Toyota Tundra 2001-06

Cylinder Head 1

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Removal & Installation



3.4L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove the engine undercover.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove or disconnect the following:

    Front exhaust pipe
     
    Air cleaner cap
     
    Mass Air Flow (MAF) meter and resonator
     

  12.  
  13. Disconnect the following cables:

    Actuator cable from the bracket, if equipped with cruise control
     
    Accelerator cable
     
    Throttle cable, if equipped with an automatic transmission
     
    Heater hose
     
    Upper radiator hose
     
    Power steering drive belt
     
    Air conditioning drive belt, by loosening the idle pulley nut and adjusting bolt
     
    Loosen the lockbolt, pivot bolt and adjusting bolt and the alternator drive belt
     
    No. 2 fan shroud by removing the 2 clips
     
    Fan with the fluid coupling and fan pulleys
     
    Power steering pump and move it aside without disconnecting the pump lines
     
    Compressor and move it aside without disconnecting the compressor lines, if equipped with air conditioning
     
    Air conditioning bracket, if equipped with air conditioning
     
    Spark plug wires with the ignition coils
     
    Spark plugs
     
    No. 2 timing belt cover
     

  14.  
  15. Remove the fan bracket, as follows:
    1. Remove the power steering adjusting strut by removing the nut.
    2.  
    3. Remove the fan bracket by removing the bolt and nut.
    4.  

  16.  
  17. Set the No. 1 cylinder at Top Dead Center (TDC) of the compression stroke.
    1. Turn the crankshaft pulley and align its groove with the timing mark0
    2.  
    3. Check that the timing marks of the camshaft timing pulleys and the No. 3 timing belt cover are aligned. If not, turn the crankshaft pulley 1 revolution (360 degrees).
    4.  

  18.  
  19. Remove the timing belt tensioner by alternately loosening the 2 bolts.
  20.  
  21. Remove the camshaft timing pulleys, as follows:
    1. Using Variable Pin Wrench Set tool 09960-10010, remove the pulley bolt, the timing pulley and the knock pin.
    2.  
    3. Remove the 2 timing pulleys with the timing belt.
    4.  

  22.  
  23. Remove or disconnect the following:

    Bolt and the No. 2 idler pulley
     
    Alternator
     

  24.  
  25. Remove the Exhaust Gas Recirculation (EGR) pipe and 2 gaskets, if equipped with an EGR valve
  26.  
  27. Remove the intake chamber stay as follows:
    1. Remove the oil filler tube and No. 1 throttle cable clamp by removing the bolt and 2 nuts.
    2.  
    3. Remove the intake chamber stay by removing the 2 bolts.
    4.  

  28.  
  29. Remove the following connectors:

    VSV connector for the fuel pressure control.
     
    Throttle position sensor
     
    IAC valve connector
     
    EGR valve gas temperature sensor, if equipped
     
    Vacuum Switching Valve (VSV) connector for the EGR valve, if equipped
     

  30.  
  31. Disconnect the following hoses:

    Positive Crankcase Ventilation (PCV) hoses
     
    Water bypass hoses.
     
    Air assist hose from the intake air connector
     
    2 vacuum sensing hoses from the VSV
     
    Evaporative Emissions (EVAP) hose
     
    Air hose, from the power steering
     
    Air hose from the air conditioning idle up valve, if equipped with air conditioning
     

  32.  
  33. Remove or disconnect the following:

    4 bolts, 2 nuts and the air intake chamber assembly
     
    Intake air connector
     

  34.  
  35. Disconnect the engine wiring harness from the intake manifold, as follows:

    Oil pressure sensor connector
     
    Crankshaft position sensor connector
     
    6 injector connectors
     
    Engine Coolant Temperature (ECT) sender gauge connector
     
    ECT sensor connector
     
    Knock (KS) sensor connector
     
    Camshaft Position (CMP) sensor connector
     
    3 engine wiring harness clamps
     
    3 bolts and the engine wiring harness from the cylinder head
     

  36.  
  37. Remove or disconnect the following:

