Toyota Tundra Service Manual: Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL STUD BOLT

(a) Install the timing chain cover stud bolt.

(1) Using an E10 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

(b) Install the oil pan stud bolt.

(1) Using an E6 and E7 "TORX" socket wrench, install the 3 stud bolts as shown in the illustration.

Torque:

for stud bolt A :

5.0 N·m {51 kgf·cm, 44 in·lbf}

for stud bolt B :

9.0 N·m {92 kgf·cm, 80 in·lbf}

2. INSTALL RING PIN

(a) Using a plastic-faced hammer, tap in new ring pins to the timing chain cover.

Standard Protrusion:

Item

Ring Pin Diameter

Specified Condition

Ring pin A

13 mm (0.512 in.)

7.5 to 8.5 mm (0.295 to 0.335 in.)

Ring pin B

11 mm (0.433 in.)

3.6 to 4.6 mm (0.142 to 0.181 in.)

3. INSTALL REAR CRANKSHAFT OIL SEAL

(a) Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge.

SST: 09223-15030

SST: 09950-70010

09951-07100

Standard depth:

0 to 1.0 mm (0 to 0.0394 in.)

NOTICE:

  • Keep the lip free from foreign matter.
  • Do not tap on the oil seal at an angle.

4. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY

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

(b) Install the O-ring to the drain pipe.

(c) Install the oil drain pipe with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

5. INSTALL ENGINE REAR OIL SEAL RETAINER

(a) Apply seal packing in a continuous line as shown in the illustration.

Seal packing:

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

Seal diameter:

2.0 to 3.0 mm (0.0787 to 0.118 in.)

Application position from inside edge of retainer:

3.5 mm (0.138 in.)

NOTICE:

  • Remove any oil from the contact surface.
  • Install the engine rear oil seal retainer within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

(b) Install the oil seal retainer with the 6 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

NOTICE:

  • Do not start the engine for at least 2 hours after installing.
  • When installing the oil seal retainer, make sure the lip of the oil seal is not damaged.
  • When installing the oil seal retainer, make sure the lip of the oil seal is not folded incorrectly.

6. INSTALL OIL STRAINER SUB-ASSEMBLY

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

(b) Install the O-ring to the oil strainer.

(c) Install the oil strainer with the 2 bolts.

Torque:

12 N·m {122 kgf·cm, 9 ft·lbf}

NOTICE:

Make sure the O-ring is not twisted or damaged.

7. INSTALL NO. 1 OIL PAN BAFFLE PLATE

(a) Install the baffle plate with the 7 bolts.

Torque:

12 N·m {122 kgf·cm, 9 ft·lbf}

8. INSTALL NO. 1 OIL PAN SUB-ASSEMBLY

(a) Apply seal packing in a continuous line as shown in the illustration.

Seal packing:

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

Standard seal diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

NOTICE:

  • Remove any oil from the contact surface.
  • Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

(b) Install the oil pan with the 14 bolts and 2 nuts.

Torque:

for bolt A :

10 N·m {102 kgf·cm, 7 ft·lbf}

for bolt B :

35 N·m {357 kgf·cm, 26 ft·lbf}

for nut :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

Do not start the engine for at least 2 hours after installing.

9. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

(a) Apply seal packing in a continuous line as shown in the illustration.

Seal packing:

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

Standard seal diameter:

3.0 to 4.0 mm (0.118 to 0.156 in.)

NOTICE:

  • Remove any oil from the contact surface.
  • Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

(b) Install the oil pan with the 14 bolts and 2 nuts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

NOTICE:

Do not start the engine for at least 2 hours after installing.

10. INSTALL NO. 1 HEAT EXCHANGER COVER

(a) Apply seal packing in a continuous line as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

Standard seal diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

NOTICE:

  • Remove any oil from the contact surface.
  • Install the No. 1 heat exchanger cover within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

(b) Install the heat exchanger cover with the 12 bolts and 2 nuts.

Torque:

for bolt C :

10 N·m {102 kgf·cm, 7 ft·lbf}

except bolt C :

21 N·m {214 kgf·cm, 15 ft·lbf}

Standard Bolt:

Item

Length

Thread Diameter

Bolt A

20 mm (0.787 in.)

8 mm (0.315 in.)

Bolt B

70 mm (2.76 in.)

8 mm (0.315 in.)

Bolt C

16 mm (0.630 in.)

6 mm (0.236 in.)

NOTICE:

Do not start the engine for at least 2 hours after installing.

11. INSTALL VENTILATION PIPE GASKET

(a) Using SST, evenly tap in a new ventilation pipe gasket until its surface is flush with the lip of the ventilation pipe.

SST: 09950-60010

09951-00360

SST: 09950-70010

09951-07100

NOTICE:

  • Do not tap the gasket at an angle.
  • Do not tap the gasket excessively.

12. INSTALL OIL RETURN PIPE GASKET

(a) Install a new oil return pipe gasket.

