Engine Mechanical - 3.4L: Removal & Installation Toyota Tacoma I рестайлинг

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.

Removal (2WD)

Refer to these figures throughout procedure. (Scheme 49)- (Scheme 51).

1. Engine and transmission are removed as an assembly. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-159020-S20413080052003110600000) . Drain cooling system, engine oil and transmission fluid. Remove hood.
2. Remove front grill for access to radiator. Disconnect necessary hoses and oil cooler lines for removal of radiator. Remove radiator. Remove fan clutch-to-fan bracket nuts. Remove radiator cooling fan with fan clutch and pulley from fan bracket.
3. Disconnect accelerator, throttle and cruise control cables. Disconnect heater hoses from engine. Disconnect brake booster hose, EVAP hose, fuel return and fuel inlet hoses. Mark and disconnect appropriate wiring and connectors for engine removal.
4. Disconnect starter ground strap. Disconnect positive battery cable. Remove 2 starter cable clamps. Disconnect starter wire connector. Disconnect wire from relay block No. 2. Disconnect generator wire.
5. Remove glove compartment door and lower finish panel to access Engine Control Module (ECM). Disconnect all ECM connectors. Disconnect 2 wiring clamps from finish panel.
6. Disconnect remaining clamps and wiring connectors for engine wiring harness from under instrument panel. Pull engine wiring harness into engine compartment.
7. Raise and support vehicle. Remove lower engine cover. Place references marks on drive shaft flange at rear differential for reassembly reference. Remove drive shaft flange-to-rear differential flange bolts/nuts and drive shaft. Install special cover in transmission to prevent fluid leak.
8. Remove bolts/nuts, front exhaust pipe support bracket, front exhaust pipe and gaskets. Front exhaust pipe contains catalytic converter and is located between crossover pipe between exhaust manifolds and rear exhaust pipe to muffler.
9. Support transmission with jack. Remove bolts holding rear mount bracket to crossmember. Install appropriate engine lift. Attach lifting chains only to provided hangers. Carefully lift engine and transmission from vehicle.

Scheme 49

Scheme 50

Scheme 51

Installation (2WD)

1. To install, reverse removal procedure using NEW gaskets. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-159020-S42029834072003110600000) . 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.

Scheme 52

Scheme 53

Removal (4WD)

Refer to these figures throughout procedure. (Scheme 54)- (Scheme 55).

1. Remove transmission prior to engine removal. For A/T, see appropriate AUTOMATIC TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. For M/T, see appropriate CLUTCHES article. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-159020-S20413080052003110600000) . 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.

Scheme 54

Scheme 55

Installation (4WD)

1. To install, reverse removal procedure using NEW gaskets. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-159020-S42029834072003110600000) . 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.

Removal

1. Remove lower engine cover. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-159020-S20413080052003110600000). 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 REPLACEMENT - 3.4L»(ref-155621) article in ENGINE.
5. Disconnect necessary electrical connectors, control cables, vacuum hoses and coolant hoses for removal of air intake chamber. (Scheme 56) Remove air intake chamber assembly.
6. Disconnect hoses and wiring from intake air connector assembly. (Scheme 56)
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 REPLACEMENT - 3.4L»(ref-155621) article in ENGINE. Disconnect camshaft position sensor connector. Remove camshaft position sensor. Remove camshaft sprockets. See «CAMSHAFT»(ref-159020-S35522861772003110600000). 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-159020-S35522861772003110600000).
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. see scheme 38 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 57) Place cylinder heads on wooden blocks on workbench.

Scheme 56

Scheme 57

Removal & Installation (Oil Pump Installed)

1. Remove timing belt and crankshaft sprocket. See «TIMING BELT REPLACEMENT - 3.4L»(ref-155621) article in ENGINE. 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.

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. For access to valve covers, air intake chamber and intake air connector must be removed. (Scheme 56)
2. Mark and disconnect necessary fuel and electrical connectors, control cables, vacuum hoses and coolant hoses for access to valve covers. Remove bolts, seal washers, valve covers and gaskets.
3. Remove timing belt and camshaft sprockets. See «TIMING BELT REPLACEMENT - 3.4L»(ref-155621) article in ENGINE. Remove camshaft position sensor. CAUTION: Since thrust clearance of camshaft is small, keep camshaft level during removal and installation or cylinder head at thrust end may be damaged and/or camshaft may be damaged.
4. To service camshafts in right cylinder head, align timing marks with 2 dots on camshaft gears by rotating camshaft using hexagonal area of camshaft. (Scheme 58) To service camshafts in left cylinder head, align timing marks with one dot on camshaft gears by rotating camshaft using hexagonal area of camshaft. (Scheme 58)
5. On all applications, secure camshaft sub-gear on exhaust camshaft to main gear with a 6 x 1.0 x 18-mm service bolt. (Scheme 59) Before removing camshaft bearing cap bolts, ensure torsional spring force of camshaft sub-gear is held by service bolt. NOTE: Camshaft bearing caps are numbered for location on top of camshaft bearing cap. Camshaft bearing cap is also stamped with either an "I" for intake camshaft or an "E" for exhaust camshaft. Arrow on top of camshaft bearing cap must point the proper direction in accordance with cylinder head application. (Scheme 60) Camshaft bearing caps must be installed in correct location.
6. Note location of camshaft bearing caps, as camshaft bearing caps are numbered for location on top of camshaft bearing cap. Camshaft bearing cap is also stamped with either an "I" for intake camshaft or an "E" for exhaust camshaft. Arrow on top of camshaft bearing cap must point the proper direction in accordance with cylinder head application. (Scheme 60) CAUTION: Camshaft bearing cap bolts must be removed in proper sequence to prevent damage to cylinder head and camshaft thrust surfaces.
7. Remove exhaust camshaft bearing cap bolts in sequence using several steps. (Scheme 61) Remove camshaft bearing caps and exhaust camshaft.
8. Remove intake camshaft bearing cap bolts in sequence using several steps. (Scheme 61) Remove camshaft bearing caps, intake camshaft and oil seal.
9. If disassembling exhaust camshaft, mount hexagonal area of camshaft in soft-jaw vise. Using spanner wrench, rotate camshaft sub-gear clockwise and remove service bolt. (Scheme 62) Remove snap ring, wave washer, camshaft sub-gear and camshaft gear spring. (Scheme 57)

