Engine Mechanical (3.4L V6): Removal & Installation Toyota 4Runner III

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

Installation (2WD)

1. To install, reverse removal procedure using NEW gaskets. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-8778-S21926401902000092200000) . Adjust control cables. Fill cooling system. Fill transmission with Dexron-III for A/T models, or SAE 75W-90 gear oil with API rating of GL-5 on M/T models.
2. When installing drive shaft equipped with a center bearing, ensure center of mounting bracket on outside of center bearing is aligned with middle of center bearing, and mounting bracket is perpendicular to drive shaft before tightening bolts.

Removal (4WD)

1. Remove transmission prior to engine removal. For A/T, see «AUTOMATIC TRANSMISSION REMOVAL & INSTALLATION»(ref-8673) article in TRANSMISSION SERVICING. For M/T, see «CLUTCHES»(ref-8668) article. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-8778-S22545962682000092200000) . Remove lower engine cover. Drain cooling system and engine oil.
2. Remove hood. Remove front grille for access to radiator. Disconnect coolant hoses, oil cooler lines and electrical connectors. Remove radiator.
3. Disconnect heater hoses and control cables. Remove fan clutch-to-bracket nuts. Remove radiator cooling fan with fan clutch and pulley from fan bracket. Remove air cleaner assembly.
4. Disconnect brake booster vacuum hose, EVAP hose, vacuum hoses, fuel inlet hose and fuel return hose.
5. Disconnect starter ground strap. Disconnect positive battery cable. Disconnect starter wire clamps and connector. Disconnect starter wire from relay block No. 2. Disconnect generator wire.
6. Remove glove compartment door and lower finish panel. Disconnect all Engine Control Module (ECM) connectors and remove ECM from its mounting.
7. Mark and disconnect remaining necessary connectors for engine removal. Pull engine wiring harness through firewall into engine compartment.
8. Install appropriate engine hanger, only using provided hanger attaching points. Remove bolts and nuts retaining front engine mount insulators to frame. Carefully lift engine from vehicle.

Installation (4WD)

1. To install, reverse removal procedure using NEW gaskets. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-8778-S21926401902000092200000) . Adjust control cables.
2. Fill cooling system. Fill transmission with Dexron-III for A/T models, or SAE 75W-90 gear oil with API rating of GL-5 on M/T models.

Scheme 54

1. Remove lower engine cover. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-8778-S22545962682000092200000). Drain cooling system. Remove front exhaust pipe.
2. Disconnect heater hose from cylinder head. Remove air cleaner assembly. Remove spark plug wires, ignition coils and spark plugs.
3. Disconnect cruise control cable, accelerator cable and A/T throttle cable. Disconnect brake booster hose, EVAP canister hose, 4WD A.D.D. vacuum hose, and both fuel hoses.
4. Remove air intake chamber brace. Remove upper timing belt cover. See «TIMING BELT»(ref-8778-S32319182122000092200000).
5. Disconnect necessary electrical connectors, control cables, vacuum hoses and coolant hoses for removal of air intake chamber. (Scheme 54) Remove air intake chamber assembly.
6. Disconnect hoses and wiring from intake air connector assembly. (Scheme 54)
7. Remove fuel injector connectors, ECT sensor connectors, wiring clamps and wiring protector from cylinder head. Remove fuel pressure regulator.
8. Remove 2 bolts and remove intake manifold brace. Remove 8 bolts, 4 nuts, 4 plate washers, and remove intake manifold assembly.
9. Remove timing belt. See «TIMING BELT»(ref-8778-S32319182122000092200000). Disconnect camshaft position sensor connector. Remove camshaft position sensor. Remove camshaft sprockets. See «CAMSHAFT»(ref-8778-S34285317822000092200000). Remove rear timing belt cover.
10. Remove generator and bracket. Remove power steering pump mounting bracket. Remove nuts and crossover pipe located between exhaust manifolds. Remove nuts and exhaust manifold heat insulators from exhaust manifolds. Remove nuts, exhaust manifolds, and gaskets.
11. Remove cylinder head covers. Remove camshafts. See «CAMSHAFT»(ref-8778-S34285317822000092200000).
12. Using an 8-mm hexagon wrench, remove recessed cylinder head bolts. The 12-point cylinder head bolts must be loosened in proper sequence to prevent cylinder head warpage. (Scheme 55) Loosen 12-point cylinder head bolts in sequence using several steps.
13. Lift cylinder head from locating dowels on cylinder block (use screwdrivers to carefully pry heads loose, if necessary). (Scheme 56) Place cylinder heads on wooden blocks on workbench.

Scheme 55

Scheme 56

Removal & Installation (Oil Pump Installed)

1. Remove timing belt and crankshaft sprocket. See «TIMING BELT»(ref-8778-S32319182122000092200000) under REMOVAL & INSTALLATION. Using a knife, cut seal lip from oil seal. Pry oil seal from oil pump body. Use care not to damage sealing surfaces.
2. To install, apply grease to seal lip of NEW oil seal. Using hammer and oil seal installer, install oil seal until oil seal surface is even with surface of oil pump body. To install remaining components, reverse removal procedure.

Removal & Installation (Oil Pump Removed)

Pry oil seal from oil pump body. To install, use hammer and oil seal installer. Install NEW oil seal until oil seal surface is even with surface of oil pump body. Apply grease to seal lip of oil seal.

Scheme 57

Scheme 58

Scheme 59

1. Raise and support vehicle. Remove lower engine cover. Drain cooling system. Disconnect upper radiator hose from engine. Remove accessory drive belts.
2. Remove lower fan shroud. Remove accessory drive belts. Remove fan clutch-to-fan bracket nuts. Remove radiator cooling fan with fan clutch and pulley from fan bracket.
3. Remove bolts/nuts, A/C compressor and power steering pump with hoses attached and secure aside. Remove bolts and A/C compressor mounting bracket. Remove engine oil dipstick tube with "O" ring.
4. Disconnect camshaft position sensor connector and spark plug wire assembly from upper timing belt cover. (Scheme 57) Remove bolts, upper timing belt cover and gaskets.
5. Remove nut and power steering pump adjusting strut. Remove bolts/nuts and fan bracket. Using pulley holder and handle, hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley.
6. Remove bolts, starter wire bracket, lower timing belt cover and gaskets. Note direction of timing belt guide installation for installation reference. (Scheme 57) Remove timing belt guide.
7. Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise (viewed from front of engine) so cylinder No. 1 is at TDC on compression stroke and timing mark on crankshaft sprocket aligns with timing mark on oil pump body. (Scheme 58) Cylinder No. 1 is front cylinder on right side when viewed from rear of engine.
8. Check that timing marks on camshaft sprockets align with timing marks on rear timing belt cover. (Scheme 58) If timing marks on camshaft sprockets are not aligned with timing marks on rear timing belt cover, rotate crankshaft clockwise one complete revolution. Remove crankshaft pulley bolt.
9. If reusing timing belt, ensure installation marks exist on timing belt at timing mark on camshaft and crankshaft sprockets, and front mark exists on timing belt. (Scheme 59) If installation marks do not exist, place installation marks on timing belt at timing mark area on camshaft and crankshaft sprockets. If front mark does not exist, place front mark on timing belt to indicate direction of timing belt installation.
10. Alternately loosen bolts and remove timing belt tensioner and dust boot. (Scheme 57) Remove timing belt.
11. If removing camshaft sprockets, install spanner wrench in holes on front of camshaft sprocket. Remove camshaft sprocket retaining bolt while using spanner wrench to hold camshaft sprocket. Remove knock pin and camshaft sprocket.
12. Remove bolts, No. 1 idler pulley and No. 2 idler pulley (if necessary). Using puller, remove crankshaft sprocket from crankshaft (if necessary).

Removal

Remove camshaft. See CAMSHAFT . Note location of adjusting shims and valve lifters for installation reference. Remove adjusting shims and valve lifters from cylinder head.

Installation

To install, reverse removal procedure. Ensure components are installed in original location and valve lifter rotates smoothly in cylinder head. If camshaft, adjusting shim or valve lifter are replaced, check valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.

1. Water pump is located on front of cylinder block, behind timing belt. (Scheme 57) Drain cooling system. Remove timing belt. See «TIMING BELT»(ref-8778-S32319182122000092200000).
2. Disconnect lower radiator hose from thermostat housing. Remove nuts, thermostat housing, gasket and thermostat. Disconnect oil cooler hose from water pump. Remove bolts and water pump.

1. Ensure sealing surface on rear of water pump is clean. Apply sealant on grooves at rear of water pump before installing. (Scheme 60) Install water pump. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-8778-S21926401902000092200000). CAUTION: Thermostat must be installed with jiggle valve facing downward, toward the oil pan. Jiggle valve is located near outer edge of thermostat.
2. To install remaining components, reverse removal procedure using NEW gasket. Ensure thermostat is installed with jiggle valve facing downward, toward the oil pan. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-8778-S21926401902000092200000). Install timing belt using proper procedure. See «TIMING BELT»(ref-8778-S32319182122000092200000). Fill cooling system.

