EGR VALVE INSTALLATION


  1. INSTALL EGR VALVE ASSEMBLY


    1. Install a new gasket and the EGR valve with the 2 bolts and 2 nuts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  2. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CJB2E01
      Text in Illustration
      *1 Bolt
      *2 Union Bolt

      Install 4 new gaskets and the water by-pass pipe sub-assembly with the 2 union bolts and 3 bolts.

      Torque:
      for Union Bolt
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      for Bolt
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

    2. Connect the 3 wire harness clamps.

    3. Connect the 2 hoses to the EGR valve.

  3. INSTALL EGR VALVE BRACKET


    1. Install the EGR valve bracket with the 4 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  4. INSTALL WIRE HARNESS AND CONNECTORS


    1. Connect the 3 connectors and 4 wire harness clamps and then install the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  5. INSTALL NO. 4 AIR HOSE


    1. A01CJ8A

      Install the No. 4 air hose with 2 new clamps.

  6. INSTALL NO. 2 INTAKE PIPE AND NO. 1 AIR HOSE


    1. Install the No. 2 intake pipe and No. 1 air hose with the 3 bolts and 2 new hose bands.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  7. ADD ENGINE COOLANT


    1. Add engine coolant.

      Specified capacity
      14.7 liters (15.5 US qts, 12.9 Imp. qts)

      Note

      Never use water as a substitute for engine coolant.

      Tech Tips


      • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

      • Contact your TOYOTA dealer for further details.

    2. Check the coolant level inside the radiator by squeezing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add coolant.

    3. Install the radiator cap sub-assembly.

    4. Slowly pour coolant into the radiator reservoir until it reaches the full line.

    5. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens.

        While the thermostat is open, circulate the coolant for several minutes.

      2. Press the inlet and outlet radiator hoses several times by hand to bleed air.

        Note


        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    6. Stop the engine and wait until the coolant cools down.

    7. Remove the radiator cap sub-assembly and check the coolant level.

    8. If the coolant level has dropped, add coolant.

    9. Check the coolant level inside the radiator reservoir tank again. If it is below the full level, add coolant.

  8. INSPECT FOR COOLANT LEAK


    1. Remove the radiator cap sub-assembly.

      CAUTION:

      Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    2. A01CIGLE02
      Text in Illustration
      *1 Radiator Cap Tester

      Fill the radiator with coolant and attach a radiator cap tester.

    3. Warm up the engine.

    4. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 19.9 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

    5. Install the radiator cap sub-assembly.