EGR VALVE INSTALLATION


  1. INSTALL WIRE HARNESS CLAMP BRACKET


    1. A01J92F

      Install the wiring harness clamp bracket with the bolt.

  2. INSTALL EGR VALVE ASSEMBLY


    1. A01J9JYE01
      Text in Illustration
      *A Nut (C), Type A
      *B Nut (C), Type B
      *1 Bolt
      *2 Stud Bolt and Nut

      Temporarily install a new gasket and the EGR valve assembly with the 2 nuts (A).

    2. Install 2 new gaskets and set the EGR valve with cooler assembly in place.

    3. Using an E8 "TORX" wrench, install the 4 stud bolts.

      Torque:
      Stud Bolt (B)
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
      Stud Bolt (C)
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    4. Temporarily install the 4 nuts (B and C) and bolt.

    5. Tighten the 2 nuts (A).

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    6. Tighten the 2 nuts (B) and bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Note

      Make sure that all installation surfaces of the EGR valve with cooler assembly are in even contact when tightening the bolts and nuts.

    7. Tighten the 2 nuts (C).

      Torque:
      Type A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Type B
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
    8. A01J9SR

      Connect the connector, wire harness clamp and 4 water hoses.

  3. INSTALL EGR PIPE ASSEMBLY


    1. A01JCSG

      Install 2 new gaskets and EGR pipe assembly with the 4 bolts.

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

      Note

      Make sure to tighten the 4 bolts evenly until the flanges of the EGR pipe assembly contact with the installation surfaces.

    2. A01JALE

      Install the wire harness support with the bolt.

    3. A01J9BB

      Connect the 2 wire harness clamps.

  4. INSTALL AIR CLEANER CASE


    1. A01JCW8

      Install the air cleaner case with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Install the hose to the 3 hose clamps.

    3. Install the air cleaner filter element.

  5. INSTALL INLET AIR CLEANER ASSEMBLY


    1. A01JBRT

      Install the inlet air cleaner assembly with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  6. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. A01J8QWE01

      Install the air cleaner cap sub-assembly with the 2 clamps.

    2. Tighten the hose clamp.

    3. A01JAMH

      Connect the mass air flow meter connector.

  7. INSTALL NO. 2 CYLINDER HEAD COVER


    1. A01JAJ9

      Engage the 3 clips to install the cover.

      Note


      • Be sure to engage the clips securely.

      • Do not apply excessive force or hit the cover to engage the clips. This may cause the cover to break.

  8. ADD COOLANT (for Engine)


    1. Tighten the radiator drain cock plug.

    2. Remove the reservoir tank cap.

    3. A01JC0TE01
      Text in Illustration
      *1 B Line

      Add coolant to B line of the reservoir tank.

      Standard Capacity
      Item Capacity
      Engine coolant

      w/ Exhaust Heat Recirculation System:

      7.2 liters (7.6 US qts, 6.3 lmp. qts)

      w/o Exhaust Heat Recirculation System:

      6.5 liters (6.8 US qts, 5.7 lmp. 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.

    4. 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.

    5. Install the reservoir tank cap.

    6. Put the engine in inspection mode Click here.

    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 low setting.


      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 hose:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

      2. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air from the system.

        CAUTION:

        When squeezing the radiator hose:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    8. A01JC0TE02
      Text in Illustration
      *1 Full Line
      *2 Low Line

      After the engine has cooled down, check that the coolant level is between full and low.

      If the coolant level is low, add coolant to the full line on the reservoir tank.

  9. INSPECT FOR COOLANT LEAK (for Engine)

    CAUTION:

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

    Note

    Before performing each inspection, turn the A/C switch off.


    1. Remove the reservoir tank cap.

    2. A01JB8R

      Fill the radiator and reservoir with coolant, and then attach a radiator cap tester.

    3. Put the engine in inspection mode Click here.

    4. Warm up the engine.

    5. Using the reservoir cap tester, increase the pressure inside the radiator to 108 kPa (1.1 kgf/cm2, 16 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator, front exhaust pipe assembly and the heater hose around and engine water pump assembly for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

    6. Remove the radiator cap tester.

    7. Install the reservoir tank cap.

  10. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)


    1. A01J9P5

      Install the outer cowl top panel sub-assembly with the 9 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. A01JBKT

      Bend the water guard plate RH and engage the claw.

    3. A01JC2W

      Bend the No. 1 heater air duct splash shield seal and engage the claw.

    4. A01JCF9

      Engage the clamp to install the wire harness.

  11. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    1. A01J9HT

      Install the outer cowl top panel with the 9 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. A01J91Q

      Bend the water guard plate RH and engage the claw.

    3. A01JA93

      Bend the No. 1 heater air duct splash shield seal and engage the claw.

    4. A01JB4QE01

      Engage the clamp*2 of the wire harness.

    5. Engage the clamp*1 and connect the connector (w/ Windshield Deicer).

    6. A01JAH2

      Engage the clamp of the wire harness.

  12. INSTALL COWL BODY MOUNTING REINFORCEMENT LH (for LHD)


    1. A01JAL3

      Install the cowl body mounting reinforcement LH with the 3 bolts.

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

  13. INSTALL COWL BODY MOUNTING REINFORCEMENT LH (for RHD)


    1. A01JDA9

      Install the cowl body mounting reinforcement LH with the 3 bolts.

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

  14. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. Install the windshield wiper motor and link assembly Click here.