Egr Cooler Installation

Using a 6 mm hexagon wrench, install the EGR valve adapter, No. 2 EGR valve, EGR cooler, 2 new gaskets, 3 plate washers with the 3 hexagon bolts.

Torque:

28 N*m{286 kgf*cm, 21 ft.*lbf}

Using a 5 mm hexagon wrench, install the bolt labeled A.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

Install a new gasket and the EGR cooler with pipe to the electric EGR control valve and No. 2 EGR valve with the 2 bolts.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

HINT:

Make sure the claws of the gasket face the electric EGR control valve.

Place a new gasket, the electric EGR control valve, another new gasket and the intake air connector onto the stud bolts of the No. 2 intake air connector and temporarily install the 3 nuts.

NOTICE:

Temporarily install the nuts so that 0 to 2 threads of each stud bolt are visible as shown in the illustration.

Set a new gasket on the intake manifold.

HINT:

Make sure the claws of the gasket face the intake manifold.

Temporarily install the intake air connector to the intake manifold with the 3 bolts in the illustration.

Temporarily install the EGR cooler with pipe and new gasket to the cylinder head with the bolt and 2 nuts.

Connect the No. 2 vacuum transmitting hose to the No. 2 EGR valve.

Tighten the 3 nuts labeled A in the illustration.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Tighten the 3 bolts labeled B in the illustration.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

NOTICE:

Tighten the bolts in the order shown in the illustration.

Tighten the bolt labeled C in the illustration.

Torque:

22 N*m{224 kgf*cm, 16 ft.*lbf}

Tighten the 2 nuts labeled D in the illustration.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

Temporarily install the air connector stay with the 3 bolts.

Tighten the bolt labeled A.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Tighten the 2 bolts labeled B.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Install the E-VRV bracket with the 2 bolts.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Install the gas filter and the gas filter bracket with the bolt.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Connect the 5 vacuum hoses.

NOTICE:

Install the vacuum hoses so that they completely cover the pipes.

Connect the 2 connectors to the electric EGR control valve and E-VRV.

Attach the wire harness clamp.

Install the EGR valve bracket with the 2 nuts.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

Attach the clamp.

Connect the engine wire with the 2 bolts.

Torque:

for bolt A:

13 N*m{131 kgf*cm, 9 ft.*lbf}

for bolt B:

22 N*m{220 kgf*cm, 16 ft.*lbf}

Connect the engine wire with the bolt.

Torque:

13 N*m{131 kgf*cm, 9 ft.*lbf}

Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

Install the No. 2 and No. 3 injection pipe clamps with the 2 bolts and 2 nuts as shown in the illustration.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

HINT:

If the painted mark on the No. 2 injection pipe has disappeared, use the illustration as a reference to install the clamps.

Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the common rail side.

Torque:

35 N*m{357 kgf*cm, 26 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (LandCruiser RM000003YMD00TX.html).

Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector side.

Torque:

35 N*m{357 kgf*cm, 26 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (LandCruiser RM000003YMD00TX.html).

Connect the No. 4 water by-pass hose to the EGR cooler.

HINT:

1. The direction of the hose clamp is indicated in the illustration.
   
2. Insert the outlet hose into the stopper.
   

Connect the No. 3 water by-pass hose to the EGR cooler.

HINT:

1. The direction of the hose clamp is indicated in the illustration.
   
2. Insert the outlet hose into the stopper.
   

Install the clamp.

Install the diesel throttle body (LandCruiser RM0000013ZB02VX_01_0001.html).

Install the cowl top ventilator louver (LandCruiser RM000001OV105JX_01_0003.html).

Tighten the radiator drain cock plug by hand.

Tighten the cylinder block drain cock plug.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the B line of the reservoir tank.

Standard Capacity:

Item		Specified Condition
for Automatic Transmission	w/ Rear Heater	14.9 liters (15.7 US qts, 13.1 Imp. qts)
	w/o Rear Heater	13.1 liters (13.8 US qts, 11.5 Imp. qts)
for Manual Transmission	w/ Rear Heater	15.0 liters (15.8 US qts, 13.2 Imp. qts)
	w/o Rear Heater	13.2 liters (13.9 US qts, 11.6 Imp. qts)

HINT:

1. TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
   
2. Please contact your TOYOTA dealer for further details.
   
3. for Cold Area Specification Vehicles:
   Please contact any authorized TOYOTA dealer or repairer or another duly qualified and equipped professional for further details.
   

NOTICE:

Never use water as a substitute for engine coolant.

Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

Install the radiator reservoir cap.

Using a wrench, install the vent plug.

Torque:

2.0 N*m{20 kgf*cm, 18 in.*lbf}

Bleed air from the cooling system.

1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
   

2. Maintain the engine speed at 2500 to 3000 rpm.
   

3. Press the inlet and outlet radiator hoses several times by hand to bleed air.
   

   CAUTION:

   When pressing the radiator hoses:

   1. Wear protective gloves.
      
   2. Be careful as the radiator hoses are hot.
      
   3. Keep your hands away from the radiator fan.
      

4. Stop the engine and wait until the coolant cools down to ambient temperature.
   

   CAUTION:

   Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

After the coolant cools down, check that the coolant level is at the FULL line.
If the coolant level is below the FULL line, add TOYOTA SLLC to the FULL line.

Fill the radiator with coolant and attach a radiator cap tester.

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm², 18 psi), and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.

Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

NOTICE:

1. The maximum hand pump pumping speed is 2 strokes per second.
   
2. The hand pump must be pushed with a full stroke during pumping.
   
3. When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.
   
4. If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.
   
5. If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.
   
6. If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use and the engine cannot be started.
   

Start the engine.

NOTICE:

1. Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.
   
2. Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.
   
3. Use a fully-charged battery.
   

1. When the engine can be started, proceed to the next step.
   

2. If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.
   

Turn the ignition switch off.

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG) and turn the intelligent tester on.

Clear the DTCs (LandCruiser RM000000PDK1DJX.html).

Start the engine.*1

Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

Allow the engine to idle for 3 minutes or more after performing the Active Test for the 5th time.

HINT:

When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

Enter the following menus: Powertrain / Engine and ECT / DTC.

Read Current DTCs.

Clear the DTCs (LandCruiser RM000000PDK1DJX.html).

HINT:

It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.

Repeat steps *1 to *3.

Enter the following menus: Powertrain / Engine and ECT / DTC.

Read Current DTCs.

OK:

No DTCs are output.

Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel leakage, repair or replace parts as necessary.

Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel leakage, repair or replace parts as necessary.

Disconnect the return hose from the common rail.

Start the engine and check for fuel leaks from the return pipe.
If there is fuel leakage, replace the common rail.

Connect the intelligent tester to the DLC3.

Start the engine and turn the intelligent tester on.

Select the Fuel Leak test from the Active Test mode on the intelligent tester.

If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.

Check that there are no leaks from any part of the fuel system.

NOTICE:

A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.

Reconnect the return hose to the common rail.

Install the No. 1 engine under cover with the 4 bolts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Install the lower front bumper cover with the clip and 5 bolts.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}