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
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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
- Safety first
- Park on level ground, set parking brake, chock rear wheels (use sturdy blocks behind wheels).
- Wear gloves and eye protection. Use jack stands after lifting — never rely on a jack alone.
- Disconnect battery negative terminal if you will be working around electrical connectors or moving the shifter with engine on.
- Tools (each tool explained and how to use it)
- Floor jack
- Use: place under a solid jacking point (consult owner's manual) and pump handle to lift vehicle. Raise only as high as needed.
- Why: gives access undercarriage to reach transmission end of cable.
- Jack stands (pair)
- Use: after lifting, place stands under strong frame points and slowly lower vehicle onto them. Check stability before working underneath.
- Why: safe support; never work under a car supported only by a jack.
- Wheel chocks
- Use: place behind wheels to stop rolling. Use in pairs (both sides) for safety.
- Why: prevents vehicle movement.
- Basic socket set (metric) with ratchet and extensions
- Use: attach the correct-size socket to remove bolts/nuts holding brackets, transmission linkage, or center console fasteners. Use extensions to reach recessed bolts.
- Why: needed to remove mounting bolts and bracket hardware.
- Combination wrench set (metric)
- Use: hold nuts or bolts where a socket cannot reach or to prevent bolt from spinning while removing nut.
- Why: some bolts may be in tight places better reached by a wrench.
- Flat-blade screwdriver
- Use: pry off plastic clips, remove trim panels, pop up retaining tabs, or lever out cotter pins.
- Why: light prying and clip removal.
- Phillips screwdriver
- Use: remove interior screws (console, trim).
- Why: many interior fasteners use Phillips heads.
- Needle-nose pliers
- Use: remove/install small clips, cotter pins, spring clips; hold small parts.
- Why: for manipulating small retaining hardware on cable ends.
- Long-nose snap-ring pliers (if cable is held by snap ring)
- Use: compress/expand retaining rings to remove or install.
- Why: some cables use snap rings to secure ends; pliers make it safe and easy.
- Hammer (rubber or small ball-peen)
- Use: tap stubborn pins or connectors gently to free them.
- Why: occasional stuck pins require gentle persuasion.
- Torque wrench (recommended)
- Use: tighten bolts to specified torque values from service manual.
- Why: ensures proper clamp force on brackets without over-tightening.
- Utility knife or cable-cutting tool
- Use: cut zip ties or damaged outer sheath if trimming is needed (not to cut inner cable).
- Why: for removing routing ties and damaged insulation safely.
- Flashlight or work light
- Use: illuminate tight, dark areas under the vehicle and inside engine bay.
- Why: visibility is essential for correct reinstallation.
- Replacement parts/tools you should buy before starting
- New shift cable assembly (specific to your Toyota model/year; “selector cable” or “shift cable” for automatic/manual)
- Why: the whole cable is commonly replaced rather than repairing the inner wire if frayed, corroded, stretched, or end fittings are damaged.
- New bushings/grommets and retaining clips (OEM or aftermarket kit)
- Why: old rubber grommets and plastic clips degrade; replacing them prevents sloppiness and future failures.
- Small packet of replacement cotter pins / spring clips / snap rings
- Why: these are cheap and often bent/damaged during removal; reuse can lead to failure.
- Anti-seize or light grease
- Why: helps prevent future corrosion and makes adjustment/smooth movement easier.
- Service manual or OEM repair guide (strongly recommended)
- Why: contains model-specific diagrams and torque specs. If unavailable, expect to follow general procedure but be cautious with torque and adjustment.
- Parts explanation (what may need replacement and why)
- Shift cable assembly
- Description: inner steel cable moving inside an outer sheath with end fittings that attach to shifter and transmission.
- Why replace: fraying, sticking, stretched cable, damaged end fittings, or severe corrosion lead to imprecise shifting or inability to select gears.
- Rubber bushings/grommets
- Description: rubber pieces where the cable passes through the firewall or mounts to the trans/shifter.
- Why replace: they deteriorate, causing slop and noise; replacement restores correct alignment and reduces wear.
- Retaining clips / clevis pin / cotter pin / snap ring
- Description: small hardware that secures cable ends to lever/pivot.
- Why replace: they often deform during removal; new hardware secures the cable properly.
- Brackets (if bent or corroded)
- Description: metal mounts that hold cable along its routing.
- Why replace: bent brackets change cable geometry; corroded brackets can break or seize clip hardware.
- Preparation steps before removing cable
- Gather all listed tools and the replacement cable and hardware.
- Mark shifter position in the cabin: put the shifter in neutral (manual) or parking/neutral as required (automatic). Note exact detent if you can — mark with tape.
- Chock wheels, raise vehicle if needed, and support on jack stands.
