Engine Mechanical (1GR-FE): Overview Toyota 4Runner IV

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1. INSPECT ENGINE COOLANT (See «ON-VEHICLE INSPECTION»(ref-235178-S35591562862006061400000) )
2. INSPECT ENGINE OIL (See «LUBRICATION SYSTEM (1GR-FE)»(/toyota/4runner/iv-2002-2005/remont/lubrication-system/#engine-lubrication-system-1gr-fe) )
3. INSPECT BATTERY SPECIFIC GRAVITY (See «STARTER»(ref-163689-S31054863022004070900000) )
4. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSY
5. INSPECT FAN AND GENERATOR V BELT HINT: Use of the automatic tensioner has made the tension and flexibility measurements unnecessary.
6. INSPECT V-RIBBED BELT TENSIONER ASSY (See «FAN AND GENERATOR V BELT»(ref-235151-S00974816002006061400000) )
7. WARM UP ENGINE
8. INSPECT IGNITION TIMING When using hand-held tester or OBD II scan tool. Connect the hand-held tester or OBD II scan tool to the DLC3. Please refer to hand held tester or OBD II scan tool operator's for further details. Ignition timing: 7-24° BTDC at idle (Transmission in neutral position) Disconnect the hand-held tester or OBD II scan tool from the DLC3. When not using hand-held tester or OBD II scan tool. Remove the air cleaner cap sub-assy. Connect the tester probe of a timing light to the wire of the ignition coil connector for No. 1 cylinder. Using SST, connect the terminals TC and CG of the DLC3. SST 09843-18040 Using the timing light, check the ignition timing. Ignition timing: 10 +/- 2° BTDC at idle (Transmission in neutral position) (Transmission in neutral position) Remove the SST from the DLC3. Check the ignition timing. Ignition timing: 7-24° BTDC at idle (Transmission in neutral position) Disconnect the timing light from the engine. Install the air cleaner cap sub-assy.
9. INSPECT ENGINE IDLE SPEED When using hand-held tester or OBD II scan tool. Connect the hand-held tester or OBD II scan tool to the DLC3. Please refer to hand held tester or OBD II scan tool operator's manual for further details. Switch the air conditioning OFF. Race the engine speed at 2, 500 RPM for approx. 90 seconds. Check the idle speed. Idle speed: 700 +/- 50 RPM (Transmission in neutral position) If the idle speed is not as specified, check the air intake system. Disconnect the hand-held tester or OBD II scan tool from the DLC3. When not using hand-held tester or OBD II scan tool. Using SST, connect tachometer probe to terminal TAC of the DLC3. SST 09843-18030 Switch the air conditioning OFF. Race the engine speed at 2, 500 RPM for approx. 90 seconds. Check the idle speed. Idle speed: 700 +/- 50 RPM (Transmission in neutral position) If the idle speed is not as specified, check the air intake system. Disconnect the tachometer from the DLC3.
10. INSPECT COMPRESSION Remove the V-bank cover. Remove the air cleaner assy. Remove the intake air surge tank (See «REPLACEMENT»(ref-235151-S06226681952006061400000) ). Remove the 6 ignition coils. Remove the 6 spark plugs. Disconnect the 6 injector connectors. Inspect the cylinder compression pressure. Insert a compression gauge into the spark plug hole. Fully open the throttle by hand. While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 RPM or more. Repeat steps through (1) to (3) for each cylinder. NOTE: This measurement must be done as quickly as possible. Compression pressure: 1.3 MPa (13.3 kgf/cm 2, 189 psi) or more Minimum pressure: 1.0 MPa (10.2 kgf/cm 2, 145 psi) Difference between each cylinder: 0.1 MPa (1.0 kgf/cm 2, 15 psi) or less If the cylinder compression in one or more cylinders is low, pour small amount of engine oil into the cylinder through the spark plug hole and repeat steps through (1) to (3) for cylinders with low compression. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. Connect the 6 injector connectors. Install the 6 spark plugs. Install the 6 ignition coils. Install the intake air surge tank (See «REPLACEMENT»(ref-235151-S06226681952006061400000) ). Install the air cleaner assy. Install the V-bank cover.
