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Removal [03/2022 - ]: Procedure

  1. REMOVE DRIVE SHAFT BEARING BRACKET 
    1. GTY1074089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY 
    1. GTY1075686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Nut
      1. Remove the bolt and 2 nuts.
      2. Using an E8 "TORX" socket wrench, remove the 2 stud bolts and compressor with motor assembly.
  3. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY 
    1. GTY997606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY) 
    1. GTY997619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    WARNING:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.
    1. GTY1132609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Type A *B Type B
  6. REMOVE MANIFOLD STAY 
    Refer to PROCEDURE - Step 13
  7. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst) 
    Refer to PROCEDURE - Step 16
  8. REMOVE EXHAUST MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 17

  9. DISCONNECT NO. 5 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 7

  10. SEPARATE THROTTLE BODY WITH MOTOR ASSEMBLY 
    Refer to PROCEDURE - Step 8
  11. DISCONNECT NO. 6 WATER BY-PASS HOSE 
    Refer to PROCEDURE - Step 9
  12. REMOVE THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 10

  13. DISCONNECT NO. 3 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 3

  14. DISCONNECT NO. 4 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 4

  15. REMOVE EGR COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 5

  16. REMOVE EGR VALVE GASKET 

    Refer to PROCEDURE - Step 6

  17. REMOVE NO. 1 EGR COOLER GASKET 

    Refer to PROCEDURE - Step 7

  18. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 5
  19. REMOVE EGR VALVE ADAPTER GASKET 

    Refer to PROCEDURE - Step 6

  20. REMOVE EGR INLET GASKET 

    Refer to PROCEDURE - Step 7

  21. DISCONNECT NO. 4 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 8

  22. DISCONNECT NO. 8 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 9

  23. REMOVE EGR VALVE ASSEMBLY 
    Refer to PROCEDURE - Step 10
  24. REMOVE NO. 3 WATER BY-PASS PIPE 
    1. GTY1076066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, remove the bolt and disconnect the No. 3 water by-pass pipe from the intake manifold.
      2. Slide the clip and remove the No. 3 water by-pass pipe from the water outlet.
  25. REMOVE NO. 2 WATER BY-PASS PIPE 
    1. GTY1075475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the bolt (A).
      2. Using an 8 mm socket wrench, remove the 2 bolts (B) and No. 2 water by-pass pipe.
  26. REMOVE INTAKE MANIFOLD 
    Refer to PROCEDURE - Step 14
  27. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 15

  28. REMOVE FUEL PIPE CLAMP 

    Refer to PROCEDURE - Step 7

  29. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 8
  30. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 9

  31. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 
    Refer to PROCEDURE - Step 10
  32. REMOVE FUEL PUMP SPACER GASKET 

    Refer to PROCEDURE - Step 11

  33. REMOVE FUEL PUMP LIFTER ASSEMBLY 

    Refer to PROCEDURE - Step 12

  34. REMOVE NO. 7 WATER BY-PASS HOSE 
    1. GTY997636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE SENSOR WIRE 
    1. GTY1077501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disconnect the 3 connectors.
      2. Disengage the 3 clamps.
      3. Using an 8 mm socket wrench, remove the bolt and sensor wire from the water inlet with thermostat sub-assembly.
  36. REMOVE NO. 6 ENGINE WIRE 
    1. GTY997954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. GTY1076014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, remove the 2 bolts and wire harness clamp bracket from the No. 1 ventilation case.
  38. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 14
  39. REMOVE NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 15

  40. REMOVE INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 16

  41. REMOVE NO. 5 ENGINE WIRE 

    Refer to PROCEDURE - Step 17

  42. REMOVE PORT FUEL INJECTOR ASSEMBLY 
    Refer to PROCEDURE - Step 18
  43. REMOVE FUEL DELIVERY PIPE 
    Refer to PROCEDURE - Step 13
  44. REMOVE DIRECT FUEL INJECTOR ASSEMBLY 
    Refer to PROCEDURE - Step 14
  45. REMOVE NOZZLE HOLDER CLAMP 

    Refer to PROCEDURE - Step 15

  46. REMOVE NO. 3 FUEL INJECTOR BACK-UP RING 
    Refer to PROCEDURE - Step 16
  47. REMOVE NO. 1 FUEL INJECTOR BACK-UP RING 

    Refer to PROCEDURE - Step 17

  48. REMOVE C-RING 

    Refer to PROCEDURE - Step 18

  49. REMOVE INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 19

  50. REMOVE FUEL INJECTOR SEAL 
    Refer to PROCEDURE - Step 20
  51. REMOVE IGNITION COIL ASSEMBLY 
    Refer to PROCEDURE - Step 2
  52. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. GTY1075773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the engine oil level dipstick.
      2. Using an 8 mm socket wrench, remove the bolt and engine oil level dipstick guide from the camshaft housing sub-assembly.
      3. Remove the O-ring from the engine oil level dipstick guide.
  53. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 
    1. GTY997953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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