LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2008 >> FJ Cruiser RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 207 (Engine Mechanical) >> Cylinder Head, Intake Manifold, Exhaust Manifold >> Removal

Cylinder Head, Intake Manifold, Exhaust Manifold: Removal

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCHARGE FUEL SYSTEM PRESSURE 

    (See PRECAUTION )

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  3. REMOVE FRONT WIPER ARM HEAD CAP (for Hatchback)  (See REMOVAL )
  4. REMOVE FRONT WIPER ARM HEAD CAP (for Sedan)  (See REMOVAL )
  5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Hatchback)  (See REMOVAL )
  6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Sedan)  (See REMOVAL )
  7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Hatchback)  (See REMOVAL )
  8. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Sedan)  (See REMOVAL )
  9. REMOVE HOOD TO COWL TOP SEAL (for Hatchback)  (See REMOVAL )
  10. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Hatchback)  (See REMOVAL )
  11. REMOVE COWL TOP VENTILATOR LOUVER LH (for Hatchback)  (See REMOVAL )
  12. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan)  (See REMOVAL )
  13. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan)  (See REMOVAL )
  14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Sedan)  (See REMOVAL )
  15. REMOVE FRONT WIPER MOTOR AND LINK (for Hatchback)  (See REMOVAL )
  16. REMOVE FRONT WIPER MOTOR AND LINK (for Sedan)  (See REMOVAL )
  17. REMOVE COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2 (for Hatchback) (See REMOVAL  )
  18. REMOVE FRONT AIR SHUTTER SEAL RH (for Sedan)  (See REMOVAL )
  19. REMOVE COWL TOP PANEL OUTER (for Hatchback) (See REMOVAL  )
  20. REMOVE COWL TOP PANEL OUTER (for Sedan)  (See REMOVAL )
  21. REMOVE BATTERY 
  22. REMOVE BATTERY TRAY 
  23. REMOVE FRONT WHEEL RH 
  24. REMOVE ENGINE UNDER COVER RH 
  25. DRAIN ENGINE OIL 
  26. DRAIN ENGINE COOLANT  (See REPLACEMENT )
  27. REMOVE CYLINDER HEAD COVER NO. 2  REMOVAL 
  28. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE NO. 1  (See REMOVAL )
  29. DISCONNECT RADIATOR HOSE NO. 3 
    1. Disconnect radiator hose No. 3.
      Fig 1: Locating Radiator Hose Clip
      G04828600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. DISCONNECT RESERVE TANK HOSE 
    1. Disconnect the reserve tank hose.
      Fig 2: Locating Reserve Tank Hose
      G04828601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE WATER FILLER SUB-ASSEMBLY 
    1. Separate radiator hose No. 1 from the cylinder head.
    2. Remove the 2 nuts and remove the water filler sub-assembly.
      Fig 3: Locating Water Filler Sub-Assembly
      G04828602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. DISCONNECT WATER BYPASS HOSE NO. 2 
    1. Disconnect water bypass hose No. 2.
      Fig 4: Locating Water Bypass Hose
      G04828603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. DISCONNECT WATER BYPASS HOSE 
    1. Disconnect the water bypass hose.
      Fig 5: Locating Water Bypass Hose
      G04828604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. DISCONNECT THROTTLE WITH MOTOR BODY CONNECTOR 
    1. Separate the wire harness clamp.
    2. Remove the nut and separate the throttle with motor body connector.
      Fig 6: Locating Throttle With Motor Body Connector
      G04828605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. DISCONNECT VENTILATION HOSE 
    1. Disconnect the ventilation hose.
      Fig 7: Identifying Ventilation Hose
      G04828606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. DISCONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Disconnect the union to connector tube hose.
  37. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY 
    Fig 8: Locating Union To Connector Tube Hose
    G04828607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE INTAKE MANIFOLD 
    1. Separate the 3 wire harness clamps shown in the illustration.
      Fig 9: Locating Wire Harness Clamps
      G04828608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and 2 nuts and remove the intake manifold.
      Fig 10: Locating Intake Manifold Bolts And Nuts
      G04828609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE OIL LEVEL GAUGE GUIDE 
    1. Remove the wire harness clamp and the bolt and remove the oil level gauge guide.
  40. DISCONNECT FUEL TUBE SUB-ASSEMBLY  (See REMOVAL )
    Fig 11: Locating Wire Harness Clamp And Bolt
    G04828610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. DISCONNECT BOOSTER VACUUM TUBE 
    1. Disconnect the booster vacuum tube.
      Fig 12: Locating Booster Vacuum Tube
      G04828611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. DISCONNECT CAMSHAFT POSITION SENSOR CONNECTOR 
    1. Disconnect the camshaft position sensor connector.
      Fig 13: Locating Camshaft Position Sensor Connector
      G04828612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. DISCONNECT ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR 
    1. Disconnect the engine coolant temperature sensor connector.
      Fig 14: Locating Engine Coolant Temperature Sensor Connector
      G04828613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. DISCONNECT HEATED OXYGEN SENSOR CONNECTOR 
    1. Remove the bolts and separate the sensor bracket.
    2. Disconnect the heated oxygen sensor connector.
      Fig 15: Locating Heated Oxygen Sensor Connector
      G04828614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. DISCONNECT HEATER WATER INLET HOSE A 
    1. Disconnect heater water inlet hose A.
      Fig 16: Locating Heater Water Inlet Hose
