Scheme 546
Scheme 547
Scheme 548
Scheme 549
Scheme 550
Scheme 551
Scheme 552
Scheme 553
Scheme 554
- INSPECT COOLANT (See «ON-VEHICLE INSPECTION»(ref-235178-S31831565622006061400000) )
- INSPECT ENGINE OIL (See «ON-VEHICLE INSPECTION»(ref-235182-S35090282412006061400000) )
- INSPECT BATTERY SPECIFIC GRAVITY (See «GENERATOR»(ref-163567-S22705679482004070600000) )
- INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSY
- INSPECT FAN AND GENERATOR V BELT HINT: Use of the automatic tensioner has made the tension and flexibility measurements unnecessary. Check that the indicator mark on the automatic tensioner is within the A range as shown in the illustration. When the mark is out of the standard range, exchange the V belt with new one.
- INSPECT V-RIBBED BELT TENSIONER ASSY (See «FAN AND GENERATOR V BELT»(ref-235152-S25929235362006061400000) )
- WARM UP ENGINE
- 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 the hand-held tester or OBD II scan tool operator's for further details. Ignition timing: 8-12° BTDC @ 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. 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: 8-12° BTDC @ idle (Transmission in neutral position) Remove the SST from the DLC3. Disconnect the timing light from the engine. INSPECT ENGINE IDLE SPEED Connect the hand-held tester or OBD II scan tool to the DLC3. Please refer to the hand-held tester or OBD II scan tool operators for further details. Race the engine speed at 2, 500 RPM for approx. 90 seconds. Check the idle speed. Idle speed: 700 +/- 50 RPM 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. INSPECT COMPRESSION Remove the throttle body cover sub-assy. Remove the air cleaner hose assy. Disconnect the throttle control motor connector. Remove the 8 ignition coils. Remove the 8 spark plugs. Disconnect the 8 injector connectors. Inspect the cylinder compression pressure. Insert a compression gauge into the spark plug hole. Fully open the throttle forcibly 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 (1) through (3) for each cylinder. NOTE: This measurement must be done in as short a time as possible. Compression pressure: 1, 226 kPa (12.5 kgf/cm 2, 178 psi) or more Minimum pressure: 981 kPa (10.0 kgf/cm 2, 142 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm 2, 14 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 (1) through (3) for cylinders with low compression. If adding oil helps the compression, chances are 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 8 injector connectors. Install the 8 spark plugs. Install the 8 ignition coils. Connect the throttle control motor connector. Install the air cleaner hose assy. Install the throttle body cover sub-assy. INSPECT CO/HC HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. Start the engine. Hold the engine 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 are prescribed by the applicable local regulations. If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. Check the heated oxygen sensor operation (See «EMISSION SYSTEMS & SUB-SYSTEMS»(ref-151984-S32663093302003010900000) ). See the (Scheme 554) below for possible causes, then inspect and correct the applicable causes if necessary.
Scheme 555
Scheme 556
Scheme 557
- REMOVE FAN AND GENERATOR V BELT Loosen the belt tension by turning the belt tensioner counterclockwise, and remove the drive belt. HINT: The pulley bolt for the belt tensioner has a left - hand thread.
- INSPECT V-RIBBED BELT TENSIONER ASSY Remove the V belt from the tensioner pulley. Then check that nothing gets caught the tensioner by turning it clockwise and counterclockwise. When a malfunction exists, replace the tensioner.
- INSTALL FAN AND GENERATOR V BELT Set the V belt to everything except the idler pulley No. 2, as shown in the illustration. Loosen the V belt by turning the belt tensioner counterclockwise. Then set the V belt to the idler pulley. After a new belt has been installed, check that the mark is within the B range as shown in the illustration.
Scheme 558
Scheme 559
Scheme 560
Scheme 561
Scheme 562
Scheme 563
Scheme 564
- DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-235178-S38479857142006061400000) )
- SEPARATE BATTERY NEGATIVE TERMINAL
- REMOVE THROTTLE BODY COVER SUB-ASSY
- REMOVE AIR CLEANER HOSE ASSY
- REMOVE RADIATOR SUPPORT SEAL UPPER
- REMOVE FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT»(ref-235152-S25929235362006061400000) )
- REMOVE OIL COOLER PIPE (See «REPLACEMENT»(ref-235152-S20839505222006061400000) )
- REMOVE TIMING BELT COVER SUB-ASSY NO. 3 LH (See «REPLACEMENT»(ref-235152-S20839505222006061400000) )
- REMOVE TIMING CHAIN OR BELT COVER NO. 2 (See «REPLACEMENT»(ref-235152-S20839505222006061400000) )
- REMOVE CYLINDER HEAD COVER SUB-ASSY Remove the 9 bolts, 9 seal washers and cylinder head cover.
- REMOVE CYLINDER HEAD COVER SUB-ASSY LH Disconnect the PCV hose. Remove the 9 bolts, 9 seal washers and cylinder head cover.
- SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with timing mark "0" of the No. 1 timing belt cover. Check that the timing marks of the camshaft timing pulleys and timing belt rear plates are aligned. If not, turn the crankshaft 1 revolution (360°) and align the mark as above.
- INSPECT VALVE CLEARANCE Check only the valves indicated. Using a feeler gauge, measure the clearance be tween the valve lifter and camshaft. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjust shim. Valve clearance (Cold): Intake 0.15-0.25 mm (0.006-0.010 in.) Exhaust 0.25-0.35 mm (0.010-0.014 in.) Turn the crankshaft 1 revolution (360°) and align the mark as above. Check only the valves indicated as shown. Measure the valve clearance.
- ADJUST VALVE CLEARANCE Remove the timing belt (See «REPLACEMENT»(ref-235152-S20839505222006061400000) ). Remove the camshafts (RH Bank) (See «REPLACEMENT»(ref-235152-S30166134142006061400000) ). Remove the camshafts (LH Bank) (See «REPLACEMENT»(ref-235152-S02049091912006061400000) ). Remove the valve lifter and adjusting shim. Determine the replacement adjusting shim size according to these Formula or Charts: Using a micrometer, measure the thickness of the removed shim. Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T: Thickness of removed shim A: Measured valve clearance N: Thickness of new shim Intake: N = T + (A - 0.20 mm) Exhaust: N = T + (A - 0.30 mm (0.012 in.)) Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 41 increments of 0.020 mm (0.0008 in.), from 2.00 mm (0.0787 in.) to 2.80 mm (0.1102 in.). Place a new adjusting shim on the valve. Place the valve lifter. Reinstall the camshafts (LH Bank) (See «REPLACEMENT»(ref-235152-S02049091912006061400000) ). Reinstall the camshafts (RH Bank) (See «REPLACEMENT»(ref-235152-S30166134142006061400000) ). Reinstall the timing belt (See «REPLACEMENT»(ref-235152-S20839505222006061400000) ). Recheck the valve clearance.
- INSTALL CYLINDER HEAD COVER SUB-ASSY LH (See «OVERHAUL»(ref-235152-S39920773902006061400000) )
- INSTALL CYLINDER HEAD COVER SUB-ASSY (See «OVERHAUL»(ref-235152-S39920773902006061400000) )
- INSTALL TIMING CHAIN OR BELT COVER NO. 2 (See «REPLACEMENT»(ref-235152-S20839505222006061400000) )
- INSTALL TIMING BELT COVER SUB-ASSY NO. 3 LH (See «REPLACEMENT»(ref-235152-S20839505222006061400000) )
- INSTALL OIL COOLER PIPE (See «REPLACEMENT»(ref-235152-S20839505222006061400000) )
- INSTALL FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT»(ref-235152-S25929235362006061400000) )
- INSTALL RADIATOR SUPPORT SEAL UPPER
- INSTALL AIR CLEANER HOSE ASSY
- INSTALL THROTTLE BODY COVER SUB-ASSY
- REFILL ENGINE COOLANT (See «REPLACEMENT»(ref-235178-S38479857142006061400000) )
Scheme 565
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Scheme 568
Scheme 569
Scheme 570
Scheme 571
Scheme 572
Scheme 573
Scheme 574
Scheme 575
Scheme 576
Scheme 577
Scheme 578
Scheme 579
Scheme 580
Scheme 581
Scheme 582
Scheme 583
Scheme 584
Scheme 585
Scheme 586
Scheme 587
Scheme 588
Scheme 589
Scheme 590
Scheme 591
Scheme 592
Scheme 593
Scheme 594
Scheme 595
- WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See «FUEL SYSTEM PRECAUTION»(/toyota/4runner/iv-2002-2005/remont/fuel-system/#engine-fuel-system-2uz-fe) )
- REMOVE AUTOMATIC TRANSMISSION ASSY (2WD DRIVE TYPE) (See «OVERHAUL - A750E & A750F»(ref-153920) )
- REMOVE AUTOMATIC TRANSMISSION ASSY (4WD DRIVE TYPE) (See «OVERHAUL - A750E & A750F»(ref-153920) )
- REMOVE HOOD SUB-ASSY Disconnect the windshield washer hose. Remove the 4 nuts, and hood sub-assy.
