Camshaft (W/ Dpf) -- Removal |
- NOTICE:
- When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.
- When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.
- After removing the injection pipes, clean them with a brush and compressed air.
| 1. REMOVE NO. 1 ENGINE UNDER COVER |
| 2. DRAIN ENGINE COOLANT |
- CAUTION:
- Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
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.
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Loosen the cylinder block drain cock plug.
Text in Illustration *1 Radiator Reservoir *2 Radiator Reservoir Cap *3 Vent Plug *4 Cylinder Block Drain Cock Plug *5 Radiator Drain Cock Plug - -
| 3. DRAIN ENGINE OIL |
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}
| 4. REMOVE RADIATOR HOSE INLET |
| 5. REMOVE FAN SHROUD |
Remove the 3 bolts and oil reservoir.
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Disconnect the No. 1 and No. 2 water by-pass hoses from the radiator.
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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.
| 6. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY |
Remove the 3 bolts, 2 cap nuts and No. 1 engine cover.
Text in Illustration 
Cap Nut
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| 7. REMOVE INTAKE AIR TEMPERATURE SENSOR |
Disconnect the intake air temperature sensor connector.
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.
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| 8. REMOVE INTERCOOLER ASSEMBLY |
Loosen the 2 hose clamps of the No. 1 air hose.
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Loosen the 2 hose clamps of the No. 2 air hose.
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Remove the 4 bolts and intercooler.
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Remove the No. 2 air hose.
Remove the 4 bolts, intake air connector and gasket.
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| 9. REMOVE DIESEL THROTTLE BODY ASSEMBLY |
Disconnect the 2 connectors.
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Remove the 2 bolts, 2 nuts, diesel throttle body and gasket.
| 10. REMOVE FRONT WHEEL LH |
| 11. REMOVE FRONT FENDER APRON SEAL UPPER |
Remove the 5 clips and front fender apron seal upper.
| 12. REMOVE FRONT FENDER SEAL |
Remove the 5 clips and front fender seal.
| 13. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE |
Remove the engine oil level dipstick.
Detach the wire harness clamp.
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Remove the bolt and engine oil level dipstick guide.
Remove the O-ring from the engine oil level dipstick guide.
| 14. DISCONNECT WATER BY-PASS HOSE |
Disconnect the 6 water by-pass hoses.
| 15. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE |
Disconnect the vacuum switching valve connector.
Disconnect the 2 vacuum transmitting hoses.
Remove the 2 bolts and manifold stay with vacuum switching valve.
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| 16. REMOVE NO. 3 CYLINDER HEAD COVER SUB-ASSEMBLY |
Remove the 3 bolts and No. 3 cylinder head cover.
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| 17. REMOVE FUEL INLET PIPE SUB-ASSEMBLY |
Remove the bolt and No. 2 injection pipe clamp.
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Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.
| 18. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY |
- NOTICE:
- After removing the injection pipe, cover the outlets on the common rail with tape to keep out foreign matter.
- After removing the injection pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
Disconnect the 4 injector connectors and electric EGR control valve connector.
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Detach the 2 wire harness clamps.
Remove the 4 nuts and 2 No. 3 injection pipe clamps.
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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
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| 19. REMOVE NO. 5 WATER BY-PASS PIPE |
Detach the 2 wire harness clamps.
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Disconnect the 2 water hoses from the electric EGR control valve.
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Remove the 2 bolts and No. 5 water by-pass pipe.
| 20. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR |
Disconnect the manifold absolute pressure sensor connector and vacuum hose.
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Remove the bolt and manifold absolute pressure sensor.
| 21. REMOVE GAS FILTER BRACKET WITH GAS FILTER |
Disconnect the vacuum hose.
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Remove the bolt and gas filter bracket with gas filter.
| 22. REMOVE WIRING HARNESS CLAMP BRACKET |
Remove the bolt and wiring harness clamp bracket.
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| 23. REMOVE THROTTLE BODY BRACKET |
Remove the 3 bolts and throttle body bracket.
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| 24. DISCONNECT ENGINE WIRE |
Detach the 2 wire harness clamps.
