EGR VALVE INSTALLATION


  1. INSTALL EGR COOLER


    1. A013675E01

      Align the matchmarks on the EGR valve and the EGR cooler.

    2. Install the EGR cooler and EGR valve with a new clip.

  2. INSTALL EGR VALVE ASSEMBLY W/ EGR COOLER


    1. Apply a light coat of engine oil to a new O-ring.

    2. Install the O-ring to the EGR cooler pipe.

    3. A01369N

      Temporarily install the EGR valve assembly w/ EGR cooler and a new gasket with the 2 bolts.

    4. A0136D4

      Temporarily install the wire harness bracket with the bolt.

    5. Tighten the EGR valve assembly w/ EGR cooler with the 2 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
    6. A01367WE01

      Using a "torx" socket wrench, install the 2 screws.

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

    7. Connect the EGR valve connector.

  3. CONNECT ECM CONNECTOR


    1. A0137ON

      Connect the 3 ECM connectors.

      Note


      • Check the ECM and the area around the ECM for water or dirt. Clean them as necessary.

      • Check the connection of the removed ECM connector for water or dirt. Clean it as necessary.

    2. A0137UF

      Turn the retainers and securely lock the connectors.

  4. CONNECT WATER HOSE


    1. A0136O3E02

      Match the axis of the connector with the axis of the pipe, and push into the connector until the connector makes a "click" sound. If the connection is excessively tight, apply a small amount of engine coolant to the tip of the pipe.

    2. After finishing the connection, check that the pipe and the connector are securely connected by pulling on them.

  5. CONNECT EGR COOLER WATER BY-PASS HOSE


    1. A0136KM

      Connect the EGR cooler water by-pass hose with the clip.

  6. CONNECT HEATER HOSE


    1. A0138V1

      Connect the heater hose with the clip.

  7. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Tighten the wire harness clamp bracket with the bolt.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
    2. A01375Q

      Connect the wire harness clamp.

  8. INSTALL FUEL FILTER BRACKET


    1. A0136F4

      Install the fuel filter bracket with the 2 bolts.

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

    2. Using a "torx" socket wrench, install the screw.

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

  9. INSTALL WIRE HARNESS


    1. A013672E01

      Connect the connector and push down the lock.

  10. CONNECT FUEL FILTER


    1. A0138SCE01

      Connect the fuel heater connector.

    2. For LHD:


      1. Connect the fuel filter warning switch connector.

    3. Using a "torx" socket wrench, install the fuel filter with the screw.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    4. A0137YYE01

      Push the 2 tube connectors into the 2 pipes until the tube connectors make a "click" sound.

      Note


      • Before installing the pipe, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.

      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

  11. INSTALL FUEL FILTER PROTECTOR


    1. A0137JM

      Using a "torx" socket wrench, install the fuel tank protector with the 2 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  12. INSTALL FUEL HOSE


    1. A01361LE01

      Push the tube connector into the pipe until the tube connector makes a "click" sound.

      Note


      • Before installing the pipe, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.

      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

  13. CONNECT VACUUM HOSE ASSEMBLY


    1. A0136S3

      Align the connector with the pipe, then push in the connector to the pipe until it makes a "click" sound to connect the vacuum hose assembly to the vacuum pump.

  14. INSTALL AIR CLEANER CASE


    1. A0137NFE01

      Install the air cleaner case, and connect the 2 wire harness clamps.

    2. A0138CME01

      Using a "torx" socket wrench, install the air cleaner case with the 2 screws.

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

  15. INSTALL PRIMING PUMP BRACKET


    1. A0138E1

      Install the priming pump bracket.

    2. A01379F

      Install the priming pump bracket to the air cleaner case.

  16. INSTALL TURBO PRESSURE SENSOR


    1. A0136NOE01

      Install the turbo pressure sensor with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    2. Connect the turbo pressure sensor connector and hose.

  17. INSTALL INLET AIR CLEANER NO.2


    1. Install the inlet air cleaner No.2.

    2. A0135TK

      Using a "torx" socket wrench, install the inlet air cleaner No.2 with the screw.

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

  18. INSTALL INLET AIR CLEANER


    1. A0137J3

      Install inlet air cleaner.

