CYLINDER HEAD REMOVAL

Note

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.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
REMOVE NO. 1 ENGINE UNDER COVER (for 4WD and Pre-Runner)
1. Remove the 4 bolts and No. 1 engine under cover.
DRAIN ENGINE COOLANT
CAUTION:

Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
1. Loosen the radiator drain cock plug.
  
  Tech Tips
  
  Collect the coolant in a container and dispose of it according to the regulations in your area.
2. Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.
3. Loosen the cylinder block drain cock plug.
DRAIN ENGINE OIL
1. Remove the oil filter cap.
2. Remove the oil drain plug, and drain the engine oil from the oil pan.
  
  Note
  
  Collect the oil in an oil disposal container.
LOOSEN FUEL TANK CAP ASSEMBLY
REMOVE INTAKE MANIFOLD (w/ EGR Cooler)

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REMOVE INTAKE MANIFOLD (w/ EGR System without EGR Cooler)

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REMOVE INTAKE MANIFOLD (w/o EGR System)

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REMOVE GLOW PLUG ASSEMBLY (w/ EGR Cooler)

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REMOVE GLOW PLUG ASSEMBLY (w/o EGR Cooler)

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REMOVE COMMON RAIL ASSEMBLY (w/ EGR Cooler)

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REMOVE COMMON RAIL ASSEMBLY (w/o EGR Cooler)

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REMOVE TIMING BELT

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REMOVE INJECTOR ASSEMBLY (w/ EGR Cooler)

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REMOVE INJECTOR ASSEMBLY (w/o EGR Cooler)

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REMOVE TURBOCHARGER SUB-ASSEMBLY (w/ EGR Cooler)

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REMOVE TURBOCHARGER SUB-ASSEMBLY (w/o EGR Cooler)

Click here
DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)
1. Remove the 4 bolts and disconnect the cooler compressor.
  
  Tech Tips
  
  It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.
REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)
1. Remove the 4 bolts and No. 1 compressor mounting bracket.
REMOVE EXHAUST MANIFOLD
1. Remove the 8 nuts and exhaust manifold.
DISCONNECT WIRE HARNESS
REMOVE CAMSHAFT TIMING PULLEY
1. Remove the bolt of the camshaft timing pulley by holding the camshaft with a wrench.
  
  Note
  
  Make sure to remove the bolt of the camshaft timing pulley with the timing belt not installed.
2. Remove the camshaft timing pulley.
REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
REMOVE NO. 2 TIMING BELT COVER
1. Remove the 4 bolts, nuts and No. 2 timing belt cover.
REMOVE CYLINDER BLOCK INSULATOR (w/ EGR Cooler)
1. Remove the cylinder block insulator from the cylinder head.
REMOVE CAMSHAFT
1. Face the key groove of the camshaft upward by turning the camshaft with a wrench.
2. Uniformly loosen the 15 bearing cap bolts in several passes in the sequence shown in the illustration.
3. Remove the 5 bearing caps, oil seal and 2 camshafts.
REMOVE CYLINDER HEAD SUB-ASSEMBLY
1. Uniformly loosen and remove the 18 cylinder head bolts in several passes in the sequence shown in the illustration.
  
  Note
  
  Head warpage or cracking could result from removing bolts in the incorrect order.
2. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.
  
  Tech Tips
  
  If the cylinder head is difficult to lift, use a screwdriver to pry between the cylinder head and block.
  
  Note
  
  Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
REMOVE CYLINDER HEAD GASKET