Toyota Tundra Service Manual: Installation

INSTALLATION

PROCEDURE

1. INSTALL WATER INLET PIPE

(a) Apply soapy water to 2 new O-rings and install them to the water inlet pipe.

(b) Install the water inlet pipe to the No. 1 heat exchanger cover.

2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

(a) Apply a light coat of engine oil to a new oil pump gasket.

(b) Install the oil pump gasket to the cylinder block.

(c) Apply a light coat of engine oil to a new O-ring.

(d) Install the O-ring to the oil pan sub-assembly.

(e) Apply seal packing in a continuous line to the timing chain cover sub-assembly as shown in the following illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

• Apply Seal Packing As Follows:

  Area	Seal Packing Diameter	Application Position from Inside Edge of Cover
  Continuous Line Area	3.0 to 4.0 mm (0.118 to 0.157 in.)	2.5 mm (0.0984 in.)
  Dashed Line Area	6.4 mm (0.252 in.) or more, or within OK area shown in illustration	7.0 mm (0.276 in.)
  Diagonal Line Area	3.0 to 4.0 mm (0.118 to 0.157 in.)	5.5 mm (0.217 in.)

  

NOTICE:

• When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
• Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
• Do not start the engine for at least 2 hours after installing.

(f) Align the oil pump drive rotor spline and crankshaft as shown in the illustration and install the timing chain cover sub-assembly.

(g) Temporarily install the 26 bolts and nut. Standard Bolt: Item Length Thread Diameter Bolt A 25 mm (0.984 in.) 8 mm (0.315 in.) Bolt B 55 mm (2.17 in.) 8 mm (0.315 in.) Bolt C 70 mm (2.76 in.) 8 mm (0.315 in.) Bolt D 35 mm (1.38 in.) 10 mm (0.394 in.) Bolt E 55 mm (2.17 in.) 10 mm (0.394 in.) Bolt F 80 mm (3.15 in.) 10 mm (0.394 in.) Text in Illustration *1 Nut NOTICE: Make sure that there is no oil on the bolt threads.

(h) Tighten the 3 bolts in several steps in the sequence shown in the illustration. Torque: 47 N·m {479 kgf·cm, 35 ft·lbf}

(i) Temporarily install the fan bracket assembly with the 5 bolts to the timing chain cover sub-assembly. Standard Bolt: Item Length Thread Diameter Bolt A 70 mm (2.76 in.) 8 mm (0.315 in.) Bolt B 80 mm (3.15 in.) 10 mm (0.394 in.)

(j) Temporarily install the V-ribbed belt tensioner assembly with the bolt and 6 mm hexagon bolt to the timing chain cover sub-assembly.

(k) Tighten the 8 bolts labeled 4 to 11 in several steps in the sequence shown in the illustration. Torque: 47 N·m {479 kgf·cm, 35 ft·lbf}

(l) Tighten the 22 bolts and nut labeled 12 to 34 in several steps in the sequence shown in the illustration.

Torque:

23 N·m {235 kgf·cm, 17 ft·lbf}

NOTICE:

After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off.

3. INSTALL FRONT CRANKSHAFT OIL SEAL

4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Install 5 new gaskets to the No. 2 camshaft bearing cap and No. 3 camshaft bearing cap.

(b) Install the cylinder head cover gasket LH to the cylinder head cover sub-assembly LH.

NOTICE:

Remove any oil from the contact surface.

(c) Apply seal packing as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal Packing

NOTICE:

• Remove any oil from the contact surface.
• Install the cylinder head cover sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

(d) Install the cylinder head cover sub-assembly LH and a new seal washer with the 14 bolts. Torque: for bolt A : 21 N·m {214 kgf·cm, 15 ft·lbf} except bolt A : 12 N·m {122 kgf·cm, 9 ft·lbf} NOTICE: Do not start the engine for at least 2 hours after the installation.

5. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

(a) Install 5 new gaskets to the No. 1 camshaft bearing cap and No. 3 camshaft bearing cap.

(b) Install the cylinder head cover gasket RH to the cylinder head cover sub-assembly RH.