    CMP sensor
     
    No. 3 (rear) timing belt cover, by removing the 6 bolts
     



    Click image to see an enlarged view

    Fig. Rear timing belt cover bolt locations-3.4L engine



    Click image to see an enlarged view

    Fig. Intake manifold bolts and nuts locations-3.4L engine



    Fuel pressure regulator
     
    Intake manifold assembly
     
    Power steering pump bracket
     
    Oil dipstick and guide
     
    Exhaust crossover pipe and gaskets, by removing the 6 nuts
     
    Left-hand exhaust manifold, by removing the heat insulator and 6 nuts
     
    Right-hand exhaust manifold, by removing the heat insulator and 6 nuts
     
    8 bolts, seal washers, cylinder head cover and gasket
     
    Both cylinder head covers
     
    Semi-circular plugs
     
    Right exhaust camshafts
     
    Right-hand intake camshaft
     
    Left exhaust camshafts
     



    Click image to see an enlarged view

    Fig. Drive gear service bolt (right side)-3.4L engine



    Click image to see an enlarged view

    Fig. Aligning the timing mark (1 dot mark) of the left camshafts-3.4L engine



    Click image to see an enlarged view

    Fig. Drive gear service bolt (left side)-3.4L engine



    Left-hand intake camshaft
     
    Valve lifters and shims from the cylinder head; arrange the valve lifters and shims in correct order
     

  38.  
  39. Remove the cylinder heads, as follows:

    Bolt and disconnect the ground strap
     
    Cylinder head (recessed head) bolt on each cylinder head, using an 8mm hexagon wrench; then repeat for the other side
     
    8 cylinder head (12-pointed head) bolts on each cylinder head, by loosening the bolts in several passes and in the reverse order of the tightening sequence
     
    16 cylinder head bolts and plate washers.
     
    Cylinder head
     

  40.  


    Click image to see an enlarged view

    Fig. Cylinder head recessed bolts-3.4L engine


To install:



Click image to see an enlarged view

Fig. Cylinder head torque sequence-3.4L (5VZ-FE) engine

  1. Clean all surfaces.
  2.  
  3. Install or connect the following:

    New cylinder head gaskets
     
    Cylinder heads
     

  4.  
  5. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
  6.  
  7. Tighten the cylinder head bolts, in sequence, using several passes, as follows:

    Step 1: 25 ft. lbs. (34 Nm)
     
    Step 2: Mark the front of the cylinder head bolt with paint
     
    Step 3: An additional 90 degrees
     
    Step 4: Check that the painted mark is now at a 90 degrees angle to the front
     

  8.  
  9. Install the recessed head cylinder head bolts, as follows:

    Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts
     
    Cylinder head bolt on each cylinder head, using a 8mm hexagon wrench; then, repeat for the other side, as shown. Tighten the bolts to 13 ft. lbs. (18 Nm).
     
    Bolt and the ground strap
     

  10.  
  11. Install or connect the following:

    Valve lifters and shims
     

  12.  


NOTE
Check that the valve lifter rotates smoothly by hand.



Camshafts
 


Click image to see an enlarged view

Fig. Aligning the right camshafts for installation-3.4L engine

Check and adjust the valve clearance
 
Semi-circular plugs
 
Cylinder head covers. Tighten the bolts, in several passes, to 53 inch lbs. (6 Nm).
 
Exhaust manifolds, with new gaskets. Tighten the nuts to 30 ft. lbs. (40 Nm).
 
Exhaust manifold heat insulators. Tighten the nuts to 71 inch lbs. (8 Nm).
 
Exhaust crossover pipe. Tighten the nuts to 33 ft. lbs. (45 Nm).
 
Alternator bracket. Tighten to 14 ft. lbs. (18 Nm).
 
Oil dipstick and guide, using a new O-ring
 
Power steering bracket. Tighten the fasteners to 14 ft. lbs. (18 Nm).
 
New gaskets and the intake manifold assembly. Tighten the bolts and nuts to 13 ft. lbs. (18 Nm).
 
Intake manifold stay with the 2 bolts. Tighten the bolts to 14 ft. lbs. (18 Nm).
 
Fuel inlet hose
 
Fuel pressure regulator
 
No. 3 timing belt cover. Tighten the bolts to 80 inch lbs. (9 Nm).
 
CMP sensor. Tighten to 71 inch lbs. (8 Nm).
 
Engine wiring harness
 

  1. Install or connect the intake air connector, as follows:

    Intake manifold. Tighten the bolts and nuts to 14 ft. lbs. (19 Nm).
     
