EGR VALVE INSTALLATION

INSTALL WIRE HARNESS CLAMP BRACKET
1. Install the wire harness clamp bracket with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }

INSTALL EGR VALVE ASSEMBLY

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).

Install a new gasket and set the EGR valve with cooler assembly in place.
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 }
Temporarily install the 4 nuts (B and C) and bolt.
Tighten the 2 nuts (A).

Torque:

21 N*m { 214 kgf*cm, 15 ft.*lbf }
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.
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 }
Connect the connector, wire harness clamp and 4 water hoses.

INSTALL EGR PIPE ASSEMBLY
1. 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. Install the wire harness support with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
3. Connect the 2 wire harness clamps.
INSTALL AIR CLEANER CASE
1. 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.
INSTALL INLET AIR CLEANER ASSEMBLY
1. Install the inlet air cleaner assembly with the 3 bolts.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
2. Connect the wire harness clamp to the inlet air cleaner assembly.
3. Install the hose to the hose clamp.
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
1. Install the air cleaner cap sub-assembly with the 2 clamps.
2. Tighten the hose clamp.
3. Connect the mass air flow meter connector.
INSTALL NO. 2 CYLINDER HEAD COVER
1. 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.

ADD COOLANT (for Engine)

Tighten the radiator drain cock plug.
Connect the hose to the air release valve. (w/ Air Release Valve)
Loosen the air release valve. (w/ Air Release Valve)
Add TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank filler opening until coolant overflows from the air release valve. Then tighten the air release valve. (w/ Air Release Valve)
Disconnect the hose from the air release valve. (w/ Air Release Valve)

Text in Illustration
*1	B Line

Add TOYOTA Super Long Life Coolant (SLLC) to the B line on 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.

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.
Put the engine in inspection mode Click here.
Install the reservoir tank cap.
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, 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.
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 lines.

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

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. 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 a radiator 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.

Text in Illustration
*1	Full Line
*2	Low Line

INSTALL OUTER COWL TOP PANEL (for LHD)

Install the outer cowl top panel with the 8 bolts and nut.

Torque:

Bolt

8.8 N*m { 90 kgf*cm, 78 in.*lbf }

Nut

12 N*m { 122 kgf*cm, 9 ft.*lbf }
Engage the clamp.

Text in Illustration
*1	No. 1 Heater Air Duct Splash Shield Seal
*2	Water Guard Plate RH

Bend the No. 1 heater air duct splash shield seal and water guard plate RH, and engage each claw.

INSTALL OUTER COWL TOP PANEL (for RHD)

Install the outer cowl top panel with the 8 bolts and nut.

Torque:

Bolt

8.8 N*m { 90 kgf*cm, 78 in.*lbf }

Nut

12 N*m { 122 kgf*cm, 9 ft.*lbf }
Engage the clamp of the wire harness.

Text in Illustration
*1	Water Guard Plate RH
*2	No. 1 Heater Air Duct Splash Shield Seal

Bend the water guard plate RH and No. 1 heater air duct splash shield seal, and engage each claw.

INSTALL COWL BODY MOUNTING REINFORCEMENT LH (for LHD)
1. Install the cowl body mounting reinforcement LH with the 3 bolts.
  
  Torque:
  
  8.8 N*m { 90 kgf*cm, 78 in.*lbf }
INSTALL COWL BODY MOUNTING REINFORCEMENT LH (for RHD)
1. Install the cowl body mounting reinforcement LH with the 3 bolts.
  
  Torque:
  
  8.8 N*m { 90 kgf*cm, 73 in.*lbf }
INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here