Cylinder Head Gasket Removal

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
2Tr-Fe Engine Mechanical. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

  2. REMOVE EXHAUST MANIFOLD

  3. SET NO. 1 CYLINDER TO TDC/COMPRESSION

  4. REMOVE TIMING CHAIN GUIDE

  5. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

  6. REMOVE CHAIN TENSIONER SLIPPER

  7. REMOVE NO. 1 CHAIN VIBRATION DAMPER

  8. REMOVE CHAIN SUB-ASSEMBLY

  9. REMOVE CAMSHAFT BEARING CAP

  10. REMOVE NO. 1 CAMSHAFT

  11. REMOVE NO. 2 CAMSHAFT

  12. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

  13. REMOVE VALVE LASH ADJUSTER ASSEMBLY

  14. REMOVE VALVE STEM CAP

  15. REMOVE CYLINDER HEAD SUB-ASSEMBLY

  16. REMOVE CYLINDER HEAD GASKET

  17. INSPECT CYLINDER HEAD SET BOLT

  18. INSPECT CYLINDER HEAD SUB-ASSEMBLY

Cylinder Head Gasket -- Removal



1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
(HILUX_TGN26 RM000000YMA02CX.html)


2. REMOVE EXHAUST MANIFOLD
(HILUX_TGN26 RM0000046EQ00JX.html)


3. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Cylinder Head Gasket Removal

  1. Temporarily install the crankshaft pulley bolt.

  1. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

    Text in Illustration
    *1
    		Timing Mark
    *2
    		Key
    HINT:
    If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

  1. Remove the crankshaft pulley bolt.



4. REMOVE TIMING CHAIN GUIDE


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Cylinder Head Gasket Removal

  1. Remove the 2 bolts, chain guide and O-ring.

    Text in Illustration
    *1
    		O-Ring


5. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

NOTICE:
Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Cylinder Head Gasket Removal
  1. When the chain tensioner is removed, do not rotate the crankshaft.
  2. When the chain is removed and the camshaft needs to be rotated, rotate the crankshaft 90° to the right.

  1. Move the stopper plate upward to release the lock and push the plunger deep into the tensioner.

    Text in Illustration
    *1
    		Plunger
    *2
    		Stopper Plate
    *3
    		Hexagon Wrench

  1. Move the stopper plate downward to set the lock and insert a hexagon wrench into the stopper plate hole.



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

  1. Remove the bolt, nut, chain tensioner and gasket.



6. REMOVE CHAIN TENSIONER SLIPPER


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Cylinder Head Gasket Removal

  1. Remove the bolt and tensioner slipper.



7. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Cylinder Head Gasket Removal

  1. Remove the 2 bolts and vibration damper.



8. REMOVE CHAIN SUB-ASSEMBLY


9. REMOVE CAMSHAFT BEARING CAP


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Cylinder Head Gasket Removal

  1. Uniformly loosen and remove the 21 bearing cap bolts in the sequence shown in the illustration.

    NOTICE:
    Uniformly loosen the bolts while keeping the camshafts level.


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

  1. Remove the oil delivery pipe and O-ring from the bearing caps.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Cylinder Head Gasket Removal

  1. Remove the 9 bearing caps.

    HINT:
    Arrange the removed parts in the correct order.


10. REMOVE NO. 1 CAMSHAFT


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


11. REMOVE NO. 2 CAMSHAFT


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


12. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

  1. Remove the 16 valve rocker arms from the cylinder head.

    HINT:
    Arrange the removed parts in the correct order.


13. REMOVE VALVE LASH ADJUSTER ASSEMBLY

  1. Remove the 16 valve lash adjusters from the cylinder head.

    HINT:
    Arrange the removed parts in the correct order.


14. REMOVE VALVE STEM CAP


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

  1. Remove the 16 valve stem caps from the cylinder head.

    HINT:
    Arrange the removed parts in the correct order.


15. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Cylinder Head Gasket Removal

  1. Uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

    NOTICE:
    1. Be careful not to drop the washers into the cylinder head.
    2. Head warpage or cracking could result from removing the bolts in the wrong order.


16. REMOVE CYLINDER HEAD GASKET

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



17. INSPECT CYLINDER HEAD SET BOLT


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Cylinder Head Gasket Removal

  1. Using a vernier caliper, measure the diameter of the most elongated threads in the measuring area.

    Standard outside diameter:
    10.76 to 10.97 mm (0.424 to 0.432 in.)
    Minimum outside diameter:
    10.40 mm (0.409 in.)
    Distance:
    30 mm (1.18 in.)
    Text in Illustration
    *1
    		Measuring area
    *2
    		Distance
    If a visual check reveals no excessively thin areas, check the center of the measuring area (see illustration) and find the area that has the smallest diameter.
    If the diameter is less than the minimum, replace the cylinder head set bolt.


18. INSPECT CYLINDER HEAD SUB-ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Cylinder Head Gasket Removal

  1. Using a precision straightedge and feeler gauge, measure the warpage of the surfaces that contact the cylinder block and manifolds.

    Maximum warpage:
    0.05 mm (0.00197 in.)
    Text in Illustration
    *a
    		Cylinder Head Lower Side
    *b
    		Intake Manifold Side
    *c
    		Exhaust Manifold Side
    If the warpage is more than the maximum, replace the cylinder head.

  1. Using a dye penetrant, check the intake ports, exhaust ports and cylinder head surface for cracks.
    If cracked, replace the cylinder head.