- REMOVE THROTTLE BODY COVER SUB-ASSY Remove the 2 cap nuts and throttle body cover sub-assy.
- REMOVE AIR CLEANER HOSE ASSY Disconnect the vacuum hoses (For P/S idle up and for fuel pressure regulator) and ventilation hose.
- REMOVE AIR CLEANER ASSY Disconnect the intake air flow meter connector. Remove the air cleaner cap and air cleaner element. Remove the 3 bolts and air cleaner assy.
- REMOVE ENGINE UNDER COVER SUB-ASSY NO. 1
- REMOVE ENGINE UNDER COVER ASSY REAR
- DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-235178-S38479857142006061400000) )
- DRAIN ENGINE OIL Remove the oil pan drain plug and drain the engine oil. Clean the oil pan drain plug and install a new gasket and it. Torque: 39 N.m (398 kgf.cm, 29 ft.lbf)
- REMOVE RADIATOR ASSY (See «REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY»(ref-235178-S28266220312006061400000) )
- REMOVE FAN SHROUD Disconnect the fasteners of clamp and oil cooler hoses from fun shroud in sequence. Remove the fun shroud with fun.
- DISCONNECT FUEL HOSE NO. 2 Observe these precautions when disconnecting the fuel tube connector. Remove the fuel pipe clamp No. 2. Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away. Disconnect the connector from the hose while pinching part A with fingers as shown in the illustration. When the connector and the pipe are stuck, pinch the fuel pipe between the hands, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away. Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag.
- DISCONNECT FUEL HOSE Observe these precautions when disconnecting the fuel tube connector. Remove the fuel pipe clamp No. 1. Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away. Disconnect the connector from the hose while pinching part A with fingers as shown in the illustration. When the connector and the pipe are stuck, pinch the fuel pipe between the hands, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away. Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag.
- DISCONNECT FUEL VAPOR FEED HOSE ASSY
- REMOVE FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT»(ref-235152-S25929235362006061400000) )
- SEPARATE VANE PUMP ASSY Disconnect the vacuum hose. Remove the nut, 2 bolts and vane pump assy. HINT: Hang up the hose instead of detaching.
- REMOVE GENERATOR ASSY (See «GENERATOR»(ref-163567-S22705679482004070600000) )
- SEPARATE COMPRESSOR Remove the nut, 3 bolts, compressor stay and compressor. HINT: Hang up the hoses instead of detaching.
- REMOVE FAN W/ FLUID COUPLING Remove the 4 nuts and fan w/ fluid coupling. Remove the fan pulley.
- REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSY Remove the bolt, and transmission oil filler tube.
- REMOVE OIL LEVEL GAGE GUIDE Remove the bolt, and oil level gage guide.
- REMOVE EXHAUST MANIFOLD SUB-ASSY RH Remove the 4 bolts and exhaust manifold heat insulator No. 1. Disconnect the oxygen sensor connector. Remove the 8 nuts and exhaust manifold sub-assy.
- REMOVE EXHAUST MANIFOLD SUB-ASSY LH Remove the 4 bolts and exhaust manifold heat insulator No. 2. Disconnect the oxygen sensor connector. Remove the 8 nuts and exhaust manifold sub-assy.
- DISCONNECT HEATER HOSE
- SEPARATE ENGINE WIRE Remove the front door scuff plate RH. (See «INSTRUMENT PANEL/METER»(/toyota/4runner/iv-2002-2005/remont/gauges-instrument-panels/#instrument-panelmeter) ) Remove the cowl side trim board RH. (See «INSTRUMENT PANEL/METER»(/toyota/4runner/iv-2002-2005/remont/gauges-instrument-panels/#instrument-panelmeter) ) Remove the glove compartment door. (See «INSTRUMENT PANEL/METER»(/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 3 ground cables from the body. Disconnect the engine wire No. 2 from the battery terminals (positive and negative) and engine room relay block.
- REMOVE ENGINE ASSY Attach the engine chain hoist to the engine hangers. Remove the 4 nut's and 4 bolt's. Lift the engine out of the vehicle slowly and carefully HINT: Make sure the engine is clear of all wiring hose and cable.
- REMOVE ENGINE WIRE Disconnect the VSV connector. Disconnect the solenoid connector.
