Installation [10/2015 - ]: Procedure

Refer to PROCEDURE - Step 8 [10/2015 - ]

1. Install a new EGR inlet gasket to the exhaust manifold (TWC: Front Catalyst).
2. Install a new EGR inlet gasket to the No. 1 EGR pipe.

1. Install a new EGR valve gasket to the EGR valve assembly.
2. Install the EGR valve assembly to the EGR cooler assembly with the 2 nuts.

   Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

3. Connect the No. 9 water by-pass hose to the EGR valve assembly and slide the clip to secure it.
4. Set the No. 2 EGR pipe.
5. Using an E6 "TORX" socket wrench, install the stud bolt to the intake manifold.

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

6. Temporarily install the EGR valve assembly, EGR cooler assembly, No. 1 EGR pipe, No. 2 EGR pipe and EGR cooler bracket with the 7 bolts and 9 nuts.
7. Tighten the 4 bolts in the order shown in the illustration.

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

   Fig 1: EGR Cooler Bracket Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Tighten the 5 nuts in the order shown in the illustration.

   Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

   Fig 2: EGR Valve & Cooler Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Using SST, tighten the nut.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Torque Wrench Fulcrum Length

   -

   -

   • SST: 09961-00950 

   Specified tightening torque 

   Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

   HINT: 

   • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

     Refer to PRECAUTION [10/2015 - 08/2016] , or refer to PRECAUTION [08/2016 - 12/2017] , or refer to PRECAUTION [12/2017 - 03/2018] , or refer to PRECAUTION [03/2018 - 08/2019] , or refer to PRECAUTION [08/2019 - ]

   • When using SST (fulcrum length of 150 mm (5.91 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 15 N*m (153 kgf*cm, 11 ft.*lbf)
10. Tighten the bolt and nut in the order shown in the illustration.

    Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

    Fig 3: EGR Pipe Tightening Sequence (2 Of 2)

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    	Bolt
    	Nut

11. Tighten the 2 bolts and 2 nuts in the order shown in the illustration.

    Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

    Fig 4: EGR Pipe Tightening Sequence (2 Of 2)

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    	Bolt
    	Nut

1. Connect the No. 6 water by-pass hose to the EGR cooler assembly and slide the clip to secure it.

1. Connect the 2 water by-pass hoses to the EGR cooler assembly and slide the 2 clips to secure them.
2. Connect the water by-pass hose assembly to the EGR valve assembly and slide the clip to secure it.

1. Connect the EGR valve assembly connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Fuel Tube Sub-assembly Connector
   *b	EGR Valve Assembly Connector

2. Connect the fuel tube sub-assembly connector.
3. Engage the wire harness clamp to the wire harness clamp bracket.

Refer to PROCEDURE - Step 11 [10/2015 - 03/2018] , or refer to PROCEDURE - Step 11 [03/2018 - ]

Refer to PROCEDURE - Step 12 [10/2015 - ]

Refer to PROCEDURE - Step 23 [10/2015 - ]

Refer to PROCEDURE - Step 4 [10/2015 - 03/2018] , or refer to PROCEDURE - Step 4 [03/2018 - ]

Refer to PROCEDURE - Step 5 [10/2015 - 03/2018] , or refer to PROCEDURE - Step 5 [03/2018 - ]

Refer to PROCEDURE - Step 8 [10/2015 - 03/2018] , or refer to PROCEDURE - Step 8 [03/2018 - ]

Refer to PROCEDURE - Step 12 [10/2015 - 08/2016] , or refer to PROCEDURE - Step 12 , or refer to PROCEDURE - Step 12 [08/2019 - ]

Refer to INSTALLATION [10/2015 - ]

1. Install the No. 2 engine under cover to the vehicle body with the 2 bolts, 2 screws and clip.

Refer to PROCEDURE - Step 5 [10/2015 - ]

Refer to PROCEDURE - Step 85 [10/2015 - 08/2019] , or refer to PROCEDURE - Step 87 [08/2019 - ]

Refer to PROCEDURE - Step 86 [10/2015 - 08/2019] , or refer to PROCEDURE - Step 88 [08/2019 - ]

Refer to PROCEDURE - Step 87 [10/2015 - 08/2019] , or refer to PROCEDURE - Step 89 [08/2019 - ]