Cylinder Head Removal

Remove the oil filler cap.

Remove the oil drain plug, and drain the engine oil from the oil pan.

NOTICE:

Collect the oil in an oil disposal container.

Remove the 2 bolts and 2 compression springs.

Disconnect the front pipe from the outlet pipe and remove the gasket.

Remove the front pipe from the pipe support.

Remove the 3 bolts, 2 nuts and engine cover.

Disconnect the IAT sensor connector.

Disconnect the manifold absolute diesel pressure sensor connector.

Disconnect the vacuum hose from the manifold absolute pressure sensor.

Loosen the 2 clamps.

Remove the 4 bolts and CAC.

Disconnect the MAF meter connector.

Loosen the hose clamp.

Remove the 2 bolts and air cleaner.

Remove the fan shroud (Toyota Fortuner RM0000014Y2007X_01_0005.html).

Remove the 4 bolts and disconnect the cooler compressor.

HINT:

It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

Remove the 4 bolts and mounting bracket.

Remove the 8 nuts and exhaust manifold w/turbocharger.

Remove the 2 bolts and stay.

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

Remove the bolt and No. 2 injection pipe clamp.

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

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





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

Disconnect the 2 fuel hoses.

Remove the check valve, 3 bolts, leakage pipe and gasket.

Remove the EGR valve and gasket.

Remove the 4 bolts, 2 nuts, manifold and gasket.

Remove the bolt and water hose clamp.

Remove the wire harness clamp.

Remove the 6 bolts and timing belt cover.

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

Uniformly loosen the 2 bolts and remove the timing belt tensioner.

Remove the timing belt.

Using a 10 mm hexagon wrench, remove the bolt, timing belt idler and washer.

HINT:

1. 
   
2. When turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.
   
3. When installing the timing belt, return the camshaft to the timing marks and then turn the crankshaft clockwise until it aligns with the timing marks.
   

Using a small screwdriver, remove the 4 holder seals by prying the portion between each holder seal and the cutout part of the cylinder head.

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

Remove the bolt of the camshaft timing pulley by 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.

Remove the union bolt, 4 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 nozzle holder clamps and 4 injectors.

HINT:

Arrange the injectors, holder clamps, washers and bolts in the correct order.

Remove the O-ring and back-up ring from each injector.

Remove the 4 injection nozzle sheets from the cylinder head.

Face the key groove of the camshaft upward by turning the camshaft with a wrench.

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

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

Uniformly loosen the 18 cylinder head bolts in several passes in the sequence shown in the illustration. Then remove the 18 cylinder head bolts and 18 washers.

NOTICE:

Head warpage or cracking could result from removing bolts in the incorrect order.

Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.

HINT:

If the cylinder head is difficult to lift, use a screwdriver to pry between the cylinder head and block.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head and cylinder block.