ELECTRIC EGR CONTROL VALVE (w/o DPF) INSTALLATION


  1. TEMPORARILY TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY

    A01BACYE03

    1. Temporarily tighten the electric EGR control valve.


      1. Install 2 new gaskets and the electric EGR control valve onto the intake air connector as shown in the illustration.

      2. A01BH7Q

        Temporarily tighten the intake air connector with electric EGR control valve to the intake manifold with the bolt and the 2 nuts.

      3. Install the vacuum hose onto the intake air connector.

      4. Temporarily tighten the manifold stay with the bolt.

  2. TEMPORARILY TIGHTEN EGR COOLER ASSEMBLY

    A01BGO0

    1. Temporarily tighten the EGR cooler assembly.


      1. Temporarily tighten the EGR cooler assembly and new gaskets.

      2. A01BBGP

        Temporarily tighten the EGR cooler assembly stay bolt.

      3. A01BEW1

        Tighten the EGR cooler assembly with the 2 nuts and 2 bolts.

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

  3. TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY

    A01BEFZ

    1. Tighten the electric EGR control valve with the bolt and 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    2. A01BBVC

      Connect the intake air temperature sensor connector.

    3. A01BG0F

      Connect the vacuum hose to the electric EGR control valve.

    4. Connect the electric EGR control valve connector.

    5. A01BH0B

      Install the vacuum regulating valve with bracket with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    6. A01BDUS

      Connect the 2 vacuum hoses to the vacuum regulating valve.

    7. Connect the vacuum regulating valve connector.

  4. TIGHTEN EGR COOLER ASSEMBLY

    A01BBGP

    1. Tighten the EGR cooler assembly stay bolt.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    2. A01BH3G

      Install the No. 2 water by-pass hose with the clip.

    3. Install the No. 4 water by-pass hose with the clip.

  5. INSTALL MANIFOLD STAY


    1. Tighten the manifold stay bolt.

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

  6. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Note

    After removing and installing, or replacing the throttle body, be sure to perform the operation check.


    1. A01BBJH

      Install a new gasket onto the intake air connector.

    2. Install the throttle body with the 2 bolts and the 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    3. A01BCMO

      Connect the 2 throttle body connectors.

  7. INSTALL NO. 4 AIR HOSE

    A01BGX6

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

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  8. CONNECT OIL RETURN HOSE

    A01BCQX

    1. Connect the oil return hose with the 2 clips.

  9. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY

    A01BBMO

    1. Install the vane pump oil reservoir assembly with the 2 bolts.

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

  10. INSTALL NO. 2 ENGINE SERVICE HOLE COVER


    1. A01BD0S

      Install the No. 2 engine service hole cover with the 3 bolts.

  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  12. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs.

    2. Fill the radiator reserve tank assembly with coolant to the top of the inlet.

      Coolant capacity
      Condition Capacity
      w/ rear heater 18.2 liters (19.2 US qts, 16.0 lmp. qts)
      w/o rear heater 16.2 liters (17.0 US qts, 14.0 lmp. 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 install the bleeder plug.

    5. A01BGFB

      Add coolant up to the B line mark in the radiator reserve tank assembly and install the radiator 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.

  13. INSPECT FOR ENGINE COOLANT LEAK

  14. INSPECT FOR EXHAUST GAS LEAK

  15. PERFORM INITIALIZATION


    1. Perform initialization procedures Click here.

      Note

      Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.