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Installation [12/2022 - 03/2023]: Procedure

  1. LOOSEN NO. 1 EGR PIPE SUB-ASSEMBLY 
    1. GTY1138691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, loosen the 4 bolts of the No. 1 EGR pipe sub-assembly.
        NOTE:
        • 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. GTY1140363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, loosen the 2 bolts EGR valve assembly.
  3. INSTALL NO. 1 EGR COOLER GASKET 
    1. GTY1147656Courtesy 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 No. 1 EGR cooler gasket are toward the EGR cooler assembly side.

  4. INSTALL EGR VALVE GASKET 
    1. GTY1143266Courtesy 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
      GTY1155815Courtesy 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 bolts and nuts.
      2. Tighten the bolts and 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 
    1. GTY1151843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Upper Side of Vehicle
      *c Left Side of Vehicle - -
      1. Connect the No. 4 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

        HINT: 

        Engage the clip within the area shown in the illustration.

  7. CONNECT NO. 3 WATER BY-PASS HOSE 
    1. GTY1141097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Upper Side of Vehicle
      *c Left Side of Vehicle - -
      1. Connect the No. 3 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

        HINT: 

        Engage the clip within the area shown in the illustration.

  8. TIGHTEN EGR VALVE ASSEMBLY 
    1. GTY1157530Courtesy 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. GTY1159282Courtesy 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 INVERTER WITH CONVERTER ASSEMBLY 

    Refer to INSTALLATION [12/2022 - ]

  11. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  12. INSPECT FOR COOLANT LEAK (for Engine) 
    Refer to PROCEDURE - Step 1
  13. INSPECT FOR EXHAUST GAS LEAK 
    1. If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

      HINT: 

      Perform "Inspection After Repairs" after repairing or replacing the exhaust system.

      Refer to INITIALIZATION [12/2022 - 03/2023]

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