LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2008 >> FJ Cruiser RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 49 (Engine Mechanical) >> Cylinder Head >> Removal

Cylinder Head: Removal

WARNING: This page is about a different car, the 2007 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCHARGE FUEL SYSTEM PRESSURE (See  REMOVAL  ) 
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.
  3. DRAIN ENGINE OIL 
    1. Remove the oil pan drain plug and drain the engine oil.
    2. Clean the oil pan drain plug and install a new gasket and the drain plug.

      Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

  4. REMOVE TIMING BELT 
    1. Remove the timing belt (see REMOVAL  ).
  5. DISCONNECT NO. 1 FUEL HOSE (See  REMOVAL  ) 
  6. DISCONNECT NO. 2 FUEL HOSE (See  REMOVAL  ) 
  7. REMOVE FRONT EXHAUST PIPE LH (See  REMOVAL  ) 
  8. REMOVE FRONT EXHAUST PIPE RH (See  REMOVAL  ) 
  9. REMOVE INTAKE MANIFOLD ASSEMBLY (See  REMOVAL  ) 
  10. REMOVE AIR SWITCHING VALVE ASSEMBLY (See  REMOVAL  ) 
  11. REMOVE AIR PUMP ASSEMBLY (See  REMOVAL  ) 
  12. REMOVE CAMSHAFT POSITION SENSOR (See  REMOVAL  ) 
  13. REMOVE VVT SENSOR (for Bank 1) (See  REMOVAL  ) 
  14. REMOVE VVT SENSOR (for Bank 2) (See  REMOVAL  ) 
  15. REMOVE KNOCK SENSOR (See  REMOVAL  ) 
  16. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 1) (See  REMOVAL  ) 
  17. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 2) (See  REMOVAL  ) 
  18. REMOVE STARTER ASSEMBLY (See  REMOVAL  ) 
  19. REMOVE WATER INLET HOUSING 
    1. Disconnect the water by-pass hose from the water inlet housing.
    2. Remove the 2 bolts and inlet housing.
  20. REMOVE FRONT WATER BY-PASS JOINT 
    1. Disconnect the ECT sensor connector and by-pass hose.
      Fig 1: Disconnecting ECT Sensor Connector & By-Pass Hose
      G04435658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 nuts, water by-pass joint and 2 gaskets.
    Fig 2: Removing Water By-Pass Joint & Gaskets
    G04435659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT HEATER HOSE 
  22. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY 
    1. Remove the bolt.
    2. Pull out the water by-pass pipe.
    3. Remove the O-ring from the water by-pass pipe.
    Fig 3: Removing Water By-Pass Pipe Sub-Assembly
    G04435660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE REAR WATER BY-PASS JOINT 
    1. Remove the 4 nuts and water by-pass joint.
    2. Remove the 2 gaskets from the water by-pass joint.
    Fig 4: Removing Rear Water By-Pass Joint
    G04435661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE OIL DIPSTICK GUIDE WITH DIPSTICK 
    1. Remove the bolt and dipstick guide with dipstick.
    2. Remove the O-ring.
  25. REMOVE IGNITION COIL 
    1. Remove the 8 bolts and 8 ignition coils.
  26. REMOVE SPARK PLUG 
  27. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    1. Remove the 9 bolts, 9 seal washers and cylinder head cover.
      Fig 5: Removing Cylinder Head Cover LH
      G04435662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH 
    1. Remove the 9 bolts, 9 seal washers and cylinder head cover.
      Fig 6: Removing Cylinder Head Cover RH
      G04435663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. WORK FOR PISTON AND VALVE DAMAGE PREVENTION 
    1. Turn the crankshaft timing pulley counterclockwise by 45° and match the timing mark with the illustrated position in Fig 7.

      HINT:

      When the No. 1 cylinder is positioned at 45° BTDC, the valve and piston do not interfere with each other even when the valve is fully open.

      Fig 7: Matching Timing Mark Turning Crankshaft Timing Pulley
      G04435664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be sure to match the cut part by turning it counterclockwise.
  30. REMOVE CAMSHAFT TIMING PULLEY LH 
    1. Hold the camshaft timing pulley with SST, loosen the 4 bolts of the timing pulley.

      SST 09960-10010 (09962-01000, 09963-01000) 

    2. Remove the timing pulley.
      Fig 8: Removing Camshaft Timing Pulley LH
      G04435665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE CAMSHAFT TIMING PULLEY RH 
    1. Hold the camshaft timing pulley with SST, loosen the 4 bolts of the timing pulley.

      SST 09960-10010 (09962-01000, 09963-01000) 

    2. Remove the timing pulley.
    Fig 9: Removing Camshaft Timing Pulley RH
    G04435666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE REAR NO. 2 TIMING BELT PLATE LH 
    1. Remove the 2 bolts and No. 2 timing belt plate.
  33. REMOVE REAR TIMING BELT PLATE LH 
    1. Remove the bolt and timing belt plate.
  34. REMOVE REAR NO. 2 TIMING BELT PLATE RH 
    1. Remove the 2 bolts and No. 2 timing belt plate.
  35. REMOVE REAR TIMING BELT PLATE RH 
    1. Remove the bolt, stud bolt and timing belt plate.
  36. REMOVE CAMSHAFT (for Bank 1) 
    NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
    1. Bring the service bolt hole of the sub-gear upward by turning the hexagon head portion of the No. 4 camshaft with a wrench.
      Fig 10: Bringing Service Bolt Hole Upward
      G04435667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Secure the sub-gear to the main gear with a service bolt.

