Common Rail (W/ Dpf) Removal

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
2Kd-Ftv Fuel. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. PRECAUTION

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER

  4. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

  5. REMOVE WIRING HARNESS CLAMP BRACKET

  6. REMOVE NO. 2 FUEL PIPE

  7. REMOVE NO. 3 NOZZLE LEAKAGE PIPE

  8. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

  9. REMOVE OIL FILTER SUB-ASSEMBLY

  10. REMOVE COMMON RAIL ASSEMBLY

Common Rail (W/ Dpf) -- Removal


NOTICE:
  1. 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.
  2. 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.
  3. 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 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 RM000004QR3009X.html).


3. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER
(HILUX_TGN26 RM000004QWO008X.html)


4. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


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

  1. Remove the bolt, nut and 2 No. 2 injection pipe clamps.



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

  1. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.



5. REMOVE WIRING HARNESS CLAMP BRACKET


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Fuel.Fuel System (W/ Dpf).Common Rail (W/ Dpf) Removal

  1. Detach the wire harness clamp.

    Text in Illustration
    *1
    		Wiring Harness Clamp Bracket

  1. Remove the bolt and wiring harness clamp bracket.



6. REMOVE NO. 2 FUEL PIPE


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

  1. Using a 6 mm hexagon wrench, remove the supply pump hollow screw and gasket.

    Text in Illustration
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Bolt
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Supply Pump Hollow Screw
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Fuel Check Valve
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Union Bolt

  1. Remove the fuel check valve, union bolt and 2 gaskets.

  1. Remove the 3 bolts and No. 2 fuel pipe.



7. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


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

  1. Disconnect the 3 fuel hoses.

    Text in Illustration
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Fuel Check Valve

  1. Remove the 2 bolts.

  1. Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.



8. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


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

  1. Remove the 2 bolts.

    Text in Illustration
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Union Bolt

  1. Remove the union bolt, gasket and No. 2 nozzle leakage pipe.



9. REMOVE OIL FILTER SUB-ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Fuel.Fuel System (W/ Dpf).Common Rail (W/ Dpf) Removal

  1. 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.


10. REMOVE COMMON RAIL ASSEMBLY

  1. Disconnect the pressure discharge valve connector.



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

  1. Remove the 2 bolts and common rail.

    NOTICE:
    Do not remove the pressure discharge valve or fuel pressure sensor.