Cylinder Head -- 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. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL |
- NOTICE:
- When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Toyota Fortuner RM000004W63000X.html).
| 2. 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}
| 3. REMOVE INTAKE MANIFOLD |
| 4. REMOVE GLOW PLUG ASSEMBLY |
| 5. REMOVE INJECTOR ASSEMBLY |
| 6. REMOVE COMMON RAIL ASSEMBLY |
| 7. REMOVE TURBOCHARGER SUB-ASSEMBLY |
| 8. REMOVE FAN SHROUD |
| 9. DISCONNECT COOLER COMPRESSOR ASSEMBLY |
Remove the 4 bolts and disconnect the cooler compressor.
- HINT:
- It is not necessary to completely remove the cooler compressor. With the hoses connected to the cooler compressor, hang the cooler compressor on the vehicle body with a rope.
| 10. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET |
Remove the 4 bolts and No. 1 compressor mounting bracket.
| 11. REMOVE EXHAUST MANIFOLD |
Remove the 8 nuts, 8 plate washers, 8 collars and exhaust manifold.
 |
Remove the gasket.
| 12. REMOVE TIMING BELT |
| 13. REMOVE CAMSHAFT TIMING PULLEY |
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.
| 14. REMOVE NO. 2 TIMING BELT COVER |
Remove the 4 bolts, nut and timing belt cover.
| 15. REMOVE CYLINDER BLOCK INSULATOR |
Remove the cylinder block insulator from the cylinder head.
 |
| 16. REMOVE CAMSHAFT |
Turn the camshaft with a wrench so that the key groove of the camshaft faces upward.
Text in Illustration *1 Key Groove
 |
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.
| 17. REMOVE VALVE LIFTER |
Remove the valve lifters.
- HINT:
- Arrange the valve lifters in the correct order.
| 18. REMOVE CYLINDER HEAD SUB-ASSEMBLY |
 |
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.
- NOTICE:
- Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
- HINT:
- If the cylinder head is difficult to lift, use a screwdriver to pry between the cylinder head and block.
| 19. REMOVE CYLINDER HEAD GASKET |