Intercooler (W/O Dpf) Removal

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

  1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

  2. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR

  3. REMOVE INTAKE AIR TEMPERATURE SENSOR

  4. REMOVE INTERCOOLER ASSEMBLY

Intercooler (W/O Dpf) -- Removal



1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


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

  1. Remove the 3 bolts, 2 cap nuts and No. 1 engine cover.

    Text in Illustration
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    		Cap Nut


2. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


  1. w/ EGR Cooler:



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

    1. Disconnect the manifold absolute pressure sensor connector.

    2. Disconnect the vacuum hose and detach the 2 clamps.

    3. Remove the 2 bolts and manifold absolute pressure sensor.



  1. w/o EGR Cooler:



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

    1. Disconnect the manifold absolute pressure sensor connector and vacuum hose.

    2. Remove the 2 bolts and manifold absolute pressure sensor.



3. REMOVE INTAKE AIR TEMPERATURE SENSOR


  1. Disconnect the intake air temperature sensor connector.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Intake Exhaust.Intake System (W/ Dpf).Intercooler (W/O Dpf) Removal


    Text in Illustration
    *A
    		w/ Intercooler
    		*B
    		w/o Mass Air Flow Meter

  1. w/ Intercooler:
    Using a 22 mm deep socket wrench, remove the intake air temperature sensor.

    HINT:
    Replace the intake air temperature sensor if it is deformed, cracked or malfunctioning. It is not necessary to replace the intake air temperature sensor each time the intercooler is replaced.

  1. w/o Mass Air Flow Meter:
    Remove the intake air temperature sensor.



4. REMOVE INTERCOOLER ASSEMBLY


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

  1. Loosen the 2 hose clamps of the No. 1 air hose.



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

  1. Loosen the 2 hose clamps of the No. 2 air hose.



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

  1. Remove the 4 bolts and intercooler.



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

  1. Remove the 4 bolts, intake air connector and gasket.