Toyota Tundra 2001-06

Valve Covers

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Removal & Installation



3.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercover
     

  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Air cleaner cap
     
    Mass Air Flow (MAF) meter and the resonator
     
    Actuator cable with the bracket, if equipped with cruise control
     
    Accelerator cable
     
    Throttle cable, if equipped with an automatic transmission
     
    Heater hose
     
    Upper radiator hose from the engine
     

  8.  
  9. Remove the power steering drive belt, as follows:
    1. Stretch the belt and loosen the fan pulley mounting nuts.
    2.  
    3. Loosen the lockbolt, pivot bolt and adjusting bolt and remove the drive belt from the engine.
    4.  

  10.  
  11. Remove or disconnect the following:

    Air conditioning drive belt, by loosening the idle pulley nut and adjusting bolt
     
    Loosen the alternator lockbolt, pivot bolt and adjusting bolt
     
    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 lines
     
    Compressor and move it aside without disconnecting the lines, if equipped with air conditioning
     
    Air conditioning bracket, if equipped with air conditioning
     
    Spark plug wires with the ignition coils
     
    Spark plugs
     
    Camshaft Position (CMP) sensor connector, from the No. 2 timing belt cover
     
    3 spark plug wire clamps from the No. 2 timing belt cover
     
    6 bolts and the timing belt cover
     
    Power steering adjusting strut by removing the nut
     
    Fan bracket by removing the bolt and nut
     

  12.  
  13. Set the No. 1 cylinder at Top Dead Center (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. 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.  

  14.  
  15. Remove or disconnect the following:

    Timing belt tensioner, by alternately loosening the 2 bolts
     
    Pulley bolt, the timing pulley and the knock pin, using Variable Pin Wrench Set 09960-10010
     
    Both timing pulleys with the timing belt
     
    No. 2 idler pulley
     
    Alternator
     
    Positive Crankcase Ventilation PCV hoses
     
    Water bypass hoses
     
    Air assist hose from the intake air connector
     
    2 vacuum sensing hoses from the Vacuum Switching Valve (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
     
    4 bolts, 2 nuts and the air intake chamber assembly
     
    Intake air connector
     
    Camshaft Position (CMP) sensor
     
    No. 3 (rear) timing belt cover by removing the 6 bolts
     
    8 bolts, seal washers, both cylinder head cover and gaskets
     

  16.  

To install:

  1. Install or connect the following:
    NOTE
    Check that the pulley bracket moves smoothly.



    Cylinder head covers. Tighten the bolts, in several passes, to 53 inch lbs. (6 Nm).
     
    Alternator bracket. Tighten the bolts to 14 ft. lbs. (18 Nm).
     
    No. 3 timing belt cover. Tighten the 6 bolts to 80 inch lbs. (9 Nm).
     
    CMP sensor. Tighten it to 71 inch lbs. (8 Nm).
     
    Intake air connector
     
    Hoses
     
    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).
     

  2.  
  3. Install the left camshaft timing pulley, as follows:
    1. Install the knock pin to the camshaft.
    2.  
    3. Align the knock pin hose of the camshaft with the knock pin groove of the timing pulley.
    4.  
    5. Slide the timing pulley on the camshaft with the flange side facing outward. Tighten the pulley bolt to 81 ft. lbs. (110 Nm).
    6.  

  4.  
  5. Set the No. 1 cylinder to 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. 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.  

  6.  
  7. 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 or equivalent, 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.  

  8.  
  9. 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.
    6.  
    7. Install the knock pin. Tighten the bolt to 81 ft. lbs. (110 Nm).
    8.  

  10.  
  11. 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.  

  12.  
  13. Install the timing belt tensioner and alternately tighten the bolts to 20 ft. lbs. (28 Nm). Using pliers, remove the 1.5mm hexagon wrench from the belt tensioner.
  14.  
  15. Check the valve timing, as follows:
    1. Slowly turn the crankshaft pulley 2 revolutions from the TDC-to-TDC. Always turn the crankshaft pulley clockwise.
    2.  
    3. Check that each pulley aligns with the timing marks. If the timing marks do not align, remove the timing belt and reinstall it.
    4.  

  16.  
  17. Install or connect the following:

    Fan bracket with the bolt and nut
     
    Power steering adjusting strut with the nut
     
    No. 2 timing belt cover. Tighten the bolts to 80 inch lbs. (9 Nm).
     
    Negative battery cable
     

  18.  
  19. Fill the radiator with engine coolant.
  20.  
  21. Start the engine and check for leaks.
  22.  
  23. Check the ignition timing.
  24.  
  25. Install the engine undercover.
  26.  
  27. Road test the vehicle.
  28.  
  29. Recheck all fluid levels.
  30.  

