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Home >> Toyota >> 2018 >> Highlander XLE, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 115 (Emission Control System (2GR-FXS) - Service Information - (Hybrid)) >> EGR Valve >> Installation [11/2016 - ] >> Procedure

Installation [11/2016 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  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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