Intercooler (W/ Glow Plug Controller) Removal

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
1Kd-Ftv Intake Exhaust. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

  2. REMOVE INTAKE AIR TEMPERATURE SENSOR

  3. REMOVE INTERCOOLER ASSEMBLY

Intercooler (W/ Glow Plug Controller) -- Removal



1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


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

  1. Remove the 3 bolts, 2 cap nuts and No. 1 engine cover.

    Text in Illustration
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Cap Nut


2. REMOVE INTAKE AIR TEMPERATURE SENSOR

  1. Disconnect the intake air temperature sensor connector.



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

  1. Using a 22 mm deep socket wrench, remove the intake air temperature sensor.

    HINT:
    Replace the intake air temperature sensor if it is deformed, cracked or malfunctioning. It is not necessary to replace the intake air temperature sensor each time the intercooler is replaced.


3. REMOVE INTERCOOLER ASSEMBLY


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

  1. Loosen the 2 hose clamps of the No. 1 air hose.



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

  1. Loosen the 2 hose clamps of the No. 2 air hose.



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

  1. Remove the 4 bolts and intercooler.

  1. Remove the No. 2 air hose.



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

  1. Remove the 4 bolts, intake air connector and gasket.