Toyota Tundra Service Manual: Installation

INSTALLATION

CAUTION / NOTICE / HINT

HINT:

Perform "Inspection After Repairs" after replacing the engine assembly, cylinder head sub-assembly RH, cylinder head sub-assembly LH, No. 1 camshaft sub-assembly, No. 2 camshaft sub-assembly, No. 3 camshaft sub-assembly, No. 4 camshaft sub-assembly, camshaft timing gear RH, camshaft timing gear LH, camshaft timing exhaust gear RH, camshaft timing exhaust gear LH, piston or piston ring (See page ).

PROCEDURE

1. REMOVE ENGINE FROM ENGINE STAND

(a) Install the 2 engine hangers with the 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 bolts and engine assembly from the engine stand.

2. INSTALL ENGINE ASSEMBLY

(a) Slowly lower the engine assembly into the engine compartment.

NOTICE:

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

(b) Attach the engine mounting insulators to the vehicle.

(c) Install the 4 engine mounting insulator bolts. Torque: 79 N·m {806 kgf·cm, 58 ft·lbf}

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

3. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

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

(b) Install the crankshaft angle sensor rotor.

Engine Side

HINT:

• Align the pin hole of the crankshaft angle sensor rotor with the pin of the crankshaft.
• As the crankshaft angle sensor rotor is not reversible, be sure to install it so that it is facing in the direction shown in the illustration.

(c) Install the drive plate and rear drive plate spacer onto the crankshaft.

*1	Drive Plate
*2	Rear Drive Plate Spacer
	Automatic Transmission Side

HINT:

As the rear drive plate spacer and the drive plate are not reversible, be sure to install them so that they are facing in the direction shown in the illustration.

(d) Install the drive plate and ring gear and bolts.

HINT:

The bolts are tightened in 2 progressive steps.

(1) Clean the bolts and bolt holes.

(2) Apply adhesive to 2 or 3 threads of the 8 bolts. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

*1 Adhesive

(3) Step 1: Install and uniformly tighten 10 new bolts in the sequence shown in the illustration. Torque: 30 N·m {306 kgf·cm, 22 ft·lbf} NOTICE: Do not reuse the drive plate installation bolts. Do not strike or damage the drive plate installation bolts. Be sure to handle them carefully.

(4) Mark the top of each drive plate installation bolt with paint.

(5) Step 2:

Tighten the drive plate installation bolts 90° as shown in the illustration.

(6) Check that the painted marks are now at a 90° angle to the top.

NOTICE:

Do not start the engine for at least an hour after installing the drive plate.

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

5. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR (for 2WD)

6. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

(a) for 2WD:

Refer to the following procedures (See page ).

(b) for 4WD:

Refer to the following procedures (See page ).

7. INSTALL STARTER ASSEMBLY

8. INSTALL STARTER COVER

9. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

10. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

11. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

12. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

13. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

14. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

15. CONNECT NO. 1 WATER BY-PASS PIPE

(a) Connect the No. 1 water by-pass pipe with the 3 bolts. Torque: 18 N·m {184 kgf·cm, 13 ft·lbf}

16. INSTALL EXHAUST PIPE ASSEMBLY

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

17. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)

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

18. INSTALL PROPELLER SHAFT ASSEMBLY

(a) for 2WD:

Refer to the following procedures (See page ).

(b) for 4WD:

Refer to the following procedures (See page ).

19. INSTALL GENERATOR ASSEMBLY

20. CONNECT VANE PUMP ASSEMBLY

21. CONNECT COOLER COMPRESSOR ASSEMBLY

22. CONNECT WIRE HARNESS AND HOSE

(a) Connect the 2 connectors and 2 clips to the engine room junction block.

(b) Install the engine wire with the nut. Then connect the 2 clips.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

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

(d) Install the ground wire with the bolt.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(e) Connect the cable to the positive (+) battery terminal.

(f) Install the wire to the positive (+) battery cable with the nut.

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

(g) Connect the air injection system hose.

(h) Install the connector bracket with the nut.

