REMOVE INTERCOOLER ASSEMBLY WITH INTAKE AIR CONNECTOR (w/ EGR Cooler)
REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER (w/ EGR Cooler)
Water Pump (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, 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 |
| 4. DRAIN ENGINE COOLANT |
- 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 INTERCOOLER ASSEMBLY WITH INTAKE AIR CONNECTOR (w/ EGR Cooler) |
| 6. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER (w/ EGR Cooler) |
| 7. 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.
| 8. REMOVE RADIATOR HOSE INLET |
| 9. REMOVE FAN SHROUD |
Remove the 3 bolts and oil reservoir.
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Disconnect the No. 1 and No. 2 water by-pass hoses from the radiator.
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Remove the 2 bolts and radiator reservoir.
Loosen the 4 nuts holding the fluid coupling with fan.
Remove the fan and generator V belt (HILUX_TGN26 RM000001477016X_01_0001.html).
Remove the 2 bolts holding the fan shroud.
Remove the 4 nuts of the fluid coupling with fan, and then remove the fan shroud together with the fluid coupling with fan.
- NOTICE:
- Be careful not to damage the radiator core.
Remove the fan pulley from the water pump.
| 10. DISCONNECT COOLER COMPRESSOR ASSEMBLY |
Remove the 4 bolts and disconnect the cooler compressor.
- HINT:
- It is not necessary to completely remove the cooler compressor. With the hoses connected to the cooler compressor, hang the cooler compressor on the vehicle body with a rope.
| 11. REMOVE NO. 2 IDLE PULLEY ASSEMBLY |
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Remove the bolt, pulley plate, No. 2 idle pulley and spacer.
| 12. REMOVE GENERATOR ASSEMBLY |
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Remove the nut and generator wire.
Disconnect the generator connector.
Remove the 2 bolts and generator.
| 13. REMOVE GENERATOR BRACKET |
Remove the bolt and generator bracket.
| 14. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY |
Remove the 4 bolts and V-ribbed belt tensioner.
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| 15. 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.
| 16. 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
| 17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY |
- NOTICE:
- If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.
w/ EGR Cooler:
Remove the 3 bolts and disconnect the 4 injector connectors.
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w/o EGR Cooler:
Disconnect the 4 injector connectors.
Disconnect the ventilation hose.
Using a small screwdriver, remove the nozzle holder seal by prying between the nozzle holder seal and the cutout part of the cylinder head cover.
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Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.
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Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.
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| 18. REMOVE NO. 1 TIMING BELT COVER |
Remove the 6 bolts, 6 washers and timing belt cover.
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| 19. REMOVE TIMING BELT |
Turn the crankshaft clockwise and align the timing marks as shown in the illustration.
Text in Illustration *1 Timing Mark - HINT:
- If reusing the timing belt, place matchmarks on the timing belt so that it can be installed exactly as before.
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Uniformly loosen and remove the 2 bolts and No. 1 timing belt tensioner.
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Remove the timing belt.
- HINT:
- If turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.
- When installing the timing belt, turn the camshaft to align the timing marks, and then turn the crankshaft clockwise to align the timing marks.
| 20. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY |
- NOTICE:
- When inspecting the No. 1 timing belt idler, do not remove it unless absolutely necessary.
Using a 10 mm hexagon wrench, remove the bolt, No. 1 timing belt idler and washer.
| 21. REMOVE CAMSHAFT TIMING PULLEY |
Remove the bolt of the camshaft timing pulley while holding the camshaft with a wrench.
- NOTICE:
- Make sure to remove the bolt of the camshaft timing pulley with the timing belt not installed.
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Remove the camshaft timing pulley.
| 22. REMOVE NO. 2 TIMING BELT COVER |
Remove the 4 bolts, nut and timing belt cover.
| 23. REMOVE WATER PUMP ASSEMBLY |
Remove the 5 bolts, 2 nuts, water pump and gasket.
Text in Illustration 
Bolt 
Nut
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