Engine Assembly Removal

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
2Tr-Fe Engine Mechanical. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. DISCHARGE FUEL SYSTEM PRESSURE

  2. PRECAUTION

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  4. REMOVE NO. 1 ENGINE UNDER COVER

  5. REMOVE NO. 2 ENGINE UNDER COVER

  6. DRAIN ENGINE COOLANT

  7. DRAIN ENGINE OIL

  8. DRAIN MANUAL TRANSMISSION OIL

  9. REMOVE INTAKE AIR CONNECTOR AND AIR CLEANER ASSEMBLY

  10. REMOVE RADIATOR GRILLE

  11. DISCONNECT RADIATOR HOSE INLET

  12. DISCONNECT RADIATOR HOSE OUTLET

  13. REMOVE FAN AND GENERATOR V BELT

  14. REMOVE AIR PUMP INLET (w/ Secondary Air Injection System)

  15. REMOVE FAN SHROUD

  16. REMOVE FAN PULLEY

  17. REMOVE RADIATOR ASSEMBLY

  18. DISCONNECT HEATER WATER HOSE

  19. DISCONNECT HOSE

  20. DISCONNECT NO. 4 AIR INJECTION SYSTEM HOSE (w/ Secondary Air Injection System)

  21. DISCONNECT NO. 2 FUEL HOSE

  22. DISCONNECT NO. 1 FUEL HOSE

  23. DISCONNECT ENGINE WIRE

  24. DISCONNECT VANE PUMP ASSEMBLY

  25. REMOVE ENGINE OIL LEVEL DIPSTICK

  26. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

  27. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)

  28. REMOVE HOOD ASSEMBLY

  29. REMOVE FRONT EXHAUST PIPE ASSEMBLY

  30. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)

  31. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for 4WD)

  32. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for Pre-Runner)

  33. REMOVE STARTER ASSEMBLY

  34. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY

  35. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

  36. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

  37. REMOVE CLUTCH COVER ASSEMBLY

  38. REMOVE CLUTCH DISC ASSEMBLY

  39. REMOVE FLYWHEEL SUB-ASSEMBLY

  40. REMOVE REAR END PLATE

  41. INSTALL ENGINE HANGER

  42. REMOVE ENGINE ASSEMBLY

  43. INSTALL ENGINE TO ENGINE STAND

Engine Assembly -- Removal



1. DISCHARGE FUEL SYSTEM PRESSURE
(HILUX_TGN26 RM000000YL4019X.html)


2. 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).


3. 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).


4. REMOVE NO. 1 ENGINE UNDER COVER


5. REMOVE NO. 2 ENGINE UNDER COVER


6. DRAIN ENGINE COOLANT


CAUTION:
Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal


Text in Illustration
*1
Radiator Cap
*2
Reservoir Cap
*3
Cylinder Block Water Drain Cock Plug
*4
Radiator Drain Cock Plug

  1. Loosen the radiator drain cock plug.

  1. Remove the radiator cap and drain the coolant.

    HINT:
    Collect the coolant in a container and dispose of it according to the regulations in your area.

  1. Loosen the cylinder block water drain cock plug and drain the coolant from the engine.



7. DRAIN ENGINE OIL

  1. Remove the oil filler cap.

  1. Remove the oil drain plug and gasket, and drain the oil into a container.



8. DRAIN MANUAL TRANSMISSION OIL
  1. R150:
    (HILUX_TGN26 RM000004R1X004X.html)
  2. R150F:
    (HILUX_TGN26 RM000004R1Z003X.html)


9. REMOVE INTAKE AIR CONNECTOR AND AIR CLEANER ASSEMBLY


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

  1. Disconnect the vacuum hose.

  1. Disconnect the No. 2 PCV hose.

  1. Disconnect the mass air flow meter connector and detach the wire harness clamps.

  1. Loosen the hose clamp and remove the 4 bolts, air cleaner and intake air connector assembly.



10. REMOVE RADIATOR GRILLE


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Put protective tape around the radiator grille.

    Text in Illustration
    *1
    		Protective Tape

  1. Remove the 2 clips and 2 screws.



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

  1. Detach the 6 claws and remove the radiator grille.



11. DISCONNECT RADIATOR HOSE INLET

  1. Disconnect the radiator hose inlet from the radiator.



12. DISCONNECT RADIATOR HOSE OUTLET

  1. Disconnect the radiator hose outlet from the radiator.



13. REMOVE FAN AND GENERATOR V BELT


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward and decrease the tension in the fan and generator V belt. Then remove the fan and generator V belt.