      G04828615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. SEPARATE WATER BYPASS PIPE NO. 1 
    1. Remove the bolt and separate water bypass pipe No. 1.
      Fig 17: Locating Separate Water Bypass Pipe With Bolt
      G04828616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. DISCONNECT WIRE HARNESS 
    1. Remove the 2 bolts and disconnect the wire harness.
      Fig 18: Locating Wire Harness Bolt
      G04828617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. SEPARATE EXHAUST PIPE ASSEMBLY FRONT 
    1. Remove the 2 bolts and 2 compression springs and separate the exhaust pipe assembly front.
      Fig 19: Locating Exhaust Pipe Assembly With Bolt
      G04828618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE MANIFOLD SUPPORT BRACKET 
    1. Remove the 3 bolts and remove the manifold support bracket.
  50. REMOVE FAN AND GENERATOR V BELT (See REMOVAL  )
  51. REMOVE GENERATOR ASSEMBLY  (See REMOVAL )
  52. REMOVE IGNITION COIL NO. 1  REMOVAL 
  53. REMOVE VENTILATION HOSE  (See REMOVAL )
  54. REMOVE VENTILATION HOSE NO. 2  (See REMOVAL )
    Fig 20: Locating Manifold Support Bracket
    G04828619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY  (See REMOVAL )
  56. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH  (See REMOVAL )
  57. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY  (See REMOVAL )
  58. REMOVE CRANKSHAFT POSITION SENSOR  (See REMOVAL )
  59. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY  (See REMOVAL )
  60. REMOVE WATER PUMP PULLEY  (See REMOVAL )
  61. REMOVE WATER PUMP ASSEMBLY  (See REMOVAL )
  62. REMOVE TRANSVERSE ENGINE, ENGINE MOUNTING BRACKET  (See REMOVAL )
  63. REMOVE OIL PUMP ASSEMBLY  (See REMOVAL )
  64. REMOVE OIL PUMP SEAL  (See REPLACEMENT )
  65. REMOVE CHAIN TENSIONER ASSEMBLY NO. 1 (See REMOVAL  )
  66. REMOVE CHAIN TENSIONER SLIPPER (See REMOVAL  )
  67. REMOVE CHAIN VIBRATION DAMPER NO. 1 (See REMOVAL  )
  68. REMOVE CHAIN SUB-ASSEMBLY 
  69. REMOVE CAMSHAFT 
    NOTE: When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.
    1. Using several steps, uniformly loosen and remove the 19 bearing cap bolts in the sequence shown in the illustration, and then remove camshaft bearing cap No. 1 and camshaft bearing cap No. 2.
      NOTE: Loosen each bolt uniformly while keeping the camshaft level.
    2. Remove the camshaft and camshaft No. 2.
      Fig 21: Locating Bearing Cap Bolts Sequence
      G04828620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. REMOVE CYLINDER HEAD SUB-ASSEMBLY 
    1. Using several steps, uniformly loosen and remove the 10 cylinder head bolts with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 plate washers.
      NOTE:
      • Do not drop the washers into the cylinder head.
      • Head warpage or cracking could result from removing the bolts in the wrong order.
        Fig 22: Locating Cylinder Head Bolts Sequence
        G04828621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE CYLINDER HEAD GASKET 
    1. Remove the cylinder head gasket.
      Fig 23: Locating Exhaust Pipe Assembly With Bolt
      G04828622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 
    1. Remove the 4 bolts and remove exhaust manifold heat insulator No. 1.
      Fig 24: Locating Exhaust Manifold Heat Insulator With Bolt
      G04828623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. REMOVE EXHAUST MANIFOLD 
    1. Remove the 3 bolts and 2 nuts and remove the exhaust manifold.
      Fig 25: Locating Exhaust Manifold And Bolt
      G04828624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE HARNESS BRACKET 
    1. Remove the bolt and remove the harness bracket.
      Fig 26: Locating Harness Bracket And Bolt
      G04828625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. REMOVE BOOSTER VACUUM TUBE 
    1. Remove the 2 bolts and remove the booster vacuum tube.
      Fig 27: Locating Booster Vacuum Tube And Bolt
      G04828626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE CAMSHAFT POSITION SENSOR 
    1. Remove the bolt and remove the camshaft position sensor.
      Fig 28: Locating Camshaft Position Sensor And Bolt
      G04828627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using SST, remove the engine coolant temperature sensor connector.

      SST 09817-33190 

      Fig 29: Identifying Engine Coolant Temperature Sensor Connector With SST
      G04828628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. REMOVE WATER BYPASS HOSE 
    1. Remove the water bypass hose.
      Fig 30: Locating Water Bypass Hose
      G04828629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE HARNESS BRACKET 
    1. Remove the bolt and remove the harness bracket.
      Fig 31: Locating Harness Bracket With Bolt
      G04828630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 
    1. Remove the 3 bolts and remove the fuel delivery pipe sub-assembly with 4 fuel injectors.
      NOTE: Do not drop the fuel injectors when removing the fuel delivery pipe sub-assembly.
  81. REMOVE FUEL INJECTOR ASSEMBLY  (See REMOVAL )
    Fig 32: Locating Fuel Delivery Pipe Sub-Assembly With Fuel Injectors
    G04828631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. REMOVE DELIVERY PIPE NO. 1 SPACER 
    1. Remove the 2 delivery pipe No. 1 spacers.
      Fig 33: Locating Delivery Pipe And Sensor
      G04828632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. REMOVE INJECTOR VIBRATION INSULATOR 
    1. Remove the 4 injector vibration insulators.
      Fig 34: Locating Injector Vibration Insulators
      G04828633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals