Toyota 5L-E engine factory workshop and repair manual
Toyota 5L-E engine factory workshop and repair manual
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5L BELT INSTALL
5L COMPONANTS
5L CRANK ANGLE SENSOR
5L DRIVE BELT COMPONANTS
5L ECD SYSTEM DIAGRAM
5L ENGINE COMPONANTS
5L ENGINE REMOVAL
5L ENGINE UNIT COMPONANTS
5L FRONT OIL SEAL INSTALL
5L FRONT OIL SEAL REMOVAL
5L FRONT SEAL COMPONANTS
5L HEAD COMPONANTS
5L HEAD INSTALL
5L HEAD REMOVAL
5L INJECTIOR NOZZLE COMPONANTS
5L INJECTOR PUMP COMPONANTS
5L REAR OIL SEAL COMPONANTS
5L SERVICE SPECS
5L TORQUE SPECS
5L VENTURI COMPONANTS
5L-E ENGINE SUP. RM817E
CAM INSTALL
CAM REMOVAL
ECD SYSTEM
ENGINE TIMING BELT COMPONANTS
ENGINE UNIT DIASSEMBLY
ENGINE UNIT REASSEMBLY
PRESSURE SENSOR
RAR OIL SEAL INSTALL
REAR OIL SEAL REMOVAL
TIMING BELT INSTALL
TIMING BELT REMOVAL
VALVE CLEARANCE ADJUSTMENT
Searchable document with bookmarks.
About the 5L-E engine
The 5L-E is a 3.0 L (2,986 cc) EFI version of the 5L engine. It is the latest member of the L family. It has a bore of 99.5 mm and stroke of 96.0 mm, with a compression ratio of 22.2:1. Output (as fitted to the Hilux is 97 PS (71 kW) at 4,000 rpm with 192 N·m (142 ft·lb) of torque at 2,400 rpm.Power output varies according to fitment. The engine number is found on the top face of the block at the front of the engine.
Applications:
Toyota Hilux
Toyota Land Cruiser Prado (J90-series)
Toyota Hiace (fifth generation, H200-series)
Toyota 5L-E engine factory workshop and repair manual
Quick summary first: a trailing arm is the big steel arm that ties the rear axle to the chassis and controls fore/aft and (partly) rotational location of the axle. Replace it when bushings or the arm itself is worn, bent or cracked. Safety first: use good jacks and jack stands, wheel chocks, gloves, eye protection, and a torque wrench. Read the factory service manual for exact torque specs and any model-specific steps.
What every component is and why it matters
- Trailing arm (arm): heavy stamped/boxed steel arm that connects axle housing to the body/chassis. Acts like a hinge/lever that limits how the axle moves forward/back and controls wheel location under load.
- Bushings (inboard/outboard): rubber or polyurethane sleeves pressed into the frame end(s) of the arm; they isolate vibration, allow pivoting and control compliance. Think of them as rubber hinges on a door — if the rubber is shredded the door slams and wiggles.
- Pivot bolt(s) and sleeves (inner metal sleeve): the bolt goes through the bushing and arm into the bracket on the chassis. The sleeve centers the bushing on the bolt.
- Axle bracket/connecter (outboard mount): where the arm fastens to the axle housing (may use a U-bolt clamp, bracket or separate bushing depending on model).
- Shock lower mount: often attached to or near the trailing arm; shocks dampen motion.
- Swaybar link and brake cable brackets: may attach to or nearby the arm; these must be disconnected to remove the arm.
- Washers, lock nuts and any crush washers: ensure correct spacing and preload.
- Grease/anti-seize: protects bolts and bushings during installation.
Theory — why this repair is needed and what happens when it’s bad
- Function: The trailing arm keeps the axle where it belongs front-to-back and resists acceleration/braking and drive forces. The bushings allow pivot but control unwanted movement.
- When bushings wear, the axle can shift slightly under load, producing clunks under acceleration/braking, loose steering feel, uneven tire wear, wandering, and vibration through the chassis. Bent arms cause alignment geometry changes (camber/toe) and can lead to rapid tire wear or unsafe handling.