    DLC1 to the bracket on the intake manifold
     
    Ground strap to the intake manifold
     
    Brake booster vacuum hose to the intake air connector
     
    2 fuel return hoses
     
    Engine wiring harness to the intake manifold
     
    Idle up valve connector, if equipped with air conditioning
     

  2.  
  3. Install or connect the following:

    Air intake chamber assembly. Tighten the bolts and nuts to 14 ft. lbs. (18.5 Nm).
     
    Hoses
     

  4.  
  5. Attach the following connectors:

    VSV connector for the fuel pressure control
     
    TP sensor connector
     
    IAC valve connector
     
    EGR gas temperature connector, if equipped with an EGR valve
     
    VSV connector, if equipped with an EGR valve
     
    Intake chamber stay
     
    New gaskets and the EGR pipe. Tighten the clamp nuts to 71 inch lbs. (8 Nm) and the EGR pipe nuts to 14 ft. lbs. (18 Nm).
     
    Alternator but do not tighten the bolts and nuts at this time.
     
    No. 2 timing belt idler. Tighten the bolt to 30 ft. lbs. (40 Nm).
     

  6.  


NOTE
Check that the pulley bracket moves smoothly.



Left camshaft timing pulley
 

  1. Set the No. 1 cylinder to TDC of the compression stroke, as follows:
    1. Turn the crankshaft pulley and align its groove with the timing mark0
    2.  
    3. Turn the camshaft, align the knock pin hole of the camshaft with the timing mark of the No. 3 timing belt cover.
    4.  
    5. Turn the camshaft timing pulley, align the timing marks of the camshaft timing pulley and the No. 3 timing belt cover.
    6.  

  2.  
  3. Connect the timing belt to the left camshaft timing pulley, as follows:
    1. Check that the installation mark on the timing belt is aligned with the end of the No. 1 timing belt cover.
    2.  
    3. Using Variable Pin Wrench Set 09960-01000, slightly turn the left camshaft timing pulley clockwise. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the left camshaft timing pulley.
    4.  
    5. Align the timing marks of the left camshaft pulley and the No. 3 timing belt cover.
    6.  
    7. Check that the timing belt has tension between the crankshaft timing pulley and the left camshaft timing pulley.
    8.  

  4.  
  5. Install the right camshaft timing pulley and the timing belt, as follows:
    1. Align the installation mark on the timing belt with the timing mark of the right camshaft timing pulley, and hang the timing belt on the right camshaft timing pulley with the flange side facing inward.
    2.  
    3. Slide the right camshaft timing pulley on the camshaft. Align the timing marks on the right camshaft timing pulley and the No. 3 timing belt cover.
    4.  
    5. Align the knock pin hole of the camshaft with the knock pin groove of the pulley and install the knock pin. Install the bolt and tighten to 81 ft. lbs. (110 Nm).
    6.  

  6.  
  7. Set the timing belt tensioner as follows:
    1. Using a press, slowly press in the pushrod using 220-2,205 lbs. (981-9,807 N) of force.
    2.  
    3. Align the holes of the pushrod and housing, pass a 1.5mm hexagon wrench through the holes to keep the setting position of the pushrod.
    4.  
    5. Release the press and install the dust boot to the tensioner.
    6.  

  8.  
  9. Install the timing belt tensioner. Tighten the bolts alternately to 20 ft. lbs. (28 Nm).
  10.  
  11. Using pliers, remove the 1.5mm hexagon wrench from the belt tensioner.
  12.  
  13. Check the valve timing.
  14.  
  15. Install or connect the following:

    Remaining components
     
    Negative battery cable
     

  16.  
  17. Fill the radiator with engine coolant.
  18.  
  19. Start the engine and check for leaks.
  20.  
  21. Check the ignition timing.
  22.  
  23. Install the engine undercover.
  24.  
  25. Road test the vehicle.
  26.  
  27. Recheck all fluid levels.
  28.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove the engine undercover.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove or disconnect the following:

    Front exhaust pipe
     
    Air cleaner cap
     
    Mass Air Flow (MAF) meter and resonator
     

  12.  
  13. Disconnect the following cables:

    Actuator cable from the bracket, if equipped with cruise control
     
    Accelerator cable
     
    Throttle cable, if equipped with an automatic transmission
     
    Heater hose
     
    Upper radiator hose
     
    Power steering drive belt
     
    Air conditioning drive belt, by loosening the idle pulley nut and adjusting bolt
     
    Loosen the lockbolt, pivot bolt and adjusting bolt and the alternator drive belt
     
    No. 2 fan shroud by removing the 2 clips
     
    Fan with the fluid coupling and fan pulleys
     
    Power steering pump and move it aside without disconnecting the pump lines
     
    Compressor and move it aside without disconnecting the compressor lines, if equipped with air conditioning
     
    Air conditioning bracket, if equipped with air conditioning
     
    Spark plug wires with the ignition coils
     
    Spark plugs
     
    No. 2 timing belt cover
     

  14.  
  15. Remove the fan bracket, as follows:
    1. Remove the power steering adjusting strut by removing the nut.
    2.  
    3. Remove the fan bracket by removing the bolt and nut.
    4.  

  16.  
  17. Set the No. 1 cylinder at Top Dead Center (TDC) of the compression stroke.
    1. Turn the crankshaft pulley and align its groove with the timing mark 0 on the No. 1 timing belt cover.
    2.  
    3. Check that the timing marks of the camshaft timing pulleys and the No. 3 timing belt cover are aligned. If not, turn the crankshaft pulley 1 revolution (360 degrees).
    4.  

  18.  
  19. Remove the timing belt tensioner by alternately loosening the 2 bolts.
  20.  
  21. Remove the camshaft timing pulleys, as follows:
    1. Using Variable Pin Wrench Set tool 09960-10010, remove the pulley bolt, the timing pulley and the knock pin.
    2.  
    3. Remove the 2 timing pulleys with the timing belt.
    4.  

  22.  
  23. Remove or disconnect the following:

    Bolt and the No. 2 idler pulley
     
    Alternator
     

  24.  
  25. Remove the Exhaust Gas Recirculation (EGR) pipe and 2 gaskets, if equipped with an EGR valve
  26.  
  27. Remove the intake chamber stay as follows:
    1. Remove the oil filler tube and No. 1 throttle cable clamp by removing the bolt and 2 nuts.
    2.  
    3. Remove the intake chamber stay by removing the 2 bolts.
    4.  

  28.  
  29. Remove the following connectors:

    VSV connector for the fuel pressure control.
     
    Throttle position sensor
     
    IAC valve connector
     
    EGR valve gas temperature sensor, if equipped
     
    Vacuum Switching Valve (VSV) connector for the EGR valve, if equipped
     

  30.  
  31. Disconnect the following hoses:

    Positive Crankcase Ventilation (PCV) hoses
     
    Water bypass hoses.
     
    Air assist hose from the intake air connector
     
    2 vacuum sensing hoses from the VSV
     
    Evaporative Emissions (EVAP) hose
     
    Air hose, from the power steering
     
    Air hose from the air conditioning idle up valve, if equipped with air conditioning
     

  32.  
  33. Remove or disconnect the following:

    4 bolts, 2 nuts and the air intake chamber assembly
     
    Intake air connector
     

  34.  
  35. Disconnect the engine wiring harness from the intake manifold, as follows:

    Oil pressure sensor connector
     
    Crankshaft position sensor connector
     
    6 injector connectors
     
    Engine Coolant Temperature (ECT) sender gauge connector
     
    ECT sensor connector
     
    Knock (KS) sensor connector
     
    Camshaft Position (CMP) sensor connector
     
    3 engine wiring harness clamps
     
    3 bolts and the engine wiring harness from the cylinder head
     

  36.  
  37. Remove or disconnect the following:

    CMP sensor
     
    No. 3 (rear) timing belt cover, by removing the 6 bolts

    Click image to see an enlarged view

    Fig. Rear timing belt cover bolt locations-3.4L engine



    Click image to see an enlarged view

    Fig. Intake manifold bolts and nuts locations-3.4L engine

     



