1988 4Runner · 98 5VZ-FE swap
Parts to buy
107 parts still to buy, check or decide, pulled from every parts table in the build.
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- Buy locally
- Long block
- Sealants and chemicals
- Tools
- Pull from the 3VZ before you sell it
- Fuel
- Wiring
- Exhaust
- Magnuson
- Cooling, accessories, install
- Fluids
Buy locally
| Item | Qty | Spec / what to get | Status | |
|---|---|---|---|---|
| ◆ ECT sensor washer (Toyota 90430-12005), 12 mm | 1 | BUY | ||
| ◆ Fuel pressure regulator O-ring (Toyota 90301-09002) | 1 | BUY | ||
| Clutch spline grease: CV/moly grease packet | 1 | BUY |
Long block
| Item | Qty | Spec / what to get | Status | |
|---|---|---|---|---|
| CHECK FOR: igniter on the donor engine. Read the part number off it (listings disagree: 89621-35010 vs 89621-35020); reuse it, new Toyota is ~$217 | 1 | REUSE / CHECK |
Sealants and chemicals
| Item | Qty | Spec / what to get | Status | |
|---|---|---|---|---|
| New engine oil for assembly + bolt threads | 5W-30 | see Buy locally |
Tools
| Item | Qty | Spec / what to get | Status | |
|---|---|---|---|---|
| Torque wrenches (in·lb and up to 250 N·m) + angle gauge, paint marker | BUY | |||
| Plastigage, feeler gauges, micrometer (for shims) | BUY | |||
| Ring expander, ring compressor, snap-ring pliers | BUY | |||
| Rear main seal driver, crank front seal driver (or substitutes) | BUY | |||
| Cam pin wrench (SST 09960-10010 or a substitute) | BUY | |||
| Crank pulley holder (for 250 N·m) | BUY / rent | |||
| Press + 1.27 mm hex key (tensioner pre-load) | access | |||
| Oil pressure sender deep socket | BUY / have |
Pull from the 3VZ before you sell it
| Item | Qty | Spec / what to get | Status | |
|---|---|---|---|---|
| 88 oil pan + its bolts/nuts | The 5VZ's pan (decision). Check the 5VZ strainer clears the pan floor | PULL | ||
| 88 dipstick + tube (keep even with the new dipstick kit) | Backup / reference for the dipstick length | PULL | ||
| 88 oil pressure sender (gauge type) | Replaces the 98 switch so the 88 oil gauge works. Loctite 243 on 2–3 threads, 15 N·m. Never connect the 88 gauge to the 98 switch (ORS: it can damage the gauge) | PULL | ||
| Temp gauge sender (single wire) | The 98 sender reads ~13–16 °F cool on the 88 gauge. Check the thread fits the 5VZ | PULL | ||
| Pigtails cut from the 3VZ harness, ~6" with connectors: oil sender and temp sender plugs/terminals (only if the 98 plugs won't fit the 88 senders), A/C clutch, alternator plug (if it's on the engine harness) | The 98 plugs may not fit the 88 sender/compressor | PULL | ||
| Old 3VZ engine harness (at least the N3/N5 mating plugs with ~12" of wire) | Becomes the plug-in conversion pigtail | PULL | ||
| 3VZ harness ground branch (brown wires to the engine ground eyelet): don't cut until wiring check 4 has run. On the bench, beep N5-3 and N5-11 (BR) engine-side cavities to the eyelet; on the truck, Ω from N5-3/N5-11 body side to chassis | The 98 harness has its own ECM grounds (EC eyelets). Only matters if an 88 body circuit grounds through this branch: if so, pin a ground wire into that N5 cavity in the adapter, with a ring terminal to chassis | CHECK | ||
| 88 R150 reverse switch branch and transfer 4WD switch branch, unwrapped whole out of the old 3VZ harness: switch plugs untouched, wires full length back to the N3 plug | Kept as-is; only the N3 end gets re-pinned into the adapter | PULL | ||
| 3VZ A/C bracket (keep for reference) | ORS grinds a boss on the 5VZ bracket; compare before grinding | PULL | ||
| Engine mount-to-frame bolts and nuts | Reused on install, 38 N·m | PULL | ||
| Every bell-housing-to-block bolt and nut | ORS: reuse the bolts from the transmission's application | PULL | ||
| Stiffening brackets (block to lower bell-housing) + bolts | Optional, for strength. 5VZ holes are 10 × 1.25; chase the threads | PULL | ||
| Rear end plate (engine plate between block and bell-housing) + bell-housing dust cover | Your 98 engine came from an A/T truck, so its plate may be the A/T type. Compare them; use whichever fits the R150 and clears the flywheel | PULL | ||
| Starter bolts (the 3VZ starter itself isn't needed) | 2 bolts, 39 N·m | PULL | ||
