Engine Unit (W/ Dpf) Removal

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

  1. REMOVE NO. 1 TIMING BELT COVER

  2. REMOVE TIMING BELT

  3. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

  4. REMOVE CRANKSHAFT PULLEY

  5. REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET

  6. REMOVE NO. 1 INTERCOOLER SUPPORT BRACKET

  7. REMOVE NO. 2 IDLE PULLEY ASSEMBLY

  8. REMOVE GENERATOR ASSEMBLY

  9. REMOVE GENERATOR BRACKET

  10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

  11. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)

  12. REMOVE TURBOCHARGER SUB-ASSEMBLY

  13. REMOVE EXHAUST MANIFOLD

  14. REMOVE WATER INLET

  15. REMOVE THERMOSTAT

  16. REMOVE WATER OUTLET

  17. REMOVE DIESEL THROTTLE BODY ASSEMBLY

  18. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

  19. REMOVE INTAKE MANIFOLD

  20. REMOVE GLOW PLUG ASSEMBLY

  21. REMOVE FUEL HOSE PROTECTOR

  22. REMOVE NO. 1 FUEL PIPE

  23. REMOVE FUEL HOSE BRACKET

  24. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY

  25. REMOVE OIL FILTER SUB-ASSEMBLY

  26. REMOVE COMMON RAIL ASSEMBLY

  27. REMOVE FUEL SUPPLY PUMP ASSEMBLY

  28. REMOVE OIL COOLER COVER SUB-ASSEMBLY

  29. REMOVE VACUUM PUMP ASSEMBLY

  30. REMOVE VANE PUMP ASSEMBLY

  31. REMOVE CRANKSHAFT POSITION SENSOR

  32. REMOVE CAMSHAFT POSITION SENSOR

  33. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

  34. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH

  35. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH

Engine Unit (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, clean them with a brush and compressed air.


1. REMOVE NO. 1 TIMING BELT COVER


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/ Dpf) Removal

  1. Remove the 6 bolts, 6 washers and timing belt cover.



2. REMOVE TIMING BELT


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/ Dpf) Removal

  1. 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.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/ Dpf) Removal

  1. Uniformly loosen and remove the 2 bolts and No. 1 timing belt tensioner.



  1. Remove the timing belt.

    HINT:
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/ Dpf) Removal
    1. If turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.
    2. When installing the timing belt, turn the camshaft to align the timing marks, and then turn the crankshaft clockwise to align the timing marks.


3. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
NOTICE:
When inspecting the No. 1 timing belt idler, do not remove it unless absolutely necessary.

  1. Using a 10 mm hexagon wrench, remove the bolt, No. 1 timing belt idler and washer.



4. REMOVE CRANKSHAFT PULLEY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/ Dpf) Removal

  1. Using SST, hold the crankshaft pulley and loosen the pulley bolt.

    SST
    09213-58014
    09330-00021


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/ Dpf) Removal

  1. Using SST, remove the pulley bolt and crankshaft pulley.

    SST
    09950-50013(09951-05010,09952-05010,09953-05020,09954-05021)
    NOTICE:
    Apply oil or grease to the threads and tip of SST (center bolt) before using it.


5. REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET

  1. Remove the 2 bolts and No. 2 intercooler support bracket.



6. REMOVE NO. 1 INTERCOOLER SUPPORT BRACKET

  1. Remove the 2 bolts and No. 1 intercooler support bracket.



7. REMOVE NO. 2 IDLE PULLEY ASSEMBLY

  1. Remove the bolt, pulley plate, No. 2 idle pulley and spacer.



8. REMOVE GENERATOR ASSEMBLY


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

  1. Remove the nut and generator wire.

  1. Disconnect the generator connector.

  1. Remove the 2 bolts and generator.



9. REMOVE GENERATOR BRACKET

  1. Remove the bolt and generator bracket.



10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/ Dpf) Removal

  1. Remove the 4 bolts and V-ribbed belt tensioner.



11. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)

  1. Remove the 4 bolts and No. 1 compressor mounting bracket.



12. REMOVE TURBOCHARGER SUB-ASSEMBLY
(HILUX_TGN26 RM000002S6F00IX.html)


13. REMOVE EXHAUST MANIFOLD


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

  1. Remove the 8 nuts, 8 plate washers, 8 collars and exhaust manifold.

  1. Remove the gasket.



14. REMOVE WATER INLET


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

  1. Disconnect the wire harness clamp.

  1. Remove the 3 bolts and water inlet.

  1. Remove the bolt and wire harness clamp bracket from the water inlet.



15. REMOVE THERMOSTAT

  1. Remove the thermostat from the cylinder block.

  1. Remove the gasket from the thermostat.



16. REMOVE WATER OUTLET


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

  1. Remove the 2 bolts, water outlet and gasket.



17. REMOVE DIESEL THROTTLE BODY ASSEMBLY


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

  1. Disconnect the 2 connectors.

  1. Remove the 2 bolts, 2 nuts, diesel throttle body and gasket.



18. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY
(HILUX_TGN26 RM000004QWO008X.html)


19. REMOVE INTAKE MANIFOLD
(HILUX_TGN26 RM0000044GF00HX.html )


20. REMOVE GLOW PLUG ASSEMBLY
(HILUX_TGN26 RM000000JIT00KX.html)


21. REMOVE FUEL HOSE PROTECTOR


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

  1. Remove the bolt, nut and fuel hose protector.



22. REMOVE NO. 1 FUEL PIPE


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

  1. Remove the No. 1 fuel pipe from the fuel hose bracket.



23. REMOVE FUEL HOSE BRACKET


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

  1. Remove the bolt and fuel hose bracket.



24. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


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

  1. Remove the 3 bolts and No. 2 cylinder head cover.



25. REMOVE OIL FILTER SUB-ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Engine Mechanical.Engine.Engine Unit (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.


26. REMOVE COMMON RAIL ASSEMBLY
(HILUX_TGN26 RM0000044W300GX.html)


27. REMOVE FUEL SUPPLY PUMP ASSEMBLY
(HILUX_TGN26 RM0000014FO01PX.html)


28. REMOVE OIL COOLER COVER SUB-ASSEMBLY

  1. Disconnect the oil pressure switch connector.

  1. Remove the 2 nuts and disconnect the No. 2 vacuum transmitting pipe from the oil cooler cover.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/ Dpf) Removal

  1. Remove the 13 bolts, oil cooler cover and gasket.



29. REMOVE VACUUM PUMP ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/ Dpf) Removal

  1. Remove the 2 nuts, vacuum pump and 2 O-rings.



30. REMOVE VANE PUMP ASSEMBLY


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

  1. Remove the 2 nuts, vane pump and O-ring.



31. REMOVE CRANKSHAFT POSITION SENSOR

  1. Disconnect the crankshaft position sensor connector.



  1. Remove the 4 clips, bolt and crankshaft position sensor.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/ Dpf) Removal



32. REMOVE CAMSHAFT POSITION SENSOR


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

  1. Disconnect the camshaft position sensor connector.

  1. Remove the bolt and camshaft position sensor.



33. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


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

  1. Disconnect the engine coolant temperature sensor connector.

  1. Remove the engine coolant temperature sensor.

  1. Remove the gasket from the engine coolant temperature sensor.



34. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/ Dpf) Removal

  1. Remove the 4 bolts and front No. 1 engine mounting bracket.

    Text in Illustration
    *A
    		RH Side
    *B
    		LH Side


35. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH

  1. Remove the 4 bolts and front No. 1 engine mounting bracket.