Cylinder Head Gasket (W/O Dpf) Removal

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
2Kd-Ftv Engine Mechanical. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. PRECAUTION

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. DRAIN ENGINE OIL

  4. REMOVE INTAKE MANIFOLD

  5. REMOVE GLOW PLUG ASSEMBLY

  6. REMOVE INJECTOR ASSEMBLY

  7. REMOVE COMMON RAIL ASSEMBLY

  8. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER

  9. REMOVE FAN SHROUD

  10. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)

  11. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)

  12. REMOVE TIMING BELT

  13. REMOVE CAMSHAFT TIMING PULLEY

  14. REMOVE NO. 2 TIMING BELT COVER

  15. REMOVE CYLINDER BLOCK INSULATOR (w/ EGR Cooler)

  16. REMOVE CAMSHAFT

  17. REMOVE VALVE LIFTER

  18. REMOVE CYLINDER HEAD SUB-ASSEMBLY

  19. REMOVE CYLINDER HEAD GASKET

Cylinder Head Gasket (W/O Dpf) -- Removal


NOTICE:
  1. 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.
  2. 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.
  3. After removing the injection pipes, clean them with a brush and compressed air.


1. PRECAUTION
NOTICE:
After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (HILUX_TGN26 RM000004QR1006X.html).


2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected (HILUX_TGN26 RM000004QR3009X.html).


3. DRAIN ENGINE OIL

  1. Remove the oil filler cap.

  1. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

  1. Wipe the oil pan and drain plug.

  1. Install a new gasket and the oil pan drain plug.

    Torque:
    34 N*m{347 kgf*cm, 25 ft.*lbf}


4. REMOVE INTAKE MANIFOLD
  1. w/ EGR Cooler: (HILUX_TGN26 RM00000143Y01ZX.html)
  2. w/o EGR Cooler: (HILUX_TGN26 RM00000143Y020X.html)


5. REMOVE GLOW PLUG ASSEMBLY
(HILUX_TGN26 RM0000013XP01CX.html)


6. REMOVE INJECTOR ASSEMBLY
(HILUX_TGN26 RM000002SY1022X.html)


7. REMOVE COMMON RAIL ASSEMBLY
(HILUX_TGN26 RM000002SY5023X.html)


8. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER
  1. w/ EGR Cooler: (HILUX_TGN26 RM00000144200ZX.html)
  2. w/o EGR Cooler: (HILUX_TGN26 RM000001442010X.html)


9. REMOVE FAN SHROUD
(HILUX_TGN26 RM000001448023X.html)


10. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)

  1. 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.


11. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)

  1. Remove the 4 bolts and No. 1 compressor mounting bracket.



12. REMOVE TIMING BELT
(HILUX_TGN26 RM00000147C01DX.html)


13. REMOVE CAMSHAFT TIMING PULLEY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Engine Mechanical.Engine.Cylinder Head Gasket (W/O Dpf) Removal

  1. 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.

  1. Remove the camshaft timing pulley.



14. REMOVE NO. 2 TIMING BELT COVER

  1. Remove the 4 bolts, nut and timing belt cover.



15. REMOVE CYLINDER BLOCK INSULATOR (w/ EGR Cooler)


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Remove the cylinder block insulator from the cylinder head.



16. REMOVE CAMSHAFT


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Engine Mechanical.Engine.Cylinder Head Gasket (W/O Dpf) Removal

  1. Turn the camshaft with a wrench so that the key groove of the camshaft faces upward.

    Text in Illustration
    *1
    		Key Groove


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Engine Mechanical.Engine.Cylinder Head Gasket (W/O Dpf) Removal

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

  1. Remove the 15 bearing cap bolts, 5 bearing caps, oil seal and 2 camshafts.



17. REMOVE VALVE LIFTER

  1. Remove the valve lifters.

    HINT:
    Arrange the valve lifters in the correct order.


18. REMOVE CYLINDER HEAD SUB-ASSEMBLY


Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Engine Mechanical.Engine.Cylinder Head Gasket (W/O Dpf) Removal

  1. 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.

  1. 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