    Fuel pressure regulator
     
    Intake manifold assembly
     
    Power steering pump bracket
     
    Oil dipstick and guide
     
    Exhaust crossover pipe and gaskets, by removing the 6 nuts
     
    Left-hand exhaust manifold, by removing the heat insulator and 6 nuts
     
    Right-hand exhaust manifold, by removing the heat insulator and 6 nuts
     
    8 bolts, seal washers, cylinder head cover and gasket
     
    Both cylinder head covers
     
    Semi-circular plugs
     
    Right exhaust camshafts
     
    Right-hand intake camshaft
     
    Left exhaust camshafts

    Click image to see an enlarged view

    Fig. Drive gear service bolt (right side)-3.4L engine



    Click image to see an enlarged view

    Fig. Aligning the timing mark (1 dot mark) of the left camshafts-3.4L engine



    Click image to see an enlarged view

    Fig. Drive gear service bolt (left side)-3.4L engine

     



    Left-hand intake camshaft
     
    Valve lifters and shims from the cylinder head; arrange the valve lifters and shims in correct order
     

  38.  
  39. Remove the cylinder heads, as follows:

    Bolt and disconnect the ground strap
     
    Cylinder head (recessed head) bolt on each cylinder head, using an 8mm hexagon wrench; then repeat for the other side
     
    8 cylinder head (12-pointed head) bolts on each cylinder head, by loosening the bolts in several passes and in the reverse order of the tightening sequence
     
    16 cylinder head bolts and plate washers.
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head recessed bolt location-3.4L engine

     

  40.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-3.4L engine

  1. Clean all surfaces.
  2.  
  3. Install or connect the following:

    New cylinder head gaskets
     
    Cylinder heads
     

  4.  
  5. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
  6.  
  7. Tighten the cylinder head bolts, in sequence, using several passes, as follows:

    Step 1: 25 ft. lbs. (34 Nm)
     
    Step 2: Mark the front of the cylinder head bolt with paint
     
    Step 3: An additional 90 degrees
     
    Step 4: Check that the painted mark is now at a 90 degrees angle to the front
     

  8.  
  9. Install the recessed head cylinder head bolts, as follows:

    Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts
     
    Cylinder head bolt on each cylinder head, using a 8mm hexagon wrench; then, repeat for the other side, as shown. Tighten the bolts to 13 ft. lbs. (18 Nm).
     
    Bolt and the ground strap
     

  10.  
  11. Install or connect the following:
    NOTE
    Check that the valve lifter rotates smoothly by hand.



    Valve lifters and shims
     



    Camshafts

    Click image to see an enlarged view

    Fig. Aligning the right camshafts for installation-3.4L engine

     
    Check and adjust the valve clearance
     
    Semi-circular plugs
     
    Cylinder head covers. Tighten the bolts, in several passes, to 53 inch lbs. (6 Nm).
     
    Exhaust manifolds, with new gaskets. Tighten the nuts to 30 ft. lbs. (40 Nm).
     
    Exhaust manifold heat insulators. Tighten the nuts to 71 inch lbs. (8 Nm).
     
    Exhaust crossover pipe. Tighten the nuts to 33 ft. lbs. (45 Nm).
     
    Alternator bracket. Tighten to 14 ft. lbs. (18 Nm).
     
    Oil dipstick and guide, using a new O-ring
     
    Power steering bracket. Tighten the fasteners to 14 ft. lbs. (18 Nm).
     
    New gaskets and the intake manifold assembly. Tighten the bolts and nuts to 13 ft. lbs. (18 Nm).
     
    Intake manifold stay with the 2 bolts. Tighten the bolts to 14 ft. lbs. (18 Nm).
     
    Fuel inlet hose
     
    Fuel pressure regulator
     
    No. 3 timing belt cover. Tighten the bolts to 80 inch lbs. (9 Nm).
     
    CMP sensor. Tighten to 71 inch lbs. (8 Nm).
     
    Engine wiring harness
     

  12.  
  13. Install or connect the intake air connector, as follows:

    Intake manifold. Tighten the bolts and nuts to 14 ft. lbs. (19 Nm).
     
    DLC1 to the bracket on the intake manifold
     
    Ground strap to the intake manifold
     
    Brake booster vacuum hose to the intake air connector
     
    2 fuel return hoses
     
    Engine wiring harness to the intake manifold
     
    Idle up valve connector, if equipped with air conditioning
     

  14.  
  15. Install or connect the following:

    Air intake chamber assembly. Tighten the bolts and nuts to 14 ft. lbs. (18.5 Nm).
     
    Hoses
     

  16.  
  17. Attach the following connectors:
    NOTE
    Check that the pulley bracket moves smoothly.



