EGR VALVE INSTALLATION


  1. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01IN07E01
      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. A01IQP8

      Install the electric EGR control valve.

  2. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY


    1. Install 2 new gaskets to the No. 2 EGR pipe and electric EGR control valve.

    2. A01IPRKE06
      Text in Illustration
      *1 Nut

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

      Standard Bolt
      Item Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 70 mm (2.76 in.)

    3. Tighten the 2 bolts labeled A shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    4. Tighten the bolt labeled B and 2 nuts shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
    5. A01IOQA

      Connect the electric EGR control valve connector.

  3. CONNECT NO. 8 WATER BY-PASS HOSE

    A01INDM

  4. CONNECT NO. 7 WATER BY-PASS HOSE

    A01ITX7

  5. INSTALL EGR VALVE BRACKET


    1. A01IPI2

      Install the 2 EGR valve brackets with the 3 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
    2. A01IPQ0

      Connect the 2 connectors and attach the 2 wire harness clamps.

  6. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. 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 }

    3. 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.

    4. A01IQ5WE01
      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.

    5. 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.

    6. Install the cap and air release plug, and warm up the engine sufficiently.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

    7. 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.

    8. A01IQM4

      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.

  7. 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. A01IU3X

      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.

  8. INSTALL NO. 1 ENGINE UNDER COVER


    1. A01IUIX

      Install the No. 1 engine under cover with the 10 clips and 6 bolts.

  9. INSTALL RADIATOR SUPPORT OPENING COVER


    1. A01IQ0Z

      Install the radiator support opening cover with the 6 clips.

  10. INSTALL NO. 1 ENGINE COVER


    1. A01INMI

      Attach the 4 clips to install the No. 1 engine cover.

  11. 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.