Exhaust Manifold W/ Turbocharger (W/O 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 NO. 1 ENGINE UNDER COVER

  4. REMOVE NO. 2 ENGINE UNDER COVER

  5. REMOVE FRONT WHEEL RH

  6. REMOVE FRONT EXHAUST PIPE ASSEMBLY

  7. REMOVE FRONT FENDER APRON SEAL UPPER

  8. REMOVE FRONT FENDER SEAL

  9. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/ No. 1 Engine Cover)

  10. REMOVE VENTILATION HOSE HEAT INSULATOR

  11. REMOVE AIR CLEANER ASSEMBLY

  12. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

  13. REMOVE TURBINE OUTLET ELBOW

  14. REMOVE TURBOCHARGER SUB-ASSEMBLY

  15. REMOVE EXHAUST MANIFOLD

Exhaust Manifold W/ Turbocharger (W/O 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 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. REMOVE NO. 2 ENGINE UNDER COVER


5. REMOVE FRONT WHEEL RH


6. 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.



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 NO. 1 ENGINE COVER SUB-ASSEMBLY (w/ No. 1 Engine Cover)


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

  1. Detach the 4 claws from the pins of the cover bracket and remove the No. 1 engine cover.

    Text in Illustration
    *1
    		Engine Cover
    *2
    		Claw
    *3
    		Pin


10. REMOVE VENTILATION HOSE HEAT INSULATOR

  1. Remove the 2 bolts and ventilation hose heat insulator.



11. REMOVE AIR CLEANER ASSEMBLY


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

  1. w/ Mass Air Flow Meter:
    Disconnect the mass air flow meter connector and detach the wire harness clamp.



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

  1. w/o Mass Air Flow Meter:
    Detach the clamp and disconnect the intake air temperature sensor connector.

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

  1. Disconnect the ventilation hose and remove the 2 bolts and air cleaner.



12. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY


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

  1. Disconnect the manifold absolute pressure sensor connector.

  1. Disconnect the vacuum hose from the gas filter.

  1. Loosen the 2 clamps.

  1. Remove the bolt and disconnect the No. 2 air cleaner pipe together with the 2 air hoses.



13. REMOVE TURBINE OUTLET ELBOW


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

  1. Remove the 2 bolts, 4 nuts, turbine outlet elbow (with turbocharger stay) and gasket from the turbocharger.

  1. Remove the 2 bolts and turbocharger stay from the turbine outlet elbow.



14. REMOVE TURBOCHARGER SUB-ASSEMBLY


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

  1. Remove the 2 bolts and manifold stay.

  1. Remove the 2 bolts, union bolt and 2 gaskets.



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

  1. Remove the 3 nuts, turbocharger (with turbo oil pipe) and gasket.



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

  1. Remove the 2 nuts, turbo oil pipe and gasket from the turbocharger.



15. REMOVE EXHAUST MANIFOLD


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

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