Oil Pump (W/ Glow Plug Controller) Removal

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

  1. PRECAUTION

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. DRAIN ENGINE OIL

  4. DRAIN ENGINE COOLANT

  5. REMOVE ENGINE ASSEMBLY

  6. REMOVE NO. 1 TIMING BELT COVER

  7. REMOVE TIMING BELT

  8. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

  9. REMOVE NO. 2 IDLE PULLEY ASSEMBLY

  10. REMOVE GENERATOR ASSEMBLY

  11. REMOVE GENERATOR BRACKET

  12. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

  13. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)

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

  15. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

  16. REMOVE NO. 2 FUEL PIPE

  17. REMOVE NO. 3 NOZZLE LEAKAGE PIPE

  18. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

  19. REMOVE WIRING HARNESS CLAMP BRACKET (for i-ART)

  20. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY

  21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

  22. REMOVE CAMSHAFT TIMING PULLEY

  23. REMOVE NO. 2 TIMING BELT COVER

  24. REMOVE ENGINE WATER PUMP ASSEMBLY

  25. REMOVE VACUUM PUMP ASSEMBLY

  26. REMOVE VANE PUMP ASSEMBLY

  27. REMOVE CAMSHAFT POSITION SENSOR

  28. REMOVE CRANKSHAFT POSITION SENSOR

  29. REMOVE PUMP DRIVE SHAFT PULLEY

  30. REMOVE CRANKSHAFT PULLEY

  31. REMOVE TIMING GEAR COVER

  32. REMOVE INJECTION GEAR

  33. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

  34. REMOVE CRANKSHAFT TIMING GEAR

  35. REMOVE IDLE GEAR THRUST PLATE

  36. REMOVE NO. 1 IDLE GEAR

  37. REMOVE NO. 1 IDLE GEAR SHAFT

  38. REMOVE FUEL SUPPLY PUMP ASSEMBLY

  39. REMOVE OIL PAN SUB-ASSEMBLY

  40. REMOVE OIL STRAINER SUB-ASSEMBLY

  41. REMOVE TIMING GEAR CASE ASSEMBLY

Oil Pump (W/ Glow Plug Controller) -- 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, 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 RM000004QR300CX.html).


3. DRAIN ENGINE OIL
  1. Remove the oil filler cap.

  1. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

  1. Wipe the oil pan and drain plug.

  1. Install a new gasket and the oil pan drain plug.

    Torque:
    34 N*m{347 kgf*cm, 25 ft.*lbf}


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.
  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 Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  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
    -
    -


5. REMOVE ENGINE ASSEMBLY
(HILUX_TGN26 RM00000147M03WX.html)


6. REMOVE NO. 1 TIMING BELT COVER


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Remove the 6 bolts, 6 washers and timing belt cover.



7. REMOVE TIMING BELT


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Turn the crankshaft clockwise and align the timing marks as shown in the illustration.

    Text in Illustration
    *1
    Timing Mark
    HINT:
    If reusing the timing belt, place matchmarks on the timing belt so that it can be installed exactly as before.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Uniformly loosen and remove the 2 bolts and No. 1 timing belt tensioner.



  1. Remove the timing belt.

    HINT:
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
    1. If turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.
    2. When installing the timing belt, turn the camshaft to align the timing marks, and then turn the crankshaft clockwise to align the timing marks.


8. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
NOTICE:
When inspecting the No. 1 timing belt idler, do not remove it unless absolutely necessary.
  1. Using a 10 mm hexagon wrench, remove the bolt, No. 1 timing belt idler and washer.



9. REMOVE NO. 2 IDLE PULLEY ASSEMBLY
  1. Remove the bolt, pulley plate, No. 2 idle pulley and spacer.



10. REMOVE GENERATOR ASSEMBLY


Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the nut and generator wire.

  1. Disconnect the generator connector.

  1. Remove the 2 bolts and generator.



11. REMOVE GENERATOR BRACKET
  1. Remove the bolt and generator bracket.



12. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Remove the 4 bolts and V-ribbed belt tensioner.



13. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)
  1. Remove the 4 bolts and No. 1 compressor mounting bracket.



14. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND COOLER
(HILUX_TGN26 RM000004QWO00HX.html)


15. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the bolt, nut and 2 No. 2 injection pipe clamps.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.



16. REMOVE NO. 2 FUEL PIPE


  1. for DPF:



      Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    1. Disconnect the vacuum switching valve connector and 2 vacuum transmitting hoses.



    2. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    3. Using a 6 mm hexagon wrench, remove the supply pump hollow screw and gasket.

      Text in Illustration
      Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
      Bolt
      Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
      Supply Pump Hollow Screw
      Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
      Fuel Check Valve
      Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
      Union Bolt
    4. Remove the fuel check valve, union bolt and 2 gaskets.

    5. Remove the 3 bolts and No. 2 fuel pipe.



  1. for i-ART:



      Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    1. Using a 6 mm hexagon wrench, remove the supply pump hollow screw and gasket.

      Text in Illustration
      Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
      Supply Pump Hollow Screw
      Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
      Fuel Check Valve
    2. Remove the fuel check valve, No. 2 fuel pipe and gasket.



17. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Disconnect the 3 fuel hoses.

    Text in Illustration
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    Fuel Check Valve
  1. Remove the 2 bolts.

  1. Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.



18. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


  1. for DPF:
    Remove the 2 bolts.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal


    Text in Illustration
    *A
    for DPF
    *B
    for i-ART
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    Union Bolt
    -
    -
  1. for i-ART:
    Remove the 3 bolts.

