Engine Assembly (W/O 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. PRECAUTION

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE HOOD SUB-ASSEMBLY

  4. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD and Pre-Runner)

  5. REMOVE NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner)

  6. DRAIN ENGINE OIL

  7. DRAIN ENGINE COOLANT

  8. DRAIN TRANSMISSION OIL

  9. DRAIN POWER STEERING FLUID

  10. REMOVE BATTERY CLAMP SUB-ASSEMBLY

  11. REMOVE BATTERY

  12. REMOVE BATTERY TRAY

  13. REMOVE AIR CLEANER ASSEMBLY

  14. REMOVE INTERCOOLER ASSEMBLY WITH INTAKE AIR CONNECTOR (w/ EGR Cooler)

  15. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/o EGR Cooler)

  16. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY (w/o EGR Cooler)

  17. REMOVE ENGINE COVER BRACKET (w/o EGR Cooler)

  18. REMOVE RADIATOR ASSEMBLY

  19. REMOVE STARTER ASSEMBLY

  20. REMOVE FRONT EXHAUST PIPE ASSEMBLY

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

  22. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

  23. DISCONNECT HEATER HOSE

  24. DISCONNECT PRESSURE FEED TUBE ASSEMBLY

  25. DISCONNECT FUEL HOSE

  26. DISCONNECT UNION TO CONNECTOR TUBE HOSE

  27. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY

  28. DISCONNECT WIRE HARNESS

  29. DISCONNECT COOLER COMPRESSOR ASSEMBLY

  30. REMOVE MANUAL TRANSMISSION ASSEMBLY

  31. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

  32. REMOVE CLUTCH COVER ASSEMBLY

  33. REMOVE CLUTCH DISC ASSEMBLY

  34. REMOVE FLYWHEEL SUB-ASSEMBLY

  35. REMOVE REAR END PLATE

  36. INSTALL ENGINE HANGERS

  37. REMOVE ENGINE ASSEMBLY

  38. INSTALL ENGINE TO ENGINE STAND

  39. REMOVE ENGINE WIRE

  40. REMOVE FRONT ENGINE MOUNTING INSULATOR

Engine Assembly (W/O 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. 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 HOOD SUB-ASSEMBLY

  1. Disconnect the washer nozzle hose.

  1. Remove the 4 bolts and hood.



4. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD and Pre-Runner)


5. REMOVE NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner)


6. DRAIN ENGINE OIL

  1. Remove the oil filler cap.

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

  1. Wipe the oil pan and drain plug.

  1. Install a new gasket and the oil pan drain plug.

    Torque:
    34 N*m{347 kgf*cm, 25 ft.*lbf}


7. 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.

  1. Loosen the radiator drain cock plug.

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


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

  1. Drain the coolant by removing the radiator reservoir cap and, using a wrench, remove the vent plug.



  1. Loosen the cylinder block drain cock plug.


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


    Text in Illustration
    *1
    		Radiator Reservoir
    		*2
    		Radiator Reservoir Cap
    *3
    		Vent Plug
    		*4
    		Cylinder Block Drain Cock Plug
    *5
    		Radiator Drain Cock Plug
    		-
    		-


8. DRAIN TRANSMISSION OIL

  1. Remove the filler plug and gasket.

  1. Remove the drain plug and gasket to drain the manual transmission oil.

  1. Install a new gasket and the drain plug.

    Torque:
    37 N*m{377 kgf*cm, 27 ft.*lbf}


9. DRAIN POWER STEERING FLUID


10. REMOVE BATTERY CLAMP SUB-ASSEMBLY

  1. Remove the bolt, nut and battery clamp.



11. REMOVE BATTERY


12. REMOVE BATTERY TRAY


13. REMOVE AIR CLEANER ASSEMBLY

  1. Disconnect the mass air flow meter connector.

  1. Loosen the hose clamp.

  1. Remove the 2 bolts and air cleaner.



14. REMOVE INTERCOOLER ASSEMBLY WITH INTAKE AIR CONNECTOR (w/ EGR Cooler)
(HILUX_TGN26 RM0000015B9014X.html)


15. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/o EGR Cooler)


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

  1. Detach the 4 claws from the pins of the engine cover bracket and remove the No. 1 engine cover.

    Text in Illustration
    *1
    		No. 1 Engine Cover
    *2
    		Claw
    *3
    		Pin


16. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY (w/o EGR Cooler)