| Clutch hose bracket (on the RH head) | Moves to the 5VZ RH head, upper rear corner, 2nd hole from the rear | PULL | ||
| Fuel supply hose + union/banjo bolts + gaskets (hard line → rail) | Fittings for the line at the RH frame rail; ORS adapts from there | PULL | ||
| Fuel return hose + clamps | Return line connection | PULL | ||
| Throttle cable bracket (on the 3VZ intake) | ORS: the 3VZ cable works with a modified bracket | PULL | ||
| Brake booster hose + one-way valve | Reused in the new booster hose; air flows booster → engine | PULL | ||
| Vacuum hoses, PCV hose, hose clamps | Spares and fittings | PULL | ||
| EVAP canister (if it's on the engine side) | Optional: ORS says the 3VZ canister works | PULL | ||
| Air box / intake tube | Only if the Magnuson intake can use them | PULL | ||
| Thermostat housing + lower radiator hose | One of the two lower-hose options (shield it from the alternator bracket) | PULL | ||
| Upper radiator hose, heater hoses + fittings, clamps | Spares / fittings while you fit new hoses | PULL | ||
| PS high-pressure hose + original banjo bolt (and the return hose) | Reused on the 5VZ pump with a new gasket. Keep the return hard line and brackets too | PULL | ||
| Engine ground straps (engine → body, engine → battery) | Reuse if in good shape | PULL | ||
| Radiator (+ cap) | ORS: use a 3VZ radiator. New or recored if it's tired | CHECK | ||
| Overflow tank | Original location | CHECK | ||
| Fan shroud | Trim the LH side to clear the 5VZ fan (ORS); the lower cover may not fit | CHECK | ||
| Throttle cable | Option: 3VZ cable with the modified bracket (or the 5VZ cable) | CHECK | ||
| Battery cables, fusible link | Reuse if they're in good shape | CHECK |
Fuel
| Item | Qty | Spec / what to get | Status | |
|---|---|---|---|---|
| DW200 255 L/h (replaces the DW100 9-101-1000 you have, 2026-10-18) | 1 | ~9–10.5 A at 40–60 psi: 12 AWG, 20A fuse | BUY | |
| DW200 install kit, strainer, tank seal | 1 | BUY | ||
| Fuel supply union at the RH frame rail (if the line ends in a male fitting) | 1 | 90404-14014 | CHECK / BUY | |
| High-pressure fuel hose to the rail (ORS EC033–EC035A or a custom line) | 1 | BUY | ||
| Fuel return hose, 1/4" fuel-injection rated + clamps | ~6 ft | BUY | ||
| 88 fuel filter | 1 | BUY | ||
| Fuel pressure gauge | 1 | 265–304 kPa (38–44 psi) base | BUY / borrow |
Wiring
| Item | Qty | Spec / what to get | Status | |
|---|---|---|---|---|
| Relays (Relay A W-L bus, Relay B pump) + weatherproof sockets | 2 | 30/87/86/85 | BUY | |
| Hidden fuel-pump kill switch: small toggle (≥ 1 A) + 18 AWG run to the cab, spade/pinned terminals | 1 | in Relay B coil ground | BUY | |
| Fuses 15 A, 15 A, 7.5 A + weatherproof holders | 3 | BUY | ||
| 12 AWG wire (DW200 feed + ground to the tank) | ~25 ft | pure copper, GXL/TXL | BUY | |
| 14 AWG wire | ~25 ft | BUY | ||
| 16 AWG wire | ~25 ft | BUY | ||
| 88-type terminals for N3/N5 (98 terminals don't fit, tested 2026-10-18): 13 small (+1 if N5-16) and 2 large needed. Measure the de-pinned 88 terminal's blade width to order | 25 small + 5 large | BUY | ||
| 98 E12 terminals for the 6 new E12 wires | 10 | BUY | ||
| IWISS IWS-1424A open-barrel crimper (24–14 AWG) | 1 | not 1424B / 1420D (Weather Pack) | BUY | |
| 18 AWG TXL/GXL pure copper (no CCA, no silicone RC wire) | ~25 ft | BUY | ||
| Add-a-fuse matching the 88 fuse type + 7.5A fuse + spade/bullet pair (OBD pin 16) | 1 | constant slot | BUY | |
| Heavy-duty junction for block A: one heavy 12–14 AWG pinned terminal (no splice); carries starter-solenoid current | 1 | BUY | ||
| Joint connectors (bus-bar plug type, pins only) for junctions B–E | 4 | Toyota-style or equivalent | BUY | |
| Small 4-pin relay + socket for the ECM A/C idle-up (AC1, E12-16) | 1 | BUY | ||
| 39 Ω 5 W resistor (only if the A/C clutch won't engage in check 12) | 1 | CHECK | ||
| Ground straps: block → battery −, block → body | 2+ | BUY | ||
| Alternator plug pigtail (only if there's no 98 Engine No.2 wire) | 1 | CHECK | ||
| A/C clutch adapter pigtail (decided 2026-10-21): plug that mates the 98 A2 clutch plug → short 18 AWG wire → ring terminal on the 88 compressor clutch lead. The 98 harness stays uncut; the 3VZ B-W clutch pigtail isn't needed. Source the A2 mating half (e.g. off a 98 compressor) | 1 | BUY | ||
| Terminals, solder sleeves, heat-shrink, split loom, harness tape, P-clamps, zip ties | lot | BUY | ||
| Heat-reflective sleeve near the exhaust | lot | BUY | ||
| Firewall grommet | 1 | CHECK |
Exhaust
| Item | Qty | Spec / what to get | Status | |
|---|---|---|---|---|
| 98 exhaust manifolds + heat insulators | 2 | warpage max 1.00 mm | REUSE / CHECK | |
| 98 crossover pipe (to modify) | 1 | REUSE / CHECK | ||
| ◆ Crossover-to-downpipe gasket + nuts (FSM marks the nuts one-time-use), if you keep the factory flange | 1 set | 62 N·m | BUY | |
| ◆ LH exhaust manifold plug gasket | 1 | BUY | ||
| Manifold and crossover studs/nuts (rusty ones break) | set | CHECK / BUY | ||
| Short pipe for the spacer, 2.5" tubing and bends | lot | BUY | ||
| O2 bungs or flanges: the 98 O2 sensors are 2-bolt flange sensors (FSM EM-101: ◆ gasket, ◆ nuts, 20 N·m), not 18 mm threaded. Weld 98-style flanges, or use threaded bungs with threaded sensors that have the 98 connector | 2 | CHECK / BUY | ||
| ◆ O2 sensor gaskets + nuts (flange type) | 2 sets | 20 N·m | BUY | |
| Flex coupler (if the 98 flex is bad) | 1 | CHECK / BUY | ||
| Catalytic converter (one cat) | 1 | 2.5" | BUY | |
| Muffler, flanges + gaskets, hangers | lot | BUY | ||
| Heat shielding | lot | BUY | ||
| Welder wire, cut-off wheels, die grinder bits | BUY |
Magnuson
| Item | Qty | Spec / what to get | Status | |
|---|---|---|---|---|
| Throttle body coolant hoses: stay on the throttle body; the TB moves onto the supercharger with them. Old rubber: replace if hard/cracked | 2 | CHECK | ||
| Fuel and timing: the kit has no FPR, injector or tune changes; it's built for stock injectors, stock ECU, premium 91+. Decided: 310cc bluetops. They're larger than stock, so the stock ECM needs a fueling plan (tune/piggyback). See research O | CHECK (fueling plan) | |||
| Intake tube, MAF housing and air filter (ORS intake, aftermarket metal cold-air kit, or custom 2.75" tubing + couplers) | 1 | — | BUY / per Magnuson manual | |
| Throttle cable: 3VZ cable with a modified TB bracket, or a 5VZ donor cable with the firewall grommet turned around | 1 | — | CHECK / BUY |
Cooling, accessories, install
| Item | Qty | Spec / what to get | Status | |
|---|---|---|---|---|
| 91–95 3VZ 4×4 engine block brackets, LH + RH (cast steel; used: eBay / junkyard / car-part.com). Check each has the 5VZ's 3-hole pattern (1 top, 2 bottom) before buying. Bolt to the 5VZ block; may need one A/C bracket boss ground flush (ORS); drive out the small coolant drain pipe below the block drain plug if it hits | 1 pair | BUY | ||
| Upper and lower radiator hoses (lower: ORS hose with the 5VZ thermostat housing, or a 3VZ housing + hose) | 2 | BUY | ||
| Heater hoses, throttle body water hoses, hose clamps | set | BUY | ||
| A/C bracket: grind one boss flush for the 91–95 brackets | CHECK | |||
| Alternator (5VZ): lower bracket adjuster cut for steering shaft clearance | 1 | 13.7–14.7 V | CHECK | |
| PS hoses: 3VZ pressure hose; return hose 3/8" + clamps | REUSE / BUY | |||
| ◆ PS banjo copper washers (crush gaskets for the pressure-hose union bolt), new | 2 (+ spares) | one each side of the banjo; union bolt 46 N·m (34 ft·lbf), tube stopper touching the pump body first (98 FSM, PS vane pump installation) | BUY | |
| Clutch slave cylinder (new or rebuilt); master cylinder check | 1 | BUY / CHECK | ||
| Heated O2 sensors B1S1 + B1S2 (98 type) | 2 | heater 11–16 Ω | BUY | |
| PCV hose, vacuum hose, brake booster hose | BUY | |||
| 5VZ pulley + clutch plate moved onto the 88 compressor on the truck, shim kept (ORS / swap thread); refrigerant stays sealed | CHECK | |||
| Battery | 1 | 12.7–12.9 V at rest | CHECK |
Fluids
| Item | Qty | Spec / what to get | Status | |
|---|---|---|---|---|
| Engine oil 5W-30 for first start, break-in and winter (FSM "preferred") | 2 fills (~12 qt) | 5.5 qt with filter (dry fill 6.2 qt) | BUY | |
| Spare Carquest 85348 filter for the early break-in change | 1 | BUY | ||
| Coolant (ethylene glycol, 50–70%) + distilled water | ~3 gal | BUY | ||
| R150 gear oil 75W-90 GL-4/GL-5 | ~2.5 qt | BUY | ||
| PS fluid (Dexron II/III) | 1 qt | BUY | ||
| Brake fluid DOT 3 (clutch bleed) | 1 pt | BUY |