      Recommended service bolt 

      SERVICE BOLT

      Thread Diameter Thread Pinch Bolt Length
      6 mm 1.0 mm 16 to 20 mm (0.63 to 0.79 in.)

      HINT:

      When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.

    3. Set a wrench to the hexagon head portion of the No. 4 camshaft. Turn the wrench so that the timing marks (2 dot marks each) on the camshaft drive and driven main gears are aligned as shown in Fig 11.
      Fig 11: Aligning Timing Marks On Camshaft Drive & Driven Main Gears
      G04435668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Uniformly loosen the 22 bearing cap bolts in several passes in the sequence shown Fig 12.
    5. Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and the No. 3 and No. 4 camshafts.
      NOTE:
      • Do not forcibly pry the camshaft with a tool.
      • Do not damage the reception part of the thrust on the cylinder head side.
        Fig 12: Removing Bearing Cap Bolts In Sequence
        G04435669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE CAMSHAFT (for Bank 2) 
    NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
    1. Bring the service bolt hole of the sub-gear upward by turning the hexagon head portion of the No. 2 camshaft with a wrench.
    2. Secure the sub-gear to the main gear with a service bolt.

      Recommended service bolt 

      SERVICE BOLT

      Thread Diameter Thread Pinch Bolt Length
      6 mm 1.0 mm 16 to 20 mm (0.63 to 0.79 in.)
      Fig 13: Bringing Service Bolt Hole By Turning
      G04435670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.

    3. Set a wrench to the hexagon head portion of the No. 2 camshaft. Turn the wrench so that the timing mark (1 dot mark) on the camshaft main gear is moved approximately 10° as shown in Fig 14.
      Fig 14: Aligning Timing Marks On Camshaft Drive & Driven Main Gears
      G04435671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Uniformly loosen the 22 bearing cap bolts in several passes in the sequence shown in Fig 15
      Fig 15: Removing Bearing Cap Bolts In Sequence
      G04435672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and the No. 1 and No. 2 camshafts.
      NOTE:
      • Do not forcibly pry the camshaft with a tool.
      • Do not damage the reception part of the thrust on the cylinder head side.
  38. REMOVE NO. 1 ENGINE HANGER 
    1. Remove the 2 bolts and engine hanger.
      Fig 16: Removing No. 1 Engine Hanger
      G04435673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE NO. 2 ENGINE HANGER 
    1. Remove the 2 bolts and engine hanger.
      Fig 17: Removing No. 2 Engine Hanger
      G04435674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE CYLINDER HEAD LH 
    1. Uniformly loosen the 10 cylinder head bolts on the cylinder head in several passes, in the sequence shown in Fig 18 . Remove the 10 cylinder head bolts and plate washers.
      Fig 18: Removing Cylinder Head Bolt LH In Sequence
      G04435675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Cylinder head warpage or cracking may result from removing bolts in the incorrect order.
      • Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
    2. Lift the cylinder head from the ring pins on the cylinder block, and place the cylinder head on wooden blocks on a bench.
    3. Remove the cylinder head together with the exhaust manifold.
      NOTE:
      • Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
      • When removing the cylinder head, tilt the cylinder head but make sure the valve lifter does not drop.

      HINT:

      If the cylinder head cannot be lifted easily, pry between the cylinder head and cylinder block with a screwdriver.

      Fig 19: Prying Between Cylinder Head & Cylinder Block With Screwdriver
      G04435676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE CYLINDER HEAD GASKET LH 
  42. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Remove the 4 bolts and heat insulator.
      Fig 20: Removing No. 2 Exhaust Manifold Heat Insulator
      G04435677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Remove the 8 nuts, exhaust manifold and gasket.
      Fig 21: Removing Exhaust Manifold Sub-Assembly LH
      G04435678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE CYLINDER HEAD RH 
    1. Uniformly loosen the 10 cylinder head bolts on the cylinder head in several passes, in the sequence shown in Fig 22 . Remove the 10 cylinder head bolts and plate washers.
      NOTE:
      • Cylinder head warpage or cracking may result from removing bolts in the incorrect order.
      • Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
    2. Lift the cylinder head from the ring pins on the cylinder block, and place the cylinder head on wooden blocks on a bench.
      Fig 22: Removing Cylinder Head Bolt RH In Sequence
      G04435679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the cylinder head together with the exhaust manifold.
      NOTE:
      • Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
      • The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly.

      HINT:

      If the cylinder head cannot be lifted easily, pry between the cylinder head and cylinder block with a screwdriver.

      Fig 23: Prying Between Cylinder Head & Cylinder Block With Screwdriver
      G04435680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE CYLINDER HEAD GASKET RH 
  46. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Remove the 4 bolts and heat insulator.
      Fig 24: Removing No. 1 Exhaust Manifold Heat Insulator
      G04435681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Remove the 8 nuts, exhaust manifold and gasket.
      Fig 25: Removing Exhaust Manifold Sub-Assembly RH
      G04435682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals