 
- 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).
 
- 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).
 
- 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
 
- 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
 
- Fill the engine oil, engine coolant and transmission oil.
- Start the engine and check for leaks.
- Check ignition timing.
- Install or connect the following:
 
 Engine undercover
 Hood
 
- Road test the vehicle and check all fluids.
2wd
- Before servicing the vehicle, refer to the Precautions Section.
- Properly relieve the fuel system pressure.
- Remove or disconnect the following:
 
 Hood
 Battery
 Engine undercovers
 
- Drain the engine coolant.
- Drain the engine oil.
- Remove or disconnect the following:
 
 Radiator
 
- 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
 
- 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
 
- Disconnect the following cables:
 
 Actuator cable with the bracket, if equipped with cruise control
 Accelerator cable
 Throttle cable, if equipped with an automatic transmission
 
- Disconnect the following hoses:
 
 Heater hoses
 Brake booster vacuum hose
 Evaporative Emission (EVAP) hose
 Fuel return hose
 Fuel inlet hose
 
- 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
 
- Detach the alternator connector and wire.
- 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
 
- 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
 
- 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
 
- Place a jack under the transmission.
- Remove or disconnect the following:
 
 Transmission rear mounting bracket, by removing the 8 bolts
 Air conditioning compressor wire clamp, if equipped with air conditioning
 
- If necessary, install a No. 2 engine hanger with 2 bolts. Tighten the 2 bolts to 30 ft. lbs. (40 Nm).
- Attach the engine hoist chain to the 2 engine hangers.
- Remove or disconnect the following:
 
 4 bolts/nuts holding the engine front mounting insulators to the frame
 Engine/transmission assembly
 
To install:
- Install or connect the following:
 
 Engine
 Engine mounts to the body mountings. Install the bolts and nuts but do not tighten at this time.
 
- Remove the engine chain hoist the No. 2 engine hanger.
- 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
 
- Install the shift lever assembly, as follows:
- 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
 
- 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
 
- Fill the engine with oil.
- Fill the engine and radiator with coolant.
- Install the engine undercover.
- Start the engine and check for leaks.
- Before servicing the vehicle, refer to the Precautions Section.
- Properly relieve the fuel system pressure.
- Remove or disconnect the following:
 
 Transmission
 Hood
 Battery from the vehicle
 Engine undercovers
 
- Drain the engine coolant.
- Drain the engine oil.
- Remove or disconnect the following:
 
 Radiator
 
- 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
 
- 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
 
- Disconnect the following cables:
 
 Actuator cable with the bracket, if equipped with cruise control
 Accelerator cable
 Throttle cable, if equipped with an automatic transmission
 
- 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
 
- Detach the starter wire and connectors as follows:
- Remove or disconnect the following:
 
 Ground strap by removing the bolt
 
- Disconnect the positive cable from the battery, as follows:
 
 3 starter wire clamps and connector
 Automatic Disconnecting Differential (ADD) indicator switch connector
 
- Detach the alternator connector and wire.
- 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
 
- Remove or disconnect the following:
 
 Air conditioning compressor wire clamp, if equipped with air conditioning
 
- If necessary, install a No. 2 engine hanger with 2 bolts. Tighten the 2 bolts to 30 ft. lbs. (40 Nm).
- Attach the engine hoist chain to the 2 engine hangers.
- Remove or disconnect the following:
 
 4 Engine front mounting insulators-to-frame bolts/nuts
 Engine
 
To install:
- Install or connect the following:
 
 Engine
 Engine mounts to the body mountings. Install the bolts and nuts but do not tighten at this time.
 
- Remove the engine chain hoist the No. 2 engine hanger.
- 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
 
- Fill the engine with oil.
- Fill the engine and radiator with coolant.
- Install or connect the following:
 
 Hood
 Engine undercover
 Transmission
 
- Start the engine and check for leaks.
These details will help.
Thanks.
FOR MORE HELP GO TO: ---





 
No comments:
Post a Comment