EGR COOLER INSTALLATION


  1. ASSEMBLE EGR VALVE ADAPTER, NO. 2 EGR VALVE ASSEMBLY AND EGR COOLER


    1. Assemble the EGR valve adapter, No. 2 EGR valve, EGR cooler and 2 gaskets. Then install the 3 plate washers and 3 hexagon bolts using a 6 mm hexagon wrench.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    2. Tighten install the hexagon bolt labeled A using a 5 mm hexagon wrench.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      A01DYIME01

  2. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Install a new gasket and electric EGR control valve to the EGR valve adapter with the 2 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      Tech Tips

      The claws of the gasket must face the electric EGR control valve.

      A01DZP0E01

  3. TEMPORARILY INSTALL ELECTRIC EGR CONTROL VALVE WITH NO. 2 EGR VALVE AND EGR COOLER


    1. Set a new gasket to the cylinder head.

    2. A01E18WE01

      Temporarily install the electric EGR control valve with No. 2 EGR valve and EGR cooler with the 2 nuts and bolt.

    3. A01E2RS

      Connect the vacuum hose to the No. 2 EGR valve.

  4. INSTALL NO. 2 INTAKE AIR CONNECTOR


    1. Set a new gasket labeled A to the No. 2 intake air connector as shown in the illustration.

    2. Insert the No. 2 intake air connector with the gasket into the electric EGR control valve.

    3. Install a new gasket labeled B to the electric EGR control valve side shown in the illustration below.

  5. TEMPORARILY INSTALL INTAKE AIR CONNECTOR


    1. Set a new gasket labeled C to the intake manifold.

    2. Temporarily install the intake air connector to the intake manifold with the 3 bolts.

    3. Temporarily tighten the intake air connector and electric EGR control valve with the 3 nuts shown in the illustration below.

      A01E1OKE01

  6. TIGHTEN NO. 2 INTAKE AIR CONNECTOR AND INTAKE AIR CONNECTOR


    1. Tighten the 3 nuts shown in the illustration below labeled A.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  7. TIGHTEN INTAKE AIR CONNECTOR AND INTAKE MANIFOLD


    1. Tighten the 3 bolts shown in the illustration below labeled B.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  8. TIGHTEN EGR COOLER


    1. Tighten the hexagon bolt shown in the illustration below labeled C.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Tighten the 2 nuts shown in the illustration below labeled D.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      A01DZCJE01

  9. INSTALL ELECTRIC VACUUM REGULATING VALVE ASSEMBLY


    1. A01DZX0

      Install the E-VRV's bracket with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    2. A01DV5Q

      Install the gas filter with gas filter bracket with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. Connect the 5 vacuum hoses see the illustration.

      Note

      Install the vacuum hoses so that they completely cover the pipes.

    4. A01DWY1

      Connect the 2 connectors to the electric EGR control valve and E-VRV.

  10. INSTALL NO. 3 WATER BY-PASS PIPE


    1. A01DZCR

      Install the No. 3 water by-pass pipe with wire harness with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  11. INSTALL VENTURI BRACKET


    1. A01E1G1

      Install the venturi bracket with the 3 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  12. INSTALL INJECTION PIPE


    1. A01DZ04

      Install the No. 1 to 3 injection pipe Click here.

  13. CONNECT NO. 4 WATER BY-PASS HOSE


    1. A01DY9YE01

      Connect the No. 4 water by-pass hose to the EGR cooler.

      Tech Tips


      • The direction of the hose clamp is indicated in the illustration.

      • Insert the outlet hose into the stopper.

  14. CONNECT NO. 3 WATER BY-PASS HOSE


    1. Connect the No. 3 water by-pass hose to the EGR cooler.

      Tech Tips


      • The direction of the hose clamp is indicated in the illustration.

      • Insert the outlet hose into the stopper.

    2. Install the clamp.

  15. INSTALL DIESEL THROTTLE BODY ASSEMBLY


    1. Remove the diesel throttle body Click here.

  16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  17. INSPECT FOR FUEL LEAK

    A01E2P1E01

    CAUTION:


    • During Active Test mode, engine speed becomes high and combustion noise becomes loud, so pay attention.

    • During Active Test mode, fuel becomes high-pressured. Be extremely careful not to expose your eyes, hands, or body to escaped fuel.


    1. Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel leakage, repair or replace parts as necessary.

    2. Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel leakage, repair or replace parts as necessary.

    3. Disconnect the return hose from the common rail.

    4. Start the engine and check for fuel leaks from the return pipe.

      If there is fuel leakage, replace the common rail.

    5. Connect the intelligent tester to the DLC3.

    6. Start the engine and push the intelligent tester main switch ON.

    7. Select the Fuel Leak test from the Active Test mode on the intelligent tester.

    8. If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.

    9. Check that there are no leaks from any part of the fuel system.

      Note

      A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.

      If there is fuel leakage, repair or replace parts as necessary.

    10. Reconnect the return hose to the common rail.

  18. INSPECT FOR COOLANT LEAK

    Note

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


    1. A01E06UE01

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

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leaks.

      If no external leaks are found, check the cylinder block and head.

  19. ADD ENGINE COOLANT


    1. Tighten the cylinder block drain cock plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Tighten the radiator drain cock plug by hand.

    3. A01DYVNE01

      Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank's B line.

      Standard capacity
      Item Specified Condition
      A/T 11.1 liters (11.7 US qts, 9.8 Imp. qts)
      M/T 9.8 liters (10.4 US qts, 8.6 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 consists of a combination of low phosphates and organic acids).

      Note

      Never use water as a substitute for engine coolant.

    4. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

    5. Install the radiator reservoir cap.

    6. A01DY58E01

      Using a wrench, install the vent plug.

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

    7. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

      2. Maintain the engine speed at 2500 to 3000 rpm.

      3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

        CAUTION:

        When pressing the radiator hoses:


        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

      4. Stop the engine and wait until the coolant cools down to ambient temperature.

        CAUTION:

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

    8. A01E2D9E01

      After the coolant cools down, check that the coolant level is at the F line.

      If the coolant level is below the F line, add TOYOTA SLLC to the F line.

  20. INSPECT FOR COOLANT LEAK

    Note

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


    1. A01E06UE01

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

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leaks.

      If no external leaks are found, check the cylinder block and head.

  21. PERFORM INITIALIZATION


    1. Perform initialization Click here.

      Note

      Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.