BannerFans.com

Monday, April 2, 2012

How to Replace Engine on Toyota Tacoma?


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
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Properly disable the SRS system.
  3. Properly relieve the fuel system pressure.
  4. Disconnect the negative battery cable. Disconnect the positive battery cable.
  5. Disconnect the windshield washer hose. Matchmark and remove the hood.
  6. Drain the engine coolant. Remove the battery. Remove the battery tray. Drain the engine oil.
  7. Remove the radiator support to frame seal, left side.
  8. Remove the fan shroud. Remove the radiator hoses. Remove the radiator.
  9. Remove the V bank cover.
  10. Remove the transmission. If equipped with manual transmission, remove the clutch cover and clutch.
  11. Remove the fan pulley. Remove the vane pump assembly. Remove the alternator.
  12. Separate the air conditioning compressor from the engine and position it to the side.
  13. Disconnect the heater hoses from the heater core. Disconnect the fuel line hoses. Remove the intake air surge tank.
  14. 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.
  15. Disconnect the ground cable from the cylinder head.
  16. Remove the front exhaust pipe assembly.
  17. Install engine hanger, tool 12281-31070 and 12282-31050 and retainer bolts 90119-08177. Attach a suitable engine lifting fixture.
  18. 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
  19. Remove the engine from the vehicle.
To install:
  1. Installation is the reverse of the removal procedure.
  2. Tighten the four mounting insulator bolts to 28 ft. lbs.
  3. 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.
  4. On the A340E automatic transmission, initialization is completed by connecting and disconnecting the negative battery cable.
  5. On the A750E automatic transmission, initialization is performed using the intelligent tester tool.
  6. Turn the ignition switch OFF.
  7. Connect the intelligent tester tool together with the controller area network vehicle interface module (CAN VIN) to the DLC3.
  8. Turn the ignition switch to the ON position.
  9. Push the intelligent tester tool main switch to the ON position.
  10. Select the items, DIAGNOSIS/ENHANCED OBD II.
  11. 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.
  12. Be sure to fill the cooling system with the proper grade and type engine coolant.
  13. Be sure to fill the engine with the proper grade and type engine oil.
  14. Check ignition timing. Check idle speed.
  15. Start the engine and check for leaks, correct as required.
2RZ-FE Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Properly relieve the fuel system pressure.
  3. Turn the ignition switch OFF .
  4. Remove or disconnect the following:

    Battery cables; negative cable first
    Hood by matchmarking the hood hinges
    Engine undercover
  5. Drain the engine oil, transmission oil and cooling system.
  6. 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
  7. Remove the power steering pump as follows:

    Nut and power steering pulley
    Both bolts and the power steering pump
  8. 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.
  9. 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
  10. Disconnect the front exhaust pipe from the exhaust manifold and catalytic converter.
  11. 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
  12. 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
  13. Position a jack and wooden block under the transmission and remove the rear engine mounting bracket.
  14. Attach an engine hoist to the engine hangers.
  15. Remove or disconnect the following:

    Nuts and bolts from the engine mounts
    Engine/transmission assembly
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. Position a jack and wooden block under the transmission.
  3. 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).
  4. Remove the jack and engine hoist.
  5. 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
  6. 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
  7. 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).
  8. 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
  9. Fill the engine oil, engine coolant and transmission oil.
  10. Start the engine and check for leaks.
  11. Check ignition timing.
  12. Install or connect the following:

    Engine undercover
    Hood
  13. Roadtest the vehicle and check all fluids.
2TR-FE Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Properly disable the SRS system.
  3. Properly relieve the fuel system pressure.
  4. Disconnect the negative battery cable. Disconnect the positive battery cable.
  5. Matchmark and remove the hood.
  6. On 4WD and PreRunner, remove the number one engine cover.
  7. On 4WD and PreRunner (regular cab) remove the number two engine cover.
  8. Drain the engine coolant. Remove the battery. Remove the battery tray. Drain the engine oil.
  9. Remove the radiator support to frame seal, left side.
  10. Remove the fan shroud. Remove the air cleaner cap sub assembly. Remove the air cleaner filter element subassembly. Remove the air cleaner case.
  11. Separate the vane pump. Remove the radiator hoses. Separate the air conditioning compressor from the engine and position it to the side.
  12. Disconnect the heater hoses from the heater core.
  13. Disconnect the fuel line hoses. Separate the fuel vapor feed hose assembly. Disconnect the number one air injection hose.
  14. 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.
  15. Remove the exhaust pipe assembly. Remove the front exhaust pipe assembly.
  16. Remove the transmission.
  17. Install engine hanger, tool 12281-75040 and retainer bolts 91552-A1020. Attach a suitable engine lifting fixture.
  18. 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
  19. Remove the engine from the vehicle.
To install:
  1. Installation is the reverse of the removal procedure.
  2. Tighten the four mounting insulator bolts to 28 ft. lbs.
  3. Be sure to fill the cooling system with the proper grade and type engine coolant.
  4. Be sure to fill the engine with the proper grade and type engine oil.
  5. Check ignition timing. Check idle speed.
  6. Start the engine and check for leaks, correct as required.
3RZ-FE Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Properly relieve the fuel system pressure.
  3. Turn the ignition switch OFF .
  4. Remove or disconnect the following:

    Battery cables; negative cable first
    Hood
    Engine undercover
  5. Drain the engine oil, transmission oil and cooling system.
  6. 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
  7. 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
  8. Remove the power steering pump as follows:

    Nut and power steering pulley
    Power steering pump
  9. 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
  10. 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
  11. Disconnect the front exhaust pipe from the exhaust manifold and catalytic converter.
  12. If equipped with manual transmission, remove the shift lever assembly as follows:
  13. Remove or disconnect the following:

    Shift lever knob
    4 screws and shift lever boot
    6 bolts, shift lever assembly and baffle
  14. 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
  15. Position a jack and wooden block under the transmission.
  16. Remove the rear engine mounting bracket.
  17. Attach an engine hoist to the engine hangers.
  18. Remove or disconnect the following:

    Nuts and bolts from the engine mounts
    Engine/transmission
To install:
  1. Attach the engine hoist to the engine hangers.
  2. 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).
  3. Remove the jack and engine hoist.
  4. 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
  5. 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
  6. 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
  7. 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).
  8. 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).
  9. 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
  10. 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
  11. Fill the engine oil, engine coolant and transmission oil.
  12. Start the engine and check for leaks.
  13. Check ignition timing.
  14. Install or connect the following:

    Engine undercover
    Hood
  15. Road test the vehicle and check all fluids.
5vz-FE Engine
2wd
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Properly relieve the fuel system pressure.
  3. Remove or disconnect the following:

    Hood
    Battery
    Engine undercovers
  4. Drain the engine coolant.
  5. Drain the engine oil.
  6. Remove or disconnect the following:

    Radiator
  7. 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
  8. 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
  9. Disconnect the following cables:

    Actuator cable with the bracket, if equipped with cruise control
    Accelerator cable
    Throttle cable, if equipped with an automatic transmission
  10. Disconnect the following hoses:

    Heater hoses
    Brake booster vacuum hose
    Evaporative Emission (EVAP) hose
    Fuel return hose
    Fuel inlet hose
  11. 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
  12. Detach the alternator connector and wire.
  13. 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
  14. 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
  15. 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
  16. Place a jack under the transmission.
  17. Remove or disconnect the following:

    Transmission rear mounting bracket, by removing the 8 bolts
    Air conditioning compressor wire clamp, if equipped with air conditioning
  18. If necessary, install a No. 2 engine hanger with 2 bolts. Tighten the 2 bolts to 30 ft. lbs. (40 Nm).
  19. Attach the engine hoist chain to the 2 engine hangers.
  20. Remove or disconnect the following:

    4 bolts/nuts holding the engine front mounting insulators to the frame
    Engine/transmission assembly
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. Remove the engine chain hoist the No. 2 engine hanger.
  3. 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
  4. Install the shift lever assembly, as follows:
  5. 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
  6. 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
  7. Fill the engine with oil.
  8. Fill the engine and radiator with coolant.
  9. Install the engine undercover.
  10. Start the engine and check for leaks.
4wd
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Properly relieve the fuel system pressure.
  3. Remove or disconnect the following:

    Transmission
    Hood
    Battery from the vehicle
    Engine undercovers
  4. Drain the engine coolant.
  5. Drain the engine oil.
  6. Remove or disconnect the following:

    Radiator
  7. 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
  8. 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
  9. Disconnect the following cables:

    Actuator cable with the bracket, if equipped with cruise control
    Accelerator cable
    Throttle cable, if equipped with an automatic transmission
  10. 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
  11. Detach the starter wire and connectors as follows:
  12. Remove or disconnect the following:

    Ground strap by removing the bolt
  13. Disconnect the positive cable from the battery, as follows:

    3 starter wire clamps and connector
    Automatic Disconnecting Differential (ADD) indicator switch connector
  14. Detach the alternator connector and wire.
  15. 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
  16. Remove or disconnect the following:

    Air conditioning compressor wire clamp, if equipped with air conditioning
  17. If necessary, install a No. 2 engine hanger with 2 bolts. Tighten the 2 bolts to 30 ft. lbs. (40 Nm).
  18. Attach the engine hoist chain to the 2 engine hangers.
  19. Remove or disconnect the following:

    4 Engine front mounting insulators-to-frame bolts/nuts
    Engine
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. Remove the engine chain hoist the No. 2 engine hanger.
  3. 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
  4. Fill the engine with oil.
  5. Fill the engine and radiator with coolant.
  6. Install or connect the following:

    Hood
    Engine undercover
    Transmission
  7. Start the engine and check for leaks.


These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html


No comments:

Post a Comment