- REMOVE INTAKE MANIFOLD ASSY Remove the 6 bolts and 4 nuts. Remove the intake manifold assy and 2 gaskets.
- REMOVE WIRING HARNESS HEAT INSULATOR NO. 2 Remove the 2 bolts and wiring harness heat insulator No. 2.
- REMOVE ENGINE WIRE NO. 2 Separate the ground cable wire clamp. Remove the 3 bolts and engine wire No. 2.
- REMOVE ENGINE MOUNTING BRACKET FRONT NO. 1 RH Remove the 4 bolts and engine mounting bracket together with engine mounting insulator.
- REMOVE ENGINE MOUNTING BRACKET FRONT NO. 1 LH Remove the 4 bolts and engine mounting bracket together with engine mounting insulator.
- REMOVE HEATER HOSE
- REMOVE HARNESS BRACKET Remove the 3 bolts and 3 wire harness bracket.
- REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (See «REPLACEMENT»(ref-235152-S35493758812006061400000) )
- REMOVE OIL COOLER PIPE Disconnect the 3 hoses. Remove the bolt nut and oil cooler pipe.
- REMOVE PUMP BRACKET Remove the 4 bolts and pump bracket.
- REMOVE TIMING BELT COVER SUB-ASSY NO. 3 LH Remove the grommet and separate the cam position sensor connector from timing belt cover sub-assy No. 3 LH. Remove the 4 bolts and timing belt cover sub-assy No. 3 LH.
- REMOVE TIMING CHAIN OR BELT COVER NO. 2 Remove the nut, 3 bolts and timing belt cover No. 2.
- REMOVE TIMING BELT COVER SUB-ASSY NO. 2 Remove the 2 bolts and timing belt cover sub-assy No. 2.
- REMOVE V-RIBBED BELT TENSIONER ASSY Remove the bolt 2 nuts and v-ribbed belt tensioner.
- REMOVE FAN BRACKET SUB-ASSY Remove the 2 nuts, 2 bolts and fan bracket sub-assy with fan pulley.
- REMOVE IGNITION COIL ASSY Remove the 8 bolts and 8 ignition coil assy.
- REMOVE CAMSHAFT POSITION SENSOR Remove the bolt, stud bolt and camshaft position sensor.
- REMOVE CRANKSHAFT POSITION SENSOR Remove the bolt and crankshaft position sensor.
- REMOVE KNOCK CONTROL SENSOR Using a SST, remove the 2 knock control sensors. SST 09816-30010
- REMOVE WATER BY PASS JOINT RR Remove the 4 nuts and water by pass joint.
- REMOVE STARTER ASSY Disconnect the engine wire No. 2. Remove the 2 bolts and starter assy.
- REMOVE WATER BY PASS PIPE SUB-ASSY Remove the bolt and water by pass.
- REMOVE WATER INLET HOUSING (See «REPLACEMENT»(ref-235178-S19700544432006061400000) )
- REMOVE WATER BY PASS JOINT FR Remove the 4 nuts, water by pass and 2 gaskets.
- REMOVE OIL COOLER ASSY Remove the 2 bolts and nut. Remove the oil cooler assy w/ bracket and gasket.
- REMOVE VENTILATION VALVE SUB-ASSY
- REPLACE PARTIAL ENGINE ASSY
- INSTALL VENTILATION VALVE SUB-ASSY Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Install the PCV valve. Torque: 27 N.m (275 kgf.cm, 20 ft.lbf) HINT: After applying the specified torque, rotate PCV valve clockwise with the port faced in the direction indicated in the illustration. Install the PCV valve cover to the PCV valve. Connect the PCV hose to the PCV valve.
