Toyota
4Runner GRN210 215 UZN210 215
Repair Manual
2Uz-Fe Engine Mechanical
Engine Unit
- HINT:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
- Replace all gaskets, O-rings and oil seals with new ones.
Remove the 4 bolts and engine hangers.
Remove the 2 water drain cocks.
Remove the 2 nuts and oil filler cap housing.
Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket.
Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket.
Remove the pulley bolt, cover plate and idler pulley.
Remove the 2 bolts and timing belt cover.
Remove the bolt, 2 nuts and belt tensioner.
Remove the 2 bolts, 2 nuts and fan bracket.
Using SST, remove the pulley bolt.
- SST
- 09213-70011 (90105-08076)
09330-00021
Using SST, remove the crankshaft pulley.
- SST
- 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05021)
Remove the 4 bolts and timing belt cover.
Remove the cover spacer and gasket.
Remove No. 1 crankshaft position sensor plate.
If reusing the timing belt, check the installation marks on the timing belt.
Check that there are 3 installation marks on the timing belt by turning the crankshaft as shown in the illustration.
If the installation marks have disappeared, put a new installation mark on the timing belt before removing each part.
Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.
Check that the timing marks of the camshaft timing pulleys and timing belt plates are aligned.
If not, turn the crankshaft 1 complete revolution (360°).
Set the No. 1 cylinder to approx. 45° BTDC/compression.
Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approx. 45°.
- NOTICE:
- If the timing belt is disengaged, having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft timing pulley and camshaft, causing damage. So always set the crankshaft pulley at the correct angle.
Alternately loosen the 2 bolts, then remove the bolts, chain tensioner and dust boot.
Using SST, loosen the tension between the camshaft timing pulley (RH bank) and crankshaft timing pulley by slightly turning the camshaft timing pulley (RH bank) counterclockwise.
- SST
- 09960-10010 (09962-01000, 09963-00350)
Disconnect the timing belt from the No. 1 timing belt idler and remove the timing belt.
Hold the crankshaft with a wrench, and remove the 8 bolts and 2 timing pulleys.
Using a 10 mm hexagon wrench, remove the bolt, idler and plate washer.
Remove the bolt and idler.
Using SST, remove the timing pulley.
- SST
- 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010)
- NOTICE:
- Do not turn the timing pulley.
Remove the 2 bolts and No. 2 rear timing belt plate RH.
Remove the bolt, stud bolt and rear timing belt plate RH.
Remove the 2 bolts and No. 2 rear timing belt plate LH.
Remove the bolt and rear timing belt plate LH.
- NOTICE:
- Since 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 receives 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.
Remove the camshafts of the RH bank.
In order to install a service bolt to the sub and main gears, turn the camshaft with a wrench. The hexagonal portion of the camshaft is used for turning the camshaft with the wrench.
Secure the sub-gear to the main gear with a service bolt.
Recommended service bolt: Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 to 20 mm (0.63 to 0.79 in.) - HINT:
- When removing the camshafts, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.
Set the timing mark (1-dot mark) of the camshaft main gear at approx. 10° angle by turning the hexagonal portion of the exhaust camshaft with a wrench.
Uniformly loosen the 22 bearing cap bolts in the order shown in the illustration, then remove all the bolts.
Remove the oil feed pipe, 9 bearing caps, oil control valve filter, camshaft housing plug and 2 camshafts.
Remove the camshafts on the LH bank.
In order to install a service bolt to the sub and main gears, turn the camshaft with a wrench. The hexagonal portion of the camshaft is used for turning the camshaft with the wrench.
Secure the sub-gear to the main gear with a service bolt.
Recommended service bolt: Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 to 20 mm (0.63 to 0.79 in.) - HINT:
- When removing the camshaft, make sure that the torsional spring force of the sub-gear has eliminated by the above operation.
Align the timing marks (2-dot marks) of the camshaft drive and driven gears by turning the hexagonal portion of the exhaust camshaft with a wrench.
Uniformly loosen the 22 bearing cap bolts in the order shown in the illustration, then remove all the bolts.
Remove the oil feed pipe, 9 bearing caps, oil control valve filter, camshaft housing plug and 2 camshafts.
- HINT:
- Arrange the bearing caps in the correct order.
Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several steps, in the order shown in the illustration. Likewise, loosen the 10 bolts on the other side. Remove the 20 cylinder head bolts and plate washers.
- NOTICE:
- Cylinder head warpage or cracking may result from removing bolts in incorrect order.
- Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks on a bench.
- NOTICE:
- Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
- The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly.
- HINT:
- If the cylinder head cannot be lifted easily, pry between the cylinder head and cylinder block with a screwdriver.
Remove the 5 bolts, 2 stud bolts, nut, water pump and gasket.
Remove the 17 bolts and 2 nuts.
Insert the blade of SST between the oil pan and No. 2 oil pan, and cut off applied sealer. Remove the No. 2 oil pan.
- SST
- 09032-00100
- NOTICE:
- Be careful not to damage the contact surface of the oil pan and the No. 2 oil pan.
- Be careful not to damage the No. 2 oil pan flange.
Remove the 2 bolts, 2 nuts and baffle plate.
Remove the 18 bolts and 2 nuts.
Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block in the order shown in the illustration.
- NOTICE:
- Be careful not to damage the contact surfaces of the cylinder block or oil pan.
Remove the 2 bolts, 2 nuts, oil strainer and gasket.
Remove the 7 bolts and stud bolt.
- HINT:
- Use a 6 mm hexagon wrench to tighten the hexagon head bolt.
Using a screwdriver, remove the oil pump by prying the portions between the oil pump and cylinder block.
- NOTICE:
- Be careful not to damage the contact surfaces of the cylinder block and oil pump.
Remove the O-ring from the cylinder block.
Remove the 7 bolts.
Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and crankshaft bearing cap.
Remove the O-ring.
Bend the 4 ventilation case claws installed on the cylinder head cover to an angle of 90° or more.
Using a screwdriver, pry out the gasket.
- NOTICE:
- Be careful not to damage the cylinder head cover. Tape the screwdriver tip.
Mount the hexagonal portion of the camshaft in a vise.
- NOTICE:
- Be careful not to damage the camshaft.
- Do not remove the 4 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the timing tube assembly with a new one.
Remove the screw plug and seal washer.
Using a 10 mm hexagon wrench, and remove the bolt.
Pull out the timing tube and drive gear assembly from the camshaft.
Using SST and a 5 mm hexagon wrench, remove the 4 bolts, drive gear and oil seal.
- SST
- 09960-10010 (09962-01000, 09963-00500)
- NOTICE:
- Be careful not to damage the timing tube.
Mount the hexagonal portion of the camshaft in a vise.
- NOTICE:
- Be careful not to damage the camshaft.
Using SST, turn the sub gear clockwise, and remove the service bolt.
- SST
- 09960-10010 (09962-01000, 09963-00500)
Recommended service bolt: Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 to 20 mm (0.63 to 0.79 in.)
Using snap ring pliers, remove the snap ring.
Remove the wave washer, sub gear and gear spring.
- HINT:
- Arrange the camshaft sub gears and gear spring (RH and LH sides).
Using a screwdriver, pry out the oil seal.
- NOTICE:
- Be careful not to damage the oil pump body. Tape the screwdriver tip.
Using a screwdriver and hammer, tap out the oil seal.
Remove the valve lifter and adjusting shim.
- HINT:
- Arrange the valve lifters and shims in the correct order.
Using SST, compress the valve spring and remove the 2 valve spring retainer locks.
- SST
- 09202-70020 (09202-01010)
Remove the spring retainer, valve spring, valve and spring seat.
- HINT:
- Arrange the valves, valve springs, spring seats and spring retainers in the correct order.
Using SST, compress the valve spring and remove the 2 valve spring retainer locks.
- SST
- 09202-70020 (09202-00010)
Remove the spring retainer, valve spring, valve and spring seat.
- HINT:
- Arrange the valves, valve springs, spring seats and spring retainers in the correct order.
Using needle-nose pliers, remove the oil seal.
Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
- Standard thrust clearance:
- 0.160 to 0.290 mm (0.0063 to 0.0114 in.)
- Maximum thrust clearance:
- 0.35 mm (0.0138 in.)
- Connecting rod thickness (Reference):
- 22.880 to 22.920 mm (0.9008 to 0.9024 in.)
Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
Remove the 2 connecting rod cap bolts.
Using the removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.
- HINT:
- Keep the lower bearing inserted with the connecting rod cap.
Clean the crank pin and bearing.
Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
Lay a strip of Plastigage across the crank pin.
Match the numbered connecting rod cap with the connecting rod.
Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.
Check that the outside mark of the connecting rod cap is facing in the correct direction.
- HINT:
- The connecting rod cap bolts are tightened in 2 progressive steps.
- If any one of the connecting rod cap bolts is broken or deformed, replace it.
Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
Install and alternately tighten the 2 connecting rod cap bolts in several steps.
- Torque:
- 25 N*m{250 kgf*cm, 18 ft.*lbf}
- NOTICE:
- Do not turn the crankshaft.
Mark the front of the connecting cap bolts with paint.
Retighten the cap bolts 90° as shown in the illustration.
Check that the painted mark is now at a 90° angle to the front.
Remove the 2 bolts, connecting rod cap and lower bearing.
Measure the Plastigage at its widest point.
- Standard oil clearance:
- 0.021 to 0.047 mm (0.0008 to 0.0019 in.)
- Maximum oil clearance:
- 0.065 mm (0.0026 in.)
- HINT:
- If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, add together the numbers imprinted on the connecting rod cap and crankshaft, then select the bearing with the same number as the total. There are 6 sizes of standard bearings, marked "2", "3", "4", "5", "6" and "7".
Item Number Mark Connecting rod cap 1 1 2 1 2 3 2 3 4 3 4 4 Crankshaft 1 2 1 3 2 1 3 2 1 3 2 3 Use bearing 2 3 4 5 6 7 - EXAMPLE:
- Connecting rod cap "3" + Crankshaft "1" = Total number 4 (Use bearing "4")
Connecting rod big end inside diameter: Mark "1" 55.000 to 55.006 mm (2.1654 to 2.1656 in.) Mark "2" 55.006 to 55.012 mm (2.1656 to 2.1658 in.) Mark "3" 55.012 to 55.018 mm (2.1658 to 2.1661 in.) Mark "4" 55.018 to 55.024 mm (2.1661 to 2.1663 in.) Crankshaft crank pin diameter: Mark "1" 51.994 to 52.000 mm (2.0470 to 2.0472 in.) Mark "2" 51.988 to 51.994 mm (2.0468 to 2.0470 in.) Mark "3" 51.982 to 51.988 mm (2.0465 to 2.0468 in.) Standard sized bearing center wall thickness: Mark "2" 1.487 to 1.490 mm (0.0585 to 0.0587 in.) Mark "3" 1.490 to 1.493 mm (0.0587 to 0.0588 in.) Mark "4" 1.493 to 1.496 mm (0.0588 to 0.0589 in.) Mark "5" 1.496 to 1.499 mm (0.0589 to 0.0590 in.) Mark "6" 1.499 to 1.502 mm (0.0590 to 0.0591 in.) Mark "7" 1.502 to 1.505 mm (0.0591 to 0.0593 in.)
Completely remove the Plastigage.
Using a ridge reamer, remove all the carbon from the top of the cylinder.
Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
- HINT:
- Keep the bearings, connecting rod and cap together.
- Arrange the piston and connecting rod assemblies in the correct order.
Check the fitting condition between the piston and piston pin.
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
Using a piston ring expander, remove the 2 piston rings.
Remove the oil ring (2 side rails and expander) by hand.
- HINT:
- Arrange the piston rings in the correct order.
Using a screwdriver, pry out the 2 snap rings.
Gradually heat the piston to approx. 60°C (140°F).
Using a plastic hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.
- HINT:
- The piston and pin are a matched set.
- Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
- Standard thrust clearance:
- 0.020 to 0.220 mm (0.0008 to 0.0087 in.)
- Maximum thrust clearance:
- 0.30 mm (0.0118 in.)
Thrust washer thickness STD 2.440 to 2.490 mm (0.0961 to 0.0980 in.) O/S 0.125 2.503 to 2.553 mm (0.0985 to 0.1005 in.)
Uniformly loosen and remove the 10 crankshaft bearing cap bolts in several steps, in the order shown in the illustration.
Using 2 screwdrivers, pry out the crankshaft bearing cap, and remove the 5 crankshaft bearing caps, 5 lower bearings and 2 lower thrust washers (No. 3 crankshaft bearing cap only).
- NOTICE:
- Be careful not to damage the cylinder block.
- HINT:
- Keep the lower bearing and crankshaft bearing cap together.
- Arrange the crankshaft bearing caps and lower thrust washers in the correct order.
Lift out the crankshaft.
Remove the 2 upper thrust washers.
- HINT:
- Arrange the upper thrust washers in the correct order.
- Keep the upper bearings together with the cylinder block.
Clean each crankshaft journal and bearing.
Check each crankshaft journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
Place the crankshaft on the cylinder block.
Lay a strip of Plastigage across each journal.
Install the 5 crankshaft bearing caps in their proper locations.
- HINT:
- The crankshaft bearing cap bolts are tightened in 2 progressive steps (Procedures "A" and "B").
- If any one of the main bearing cap bolts is broken or deformed, replace it.
Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts.
Install and uniformly tighten the 10 crankshaft bearing cap bolts in several steps, in the order shown in the illustration (Procedure "A").
- Torque:
- 27 N*m{275 kgf*cm, 20 ft.*lbf}
- NOTICE:
- Do not turn the crankshaft.
Mark the front of the crankshaft bearing cap bolts with paint.
Retighten the crankshaft bearing cap bolts by 90° in the order shown (Procedure "B").
Check that the painted mark is now at a 90° angle to the front.
Remove the crankshaft bearing caps.
Measure the Plastigage at its widest point.
- Standard clearance:
No. 1 and No. 5 Others 0.028 to 0.046 mm
(0.0011 to 0.0018 in.)0.040 to 0.058 mm
(0.0016 to 0.0023 in.)
- Maximum clearance:
No. 1 and No. 5 Others 0.065 mm (0.0026 in.) 0.065 mm (0.0026 in.)
- HINT:
- If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, add together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of the standard bearings. For No. 1 and No. 5 position bearings, use bearings marked "3", "4", "5", "6" and "7". For the other position bearings, use bearings marked "1", "2", "3", "4" and "5".
No. 1 and No. 5: - Use bearing Cylinder block (A)
+
Crankshaft (B)0 to 5 3 6 to 11 4 12 to 17 5 18 to 23 6 24 to 28 7 - EXAMPLE:
- Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "5")
Others: - Use bearing Cylinder block (A)
+
Crankshaft (B)0 to 5 1 6 to 11 2 12 to 17 3 18 to 23 4 24 to 28 5 - EXAMPLE:
- Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "3")
Cylinder block crankshaft journal bore diameter (A): Mark "00" 72.000 mm (2.8347 in.) Mark "01" 72.001 mm (2.8347 in.) Mark "02" 72.002 mm (2.8347 in.) Mark "03" 72.003 mm (2.8348 in.) Mark "04" 72.004 mm (2.8348 in.) Mark "05" 72.005 mm (2.8348 in.) Mark "06" 72.006 mm (2.8349 in.) Mark "07" 72.007 mm (2.8349 in.) Mark "08" 72.008 mm (2.8350 in.) Mark "09" 72.009 mm (2.8350 in.) Mark "10" 72.010 mm (2.8350 in.) Mark "11" 72.011 mm (2.8351 in.) Mark "12" 72.012 mm (2.8351 in.) Mark "13" 72.013 mm (2.8352 in.) Mark "14" 72.014 mm (2.8352 in.) Mark "15" 72.015 mm (2.8352 in.) Mark "16" 72.016 mm (2.8353 in.) Crankshaft journal diameter (B): Mark "00" 67.000 mm (2.6378 in.) Mark "01" 66.999 mm (2.6378 in.) Mark "02" 66.998 mm (2.6377 in.) Mark "03" 66.997 mm (2.6377 in.) Mark "04" 66.996 mm (2.6376 in.) Mark "05" 66.995 mm (2.6376 in.) Mark "06" 66.994 mm (2.6376 in.) Mark "07" 66.993 mm (2.6375 in.) Mark "08" 66.992 mm (2.6375 in.) Mark "09" 66.991 mm (2.6374 in.) Mark "10" 66.990 mm (2.6374 in.) Mark "11" 66.989 mm (2.6374 in.) Mark "12" 66.988 mm (2.6373 in.) Standard bearing center wall thickness No. 1 and No. 5: Mark "3" 2.487 to 2.490 mm (0.0979 to 0.0980 in.) Mark "4" 2.490 to 2.493 mm (0.0980 to 0.0982 in.) Mark "5" 2.493 to 2.496 mm (0.0982 to 0.0983 in.) Mark "6" 2.496 to 2.499 mm (0.0983 to 0.0984 in.) Mark "7" 2.499 to 2.502 mm (0.0984 to 0.0985 in.) Others: Mark "1" 2.481 to 2.484 mm (0.0977 to 0.0978 in.) Mark "2" 2.484 to 2.487 mm (0.0978 to 0.0979 in.) Mark "3" 2.487 to 2.490 mm (0.0979 to 0.0980 in.) Mark "4" 2.490 to 2.493 mm (0.0980 to 0.0982 in.) Mark "5" 2.493 to 2.496 mm (0.0982 to 0.0983 in.)
Completely remove the Plastigage.
Lift up the crankshaft.
Remove the 5 upper crankshaft bearings and 2 upper thrust washers from the cylinder block.
- HINT:
- Arrange the crankshaft bearing caps, bearings and thrust washers in the correct order.