11. INSPECT CO/HC HINT: This check for determining whether or not the idle CO/HC complies with regulations. Start the engine. Keep the engine speed at 2, 500 RPM for approx. 180 seconds. Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into tailpipe during idling. Immediately check CO/HC concentration at idle and/or 2, 500 RPM. HINT: When performing the 2 mode (2, 500 RPM and idle) test, follow the measurement order prescribed by the applicable local regulations. If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. Check the A/F sensor and heated oxygen sensor operation (See «DTC P0136 OXYGEN SENSOR CIRCUIT MALFUNCTION (BANK 1 SENSOR 2) DTC P0156 OXYGEN SENSOR CIRCUIT MALFUNCTION (BANK 2 SENSOR 2)»(ref-157557-S10480562742003081500000) and See «DTC P2195 OXYGEN (A/F) SENSOR SIGNAL STUCK LEAN (BANK 1 SENSOR 1), DTC P2196 OXYGEN (A/F) SENSOR SIGNAL STUCK RICH (BANK 1 SENSOR 1), DTC P2197 OXYGEN (A/F) SENSOR SIGNAL STUCK LEAN (BANK 2 SENSOR 1), DTC P2198 OXYGEN (A/F) SENSOR SIGNAL STUCK RICH (BANK 2 SENSOR 1)»(ref-157557-S09678059722003082500000) ). See the (Scheme 22) below for possible causes, then inspect and correct the applicable causes if necessary.

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1. REMOVE ENGINE UNDER COVER SUB-ASSY NO. 1 Remove the 4 bolts and engine under cover.
2. REMOVE FAN AND GENERATOR V BELT While releasing the belt tension by turning the belt tensioner counterclockwise, and remove the V-ribbed belt from the belt tensioner.
3. INSPECT V-RIBBED BELT TENSIONER ASSY Check that nothing gets caught the tensioner by turning it clockwise and counterclockwise. If a malfunction exists, replace the tensioner.
4. INSTALL FAN AND GENERATOR V BELT While turning the belt tensioner counterclockwise, align with its holes, and then insert a bar of 6 mm (0.24 in.) into the holes to fix the belt tensioner. Install the V-ribbed belt. While turning the belt tensioner counterclockwise, remove the bar. If it is hard to install the V-ribbed belt, perform the following procedure. Put the V-ribbed belt on everything except the P/S pump as shown in the illustration. While releasing the belt tension by turning the belt tensioner counterclockwise, put the V-ribbed belt on the P/S pump.
5. INSTALL ENGINE UNDER COVER SUB-ASSY NO.1 Install the engine under cover with the 4 bolts. Torque: 29 N.m (296 kgf.cm, 21 ft.lbf)

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1. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-235178-S21524750362006061400000) )
2. DISCONNECT VENTILATION HOSE NO. 2
3. REMOVE AIR CLEANER ASSY
4. REMOVE INTAKE AIR SURGE TANK (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
5. REMOVE IGNITION COIL ASSY
6. REMOVE CYLINDER HEAD COVER SUB-ASSY (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
7. REMOVE CYLINDER HEAD COVER SUB-ASSY LH (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
8. SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above.
9. INSPECT VALVE CLEARANCE Check the valves indicated in the illustration. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): Intake 0.15-0.25 mm (0.006-0.010 in.) Exhaust 0.29-0.39 mm (0.011-0.015 in.) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): Intake 0.15-0.25 mm (0.006-0.010 in.) Exhaust 0.29-0.39 mm (0.011-0.015 in.) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): Intake 0.15-0.25 mm (0.006-0.010 in.) Exhaust 0.29-0.39 mm (0.011-0.015 in.) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.
10. ADJUST VALVE CLEARANCE Set No. 1 cylinder to TDC/compression. Turn the crankshaft pulley, and align the notch with the timing mark "0" of the timing chain cover. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360 °) and align the timing marks as above. Place paint marks on the No. 1 chain links that correspond with the timing marks of the camshaft timing gears. Remove the chain tensioner assy No. 1. NOTE: Never rotate the crankshaft with the chain tensioner removed. When rotating the camshaft with the timing chain removed, turn the crankshaft counterclockwise 40° from the TDC first. Remove the 4 bolts, timing chain cover plate and gasket. While rotating the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as shown in the illustration. While rotating the stopper plate of the tensioner downward, insert a bar of phis 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate. Remove the 2 bolts and chain tensioner. Remove the No. 2 camshaft. NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. While raising up the chain tensioner No. 2, insert a pin of 4 phis 1.0 mm (0.039 in.) into the hole to fix it. Hold the hexagonal portion of the No. 2 camshaft with a wrench, and remove the camshaft timing gear set bolt. NOTE: Be careful not to damage the cylinder head and valve lifter with the wrench. Separate the camshaft timing gear from the No. 2 camshaft. Rotate the camshaft counterclockwise using the wrench so that the cam lobes of No. 1 cylinder faces upward as shown in the illustration. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Remove the 4 bearing caps and No. 2 camshaft. Remove the chain tensioner assy No. 2. Remove the chain tensioner No. 2 bolt, and then remove the chain tensioner No. 2 and camshaft timing gear. Remove the camshaft. NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Hold the hexagonal portion of the No. 1 camshaft with a wrench, and loosen the camshaft timing gear set bolt. NOTE: Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly. Slide the camshaft timing gear and separate the No. 1 chain from the camshaft timing gear. Rotate the No. 1 camshaft counterclockwise using the wrench so that the Exploded View Of as shown in the illustration. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Remove the 4 bearing caps. Remove the camshaft timing gear set bolt with the No. 1 camshaft lifted up, and then remove the No. 1 camshaft and camshaft timing gear w/ No. 2 chain. Tie the No. 1 chain with a string as shown in the illustration. NOTE: Be careful not to drop anything inside the timing chain cover. Remove the No. 4 camshaft sub-assy. NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. While pushing down the chain tensioner No. 3, insert a pin of phis 1.0 mm (0.039 in.) into the hole to fix it. Hold the hexagonal portion of the No. 4 camshaft with a wrench, and remove the camshaft timing gear set bolt. NOTE: Be careful not to damage the cylinder head and valve lifter with the wrench. Separate the camshaft timing gear from the No. 4 camshaft. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Remove the 4 bearing caps and No. 4 camshaft. Remove the chain tensioner assy No. 3. Remove the chain tensioner No. 3 bolt, and then remove the chain tensioner No. 3 and camshaft timing gear. Remove the No. 3 camshaft sub-assy. NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Remove the 4 bearing caps. Hold the No. 1 chain, and remove the No. 3 camshaft, camshaft timing gear and No. 2 chain. Tie the No. 1 chain with a string as shown in the illustration. NOTE: Be careful not to drop anything inside the timing chain cover. Remove the valve lifters. Determine the replacement valve lifter size according to these Formula or Charts: Using a micrometer, measure the thickness of the removed lifter. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value. T: Thickness of removed lifter A: Measured valve clearance N: Thickness of new lifter Intake: N = T + (A - 0.20 mm (0.008 in.)) Exhaust: N = T + (A - 0.30 mm (0.012 in.)) Select a new lifter with a thickness as close as possible to the calculated value. HINT: Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.). Install the No. 3 camshaft sub-assy. NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Align the mark link (yellow) with the timing mark (2 dot marks) of the camshaft timing gear as shown in the illustration. Apply new engine oil to the thrust portion and journal of the camshafts. Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear. Set the No. 3 camshaft onto the LH cylinder head with the cam lobes of the No. 2 cylinder faces downward as shown in the illustration. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil on the threads of the bearing cap bolts. Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0N.m (92kgf.cm, 80in..lbf) for 10 mm (0.39 in.) head 24N.m (245kgf.cm, 18ft.lbf) for 12 mm (0.47 in.) head Align the paint mark of the No. 1 chain with the timing marks of the camshaft timing gear. Install the chain tensioner assy No. 3. While pushing in the tensioner, insert a pin of phis 1.0 mm (0.039 in.) into the hole to hold it. Temporarily install the camshaft timing gear and chain tensioner No. 3 and align the mark links (yellow) with the timing marks (1 dot mark and 2 dot marks) of the camshaft timing gears. Tighten the chain tensioner No. 3 bolt. Torque: 19N.m (194kgf.cm, 14ft.lbf) Install the No. 4 camshaft sub-assy. NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Align the knock pin hole in the camshaft timing gear with the knock pin of he No. 4 camshaft, and insert the No. 4 camshaft into the camshaft timing gear. Temporarily install the camshaft timing gear set bolt. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0N.m (92kgf.cm, 80in..lbf) for 10 mm (0.39 in.) head 24N.m (245kgf.cm, 18ft.lbf) for 12 mm (0.47 in.) head Hold the hexagonal portion of the No. 4 camshaft with a wrench, and tighten the camshaft timing gear set bolt. Torque: 100N.m (1, 020kgf.cm, 74ft.lbf) Remove the pin from the chain tensioner No. 3. Install the camshaft. NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Align the mark link (yellow) with the timing mark (1 dot mark) of the camshaft timing gear as shown in the illustration. Apply new engine oil to the thrust portion and journal of the camshafts. Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear. Align the knock pin hole in the camshaft timing gear with the knock pin of the No. 1 camshaft, and insert the No. 1 camshaft into the camshaft timing gear. Temporarily install the camshaft timing gear set bolt. Set the No. 1 camshaft onto the RH cylinder head with the cam lobes of the No. 1 cylinder faces downward as shown in the illustration. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0N.m (92kgf.cm, 80in..lbf) for 10 mm (0.39 in.) head 24N.m (245kgf.cm, 18ft.lbf) for 12 mm (0.47 in.) head Rotate the No. 1 camshaft clockwise using hexagonal portion of the No. 1 camshaft so that the timing mark of the camshaft timing gear is aligned with the timing marks of the camshaft bearing cap. Align the paint mark of the No. 1 chain with the timing mark of the camshaft timing gear. Hold the hexagonal portion of the No. 1 camshaft with a wrench, and tighten the camshaft timing gear set bolt. Torque: 100N.m (1, 020kgf.cm, 74ft.lbf) Install the chain tensioner assy No. 2. While pushing in the tensioner, insert a pin of phis 1.0 mm (0.039 in.) into the hole to fix it. Temporarily install the camshaft timing gear and chain tensioner No. 2 and align the mark links (yellow) with the timing marks (1 dot mark) of the camshaft timing gears. Tighten the chain tensioner No. 2 bolt. Torque: 19N.m (194kgf.cm, 14ft.lbf) Install the No. 2 camshaft. NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Set the No. 2 camshaft onto the RH cylinder head with the cam lobes of No. 1 cylinder faces upward as shown in the illustration. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0N.m (92kgf.cm, 80in..lbf) for 10 mm (0.39 in.) head 24N.m (245kgf.cm, 18ft.lbf) for 12 mm (0.47 in.) head Rotate the No. 2 camshaft clockwise using the wrench so that the knock pin of the No. 2 camshaft is aligned with the knock pin hole of the camshaft timing gear. Hold the hexagonal portion of the No. 2 camshaft with a wrench, and install the camshaft timing gear set bolt. Torque: 100N.m (1, 020kgf.cm, 74ft.lbf) Remove the pin from the chain tensioner No. 2. Install the chain tensioner assy No. 1. While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration. While turning the stopper plate of the tensioner counterclockwise, insert a bar of phis 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate. Install the chain tensioner with the 2 bolts. Torque: 9.0N.m (92kgf.cm, 80in.lbf) Remove the bar from the chain tensioner. Install a new gasket and the timing chain cover plate with the 4 bolts. Torque: 9.0N.m (92kgf.cm, 80in..lbf) Turn the crankshaft pulley 2 complete revolutions slowly, and align the notch with the timing mark "0" of the timing chain cover. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.
11. INSTALL CYLINDER HEAD COVER SUB-ASSY LH (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
12. INSTALL CYLINDER HEAD COVER SUB-ASSY (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
13. INSTALL IGNITION COIL ASSY Torque: 9.0N.m (92kgf.cm, 80in..lbf)
14. INSTALL INTAKE AIR SURGE TANK (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
15. INSTALL AIR CLEANER ASSY
16. CONNECT VENTILATION HOSE NO. 2
17. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-235178-S21524750362006061400000) )
18. CHECK FOR ENGINE COOLANT LEAKS (See «ON-VEHICLE INSPECTION»(ref-235178-S35591562862006061400000) )
19. INSPECT IGNITION TIMING (See «INSPECTION»(ref-235151-S08614278762006061400000) ) SST 09843-18040

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1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See «PRECAUTION»(/toyota/4runner/iv-2002-2005/remont/fuel-system/#engine-fuel-system-1gr-fe) )
2. REMOVE AUTOMATIC TRANSMISSION ASSY (2WD DRIVE TYPE) (See «A340E»(ref-158065-S01947165072003090900000) )
3. REMOVE AUTOMATIC TRANSMISSION ASSY (4WD DRIVE TYPE) (See «A340F»(ref-158065-S23854566212003090900000) )
4. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-235178-S21524750362006061400000) )
5. DRAIN ENGINE OIL (See «REPLACEMENT»(/toyota/4runner/iv-2002-2005/remont/lubrication-system/#engine-lubrication-system-1gr-fe__replacement) )
6. REMOVE BATTERY
7. REMOVE HOOD SUB-ASSY Disconnect the windshield washer hose. Separate the 2 hood supports. Remove the 4 bolts and hood.
8. DISCONNECT VENTILATION HOSE NO. 2
9. REMOVE AIR CLEANER ASSY
10. REMOVE RADIATOR SUPPORT SEAL UPPER Remove the 11 clips and radiator support seal upper.
11. REMOVE RADIATOR ASSY (See «RADIATOR ASSY (1GR-FE)»(ref-235178-S32255639492006061400000) )
12. REMOVE FAN SHROUD Unfasten the hose clamp, and separate the 2 oil cooler hoses from the fan shroud. Remove the fan shroud.
13. LOOSEN FAN W/ FLUID COUPLING (See «WATER PUMP ASSY (1GR-FE)»(ref-235178-S08159351802006061400000) )
14. REMOVE FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT»(ref-235151-S00974816002006061400000) )
15. REMOVE FAN W/ FLUID COUPLING Remove the 4 bolts and fan w/ fluid coupling.
16. REMOVE FAN PULLEY
17. SEPARATE VANE PUMP ASSY (See «REPLACEMENT»(ref-235151-S06007633702006061400000) )
18. REMOVE GENERATOR ASSY (See «GENERATOR»(ref-163567-S22705679482004070600000) )
19. SEPARATE COOLER COMPRESSOR ASSY (See «CRANKSHAFT POSITION SENSOR»(ref-151984-S30853055372003010900000) )
20. DISCONNECT FUEL PIPE SUB-ASSY NO.1 (See «PRECAUTION»(/toyota/4runner/iv-2002-2005/remont/fuel-system/#engine-fuel-system-1gr-fe) )
21. DISCONNECT FUEL PIPE SUB-ASSY NO. 2 (See «PRECAUTION»(/toyota/4runner/iv-2002-2005/remont/fuel-system/#engine-fuel-system-1gr-fe) )
22. DISCONNECT HEATER WATER INLET HOSE B
23. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
24. REMOVE INTAKE AIR SURGE TANK (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
25. SEPARATE ENGINE WIRE Remove the front door scuff plate RH «REPLACEMENT»(ref-190151-S36588775042005091500000) ). Remove the cowl side trim board RH (See «COMPONENTS»(/toyota/4runner/iv-2002-2005/remont/gauges-instrument-panels/#instrument-panelmeter) ). Remove the glove compartment door (See «COMPONENTS»(/toyota/4runner/iv-2002-2005/remont/gauges-instrument-panels/#instrument-panelmeter) ). Disconnect each connector for the ECM, four wheel drive control ECU (4WD only) and instrument panel wire before pull out the engine wire into the engine room. Disconnect the front differential connector.
26. SEPARATE ENGINE WIRE NO. 2 Disconnect the ground cable from the cylinder block.
27. REMOVE ENGINE ASSY Install the 2 engine hangers with the 4 bolts as shown in the illustration. Part No.: Engine hanger No. 1 12281-31060 Engine hanger No. 2 12282-31040 Bolt 90119-08177 Torque: 33 N.m (336 kgf.cm, 24 ft.lbf) Attach the engine sling device and hang the engine with the chain block. Remove the 4 bolts and 4 nuts, and separate the engine mounting brackets from the frame brackets. Lift the engine out of the vehicle carefully. NOTE: Make sure the engine is clear of all wiring and hoses. Place the engine onto a working bench.
28. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (See «REPLACEMENT»(ref-235151-S07855546802006061400000) )
29. REMOVE ENGINE WIRE
30. REMOVE RADIATOR HOSE NO.1
31. REMOVE RADIATOR OUTLET, NO. 2 HOSE CLAMP OR CLIP
32. REMOVE HEATER WATER INLET HOSE A
33. REMOVE HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
34. REMOVE VENTILATION HOSE
35. REMOVE VENTILATION HOSE NO. 2
36. REMOVE EXHAUST MANIFOLD SUB-ASSY RH Remove the 6 nuts, exhaust manifold and gasket.
37. REMOVE EXHAUST MANIFOLD SUB-ASSY LH Remove the 6 nuts, exhaust manifold and gasket.
38. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 RH Remove the 4 bolts and engine mounting bracket w/ engine mounting insulator.
39. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 LH Remove the 3 bolts and engine mounting bracket w/ engine mounting insulator.
40. REMOVE IDLER PULLEY SUB-ASSY NO. 2 Remove the 2 bolts and 2 idler pulleys.
41. REMOVE IDLER PULLEY SUB-ASSY NO.1 Remove the bolt and idler pulley.
42. REMOVE V-RIBBED BELT TENSIONER ASSY (See «REPLACEMENT»(ref-235151-S06007633702006061400000) )
43. REMOVE WATER INLET (See «WATER PUMP ASSY (1GR-FE)»(ref-235178-S08159351802006061400000) )
44. REMOVE OIL FILTER BRACKET SUB-ASSY Remove the 3 bolts, 2 nuts, oil filter bracket and gasket.
45. REMOVE INTAKE MANIFOLD (See «REPLACEMENT»(ref-235151-S10445535042006061400000) )
46. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY Remove the 2 bolts and 2 camshaft timing oil control valves.
47. REMOVE WATER BY PASS JOINT RR (See «REPLACEMENT»(ref-235151-S10445535042006061400000) )
48. REMOVE OIL FILLER CAP SUB-ASSY
49. REMOVE OIL FILLER CAP HOUSING Remove the 2 nuts, oil filler cap housing and gasket.
50. REMOVE IGNITION COIL ASSY
51. REMOVE SPARK PLUG
52. REMOVE OIL LEVEL GAUGE SUB-ASSY
53. REPLACE PARTIAL ENGINE ASSY
54. INSPECT INTAKE MANIFOLD FOR FLATNESS Using a precision straight edge and feeler gauge, measure flatness for the surface contacted the cylinder head and intake air surge tank. Maximum warpage: Intake air surge tank side: 0.8 mm (0.031 in.) Cylinder head side: 0.2 mm (0.008 in.) If warpage is greater than maximum, replace the intake manifold.
55. INSPECT EXHAUST MANIFOLD FOR FLATNESS Using a precision straight edge and feeler gauge, measure flatness for the surface contacted the cylinder head. Maximum warpage: 0.7 mm (0.028 in.) If warpage is greater than maximum, replace the exhaust manifold. HINT: Maximum warpage of each installation surface: 0.3 mm (0.012 in.)
56. INSTALL OIL LEVEL GAUGE SUB-ASSY
57. INSTALL SPARK PLUG Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
58. INSTALL IGNITION COIL ASSY Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)
59. INSTALL OIL FILLER CAP HOUSING Install a new gasket and oil filler cap housing with the 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)
60. INSTALL OIL FILLER CAP SUB-ASSY
61. INSTALL WATER BY PASS JOINT RR (See «REPLACEMENT»(ref-235151-S10445535042006061400000) )
62. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Insert the camshaft timing oil control valves to each cylinder head, and tighten the 2 bolts. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)
63. INSTALL INTAKE MANIFOLD (See «REPLACEMENT»(ref-235151-S10445535042006061400000) )
64. INSTALL OIL FILTER BRACKET SUB-ASSY Install a new gasket and oil filter bracket with the 3 bolts and 2 nuts. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
65. INSTALL WATER INLET (See «WATER PUMP ASSY (1GR-FE)»(ref-235178-S08159351802006061400000) )
66. INSTALL V-RIBBED BELT TENSIONER ASSY (See «REPLACEMENT»(ref-235151-S06007633702006061400000) )
67. INSTALL IDLER PULLEY SUB-ASSY NO.1 (See «REPLACEMENT»(ref-235151-S06007633702006061400000) )
68. INSTALL IDLER PULLEY SUB-ASSY NO. 2 (See «REPLACEMENT»(ref-235151-S06007633702006061400000) )
69. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH Install the engine mounting bracket w/ engine mounting insulator with the 3 bolts. Torque: 43 N.m (435 kgf.cm, 31 ft.lbf)
70. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 RH Install the engine mounting bracket w/ engine mounting insulator with the 4 bolts. Torque: 43 N.m (435 kgf.cm, 31 ft.lbf)
71. INSTALL EXHAUST MANIFOLD SUB-ASSY LH (See «REPLACEMENT»(ref-235151-S05978335012006061400000) )
72. INSTALL EXHAUST MANIFOLD SUB-ASSY RH (See «REPLACEMENT»(ref-235151-S10445535042006061400000) )
73. INSTALL VENTILATION HOSE NO. 2
74. INSTALL VENTILATION HOSE
75. INSTALL HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
76. INSTALL HEATER WATER INLET HOSE A
77. INSTALL RADIATOR OUTLET, NO. 2 HOSE CLAMP OR CLIP
78. INSTALL RADIATOR HOSE NO.1
79. INSTALL ENGINE WIRE
80. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (See «REPLACEMENT»(ref-235151-S07855546802006061400000) )
81. INSTALL ENGINE ASSY Attach the engine sling device and hang the engine with the chain block. Lower the engine into the engine compartment carefully. Attach the engine mounting brackets to the frame brackets. Install the engine mounting brackets to the frame brackets with the 4 bolts and 4 nuts. Torque: 38 N.m (387 kgf.cm, 28 ft.lbf) Remove the 4 bolts and 2 engine hangers.
82. INSTALL ENGINE WIRE NO. 2 Install the ground cable to the cylinder block. Torque: 13 N.m (133 kgf.cm, 9 ft.lbf)
83. INSTALL ENGINE WIRE Connect the front differential connector. Insert the engine wire to the vehicle room, and install the grommet. Connect each connector for the ECM, four wheel drive control ECU (4WD only) and instrument panel wire. Install the glove compartment door. Install the cowl side trim board RH. Install the front door scuff plate RH.
