Toyota Tundra Service Manual: Disassembly

DISASSEMBLY

PROCEDURE

1. REMOVE OIL FILTER ELEMENT

2. REMOVE OIL FILTER BRACKET

3. REMOVE CRANKSHAFT PULLEY

4. REMOVE OIL FILLER CAP SUB-ASSEMBLY

5. REMOVE OIL FILLER CAP HOUSING

(a) Remove the 2 bolts, filler cap housing and gasket.

6. REMOVE SPARK PLUG

(a) Using a 16 mm plug wrench, remove the 8 spark plugs.

7. REMOVE VVT SENSOR

(a) LH: Remove the 2 bolts and 2 VVT sensors.

(b) RH: Remove the 2 bolts and 2 VVT sensors.

8. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the bolt and camshaft position sensor.

9. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR

(a) Remove the 2 bolts and sensor protector.

10. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the bolt and crankshaft position sensor.

11. REMOVE CAMSHAFT OIL CONTROL VALVE ASSEMBLY

(a) LH: Remove the 2 bolts and 2 oil control valves.

(b) RH: Remove the 2 bolts and 2 oil control valves.

12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Remove the 14 bolts, seal washer, cylinder head cover and gasket. HINT: Make sure the removed parts are returned to the same places they were removed from.

(b) Remove the 5 gaskets from the camshaft bearing caps (No. 2, No. 3).

13. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH

(a) Remove the 14 bolts, seal washer, cylinder head cover and gasket. HINT: Make sure the removed parts are returned to the same places they were removed from.

(b) Remove the 5 gaskets from the camshaft bearing caps (No. 1, No. 3).

14. REMOVE OIL CONTROL VALVE FILTER

(a) LH:

Remove the 3 bolts, cylinder head cover spacer, gasket and valve filter.

(b) RH: Remove the 3 bolts, cylinder head cover spacer, gasket and valve filter.

15. REMOVE SPARK PLUG TUBE GASKET

(a) Bend the 4 ventilation baffle plate claws on the cylinder head cover to an angle of 90° or more.

(b) Using a screwdriver, pry out the gaskets.

NOTICE:

Be careful not to damage the cylinder head cover.

HINT:

• Be careful not to damage the gasket when removing it, as the removed gasket needs to be used when installing a new one.
• Tape the screwdriver tip before use.

16. REMOVE WATER PUMP ASSEMBLY

17. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

18. REMOVE WATER INLET PIPE

19. REMOVE FRONT CRANKSHAFT OIL SEAL

(a) Place the timing chain cover on wooden blocks.

(b) Place the oil pump on a wooden block.

(c) Using a screwdriver and wooden block, pry out the oil seal.

NOTICE:

Do not damage the surface of the oil seal press fit hole.

HINT:

Tape the screwdriver tip before use.

20. SET NO. 1 CYLINDER TO TDC / COMPRESSION

(a) Temporarily install the pulley set bolt.

(b) Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

HINT:

If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

21. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH

22. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH

23. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH

24. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH

25. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

26. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH

27. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH

28. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH

29. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH

30. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

31. REMOVE CRANKSHAFT TIMING GEAR KEY

(a) Using a screwdriver, remove the 2 timing gear keys from the crankshaft.

32. REMOVE CAMSHAFT BEARING CAP LH

33. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

34. REMOVE CAMSHAFT BEARING CAP RH

35. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

36. REMOVE VALVE ROCKER ARM SUB-ASSEMBLY

(a) Remove the 32 valve rocker arms from the cylinder head.

HINT:

Arrange the removed parts in the correct order.

37. REMOVE VALVE LASH ADJUSTER ASSEMBLY

(a) Remove the 32 valve lash adjusters from the cylinder head.

HINT:

Arrange the removed parts in the correct order.

38. REMOVE VALVE STEM CAP

(a) Remove the 32 valve stem caps from the cylinder head.

HINT:

Arrange the removed parts in the correct order.

39. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

40. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

41. REMOVE CYLINDER HEAD GASKET LH

42. REMOVE CYLINDER HEAD GASKET RH

43. REMOVE CYLINDER BLOCK WATER JACKET SPACER

(a) Remove the 2 water jacket spacers from the cylinder head.

NOTICE:

Be sure to remove the water jacket spacers. If not, they may fall and become damaged when the cylinder block is inverted.

44. REMOVE OIL RETURN PIPE GASKET

(a) Using a screwdriver, pry out the oil return pipe gasket. HINT: Tape the screwdriver tip before use.

45. REMOVE VENTILATION PIPE GASKET

(a) Using a screwdriver, pry out the ventilation pipe gasket. HINT: Tape the screwdriver tip before use.

46. REMOVE NO. 1 HEAT EXCHANGER COVER

(a) Remove the 12 bolts and 2 nuts.

(b) Remove the heat exchanger by prying between the heat exchanger and cylinder block with a screwdriver. HINT: Tape the screwdriver tip before use.

47. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 14 bolts and 2 nuts.

(b) Insert the blade of oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan. NOTICE: Be careful not to damage the contact surfaces of the oil pans.

48. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY

(a) Remove the 14 bolts and 2 nuts. HINT: Be sure to clean the bolts and stud bolts, and check the threads for cracks or other damage.

(b) Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan. HINT: Tape the screwdriver tip before use.

49. REMOVE NO. 1 OIL PAN BAFFLE PLATE

(a) Remove the 7 bolts and baffle plate.

50. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the 2 bolts, oil strainer and O-ring.

51. REMOVE ENGINE REAR OIL SEAL RETAINER

(a) Remove the 6 bolts and oil seal retainer.

(b) Using a screwdriver, pry out the oil seal retainer. HINT: Tape the screwdriver tip before use.

52. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY

(a) Remove the bolt and oil drain pipe.

(b) Remove the O-ring.

53. REMOVE REAR CRANKSHAFT OIL SEAL

(a) Place the oil seal retainer on wooden blocks.

(b) Using a screwdriver and hammer, tap out the oil seal.

54. REMOVE RING PIN

NOTICE:

It is not necessary to remove the ring pin unless it is being replaced.

55. REMOVE STUD BOLT

NOTICE:

If the stud bolt is deformed or its threads are damaged, replace it.