Toyota Tundra Service Manual: Removal

REMOVAL

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (See page ).

2. DISCHARGE FUEL SYSTEM PRESSURE

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

4. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

(a) Remove the front wiper motor and link (See page ).

5. REMOVE NO. 1 ENGINE UNDER COVER

6. DRAIN ENGINE OIL

7. DRAIN ENGINE COOLANT

8. REMOVE HOOD SUB-ASSEMBLY

(a) Using a screwdriver, release the 2 clips and remove the 2 hood supports assembly. HINT: Tape the screwdriver tip before use. CAUTION: Remove the hood support assembly while supporting the hood by hand.

(b) Remove the 4 bolts and hood.

9. REMOVE V-BANK COVER SUB-ASSEMBLY

(a) Raise the front of the V-bank cover to detach the 2 pins. Then remove the 2 V-bank cover hooks from the bracket, and remove the V-bank cover.

10. REMOVE AIR CLEANER HOSE ASSEMBLY

(a) Disconnect the vacuum sensing hose and ventilation hose.

(b) Loosen the 2 clamps.

(c) Remove the air cleaner hose.

11. REMOVE AIR CLEANER ASSEMBLY

(a) Remove the air cleaner cap. (1) Disconnect the MAF meter connector. (2) Using a clip remover, detach the wire harness clamp. (3) for Type A: Unfasten the 4 hook clamps and then remove the air cleaner cap. (4) for Type B: Unfasten the 2 hook clamps and then remove the air cleaner cap.

(b) Remove the air cleaner element.

(c) Remove the 2 bolts and air cleaner case.

12. REMOVE COWL TOP OUTER PANEL SUB-ASSEMBLY

13. REMOVE FRONT FENDER APRON SEAL RH

14. REMOVE FRONT FENDER APRON SEAL REAR RH

15. REMOVE FRONT FENDER APRON SEAL LH

16. REMOVE FRONT FENDER APRON SEAL REAR LH

17. REMOVE INLET RADIATOR HOSE

18. DISCONNECT OUTLET RADIATOR HOSE

19. REMOVE RADIATOR GRILLE SUB-ASSEMBLY

20. REMOVE RADIATOR SIDE DEFLECTOR RH

21. REMOVE RADIATOR SIDE DEFLECTOR LH

22. REMOVE FAN AND GENERATOR V BELT

23. REMOVE FAN SHROUD

24. REMOVE RADIATOR ASSEMBLY

25. DISCONNECT NO. 12 WATER BY-PASS HOSE

26. DISCONNECT NO. 13 WATER BY-PASS HOSE

27. REMOVE EGR VALVE ASSEMBLY

28. REMOVE EGR VALVE BRACKET

29. REMOVE VENTILATION HOSE ASSEMBLY

30. REMOVE AIR TUBE SUB-ASSEMBLY LH

31. REMOVE INTAKE MANIFOLD

32. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Remove the fuel pipe clamp.

(b) Disconnect the No. 1 fuel pipe (See page ).

33. DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY

(a) Disconnect the No. 2 fuel tube (See page ).

34. DISCONNECT WIRE HARNESS AND HOSE

(a) Disconnect the clamp and ECM connector. HINT: Refer to the following procedures to disconnect the ECM connector (See page ).

(b) Disconnect the No. 4 water by-pass hose.

(c) Disconnect the 2 heater hoses.

(d) Disconnect the 4 connectors from the connector holder block.

(e) Remove the bolt and disconnect the clamp and ground wire.

(f) Disconnect the air pump connector and 2 clamps.

(g) Remove the nut and connector bracket.

(h) Disconnect the air injection system hose.

(i) Remove the nut and disconnect the wire from the positive (+) battery cable.

(j) Disconnect the cable from the positive (+) battery terminal.

(k) Remove the bolt and disconnect the ground wire.

(l) Disconnect the 4 air injection control driver connectors.

(m) Remove the nut and disconnect the wire and 2 clips from the engine room junction block.

(n) Disconnect the 2 connectors and 2 clips from the engine room junction block.

35. DISCONNECT COOLER COMPRESSOR ASSEMBLY

36. DISCONNECT VANE PUMP ASSEMBLY

37. REMOVE GENERATOR ASSEMBLY

38. REMOVE PROPELLER SHAFT ASSEMBLY

(a) for 2WD:

Refer to the following procedures (See page ).

(b) for 4WD:

Refer to the following procedures (See page ).

39. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)

(a) Remove the front propeller shaft (See page ).

40. REMOVE EXHAUST PIPE ASSEMBLY

(a) Remove the exhaust pipe assembly (See page ).

41. DISCONNECT NO. 1 WATER BY-PASS PIPE

(a) Remove the 3 bolts and disconnect the No. 1 water by-pass pipe.

42. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

43. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

44. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

45. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

46. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

47. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

48. REMOVE STARTER COVER

49. REMOVE STARTER ASSEMBLY

50. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

(a) for 2WD:

Refer to the following procedures (See page ).

(b) for 4WD:

Refer to the following procedures (See page ).

51. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR (for 2WD)

52. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR (for 4WD)

53. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

(a) Using SST, hold the crankshaft. SST: 09213-70011 SST: 09330-00021

(b) Remove the 10 bolts, rear drive plate spacer, drive plate and crankshaft angle sensor rotor.

54. REMOVE ENGINE ASSEMBLY

(a) Install 2 engine hangers with 2 bolts as shown in the illustration. Torque: 43 N·m {438 kgf·cm, 32 ft·lbf} Engine hanger 12281-38150 Bolt 90119-A0166

(b) Attach an engine sling device and hang the engine with a chain block.

(c) Remove the 4 engine mounting insulator bolts.

(d) Lift the engine out from the vehicle slowly and carefully.

NOTICE:

Make sure the engine is clear of all wiring, hoses and cables.

55. INSTALL ENGINE TO ENGINE STAND

(a) Install the engine to an engine stand with the bolts.

(b) Remove the 2 bolts and 2 engine hangers.