Scheme 60

Removal (2WD)

1. Raise and support vehicle. Drain engine oil. On Tundra, remove oil dipstick, dipstick tube guide and "O" ring. Remove timing belt and No. 1 idler pulley. See «TIMING BELT»(ref-8778-S32319182122000092200000) . On all models, remove crankshaft pulley. On A/T models, remove oil cooler line as necessary to access to oil pan.
2. Remove bolts and stiffener plate (if equipped). Stiffener plate is bolted on rear corner of cylinder block and front of transmission. Disconnect starter wire clamp. Remove crankshaft position sensor.
3. Remove 17 bolts and 2 nuts and remove oil pan. Remove bolts and nuts, oil pump pick-up tube with gasket and oil pan baffle plate from cylinder block (if necessary).

1. Install oil pan baffle plate (if removed). Using NEW gasket, install oil pump pick-up tube (if removed). Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-8778-S21926401902000092200000) .
2. Ensure sealing surfaces are clean. Apply bead of sealant on inside of bolt and nut holes and at center of oil pan sealing surface, between the bolt and nut holes. Install oil pan. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-8778-S21926401902000092200000) . To install remaining components, reverse removal procedure. Fill crankcase with oil.

Scheme 61

Scheme 62

1. Raise and support vehicle. Drain engine oil and front differential fluid. Front differential must be removed for oil pan removal.
2. Remove lower engine covers for access to front differential and engine. Place references marks on drive shaft flange at front differential and transfer case for reassembly reference. Remove drive shaft flange bolts and nuts at transfer case and front differential. Remove front drive shaft.
3. Front axle shafts must be disconnected from side gear shafts on each side of front differential. Front axle shafts do not have to be removed from vehicle for removal of front differential.
4. Place references marks on front axle shaft flanges at side gear shaft flanges on front differential. Remove front axle shaft flange-to-side gear shaft flange nuts.
5. Disconnect necessary electrical connectors and hoses for removal of front differential. Remove bolts/nuts and front crossmember for access to front differential.
6. Support front differential with transmission jack. Remove front differential rear mount bolt and nut and front differential mount bolts. (Scheme 61)or (Scheme 62). Lower front differential from vehicle.
7. On A/T models, remove oil cooler line as necessary to access oil pan. On all models, remove bolts and stiffener plate. Stiffener plate is bolted on rear corner of cylinder block and front of transmission. Disconnect starter wire clamp. Remove crankshaft position sensor.
8. Remove 17 bolts and 2 nuts and remove oil pan. Remove bolts and nuts, oil pump pick-up tube with gasket and oil pan baffle plate from cylinder block (if necessary).

1. Install oil pan baffle plate (if removed). Using NEW gasket, install oil pump pick-up tube (if removed). Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-8778-S21926401902000092200000) .
2. Ensure sealing surfaces are clean. Apply bead of sealant on inside of bolt and nut holes and at center of oil pan sealing surface, between bolt and nut holes. Install oil pan. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-8778-S21926401902000092200000) .
3. To install remaining components, reverse removal procedure. Ensure drive shaft flange reference marks and front axle shaft flange reference marks are aligned. Tighten bolt/nuts to specification. Fill crankcase with oil. Fill front differential with SAE 75W-90 gear oil with API rating of GL-5.

Removal & Disassembly

1. Disconnect negative battery cable. Raise and support vehicle. Remove oil pan. See «OIL PAN»(ref-8778-S02672542462000092200000) under REMOVAL & INSTALLATION.
2. Remove 8 bolts and remove ground strap and oil pump from cylinder block. Remove "O" ring from cylinder block. Remove oil pump body cover. Remove drive and driven rotors. Remove spring and relief valve. (Scheme 63)

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Ensure rotors are installed in oil pump body with identification mark facing oil pump body cover. (Scheme 63)
2. Tighten oil pump body cover screws to specification. See «TORQUE SPECIFICATIONS»(ref-8778-S21926401902000092200000). Using oil seal installer, install crankshaft front seal (if removed) until seal surface is even with surface of oil pump body. Coat seal lip with grease.
3. To install, reverse removal procedure. Ensure NEW "O" ring is installed in groove on cylinder block. (Scheme 64) Apply sealant on oil pump body-to-cylinder block contact surfaces before installing oil pump. Ensure splined teeth on drive rotor of oil pump engage with splines on crankshaft.
4. Tighten oil pump bolts to specification. See «TORQUE SPECIFICATIONS»(ref-8778-S21926401902000092200000). To install remaining components, reverse removal procedure.

Scheme 63

Scheme 64

1. Oil cooler is located on side of cylinder block, behind oil filter. (Scheme 65) Drain cooling system. Disconnect oil cooler hoses at oil cooler.
2. Remove oil cooler union bolt and gasket from center of oil cooler. Remove oil cooler and "O" ring.
3. To install, reverse removal procedure using NEW gasket and "O" ring. Tighten oil cooler union bolt to specification. See «TORQUE SPECIFICATIONS»(ref-8778-S21926401902000092200000). Fill cooling system.

Scheme 65