Exhaust Pipe (W/ 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 TAILPIPE ASSEMBLY

  2. REMOVE CENTER EXHAUST PIPE ASSEMBLY

  3. REMOVE NO. 2 ENGINE UNDER COVER

  4. SUPPORT TRANSMISSION AND TRANSFER ASSEMBLY

  5. REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY

  6. REMOVE NO. 2 EXHAUST PIPE SUPPORT BRACKET

  7. REMOVE AIR FUEL RATIO SENSOR

  8. REMOVE FRONT EXHAUST PIPE ASSEMBLY

  9. REMOVE EXHAUST GAS TEMPERATURE SENSOR

  10. REMOVE NO. 2 EXHAUST GAS TEMPERATURE SENSOR

  11. REMOVE WIRING HARNESS CLAMP BRACKET

  12. REMOVE NO. 3 EXHAUST GAS TEMPERATURE SENSOR

  13. REMOVE EXHAUST PIPE CLAMP SUB-ASSEMBLY

  14. REMOVE MONOLITHIC CONVERTER PROTECTOR

  15. REMOVE CONVERTER PROTECTOR STAY

Exhaust Pipe (W/ Dpf) -- Removal



1. REMOVE TAILPIPE ASSEMBLY
  1. Remove the 2 bolts and 2 nuts.

  1. Disconnect the tailpipe from the center exhaust pipe and remove the gasket.

  1. Remove the tailpipe from the exhaust pipe support.



2. REMOVE CENTER EXHAUST PIPE ASSEMBLY
  1. Remove the 2 bolts and 2 compression springs.

  1. Disconnect the center exhaust pipe from the 3 exhaust pipe supports.

  1. Remove the gasket.



3. REMOVE NO. 2 ENGINE UNDER COVER


4. SUPPORT TRANSMISSION AND TRANSFER ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Support the transmission and transfer with a transmission jack.



5. REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY
  1. Support the transmission rear side with a support stand.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Intake Exhaust.Intake System (W/ Dpf).Exhaust Pipe (W/ Dpf)  Removal
  1. Remove the 4 set bolts of the rear No. 1 engine mounting insulator.

  1. Remove the 4 bolts, 4 nuts and No. 3 frame crossmember sub-assembly.



6. REMOVE NO. 2 EXHAUST PIPE SUPPORT BRACKET


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the 2 bolts and No. 2 exhaust pipe support bracket from the No. 3 frame crossmember.



7. REMOVE AIR FUEL RATIO SENSOR


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Intake Exhaust.Intake System (W/ Dpf).Exhaust Pipe (W/ Dpf)  Removal
  1. for 2WD:
    Detach the clamp.

    Text in Illustration
    *A
    for 2WD
    *B
    for 4WD
  1. Disconnect the air fuel ratio sensor connector.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Intake Exhaust.Intake System (W/ Dpf).Exhaust Pipe (W/ Dpf)  Removal
  1. Using SST, remove the air fuel ratio sensor from the front exhaust pipe.

    SST
    09224-00010


8. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Disconnect the exhaust gas temperature sensor connector and detach the clamp.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Disconnect the No. 2 exhaust gas temperature sensor connector.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Intake Exhaust.Intake System (W/ Dpf).Exhaust Pipe (W/ Dpf)  Removal
  1. Disconnect the No. 3 exhaust gas temperature sensor connector and detach the clamp.

    Text in Illustration
    *A
    for 4WD
    *B
    for 2WD


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Disconnect the No. 6 exhaust pipe air hose and No. 7 exhaust pipe air hose from the front exhaust pipe.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the 2 exhaust pipe supports.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the 3 nuts and front exhaust pipe.

  1. Remove the gasket.



9. REMOVE EXHAUST GAS TEMPERATURE SENSOR


Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
NOTICE:
If the sensor is dropped, replace it with a new one.
  1. Using a 14 mm union nut wrench, remove the exhaust gas temperature sensor.



10. REMOVE NO. 2 EXHAUST GAS TEMPERATURE SENSOR


Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
NOTICE:
If the sensor is dropped, replace it with a new one.
  1. Detach the 5 clamps.

  1. Using a 14 mm union nut wrench, remove the No. 2 exhaust gas temperature sensor.



11. REMOVE WIRING HARNESS CLAMP BRACKET


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the bolt and wiring harness clamp bracket.



12. REMOVE NO. 3 EXHAUST GAS TEMPERATURE SENSOR


Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
NOTICE:
If the sensor is dropped, replace it with a new one.
  1. Using a 14 mm union nut wrench, remove the No. 3 exhaust gas temperature sensor.



13. REMOVE EXHAUST PIPE CLAMP SUB-ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the bolt, nut and exhaust pipe clamp.



14. REMOVE MONOLITHIC CONVERTER PROTECTOR


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the 4 bolts and 4 nuts.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Intake Exhaust.Intake System (W/ Dpf).Exhaust Pipe (W/ Dpf)  Removal
  1. Remove the upper monolithic converter protector and lower monolithic converter protector.

    Text in Illustration
    *1
    Upper Monolithic Converter Protector
    *2
    Lower Monolithic Converter Protector


15. REMOVE CONVERTER PROTECTOR STAY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Intake Exhaust.Intake System (W/ Dpf).Exhaust Pipe (W/ Dpf)  Removal
  1. Remove the 2 No. 1 converter protector stays and 2 No. 2 converter protector stays.

    Text in Illustration
    *1
    No. 1 Converter Protector Stay
    *2
    No. 2 Converter Protector Stay