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

  1. Disconnect the manifold absolute pressure sensor connector.

  1. Disconnect the vacuum hose from the gas filter.

  1. Loosen the 2 clamps.

  1. Remove the bolt and disconnect the No. 2 air cleaner pipe together with the 2 air hoses.



17. REMOVE ENGINE COVER BRACKET (w/o EGR Cooler)

  1. Remove the 2 bolts and engine cover bracket.



18. REMOVE RADIATOR ASSEMBLY
(HILUX_TGN26 RM00000144G01ZX.html)


19. REMOVE STARTER ASSEMBLY
(HILUX_TGN26 RM0000013XL04CX.html)


20. REMOVE FRONT EXHAUST PIPE ASSEMBLY
(HILUX_TGN26 RM00000121301EX.html)


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


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



22. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
(HILUX_TGN26 RM000000ZZ3029X.html)


23. DISCONNECT HEATER HOSE


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

  1. Disconnect the 2 heater hoses.



24. DISCONNECT PRESSURE FEED TUBE ASSEMBLY


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

  1. Disconnect the oil reservoir to pump hose.



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

  1. Disconnect the pressure feed tube.



25. DISCONNECT FUEL HOSE


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

  1. Disconnect the 2 fuel hoses.



26. DISCONNECT UNION TO CONNECTOR TUBE HOSE


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

  1. Disconnect the union to connector tube hose.



27. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY


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

  1. Slightly bend the upper part of the glove compartment door to release the 2 stoppers and open the glove compartment door until it is horizontal.

    Text in Illustration
    *1
    		Stopper


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

  1. Pull the glove compartment door toward the rear of the vehicle to detach the 2 hinges and remove the glove compartment door.

    Text in Illustration
    *1
    		Hinge


28. DISCONNECT WIRE HARNESS


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

  1. Remove the upper relay block cover.

  1. Remove the side relay block cover.

  1. Remove the nut and disconnect the engine room junction block wire.

  1. Disconnect the 2 engine room junction block connectors.

  1. Remove the bolt and disconnect the ground cable.



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

  1. Remove the 2 nuts, detach the clamp and disconnect the wire harness.



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

  1. Disconnect the 3 injector driver connectors.



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

  1. w/ EGR Cooler:
    Disconnect the turbo motor driver connector.

  1. for 4WD:
    Disconnect the 4WD control ECU connector.

  1. Disconnect the 4 ECM connectors.



29. DISCONNECT COOLER COMPRESSOR ASSEMBLY

  1. 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.


30. REMOVE MANUAL TRANSMISSION ASSEMBLY
  1. for 2WD: (HILUX_TGN26 RM0000011B201AX.html)
  2. for 4WD: (HILUX_TGN26 RM0000011AL00YX.html)


31. 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.



32. REMOVE CLUTCH COVER ASSEMBLY


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


33. 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.


34. REMOVE FLYWHEEL SUB-ASSEMBLY


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

  1. Using SST, hold the crankshaft pulley.

    SST
    09213-58014
    09330-00021


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

  1. Remove the 8 bolts and flywheel.



35. REMOVE REAR END PLATE

  1. Remove the bolt and rear end plate.



36. INSTALL ENGINE HANGERS


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

  1. Install a No. 1 engine hanger and No. 2 engine hanger with 2 bolts as shown in the illustration.

    Torque:
    for No. 1 engine hanger:
    25 N*m{255 kgf*cm, 18 ft.*lbf}
    for No. 2 engine hanger:
    60 N*m{612 kgf*cm, 44 ft.*lbf}
    Text in Illustration
    *1
    		No. 1 Engine Hanger
    *2
    		No. 2 Engine Hanger
    NOTICE:
    Install the engine hangers with new bolts.
    HINT:
    Part No.
    No. 1 Engine Hanger
    		12284-30020
    No. 2 Engine Hanger
    		12282-67030
    Bolt
    		91552-81014 and 91642-81030


37. REMOVE ENGINE ASSEMBLY


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

  1. Attach an engine sling device and hang the engine with a chain block.

  1. Remove the 4 bolts and 4 nuts.

  1. Remove the engine by operating the engine sling device and chain block.



38. INSTALL ENGINE TO ENGINE STAND

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

  1. Remove the 2 bolts and 2 engine hangers.



39. REMOVE ENGINE WIRE

  1. Remove the engine wire from the engine.



40. REMOVE FRONT ENGINE MOUNTING INSULATOR


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

  1. Remove the 2 nuts and 2 front engine mounting insulators.

    Text in Illustration
    *a
    		RH Side
    *b
    		LH Side