Toyota Tundra Service Manual: Disassembly

(a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

Standard thrust clearance:

0.15 to 0.55 mm (0.00591 to 0.0217 in.)

Maximum thrust clearance:

0.70 mm (0.0276 in.)

If the thrust clearance is more than the maximum, replace one or more connecting rods as necessary.

If necessary, replace the crankshaft.

(b) Remove the 2 connecting rod cap bolts.

(c) Using the 2 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 to the connecting rod cap.

(f) Lay a strip of Plastigage on the crank pin.

(g) Check that the front mark of the connecting rod cap is facing forward.

(h) Install and alternately tighten the bolts of the connecting rod cap in several steps.

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

NOTICE:

Do not turn the crankshaft.

(i) Mark the front side of each connecting rod cap bolt with paint.

(l) Remove the 2 connecting rod cap bolts.

(m) Using the 2 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 to the connecting rod cap.

Connecting rod

1

2

1

2

3

2

3

4

3

4

Crankshaft

1

2

1

3

2

1

3

2

1

3

2

3

Use bearing

2

3

4

5

6

7

2

1.489 to 1.492 mm (0.0586 to 0.0587 in.)

3

1.492 to 1.495 mm (0.0587 to 0.0589 in.)

4

1.495 to 1.498 mm (0.0589 to 0.0590 in.)

5

1.498 to 1.501 mm (0.0590 to 0.0591 in.)

6

1.501 to 1.504 mm (0.0591 to 0.0592 in.)

7

1.504 to 1.507 mm (0.0592 to 0.0593 in.)

1

56.000 to 56.006 mm (2.20472 to 2.20496 in.)

2

56.006 to 56.012 mm (2.20496 to 2.20519 in.)

3

56.012 to 56.018 mm (2.20519 to 2.20543 in.)

4

56.018 to 56.024 mm (2.20543 to 2.20566 in.)

1

52.994 to 53.000 mm (2.08637 to 2.08661 in.)

2

52.988 to 52.994 mm (2.08614 to 2.08637 in.)

3

52.982 to 52.988 mm (2.08590 to 2.08614 in.)

(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.

(a) Using a piston ring expander, remove the 2 compression rings.

(1) Using a small screwdriver, pry off the 2 snap rings from the piston.

(2) Gradually heat the piston to approximately 80°C (176°F).

(3) Using a brass bar and plastic-faced hammer, lightly tap out the piston pin. Then 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.

(1) Using a gasket scraper, remove the carbon from the piston top.

(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.

(3) Using solvent and a brush, thoroughly clean the piston.

NOTICE:

Do not use a wire brush.

(a) 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 (0.000787 to 0.00866 in.)

Maximum thrust clearance:

0.30 mm (0.0118 in.)

If the thrust clearance is more than the maximum, replace the thrust washers as a set.

Standard thrust washer thickness:

2.44 to 2.49 mm (0.0961 to 0.0980 in.)

If necessary, replace the crankshaft.

(a) Uniformly loosen and remove the 10 bearing cap bolts and 10 seal washers in several steps, in the sequence shown in the illustration.

(b) Uniformly loosen and remove the 20 bearing cap bolts in several steps, in the sequence shown in the illustration.

(c) Using a screwdriver, slightly pry up the 5 main bearing caps.

HINT:

• Tape the screwdriver tip before use.
• Keep the lower bearing and crankshaft bearing cap together.

NOTICE:

• Be careful not to damage the joint surface of the cylinder block and main bearing caps.
• Pry up the left and right side of the cap little by little.

(a) Remove the thrust washer set from the cylinder block and No. 3 bearing cap.

(a) Using a 5 mm hexagon wrench, remove the 4 bolts and 4 oil nozzles.