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Installation [11/2016 - ]: Procedure

WARNING: This page is about a different car, the 2019 Toyota Highlander, 2018 Toyota Highlander, and 2017 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL NO. 2 EGR PIPE GASKET 

    Refer to PROCEDURE - Step 8

  2. INSTALL EGR INLET GASKET 
    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.
  3. INSTALL EGR VALVE ASSEMBLY 
    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: Tightening Sequence Of EGR Cooler Bracket
      GTY654122Courtesy 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: Tightening Sequence Of EGR Valve Assembly & EGR Cooler Assembly
      GTY656732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using SST, tighten the nut.
      GTY716432Courtesy 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 [11/2016 - ]

      • 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: Tightening Sequence Of EGR Pipe
      GTY672396Courtesy 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: Tightening Sequence Of EGR Pipe
      GTY732495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  4. CONNECT NO. 6 WATER BY-PASS HOSE 
    1. Connect the No. 6 water by-pass hose to the EGR cooler assembly and slide the clip to secure it.
  5. CONNECT WATER BY-PASS HOSE ASSEMBLY 
    1. Connect the 2 water by-pass hose assemblies 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.
  6. CONNECT WIRE HARNESS 
    1. Connect the EGR valve assembly connector.
      GTY697905Courtesy 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.
  7. INSTALL RESERVOIR BRACKET 

    Refer to PROCEDURE - Step 41

  8. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 

    Refer to PROCEDURE - Step 42

  9. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 19

  10. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 10

  11. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [02/2014 - ]

  12. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  13. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 3

  14. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 10

  15. INSTALL FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 26

  16. INSTALL NO. 2 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 83

  17. INSTALL NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 84

  18. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 74

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