    VSV connector for the fuel pressure control
     
    TP sensor connector
     
    IAC valve connector
     
    EGR gas temperature connector, if equipped with an EGR valve
     
    VSV connector, if equipped with an EGR valve
     
    Intake chamber stay
     
    New gaskets and the EGR pipe. Tighten the clamp nuts to 71 inch lbs. (8 Nm) and the EGR pipe nuts to 14 ft. lbs. (18 Nm).
     
    Alternator but do not tighten the bolts and nuts at this time.
     
    No. 2 timing belt idler. Tighten the bolt to 30 ft. lbs. (40 Nm).
     



    Left camshaft timing pulley
     

  18.  
  19. Set the No. 1 cylinder to TDC of the compression stroke, as follows:
    1. Turn the crankshaft pulley and align its groove with the timing mark 0 on the No. 1 timing belt cover.
    2.  
    3. Turn the camshaft, align the knock pin hole of the camshaft with the timing mark of the No. 3 timing belt cover.
    4.  
    5. Turn the camshaft timing pulley, align the timing marks of the camshaft timing pulley and the No. 3 timing belt cover.
    6.  

  20.  
  21. Connect the timing belt to the left camshaft timing pulley, as follows:
    1. Check that the installation mark on the timing belt is aligned with the end of the No. 1 timing belt cover.
    2.  
    3. Using Variable Pin Wrench Set 09960-01000, slightly turn the left camshaft timing pulley clockwise. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the left camshaft timing pulley.
    4.  
    5. Align the timing marks of the left camshaft pulley and the No. 3 timing belt cover.
    6.  
    7. Check that the timing belt has tension between the crankshaft timing pulley and the left camshaft timing pulley.
    8.  

  22.  
  23. Install the right camshaft timing pulley and the timing belt, as follows:
    1. Align the installation mark on the timing belt with the timing mark of the right camshaft timing pulley, and hang the timing belt on the right camshaft timing pulley with the flange side facing inward.
    2.  
    3. Slide the right camshaft timing pulley on the camshaft. Align the timing marks on the right camshaft timing pulley and the No. 3 timing belt cover.
    4.  
    5. Align the knock pin hole of the camshaft with the knock pin groove of the pulley and install the knock pin. Install the bolt and tighten to 81 ft. lbs. (110 Nm).
    6.  

  24.  
  25. Set the timing belt tensioner as follows:
    1. Using a press, slowly press in the pushrod using 220-2,205 lbs. (981-9,807 N) of force.
    2.  
    3. Align the holes of the pushrod and housing, pass a 1.5mm hexagon wrench through the holes to keep the setting position of the pushrod.
    4.  
    5. Release the press and install the dust boot to the tensioner.
    6.  

  26.  
  27. Install the timing belt tensioner. Tighten the bolts alternately to 20 ft. lbs. (28 Nm).
  28.  
  29. Using pliers, remove the 1.5mm hexagon wrench from the belt tensioner.
  30.  
  31. Check the valve timing.
  32.  
  33. Install or connect the following:

    Remaining components
     
    Negative battery cable
     

  34.  
  35. Fill the radiator with engine coolant.
  36.  
  37. Start the engine and check for leaks.
  38.  
  39. Check the ignition timing.
  40.  
  41. Install the engine undercover.
  42.  
  43. Road test the vehicle.
  44.  
  45. Recheck all fluid levels.
  46.  