    NOTICE:
    When removing the fan and generator V belt, do not use the idle pulley's bolt.
    HINT:
    After removing the fan and generator V belt, move the tensioner upward as far as possible.


14. REMOVE AIR PUMP INLET (w/ Secondary Air Injection System)


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Remove the bolt and disconnect the air pump inlet.



15. REMOVE FAN SHROUD


Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Disconnect the reservoir hose from the upper radiator tank.

  1. Loosen the 4 nuts holding the fluid coupling fan.

  1. Remove the fan and generator V belt (HILUX_TGN26 RM000000YMP01OX_01_0001.html).

  1. Remove the 2 bolts holding the fan shroud.

  1. Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan.

    NOTICE:
    Be careful not to damage the radiator core.

  1. Remove the fan pulley from the engine water pump.



16. REMOVE FAN PULLEY


17. REMOVE RADIATOR ASSEMBLY


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

  1. w/ Airbag System:

    1. Using a clip remover, detach the 4 clamps from the radiator as shown in the illustration.

      HINT:
      Tape the clip remover tip before use.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Remove the 4 bolts and radiator.



18. DISCONNECT HEATER WATER HOSE


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

  1. Disconnect the heater water inlet hose and heater water outlet hose from the heater pipe.



19. DISCONNECT HOSE


Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Disconnect the vacuum hose (for the brake master cylinder).

  1. Disconnect the purge line hose.



20. DISCONNECT NO. 4 AIR INJECTION SYSTEM HOSE (w/ Secondary Air Injection System)


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

  1. Loosen the clamp and disconnect the No. 4 air injection system hose.



21. DISCONNECT NO. 2 FUEL HOSE


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

  1. Disconnect the No. 2 fuel hose.



22. DISCONNECT NO. 1 FUEL HOSE


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

  1. Disconnect the No. 1 fuel hose (HILUX_TGN26 RM000000YL4019X.html).



23. DISCONNECT ENGINE WIRE


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

  1. Disconnect the ECM connectors from the cabin.

    1. Remove the glove compartment door.

    2. Disconnect the 4 ECM connectors.



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

  1. w/ Secondary Air Injection System:
    Disconnect the air injection driver connector.

  1. Detach the wire harness clamp.

  1. Remove the bolt and disconnect the ground wire.

  1. Pull out the engine wire from the cabin.

  1. w/ Secondary Air Injection System:
    Disconnect the air fuel ratio sensor connector.

  1. w/o Secondary Air Injection System:
    Disconnect the heated oxygen sensor connector.

  1. Remove the bolt and disconnect the sensor bracket from the right side of the frame.



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

  1. Remove the bolt and disconnect the ground wire from the left side of the frame.

  1. Remove the nut and disconnect the ground wire from the body.

  1. Remove the engine room relay block cover (upper).



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Remove the engine room relay block cover (side).

    1. Using a screwdriver, detach the 4 claws and remove the relay block cover.

      Text in Illustration
      *a
      		Pull
      HINT:
      Tape the screwdriver tip before use.

  1. Remove the nut and disconnect the cable from the engine room junction block.

  1. Disconnect the 2 engine room junction block connectors and wire clamp.

  1. Remove the bolt and disconnect the wire clamp from the front engine mounting bracket LH.



24. DISCONNECT VANE PUMP ASSEMBLY

  1. Disconnect the oil pressure switch connector.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Remove the 2 bolts and disconnect the vane pump from the engine.

  1. Support the vane pump securely.



25. REMOVE ENGINE OIL LEVEL DIPSTICK


26. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

  1. Remove the bolt, engine oil level dipstick guide and O-ring.

    NOTICE:
    Cover the dipstick guide hole to prevent foreign matter from entering it.


27. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


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

  1. Remove the bolt and disconnect the suction hose sub-assembly from the engine.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Disconnect the cooler compressor connector.

  1. Remove the 4 bolts and disconnect the cooler compressor from the engine.

  1. Support the cooler compressor securely.

    HINT:
    It is not necessary to completely remove the cooler compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.


28. REMOVE HOOD ASSEMBLY


Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Disconnect the washer nozzle hose.

  1. Remove the 4 bolts and hood.

    NOTICE:
    Be careful not to damage the vehicle.


29. REMOVE FRONT EXHAUST PIPE ASSEMBLY

  1. w/ Secondary Air Injection System:
    Disconnect the air fuel ratio sensor connector and detach the wire harness clamp.

  1. Disconnect the heated oxygen sensor connector and detach the wire harness clamp.

  1. Remove the 4 bolts, 2 nuts and 2 compression springs.

  1. Remove the front exhaust pipe from the exhaust pipe support.



30. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Place matchmarks on the propeller shaft flange and differential flange.

    Text in Illustration
    *1
    		Matchmark

  1. Remove the 4 nuts, 4 bolts and 4 washers and disconnect the propeller shaft.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Place matchmarks on the propeller shaft flange and transfer flange.

    Text in Illustration
    *1
    		Matchmark

  1. Remove the 4 nuts, 4 washers and front propeller shaft.



31. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for 4WD)


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Place matchmarks on the propeller shaft flange and transfer flange.

    Text in Illustration
    *1
    		Matchmark

  1. Remove the 4 nuts and 4 washers and disconnect the propeller shaft.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Place matchmarks on the propeller shaft flange and differential flange.

    Text in Illustration
    *1
    		Matchmark

  1. Remove the 4 nuts, 4 bolts and 4 washers.



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

  1. Remove the 2 set bolts and 2 plates of the center support bearing from the frame crossmember.

  1. Remove the propeller shaft.



32. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for Pre-Runner)


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Place matchmarks on the propeller shaft flange and differential flange.

    Text in Illustration
    *1
    		Matchmark

  1. Remove the 4 nuts, 4 bolts and 4 washers and disconnect the propeller shaft.



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

  1. Remove the 2 set bolts and 2 plates of the center support bearing from the frame crossmember.

  1. Pull out the propeller shaft.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Install SST to the extension housing to prevent oil leakage.

    SST
    09325-40010


33. REMOVE STARTER ASSEMBLY


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

  1. Disconnect the starter connector.

  1. Disconnect the terminal cap.

  1. Remove the nut and disconnect the starter wire.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Remove the bolt and disconnect the clutch flexible hose bracket.

  1. Remove the bolt and starter.



34. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Remove the 2 bolts and disconnect the release cylinder assembly.



35. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY
  1. R150:
    (HILUX_TGN26 RM0000011B200RX.html)
  2. R150F:
    (HILUX_TGN26 RM0000011AL00IX.html)


36. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR
HINT:
Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary.

  1. Remove the 4 bolts and rear No. 1 engine mounting insulator.



37. REMOVE CLUTCH COVER ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Place matchmarks on the clutch cover and flywheel.

    Text in Illustration
    *1
    		Matchmark

  1. Loosen each set bolt one turn at a time until spring tension is released.

  1. Remove the 6 set bolts and pull off the clutch cover.

    NOTICE:
    Do not drop the clutch disc.


38. REMOVE CLUTCH DISC ASSEMBLY
NOTICE:
Keep the lining part of the clutch disc, the pressure plate and the surface of the flywheel away from oil and foreign matter.


39. REMOVE FLYWHEEL SUB-ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Using SST, hold the crankshaft.

    SST
    09213-54015(91651-60855)
    09330-00021


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

  1. Remove the 10 bolts and flywheel.



40. REMOVE REAR END PLATE

  1. Remove the bolt and disconnect the No. 1 water by-pass pipe from the rear end plate.

  1. Remove the bolt and rear end plate.



41. INSTALL ENGINE HANGER


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Install 2 engine hangers with 2 bolts.

    Torque:
    42 N*m{428 kgf*cm, 31 ft.*lbf}
    Text in Illustration
    *a
    		Rear Side
    *b
    		Front Side
    HINT:
    No. 1 Engine Hanger
    		12281-0C010
    Bolt
    		90105-T0129


42. REMOVE ENGINE ASSEMBLY

  1. Attach an engine sling device to the engine hangers.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Remove the 4 bolts and 4 nuts holding the engine mounting brackets to the frame.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fe Engine Mechanical.Engine.Engine Assembly Removal

  1. Lift the engine out of the vehicle slowly and carefully.

    Text in Illustration
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Lift
    NOTICE:
    Make sure to disconnect all the wires, hoses and cables from the engine. Keep the disconnected wires, hoses and cables off of the engine.


43. INSTALL ENGINE TO ENGINE STAND

  1. Install the engine to an engine stand with bolts.

    NOTICE:
    1. Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.
    2. With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

  1. Remove the 2 bolts and 2 engine hangers.