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1GD-FTV EMISSION CONTROL MONOLITHIC CONVERTER(w/ DPF) REMOVAL
CAUTION / NOTICE / HINT
CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.
PROCEDURE
1.DRAIN ENGINE COOLANT
Click hereEngine / Hybrid System>1GD-FTV COOLING>COOLANT>REPLACEMENT
2.REMOVE FRONT EXHAUST PIPE ASSEMBLY 17410
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST PIPE>REMOVAL
3.REMOVE FUEL ADDITION INJECTOR ASSEMBLY
Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>EXHAUST FUEL ADDITION
INJECTOR>REMOVAL
4.REMOVE FRONT FENDER SEAL 53882F
a. for 2WD:
Remove the 5 clips and front fender seal from the body.
b. for 4WD and Pre-Runner:
Remove the 6 clips and front fender seal from the body.
5.REMOVE AIR CLEANER CAP AND HOSE
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>REMOVAL
6.REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 17801
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>REMOVAL
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7.REMOVE AIR CLEANER CASE SUB-ASSEMBLY 17701
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>REMOVAL
8.REMOVE DIFFERENTIAL PRESSURE SENSOR 89481B
Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>DIFFERENTIAL PRESSURE SENSOR>REMOVAL
9.REMOVE EXHAUST GAS TEMPERATURE SENSOR 89425
Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>EXHAUST GAS TEMPERATURE
SENSOR>REMOVAL
10.REMOVE NO. 1 VACUUM PIPE 25733A
CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.
a.
Remove the nut and clamp from the No. 1 vacuum pipe and No. 2 vacuum pipe.
b.
Using a 17 mm union nut wrench, remove the No. 1 vacuum pipe from the exhaust manifold converter sub-
assembly.
11.REMOVE NO. 2 VACUUM PIPE 25734
CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.
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a.
Using a 17 mm union nut wrench, remove the No. 2 vacuum pipe from the exhaust manifold converter sub-
assembly.
b.
Remove the clamp from the pipe clamp.
12.REMOVE PIPE CLAMP 17578B
CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.
a.
Remove the 3 bolts and pipe clamp from the engine cover bracket.
13.REMOVE ENGINE COVER BRACKET 12631A
CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.
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a.
Detach the 2 clamp and disconnect the engine wire from the engine cover bracket.
b.
Remove the 2 bolts and engine cover bracket from the cylinder head sub-assembly.
14.REMOVE NO. 2 INTERMEDIATE SHAFT SUB-ASSEMBLY (for RHD) 45203
Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR>REMOVAL
15.REMOVE UPPER ARM BUSH HEAT INSULATOR 48691
CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.
a.
Remove the 2 bolt and upper arm bush heat insulator from the body.
16.REMOVE AIR FUEL RATIO SENSOR 89467B
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Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>AIR FUEL RATIO SENSOR>REMOVAL
17.REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 17167
CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.
a.
Remove the 3 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold.
18.REMOVE NO. 1 TURBO INSULATOR 17271
CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.
a.
Remove the 3 bolts and No. 1 turbo insulator from the exhaust manifold and turbocharger sub-assembly.
19.REMOVE NO. 2 EXHAUST PIPE SUPPORT STAY 17118
CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.
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a.
Remove the bolt, 2 nuts and No. 2 exhaust pipe support stay from the cylinder block sub-assembly and
exhaust manifold converter sub-assembly.
20.REMOVE EXHAUST PIPE SUPPORT STAY 17118
CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.
a.
Remove the 3 bolts and exhaust pipe support stay from the cylinder block sub-assembly and exhaust
manifold converter sub-assembly.
21.REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY 25051
CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.
a.
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Remove the nut, exhaust pipe clamp and exhaust manifold converter sub-assembly from the turbocharger
sub-assembly.
b. Remove the gasket.
© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.
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