Exhaust Manifold W/ Turbocharger (W/O Dpf) Removal

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
1Kd-Ftv Intake Exhaust. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. PRECAUTION

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE INTERCOOLER ASSEMBLY

  4. REMOVE FRONT WHEEL RH

  5. REMOVE NO. 1 ENGINE UNDER COVER

  6. REMOVE NO. 2 ENGINE UNDER COVER

  7. DRAIN ENGINE COOLANT

  8. REMOVE FRONT FENDER APRON SEAL UPPER

  9. REMOVE FRONT FENDER SEAL

  10. REMOVE FRONT EXHAUST PIPE ASSEMBLY

  11. REMOVE AIR CLEANER ASSEMBLY

  12. REMOVE VENTILATION PIPE

  13. REMOVE COMPRESSOR INLET ELBOW

  14. REMOVE NO. 1 TURBO INSULATOR

  15. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

  16. REMOVE NO. 1 TURBO WATER HOSE

  17. REMOVE TURBINE OUTLET ELBOW

  18. REMOVE TURBOCHARGER STAY

  19. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

  20. REMOVE TURBOCHARGER SUB-ASSEMBLY

  21. REMOVE EXHAUST MANIFOLD

  22. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY

Exhaust Manifold W/ Turbocharger (W/O Dpf) -- Removal



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 INTERCOOLER ASSEMBLY
(HILUX_TGN26 RM0000015B9015X.html)


4. REMOVE FRONT WHEEL RH


5. REMOVE NO. 1 ENGINE UNDER COVER


6. REMOVE NO. 2 ENGINE UNDER COVER


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 Ggn25.1Kd-Ftv Intake Exhaust.Intake System (W/O Glow Plug Controller).Exhaust Manifold W/ Turbocharger (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. REMOVE FRONT FENDER APRON SEAL UPPER

  1. Remove the 5 clips and front fender apron seal upper.



9. REMOVE FRONT FENDER SEAL

  1. Remove the 5 clips and front fender seal.



10. REMOVE FRONT EXHAUST PIPE ASSEMBLY

  1. Remove the 2 bolts and 2 compression springs.

  1. Disconnect the front exhaust pipe from the turbine outlet elbow and remove the gasket.

  1. Remove the front exhaust pipe from the exhaust pipe support.



11. 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.



12. REMOVE VENTILATION PIPE


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

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



13. 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.



14. REMOVE NO. 1 TURBO INSULATOR


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

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



15. 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.



16. REMOVE NO. 1 TURBO WATER HOSE


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

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



17. REMOVE TURBINE OUTLET ELBOW


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

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



18. REMOVE TURBOCHARGER STAY


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

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



19. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Intake Exhaust.Intake System (W/O Glow Plug Controller).Exhaust Manifold W/ Turbocharger (W/O Dpf) 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.


20. REMOVE TURBOCHARGER SUB-ASSEMBLY


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

  1. Remove the 3 nuts, turbocharger and gasket.



21. 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.



22. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY


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

  1. Remove the 2 nuts, bolt, No. 1 turbo water pipe and gasket.