Common Rail (W/ 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 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 RM000004QR300CX.html).
| 3. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER |
| 4. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY |
Remove the bolt, nut and 2 No. 2 injection pipe clamps.
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Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
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| 5. REMOVE WIRING HARNESS CLAMP BRACKET |
Detach the wire harness clamp.
Text in Illustration *1 Wiring Harness Clamp Bracket
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Remove the bolt and wiring harness clamp bracket.
| 6. REMOVE NO. 2 FUEL PIPE |
for DPF:
Disconnect the vacuum switching valve connector and 2 vacuum transmitting hoses.
Using a 6 mm hexagon wrench, remove the supply pump hollow screw and gasket.
Text in Illustration 
Bolt 
Supply Pump Hollow Screw 
Fuel Check Valve 
Union Bolt Remove the fuel check valve, union bolt and 2 gaskets.
Remove the 3 bolts and No. 2 fuel pipe.
for i-ART:
Using a 6 mm hexagon wrench, remove the supply pump hollow screw and gasket.
Text in Illustration Supply Pump Hollow Screw Fuel Check Valve Remove the fuel check valve, No. 2 fuel pipe and gasket.
| 7. REMOVE NO. 3 NOZZLE LEAKAGE PIPE |
Disconnect the 3 fuel hoses.
Text in Illustration Fuel Check Valve
 |
Remove the 2 bolts.
Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.
| 8. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY |
for DPF:
Remove the 2 bolts.
Text in Illustration *A for DPF *B for i-ART Union Bolt - -
for i-ART:
Remove the 3 bolts.
Remove the union bolt, gasket and No. 2 nozzle leakage pipe.
| 9. 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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| 10. REMOVE VACUUM CONTROL VALVE SET (for i-ART) |
Disconnect the 2 vacuum switching valve connectors and 3 vacuum hoses.
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Remove the 2 bolts and vacuum control valve set.
| 11. REMOVE COMMON RAIL ASSEMBLY |
Disconnect the pressure discharge valve connector.
Remove the 2 bolts and common rail.
Text in Illustration *A for DPF *B for i-ART - NOTICE:
- for DPF:
Do not remove the pressure discharge valve or fuel pressure sensor. - for i-ART:
Do not remove the pressure discharge valve.
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