- INSTALL OIL COOLER ASSY Place the new O-ring into the groove of oil pump. Apply a light coat of engine oil on the O-ring. Install the oil cooler assy with the 2 bolts and nut. Torque: Bolt 18 N.m (185 kgf.cm, 13 ft.lbf) Nut 18 N.m (185 kgf.cm, 13 ft.lbf)
- INSTALL WATER BY PASS JOINT FR Attach the 2 gaskets, with put the flat area of the part, shown in the illustration, to the engine front side. Install the water by pass joint with the 4 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
- INSTALL WATER INLET HOUSING (See «REPLACEMENT»(ref-235178-S19700544432006061400000) )
- INSTALL WATER BY PASS PIPE SUB-ASSY Install a new O-ring to the water by pass pipe. Apply soapy water to the O-ring. Push in the water by pass pipe end into the pipe hole of the water pump. Install the water by pass pipe with the bolt. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
- INSTALL STARTER ASSY Install the starter assy with 2 bolts. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) Connect the engine wire No. 2. Torque: 9.8 N.m (100 kgf.cm, 7.2 ft.lbf)
- INSTALL WATER BY PASS JOINT RR Attach the 2 gaskets, with put the flat area of the part, shown in the illustration, to the engine rear side. Install the 4 nuts holding the water bypass joint to the cylinder head. Alternately tighten the nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
- INSTALL KNOCK CONTROL SENSOR Using a SST, install the 2 knock control sensors. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
- INSTALL CRANKSHAFT POSITION SENSOR Install the crankshaft position sensor with bolt. Torque: 6.5 N.m (65 kgf.cm, 58 in..lbf)
- INSTALL CAMSHAFT POSITION SENSOR Install the camshaft position sensor with bolt and stud bolt. Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf)
- INSTALL IGNITION COIL ASSY Install the 8 ignition coil assy with 8 bolts. Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf)
- INSTALL FAN BRACKET SUB-ASSY Install the fan bracket with 2 bolts and 2 nuts. Torque: 12 mm head 16 N.m (160 kgf.cm, 12 ft.lbf) 14 mm head 32 N.m (330 kgf.cm, 24 ft.lbf)
- INSTALL V-RIBBED BELT TENSIONER ASSY Install the v-ribbed belt tensioner with the bolt and 2 nuts. Torque: Bolt 16 N.m (160 kgf.cm, 12 ft.lbf) Nut 16 N.m (160 kgf.cm, 12 ft.lbf)
- INSTALL TIMING BELT COVER SUB-ASSY NO. 2 Install timing belt cover sub-assy No. 2 with the 2 bolts. Torque: 16 N.m (160 kgf.cm, 12 ft.lbf)
- INSTALL TIMING CHAIN OR BELT COVER NO. 2 Install the timing chain or belt cover with the nut and 2 bolts. Torque: Bolt 7.5 N.m (80 kgf.cm, 66 in..lbf) Nut 7.5 N.m (80 kgf.cm, 66 in..lbf)
- INSTALL TIMING BELT COVER SUB-ASSY NO. 3 LH Install the timing belt cover sub-assy with 4 bolts. Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf) Install the cam position sensor connector and grommet to the timing belt cover.
- INSTALL PUMP BRACKET Install the pump bracket with 4 bolts. Torque: 43 N.m (438 kgf.cm, 32 ft.lbf)
- INSTALL OIL COOLER PIPE Install the oil cooler pipe with bolt and nut. Torque: Bolt 7.5 N.m (80 kgf.cm, 66 in..lbf) Nut 7.5 N.m (80 kgf.cm, 66 in..lbf) Connect the 3 hoses.
- INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (See «REPLACEMENT»(ref-235152-S35493758812006061400000) )
- INSTALL HARNESS BRACKET Torque: 8.0 N.m (80 kgf.cm, 71 in..lbf)
- INSTALL HEATER HOSE
- INSTALL ENGINE MOUNTING BRACKET FRONT NO. 1 LH Install the engine mounting bracket and engine mounting insulator with 4 bolts. Torque: 36 N.m (367 kgf.cm, 27 ft.lbf)
- INSTALL ENGINE MOUNTING BRACKET FRONT NO. 1 RH Install the engine mounting bracket and engine mounting insulator with 4 bolts. Torque: 36 N.m (367 kgf.cm, 27 ft.lbf)
- INSTALL ENGINE WIRE NO. 2 Install engine wire protector with 3 bolts. Connect the ground cable wire clamp with bolt.
- INSTALL WIRING HARNESS HEAT INSULATOR NO. 2 Install the wiring harness heat insulator with 2 bolts. Torque: 17 N.m (175 kgf.cm, 13 ft.lbf)
- INSTALL INTAKE MANIFOLD ASSY Place 2 new gaskets on the cylinder heads with white painted mark facing upward. NOTE: Align the port holes of the gasket and cylinder head. Be careful of the installation direction. Place the intake manifold assembly on the cylinder heads. Install and uniformly tighten the 6 bolts and 4 nuts in several passes. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
- INSTALL ENGINE WIRE
- INSTALL ENGINE ASSY Attach the engine chain hoist to the engine hangers. Slowly lower the engine assembly into the engine compartment. Attach the engine mounting brackets to the frame brackets. Install the 4 nuts and 4 bolts holding the engine mounting brackets to the frame brackets. Torque: 38 N.m (387 kgf.cm, 28 ft.lbf) Remove the engine chain hoist.
