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Installation [08/2015 - ]: Procedure

  1. INSTALL EGR VALVE BRACKET 
    1. Install the EGR valve bracket with the 3 bolts.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  2. INSTALL NO. 3 EGR PIPE SUB-ASSEMBLY 
    1. Install a new gasket and the No. 3 EGR pipe sub-assembly with the 2 nuts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  3. INSTALL EGR INLET 
    1. GTY278873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install a new gasket and the EGR inlet with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      TEXT IN ILLUSTRATION

      *1 EGR Inlet
      *2 Gasket
      *3 EGR Valve Assembly
      NOTE:

      Make sure the claws of the gasket are not caught between the EGR inlet and EGR valve assembly.

  4. INSTALL EGR VALVE ASSEMBLY 

    HINT: 

    Perform "Inspection After Repairs" after replacing the EGR valve assembly (Refer to INITIALIZATION [08/2015 - ] ).

    1. Install a new gasket to the intake manifold.
    2. Install a new gasket to the No. 2 EGR pipe.
    3. GTY255887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Temporarily install the EGR valve assembly to the intake manifold with the 2 bolts and 4 nuts.

      NOTE:

      Be careful not to damage the intake manifold when installing the EGR valve assembly.

    4. Fig 1: EGR Valve Assembly Tightening Sequence
      GTY618547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Using several steps, uniformly tighten the 2 bolts and 4 nuts in the sequence shown in the illustration.

      for bolt 

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      for nut 

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    5. Attach the wire harness clamp and connect the EGR valve connector.
  5. CONNECT NO. 13 WATER BY-PASS HOSE 
    1. GTY460424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connect the No. 13 water by-pass hose.

      TEXT IN ILLUSTRATION

      *1 Paint Mark (Blue)
      *a 13 to 17 mm (0.512 to 0.669 in.)
      *b 5 mm (0.197 in.)

      HINT: 

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

  6. CONNECT NO. 12 WATER BY-PASS HOSE 
    1. GTY463029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connect the No. 12 water by-pass hose.

      TEXT IN ILLUSTRATION

      *1 Paint Mark (Green)
      *a 13 to 17 mm (0.512 to 0.669 in.)
      *b 5 mm (0.197 in.)

      HINT: 

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

  7. INSTALL AIR CLEANER CAP AND HOSE 

    Refer to PROCEDURE - Step 53 [08/2015 - 08/2020] , or refer to PROCEDURE - Step 53 [08/2020 - ]

  8. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 6

  9. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  10. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 88 [08/2015 - 08/2020] , or refer to PROCEDURE - Step 88 [08/2020 - ]

  11. INSTALL LOWER FRONT BUMPER COVER 

    Refer to PROCEDURE - Step 89 [08/2015 - 08/2020] , or refer to PROCEDURE - Step 89 [08/2020 - ]

  12. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 80 [08/2015 - 08/2020] , or refer to PROCEDURE - Step 80 [08/2020 - ]

  13. INSTALL UPPER RADIATOR SUPPORT SEAL 

    Refer to PROCEDURE - Step 81 [08/2015 - 08/2020] , or refer to PROCEDURE - Step 81 [08/2020 - ]

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