Egr Cooler (W/ Dpf) Removal

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

  1. PRECAUTION

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE DIESEL THROTTLE BODY ASSEMBLY

  4. REMOVE NO. 1 ENGINE UNDER COVER

  5. DRAIN ENGINE COOLANT

  6. REMOVE FRONT WHEEL LH

  7. REMOVE FRONT FENDER APRON SEAL UPPER

  8. REMOVE FRONT FENDER SEAL

  9. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

  10. DISCONNECT WATER BY-PASS HOSE

  11. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE

  12. REMOVE NO. 3 CYLINDER HEAD COVER SUB-ASSEMBLY

  13. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

  14. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

  15. REMOVE NO. 5 WATER BY-PASS PIPE

  16. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR

  17. REMOVE GAS FILTER BRACKET WITH GAS FILTER

  18. REMOVE WIRING HARNESS CLAMP BRACKET

  19. REMOVE THROTTLE BODY BRACKET

  20. DISCONNECT ENGINE WIRE

  21. DISCONNECT NO. 3 WATER BY-PASS PIPE

  22. REMOVE EGR VALVE BRACKET

  23. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER

  24. REMOVE INTAKE AIR CONNECTOR WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

  25. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

  26. REMOVE EGR VALVE ADAPTER

  27. REMOVE NO. 2 EGR VALVE ASSEMBLY

  28. REMOVE EGR COOLER INSULATOR

Egr Cooler (W/ Dpf) -- Removal


NOTICE:
  1. When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.
  2. When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.
  3. After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.


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 DIESEL THROTTLE BODY ASSEMBLY
(HILUX_TGN26 RM0000013ZD01PX.html)


4. REMOVE NO. 1 ENGINE UNDER COVER


5. 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 Ggn25.2Kd-Ftv Emission Control.Emission Control System (W/ Dpf).Egr Cooler (W/ 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
    		-
    		-


6. REMOVE FRONT WHEEL LH


7. REMOVE FRONT FENDER APRON SEAL UPPER

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



8. REMOVE FRONT FENDER SEAL

  1. Remove the 5 clips and front fender seal.



9. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

  1. Remove the engine oil level dipstick.



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

  1. Detach the wire harness clamp.

  1. Remove the bolt and engine oil level dipstick guide.

  1. Remove the O-ring from the engine oil level dipstick guide.



10. DISCONNECT WATER BY-PASS HOSE


  1. Disconnect the 6 water by-pass hoses.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Emission Control.Emission Control System (W/ Dpf).Egr Cooler (W/ Dpf) Removal



11. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE

  1. Disconnect the vacuum switching valve connector.

  1. Disconnect the 2 vacuum transmitting hoses.



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

  1. Remove the 2 bolts and manifold stay with vacuum switching valve.



12. REMOVE NO. 3 CYLINDER HEAD COVER SUB-ASSEMBLY


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

  1. Remove the 3 bolts and No. 3 cylinder head cover.



13. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


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

  1. Remove the bolt and No. 2 injection pipe clamp.

  1. Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.



14. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY
NOTICE:
  1. After removing the injection pipe, cover the outlets on the common rail with tape to keep out foreign matter.
  2. After removing the injection pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.


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

  1. Disconnect the 4 injector connectors and electric EGR control valve connector.

  1. Detach the 2 wire harness clamps.



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

  1. Remove the 4 nuts and 2 No. 3 injection pipe clamps.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Emission Control.Emission Control System (W/ Dpf).Egr Cooler (W/ Dpf) Removal

  1. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

    Text in Illustration
    *a
    		Injector Side
    *b
    		Common Rail Side


15. REMOVE NO. 5 WATER BY-PASS PIPE


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

  1. Detach the 2 wire harness clamps.



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

  1. Disconnect the 2 water hoses from the electric EGR control valve.

  1. Remove the 2 bolts and No. 5 water by-pass pipe.



16. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


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

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

  1. Remove the bolt and manifold absolute pressure sensor.



17. REMOVE GAS FILTER BRACKET WITH GAS FILTER


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

  1. Disconnect the vacuum hose.

  1. Remove the bolt and gas filter bracket with gas filter.



18. REMOVE WIRING HARNESS CLAMP BRACKET


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

  1. Remove the bolt and wiring harness clamp bracket.



19. REMOVE THROTTLE BODY BRACKET


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

  1. Remove the 3 bolts and throttle body bracket.



20. DISCONNECT ENGINE WIRE


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

  1. Detach the 2 wire harness clamps.

  1. Remove the bolt and disconnect the engine wire.



21. DISCONNECT NO. 3 WATER BY-PASS PIPE


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

  1. Remove the 2 bolts and disconnect the No. 3 water by-pass pipe.



22. REMOVE EGR VALVE BRACKET


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

  1. Remove the 3 bolts and EGR valve bracket.



23. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER


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

  1. Disconnect the fuel pressure sensor connector from the common rail.



  1. Remove the 5 bolts, 2 nuts and electric EGR control valve with No. 2 EGR valve and EGR cooler.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Emission Control.Emission Control System (W/ Dpf).Egr Cooler (W/ Dpf) Removal


    Text in Illustration
    *1
    		Gasket
    		-
    		-

  1. Remove the 2 gaskets from the cylinder head and intake manifold.



24. REMOVE INTAKE AIR CONNECTOR WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY


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

  1. Remove the 3 nuts, intake air connector with electric EGR control valve and gasket.



25. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

  1. Remove the electric EGR control valve and gasket from the intake air connector.



26. REMOVE EGR VALVE ADAPTER


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

  1. Using a 6 mm hexagon wrench, remove the 3 hexagon socket head cap bolts, 3 plate washers, EGR valve adapter and gasket.



27. REMOVE NO. 2 EGR VALVE ASSEMBLY


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

  1. Remove the bolt, No. 2 EGR valve and gasket.



28. REMOVE EGR COOLER INSULATOR


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Emission Control.Emission Control System (W/ Dpf).Egr Cooler (W/ Dpf) Removal

  1. Remove the 2 EGR cooler insulators from the EGR cooler.

    Text in Illustration
    *1
    		No. 2 EGR Cooler Insulator
    *2
    		No. 1 EGR Cooler Insulator