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Remove the bolt and disconnect the engine wire.
| 25. DISCONNECT NO. 3 WATER BY-PASS PIPE |
Remove the 2 bolts and disconnect the No. 3 water by-pass pipe.
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| 26. REMOVE EGR VALVE BRACKET |
Remove the 3 bolts and EGR valve bracket.
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| 27. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER |
Disconnect the fuel pressure sensor connector from the common rail.
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Remove the 5 bolts, 2 nuts and electric EGR control valve with No. 2 EGR valve and EGR cooler.
Text in Illustration *1 Gasket - -
Remove the 2 gaskets from the cylinder head and intake manifold.
| 28. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY |
Remove the bolt, nut and 2 No. 2 injection pipe clamps.
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Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
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| 29. REMOVE WIRING HARNESS CLAMP BRACKET |
Detach the wire harness clamp.
Text in Illustration *1 Wiring Harness Clamp Bracket
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Remove the bolt and wiring harness clamp bracket.
| 30. REMOVE NO. 2 FUEL PIPE |
Using a 6 mm hexagon wrench, remove the supply pump hollow screw and gasket.
Text in Illustration 
Bolt Supply Pump Hollow Screw 
Fuel Check Valve 
Union Bolt
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Remove the fuel check valve, union bolt and 2 gaskets.
Remove the 3 bolts and No. 2 fuel pipe.
| 31. REMOVE NO. 3 NOZZLE LEAKAGE PIPE |
Disconnect the 3 fuel hoses.
Text in Illustration Fuel Check Valve
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Remove the 2 bolts.
Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.
| 32. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY |
Remove the 2 bolts.
Text in Illustration Union Bolt
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Remove the union bolt, gasket and No. 2 nozzle leakage pipe.
| 33. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY |
Remove the 3 bolts and No. 2 cylinder head cover.
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| 34. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY |
- NOTICE:
- If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.
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.
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Disconnect the ventilation hose.
Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.
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Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.
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| 35. REMOVE INJECTOR ASSEMBLY |
Remove the union bolt, 4 injector hollow screws, 5 gaskets and nozzle leakage pipe.
Text in Illustration *1 Union Bolt - NOTICE:
- When removing the nozzle leakage pipe, place a cushion under the pipe.
- Be careful not to deform or scratch the union seal surface.
- After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
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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.
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Remove the O-ring from each injector.
Remove the 4 injection nozzle seats from the cylinder head.
| 36. REMOVE NO. 1 TIMING BELT COVER |
Remove the 6 bolts, 6 washers and timing belt cover.
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| 37. REMOVE TIMING BELT |
Turn the crankshaft clockwise and align the timing marks as shown in the illustration.
Text in Illustration *1 Timing Mark - HINT:
- If reusing the timing belt, place matchmarks on the timing belt so that it can be installed exactly as before.
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Uniformly loosen and remove the 2 bolts and No. 1 timing belt tensioner.
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Remove the timing belt.
- HINT:
- If turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.
- When installing the timing belt, turn the camshaft to align the timing marks, and then turn the crankshaft clockwise to align the timing marks.
| 38. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY |
- NOTICE:
- When inspecting the No. 1 timing belt idler, do not remove it unless absolutely necessary.
Using a 10 mm hexagon wrench, remove the bolt, No. 1 timing belt idler and washer.
| 39. REMOVE CAMSHAFT TIMING PULLEY |
Remove the bolt of the camshaft timing pulley while holding the camshaft with a wrench.
- NOTICE:
- Make sure the timing belt is not installed when removing the bolt of the camshaft timing pulley.
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Remove the camshaft timing pulley.
| 40. REMOVE NO. 2 TIMING BELT COVER |
Remove the 4 bolts, nut and No. 2 timing belt cover.
| 41. REMOVE CAMSHAFT |
Turn the camshaft with a wrench so that the key groove of the camshaft faces upward.
Text in Illustration *1 Key Groove
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Uniformly loosen the 15 bearing cap bolts in several passes in the sequence shown in the illustration.
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Remove the 15 bearing cap bolts, 5 bearing caps, oil seal and 2 camshafts.