  1. Remove the union bolt, gasket and No. 2 nozzle leakage pipe.



19. REMOVE WIRING HARNESS CLAMP BRACKET (for i-ART)


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Detach the 6 wire harness clamps.

  1. Remove the 3 bolts and 2 wiring harness clamp brackets.



20. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the 3 bolts and No. 2 cylinder head cover.



21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
NOTICE:
If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Using a small screwdriver, remove the nozzle holder seal by prying between the nozzle holder seal and the cutout part of the cylinder head cover.

  1. Disconnect the ventilation hose.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.



22. REMOVE CAMSHAFT TIMING PULLEY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Remove the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

    NOTICE:
    Make sure the timing belt is not installed when removing the bolt of the camshaft timing pulley.
  1. Remove the camshaft timing pulley.



23. REMOVE NO. 2 TIMING BELT COVER
  1. Remove the 4 bolts, nut and No. 2 timing belt cover.



24. REMOVE ENGINE WATER PUMP ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the 5 bolts, 2 nuts, engine water pump and gasket.



25. REMOVE VACUUM PUMP ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Remove the 2 nuts, vacuum pump and 2 O-rings.



26. REMOVE VANE PUMP ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the 2 nuts, vane pump and O-ring.



27. REMOVE CAMSHAFT POSITION SENSOR


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Disconnect the camshaft position sensor connector.

  1. Remove the bolt and camshaft position sensor.



28. REMOVE CRANKSHAFT POSITION SENSOR
  1. Disconnect the crankshaft position sensor connector.



  1. Detach the 4 clips, and remove the bolt and crankshaft position sensor.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal



29. REMOVE PUMP DRIVE SHAFT PULLEY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Remove the 4 bolts, No. 2 camshaft timing pulley flange and pump drive shaft pulley.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Using SST, hold the crankshaft pulley and remove the nut and O-ring.

    SST
    09213-58014
    09330-00021


30. REMOVE CRANKSHAFT PULLEY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Using SST, hold the crankshaft pulley and loosen the pulley bolt.

    SST
    09213-58014
    09330-00021


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Using SST, remove the pulley bolt and crankshaft pulley.

    SST
    09950-50013(09951-05010,09952-05010,09953-05020,09954-05021)


31. REMOVE TIMING GEAR COVER
NOTICE:
As the fuel supply pump is not installed, the injection gear is loose inside the timing gear case. Do not allow the injection gear to fall.
HINT:
To prevent the injection gear from falling, temporarily install the fuel supply pump.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the 14 bolts and 2 nuts.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Pry the timing gear cover at the locations shown in the illustration and remove the timing gear cover.

    NOTICE:
    Be careful not to drop the injection gear.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Remove the O-ring from the timing gear case.



32. REMOVE INJECTION GEAR


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Secure the No. 2 idle sub gear to the No. 1 idle gear with a service bolt.

    Torque:
    8.0 N*m{82 kgf*cm, 71 in.*lbf}
    NOTICE:
    If the bolt hole of the No. 2 idle sub gear is not aligned with the bolt hole of the No. 1 idle gear, rotate the crankshaft counterclockwise to align the bolt holes. Then install the service bolt.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the injection gear.



33. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the No. 1 crankshaft position sensor plate.



34. REMOVE CRANKSHAFT TIMING GEAR


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Using SST, remove the crankshaft timing gear.

    SST
    09950-50013(09951-05010,09952-05010,09953-05010,09954-05021)


35. REMOVE IDLE GEAR THRUST PLATE


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the 2 bolts and idle gear thrust plate.



36. REMOVE NO. 1 IDLE GEAR


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the No. 1 idle gear together with the No. 2 idle sub gear.



37. REMOVE NO. 1 IDLE GEAR SHAFT


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the No. 1 idle gear shaft.



38. REMOVE FUEL SUPPLY PUMP ASSEMBLY
  1. Disconnect the 2 fuel hoses.

  1. for DPF:
    Disconnect the fuel temperature sensor connector from the fuel supply pump.

  1. Disconnect the suction control valve connector from the fuel supply pump.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Remove the 4 bolts indicated by the arrows in the illustration.

  1. Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Remove the set nut and O-ring while holding the crankshaft pulley using SST.

    SST
    09213-58014
    09330-00021


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Loosen the 2 nuts.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Using SST, disconnect the fuel supply pump from the injection gear.

    SST
    09950-50013(09951-05010,09952-05010,09953-05020,09954-05021)
    NOTICE:
    Apply lubricant to the threads and tip of SST (center bolt) before using it.
  1. Remove the 2 nuts and fuel supply pump.

    NOTICE:
    1. Do not hold or carry the fuel supply pump by the pipe.
    2. The fuel supply pump must be kept horizontal.
  1. Remove the O-ring.



39. REMOVE OIL PAN SUB-ASSEMBLY
  1. Remove the 22 bolts and 2 nuts.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Insert the blade of an oil pan seal cutter between the oil pan and cylinder block, cut through the applied sealer and remove the oil pan.

    NOTICE:
    1. Do not use the oil pan seal cutter for the area between the oil pan and timing belt case, or for the area between the oil pan and rear oil seal retainer.
    2. Be careful not to damage the oil pan flange.


40. REMOVE OIL STRAINER SUB-ASSEMBLY
  1. Remove the 2 bolts, 2 nuts, oil strainer and gasket.



41. REMOVE TIMING GEAR CASE ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Remove the union bolt and 8 bolts.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Pry the timing gear case at the location shown in the illustration and remove the gear case and gasket.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Lubrication.Lubrication System.Oil Pump (W/ Glow Plug Controller)  Removal
  1. Remove the 2 O-rings.