4.0L Engine
Bank 1
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly discharge the fuel system pressure.
  4.  
  5. Properly disarm the SRS system.
  6.  
  7. Disconnect the negative battery cable. Disconnect the positive battery cable. Remove the battery.
  8.  
  9. Remove the V bank cover. Remove the number one engine undercover assembly.
  10.  
  11. Disconnect the number one fuel pipe subassembly. Disconnect the number two fuel pipe subassembly.
  12.  
  13. Remove the drive belt. Remove the radiator shroud and fan.
  14.  
  15. Drain the cooling system. Disconnect the upper and lower radiator hoses. As required, remove the radiator from the vehicle.
  16.  
  17. Remove the alternator. Disconnect the power steering pump and position it to the side. Disconnect the air conditioning compressor and position it to the side.
  18.  
  19. Remove the intake air surge tank. Remove the ignition coil assembly. Remove the VVT sensor.
  20.  
  21. Remove the camshaft timing oil control valve assembly. Remove the cylinder head covers. Remove the oil level gauge guide.
  22.  
  23. Disconnect the fuel injector connectors. Remove the ten intake manifold retaining bolts. Remove the intake manifold from the engine.
  24.  
  25. Disconnect the engine coolant temperature sensor connector. Disconnect the heater hose. Remove the two bolts and four nuts, and then remove the water bypass joint RR and two gaskets. Remove the O-ring from the water outlet hose.
  26.  
  27. Remove the oil control valve filter from the cylinder head.
  28.  
  29. Disconnect the two heated oxygen sensor connectors. Remove the front exhaust pipe retaining bolts. Remove the front exhaust pipe. Remove the front exhaust pipe subassembly. Remove the three bolts and remove the exhaust manifold stay.
  30.  
  31. Disconnect the air fuel ratio sensor connector. Remove the six nuts; remove the exhaust manifold and gasket.
  32.  
  33. Remove the belt tensioner assembly. Remove the timing chain.
  34.  
  35. While raising the chain tensioner number two, insert a 0.039 inch diameter pin, into the hole. Hold the hexagonal portion of the camshaft in place, using a wrench.
    NOTE
    Be careful not to damage the cylinder head and valve lifter with the wrench.

  36.  
  37. Remove the two bolts. Remove the camshaft timing gear, camshaft timing gear assembly and timing chain number two.
    NOTE
    Do not disassemble the camshaft timing gear assembly.

  38.  
  39. Remove the bolt and then remove the chain tensioner number two.
  40.  
  41. Remove the camshafts.
  42.  
  43. Remove the two bolts. Separate the two ground cables.
  44.  
  45. Loosen the cylinder head retaining bolts in several steps and in the proper removal sequence. Remove the bolts.
    NOTE
    Be careful not to drop the washers into the cylinder head. Head warpage and cracking could result in removing the bolts in the wrong order.

  46.  
  47. Lift the cylinder head from the dowels on the cylinder block and remove it from the engine.

    Click image to see an enlarged view

    Fig. Bank 1 cylinder head bolt loosening sequence-4.0L engine



    Click image to see an enlarged view

    Fig. Cylinder head gasket sealant application-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 1cylinder head gasket positioning-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 1 cylinder head bolt torque sequence-4.0L engine

  48.  

To install:

  1. Before installing, thoroughly clean the gasket mating surfaces and check for warpage. Remove any old packing material. Be careful not to drop any oil on the contact surfaces of the cylinder head or engine block.
  2.  
  3. Apply continuous beads of seal packing, part number 08826-00080 or equivalent, to the cylinder head gasket. Bead width should be 0.098-0.118 inch.
    NOTE
    Install the cylinder head gasket within three minutes after applying the seal packing. Install the cylinder head bolts within fifteen minutes after applying the seal packing.

  4.  
  5. Be sure to position the cylinder head gasket on the engine block with the lot number stamp facing upward.
    NOTE
    Be sure that the head gasket is installed in the correct direction. Position the gasket gently in order to avoid damaging the gasket with the bottom part of the cylinder head.

  6.  
  7. Apply a light coat of clean engine oil to the cylinder head bolts. Tighten the cylinder head bolts, in two successive steps, to specification and in the proper sequence.
    NOTE
    Replace defective bolts, as required.

  8.  
  9. Continue the installation in the reverse of the removal procedure.
  10.  
  11. Be sure to fill the cooling system with the proper grade and type engine coolant.
  12.  
  13. Be sure to fill the engine oil with the proper grade and type oil.
    NOTE
    Do not fill the engine with oil for at least four hours after the cylinder head has been installed.

  14.  
  15. Start the engine and check for leaks. Correct as required.
  16.  

