REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE (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)
Common Rail (W/O Dpf) -- 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 and fuel inlet pipe, 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 RM000004QR1003X.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 RM000004QR3003X.html).
| 3. REMOVE DIESEL THROTTLE BODY ASSEMBLY (w/ EGR Cooler) |
| 4. REMOVE NO. 1 ENGINE UNDER COVER |
| 5. REMOVE NO. 2 ENGINE UNDER COVER |
| 6. 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 - -
| 7. DRAIN ENGINE OIL |
Remove the oil filler cap.
Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.
Wipe the oil pan and drain plug.
Install a new gasket and the oil pan drain plug.
- Torque:
- 34 N*m{347 kgf*cm, 25 ft.*lbf}
| 8. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY (w/o EGR Cooler) |
Disconnect the manifold absolute pressure sensor connector.
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Disconnect the vacuum hose from the gas filter.
Loosen the 2 clamps.
Remove the bolt and disconnect the No. 2 air cleaner pipe together with the 2 air hoses.
| 9. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE (w/ EGR Cooler) |
Disconnect the 2 vacuum switching valve connectors and the 3 vacuum transmitting hoses.
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Remove the 2 bolts and manifold stay with vacuum switching valve.
| 10. REMOVE MANIFOLD STAY (w/o EGR Cooler) |
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Remove the 2 bolts and manifold stay.
| 11. REMOVE OIL FILTER SUB-ASSEMBLY |
Using SST, remove the oil filter.
- SST
- 09228-07501
- HINT:
- Insert the drain hose in the oil filter. Put the disposal container beneath the drain hose to collect the oil from the oil filter.
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| 12. 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.
| 13. DISCONNECT NO. 4 WATER BY-PASS HOSE (w/ EGR Cooler) |
Disconnect the No. 4 water by-pass hose from the EGR cooler.
| 14. 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.
| 15. 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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| 16. 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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| 17. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ EGR Cooler) |
w/ EGR Cooler:
Disconnect the 2 connectors.
Disconnect the 5 vacuum hoses.
Remove the bolt and No. 1 gas filter with the gas filter bracket.
Remove the 2 bolts and electric vacuum regulating valve bracket together with the vacuum damper.
- NOTICE:
- Do not remove the electric vacuum regulating valve from the bracket.
w/o EGR Cooler:
Disconnect the connector.
Disconnect the 2 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.
| 18. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/ EGR Cooler) |
Remove the 3 nuts, No. 2 intake air connector and gasket.
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| 19. REMOVE INTAKE AIR CONNECTOR (w/ EGR Cooler) |
Remove the 3 bolts, intake air connector and 2 gaskets.
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| 20. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER (w/ EGR Cooler) |
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.
| 21. 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
| 22. 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
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| 23. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE (w/ EGR Cooler) |
Remove the engine oil level dipstick.
Remove the bolt and injection pipe clamp.
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Remove the bolt and engine oil level dipstick guide.
Remove the O-ring from the engine oil level dipstick guide.
| 24. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE (w/o EGR Cooler) |
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Remove the engine oil level dipstick.
Remove the bolt and injection pipe clamp.
Remove the bolt and engine oil level dipstick guide.
Remove the O-ring from the engine oil level dipstick guide.
| 25. REMOVE FUEL INLET PIPE SUB-ASSEMBLY |
Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.
Text in Illustration *a Common Rail Side *b Fuel Supply Pump Side
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| 26. REMOVE COMMON RAIL ASSEMBLY |
- NOTICE:
- Do not remove the pressure discharge valve or fuel pressure sensor.
Disconnect the 2 connectors.
w/ EGR Cooler:
Remove the 2 bolts, common rail and No. 2 intake manifold insulator.
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w/o EGR Cooler:
Remove the 2 bolts and common rail.