EGR VALVE (w/ DPF) INSTALLATION


  1. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Install the wiring harness connector to the electric EGR control valve.

    2. Install a new gasket, the 2 stud bolts and the electric EGR control valve.

      Tech Tips

      Be sure to install the gasket together with the electric EGR control valve.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  2. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY


    1. Install 2 new gaskets and the No. 2 EGR pipe with the 3 bolts and 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  3. INSTALL EGR VALVE BRACKET


    1. Install the EGR valve bracket with the 2 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  4. CONNECT WIRING HARNESS CONNECTOR


    1. Attach the clamp and connect the wiring harness connector.

  5. CONNECT WATER BY-PASS HOSE


    1. Connect the 2 water by-pass hoses.

  6. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (for Automatic Transmission)


    1. Install a new O-ring to the transmission oil filler tube.

    2. Apply a small amount of clean transmission oil to the O-ring.

    3. Install the transmission oil filler tube with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  7. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs.

    2. Fill the radiator reservoir with coolant to the top of the inlet.

      Standard Capacity
      Item Specified Condition
      w/o Heater 13.6 liters (14.4 US qts, 12.0 Imp. qts)
      w/ Front Heater 14.6 liters (15.4 US qts, 12.8 Imp. qts)
      w/ Front and Rear Heaters 16.6 liters (17.5 US qts, 14.6 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use of improper coolants may damage the engine cooling system.

      • Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

    3. Loosen the bleeder plug of the outlet housing.

    4. When air is bled and the coolant drains out, firmly tighten the bleeder plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A01BGFB

      Add coolant up to the B line mark in the radiator reservoir and install the reservoir cap.

    6. Warm up the engine until the thermostat opens.


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

        Tech Tips

        The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    7. A01BBOM

      After the engine cools down, check that the coolant level is between the LOW and FULL level marks.

  8. INSPECT FOR COOLANT LEAK

    CAUTION:

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


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

    2. Warm up the engine.

    3. 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.

      Tech Tips

      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.

  9. PERFORM ELECTRIC EGR CONTROL VALVE COMPENSATION RESET

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