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Removal [09/2018 - 10/2020]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Refer to PRECAUTION [10/2017 - 09/2019] , or refer to PRECAUTION [09/2019 - 10/2020]

  2. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [09/2018 - 10/2020]

  3. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [09/2018 - 10/2020]

  4. REMOVE INVERTER COVER ASSEMBLY RH 

    Refer to PROCEDURE - Step 9

  5. REMOVE CONNECTOR COVER 

    Refer to PROCEDURE - Step 12

  6. CHECK TERMINAL VOLTAGE 

    Refer to PROCEDURE - Step 13

  7. TEMPORARILY INSTALL CONNECTOR COVER 

    Refer to PROCEDURE - Step 14

  8. REMOVE INVERTER TERMINAL COVER 

    Refer to PROCEDURE - Step 15

  9. DISCONNECT GENERATOR CABLE 

    Refer to PROCEDURE - Step 16

  10. DISCONNECT MOTOR CABLE 

    Refer to PROCEDURE - Step 17

  11. REMOVE INTAKE AIR SURGE TANK ASSEMBLY 

    Refer to REMOVAL [10/2017 - 10/2020]

  12. REMOVE EGR VALVE ASSEMBLY 

    Refer to REMOVAL [10/2017 - ] 

  13. REMOVE INVERTER MOTOR CABLE BRACKET ASSEMBLY 
    1. Detach the 3 clamps and disconnect the generator cable and motor cable from the inverter motor cable bracket assembly.
      GTY821233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and inverter motor cable bracket assembly from the inverter assembly.
      GTY821239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FENDER APRON BRACE SUB-ASSEMBLY RH 
    1. Detach the clamp and disconnect the hose from the fender apron brace sub-assembly RH.
      GTY835191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and fender apron brace sub-assembly RH from the body.
  15. REMOVE INLET HEATER WATER HOSE 
    1. Slide the 2 clamps and remove the inlet heater water hose from the No. 3 water by-pass pipe and heater pipe.
      GTY811288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE OUTLET HEATER WATER HOSE 
    1. Slide the 2 clamps and remove the outlet heater water hose from the No. 2 water by-pass pipe and heater pipe.
  17. REMOVE NO. 1 EGR PIPE 
    WARNING:

    To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

    1. Remove the 2 bolts, 2 nuts and No. 1 EGR pipe from the exhaust manifold assembly RH and EGR cooler assembly.
      GTY801795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for 2WD
      *B for AWD
    2. Remove the 2 gaskets from the No. 1 EGR pipe and EGR cooler assembly.
  18. REMOVE NO. 4 WATER BY-PASS HOSE 
    1. Slide the clamp and remove the No. 4 water by-pass hose from the No. 3 water by-pass pipe.
      GTY821238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 3 WATER BY-PASS PIPE 
    1. Remove the bolt and engine motor cable clamp bracket.
      GTY821237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clamp and remove the No. 3 water by-pass pipe from the EGR cooler assembly.
  20. DISCONNECT NO. 12 WATER BY-PASS HOSE 
    1. Slide the clamp and disconnect the No. 12 water by-pass hose from the EGR cooler assembly.
      GTY821236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE EGR COOLER ASSEMBLY 
    WARNING:

    To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

    1. Remove the bolt, nut and EGR cooler assembly from the cylinder head sub-assembly RH.
      GTY835366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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