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

1. If reassembling exhaust camshaft, install camshaft gear spring and camshaft sub-gear on exhaust camshaft. Ensure pins on camshaft sub-gear engage with ends of camshaft gear spring. Install wave washer and snap ring on exhaust camshaft.
2. Using spanner wrench, rotate camshaft sub-gear clockwise until holes in main gear and camshaft sub-gear are aligned. Temporarily install service bolt. (Scheme 62) Ensure gear teeth of main gear and camshaft sub-gear are aligned. Tighten service bolt.
3. Apply engine oil to thrust surfaces and journals of camshafts. Install intake camshaft on cylinder head. Rotate intake camshaft so timing mark with 2 dots on right cylinder head applications or timing mark with one dot on left cylinder head applications is properly positioned with surface on cylinder head. (Scheme 63)
4. Apply engine oil to seal lip on NEW oil seal. Install oil seal on intake camshaft. Apply sealant on No. 1 intake camshaft bearing cap at bearing cap-to-cylinder head surface.
5. Install intake camshaft bearing caps in numerical order. Ensure arrow on top of camshaft bearing cap is pointing toward proper direction in accordance with cylinder head application. (Scheme 60)
6. Coat camshaft bearing cap bolt-to-camshaft bearing cap surface and bolt threads with engine oil. Install and tighten intake camshaft bearing cap bolts to specification in sequence using several steps. see scheme 37 See «TORQUE SPECIFICATIONS»(ref-159020-S42029834072003110600000).
7. Install exhaust camshaft on cylinder head so timing marks with 2 dots on right cylinder head applications or timing mark with one dot on left cylinder head applications is aligned with timing mark on intake camshaft. (Scheme 58)
8. Install exhaust camshaft bearing caps in numerical order. Ensure arrow on top of camshaft bearing cap is pointing toward proper direction in accordance with cylinder head application. (Scheme 60)
9. Coat camshaft bearing cap bolt-to-camshaft bearing cap surface and bolt threads with engine oil. Install and tighten exhaust camshaft bearing cap bolts to specification in sequence using several steps. see scheme 37 See «TORQUE SPECIFICATIONS»(ref-159020-S42029834072003110600000). CAUTION: Ensure service bolt is removed from camshaft sub-gear on exhaust camshafts.
10. On all cylinder head applications, remove service bolt from exhaust camshaft. Check and adjust valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(ref-159020-S35440396232003110600000) under ADJUSTMENTS.
11. Apply sealant to grooves of semi-circular plugs and install in cylinder head (if removed). (Scheme 57) Before installing valve cover and gasket, apply sealant at front and rear areas of the cylinder head. see scheme 8
12. Using NEW gasket, install valve cover. Install and tighten valve cover bolts to specification in several steps. See «TORQUE SPECIFICATIONS»(ref-159020-S42029834072003110600000).
13. To install remaining components, reverse removal procedure using NEW gaskets. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-159020-S42029834072003110600000).
14. When installing camshaft position sensor, ensure pin on camshaft position sensor engages with hole in cylinder head. Install timing belt using proper procedure. See «TIMING BELT REPLACEMENT - 3.4L»(ref-155621) article in ENGINE. Fill cooling system.

Scheme 63

1. Water pump is located on front of cylinder block, behind timing belt. (Scheme 64) Drain cooling system. Remove timing belt. See «TIMING BELT REPLACEMENT - 3.4L»(ref-155621) article in ENGINE.
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.

Scheme 64

1. Ensure sealing surface on rear of water pump is clean. Apply sealant on grooves at rear of water pump before installing. (Scheme 65) Install water pump. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159020-S42029834072003110600000). 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-159020-S42029834072003110600000). Install timing belt using proper procedure. See «TIMING BELT REPLACEMENT - 3.4L»(ref-155621) article in ENGINE. Fill cooling system.

Scheme 65

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 REPLACEMENT - 3.4L»(ref-155621) article in ENGINE. 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-159020-S42029834072003110600000) .
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-159020-S42029834072003110600000) . To install remaining components, reverse removal procedure. Fill crankcase with oil.

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 66)or (Scheme 67). 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).

Scheme 66

Scheme 67

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-159020-S42029834072003110600000) .
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-159020-S42029834072003110600000) .
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-159020-S25459858642003110600000) 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 68)

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 68)
2. Tighten oil pump body cover screws to specification. See «TORQUE SPECIFICATIONS»(ref-159020-S42029834072003110600000). 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 69) 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-159020-S42029834072003110600000). To install remaining components, reverse removal procedure.

Scheme 68

Scheme 69

1. Oil cooler is located on side of cylinder block, behind oil filter. (Scheme 70) 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-159020-S42029834072003110600000). Fill cooling system.

Scheme 70