- Remove any center console or interior trim blocking access to shifter base per your model (use screwdrivers, pliers).
- Disconnect battery negative terminal if you will be reaching electrical components or moving shifter repeatedly.
- Removal procedure (general Toyota-style)
- Locate cable ends: one end at the shifter inside the vehicle, the other at the transmission selector/shift lever under the vehicle.
- Take clear photos or make marks on cable and linkage positions so you can reinstall in same orientation.
- Inside cabin: remove any retaining clip or pin securing cable to shifter linkage. Use pliers or screwdriver to pry clips; remove cable end from the shifter.
- Remove console or trim carefully and pull cable boot out of shifter hole, noting any rubber grommet condition.
- Under vehicle: follow cable down to where it attaches to transmission. Remove any heat shields or obstructing covers as needed (socket set).
- Remove mounting bolts/brackets along the cable route (sockets/wrenches). Keep bolts grouped in order for reassembly.
- At transmission end: remove retaining pin/clip or snap ring securing the cable to the selector arm. Use pliers/snap-ring pliers as required; a small hammer and punch may help free a stuck pin.
- Pull cable out of its firewall grommet; if grommet is stuck, pry it gently with a flat screwdriver or cut it out with a knife (replace it with new grommet).
- Pull the full cable assembly out from under the vehicle/engine bay. Note routing so new cable follows same path.
- Installation procedure
- Compare new cable to old one: check length, end fittings, grommet size, and mounting points. If different, do not force — get correct part.
- Route new cable in the exact same path as the old one, avoiding hot surfaces (exhaust) and sharp edges. Secure loosely with original brackets.
- Insert firewall grommet/new rubber grommet and push cable through to shifter area.
- Attach transmission end: place cable end onto selector arm and install new retaining pin/clip/cotter pin/snap ring as required. Make sure clip is fully seated.
- Install cable mounting brackets and tighten bolts finger-tight first, then torque to spec if available. Keep cable routed with smooth curves (no kinks).
- Attach interior end to shifter linkage: seat cable end on lever, reinstall retaining clip/pin and replace any rubber boots.
- Reinstall console/trim panels.
- Final tighten: secure all bracket bolts to proper torque (use service manual values if available; otherwise snug plus a small quarter-turn — be cautious).
- Adjustment and testing
- Adjustment basics: shift cable must be adjusted so shifter detents match transmission positions (neutral aligns with transmission neutral).
- General adjustment method (common for Toyota):
- With parking brake on and wheels chocked, set shifter to neutral (manual) or park/neutral per type.
- Loosen adjustment lock nuts on the cable (near transmission or intermediate bracket).
- Move cable housing until transmission selector is in the matching position (often by gently moving the transmission lever by hand while lining up marks you made).
- Tighten lock nuts while holding cable in position. Ensure no play or binding.
- Operation test:
- With vehicle still safely supported (or on ground if lowered), start engine (if needed) and cycle shifter through all positions slowly. For manuals, make sure gears engage and shift smoothly. For automatics, ensure each detent corresponds to the correct gear (park, reverse, neutral, drive).
- Drive slowly in a safe area and verify smooth and accurate shifting.
- Recheck bolts and clips after first short drive and retighten if necessary.
- Troubleshooting tips (brief)
- If shifting still sloppy: check for worn bushings/grommets, misrouted cable, bent bracket, or incorrectly adjusted cable.
- If cable is binding: ensure it is not chafing a sharp edge, looped too tightly, or trapped by a bracket.
- If new cable doesn’t match old: get the exact OEM or confirmed-fit replacement — wrong end fittings or length will cause poor function.
- Why parts are sometimes replaced rather than repaired
- Inner cable fray or corrosion is dangerous — replacement prevents failure.
- Rubber grommets and plastic clips are low-cost and degrade; replacing prevents future problems.
- Replacing the whole assembly guarantees proper geometry and life; splicing or jury-rigging leads to premature issues.
- Final checks and clean-up
- Verify all hardware is tight, clips installed, brackets secure, and cable boot/grommet seated.
- Remove wheel chocks and lower vehicle only after testing and final checks are complete.
- Dispose of old cable and damaged clips responsibly; keep spare clips for future small repairs.
- Quick parts-buy checklist to bring to the parts store or order online
- Exact-shape shift cable assembly for your Toyota model & year (state transmission type: manual or automatic when ordering)
- Firewall grommet and any specific rubber bushings
- Retaining clips, cotter pins, or snap rings (small assortment)
- Anti-seize or light grease
- Final safety reminder
- If any step feels beyond your comfort or requires removal of major components (exhaust, transmission crossmember), stop and consult a professional mechanic or a shop manual for model-specific guidance.
No extra commentary. rteeqp73
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