Torque:

6.0 N·m {61 kgf·cm, 53 in·lbf}

(i) Connect the 2 clamps and air pump connector.

(j) Connect the clamp and ground wire with the bolt.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(k) Connect the 4 connectors to the connector holder block.

(l) Connect the 2 heater hoses.

(m) Connect the No. 4 water by-pass hose.

(n) Connect the ECM connector and clamp. HINT: Refer to the following procedures to connect the ECM connector (See page ).

23. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY

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

24. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Connect the No. 1 fuel pipe (See page ).

(b) Install the fuel pipe clamp.

25. INSTALL INTAKE MANIFOLD

26. INSTALL AIR TUBE SUB-ASSEMBLY LH

27. INSTALL VENTILATION HOSE ASSEMBLY

28. INSTALL EGR VALVE BRACKET

29. INSTALL EGR VALVE ASSEMBLY

30. CONNECT NO. 13 WATER BY-PASS HOSE

31. CONNECT NO. 12 WATER BY-PASS HOSE

32. INSTALL RADIATOR ASSEMBLY

33. INSTALL FAN SHROUD

34. INSTALL FAN AND GENERATOR V BELT

35. INSTALL RADIATOR SIDE DEFLECTOR LH

36. INSTALL RADIATOR SIDE DEFLECTOR RH

37. INSTALL RADIATOR GRILLE SUB-ASSEMBLY

38. CONNECT OUTLET RADIATOR HOSE

39. INSTALL INLET RADIATOR HOSE

40. INSTALL FRONT FENDER APRON SEAL REAR LH

41. INSTALL FRONT FENDER APRON SEAL LH

42. INSTALL FRONT FENDER APRON SEAL REAR RH

43. INSTALL FRONT FENDER APRON SEAL RH

44. INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY

45. INSTALL AIR CLEANER ASSEMBLY

(a) Install the air cleaner case with the 2 bolts. Torque: 5.0 N·m {51 kgf·cm, 44 in·lbf}

(b) Install the air cleaner element to the air cleaner case.

(c) Install the air cleaner cap. (1) for Type A: Install the air cleaner cap and fasten the 4 hook clamps. (2) for Type B: Install the air cleaner cap and fasten the 2 hook clamps. (3) Connect the MAF meter connector. (4) Attach the wire harness clamp.

46. INSTALL AIR CLEANER HOSE ASSEMBLY

(a) Install the air cleaner hose with the 2 clamps. Torque: 4.0 N·m {41 kgf·cm, 35 in·lbf}

(b) Connect the ventilation hose and vacuum sensing hose.

47. ADD ENGINE OIL

48. ADD ENGINE COOLANT

49. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

50. INSPECT FOR OIL LEAK

51. INSPECT FOR COOLANT LEAK

52. INSPECT FOR EXHAUST GAS LEAK

53. INSPECT FOR FUEL LEAK

54. INSPECT SHIFT LEVER POSITION

(a) for Column Shift:

Refer to the following procedures (See page ).

(b) for Floor Shift:

Refer to the following procedures (See page ).

55. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) Attach the 2 V-bank cover hooks to the bracket. Then align the 2 V-bank cover grommets with the 2 pins, and press down on the V-bank cover to attach the pins.

56. INSTALL HOOD SUB-ASSEMBLY

(a) Install the hood with the 4 bolts. Torque: 13 N·m {133 kgf·cm, 10 ft·lbf}

(b) Attach the lower part of the 2 hood supports to the hood support bolt ball joints.

CAUTION:

Install the hood support while supporting the hood by hand.

(c) Attach the hood support clips.

NOTICE:

Check that the hood support is engaged in the ball joint and that it cannot be pulled out.

57. ADJUST HOOD SUB-ASSEMBLY

58. INSTALL NO. 1 ENGINE UNDER COVER

59. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY

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

60. INSPECT IGNITION TIMING

61. INSPECT ENGINE IDLE SPEED

62. INSPECT CO/HC

63. CHECK ENGINE OIL LEVEL

64. CHECK ENGINE COOLANT LEVEL