  19. INSTALL ENGINE ROOM RELAY BLOCK


    1. A0136JUE04

      Connect the engine room relay block with the clamp.

    2. Install the engine room relay block with the 2 bolts.

      Torque:
      Bolt A
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
      Bolt B
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
    3. A0136CAE02

      Install the relay block cover upper.

  20. INSTALL MASS AIR FLOW METER


    1. Apply a light coat of engine oil to a new O-ring.

    2. Install the O-ring to the mass air flow meter.

    3. A0136T5

      Using a "torx" socket wrench, install the mass air flow meter with the 2 screws.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

    4. Connect the mass air flow meter connector.

  21. INSTALL AIR HOSE


    1. A0136X8E03

      Install the air hose with the clamp and a new clip.

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

  22. INSTALL AIR CLEANER CAP


    1. A0136JLE01

      Using a "torx" socket wrench, install the air cleaner cap with the 3 screws.

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

  23. ADD ENGINE COOLANT


    1. A01375N

      Install the drain plug with an O-ring and a new clip.

    2. Connect the radiator hose No.2.

    3. Pour engine coolant into the reserve tank assembly.

      Capacity
      4.0 to 4.4 L

      Note

      Do not substitute water for engine coolant.

      Tech Tips


      • Use of improper engine coolant may damage the engine coolant system.

      • Use only Premium Long Life Coolant for 1WZ and 2WZ-TV. Pre-mixed. Green. or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate engine 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).

    4. Check the engine coolant level inside the radiator assembly by pressing the inlet and outlet radiator hoses several times by hand. If the engine coolant level goes down, add engine coolant.

    5. A0136NJ

      Connect the water by-pass hose with the hose clamp.

      Tech Tips

      Connect the water by-pass hose, when the fluid flows clean and without air bubbles.

    6. Slowly pour engine coolant into the radiator reservoir until it reaches the FULL line.

    7. Install the reservoir tank cap sub-assembly securely.

  24. INSTALL BATTERY


    1. A01382G

      Install the battery and clamp with the bolt.

      Torque:
      15 N*m  { 154 kgf*cm, 11 ft.*lbf }

    2. Connect the positive battery cable.

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

  25. CHECK FOR ENGINE COOLANT LEAKS


    1. Start the engine.

    2. Maintain the engine speed at 1,500 rpm until the first cooling cycle (cooling fan on).

    3. Stop the engine and wait for cool down.

    4. If necessary top up the level to the maximum mark.

  26. INSTALL ENGINE COVER


    1. A0138OOE02

      Align the 3 claws to install the engine cover.

  27. INSTALL COWL TOP PANEL OUTER


    1. A0136J7

      Install the cowl top panel outer with the 10 bolts.

      Torque:
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }

  28. INSTALL COWL TOP VENTILATOR LOUVER RH


    1. Connect the washer hose.

    2. A0136GYE01

      Engage the 8 claws and install the cowl top ventilator louver RH.

    3. Install the clip.

  29. INSTALL COWL TOP VENTILATOR LOUVER LH


    1. Connect the washer hose.

    2. A0136Y2E01

      Engage the 9 claws and install the cowl top ventilator louver LH.

    3. Install the clip.

  30. INSTALL HOOD TO COWL TOP SEAL

    A01379NE01

    1. Engage the 8 clips and install the hood to cowl top seal.

  31. INSTALL FRONT WIPER ARM LH

    A01390ME03

    1. Scrape any metal powder off the serrated part of the wiper arm with a round file or equivalent (when reinstalling).

    2. Clean the wiper pivot serrations with a wire brush.

    3. Operate the wiper, then stop the windshield wiper motor assembly in the automatic stop position.

    4. Provisionally install the front wiper main arm with the nut.

    5. Install the front wiper secondary arm onto the front wiper motor and link assembly.

    6. A0138WNE04

      Align the blade tip with the mark on the windshield glass, as shown in the illustration.

    7. Tighten the nut of the front wiper main arm.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

  32. INSTALL FRONT WIPER ARM HEAD CAP

    A0137M4

    1. Engage the claw and install the front wiper arm head cap.