REMOVE NO. 1 GAS FILTER WITH GAS FILTER BRACKET (w/ EGR Cooler)
REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ EGR Cooler)
REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER (w/ EGR Cooler)
Fuel Injector (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) |
| 4. REMOVE DIESEL THROTTLE BODY ASSEMBLY (w/ EGR Cooler) |
| 5. REMOVE INTERCOOLER ASSEMBLY (w/o EGR Cooler) |
| 6. CHECK INJECTOR COMPENSATION CODE |
- HINT:
- If the injector compensation code is not correctly registered, it may cause malfunctions.
Read the injector compensation code.
- w/ EGR Cooler: (HILUX_TGN26 RM0000012XK07FX_02_0003.html)
- w/o EGR Cooler: (HILUX_TGN26 RM0000012XK07GX_02_0003.html)
- w/ EGR Cooler: (HILUX_TGN26 RM0000012XK07FX_02_0003.html)
Check that the compensation code of the installed injector is the same as the code registered in the ECM. If the code is not the same, register the injector compensation code on the injector.
- w/ EGR Cooler: (HILUX_TGN26 RM0000012XK07FX.html)
- w/o EGR Cooler: (HILUX_TGN26 RM0000012XK07GX.html)
- w/ EGR Cooler: (HILUX_TGN26 RM0000012XK07FX.html)
| 7. 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
 |
Disconnect the No. 3 water by-pass hose from the EGR cooler.
| 8. DISCONNECT NO. 4 WATER BY-PASS HOSE (w/ EGR Cooler) |
Disconnect the No. 4 water by-pass hose from the EGR cooler.
| 9. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY |
- 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.
| 10. 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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| 11. 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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| 12. REMOVE NO. 1 GAS FILTER WITH GAS FILTER BRACKET (w/ EGR Cooler) |
Disconnect the 2 vacuum hoses.
 |
Remove the bolt and No. 1 gas filter with gas filter bracket.
| 13. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ EGR Cooler) |
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.
| 14. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/ EGR Cooler) |
Remove the 3 nuts, No. 2 intake air connector and gasket.
 |
| 15. REMOVE INTAKE AIR CONNECTOR (w/ EGR Cooler) |
Remove the 3 bolts, intake air connector and 2 gaskets.
 |
| 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. 4 INJECTION PIPE SUB-ASSEMBLY |
- NOTICE:
- If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection pipe clamp with a new one.
w/ EGR Cooler:
Remove the bolt and disconnect the injection pipe clamp.
Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
Text in Illustration *a Injector Side *b Common Rail Side
w/o EGR Cooler:
Remove the 2 bolts and disconnect the 2 injection pipe clamps.
Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
Text in Illustration *a Injector Side *b Common Rail Side
| 18. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY |
Disconnect the 3 fuel hoses.
Remove the union bolt, 3 bolts, No. 2 nozzle leakage pipe and gasket.
Text in Illustration *A w/ EGR Cooler *B w/o EGR Cooler *1 Union Bolt
 |
| 19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY |
- NOTICE:
- If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.
Remove the 3 bolts and disconnect the 4 connectors.
 |
Disconnect the ventilation hose.
Using a small screwdriver, remove the nozzle holder seal by prying between the nozzle holder seal and the cutout part of the cylinder head cover.
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Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.
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Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.
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| 20. REMOVE INJECTOR ASSEMBLY |
Remove the union bolt, 4 injector hollow screws, 5 gaskets and nozzle leakage pipe.
Text in Illustration *1 Union Bolt - NOTICE:
- When removing the nozzle leakage pipe, place a cushion under the pipe.
- Be careful not to deform or scratch the union seal surface.
- After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
 |
Remove the 4 bolts, 4 washers, 4 No. 1 nozzle holder clamps and 4 injectors.
- HINT:
- Arrange the injectors, No. 1 nozzle holder clamps, washers and bolts in the correct order.
 |
Remove the O-ring from each injector.
Remove the 4 injection nozzle seats from the cylinder head.