13. INSTALL CYLINDER BLOCK WATER JACKET SPACER

(a) Install the 2 water jacket spacers as shown in the illustration.

NOTICE:

  • Face the cutouts indicated by the arrows in illustration away from the engine.
  • Face the "up mark" as shown in the illustration.

14. INSTALL CYLINDER HEAD GASKET RH

15. INSTALL CYLINDER HEAD GASKET LH

16. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH

17. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

18. INSTALL VALVE STEM CAP

(a) Apply a light coat of engine oil to the valve stem caps.

(b) Install the 32 valve stem caps to the cylinder head.

19. INSTALL VALVE LASH ADJUSTER ASSEMBLY

(a) Inspect the valve lash adjuster (See page ).

(b) Install the 32 valve lash adjusters to the cylinder head.

NOTICE:

Install the lash adjuster at the same place it was removed from.

20. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

(a) Apply engine oil to the lash adjuster tips and valve stem cap ends.

(b) Install the 32 valve rocker arms as shown in the illustration.

21. INSTALL CAMSHAFT BEARING CAP RH

22. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

23. INSTALL CAMSHAFT BEARING CAP LH

24. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

25. INSTALL CRANKSHAFT TIMING GEAR KEY

(a) Install the timing gear key.

HINT:

The other timing gear key will be installed at a later step.

26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

27. INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH

28. INSTALL NO. 1 CHAIN VIBRATION DAMPER RH

29. INSTALL NO. 1 CHAIN TENSIONER SLIPPER RH

30. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH

31. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

32. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH

33. INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH

34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH

35. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH

36. TIGHTEN CAMSHAFT TIMING GEAR

37. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION

(a) Temporarily install the pulley set bolt.

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

(c) Remove the crankshaft pulley set bolt.

38. INSTALL WATER INLET PIPE

39. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

40. INSTALL WATER PUMP ASSEMBLY

41. INSTALL FRONT CRANKSHAFT OIL SEAL

(a) Apply MP grease to the lip of a new oil seal.

(b) Using SST and a hammer, tap in the oil seal to a depth between 0 to 1.0 mm (0 to 0.0394 in.) from the timing chain cover edge.

SST: 09223-22010

SST: 09506-35010

NOTICE:

  • Keep the lip free from foreign matter.
  • Do not tap oil seal at an angle.

42. INSTALL CRANKSHAFT TIMING GEAR KEY

(a) Install the crankshaft timing gear key to the crankshaft.

43. INSTALL SPARK PLUG TUBE GASKET

(a) Using a cutter knife, cut off the seal part of the removed gasket.

(b) Using the removed gasket and a hammer, tap in a new gasket until it stops.

HINT:

If the removed gasket does not fit on the new one, correct the removed one with pliers.

(c) Apply a light coat of MP grease to the gasket lip.

(d) Return the 4 ventilation baffle plate claws to the original positions.

44. INSTALL OIL CONTROL VALVE FILTER

(a) LH:

(1) Install the valve filter in the cylinder head cover.

(2) Install a new gasket and the cylinder head cover spacer with the 3 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) RH:

(1) Install the valve filter in the cylinder head cover.

(2) Install a new gasket and the cylinder head cover spacer with the 3 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

(a) Install 5 new gaskets to the camshaft bearing caps. (No. 1, No. 3).

(b) Install the cover gasket to the cylinder head cover.

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

NOTICE:

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

(d) Install the cylinder head cover washer with a new seal and 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.

46. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Install 5 new gaskets to the camshaft bearing caps (No. 2, No. 3).

(b) Install the cover gasket to the cylinder head cover.

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

NOTICE:

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

(d) Install the cylinder head cover washer with a new seal and 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.

47. INSTALL CAMSHAFT OIL CONTROL VALVE ASSEMBLY

(a) LH:

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

(2) Install the 2 O-rings to the 2 oil control valves.

(3) Install the 2 oil control valves with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) RH:

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

(2) Install the 2 O-rings to the 2 oil control valves.

(3) Install the 2 oil control valves with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

48. INSTALL CRANKSHAFT POSITION SENSOR

(a) Install the crankshaft position sensor with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

49. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR

(a) Install the sensor protector with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

50. INSTALL CAMSHAFT POSITION SENSOR

(a) Install the camshaft position sensor with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

51. INSTALL VVT SENSOR

(a) LH:

(1) Install the 2 VVT sensors with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) RH:

(1) Install the 2 VVT sensors with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

52. INSTALL SPARK PLUG

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

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

53. INSTALL OIL FILLER CAP HOUSING

(a) Align the protrusion of a new gasket with the cutout of the oil filler cap housing, and install the gasket to the housing.

(b) Install the cap housing with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

54. INSTALL OIL FILLER CAP SUB-ASSEMBLY

55. INSTALL CRANKSHAFT PULLEY

56. INSTALL OIL FILTER BRACKET

57. INSTALL OIL FILTER ELEMENT

    Precaution

    Removal

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