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Installation [11/2021 - ]: Procedure

  1. LOOSEN NO. 1 EGR PIPE SUB-ASSEMBLY 
    1. GTY1079710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, loosen the 4 bolts of the No. 1 EGR pipe sub-assembly.

        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. LOOSEN EGR VALVE ASSEMBLY 
    1. GTY1078021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, loosen the 2 bolts of the EGR valve assembly.
  3. INSTALL NO. 1 EGR COOLER GASKET 
    1. GTY1077789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Claw - -
      1. Install a new No. 1 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.

  4. INSTALL EGR VALVE GASKET 
    1. GTY1077820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Claw - -
      1. Install a new EGR valve gasket to the EGR cooler assembly.
        NOTE:

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

  5. INSTALL EGR COOLER ASSEMBLY 
    1. Fig 1: EGR Cooler Assembly Bolts And Nuts Tightening Sequence
      GTY1078928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt or Nut - -
      1. for Type A:

        Temporarily install the EGR cooler assembly to the cylinder head sub-assembly and EGR valve assembly with the 3 bolts and 2 nuts.

      2. for Type A:

        Tighten the 3 bolts and 2 nuts in the order shown in the illustration.

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

      3. for Type B:

        Temporarily install the EGR cooler assembly to the cylinder head sub-assembly and EGR valve assembly with the 2 bolts and 3 nuts.

      4. for Type B:

        Tighten the 2 bolts and 3 nuts in the order shown in the illustration.

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

  6. CONNECT NO. 4 WATER BY-PASS HOSE 
  7. CONNECT NO. 3 WATER BY-PASS HOSE 
  8. TIGHTEN EGR VALVE ASSEMBLY 
    1. GTY1078021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. 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. TIGHTEN NO. 1 EGR PIPE SUB-ASSEMBLY 
    1. GTY1079711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. 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) 

  10. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 
    Refer to PROCEDURE - Step 5
  11. CONNECT NO. 2 VENTILATION HOSE 
    Refer to PROCEDURE - Step 6
  12. CONNECT VACUUM HOSE 
  13. INSTALL INLET AIR CLEANER ASSEMBLY 
    Refer to PROCEDURE - Step 8
  14. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 48
  15. INSTALL RADIATOR UPPER AIR GUIDE PLATE 
  16. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 5

  17. INSPECT FOR COOLANT LEAK (for Engine) 
    Refer to PROCEDURE - Step 1
  18. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 4

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