- Analogy: the trailing arm is like the arm of a person holding a weight. The elbow joint (bushing) needs to be tight and aligned; if the elbow is sloppy the hand (wheel/axle) flails around.
What can go wrong (symptoms and failure modes)
- Worn bushings: clunks, vibration, axle shift, cheeky handling.
- Cracked or bent arm: severe misalignment, tire rubbing, structural failure.
- Seized pivot bolts: difficult removal — may require heat, cutting or replacement of hardware.
- Incorrect re-torque/preload: torquing bushings with suspension unloaded can preload and cause accelerated bushing failure or strange geometry.
- Damaged sleeves/washers: incorrect spacing causes binding or excess play.
- Forgetting to torque with vehicle at ride height: bushings torqued unloaded can preload and twist under load.
- Brake/ABS cable interference or routing errors after reassembly.
- Rusted bracket or axle threads damaged when removing seized fasteners.
Tools & parts you’ll need
- New trailing arm(s) or new bushings + sleeves if reusing arms.
- Factory service manual or OEM torque specs (essential).
- Hydraulic floor jack and quality jack stands.
- Wheel chocks.
- Socket set, deep sockets, wrenches (including large sizes for pivot bolts).
- Breaker bar and/or impact gun (careful with final torque).
- Torque wrench (essential).
- Penetrating oil (PB Blaster, WD-40 specialist).
- Hammer, pry bar.
- Punch or drift for loosening bolts.
- Grinder or cutting tool (as last resort for seized bolts).
- Hydraulic press or bushing driver set (if pressing bushings).
- Bench vise, torch (for stubborn bushings/bolts – use heat safely).
- Anti-seize and grease.
- Replacement nuts/bolts (don’t reuse heavily corroded fasteners).
- Safety gear: gloves, eye protection.
Step-by-step procedure (beginner-friendly, detailed)
1) Preparation
- Read the factory service manual for your specific vehicle for exact locations, torque figures, and any special procedures.
- Park on level ground, make sure parking brake is on. Block front wheels with chocks.
- Gather parts and tools. Replace both sides if one side is bad — suspension components wear together.
2) Lift and secure the vehicle
- Loosen rear wheel lug nuts slightly while on the ground.
- Jack the rear using the manufacturer’s designated jacking points and support the vehicle on jack stands under the chassis or axle — use stands, never rely on the jack.
- Remove the wheel(s).
3) Support the axle
- Place a floor jack under the differential housing and support it with a block of wood to spread load. The jack must support the axle to prevent it from dropping when the trailing arm is removed.
4) Disconnect related components
- Remove the lower shock bolt(s) if the shock lower mount is attached to the trailing arm. Keep hardware ordered.
- Remove swaybar end-link(s) if they attach to the arm.
- Remove any brake line brackets, parking brake cable brackets, ABS sensor clips attached to the arm — label wiring or brackets to reattach in same position.
- If the trailing arm attaches to the axle with U-bolts or a clamp, undo those bolts.
5) Mark alignment and orientation
- Before removing, mark the position of the trailing arm relative to axle and chassis with a scribe/marker or take photos. That helps you re-install to the same relative position and minimize alignment changes.
6) Remove pivot bolts
- Spray penetrating oil on pivot bolts and allow time to soak.
- Support the arm with the jack. Remove nuts/bolts holding the inboard (frame) pivot and outboard (axle) mount. If bolts are seized, apply penetrating oil and tap the bolt head to help. Use heat on the nut (not on rubber) if needed, or cut and replace hardware if necessary.
- Carefully lower the trailing arm out of the vehicle. If it is stuck, use a pry bar—avoid bending the arm.
7A) If replacing the entire trailing arm
- Compare new arm to old one. Transfer any brackets, sleeves, or sensor clips.
- Replace any worn bolts or use OEM-specified bolts.
