EGR VALVE INSTALLATION

INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY
1. Text in Illustration
  
  *1 Protrusion
  
  Install a new gasket.
  
  Note
  
  Make sure the protrusion of the gasket is facing upward as shown in the illustration.
2. Install the electric EGR control valve.

Text in Illustration
*1	Protrusion

INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY

Install a new gasket to the electric EGR control valve.

Text in Illustration
*1	Nut

Temporarily install the No. 2 EGR pipe with the 3 bolts and 2 nuts.

Bolt Length

Item	Specified Condition
Bolt A	25 mm (0.984 in.)
Bolt B	70 mm (2.76 in.)

Tighten the 2 bolts labeled A shown in the illustration.

Torque:

24 N*m { 245 kgf*cm, 18 ft.*lbf }
Tighten the bolt and 2 nuts labeled B shown in the illustration.

Torque:

24 N*m { 245 kgf*cm, 18 ft.*lbf }
Connect the electric EGR control valve connector.

CONNECT NO. 8 WATER BY-PASS HOSE
CONNECT NO. 7 WATER BY-PASS HOSE
INSTALL EGR VALVE BRACKET
1. Install the 2 EGR valve brackets with the 3 bolts.
  
  Torque:
  
  24 N*m { 245 kgf*cm, 18 ft.*lbf }
2. Connect the 2 connectors and attach the 2 wire harness clamps.

ADD ENGINE COOLANT

Tighten the radiator drain cock plug by hand.
Tighten the cylinder block drain cock plug.

Torque:

for Type A

13 N*m { 130 kgf*cm, 9 ft.*lbf }

for Type B

25 N*m { 255 kgf*cm, 18 ft.*lbf }

Add TOYOTA Super Long Life Coolant (SLLC) to the radiator reservoir filler opening.

Standard Capacity

Item	Specified Condition
w/o Power Heater	7.4 liters (7.8 US qts, 6.5 Imp. qts)
w/ Power Heater	7.8 liters (8.2 US qts, 6.9 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).

Note

Never use water as a substitute for engine coolant.

Text in Illustration

*1 Air Release Plug

Remove the radiator cap and air release plug and add coolant to the B line of the reservoir tank.
Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

If the coolant level is low, add coolant.
Install the cap and air release plug, and warm up the engine sufficiently.

Torque:

2.0 N*m { 20 kgf*cm, 18 in.*lbf }
Bleed air from the cooling system.
Note
- Before starting the engine, turn the A/C switch off.
- Adjust the air conditioning temperature setting to MAX (HOT).
- Adjust the air conditioning blower setting to Lo.
1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.
  
  Tech Tips
  
  The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand and sensing vibrations when the engine coolant starts to flow inside the hose.
  CAUTION:
  When squeezing the radiator hoses:
  - Wear protective gloves.
  - Be careful as the radiator hoses are hot.
  - Keep your hands away from the radiator fan.
2. After the engine has warmed up, run the engine according to the following pattern for at least 7 minutes: 3000 rpm for 5 seconds, and then idle speed for 45 seconds (repeat this pattern at least 8 times).
3. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air from the system.
  CAUTION:
  When squeezing the radiator hoses:
  - Wear protective gloves.
  - Be careful as the radiator hoses are hot.
  - Keep your hands away from the radiator fan.
After the engine has cooled down, check that the coolant level is between FULL and LOW.

If the coolant level is low, add coolant until the coolant level leaks the reservoir tank FULL line.

INSPECT FOR COOLANT LEAK
1. Remove the radiator reservoir cap.
  
  CAUTION:
  
  To avoid the danger of being burned, do not remove the radiator reservoir cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
2. Fill the radiator with coolant, and then attach 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 and water pump for leakage.
  
  If there are no signs of external coolant leaks, check the heater core, cylinder block and head.
5. Reinstall the radiator reservoir cap.
INSTALL ENGINE UNDER COVER
1. Install the engine under cover with the 11 clips.
INSTALL FRONT LOWER BUMPER ABSORBER
1. Insert the 2 hooks of the front lower bumper absorber into the installation holes on the body to install the front lower bumper absorber.
2. Install the 8 bolts and 3 screws.
3. Install the 4 screws and 2 bolts.
INSTALL RADIATOR SUPPORT OPENING COVER
1. Install the radiator support opening cover with the 8 clips.
INSTALL NO. 1 ENGINE COVER
1. Attach the 4 clips to install the No. 1 engine cover.
PERFORM ELECTRIC EGR CONTROL VALVE FULLY CLOSED POSITION LEARNING

Tech Tips

Be sure to turn off the ignition switch before performing this operation.
1. Turn the ignition switch to ON.
2. Turn the ignition switch off and wait 30 seconds.
  
  Tech Tips
  
  The fully closed position of the electric EGR control valve is learned when the ignition switch is turned off.