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Installation [08/2021 - ]: Procedure

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  1. INSTALL EGR COOLER ASSEMBLY 
    1. Using an 8 mm socket wrench, loosen the 4 bolts of the No. 1 EGR pipe sub-assembly.
      GTY1000497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      • As the bolts of the No. 1 EGR pipe sub-assembly are only to be loosened, it is not necessary to replace the EGR inlet gasket and EGR valve adapter gasket.
      • If the No. 1 EGR pipe sub-assembly is removed, it is necessary to replace the EGR inlet gasket and EGR valve adapter gasket with new ones.
    2. Using an 8 mm socket wrench, loosen the 2 bolts of the EGR valve assembly.
      GTY1000500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new EGR cooler gasket to the EGR cooler assembly.
      NOTE:

      Make sure that the claws of the EGR cooler gasket are toward the EGR cooler assembly side.

      GTY1001304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Claw
    4. Install a new EGR valve gasket to the EGR cooler assembly.
      NOTE:

      Make sure that the claws of the EGR cooler gasket are toward the EGR cooler assembly side.

    5. Type A:
      Fig 1: EGR Cooler Assembly Bolts And Nuts Tightening Sequence
      GTY1000306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt or Nut
      1. Temporarily install the EGR cooler assembly to the cylinder head sub-assembly and EGR valve assembly with the 3 bolts and 2 nuts.
      2. Tighten the 3 bolts and 2 nuts in the order shown in the illustration.

        Torque: 24 N.m (245 kgf/cm, 18 ft.lbf) 

    6. Type B:
      1. Temporarily install the EGR cooler assembly to the cylinder head sub-assembly and EGR valve assembly with the 2 bolts and 3 nuts.
      2. Tighten the 2 bolts and 3 nuts in the order shown in the illustration.

        Torque: 24 N.m (245 kgf/cm, 18 ft.lbf) 

    7. Connect the No. 3 water by-pass hose and No. 4 water by-pass hose to the EGR cooler assembly and slide the 2 clips to secure them.
    8. Using an 8 mm socket wrench, tighten the 2 bolts of the EGR valve assembly.

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

    9. Using an 8 mm socket wrench, tighten the 4 bolts of the No. 1 EGR pipe sub-assembly.

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

  2. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 3

  3. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 49

  4. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 2

  5. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  6. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 9

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