Camshaft (W/ Glow Plug Controller) 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 RM000001477015X_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

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.

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 No. 2 air hose.

Remove the 4 bolts, intake air connector and gasket.

Disconnect the 2 connectors.

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

Remove the 5 clips and front fender apron seal upper.

Remove the 5 clips and front fender seal.

for DPF:
Remove the engine oil level dipstick.

for i-ART:
Remove the engine oil level dipstick and gasket.

Detach the wire harness clamp.

Remove the bolt and engine oil level dipstick guide.

Remove the O-ring from the engine oil level dipstick guide.

Disconnect the 6 water by-pass hoses.

Disconnect the vacuum switching valve connector.

Disconnect the 2 vacuum hoses.

Remove the 2 bolts and manifold stay with vacuum switching valve.

Remove the fuel pipe insulator from the fuel pipes.

Remove the 3 bolts and No. 3 cylinder head cover.

Remove the bolt and No. 2 injection pipe clamp.

Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

Disconnect the 4 injector connectors and electric EGR control valve connector.

Detach the 2 wire harness clamps.

Remove the 4 nuts and 2 No. 3 injection pipe clamps.

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

Detach the 2 wire harness clamps.

Disconnect the 2 water hoses from the electric EGR control valve.

Remove the 2 bolts and No. 5 water by-pass pipe.

Disconnect the manifold absolute pressure sensor connector and vacuum hose.

Remove the bolt and manifold absolute pressure sensor.

Disconnect the vacuum hose.

Remove the bolt and gas filter bracket with gas filter.

Remove the bolt and wiring harness clamp bracket.

Remove the 3 bolts and throttle body bracket.

Detach the 2 wire harness clamps.

Remove the bolt and disconnect the engine wire.

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

Remove the 3 bolts and EGR valve bracket.

for DPF:
Disconnect the fuel pressure sensor connector from the common rail.

Remove the 5 bolts, 2 nuts and electric EGR control valve with No. 2 EGR valve and EGR cooler.

Remove the 2 gaskets from the cylinder head and intake manifold.

Remove the bolt, nut and 2 No. 2 injection pipe clamps.

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

for DPF:

1. Disconnect the vacuum switching valve connector and 2 vacuum transmitting hoses.
   





2. 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

3. Remove the fuel check valve, union bolt and 2 gaskets.
   

4. Remove the 3 bolts and No. 2 fuel pipe.
   

for i-ART:

1. Using a 6 mm hexagon wrench, remove the supply pump hollow screw and gasket.
   

   Text in Illustration

   	Supply Pump Hollow Screw
   	Fuel Check Valve

2. Remove the fuel check valve, No. 2 fuel pipe and gasket.
   

Disconnect the 3 fuel hoses.

Text in Illustration

Fuel Check Valve

Remove the 2 bolts.

Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.

for DPF:
Remove the 2 bolts.

Text in Illustration

*A	for DPF	*B	for i-ART
	Union Bolt	-	-

for i-ART:
Remove the 3 bolts.

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

Detach the wire harness clamp.

Remove the bolt and wiring harness clamp bracket.

Remove the 3 bolts and No. 2 cylinder head cover.

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.

Disconnect the ventilation hose.

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 nozzle leakage 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 the timing belt is not installed when removing the bolt of the camshaft timing pulley.

Remove the camshaft timing pulley.

Remove the 4 bolts, nut and No. 2 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.