- INSTALL ENGINE WIRE
- CONNECT HEATER HOSE
- INSTALL EXHAUST MANIFOLD SUB-ASSY LH Place a new gasket on the cylinder head with the white painted marks facing the manifold side. NOTE: Be careful of the installation direction. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes. Torque: 44 N.m (450 kgf.cm, 33 ft.lbf) Install the heat insulator with the 4 bolts. Torque: 7.8 N.m (80 kgf.cm, 69 in..lbf)
- INSTALL EXHAUST MANIFOLD SUB-ASSY RH Place a new gasket on the cylinder head with the white painted marks facing the manifold side. NOTE: Be careful of the installation direction. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes. Torque: 44 N.m (450 kgf.cm, 33 ft.lbf) Install the heat insulator with the 4 bolts. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf)
- INSTALL OIL LEVEL GAGE GUIDE Install the new O-ring to the oil level gage guide. Install the oil level gage guide with the belt. Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
- INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSY Install the transmission oil filler tube sub-assy with the bolt. Torque: 12 N.m (122 kgf.cm, 9 ft.lbf)
- INSTALL FAN W/ FLUID COUPLING Install the fan pulley to the engine. Install the fan w/ fluid coupling with the 4 nuts. Torque: 29 N.m (296 kgf.cm, 21 ft.lbf)
- INSTALL COMPRESSOR Install the compressor with stay, nut and 3 bolts. Torque: Bolt 47 N.m (475 kgf.cm, 34 ft.lbf) Nut 25 N.m (255 kgf.cm, 18 ft.lbf)
- INSTALL GENERATOR ASSY (See «GENERATOR»(ref-163567-S22705679482004070600000) )
- INSTALL VANE PUMP ASSY Install the vane pump assy with nut and 2 bolts. Torque: Bolt 43 N.m (438 kgf.cm, 32 ft.lbf) Nut 43 N.m (438 kgf.cm, 32 ft.lbf)
- INSTALL FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT»(ref-235152-S25929235362006061400000) )
- CONNECT FUEL VAPOR FEED HOSE ASSY
- CONNECT FUEL HOSE
- CONNECT FUEL HOSE NO. 2
- INSTALL FAN SHROUD Install the fan shroud with fan into the engine room. Clamp the 2 oil cooler hoses to fan shroud. Torque: 5.0 N.m (51 kgf.cm, 44 in..lbf)
- INSTALL RADIATOR ASSY (See «REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY»(ref-235178-S28266220312006061400000) )
- REFILL ENGINE COOLANT (See «REPLACEMENT»(ref-235178-S38479857142006061400000) )
- ADD ENGINE OIL
- INSTALL ENGINE UNDER COVER ASSY REAR
- INSTALL ENGINE UNDER COVER SUB-ASSY NO. 1
- INSTALL AIR CLEANER ASSY Install the air cleaner assy with 3 bolts. Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) Connect the wire harness clamp and ground cable. Torque: 8.3 N.m (85 kgf.cm, 73 in..lbf)
- INSTALL AIR CLEANER HOSE ASSY
- INSTALL THROTTLE BODY COVER SUB-ASSY Install the throttle body cover sub-assy with 2 nuts. Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf)
- INSTALL HOOD SUB-ASSY Install the hood with 4 bolt's. Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) Connect the windshield washer hose.
- INSTALL AUTOMATIC TRANSMISSION ASSY (4WD DRIVE TYPE) (See «OVERHAUL - A750E & A750F»(ref-153920) )
- INSTALL AUTOMATIC TRANSMISSION ASSY (2WD DRIVE TYPE) (See «OVERHAUL - A750E & A750F»(ref-153920) )
- CHECK FOR ENGINE COOLANT LEAKS (See «ON-VEHICLE INSPECTION»(ref-235178-S31831565622006061400000) )
- CHECK FOR EXHAUST GAS LEAKS
- INSPECT FOR FUEL LEAKS (See «FUEL SYSTEM PRECAUTION»(/toyota/4runner/iv-2002-2005/remont/fuel-system/#engine-fuel-system-2uz-fe) )
- INSPECT AUTOMATIC TRANSMISSION FLUID (See «A750E & A750F»(ref-158065-S38974979552003090900000) )
- INSPECT ENGINE OIL LEAKS
See also:
• FUEL SYSTEM PRECAUTION
• INSTRUMENT PANEL/METER