4.0L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect cable from negative battery terminal.
  4.  
  5. Drain engine coolant.
  6.  
  7. Remove v-bank cover.
  8.  
  9. Remove air cleaner assembly.
  10.  
  11. Disconnect the 2 water by-pass hoses.
  12.  
  13. Disconnect the fuel vapor feed hose.
  14.  
  15. Disconnect the ventilation hose.
  16.  
  17. Disconnect the 2 VSV connectors.
  18.  
  19. Disconnect the throttle body w/ motor connector.
  20.  
  21. Separate the 3 wire harness clamps and hose clamp.
  22.  
  23. Remove the nut, then separate the clutch flexible hose bracket from the surge tank stay (w/ Manual Transmission).
  24.  
  25. Remove the 2 bolts and throttle body bracket.
  26.  
  27. Remove the bolt and oil baffle plate.
  28.  
  29. Remove the 4 bolts and 2 surge tank stays.
  30.  
  31. Remove the 2 nuts.
  32.  
  33. Remove the 4 bolts, intake air surge tank and gasket.
  34.  
  35. Disconnect the 3 connectors.
  36.  
  37. Remove the 3 bolts, then remove the 3 ignition coils.
  38.  
  39. Remove the 10 bolts, 3 seal washers, 2 nuts, right cylinder head cover and gasket.
  40.  
  41. Remove the 10 bolts, 3 seal washers, 2 nuts, left cylinder head cover and gasket.
  42.  

To install:

  1. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head covers.
  2.  
  3. Install the cylinder head covers within 3 minutes of applying seal packing Part No. 08826-00080 or equivalent. Tighten the cylinder head cover bolts and nuts within 15 minutes of installing the cylinder head covers. Otherwise, the seal packing mush be removed and reapplied.
  4.  
  5. Install the seal washers onto the bolts.

    Click image to see an enlarged view

    Fig. Right valve cover bolt identification-1GR-FE



    Click image to see an enlarged view

    Fig. Left valve cover bolt identification-1GR-FE

  6.  
  7. Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps as follows:
    1. Bolts labeled A: 10 Nm (7.4 ft. lbs.)
    2.  
    3. Bolts labeled B: 9.0 Nm (80 in. lbs.)
    4.  
    5. Nuts: 9.0 Nm (80 in. lbs.)
    6.  

  8.  
  9. Install the ignition coils and tighten the bolts to 10 Nm (7.4 ft. lbs.)
  10.  
  11. Install a new gasket onto the intake air surge tank.
  12.  
  13. Install the intake air surge tank with the 4 bolts and tighten to 28 Nm (21 ft. lbs)
  14.  
  15. Install the 2 intake air surge tank nuts and tighten to 28 Nm (21 ft. lbs)
  16.  
  17. Install the 2 surge tank stays with the 4 bolts and tighten to 21 Nm (15 ft. lbs)
  18.  
  19. Install the oil baffle plate with the bolt and tighten to 9.0 Nm (80 in. lbs.)
  20.  
  21. Install the throttle body bracket with the 2 bolts and tighten to 21 Nm (15 ft. lbs)
  22.  
  23. Install the clutch flexible hose bracket with the nut (w/ Manual Transmission) and tighten to 24 Nm (18 ft. lbs)
  24.  
  25. Install the 3 wire harness clamps and hose clamp.
  26.  
  27. Connect the throttle body w/ motor connector.
  28.  
  29. Connect the 2 VSV connectors.
  30.  
  31. Connect the ventilation hose.
  32.  
  33. Connect the fuel vapor feed hose.
  34.  
  35. Connect the 2 water by-pass hoses.
  36.  
  37. Install air cleaner assembly.
  38.  
  39. Connect cable to negative battery terminal.
  40.  
  41. Add engine coolant.
  42.  
  43. Check for engine coolant leakage.
  44.  
  45. Install the V-bank cover with the 2 nuts and tighten to 7.5 Nm (66 in. lbs.)
  46.  

4.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove battery clamp cover.
  4.  
  5. Remove throttle body cover.
  6.  
  7. Remove air cleaner and intake air connector assembly.
  8.  
  9. Remove ignition coils.
  10.  
  11. Remove the 9 bolts, seal washers and the right cylinder head cover.
  12.  
  13. Remove the oil dipstick for the transmission.
  14.  
  15. Disconnect the PCV hose.
  16.  
  17. Disconnect the engine wire clamp from the wire bracket on the cylinder head cover.
  18.  
  19. Remove the 9 bolts, 9 seal washers and the left cylinder head cover.
  20.  

To install:

  1. Installation is the reverse of the removal procedure. Install the valve covers with new gaskets and tighten the bolts to 6 Nm (53 in. lbs.).
  2.  

 
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