Engine Unit (W/O Glow Plug Controller) Removal

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
1Kd-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 INTERCOOLER SUPPORT BRACKET

  7. REMOVE VENTILATION PIPE

  8. REMOVE COMPRESSOR INLET ELBOW

  9. REMOVE NO. 1 TURBO INSULATOR

  10. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

  11. REMOVE NO. 1 TURBO WATER HOSE

  12. REMOVE TURBINE OUTLET ELBOW

  13. REMOVE TURBOCHARGER STAY

  14. DISCONNECT TURBO OIL INLET PIPE SUB-ASSEMBLY

  15. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER

  16. REMOVE NO. 2 IDLE PULLEY ASSEMBLY

  17. REMOVE GENERATOR ASSEMBLY

  18. REMOVE GENERATOR BRACKET

  19. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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

  21. REMOVE WATER INLET

  22. REMOVE THERMOSTAT

  23. REMOVE WATER OUTLET

  24. REMOVE DIESEL THROTTLE BODY ASSEMBLY

  25. REMOVE INTAKE MANIFOLD

  26. REMOVE GLOW PLUG ASSEMBLY

  27. REMOVE OIL FILTER SUB-ASSEMBLY

  28. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

  29. REMOVE COMMON RAIL ASSEMBLY

  30. REMOVE FUEL SUPPLY PUMP ASSEMBLY

  31. REMOVE OIL COOLER COVER SUB-ASSEMBLY

  32. REMOVE TIMING GEAR COVER INSULATOR (w/ EGR Cooler)

  33. REMOVE VACUUM PUMP ASSEMBLY

  34. REMOVE VANE PUMP ASSEMBLY

  35. REMOVE CRANKSHAFT POSITION SENSOR

  36. REMOVE CAMSHAFT POSITION SENSOR

  37. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

  38. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH

  39. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH

Engine Unit (W/O Glow Plug Controller) -- 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 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) Removal

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



2. REMOVE TIMING BELT


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) 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 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) 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 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) 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 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) 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 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) Removal

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

    SST
    09950-50013(09951-05010,09952-05010,09953-05020,09954-05021)


5. REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET

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



6. REMOVE INTERCOOLER SUPPORT BRACKET

  1. Remove the 2 bolts and intercooler support bracket.



7. REMOVE VENTILATION PIPE


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

  1. Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe.



8. REMOVE COMPRESSOR INLET ELBOW


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

  1. Disconnect the 2 connectors from the turbocharger.

  1. Detach the wire harness clamp.

  1. Remove the 2 nuts, compressor inlet elbow and gasket.



9. REMOVE NO. 1 TURBO INSULATOR


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

  1. Remove the 2 bolts and No. 1 turbo insulator.



10. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


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

  1. Remove the bolt and No. 1 exhaust manifold heat insulator.



11. REMOVE NO. 1 TURBO WATER HOSE


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

  1. Remove the 2 No. 1 turbo water hoses.



12. REMOVE TURBINE OUTLET ELBOW


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

  1. Remove the 3 nuts, turbine outlet elbow and gasket.



13. REMOVE TURBOCHARGER STAY


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

  1. Remove the 2 bolts, nut and turbocharger stay.



14. DISCONNECT TURBO OIL INLET PIPE SUB-ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) Removal

  1. Remove the 2 bolts, 2 nuts, union bolt, turbo oil inlet pipe and 3 gaskets.

    NOTICE:
    Do not loosen the nut labeled A.


15. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER


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

  1. Remove the 8 nuts, 8 plate washers, 8 collars and exhaust manifold with turbocharger shown in the illustration.



16. REMOVE NO. 2 IDLE PULLEY ASSEMBLY


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

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



17. 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.



18. REMOVE GENERATOR BRACKET

  1. Remove the bolt and generator bracket.



19. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) Removal

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



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

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



21. 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.



22. REMOVE THERMOSTAT

  1. Remove the thermostat from the cylinder block.

  1. Remove the gasket from the thermostat.



23. REMOVE WATER OUTLET


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

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



24. REMOVE DIESEL THROTTLE BODY ASSEMBLY


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

  1. Disconnect the 2 connectors.



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

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



25. REMOVE INTAKE MANIFOLD
(HILUX_TGN26 RM00000143Y01YX.html)


26. REMOVE GLOW PLUG ASSEMBLY
(HILUX_TGN26 RM0000013XP01BX.html)


27. REMOVE OIL FILTER SUB-ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) 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.


28. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) Removal

  1. Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

    Text in Illustration
    *a
    		Common Rail Side
    *b
    		Fuel Supply Pump Side


29. REMOVE COMMON RAIL ASSEMBLY
NOTICE:
Do not remove the pressure discharge valve or fuel pressure sensor.

  1. Disconnect the 2 connectors.



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

  1. Remove the 2 bolts, common rail and No. 2 intake manifold insulator.



30. REMOVE FUEL SUPPLY PUMP ASSEMBLY


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

  1. Disconnect the 2 fuel hoses.



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

  1. Disconnect the fuel temperature sensor connector and suction control valve connector.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) Removal

  1. Remove the 4 bolts indicated by the arrows in the illustration.

  1. Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) Removal

  1. Remove the set nut and O-ring while holding the crankshaft pulley using SST.

    SST
    09213-58014
    09330-00021


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

  1. Loosen the 2 nuts.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) Removal

  1. Using SST, disconnect the fuel supply pump from the injection gear.

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

  1. Remove the 2 nuts and fuel supply pump.

    NOTICE:
    1. Do not hold or carry the fuel supply pump by the pipe.
    2. The fuel supply pump must be kept horizontal.

  1. Remove the O-ring.



31. 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 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) Removal

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



32. REMOVE TIMING GEAR COVER INSULATOR (w/ EGR Cooler)


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

  1. Remove the bolt and timing gear cover insulator.



33. REMOVE VACUUM PUMP ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) Removal

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



34. REMOVE VANE PUMP ASSEMBLY


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

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



35. REMOVE CRANKSHAFT POSITION SENSOR

  1. Disconnect the crankshaft position sensor connector.



  1. Detach the 4 clips, and remove the bolt and crankshaft position sensor.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) Removal



36. 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.



37. 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.



38. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Engine Unit (W/O Glow Plug Controller) Removal

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

    Text in Illustration
    *A
    		RH Side
    *B
    		LH Side


39. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH

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