Exhaust Manifold W/ Turbocharger (W/ Egr Cooler) Reassembly

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

  1. INSTALL ACTUATOR ASSEMBLY WITH BRACKET

Exhaust Manifold W/ Turbocharger (W/ Egr Cooler) -- Reassembly



1. INSTALL ACTUATOR ASSEMBLY WITH BRACKET


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Intake Exhaust.Intake System (W/ Dpf).Exhaust Manifold W/ Turbocharger (W/ Egr Cooler) Reassembly

  1. Using SST, apply pressure to the actuator.

    SST
    09992-00242
    NOTICE:
    Never apply more than 156 kPa (1.60 kgf/cm2, 23 psi) of pressure to the actuator.
    HINT:
    The actuator push rod stroke is determined by the plate washer shown in the illustration.
    Text in Illustration
    *1
    		Plate Washer

  1. Install the actuator with the 2 bolts and E-ring.

    Torque:
    8.5 N*m{87 kgf*cm, 75 in.*lbf}


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Intake Exhaust.Intake System (W/ Dpf).Exhaust Manifold W/ Turbocharger (W/ Egr Cooler) Reassembly

  1. Set a dial indicator as shown in the illustration.

    Text in Illustration
    *a
    		Push Rod Stroke

  1. Using SST, apply a pressure of 114 kPa (1.16 kgf/cm2, 16.4 psi) to the actuator and measure the push rod stroke.

    SST
    09992-00242

  1. Select the plate washer according to the table below.

    Plate Washer Selection Chart
    Stroke Measurement mm (in.)
    		Required Plate Washer Thickness mm (in.)
    1.20 to 1.70 (0.0472 to 0.0669)
    		-
    1.71 to 2.20 (0.0673 to 0.0866)
    		0.5 (0.020)
    2.21 to 2.70 (0.0870 to 0.1063)
    		1.0 (0.039)
    2.71 to 3.20 (0.1067 to 0.1260)
    		1.5 (0.059)
    3.21 to 3.70 (0.1264 to 0.4517)
    		2.0 (0.079)
    3.71 to 4.20 (0.1461 to 0.1654)
    		2.5 (0.098)
    4.21 to 4.70 (0.1657 to 0.1850)
    		3.0 (0.118)
    4.71 to 5.20 (0.1854 to 0.2047)
    		3.5 (0.138)
    5.21 to 5.70 (0.2051 to 0.2244)
    		4.0 (0.157)
    5.71 to 6.20 (0.2248 to 0.2441)
    		4.5 (0.177)
    6.21 to 6.70 (0.2445 to 0.2638)
    		5.0 (0.197)
    6.71 to 7.20 (0.2642 to 0.2827)
    		5.5 (0.217)
    7.21 to 7.70 (0.2839 to 0.3031)
    		6.0 (0.236)
    7.71 to 8.20 (0.3035 to 0.3228)
    		6.5 (0.256)
    NOTICE:
    1. Use a combination of plate washers of 0.5 mm (0.020 in.), 1.0 mm (0.039 in.) and 3.0 mm (0.118 in.) thickness.
    1. Use plate washers of the same thickness between the 2 locations of the actuator and compressor housing.
    1. If the plate washer thickness exceeds 3.5 mm (0.138 in.), replace the actuator installation bolts with the bolts from the kit.

  1. Using SST, apply 114 kPa (1.16 kgf/cm2, 16.4 psi) of pressure to the actuator, and install the selected plate washers between the actuator and compressor housing with the 2 bolts and E-ring.

    SST
    09992-00242
    Torque:
    8.5 N*m{87 kgf*cm, 75 in.*lbf}

  1. Using SST, apply a pressure of 114 kPa (1.16 kgf/cm2, 16.4 psi) to the actuator, and measure the actuator push rod stroke.

    SST
    09992-00242
    Standard stroke:
    1.20 to 1.70 mm (0.0472 to 0.0669 in.)
    If the stroke is outside the specified range, select plate washers again.

  1. Connect the actuator hose.

  1. Remove SST.

  1. Apply yellow paint in lines across the actuator bolts and actuator bracket to indicate that the actuator has been correctly installed.