Bank 2
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly discharge the fuel system pressure.
  4.  
  5. Properly disarm the SRS system.
  6.  
  7. Disconnect the negative battery cable. Disconnect the positive battery cable. Remove the battery.
  8.  
  9. Remove the V bank cover. Remove the number one engine undercover assembly.
  10.  
  11. Disconnect the number one fuel pipe subassembly. Disconnect the number two fuel pipe subassembly.
  12.  
  13. Remove the drive belt. Remove the radiator shroud and fan.
  14.  
  15. Drain the cooling system. Disconnect the upper and lower radiator hoses. As required, remove the radiator from the vehicle.
  16.  
  17. Remove the alternator. Disconnect the power steering pump and position it to the side. Disconnect the air conditioning compressor and position it to the side.
  18.  
  19. Remove the intake air surge tank. Remove the ignition coil assembly. Remove the VVT sensor.
  20.  
  21. Remove the camshaft timing oil control valve assembly. Remove the cylinder head covers. Remove the oil level gauge guide.
  22.  
  23. Disconnect the fuel injector connectors. Remove the ten intake manifold retaining bolts. Remove the intake manifold from the engine.
  24.  
  25. Disconnect the engine coolant temperature sensor connector. Disconnect the heater hose. Remove the two bolts and four nuts, and then remove the water bypass joint RR and two gaskets. Remove the O-ring from the water outlet hose.
  26.  
  27. Remove the oil control valve filter from the cylinder head.
  28.  
  29. Disconnect the two heated oxygen sensor connectors. Remove the front exhaust pipe retaining bolts. Remove the front exhaust pipe. Remove the front exhaust pipe subassembly. Remove the three bolts and remove the exhaust manifold stay.
  30.  
  31. Disconnect the air fuel ratio sensor connector. Remove the six nuts; remove the exhaust manifold and gasket.
  32.  
  33. Remove the belt tensioner assembly. Remove the timing chain.
  34.  
  35. Remove the two bolts and then remove the chain vibration damper number one.
  36.  
  37. While pushing down on chain tensioner number two, insert a 0.039 inch diameter pin, into the hole. Hold the hexagonal portion of the camshaft in place, using a wrench.
    NOTE
    Be careful not to damage the cylinder head and valve lifter with the wrench.

  38.  
  39. Remove the two bolts. Remove the camshaft timing gear, camshaft timing gear assembly and timing chain number two.
    NOTE
    Do not disassemble the camshaft timing gear assembly.

  40.  
  41. Remove the bolt and then remove the chain tensioner number three.
  42.  
  43. Remove the camshafts.
  44.  
  45. Remove the two bolts. Separate the two ground cables.
  46.  
  47. Loosen the cylinder head retaining bolts in several steps and in the proper removal sequence. Remove the bolts.
    NOTE
    Be careful not to drop the washers into the cylinder head. Head warpage and cracking could result in removing the bolts in the wrong order.

  48.  
  49. Lift the cylinder head from the dowels on the cylinder block and remove it from the engine.

    Click image to see an enlarged view

    Fig. Bank 2 recessed cylinder head bolt loosening sequence-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 2 cylinder head bolt loosening sequence-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 2 cylinder head gasket positioning-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 2 Cylinder head bolt torque sequence-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 2 recessed cylinder head bolt torque sequence-4.0L engine

  50.  

To install:

  1. Before installing, thoroughly clean the gasket mating surfaces and check for warpage. Remove any old packing material. Be careful not to drop any oil on the contact surfaces of the cylinder head or engine block.
  2.  
  3. Apply continuous beads of seal packing, part number 08826-00080 or equivalent, to the cylinder head gasket. Bead width should be 0.098-0.118 inch.
    NOTE
    Install the cylinder head gasket within three minutes after applying the seal packing. Install the cylinder head bolts within fifteen minutes after applying the seal packing.

  4.  
  5. Be sure to position the cylinder head gasket on the engine block with the lot number stamp facing upward.
    NOTE
    Be sure that the head gasket is installed in the correct direction. Position the gasket gently in order to avoid damaging the gasket with the bottom part of the cylinder head.

  6.  
  7. Apply a light coat of clean engine oil to the cylinder head bolts. Tighten the cylinder head bolts, in two successive steps, to specification and in the proper sequence.
    NOTE
    Replace defective bolts, as required.

  8.  
  9. Continue the installation in the reverse of the removal procedure.
  10.  
  11. Be sure to fill the cooling system with the proper grade and type engine coolant.
  12.  
  13. Be sure to fill the engine oil with the proper grade and type oil.
    NOTE
    Do not fill the engine with oil for at least four hours after the cylinder head has been installed.

  14.  
  15. Start the engine and check for leaks. Correct as required.

    Click image to see an enlarged view

    Fig. Cylinder head and related components-2001-2004 4.7L engine

  16.  

 
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