EGR VALVE REMOVAL

Info Added 2017-10-06

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during EGR valve assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure	Necessary Procedures	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Disconnect cable from negative auxiliary battery terminal	Memorize steering angle neutral point	Lane departure alert system (w/ Steering Control)	Click here
		Simple intelligent parking assist system*1
		Toyota parking assist-sensor system*1
		Pre-collision system
	Initialize back door lock	Power door lock control system	Click here
Replacement of EGR valve assembly	Inspection After Repair	Poor idle, etc. Engine start function, etc.	Click here

*1: When performing learning using the GTS.

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CAUTION:

Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

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To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

PROCEDURE

PRECAUTION

Note

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

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DISCONNECT ENGINE WIRE

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REMOVE AUXILIARY BATTERY

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REMOVE SERVICE PLUG GRIP

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REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

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REMOVE WATER GUARD PLATE LH

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REMOVE COWL BODY MOUNTING REINFORCEMENT LH

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REMOVE COWL BODY MOUNTING REINFORCEMENT RH

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REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

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REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

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REMOVE NO. 1 ENGINE UNDER COVER

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DRAIN ENGINE COOLANT (for Engine)

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REMOVE ECM

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REMOVE BATTERY CLAMP SUB-ASSEMBLY

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SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY

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DISCONNECT ENGINE WIRE

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REMOVE CONNECTOR COVER ASSEMBLY

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CHECK TERMINAL VOLTAGE

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TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

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DISCONNECT HV FLOOR UNDER WIRE

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DISCONNECT HV AIR CONDITIONING WIRE

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SEPARATE INVERTER WITH CONVERTER ASSEMBLY

CAUTION:

Wear insulated gloves.
1. Remove the 5 bolts and 2 nuts and separate the inverter with converter assembly.
  Note
  - To prevent damage due to static electricity, do not touch the terminals of the inverter with converter assembly connector.
  - Make sure to seal the inverter with converter assembly with the connector cover assembly or tape (non-residue type) etc., to prevent entry of foreign matter and water.
2. *a Rope
  
  Using a rope or equivalent, secure the inverter with converter assembly with the hood hinge.
  Note
  - Be careful not to damage the surrounding components when securing the inverter with converter assembly.
  - To prevent damage to the inverter with converter assembly, do not hold the coolant pipe, bracket or connector when securing the inverter with converter assembly.
  - To prevent damage due to static electricity, do not touch the terminals of the inverter with converter assembly connector.
  - Make sure to seal the inverter with converter assembly with the connector cover assembly or tape (non-residue type) etc., to prevent entry of foreign matter and water.
REMOVE EGR PIPE ASSEMBLY

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REMOVE EGR VALVE ASSEMBLY
1. Disconnect the EGR valve assembly connector.
2. Slide the clip and disconnect the No. 6 water by-pass hose from the EGR valve assembly.
3. Slide the clip and disconnect the water by-pass hose from the EGR valve assembly.
4. Remove the 3 nuts.
5. Using an E8 "TORX" socket wrench, remove the stud bolt from the camshaft housing sub-assembly.
  
  Tech Tips
  
  If a stud bolt is deformed or the threads are damaged, replace it.
6. Remove the EGR valve assembly from the EGR pipe with cooler sub-assembly.
7. Remove the EGR valve gasket from the EGR valve assembly.