Camshaft (W/O Dpf) Removal

Loosen the radiator drain cock plug.

HINT:

Collect the coolant in a container and dispose of it according to the regulations in your area.

Drain the coolant by removing the radiator reservoir cap and, using a wrench, remove the vent plug.

Loosen the cylinder block drain cock plug.

Remove the oil filler cap.

Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

Wipe the oil pan and drain plug.

Install a new gasket and the oil pan drain plug.

Torque:

34 N*m{347 kgf*cm, 25 ft.*lbf}

Remove the 3 bolts and oil reservoir.

Disconnect the No. 1 and No. 2 water by-pass hoses from the radiator.

Remove the 2 bolts and radiator reservoir.

Loosen the 4 nuts holding the fluid coupling with fan.

Remove the fan and generator V belt (HILUX_TGN26 RM000001477016X_01_0001.html).

Remove the 2 bolts holding the fan shroud.

Remove the 4 nuts of the fluid coupling with fan, and then remove the fan shroud together with the fluid coupling with fan.

NOTICE:

Be careful not to damage the radiator core.

Remove the fan pulley from the water pump.

Remove the 3 bolts, 2 cap nuts and No. 1 engine cover.

Text in Illustration

Cap Nut

w/ EGR Cooler:

1. Disconnect the manifold absolute pressure sensor connector.
   

2. Disconnect the vacuum hose and detach the 2 clamps.
   

3. Remove the 2 bolts and manifold absolute pressure sensor.
   

w/o EGR Cooler:

1. Disconnect the manifold absolute pressure sensor connector and vacuum hose.
   

2. Remove the 2 bolts and manifold absolute pressure sensor.
   

Disconnect the intake air temperature sensor connector.

w/ Intercooler:
Using a 22 mm deep socket wrench, remove the intake air temperature sensor.

HINT:

Replace the intake air temperature sensor if it is deformed, cracked or malfunctioning. It is not necessary to replace the intake air temperature sensor each time the intercooler is replaced.

w/o Mass Air Flow Meter:
Remove the intake air temperature sensor.

Loosen the 2 hose clamps of the No. 1 air hose.

Loosen the 2 hose clamps of the No. 2 air hose.

Remove the 4 bolts and intercooler.

Remove the 4 bolts, intake air connector and gasket.

Disconnect the 2 connectors.

Remove the 2 bolts, 2 nuts, diesel throttle body and gasket.

Detach the 4 claws from the pins of the engine cover bracket and remove the No. 1 engine cover.

Remove the 2 bolts and engine cover bracket.

Disconnect the manifold absolute pressure sensor connector.

Disconnect the vacuum hose from the gas filter.

Loosen the 2 clamps.

Remove the bolt and disconnect the No. 2 air cleaner pipe together with the 2 air hoses.

Remove the clamp.

Disconnect the No. 3 water by-pass hose from the EGR cooler.

Disconnect the No. 4 water by-pass hose from the EGR cooler.

w/ EGR Cooler:

1. Remove the 2 nuts and No. 3 injection pipe clamp.
   





2. Remove the 2 bolts and 2 No. 2 injection pipe clamps.
   





3. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
   

   Text in Illustration

   *a	Injector Side
   *b	Common Rail Side

w/o EGR Cooler:

1. Remove the bolt and No. 2 injection pipe clamp.
   

   Text in Illustration

   *1	No. 2 Injection Pipe Clamp
   *2	No. 3 Injection Pipe Clamp
   *a	Injector Side
   *b	Common Rail Side

2. Remove the 2 nuts and No. 3 injection pipe clamp.
   

3. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
   

Remove the 3 bolts and No. 2 intake air connector bracket.

Remove the 2 bolts and disconnect the No. 3 water by-pass pipe with wire harness.

w/ EGR Cooler:

1. Disconnect the 2 connectors.
   





2. Disconnect the 5 vacuum hoses.
   

3. Remove the bolt and No. 1 gas filter with the gas filter bracket.
   





4. Remove the 2 bolts and electric vacuum regulating valve bracket together with the vacuum damper.
   

   NOTICE:

   Do not remove the electric vacuum regulating valve from the bracket.

w/o EGR Cooler:

1. Disconnect the connector.
   

2. Disconnect the 2 vacuum hoses.
   

3. Remove the 2 bolts and electric vacuum regulating valve together with the bracket.
   

   NOTICE:

   Do not remove the electric vacuum regulating valve from the bracket.

Remove the 3 nuts, No. 2 intake air connector and gasket.

Remove the 3 bolts, intake air connector and 2 gaskets.

Disconnect the vacuum hose from the No. 2 EGR valve.

Remove the bolt, 2 nuts, electric EGR control valve with No. 2 EGR valve and EGR cooler.

Remove the gasket from the cylinder head.

w/ EGR Cooler:

1. Remove the bolt and disconnect the injection pipe clamp.
   





2. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
   

   Text in Illustration

   *a	Injector Side
   *b	Common Rail Side

w/o EGR Cooler:

1. Remove the 2 bolts and disconnect the 2 injection pipe clamps.
   





2. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
   

   Text in Illustration

   *a	Injector Side
   *b	Common Rail Side

Disconnect the 3 fuel hoses.

Remove the union bolt, 3 bolts, No. 2 nozzle leakage pipe and gasket.

w/ EGR Cooler:
Remove the 3 bolts and disconnect the 4 injector connectors.

w/o EGR Cooler:
Disconnect the 4 injector connectors.

Disconnect the ventilation hose.

Using a small screwdriver, remove the nozzle holder seal by prying between the nozzle holder seal and the cutout part of the cylinder head cover.

Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.

Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

Remove the union bolt, 4 injector hollow screws, 5 gaskets and nozzle leakage pipe.

NOTICE:

1. When removing the nozzle leakage pipe, place a cushion under the pipe.
   
2. Be careful not to deform or scratch the union seal surface.
   
3. After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
   

Remove the 4 bolts, 4 washers, 4 No. 1 nozzle holder clamps and 4 injectors.

HINT:

Arrange the injectors, No. 1 nozzle holder clamps, washers and bolts in the correct order.

Remove the O-ring from each injector.

Remove the 4 injection nozzle seats from the cylinder head.

Remove the 6 bolts, 6 washers and timing belt cover.

Turn the crankshaft clockwise and align the timing marks as shown in the illustration.

HINT:

If reusing the timing belt, place matchmarks on the timing belt so that it can be installed exactly as before.

Uniformly loosen and remove the 2 bolts and No. 1 timing belt tensioner.

Remove the timing belt.

HINT:

1. If turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.
   
2. When installing the timing belt, turn the camshaft to align the timing marks, and then turn the crankshaft clockwise to align the timing marks.
   

Using a 10 mm hexagon wrench, remove the bolt, No. 1 timing belt idler and washer.

Remove the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

NOTICE:

Make sure to remove the bolt of the camshaft timing pulley with the timing belt not installed.

Remove the camshaft timing pulley.

Remove the 4 bolts, nut and timing belt cover.

Turn the camshaft with a wrench so that the key groove of the camshaft faces upward.

Uniformly loosen the 15 bearing cap bolts in several passes in the sequence shown in the illustration.

Remove the 15 bearing cap bolts, 5 bearing caps, oil seal and 2 camshafts.