Engine Controls - Remove/install/overhaul Toyota 4Runner II

INTRODUCTION

Removal, overhaul and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

DISTRIBUTOR (2.4L)

Note. For timing specifications and procedures, see ADJUSTMENTS article in the ENGINE PERFORMANCE Section.

Removal

Disconnect negative battery cable. Disconnect spark plug wires. Remove distributor cap. Disconnect distributor wiring connector. Remove distributor hold-down bolt. Remove distributor. Remove "O" ring from distributor housing and discard.

Scheme 1

1. Install new "O" ring into housing. Coat "O" ring with oil. Turn crankshaft until No. 1 cylinder is in compression stroke and timing mark aligns with 5°BTDC mark on timing case cover. Check that rocker arms on No. 1 cylinder are loose. If rocker arms are not loose, turn crankshaft one full turn.
2. Temporarily install rotor. Begin inserting distributor with rotor pointing upward and distributor mounting hole aligned with center of mounting bolt hole. When fully installed, rotor will rotate to position shown. (Scheme 1)
3. Align signal rotor tooth with signal generator (pick-up coil) projection. (Scheme 2) Install distributor cap and spark plug wires. Connect distributor wiring connector.
4. Connect negative battery cable. Set ignition timing. Tighten distributor hold-down bolt. See TORQUE SPECIFICATIONS at end of this article.

Scheme 2

Scheme 3

1. Disconnect negative battery cable. Disconnect spark plug wires. Disconnect distributor connector. Remove distributor cap and dust-proof packing.
2. Set No. 1 cylinder to TDC of compression strike. Ensure distributor rotor points in direction shown. (Scheme 3) Remove distributor hold-down bolt. Remove distributor. Remove "O" ring from distributor housing and discard.

Installation

1. Install new "O" ring into distributor housing. Coat "O" ring with oil. Align protrusion on top of drive gear teeth with groove on distributor housing.
2. Insert distributor with housing groove aligned with groove on No. 4 camshaft bearing cap. (Scheme 4) Install distributor hold-down bolt, distributor cap and spark plug wires.
3. Connect distributor wiring connector. Connect negative battery cable. Set ignition timing. Tighten distributor hold-down bolt. See TORQUE SPECIFICATIONS at end of article.

Scheme 4

FUEL SYSTEM PRESSURE RELEASE

Disconnect negative battery terminal. Place container under fitting to be loosened. Use a rag to cover fuel line/component. Slowly loosen fitting, allowing pressurized fuel to spill into container. After fuel system pressure is released, disconnect and plug fitting.

Removal & Installation

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect and plug fuel lines. Drain fuel and remove fuel tank. Remove screws securing fuel pump and bracket assembly to fuel tank. Remove fuel pump and bracket assembly.
2. Pull lower end of fuel pump (with filter) from bracket. Remove 2 nuts securing fuel pump wires to fuel pump. Disconnect wires. Disconnect fuel hose from fuel pump. Remove fuel pump. To install, reverse removal procedure.

FUEL INJECTORS & FUEL RAILS (2.4L)

Note. Always install new grommets and "O" rings when removing or replacing fuel injectors. Ensure injectors rotate smoothly in injector ports and fuel rail. If injectors DO NOT rotate smoothly, check "O" rings for proper installation.

Removal (2.4L)

1. Disconnect negative battery cable. Drain coolant. Disconnect accelerator cable. Disconnect throttle cable (A/T). Disconnect ground strap from rear side of engine.
2. Disconnect all water, vacuum, and air hoses as required. Remove EGR modulator. Disconnect all electrical wiring as required. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove union bolt holding cold start injector pipe to air intake chamber. Remove bolts holding EGR pipe to air intake chamber.
3. Remove bolts holding manifold bracket to air intake chamber. Remove strap and fuel hose clamp. Remove intake air chamber with throttle body, resonator and gasket. Disconnect fuel hose from fuel rail. Remove bolts and fuel rail with injectors. Pull injectors from fuel rail.

1. Install grommet and new "O" ring to each injector. Apply a light coat of gasoline and install injectors to fuel rail. Ensure injectors rotate smoothly. If injectors do not rotate smoothly, check that "O" rings are properly installed.
2. Install insulators into injector hole of intake manifold. Position injectors with fuel rail to manifold. Install and tighten fuel rail bolts. To complete installation, reverse removal procedure. Tighten all nuts and bolts. See TORQUE SPECIFICATIONS at end of article. Check for fuel leaks.

FUEL INJECTORS & FUEL RAILS (3.0L)

Note. Always install new grommets and "O" rings when removing or replacing fuel injectors. Ensure injectors rotate smoothly in injector ports and fuel rail. If injectors DO NOT rotate smoothly, check "O" rings for proper installation.

Removal (3.0L)

1. Disconnect negative battery cable. Drain coolant. Disconnect throttle position sensor connector. Disconnect canister vacuum hose from throttle body. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect vacuum and fuel hoses from fuel pressure regulator. Disconnect PCV hose from union.
2. Disconnect water by-pass hose. Disconnect cold start injector connector and tube. Disconnect vacuum hose from gas filter. Disconnect EGR gas temperature sensor connector. Disconnect EGR vacuum hoses. Disconnect air hose from reed valve.
3. Remove 6 bolts, 2 nuts and air intake chamber. Disconnect electrical connectors as required. Disconnect vacuum hose from bimetallic vacuum switching valve. Remove 4 union bolts and 2 fuel pipes. Remove 4 nuts and fuel rails with injectors. Remove injectors from fuel rails.

1. Install new grommets and "O" rings on injectors. Install 6 injectors on fuel rails. Install spacers and insulators. Install injectors on fuel rails.
2. Install injectors with fuel rail into intake manifold. Ensure injectors rotate smoothly. If injectors do not rotate smoothly, check "O" rings for proper installation. Position injector connectors upward.
3. Install 4 fuel rail nuts. To complete installation, reverse removal procedure. Tighten all nuts and bolts. See TORQUE SPECIFICATIONS at end of article.

Disconnect sensor electrical connector. Remove 2 mounting nuts or bolts. Remove sensor. Some sub-oxygen sensors screw into exhaust manifold or header pipe.

Note. When removing sensor, protect its permanent pigtail from damage. Ensure sensor is free of contaminants. Avoid using cleaning solvents of any type.

Install sensor. Install nuts or bolts. Connect electrical connector. Oxygen sensor torque specification is not available from manufacturer.

1. Disconnect negative battery cable. Drain coolant. Remove intake air connector. Disconnect accelerator cable from throttle linkage. Disconnect A/C idle-up hose, PCV hose and coolant by-pass hose(s).
2. Label and disconnect emission control vacuum hoses. Unplug throttle position sensor. Remove throttle body. To install, reverse removal procedure. Tighten all nuts and bolts. See TORQUE SPECIFICATIONS at end of article.

1. Disconnect negative battery cable. Drain coolant. Disconnect air cleaner hose. Unplug throttle position sensor. Label and disconnect emission control vacuum hoses.
2. Disconnect accelerator and throttle cables from throttle linkage. Disconnect coolant by-pass hoses. Remove throttle body. To install, reverse removal procedure. Tighten all nuts and bolts. See TORQUE SPECIFICATIONS at end of article.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS (1)

TORQUE SPECIFICATIONS