Page 1857 of 3115

A17668A19481
(k)
(j)(i)
(n)(m)
(l)
B15320B16469No. 1 Water Bypass Hose
A17670
Wire Clamp
A08664
Wire Protector
Ground Cable
EM-36
- ENGINE MECHANICALCYLINDER HEAD
1609 Author: Date:
2004 LAND CRUISER (RM1071U)
(h) Disconnect the fuel pressure regulator vacuum hose from
the fuel pressure regulator pipe.
(i) Disconnect the PCV hose from the PCV valve on the LH
cylinder head.
(j) Disconnect the EVAP hose (from charcoal canister) from
VSV for EVAP.
(k) Disconnect the EVAP hose (from charcoal canister) from
the EVAP pipe on the intake manifold.
(l) Disconnect the EVAP hose (from intake air connector)
from the EVAP pipe on the intake manifold.
(m) Disconnect the PS air hose from the intake manifold.
(n) Disconnect the No.1 water bypass hose from the front wa-
ter by-pass joint.
(o) Disconnect the 2 wire clamps from the wire clamp bracket
on the RH delivery pipe.
(p) Remove the 2 bolts and disconnect the engine wire pro-
tector from the rear water bypass joint and the RH cylinder
head.
(q) Remove the guide for A/T bracket from the LH cylinder
head.
(r) Remove the 2 ground cables from the RH and LH cylinder
head.
Page 1858 of 3115

A19472
A17671A19482
A17679
A09148
EVAP Pipe
A08655
- ENGINE MECHANICALCYLINDER HEAD
EM-37
1610 Author: Date:
2004 LAND CRUISER (RM1071U)
(s) Remove the 2 bolts and disconnect the engine wire pro-
tector from the intake manifold.
(t) Remove the engine wire from the engine hanger.
(u) Remove the engine wire from the wire bracket.
(v) Remove the RH rear and the LH front V-bank cover
brackets.
(w) Remove the 6 bolts, the 4 nuts, the intake manifold as-
sembly and the 2 gaskets.
13. DISASSEMBLE UPPER AND LOWER INTAKE MAN-
IFOLDS
(a) Remove the throttle body (See page SF-36).
(b) Remove the 13 bolts, the 3 nuts, the upper intake man-
ifold and the gasket.
(c) Disconnect the EVAP hose from the upper intake man-
ifold, and remove the accelerator cable clamp and VSV
for EVAP.
(d) Remove the bolt, the union, the 2 gaskets and the brake
booster tube from the upper intake manifold.
(e) Remove the 2 bolts and the EVAP pipe from the intake
manifold.
(f) Disconnect the fuel return hose from the fuel pressure
regulator.
(g) Remove the 3 bolts holding the fuel return hose from the
lower intake manifold.
(h) Remove the fuel pressure regulator, the fuel pressure
pulsation damper and the 2 gaskets.
(i) Remove the bolt and the rear fuel pipe.
(j) Remove the 2 delivery pipes and the 8 injectors (See
page
SF-22).
Page 1859 of 3115
A05516
A05517
A05564
EM-38
- ENGINE MECHANICALCYLINDER HEAD
1611 Author: Date:
2004 LAND CRUISER (RM1071U)
14. REMOVE WATER INLET AND INLET HOUSING AS-
SEMBLY (See page CO-6)
15. REMOVE FRONT WATER BYPASS JOINT
Remove the 4 nuts, the water bypass joint and the 2 gaskets.
16. REMOVE REAR WATER BYPASS JOINT
Remove the 4 nuts, the water bypass joint and the 2 gaskets.
17. REMOVE ENGINE HANGERS
18. REMOVE OIL DIPSTICK AND GUIDE FOR A/T
19. REMOVE CYLINDER HEAD COVERS
Remove the 18 bolts, the 18 seal washers, the cylinder head
cover and gasket. Remove the 2 cylinder head covers.
20. IF NECESSARY, REMOVE SEMI-CIRCULAR PLUGS
AND CAMSHAFT HOUSING PLUGS
21. REMOVE CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being removed.
Otherwise, excessive pressure is put on the cylinder head
journal thrust, causing a burr on the journal and damage on
the camshaft. To avoid this, follow the steps below.
Page 1860 of 3115

