3.3.4 Remove Air Rail It sounds like some folks have left the air rail in place either temporarily or indefinitely, but most people remove it entirely and plug the holes using parts from the JimC kit or the Toyota OEM AIR port plugs. The rail has a check valve that should keep exhaust gas from leaking out of the disconnected rail, but the check valve is often failed due to age. If the check valve is bad, then the disconnected rail cannot be safely left in place. The air rail comes off easy for some people. If the 17mm nuts all come off with an open end wrench, congratulations, you have a sellable rail. If the rail is behaving normally, i.e.
is rusted through or impossible to remove with an open end wrench, then try this removal technique:
Use a sharp chisel to shear off all 6 of the rusty tubes, right on top of the nut Put on a 17mm short socket using a long flex ratchet Wrench the nut off the top of the fitting Put a 17mm mid socket on the fitting in the head w/ long flex ratchet and wrench it out of there Install allen plug 3.3.5 Remove EGR System Unscrew flexible metal hose from EGR valve Loosen two large bolts holding on EGR cooler enough to pull it away from the block Unbolt EGR "J" pipe from the exhaust manifold You should now be able to remove the "J" pipe by jiggling the EGR cooler Remove two large bolts from EGR cooler and remove it Install block-off plate and gasket on exhaust manifold, or weld coin into bottom of exhaust manifold:
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