EGR COOLER INSTALLATION


  1. INSTALL EGR COOLER SUB-ASSEMBLY


    1. A003V4ME01
      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 cooler sub-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" socket 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. A003WCO

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

  2. 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. A003XYD

      Connect the 2 wire harness clamps.

  3. INSTALL AIR CLEANER CASE


    1. Install the air cleaner case with the 2 bolts.

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

    2. Install the water hose to the hose clamp.

    3. Install the air cleaner filter element sub-assembly.

  4. INSTALL INLET AIR CLEANER ASSEMBLY


    1. Install the inlet air cleaner assembly to the air cleaner case.

    2. Install the inlet air cleaner assembly with the 2 bolts and 2 clips.

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

    3. Connect the wire harness clamp to the inlet air cleaner assembly.

    4. Install the water hose to the hose clamp.

  5. 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.

    4. Connect the wire harness clamp.

  6. INSTALL NO. 2 CYLINDER HEAD COVER


    1. A003WMM

      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.

  7. ADD COOLANT (for Engine)


    1. Tighten the radiator drain cock plug.

    2. A003ZK5E01
      Text in Illustration
      *1 B Line

      Add coolant to B line of the reserve tank.

      Standard Capacity
      Item Capacity
      Engine coolant

      w/ Exhaust Heat Recirculation System:

      6.9 liters (7.3 US qts, 6.1 lmp. qts)

      w/o Exhaust Heat Recirculation System:

      6.5 liters (6.9 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.

    3. Squeeze the radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level is low, add coolant.

    4. Put the engine in inspection mode Click here.

    5. Install the reserve tank cap.

    6. 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. (●1)

        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 fans.

      2. Stop the engine and wait until the coolant cools down. Then if the coolant level is below the low line, add coolant so that the level will be between the full and low lines. (●2)

      3. Repeat the steps from (●1) to (●2) until the coolant level of the reserve tank remains above the low line.

    7. A003ZK5E02
      Text in Illustration
      *1 Full Line
      *2 Low Line

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

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

  8. INSPECT FOR COOLANT LEAK (for Engine)

    CAUTION:

    Do not remove the reserve 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 reserve tank cap.

    2. A003VSX

      Fill the reserve tank 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, the heater hose around the engine coolant temperature sensor 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 reserve tank cap.

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


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

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

    2. w/ Wiper Deicer:

      Engage the 3 clamps to install the wire harness.

    3. Engage the clamp to install the wire harness.

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


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

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

    2. w/ Wiper Deicer:

      Engage the 3 clamps to install the wire harness.

    3. Engage the clamp to install the wire harness.

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


    1. Install the cowl body mounting reinforcement LH with the 2 bolts.

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

  12. INSTALL COWL BODY MOUNTING REINFORCEMENT RH (for RHD)


    1. Install the cowl body mounting reinforcement RH with the 2 bolts.

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

  13. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)


    1. Engage the claw and guide to install the No. 2 heater air duct splash shield seal.

  14. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    1. Engage the claw and guide to install the No. 2 heater air duct splash shield seal.

  15. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)


    1. Engage the 2 claws to install the No. 1 heater air duct splash shield seal.

  16. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    1. Engage the 2 claws to install the No. 1 heater air duct splash shield seal.

  17. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here