Intake Manifold (W/ Egr Cooler) -- Removal |
- NOTICE:
- 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.
- 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.
- After removing the injection pipes, 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 RM000004QR1003X.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 RM000004QR3003X.html).
| 3. REMOVE NO. 1 ENGINE UNDER COVER |
| 4. 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.
Loosen the radiator drain cock plug.
- HINT:
- Collect the coolant in a container and dispose of it according to the regulations in your area.
Drain the coolant by removing the radiator reservoir cap and, using a wrench, remove the vent plug.
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Loosen the cylinder block drain cock plug.
Text in Illustration *1 Radiator Reservoir *2 Radiator Reservoir Cap *3 Vent Plug *4 Cylinder Block Drain Cock Plug *5 Radiator Drain Cock Plug - -
| 5. REMOVE DIESEL THROTTLE BODY ASSEMBLY |
| 6. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE |
Disconnect the 2 vacuum switching valve connectors and the 3 vacuum transmitting hoses.
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Remove the 2 bolts and manifold stay with vacuum switching valve.
| 7. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE |
Remove the engine oil level dipstick.
Remove the bolt and injection pipe clamp.
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Remove the bolt and engine oil level dipstick guide.
Remove the O-ring from the engine oil level dipstick guide.
| 8. REMOVE ELECTRIC EGR CONTROL VALVE WITH NO. 2 EGR VALVE AND EGR COOLER |
| 9. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY |
- NOTICE:
- If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection pipe clamp with a new one.
w/ EGR Cooler:
Remove the bolt and disconnect the injection pipe clamp.
Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
Text in Illustration *a Injector Side *b Common Rail Side
w/o EGR Cooler:
Remove the 2 bolts and disconnect the 2 injection pipe clamps.
Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
Text in Illustration *a Injector Side *b Common Rail Side
| 10. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY |
Disconnect the 3 fuel hoses.
Remove the union bolt, 3 bolts, No. 2 nozzle leakage pipe and gasket.
Text in Illustration *A w/ EGR Cooler *B w/o EGR Cooler *1 Union Bolt
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| 11. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET |
Remove the bolt and No. 3 intercooler support bracket.
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| 12. REMOVE INTAKE MANIFOLD INSULATOR |
Remove the 2 bolts and intake manifold insulator from the intake manifold.
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| 13. REMOVE INTAKE MANIFOLD |
Disconnect the vacuum hose and vacuum switching valve connector.
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Remove the 4 bolts, 2 nuts, intake manifold and gasket.