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Home >> Toyota Truck >> 2005 >> Highlander 2WD V6-3.3L (3MZ-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Partial Engine Assembly Replacement >> Part 3

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PARTIAL ENGINE ASSEMBLY
REPLACEMENT





81. INSPECT INTAKE AIR SURGE TANK
a. Using a precision straight edge and feeler gauge, mea sure the surface contacting the cylinder head for war page.
Maximum warpage: 0.10 mm (0.0039 inch)
If the warpage is greater than the maximum, replace the manifold.





82. REMOVE INTAKE MANIFOLD
a. Remove the nut and disconnect the ground cable.
b. Disconnect the 6 fuel injector connectors.





c. Uniformly loosen and remove the 9 bolts and 2 nuts in the sequence shown in the illustration. Remove the intake manifold.





83. INSPECT INTAKE MANIFOLD
a. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head and intake air surge tank for warpage.





Maximum warpage

If warpage is greater than the maximum, replace the manifold.





84. REMOVE WATER OUTLET
a. Disconnect the radiator hose inlet.
b. Disconnect the engine coolant temperature sensor connector.
c. Remove the clamp.
d. Remove the 2 bolts, 2 nuts and 2 washers.
e. Lock the hose clamp as shown in the illustration and remove the water outlet together with the water bypass hose No. 1.
f. Remove the 2 gaskets from the 2 cylinder heads.
85. REMOVE IGNITION COIL ASSEMBLY
86. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2





a. Disconnect the A/F sensor connector.
b. Remove the bolt, nut and insulator No. 3.





c. Remove the 2 bolts and insulator No. 2.





d. Uniformly loosen and remove the 7 nuts in the sequence shown in the illustration.
e. Remove the converter and gasket.





f. Remove the 2 bolts and manifold stay.





87. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2
a. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0196 inch)
If the warpage is greater than the maximum, replace the manifold.
88. REMOVE ENGINE MOUNTING BRACKET RH





89. REMOVE PUMP BRACKET
a. Remove the 3 bolts and pump bracket.
90. REMOVE GENERATOR BRACKET NO.1
91. REMOVE COMPRESSOR MOUNTING BRACKET NO.1
92. REMOVE WATER INLET PIPE
93. REMOVE WATER INLET
94. REMOVE THERMOSTAT





95. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Remove the oil pressure switch.
96. REMOVE KNOCK SENSOR
a. Remove the 2 nuts and 2 sensors.
97. REPLACE PARTIAL ENGINE ASSEMBLY





98. INSTALL KNOCK SENSOR
a. Install the 2 knock sensors with the 2 nuts, as shown in the illustration.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
99. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Part No. 08833-00080 THREE BOND 1344, LOCTITE 242 or equivalent
b. Install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
100. INSTALL THERMOSTAT
101. INSTALL WATER INLET
102. INSTALL WATER INLET PIPE
103. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
104. INSTALL GENERATOR BRACKET NO.1
Torque: 58 Nm (591 kgf-cm, 43 ft. lbs.)
105. INSTALL PUMP BRACKET
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.)
106. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
107. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2





a. Install the manifold stay with the 2 bolts, as shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)





b. Install a new gasket and the converter sub-assembly No. 2 with the 7 nuts. Uniformly, tighten the 7 nuts in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
c. Retighten nuts 1 and 2 as shown in the illustration.





d. Install the insulator No. 2 with the bolt and nut, as shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





e. Install the insulator No. 3 with the bolt and nut, as shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
f. Connect the A/F sensor connector.
108. INSTALL IGNITION COIL ASSEMBLY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
109. INSTALL WATER OUTLET
a. Install 2 new gaskets to the 2 cylinder heads.
b. Install the water outlet together with the water bypass hose No. 1 and unlock the hose clamp.
c. Tighten the 2 bolts, 2 nuts and 2 washers.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
d. Install the clamp.
e. Connect the engine coolant temperature sensor connector.
f. Connect the radiator hose inlet.





110. INSTALL INTAKE MANIFOLD
a. Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Uniformly tighten the bolts and nuts in the sequence shown in the illustration.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
b. Retighten the water outlet mounting bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
c. Install the ground cable with the nut.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
d. Connect the heater inlet water hose.
111. INSTALL INTAKE AIR SURGE TANK





a. Install a new gasket to the intake air surge tank.
b. Install the intake air surge tank and emission control valve bracket with the 2 nuts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
c. Using a socket hexagon wrench 8, tighten the 4 bolts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)





d. Install the surge tank stay No. 2 with the 2 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
e. Install the surge tank stay No. 1 with the 2 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
f. Install the engine hanger No. 1 with the 2 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)





g. Install the pressure feed tube with the 3 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)





h. Connect the ventilation hose.





i. Connect the union to the check valve hose.
j. Connect the water bypass hose No. 2.
k. Connect the water bypass hose No. 3.
l. Connect the throttle motor connector.
112. INSTALL EMISSION CONTROL VALVE SET





a. Install the emission control valve set with the 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
b. Install the clamp.
c. Connect the 2 vacuum hoses.
d. Connect the fuel vapor feed hose No. 2.
e. Connect the fuel vapor feed hose No. 1.





f. Install the wire harness clamp.
g. Connect the 2 VSV connectors.
113. INSTALL ENGINE HANGER NO.2
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
114. REMOVE ENGINE STAND
115. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY
116. INSTALL ENGINE MOUNTING BRACKET RR
117. INSTALL AUTOMATIC TRANSAXLE W/TRANSFER (4WD TYPE)
118. INSTALL TRANSFER STIFFENER PLATE RH (4WD TYPE)
119. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (2WD TYPE)
120. INSTALL ENGINE MOUNTING BRACKET FR
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