REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE (w/ EGR Cooler)
REMOVE ELECTRIC EGR CONTROL VALVE WITH NO. 2 EGR VALVE AND EGR COOLER (w/ EGR Cooler)
REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY (w/o EGR Cooler)
REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ EGR System without EGR Cooler)
REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY (w/ EGR System without EGR Cooler)
REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System without EGR Cooler)
Intake Manifold (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 RM000004QR3009X.html).
| 3. REMOVE NO. 1 ENGINE UNDER COVER (w/ EGR Cooler) |
| 4. 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 - -
| 5. REMOVE DIESEL THROTTLE BODY ASSEMBLY |
| 6. REMOVE MANIFOLD STAY (w/o EGR Cooler) |
Remove the 2 bolts and manifold stay.
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| 7. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE (w/ EGR Cooler) |
Disconnect the 2 vacuum switching valve connectors and the 4 vacuum transmitting hoses.
Remove the 2 bolts and manifold stay with vacuum switching valve.
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| 8. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE |
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.
| 9. REMOVE ELECTRIC EGR CONTROL VALVE WITH NO. 2 EGR VALVE AND EGR COOLER (w/ EGR Cooler) |
| 10. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY (w/o EGR Cooler) |
- 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.
| 11. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ EGR System without 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.
| 12. REMOVE VACUUM SWITCHING VALVE BRACKET (w/o EGR System) |
Remove the 2 bolts and vacuum switching valve bracket.
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| 13. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET (w/o EGR Cooler) |
Remove the 3 bolts and No. 2 intake air connector bracket.
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| 14. REMOVE INTAKE AIR CONNECTOR (w/o EGR Cooler) |
Remove the 2 nuts, bolt and intake air connector.
| 15. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY (w/ EGR System without EGR Cooler) |
Remove the 2 bolts, 2 nuts, No. 1 EGR pipe and 2 gaskets.
Text in Illustration *1 Gasket
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| 16. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System without EGR Cooler) |
w/ EGR Cooler:
Remove the 2 bolts, electric EGR control valve and gasket.
w/o EGR Cooler:
Remove the electric EGR control valve and gasket.
| 17. REMOVE VACUUM CONTROL VALVE SET (w/ EGR Cooler) |
Disconnect the 2 connectors and 3 vacuum hoses.
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Remove the 2 bolts and vacuum control valve set.
| 18. 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
| 19. 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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| 20. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET (w/ EGR Cooler) |
Remove the bolt and No. 3 intercooler support bracket.
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| 21. REMOVE INTAKE MANIFOLD INSULATOR (w/ EGR Cooler) |
Remove the 2 bolts and intake manifold insulator from the intake manifold.
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| 22. REMOVE INTAKE MANIFOLD |
w/ EGR Cooler:
Disconnect the common rail sub-harness connector from the intake manifold.
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w/o EGR Cooler:
Disconnect the vacuum hose and vacuum switching valve connector.
Remove the 4 bolts, 2 nuts, intake manifold and gasket.
Text in Illustration *A w/ EGR Cooler *B w/o EGR Cooler