REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY (w/ EGR Cooler)
REMOVE NO. 1 GAS FILTER WITH GAS FILTER BRACKET (w/ EGR Cooler)
REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER (w/ EGR Cooler)
Egr Valve (W/O Glow Plug Controller) -- Removal |
- NOTICE:
- 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.
- After removing the injection pipes, clean them with a brush and compressed air.
| 1. PRECAUTION |
- NOTICE:
- After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (HILUX_TGN26 RM000004QR1006X.html).
| 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL |
- NOTICE:
- When disconnecting the cable, some systems need to be initialized after the cable is reconnected (HILUX_TGN26 RM000004QR300CX.html).
| 3. DRAIN ENGINE COOLANT (w/ EGR Cooler) |
- 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.
Loosen the radiator drain cock plug.
- HINT:
- Collect the coolant in a container and dispose of it according to the regulations in your area.
Drain the coolant by removing the radiator reservoir cap and, using a wrench, remove the vent plug.
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Loosen the cylinder block drain cock plug.
Text in Illustration *1 Radiator Reservoir *2 Radiator Reservoir Cap *3 Vent Plug *4 Cylinder Block Drain Cock Plug *5 Radiator Drain Cock Plug - -
| 4. REMOVE DIESEL THROTTLE BODY ASSEMBLY |
| 5. DISCONNECT NO. 3 WATER BY-PASS HOSE (w/ EGR Cooler) |
Remove the clamp.
Text in Illustration *1 No. 4 Water By-pass Hose *2 No. 3 Water By-pass Hose
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Disconnect the No. 3 water by-pass hose from the EGR cooler.
| 6. DISCONNECT NO. 4 WATER BY-PASS HOSE (w/ EGR Cooler) |
Disconnect the No. 4 water by-pass hose from the EGR cooler.
| 7. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY (w/ EGR Cooler) |
- NOTICE:
- After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.
- After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
w/ EGR Cooler:
Remove the 2 nuts and No. 3 injection pipe clamp.
Remove the 2 bolts and 2 No. 2 injection pipe clamps.
Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
Text in Illustration *a Injector Side *b Common Rail Side
w/o EGR Cooler:
Remove the bolt and No. 2 injection pipe clamp.
Text in Illustration *1 No. 2 Injection Pipe Clamp *2 No. 3 Injection Pipe Clamp *a Injector Side *b Common Rail Side Remove the 2 nuts and No. 3 injection pipe clamp.
Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
| 8. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET (w/ EGR Cooler) |
Remove the 3 bolts and No. 2 intake air connector bracket.
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| 9. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET (w/o EGR Cooler) |
Remove the 3 bolts and No. 2 intake air connector bracket.
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| 10. DISCONNECT NO. 3 WATER BY-PASS PIPE (w/ EGR Cooler) |
Remove the 2 bolts and disconnect the No. 3 water by-pass pipe with wire harness.
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| 11. REMOVE NO. 1 GAS FILTER WITH GAS FILTER BRACKET (w/ EGR Cooler) |
Disconnect the 2 vacuum hoses.
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Remove the bolt and No. 1 gas filter with gas filter bracket.
| 12. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY |
w/ EGR Cooler:
Disconnect the connector.
Disconnect the 4 vacuum hoses.
Remove the 2 bolts and electric vacuum regulating valve with bracket.
- NOTICE:
- Do not remove the electric vacuum regulating valve from the bracket.
w/o EGR Cooler:
Disconnect the 2 connectors.
Disconnect the 3 vacuum hoses.
Remove the 2 bolts and electric vacuum regulating valve together with the bracket.
- NOTICE:
- Do not remove the electric vacuum regulating valve from the bracket.
Remove the bolt and vacuum switching valve.
| 13. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/ EGR Cooler) |
Remove the 3 nuts, No. 2 intake air connector and gasket.
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| 14. REMOVE INTAKE AIR CONNECTOR (w/ EGR Cooler) |
Remove the 3 bolts, intake air connector and 2 gaskets.
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| 15. REMOVE INTAKE AIR CONNECTOR (w/o EGR Cooler) |
Remove the 2 nuts, bolt and intake air connector.
| 16. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER (w/ EGR Cooler) |
Disconnect the EGR valve position sensor connector.
Disconnect the vacuum hose from the No. 2 EGR valve.
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Remove the bolt, 2 nuts, electric EGR control valve with No. 2 EGR valve and EGR cooler.
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Remove the gasket from the cylinder head.
| 17. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY (w/o EGR Cooler) |
Remove the 2 bolts, 2 nuts, No. 1 EGR pipe and 2 gaskets.
Text in Illustration *1 Gasket
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| 18. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY |
w/ EGR Cooler:
Remove the 2 bolts, electric EGR control valve and gasket.
w/o EGR Cooler:
Remove the electric EGR control valve and gasket.
| 19. REMOVE EGR VALVE ADAPTER (w/ EGR Cooler) |
Using a 6 mm hexagon wrench, remove the 3 hexagon bolts, 3 plate washers, EGR valve adapter and gasket.
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| 20. REMOVE NO. 2 EGR VALVE ASSEMBLY (w/ EGR Cooler) |
Using a 5 mm hexagon wrench, remove the hexagon bolt, No. 2 EGR valve and gasket.
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