Fuel Injector (W/ Dpf) Removal

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

  1. PRECAUTION

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER

  4. CHECK INJECTOR COMPENSATION CODE

  5. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

  6. REMOVE WIRING HARNESS CLAMP BRACKET

  7. REMOVE NO. 2 FUEL PIPE

  8. REMOVE NO. 3 NOZZLE LEAKAGE PIPE

  9. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

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

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

  12. REMOVE INJECTOR ASSEMBLY

Fuel Injector (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 and fuel inlet pipe, 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 ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER
(HILUX_TGN26 RM000004QWO008X.html)


4. CHECK INJECTOR COMPENSATION CODE
HINT:
If the injector compensation code is not correctly registered, it may cause malfunctions.

  1. Read the injector compensation code (HILUX_TGN26 RM0000012XK059X_02_0003.html).

  1. Check that the compensation code of the installed injector is the same as the code registered in the ECM. If the code is not the same, register the injector compensation code on the injector (HILUX_TGN26 RM0000012XK059X.html).



5. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


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

  1. Remove the bolt, nut and 2 No. 2 injection pipe clamps.



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

  1. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.



6. REMOVE WIRING HARNESS CLAMP BRACKET


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Injector (W/ Dpf) Removal

  1. Detach the wire harness clamp.

    Text in Illustration
    *1
    		Wiring Harness Clamp Bracket

  1. Remove the bolt and wiring harness clamp bracket.



7. REMOVE NO. 2 FUEL PIPE


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

  1. Using a 6 mm hexagon wrench, remove the supply pump hollow screw and gasket.

    Text in Illustration
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Bolt
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Supply Pump Hollow Screw
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Fuel Check Valve
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Union Bolt

  1. Remove the fuel check valve, union bolt and 2 gaskets.

  1. Remove the 3 bolts and No. 2 fuel pipe.



8. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


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

  1. Disconnect the 3 fuel hoses.

    Text in Illustration
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Fuel Check Valve

  1. Remove the 2 bolts.

  1. Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.



9. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


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

  1. Remove the 2 bolts.

    Text in Illustration
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Union Bolt

  1. Remove the union bolt, gasket and No. 2 nozzle leakage pipe.



10. 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.



11. 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.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Injector (W/ Dpf) Removal

  1. 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.

  1. Disconnect the ventilation hose.



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

  1. Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.



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

  1. Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.



12. REMOVE INJECTOR ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Injector (W/ Dpf) Removal

  1. Remove the union bolt, 4 injector hollow screws, 5 gaskets and nozzle leakage pipe.

    Text in Illustration
    *1
    		Union Bolt
    NOTICE:
    1. When removing the nozzle leakage pipe, place a cushion under the pipe.
    2. Be careful not to deform or scratch the union seal surface.
    3. After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Injector (W/ Dpf) Removal

  1. Remove the 4 bolts, 4 washers, 4 No. 1 nozzle holder clamps and 4 injectors.

    HINT:
    Arrange the injectors, No. 1 nozzle holder clamps, washers and bolts in the correct order.

  1. Remove the O-ring from each injector.

  1. Remove the 4 injection nozzle seats from the cylinder head.