Thermostat Removal

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
1Kd-Ftv Cooling. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. REMOVE INTERCOOLER ASSEMBLY WITH INTAKE AIR CONNECTOR

  2. REMOVE NO. 1 ENGINE UNDER COVER

  3. DRAIN ENGINE COOLANT

  4. REMOVE AIR CLEANER ASSEMBLY

  5. REMOVE VENTILATION PIPE

  6. REMOVE COMPRESSOR INLET ELBOW (w/ DPF)

  7. REMOVE COMPRESSOR INLET ELBOW (w/o DPF)

  8. DISCONNECT NO. 1 AUTOMATIC TRANSMISSION OIL COOLER TUBE CLAMP (for Automatic Transmission)

  9. DISCONNECT RADIATOR HOSE OUTLET

  10. REMOVE WATER INLET

  11. REMOVE THERMOSTAT

Thermostat -- Removal



1. REMOVE INTERCOOLER ASSEMBLY WITH INTAKE AIR CONNECTOR
  1. w/ Glow Plug Controller: (HILUX_TGN26 RM0000015B901EX.html)
  2. w/o Glow Plug Controller: (HILUX_TGN26 RM0000015B9015X.html)


2. REMOVE NO. 1 ENGINE UNDER COVER


3. 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 Ggn25.1Kd-Ftv Cooling.Cooling System.Thermostat 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
    		-
    		-


4. REMOVE AIR CLEANER ASSEMBLY

  1. Disconnect the mass air flow meter connector.

  1. Loosen the hose clamp.

  1. Remove the 2 bolts and air cleaner.



5. REMOVE VENTILATION PIPE


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

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



6. REMOVE COMPRESSOR INLET ELBOW (w/ DPF)


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

  1. Remove the No. 7 water by-pass hose and No. 9 water by-pass hose from the compressor inlet elbow.

  1. Remove the 2 nuts, compressor inlet elbow and gasket from the turbocharger sub-assembly.



7. REMOVE COMPRESSOR INLET ELBOW (w/o DPF)


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

  1. Disconnect the 2 connectors from the turbocharger.

  1. Detach the wire harness clamp.

  1. Remove the 2 nuts, compressor inlet elbow and gasket.



8. DISCONNECT NO. 1 AUTOMATIC TRANSMISSION OIL COOLER TUBE CLAMP (for Automatic Transmission)


Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Cooling.Cooling System.Thermostat Removal

  1. Remove the bolt and disconnect the No. 1 automatic transmission oil cooler tube clamp.



9. DISCONNECT RADIATOR HOSE OUTLET

  1. Disconnect the radiator hose outlet from the water inlet.



10. REMOVE WATER INLET


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

  1. Disconnect the wire harness clamp.

  1. Remove the 3 bolts and water inlet.

  1. Remove the bolt and wire harness clamp bracket from the water inlet.



11. REMOVE THERMOSTAT

  1. Remove the thermostat from the cylinder block.

  1. Remove the gasket from the thermostat.