Camshaft Removal

Disconnect the No. 1 vacuum transmitting hose sub-assembly from the vacuum pump assembly.

Remove the 3 bolts and vacuum pump assembly from the cylinder head sub-assembly.

Remove the 2 O-rings from the vacuum pump assembly.

Remove the camshaft oil seal retainer from the No. 3 camshaft bearing cap and cylinder head sub-assembly.

w/ Rear Air Conditioning System:

1. Slide the 2 clamps and disconnect the 2 water hoses from the water pipe.
   

2. Slide the 2 clamps and disconnect the 2 water hoses from the air conditioning unit assembly.
   

3. Slide the 2 clamps and disconnect the 2 water hoses from the No. 2 water by-pass pipe.
   

w/o Rear Air Conditioning System:

1. Slide the 2 clamps and disconnect the 2 water hoses from the air conditioning unit assembly.
   

2. Slide the 2 clamps and disconnect the 2 water hoses from the No. 2 water by-pass pipe.
   

Slide the clamp and disconnect the No. 13 water by-pass hose from the water outlet sub-assembly.

Slide the clamp and disconnect the No. 15 water by-pass hose from the water by-pass pipe.

Slide the clamp and disconnect the No. 16 water by-pass hose from the No. 1 EGR cooler.

Remove the 3 bolts and No. 2 water by-pass pipe from the cylinder head cover sub-assembly, No. 3 water by-pass pipe sub-assembly and No. 2 engine cover bracket.

Remove the 2 bolts and No. 3 engine cover bracket from the engine cover bracket and No. 2 engine cover bracket.

Remove the 2 bolts and No. 2 engine cover bracket from the No. 3 water by-pass pipe sub-assembly and No. 2 EGR valve assembly.

Remove the bolt, union bolt and gasket and disconnect the No. 1 fuel pipe from the cylinder head cover sub-assembly and exhaust fuel addition injector assembly.

Disconnect the No. 4 fuel pipe and remove the No. 1 fuel pipe (LandCruiser RM0000028RU05SX.html).

Slide the 2 clips and disconnect the No. 20 water by-pass hose from the compressor inlet elbow and No. 3 water by-pass pipe.

Slide the clip and disconnect the No. 19 water bypass hose from the compressor inlet elbow.

Remove the bolt and disconnect the PCV pipe from the compression inlet elbow.

Slide the 2 clips and remove the PCV pipe.

Slide the clamp and disconnect the No. 4 water bypass hose from the No. 1 injector holder.

Slide the clamp and disconnect the No. 5 water by-pass hose from the No. 1 injector holder.

Remove the connector from the exhaust fuel addition injector assembly.

Remove the 3 nuts and No. 1 injector holder from the exhaust manifold.

Remove the 3 nuts and No. 2 exhaust manifold heat insulator from the No. 1 injector holder.

Remove the gasket.

Disconnect the connector from the differential pressure sensor.

Remove the bolt and differential pressure sensor from the pipe clamp.

Slide the 2 clamps and remove the 2 No. 1 air hoses from the differential pressure sensor.

Disconnect the 3 connectors from the 3 exhaust gas temperature sensors.

Remove the nut and disconnect the No. 3 exhaust gas temperature sensor from the No. 1 vacuum pipe.

Remove the bolt and open the clamp of the pipe clamp.

Detach the 3 connectors from the pipe clamp.

Using a 14 mm union nut wrench, remove the exhaust gas temperature sensor from the exhaust manifold converter sub-assembly.

Using a 14 mm union nut wrench, remove the No. 2 exhaust gas temperature sensor from the exhaust manifold converter sub-assembly.

Using a 14 mm union nut wrench, remove the No. 3 exhaust gas temperature sensor from the exhaust manifold converter sub-assembly.

Remove the nut and clamp from the No. 1 vacuum pipe and No. 2 vacuum pipe.

Using a 17 mm union nut wrench, remove the No. 1 vacuum pipe from the exhaust manifold converter sub-assembly.

Using a 17 mm union nut wrench, remove the No. 2 vacuum pipe from the exhaust manifold converter sub-assembly.

Remove the clamp from the pipe clamp.

Remove the 3 bolts and pipe clamp from the engine cover bracket.

Detach the 2 clamp and disconnect the engine wire from the engine cover bracket.

Remove the 2 bolts and engine cover bracket from the cylinder head sub-assembly.

Detach the clamp and disconnect the No. 1 fuel hose from the air tube support bracket.

Remove the 3 bolts and air tube support bracket.

Disconnect the connector from the intake air temperature sensor.

Loosen the hose clamp and remove the air tube assembly from the diesel throttle body assembly.

for Cold Area Specification Vehicles:
Slide the 2 clips and disconnect the No. 11 water by-pass hose and No. 14 water by-pass hose from the diesel throttle body assembly.

Disconnect the connector and clamp.

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

Disconnect the connector to remove the emission control valve wire from the diesel throttle body assembly.

Disconnect the 2 vacuum hoses from the turbo pressure sensor and intake manifold.

Remove the gas filter from the gas filter bracket.

Disconnect the connector from the turbo pressure sensor.

Remove the bolt and turbo pressure sensor from the No. 3 water by-pass pipe sub-assembly.

Remove the bolt, nut and EGR valve bracket from the electric EGR control valve assembly and intake manifold.

Remove the bolt, 4 nuts and No. 2 EGR pipe from the electric EGR control valve assembly and intake manifold.

Remove the 2 gaskets.

Disconnect the No. 4 fuel hose from the No. 3 water by-pass pipe sub-assembly.

Slide the clamp and disconnect the No. 8 water by-pass hose from the No. 3 water by-pass pipe sub-assembly.

Slide the clamp and disconnect the No. 9 water by-pass hose from the electric EGR control valve assembly.

Remove the 2 bolts and No. 3 water by-pass pipe sub-assembly from the No. 1 EGR cooler.

Slide the clamp and disconnect the No. 7 water by-pass hose from the No. 1 EGR cooler.

Slide the clamp and disconnect the water hose from the No. 2 EGR valve assembly.

Remove the 2 bolts and disconnect the No. 4 water by-pass pipe sub-assembly from the intake manifold.

Remove the bolt and disconnect the No. 1 EGR pipe sub-assembly from the vacuum transmitting pipe sub-assembly.

Remove the 4 nuts and the No. 1 EGR pipe sub-assembly from the exhaust manifold and EGR valve adapter.

Remove the 2 gaskets.

Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.

Remove the bolt and disconnect the engine wire bracket.

Disconnect the connector from the vacuum control valve set.

Disconnect the 2 vacuum hoses from the No. 2 vacuum transmitting pipe sub-assembly and No. 2 EGR valve assembly.

Remove the 2 bolts and vacuum control valve set from the intake manifold.

Remove the 4 bolts and No. 1 EGR cooler and No. 2 EGR valve assembly with electric EGR control valve assembly from the intake manifold.

Disconnect the pressure discharge valve connector from the common rail assembly.

Remove the bolt and wiring harness clamp bracket from the cylinder head cover sub-assembly.

Remove the bolt and harness bracket.

Slide the clamp and disconnect the No. 5 fuel hose from the nozzle leakage pipe assembly.

Remove the 4 union bolts and 4 gaskets.

Remove the bolt and nozzle leakage pipe assembly.

Using SST, loosen the No. 1 and No. 2 injection pipe sub-assemblies and 8 union nuts of the fuel injector assembly side and common rail assembly side.

SST

09245-11010

Remove the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

NOTICE:

When removing the No. 1 injection pipe subassembly and No. 2 injection pipe sub-assembly, store the injector assemblies in the correct order so that they can be returned to their original locations when reassembling.

Remove the 4 nozzle holder clamp bolts, 4 washers and 4 nozzle holder clamps.

Remove the 4 fuel injector assemblies and 4 injection nozzle seats from the cylinder head sub-assembly.

NOTICE:

When removing the injector assembly, store the injector assemblies in the correct order so that they can be returned to their original locations when reassembling.

Remove the O-ring from each injector assembly.

Remove the 4 nozzle holder gaskets from the cylinder head cover sub-assembly.

Disconnect the camshaft position sensor connector.

Remove the bolt and camshaft position sensor from the cylinder head cover sub-assembly.

Remove the 14 bolts, 4 nozzle holder clamp seats, 2 nuts and cylinder head cover sub-assembly from the cylinder head sub-assembly.

Text in Illustration

	Bolt
	Nut
	Nozzle Holder Clamp Seat

Remove the cylinder head cover gasket, No. 2 cylinder head cover gasket and 2 camshaft bearing cap oil hole gaskets from the cylinder head cover sub-assembly.

Align the timing mark of the crankshaft pulley and timing chain cover by rotating the crankshaft clockwise.

Make sure that the timing mark of the camshaft timing sprocket is at the top.

HINT:

If the timing mark is not at the top, turn the crankshaft pulley 1 revolution so that the timing mark is at the top (set the No. 1 piston to TDC/ compression).

Place paint marks on the No. 2 chain sub-assembly.

Remove the bolt and timing chain guide from the cylinder head sub-assembly.

Remove the oil pump relief valve plug and gasket from timing chain cover.

Insert a pin into stopper plate hole of the No. 2 chain tensioner assembly and lock the No. 2 chain tensioner assembly.

Hold the hexagonal portion of the camshaft with a wrench and loosen the 2 bolts from the No. 1 camshaft and No. 2 camshaft.

CAUTION:

Be careful not to damage the cylinder head sub-assembly with the wrench.

Remove the 2 bolts and No. 3 camshaft bearing cap from the cylinder head sub-assembly.

Using several steps, and remove the 20 bolt, No. 1 camshaft bearing cap and 8 No. 2 camshaft bearing caps from the cylinder head sub-assembly.

Raise the No. 1 camshaft and remove the bolt from the No. 1 camshaft.

Raise the No. 2 camshaft and remove the bolt from the No. 2 camshaft.

Remove the No. 2 camshaft from the camshaft timing sprocket.

Remove the camshaft timing sprocket from the No. 2 chain sub-assembly.

Remove the No. 1 camshaft from the camshaft timing sprocket.

Remove the camshaft timing sprocket from the No. 2 chain sub-assembly.

Suspend the No. 2 chain sub-assembly with a string or equivalent.

HINT:

Be careful not to drop the No. 2 chain sub-assembly inside the timing chain cover assembly.