A04456
No. 2 Idler
Pulley Bolt
Crankshaft
Pulley BoltTiming
Mark
A04467Service Bolt
A04468
A04469
8101241
14161862
19
2021
22
1315175
79113
- ENGINE MECHANICALCYLINDER HEAD
EM-39
1612 Author: Date:
2004 LAND CRUISER (RM1071U)
(a) Check the crankshaft pulley position.
Check that the timing mark of the crankshaft pulley is
aligned with the centers of the crankshaft pulley bolt and
the idler pulley bolt.
NOTICE:
Having the crankshaft pulley at the wrong angle can cause
the piston head and the valve head to come into contact
with each other when removing the camshaft, causing
damage on them. So always set the crankshaft pulley at the
correct angle.
(b) Remove the RH camshafts.
(1) Move a service bolt of the sub-gear upward by turn-
ing the hexagon shaped port of the exhaust cam-
shaft with a wrench.
(2) Secure the sub-gear to the main gear with a service
bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 - 20 mm
HINT:
When removing the camshafts, make sure that the torsional
spring force of the sub-gear is eliminated by the above opera-
tion.
(3) Set the timing mark (1 dot mark) of the camshaft
main gear at approx. 10° angle by turning the hexa-
gon wrench head portion of the exhaust camshaft
with a wrench.
(4) Uniformly loosen and remove the 22 bearing cap
bolts a little at a time for several times in the se-
quence shown.
(5) Remove the oil feed pipe, 9 bearing caps, cam shaft
timing oil control valve and camshafts.
Page 1861 of 3115

A02856Service Bolt
A02857
Align
A04470
4
6
108
1
16
12
18 2
19 20 2221
15
3
5
97
14
1713
11
A02859
A02850
SST
Service Bolt
Turn EM-40
- ENGINE MECHANICALCYLINDER HEAD
1613 Author: Date:
2004 LAND CRUISER (RM1071U)
(c) Remove the LH camshafts.
(1) Move a service bolt of the sub-gear upward by turn-
ing the hexagon shaped port of the exhaust cam-
shaft with a wrench.
(2) Secure the sub-gear to the main gear with a service
bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 - 20 mm
HINT:
When removing the camshaft, make sure that the torsional
spring force of the sub-gear is eliminated by the above opera-
tion.
(3) Align the timing mark (2 dot marks) of the camshaft
drive gear by turning the hexagon wrench head por-
tion of the exhaust camshaft with a wrench.
(4) Evenly loosen and remove the 22 bearing cap bolts
a little at a time for several times as in the sequence
shown.
(5) Remove the oil feed pipe, 9 bearing caps, and cam-
shafts.
HINT:
Arrange the bearing caps in correct order for installation.
22. DISASSEMBLE EXHAUST CAMSHAFTS
(a) Mount the hexagon wrench head portion of the camshaft
in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Using SST, turn the sub-gear clockwise, and remove the
service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
Page 1862 of 3115
A02861
A04471
Oil Seal
A04472
RH Cylinder Head
LH Cylinder HeadFront
19
108
76
5
4
32
1
351082
4697
- ENGINE MECHANICALCYLINDER HEAD
EM-41
1614 Author: Date:
2004 LAND CRUISER (RM1071U)
(c) Using snap ring pliers, remove the snap ring.
(d) Remove the wave washer.
(e) Remove the camshaft sub-gear.
(f) Remove the camshaft gear spring.
HINT:
Arrange the camshaft sub-gears and gear spring (RH and LH
sides).
NOTICE:
Be careful not to damage the camshaft timing tube.
23. REMOVE OIL SEAL FROM INTAKE CAMSHAFT
24. REMOVE SPARK PLUGS
25. REMOVE CYLINDER HEAD AND EXHAUST MAN-
IFOLD ASSEMBLIES
(a) Uniformly loosen the 10 cylinder head bolts on one side
of each cylinder head in a little at a time for several times
as in the sequence shown, then do the other side as
shown. Remove the 20 cylinder head bolts and the plate
washers.
NOTICE:
Removing the bolts in incorrect order could cause a
warp or cracks in the cylinder head.
Page 1863 of 3115
A04473
RH Cylinder Head
LH Cylinder HeadA
A
A02871
A05498
EM-42
- ENGINE MECHANICALCYLINDER HEAD
1615 Author: Date:
2004 LAND CRUISER (RM1071U)
Do not drop the plate washer of the cylinder head bolt
into A area in the illustration. It will fall down to the oil
pan through the cylinder head and the cylinder block.
(b) Lift the cylinder head from the dowels on the cylinder
block, and place the 2 cylinder heads on wooden blocks.
HINT:
After lifting off the cylinder head, pry off the cylinder head and
the cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the
cylinder head and the cylinder block.
The cylinder head should not be tilted so to secure the
valve lifter. If the cylinder head is tilted, remove the
valve lifter and check that the adjusting shim is set
correctly.
26. REMOVE RH EXHAUST MANIFOLD FROM CYLINDER
HEAD
(a) Remove the 4 bolts and the heat insulator.
(b) Remove the 8 nuts, the exhaust manifold and the gasket.
Page 1864 of 3115
A05518
- ENGINE MECHANICALCYLINDER HEAD
EM-43
1616 Author: Date:
2004 LAND CRUISER (RM1071U)
27. REMOVE LH EXHAUST MANIFOLD FROM CYLINDER
HEAD
(a) Remove the 4 bolts and the heat insulator.
(b) Remove the 8 nuts, the exhaust manifold and the gasket.