7B) If only replacing bushings
- Press out old bushings with a hydraulic press or use an appropriate bushing driver kit. Heat the outer shell if needed (careful—do not heat rubber).
- Clean bores of rust and debris; paint or coat to slow future corrosion.
- Press in new bushings and sleeves; many bushings are directional—note orientation. Use grease if bushing manufacturer instructs (many rubber bushings are dry; urethane often needs grease).
8) Reinstall trailing arm
- Position the arm into place. Fit the outboard end to the axle first or as the manual specifies.
- Insert pivot bolts and hand-thread nuts. Do not fully torque pivot bolts now if the manual says to torque with suspension loaded.
- Reattach U-bolts, shock lower bolts, swaybar links, brake brackets and ABS clips.
9) Pre-torque checks and sequence
- Tighten all accessory bolts (shock, link, brackets) to spec first.
- For pivot bolts through flexible bushings, many manufacturers require final torque with the vehicle at normal ride height to avoid preloading rubber bushings. To accomplish that:
- Lower the axle slowly so the suspension is supporting the vehicle (wheels on ground with vehicle stable on stands, or lower the vehicle carefully onto ramps/ground).
- With vehicle weight on suspension, set final torque on pivot bolts to factory spec.
- If you can’t lower vehicle, support the axle at approximate ride height with the jack and torque to spec per manual instructions.
10) Final reassembly
- Reinstall wheels, lower vehicle, torque wheel lug nuts to spec.
- Double-check all fasteners for correct torque and that cables/lines have proper routing and no binding.
- Clean tools and workspace.
11) Test and verify
- Start with a slow test drive. Listen and feel for clunks, vibration, or unusual handling.
- Have wheel alignment checked (toe and camber) after trailing arm replacement — this is important. Even if you reinstalled in the same position, replacement can change geometry.
- Re-torque pivot bolts after a short road test if manufacturer recommends (some require re-torque after initial use).
Tips, troubleshooting and common challenges
- Seized bolts: penetrating oil + time, use a breaker bar. If nut spins with bolt, hold one side with a second wrench. Heat the nut (not rubber parts) to expand metal. As a last resort, grind off bolt head or cut through and replace hardware.
- Bushings pressed-out/in: a bench vise and sockets can work for small jobs; a hydraulic press is best. Use backing plates and a sleeve so you don’t damage the arm.
- Replacing hardware: always prefer new grade-bolts and torque-to-yield bolts replaced with OEM items. Do not reuse heavily corroded nuts/bolts.
- Preload issue: torqueing the pivot bolts with the suspension unloaded will twist rubber bushings internally, reducing bushing life and changing alignment. Always follow manual instructions for “torque with vehicle on ground” or “torque with load.”
- Rust prevention: clean and lightly coat mounting points with rust-inhibitor or paint where appropriate.
- Alignment: expect toe/camber changes. Get a professional alignment after the job.
Safety callouts (non-negotiable)
- Never work under a vehicle supported only by a hydraulic jack. Use rated jack stands on a solid surface.
- Use eye protection when grinding, heating or pressing bushings.
- Be careful with heat near rubber, brake lines, fuel lines and wiring.
- Replace any component that shows structural cracks or severe corrosion rather than attempting repair.
Final checklist before driving
- All fasteners tightened to spec.
- Bushings correctly seated and sleeves present.
- Brake lines/cables routed correctly and not pinched.
- Shock absorbers and swaybar links reattached.
- Wheel lug nuts torqued to spec.
- Vehicle lowered to ride height and pivot bolts torqued if required.
- Test drive and get wheel alignment.
If you want model-specific torque numbers, bolt sizes, or pictures for the exact Toyota model that uses the 5L‑E engine (Hilux/Hiace/others vary by year), get the factory repair manual or I can provide nominal bolt size/torque ranges with a strong caveat to verify with the manual. rteeqp73
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Toyota 2E Engine Crankshaft Replacement/Rebuild Toyota 2E engine gets a new 4EFE Crankshaft Engine teardown video: https://www.youtube.com/watch?v=ClbT_eapzmU.
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