NOTICE:

Remove any oil from the contact surface.

(c) Apply seal packing as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal Packing

NOTICE:

• Remove any oil from the contact surface.
• Install the cylinder head cover sub-assembly RH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

(d) Install the cylinder head cover sub-assembly RH and a new seal washer with the 14 bolts. Torque: for bolt A : 21 N·m {214 kgf·cm, 15 ft·lbf} except bolt A : 12 N·m {122 kgf·cm, 9 ft·lbf} NOTICE: Do not start the engine for at least 2 hours after the installation.

6. INSTALL IGNITION COIL ASSEMBLY

(a) Install the 8 ignition coils with the 8 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

7. CONNECT NO. 3 AIR TUBE

(a) Install a new gasket to the No. 3 air tube.

(b) Connect the No. 3 air tube with the 2 nuts and bolt. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf} Text in Illustration *1 No. 3 Air Tube *2 Exhaust Manifold *a Claw NOTICE: Make sure the gasket's claws are not caught between the No. 3 air tube and exhaust manifold.

(c) Install the wire harness clamp bracket with the bolt to the cylinder head cover sub-assembly RH.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

8. CONNECT NO. 4 AIR TUBE

(a) Install a new gasket to the No. 4 air tube.

(b) Connect the No. 4 air tube with the 2 nuts and bolt. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf} Text in Illustration *1 No. 4 Air Tube *2 Exhaust Manifold *a Claw NOTICE: Make sure the gasket's claws are not caught between the No. 4 air tube and exhaust manifold.

(c) Install the wire harness clamp bracket with the bolt to the cylinder head cover sub-assembly LH.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

9. INSTALL CRANKSHAFT PULLEY

(a) Align the key groove of the crankshaft pulley with the crankshaft pulley set key, and slide on the crankshaft pulley to install it. Text in Illustration *a Hold *b Turn

(b) Using SST, install the crankshaft pulley set bolt.

SST: 09213-70011

SST: 09330-00021

Torque:

300 N·m {3059 kgf·cm, 221 ft·lbf}

10. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

(a) Install the No. 1 idler pulley sub-assembly to the timing chain cover sub-assembly with the bolt.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

11. INSTALL WATER PUMP PULLEY

12. INSTALL NO. 3 WATER BY-PASS PIPE

HINT:

Perform this procedure only when replacement of the No. 3 water by-pass pipe is necessary.

(a) Install the No. 3 water by-pass pipe to the front water by-pass joint with the bolt. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf} Text in Illustration *a Stopper *b Protrusion NOTICE: Align the notch of the stopper with the protrusion of the front water by-pass joint.

13. INSTALL FRONT WATER BY-PASS JOINT

(a) Install 2 new gaskets and the front water by-pass joint to the cylinder head with the 4 nuts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(b) Install the No. 2 water by-pass hose to the front water by-pass joint, and slide the clamp to secure the hose.

14. CONNECT NO. 10 WATER BY-PASS HOSE

(a) Connect the No. 10 water by-pass hose to the front water by-pass joint, and slide the clamp to secure the hose. Text in Illustration *1 No. 9 Water By-pass Hose *2 No. 10 Water By-pass Hose *a Paint Mark (Orange) *b Paint Mark (Yellow)

15. CONNECT NO. 9 WATER BY-PASS HOSE

(a) Connect the No. 9 water by-pass hose to the front water by-pass joint, and slide the clamp to secure the hose.

16. INSTALL WATER INLET HOUSING

(a) Install a new gasket to the timing chain cover sub-assembly. Text in Illustration *1 Gasket

(b) Install the water inlet housing with the 3 bolts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

17. CONNECT NO. 5 WATER BY-PASS HOSE

18. CONNECT NO. 8 WATER BY-PASS HOSE

19. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

(a) Connect the No. 2 water by-pass hose to the water by-pass pipe sub-assembly, and slide the clamp to secure the hose.

(b) Install the water by-pass pipe sub-assembly to the cylinder head cover sub-assembly RH with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

20. INSTALL AIR TUBE SUB-ASSEMBLY RH

(a) Install the air tube sub-assembly RH to the cylinder head cover sub-assembly RH with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

21. INSTALL NO. 1 WATER BY-PASS HOSE

22. INSTALL NO. 3 ENGINE COVER

23. INSTALL NO. 4 ENGINE COVER

24. INSTALL GENERATOR ASSEMBLY

25. CONNECT VANE PUMP ASSEMBLY

(a) Connect the vane pump assembly to the timing chain cover sub-assembly with the 2 bolts.

Torque:

28 N·m {286 kgf·cm, 21 ft·lbf}

HINT:

Before performing the following procedures, move the spacer until the vane pump assembly can be installed.

26. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

27. INSTALL OIL FILTER BRACKET

(a) Apply a light coat of engine oil to 2 new O-rings.

(b) Install the 2 O-rings to the timing chain cover sub-assembly.

(c) Install the oil filter bracket to the timing chain cover sub-assembly with the 2 nuts and 2 bolts.

Torque:

35 N·m {357 kgf·cm, 26 ft·lbf}

28. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY

29. INSTALL OIL FILTER ELEMENT

30. CONNECT COOLER COMPRESSOR ASSEMBLY

(a) Connect the cooler compressor assembly with the 2 stud bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Install the 2 bolts and 2 nuts.

Torque:

25 N·m {250 kgf·cm, 18 ft·lbf}

NOTICE:

Tighten the bolts and nuts in the order shown in the illustration to connect the cooler compressor assembly.

31. CONNECT HEATER HOSE AND NO. 1 WATER BY-PASS PIPE

(a) Connect the No. 1 water by-pass pipe with the 2 bolts to the cylinder head cover sub-assembly RH.

Torque:

18 N·m {184 kgf·cm, 13 ft·lbf}

(b) Connect the heater hose to the water by-pass pipe sub-assembly, and slide the clamp to secure the hose.

32. CONNECT NO. 3 AIR INJECTION SYSTEM HOSE

(a) Connect the No. 3 air injection system hose to the air tube sub-assembly RH, and slide the clamp to secure the hose.

33. CONNECT ENGINE WIRE

(a) Connect the wire harness clamp bracket to the timing chain cover sub-assembly with the bolt.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(b) Engine Room RH Side:

(1) Connect the 9 clamps.

(2) Connect the 2 air pump connectors.

(3) Install the ground wire RH with the bolt.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(4) Connect the noise filter connector.

(5) Connect the 2 VVT sensor connectors.

(6) Connect the injector connector.

(7) Connect the 4 ignition coil connectors.

(8) Connect the 2 camshaft timing oil control valve connectors.

(9) Connect the power steering oil pressure switch connector and solenoid valve connector.

(10) for 4WD:

Connect the clamp and junction connector.

(c) Engine Room LH Side:

(1) Connect the cooler compressor connector.

(2) Connect the 6 clamps.

(3) Connect the camshaft position sensor connector.

(4) Connect the 2 camshaft timing oil control valve connectors.

(5) Connect the engine coolant temperature sensor connector.

(6) Install the ground wire LH with the bolt.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(7) Connect the noise filter connector.

(8) Connect the 2 VVT sensor connectors.

(9) Connect the 4 ignition coil connectors.

(10) Connect the injector connector.

(11) Connect the 2 wire harness clamps.

(12) Connect the 4 air injection control driver connectors.

(13) Connect the 2 connectors and attach the 2 clamps to the engine room junction block.

(14) Install the engine room relay block cover.

34. INSTALL AIR SWITCHING VALVE ASSEMBLY (for Bank 2)

35. CONNECT NO. 1 AIR HOSE

36. INSTALL AIR SWITCHING VALVE ASSEMBLY (for Bank 1)

37. INSTALL INTAKE MANIFOLD

(See page )

38. INSTALL RADIATOR ASSEMBLY

(See page )

39. ADD ENGINE OIL

40. ADD ENGINE COOLANT

41. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

42. INSPECT FOR OIL LEAK

43. INSPECT FOR COOLANT LEAK

44. CHECK ENGINE OIL LEVEL