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Removal [03/2023 - ]: Procedure

  1. REMOVE WIRE HARNESS CLAMP BRACKET 
    Refer to PROCEDURE - Step 6
  2. REMOVE AIR FUEL RATIO SENSOR 
    Refer to PROCEDURE - Step 7
  3. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    Refer to PROCEDURE - Step 13
  4. REMOVE MANIFOLD STAY 
    Refer to PROCEDURE - Step 14
  5. REMOVE EXHAUST MANIFOLD 
    Refer to PROCEDURE - Step 16
  6. DISCONNECT NO. 5 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 4

  7. SEPARATE THROTTLE BODY WITH MOTOR ASSEMBLY 
    Refer to PROCEDURE - Step 5
  8. DISCONNECT NO. 8 WATER BY-PASS HOSE 
    Refer to PROCEDURE - Step 6
  9. REMOVE THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 7

  10. DISCONNECT NO. 3 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 3

  11. DISCONNECT NO. 4 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 4

  12. REMOVE EGR COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 5

  13. REMOVE EGR VALVE GASKET 

    Refer to PROCEDURE - Step 6

  14. REMOVE NO. 1 EGR COOLER GASKET 

    Refer to PROCEDURE - Step 7

  15. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 2
  16. REMOVE EGR VALVE ADAPTER GASKET 

    Refer to PROCEDURE - Step 3

  17. REMOVE EGR INLET GASKET 

    Refer to PROCEDURE - Step 4

  18. REMOVE NO. 4 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 5

  19. REMOVE NO. 8 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 6

  20. REMOVE EGR VALVE ASSEMBLY 
    Refer to PROCEDURE - Step 7
  21. REMOVE NO. 3 WATER BY-PASS PIPE 
    1. GTY1151780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Slide the clip and disconnect the No. 3 water by-pass pipe from the water outlet sub-assembly.
      2. Using an 8 mm socket wrench, remove the bolt and No. 3 water by-pass pipe from the intake manifold.
  22. REMOVE INTAKE MANIFOLD STAY 
    Refer to PROCEDURE - Step 13
  23. REMOVE INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 14

  24. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 15

  25. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. GTY1152645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the fuel pipe clamp from the fuel tube connector.
      2. Disconnect the fuel tube sub-assembly from the fuel (engine room side) pump assembly.

        Refer to PRECAUTION [03/2023 - ]

      3. Disconnect the fuel tube sub-assembly from the fuel delivery pipe sub-assembly.

        Refer to PRECAUTION [03/2023 - ]

  26. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 5
  27. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 
    Refer to PROCEDURE - Step 6
  28. REMOVE FUEL PUMP SPACER GASKET 

    Refer to PROCEDURE - Step 7

  29. REMOVE FUEL PUMP LIFTER ASSEMBLY 

    Refer to PROCEDURE - Step 8

  30. REMOVE WATER BY-PASS HOSE ASSEMBLY 
    1. GTY1152169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE SENSOR WIRE 
    1. GTY1159882Courtesy 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.
  32. REMOVE NO. 6 ENGINE WIRE 
    1. GTY1152165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 5
  34. REMOVE FUEL DELIVERY SPACER 

    Refer to PROCEDURE - Step 6

  35. REMOVE INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 7

  36. REMOVE NO. 5 ENGINE WIRE 

    Refer to PROCEDURE - Step 8

  37. REMOVE PORT FUEL INJECTOR ASSEMBLY 
    Refer to PROCEDURE - Step 9
  38. REMOVE FUEL DELIVERY PIPE 
    Refer to PROCEDURE - Step 3
  39. REMOVE DIRECT FUEL INJECTOR ASSEMBLY 
    Refer to PROCEDURE - Step 4
  40. REMOVE NOZZLE HOLDER CLAMP 

    Refer to PROCEDURE - Step 5

  41. REMOVE NO. 3 FUEL INJECTOR BACK-UP RING 
    Refer to PROCEDURE - Step 6
  42. REMOVE NO. 1 FUEL INJECTOR BACK-UP RING 

    Refer to PROCEDURE - Step 7

  43. REMOVE C-RING 

    Refer to PROCEDURE - Step 8

  44. REMOVE INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 9

  45. REMOVE FUEL INJECTOR SEAL 
    Refer to PROCEDURE - Step 10
  46. REMOVE IGNITION COIL ASSEMBLY 
    Refer to PROCEDURE - Step 2
  47. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. GTY1149682Courtesy 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.
  48. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 2
  49. REMOVE ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING) 
    1. GTY1103149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 
    1. GTY1152166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. GTY1141205Courtesy 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. Using an 8 mm socket wrench, remove the bolt and wire harness clamp bracket from the camshaft housing sub-assembly.
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