EGR VALVE > INSTALLATION

for Preparation Click here



1. INSTALL EGR VALVE ASSEMBLY

HINT:
After replacing the EGR valve assembly, perform the "Inspection After Repair" (Click here).
  1. Install a new gasket.

  1. Install the EGR valve assembly with the 2 bolts.

  1. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }
  1. Connect the No. 1 water by-pass hose.



    A266465
  1. Install the EGR valve bracket with the 2 bolts and nut.

    Torque:
    25 N*m{ 255 kgf*cm , 18 ft.*lbf }
  1. Connect the clamp and No. 5 water by-pass hose.

  1. Install the wire harness clamp bracket with the bolt.

    Torque:
    13 N*m{ 127 kgf*cm , 9 ft.*lbf }


    A267673
  1. Connect the 2 connectors and wire harness clamp.



2. INSTALL NO. 2 EGR PIPE


    A268229
  1. Install 2 new gaskets and the No. 2 EGR pipe with the 2 bolts and 2 nuts.

    Torque:
    Bolt:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }
    Nut:
    25 N*m{ 255 kgf*cm , 18 ft.*lbf }

    NOTICE:
    Make sure to tighten the 4 bolts evenly until the flanges of the EGR pipe assembly contact the installation surfaces.
  1. Connect the clamp and No. 2 water by-pass hose.

  1. Connect the wire harness clamp.



3. ADD COOLANT (for Engine)


    A267961E01
  1. Insert the engine drain cock plug.

    Text in Illustration 
    *1
    Hose
  1. Disconnect the hose from the engine drain cock plug.

  1. Install the stop ring.

  1. Tighten the radiator drain cock plug by hand.



    A206788E05
  1. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC) from the water filler. (Coolant level should be within 20 mm (0.787 in.) from the filler tube end.)

    Text in Illustration 
    *a
    Filler Tube End
    *b
    Coolant Level
    *c
    20 mm

    Standard Capacity:
    5.2 liters (5.5 US qts, 4.6 lmp. qts)

    NOTICE:
    Never use water as a substitute for engine coolant.

    HINT:
    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).
  1. Remove the reserve tank cap.



    A275622E01
  1. Slowly pour coolant into the radiator reserve tank assembly until it reaches the full line.

    Text in Illustration 
    *a
    Full Line
    *b
    Low Line
  1. Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant.
    If the coolant level is low, add coolant.

  1. Install the water filler cap sub-assembly and reserve tank cap.

  1. Put the engine in inspection mode (Click here).

  1. Bleed air from the cooling system.

    NOTICE:
    1. Before starting the engine, turn the A/C switch off.
    2. Adjust the heater control to the maximum hot setting.
    3. Adjust the blower speed to the low setting.

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

      HINT:
      The thermostat open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.
    2. Squeeze the No. 1 and No. 2 radiator hoses several times by hand to bleed air.

      CAUTION:
      When squeezing the radiator hoses:
      1. Wear protective gloves.
      2. Be careful as the radiator hoses are hot.
      3. Keep your hands away from the cooling fan.

      NOTICE:
      1. Make sure that the radiator reserve tank assembly still has some coolant in it.
      2. If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.
      3. If there is not enough coolant, the engine may overheat or be seriously damaged.
      4. If the radiator reserve tank assembly does not have enough coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the reserve tank assembly is filled to the full line.
  1. Stop the engine and wait until the engine coolant cools down.

  1. Add engine coolant to the full line on the radiator reserve tank assembly.



4. INSPECT FOR COOLANT LEAK (for Engine)

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


    A268671
  1. Fill the radiator with coolant and attach a radiator cap tester.

  1. Put the engine in inspection mode (Click here).

  1. Warm up the engine.

  1. 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, engine water pump, front exhaust pipe assembly and engine coolant temperature sensor for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.