EGR VALVE INSTALLATION

INSTALL FUEL PUMP PROTECTOR

1. Install the fuel pump protector to the cylinder head cover sub-assembly with the 2 bolts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

INSTALL AIR CLEANER CASE SUB-ASSEMBLY

1. 

   Text in Illustration

   *a	Hole
   *b	Projection

   Insert the projection of the air cleaner case sub-assembly into the hole of the No. 1 air cleaner bracket as shown in the illustration.

2. Install the 2 bolts.

   Torque:

   5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

3. Connect the wire harness clamp.

INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

1. Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.

   Note

   Install the air cleaner filter element sub-assembly with the printed side facing the vehicle left.

INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

1. Connect the air cleaner cap with air cleaner hose to the throttle body with motor assembly.

2. Install the air cleaner cap with air cleaner hose with the 2 guides and 2 air cleaner cap clamps.

3. Tighten the hose clamp.

4. Connect the union to connector tube hose to the air cleaner hose sub-assembly.

5. Engage the wire harness clamp.

6. Connect the mass air flow meter sub-assembly connector.

7. Engage the ventilation hose clamp.

8. Connect the ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.

ADD ENGINE COOLANT (for Engine)

1. Tighten the radiator drain cock plug by hand.

2. Slowly fill the radiator assembly with engine coolant.

   Specified Capacity
   7.3 liters (7.7 US qts, 6.4 Imp. qts)

   Note

   Do not substitute plain water for engine coolant.

   Tech Tips

   TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damaging 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).

3. Remove the reserve tank cap.

4. Slowly pour engine coolant into the radiator reserve tank assembly until it reaches the full line.

5. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.

   If the engine coolant level is low, add engine coolant.

6. Install the radiator cap sub-assembly and reserve tank cap.

7. Bleed air from the cooling system.

   Note

   
   

   • Before starting the engine, turn the A/C switch off.

   • Adjust the heater control to the maximum hot setting.

   • Adjust the blower speed to the low setting.

   
   

   1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the engine coolant for several minutes.

      Tech Tips

      The thermostat open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the No. 2 radiator hose.

   2. Maintain the engine speed at 2500 to 3000 rpm.

   3. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air from the cooling system.

      CAUTION:

      When squeezing the No. 1 radiator hose and No. 2 radiator hose:

      
      

      • Wear protective gloves.

      • Be careful as the No. 1 radiator hose and No. 2 radiator hose are hot.

      • Keep your hands away from the fan and No. 2 fan.

      Note

      
      

      • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

      • Make sure that the radiator reserve tank assembly still has some engine coolant in it.

      • If the radiator reserve tank assembly does not have enough engine coolant, the engine may overheat or be seriously damaged.

      • If the radiator reserve tank assembly does not have enough engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the radiator reserve tank assembly is filled to the full line.

8. Stop the engine, and wait until the engine coolant cools down.

9. Add engine coolant to the full line on the radiator reserve tank assembly.

INSPECT FOR COOLANT LEAK (for Engine)

1. Remove the radiator cap sub-assembly.

2. 

   Text in Illustration

   *a	Radiator Cap Tester

   Fill the radiator assembly with engine coolant, and then install a radiator cap tester.

3. Warm up the engine.

4. Pump the radiator cap tester to 118 kPa (1.2 kgf/cm², 17 psi), and then check that the pressure does not drop.

   
   

   • If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leaks.

   • If there are no signs of external engine coolant leaks, check the heater core, cylinder block sub-assembly and cylinder head sub- assembly.

5. Remove the radiator cap tester.

6. Install the radiator cap sub-assembly.

INSPECT FOR EXHAUST GAS LEAK

If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

1. Perform Inspection After Repair after repairing an exhaust gas leak Click here.

INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

1. Engage the 3 grommets to install the No. 1 engine cover sub-assembly.