EGR COOLER INSTALLATION


  1. INSTALL NO. 1 EXHAUST PIPE HEAT INSULATOR SUB-ASSEMBLY


    1. Install the No. 1 exhaust pipe heat insulator sub-assembly with the 3 bolts.

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

  2. INSTALL EGR PIPE CONNECTOR


    1. Install a new gasket and the EGR pipe connector to the EGR cooler sub-assembly with the 3 nuts.

      Torque:
      69 N*m  { 699 kgf*cm, 51 ft.*lbf }

  3. INSTALL EGR COOLER SUB-ASSEMBLY


    1. Temporarily install the EGR cooler sub-assembly.

    2. Connect the No. 1 water by-pass hose and No. 2 water by-pass hose to the water by-pass pipe sub-assembly and slide the 2 clamps to secure the hose.

    3. A01CIZKE01

      Connect the No. 5 radiator hose and water by-pass hose to the water by-pass pipe sub-assembly and slide the 2 clamps to secure the hose.

    4. Connect the reserve tank hose to the water by-pass pipe sub-assembly and slide the clamp to secure the hose.

    5. Temporarily install 2 new gaskets and the EGR cooler sub-assembly with the 6 bolts.

    6. Tighten the 6 bolts in the order from A to C shown in the illustration.

      Torque:
      bolt A, B
      69 N*m  { 699 kgf*cm, 51 ft.*lbf }
      bolt C
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

    7. Retighten bolt A shown in the illustration.

      Torque:
      69 N*m  { 699 kgf*cm, 51 ft.*lbf }

  4. INSTALL EGR PIPE INSULATOR


    1. Install the EGR pipe insulator with the 2 bolts.

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

  5. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  6. INSTALL REAR ENGINE SIDE SHUTTER


    1. Install the rear engine side shutter to the rear cab mounting bracket sub-assembly with the 4 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  7. ADD ENGINE COOLANT

    CAUTION:

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

    Note

    Do not substitute plain water for engine coolant.


    1. Add engine coolant.

      Standard capacity
      14.2 liters (15.0 US qts, 12.5 Imp. qts)

      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).

    2. Check the coolant level inside the radiator by squeezing the inlet radiator hose and outlet radiator hose 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 F 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. Maintain the engine speed at a speed between 2500 and 3000 rpm.

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

        Note


        • Wear protective gloves.

        • 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 to ambient temperature.

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

      If the coolant level has dropped, add coolant.

    8. Check the coolant level inside the radiator reservoir assembly again.

      If the coolant level is below the F line, add coolant to F line.

  8. INSPECT FOR COOLANT LEAK

    CAUTION:

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

    Note

    Before each inspection, turn the A/C switch off.


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

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 20 psi), and check that the pressure does not drop.

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