84. INSTALL INTAKE AIR SURGE TANK (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
85. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
86. CONNECT HEATER WATER INLET HOSE B
87. CONNECT FUEL PIPE SUB-ASSY NO. 2 (See «PRECAUTION»(/toyota/4runner/iv-2002-2005/remont/fuel-system/#engine-fuel-system-1gr-fe) )
88. CONNECT FUEL PIPE SUB-ASSY NO.1 (See «PRECAUTION»(/toyota/4runner/iv-2002-2005/remont/fuel-system/#engine-fuel-system-1gr-fe) )
89. INSTALL COOLER COMPRESSOR ASSY (See «CRANKSHAFT POSITION SENSOR»(ref-151984-S30853055372003010900000) )
90. INSTALL GENERATOR ASSY (See «GENERATOR»(ref-163567-S22705679482004070600000) )
91. INSTALL VANE PUMP ASSY (See «REPLACEMENT»(ref-235151-S06007633702006061400000) )
92. INSTALL FAN PULLEY
93. INSTALL FAN W/ FLUID COUPLING Temporarily install the fan w/ fluid coupling with the 4 nuts.
94. INSTALL FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT»(ref-235151-S00974816002006061400000) )
95. FULLY TIGHTEN FAN W/ FLUID COUPLING (See «WATER PUMP ASSY (1GR-FE)»(ref-235178-S08159351802006061400000) )
96. INSTALL FAN SHROUD Put the fan shroud into the engine room. Fasten the 2 oil cooler hoses with the hose clamp.
97. INSTALL RADIATOR ASSY (See «RADIATOR ASSY (1GR-FE)»(ref-235178-S32255639492006061400000) )
98. INSTALL RADIATOR SUPPORT SEAL UPPER
99. INSTALL AIR CLEANER ASSY)
100. CONNECT VENTILATION HOSE NO. 2
101. INSTALL HOOD SUB-ASSY Install the hood with the 4 bolts. Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) Tighten the 2 hood supports. Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) Connect the windshield washer hose.
102. ADJUST HOOD SUB-ASSY (See «ADJUSTMENT»(ref-190145-S16202834202005091500000) )
103. INSTALL BATTERY
104. ADD ENGINE OIL (See «REPLACEMENT»(/toyota/4runner/iv-2002-2005/remont/lubrication-system/#engine-lubrication-system-1gr-fe__replacement) )
105. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-235178-S21524750362006061400000) )
106. INSTALL AUTOMATIC TRANSMISSION ASSY (2WD DRIVE TYPE) (See «A340E»(ref-158065-S01947165072003090900000) )
107. INSTALL AUTOMATIC TRANSMISSION ASSY (4WD DRIVE TYPE) (See «A340F»(ref-158065-S23854566212003090900000) )
108. CHECK FOR ENGINE COOLANT LEAKS (See «ON-VEHICLE INSPECTION»(ref-235178-S35591562862006061400000) )
109. CHECK FOR FUEL LEAKS (See «FUEL SYSTEM - 1GR-FE»(/toyota/4runner/iv-2002-2005/remont/fuel-system/#engine-fuel-system-1gr-fe) )
110. CHECK FOR ENGINE OIL LEAKS
111. INSTALL V-BANK COVER Install the V-bank cover with the 2 nuts. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf)
112. INSPECT IGNITION TIMING (See «INSPECTION»(ref-235151-S08614278762006061400000) ) SST 09843-18040
113. INSPECT ENGINE IDLE SPEED (See «INSPECTION»(ref-235151-S08614278762006061400000) ) SST 09843-18030
114. INSPECT CO/HC (See «INSPECTION»(ref-235151-S08614278762006061400000) )

See also:
• LUBRICATION SYSTEM (1GR-FE)
• PRECAUTION
• REPLACEMENT
• COMPONENTS