Exhaust Manifold W/ Turbocharger (W/ Egr Cooler) 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. PRECAUTION

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE INTERCOOLER ASSEMBLY

  4. REMOVE NO. 1 ENGINE UNDER COVER

  5. REMOVE NO. 2 ENGINE UNDER COVER

  6. REMOVE FRONT WHEEL RH

  7. REMOVE FRONT EXHAUST PIPE ASSEMBLY

  8. REMOVE FRONT FENDER APRON SEAL UPPER

  9. REMOVE FRONT FENDER SEAL

  10. REMOVE AIR CLEANER ASSEMBLY

  11. REMOVE VENTILATION PIPE

  12. REMOVE COMPRESSOR INLET ELBOW

  13. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

  14. REMOVE TURBINE OUTLET ELBOW

  15. REMOVE TURBOCHARGER STAY

  16. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY (w/ Intercooler)

  17. REMOVE TURBOCHARGER SUB-ASSEMBLY (w/ Intercooler)

  18. REMOVE EXHAUST MANIFOLD

Exhaust Manifold W/ Turbocharger (W/ Egr Cooler) -- Removal



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 RM000004QR3008X.html).


3. REMOVE INTERCOOLER ASSEMBLY
(HILUX_TGN26 RM0000015B9014X.html)


4. REMOVE NO. 1 ENGINE UNDER COVER


5. REMOVE NO. 2 ENGINE UNDER COVER


6. REMOVE FRONT WHEEL RH


7. REMOVE FRONT EXHAUST PIPE ASSEMBLY

  1. Remove the 2 bolts and 2 compression springs.

  1. Disconnect the front exhaust pipe from the turbine outlet elbow and remove the gasket.

  1. Remove the front exhaust pipe from the exhaust pipe support.



8. REMOVE FRONT FENDER APRON SEAL UPPER

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



9. REMOVE FRONT FENDER SEAL

  1. Remove the 5 clips and front fender seal.



10. REMOVE AIR CLEANER ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Kd-Ftv Intake Exhaust.Intake System (W/ Dpf).Exhaust Manifold W/ Turbocharger (W/ Egr Cooler) Removal

  1. Disconnect the mass air flow meter connector and detach the wire harness clamp.

  1. Loosen the hose clamp of the compressor inlet elbow.

  1. Remove the 2 bolts and air cleaner.

  1. Loosen the hose clamp and remove the No. 1 air cleaner hose.



11. REMOVE VENTILATION PIPE

  1. Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe.



12. REMOVE COMPRESSOR INLET ELBOW

  1. Loosen the clamp, and then remove the compressor inlet elbow and air cleaner hose from the turbocharger.



13. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


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

  1. Remove the 2 bolts and No. 1 exhaust manifold heat insulator.



14. REMOVE TURBINE OUTLET ELBOW


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

  1. Remove the 4 nuts, turbine outlet elbow and gasket.



15. REMOVE TURBOCHARGER STAY


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

  1. Remove the 2 bolts, nut and turbocharger stay.



16. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY (w/ Intercooler)


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

  1. Remove the 2 bolts, 2 nuts, union bolt, turbo oil inlet pipe and 3 gaskets.



17. REMOVE TURBOCHARGER SUB-ASSEMBLY (w/ Intercooler)


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

  1. Remove the 3 nuts, turbocharger and gasket.



18. REMOVE EXHAUST MANIFOLD


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

  1. Remove the 8 nuts, 8 plate washers, 8 collars and exhaust manifold as shown in the illustration.