Engine Unit Removal

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
2Tr-Fbe Engine Mechanical. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. REMOVE IGNITION COIL ASSEMBLY

  2. REMOVE PCV PIPE

  3. REMOVE GENERATOR ASSEMBLY

  4. REMOVE ENGINE WIRE

  5. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

  6. REMOVE FUEL DELIVERY PIPE WITH FUEL INJECTOR

  7. REMOVE PURGE VSV

  8. REMOVE INTAKE MANIFOLD

  9. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

  10. REMOVE NO. 4 INTAKE PIPE

  11. REMOVE AIR SWITCHING VALVE ASSEMBLY

  12. REMOVE EXHAUST MANIFOLD

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

  14. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

  15. REMOVE HEATER WATER INLET HOSE

  16. REMOVE HEATER WATER OUTLET HOSE

  17. REMOVE NO. 1 WATER BY-PASS PIPE

  18. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH

  19. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH

Engine Unit -- Removal



1. REMOVE IGNITION COIL ASSEMBLY


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

  1. Disconnect the 4 ignition coil connectors.

  1. Remove the 4 bolts and pull out the 4 ignition coils.



2. REMOVE PCV PIPE

  1. Disconnect the PCV hose from the PCV valve sub-assembly and intake manifold.

  1. Remove the bolt and PCV pipe.



3. REMOVE GENERATOR ASSEMBLY

  1. Detach the terminal cap.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fbe Engine Mechanical.Engine.Engine Unit Removal

  1. Remove the nut, bolt and disconnect the generator wire.

  1. Disconnect the generator connector.

  1. Remove the 2 bolts and generator.



4. REMOVE ENGINE WIRE

  1. Disconnect the oil pressure switch connector.

  1. Disconnect the noise filter connector.

  1. Disconnect the camshaft position sensor connector.

  1. Disconnect the 4 injector connectors.

  1. Disconnect the crankshaft position sensor connector.

  1. Disconnect the camshaft timing oil control valve connector.

  1. Disconnect the purge VSV connector.

  1. Disconnect the throttle body connector.

  1. Disconnect the engine coolant temperature sensor connector.

  1. Disconnect the knock sensor connector.

  1. Disconnect the wire harness from the clamps.

  1. Remove the 2 bolts and wire harness from the engine.



5. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

  1. Disconnect the throttle position sensor and control motor connector.

  1. Disconnect the 2 water by-pass hoses.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fbe Engine Mechanical.Engine.Engine Unit Removal

  1. Remove the 2 bolts, 2 nuts and throttle body with motor.

  1. Remove the gasket from the intake manifold.



6. REMOVE FUEL DELIVERY PIPE WITH FUEL INJECTOR
CAUTION:
Be careful not to drop the injectors when removing the delivery pipe.


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

  1. Disconnect the 4 clamps and wire harness from the delivery pipe.

  1. Disconnect the vacuum hose.



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

  1. Disconnect the 4 injector connectors.

  1. Remove the 2 bolts and fuel delivery pipe together with the fuel injectors.

    NOTICE:
    Be careful not to drop the fuel injectors when removing the fuel delivery pipe.

  1. Remove the 2 No. 1 delivery pipe spacers.

  1. Remove the 4 injector vibration insulators.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fbe Engine Mechanical.Engine.Engine Unit Removal

  1. Using 2 screwdrivers, pry out the 4 spacers from the cylinder head.

    HINT:
    Tape the screwdriver tips before use.

  1. Remove the 4 O-rings.



7. REMOVE PURGE VSV


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

  1. Disconnect the purge VSV connector.

  1. Disconnect the 2 purge line hoses from the purge VSV.

  1. Remove the bolt and purge VSV together with the bracket.

  1. Remove the bolt and bracket.



8. REMOVE INTAKE MANIFOLD

  1. Disconnect the crankshaft position sensor from the clamp.



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

  1. Remove the 5 bolts, 2 nuts, intake manifold and gasket.



9. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


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

  1. Remove the 5 bolts and heat insulator.



10. REMOVE NO. 4 INTAKE PIPE


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

  1. Remove the 4 nuts, No. 4 intake pipe and 2 gaskets.



11. REMOVE AIR SWITCHING VALVE ASSEMBLY


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

  1. Disconnect the air switching valve connector.

  1. Remove the 2 nuts and air switching valve assembly.



12. REMOVE EXHAUST MANIFOLD


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

  1. Remove the 8 nuts and exhaust manifold.

  1. Remove the gasket.



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


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fbe Engine Mechanical.Engine.Engine Unit Removal

  1. Remove the 5 bolts and mounting bracket.



14. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fbe Engine Mechanical.Engine.Engine Unit Removal

  1. Remove the bolt, pulley and spacer.



15. REMOVE HEATER WATER INLET HOSE


16. REMOVE HEATER WATER OUTLET HOSE


17. REMOVE NO. 1 WATER BY-PASS PIPE


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

  1. Remove the 2 nuts, water by-pass pipe and gasket.



18. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fbe Engine Mechanical.Engine.Engine Unit Removal

  1. Remove the 4 bolts and engine mounting bracket.



19. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fbe Engine Mechanical.Engine.Engine Unit Removal

  1. Remove the 4 bolts and engine mounting bracket.