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Removal [11/2022 - ]: Procedure

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  1. DISCONNECT NO. 2 RADIATOR HOSE 
    1. GTY1103141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE FUEL HOSE BRACKET 
    1. GTY1103142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 6
  4. REMOVE EXHAUST MANIFOLD 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 8
  5. REMOVE MANIFOLD STAY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 7
  6. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 4
  7. REMOVE THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 6

  8. DISCONNECT NO. 3 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 3

  9. DISCONNECT NO. 4 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 4

  10. REMOVE EGR COOLER ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 5
  11. REMOVE NO. 1 EGR COOLER GASKET 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 7
  12. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 2
  13. REMOVE EGR VALVE ADAPTER GASKET 

    Refer to PROCEDURE - Step 3

  14. REMOVE EGR INLET GASKET 

    Refer to PROCEDURE - Step 4

  15. DISCONNECT NO. 4 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 5

  16. DISCONNECT NO. 8 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 6

  17. REMOVE EGR VALVE ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 7
  18. REMOVE EGR VALVE GASKET 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 6
  19. REMOVE NO. 3 WATER BY-PASS PIPE 
    1. GTY1109255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, remove the bolt and No. 3 water by-pass pipe from the intake manifold.
      2. Slide the clip and disconnect the No. 3 water by-pass pipe from the water outlet sub-assembly.
  20. REMOVE INTAKE MANIFOLD STAY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 12
  21. REMOVE INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 13

  22. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 14

  23. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. GTY1106227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disconnect the fuel tube sub-assembly from the fuel pump assembly.

        HINT: 

        Refer to PRECAUTION [11/2022 - ]

      2. Disconnect the fuel tube sub-assembly from the fuel delivery pipe with sensor assembly.

        HINT: 

        Refer to PRECAUTION [11/2022 - ]

  24. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. GTY1108789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the bolt.
      2. Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.
  25. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 8
  26. REMOVE FUEL PUMP FLANGE 

    Refer to PROCEDURE - Step 9

  27. REMOVE FUEL PUMP SPACER GASKET 
  28. REMOVE FUEL PUMP LIFTER ASSEMBLY 
  29. REMOVE WATER BY-PASS HOSE ASSEMBLY 
    1. GTY1108349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE SENSOR WIRE 
    1. GTY1103146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE NO. 6 ENGINE WIRE 
    1. GTY1103147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 3
  33. REMOVE FUEL DELIVERY SPACER 

    Refer to PROCEDURE - Step 3

  34. REMOVE INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 5

  35. REMOVE NO. 5 ENGINE WIRE 

    Refer to PROCEDURE - Step 6

  36. REMOVE PORT FUEL INJECTOR ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 7
  37. REMOVE FUEL DELIVERY PIPE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 3
  38. REMOVE DIRECT FUEL INJECTOR ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 4
  39. REMOVE NOZZLE HOLDER CLAMP 

    Refer to PROCEDURE - Step 5

  40. REMOVE NO. 3 FUEL INJECTOR BACK-UP RING 

    Refer to PROCEDURE - Step 6

  41. REMOVE NO. 1 FUEL INJECTOR BACK-UP RING 

    Refer to PROCEDURE - Step 7

  42. REMOVE C-RING 

    Refer to PROCEDURE - Step 8

  43. REMOVE INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 9

  44. REMOVE FUEL INJECTOR SEAL 

    Refer to PROCEDURE - Step 10

  45. REMOVE IGNITION COIL ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  46. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. GTY1105673Courtesy 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 cylinder head sub-assembly.
      3. Remove the O-ring from the engine oil level dipstick guide.
  47. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  48. REMOVE ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING) 
    1. GTY1103149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 
    1. GTY1108373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. GTY1103439Courtesy 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.
      2. Remove the bolt and wire harness clamp bracket from the stiffening crankcase assembly.
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