Egr Valve -- Installation |
| 1. INSTALL NO. 2 EGR VALVE ASSEMBLY |
Using an E8 "TORX" socket wrench, install the 4 stud bolts to the No. 2 EGR valve assembly.
- Torque:
- 10 N*m{102 kgf*cm, 7 ft.*lbf}
Install a new gasket and the No. 2 EGR valve assembly to the No. 1 EGR cooler with the 4 bolts.
- Torque:
- 25 N*m{255 kgf*cm, 18 ft.*lbf}
| 2. INSTALL EGR VALVE ADAPTER |
Install a new gasket and the EGR valve adapter to the No. 2 EGR valve assembly with the 2 bolts.
- Torque:
- 25 N*m{255 kgf*cm, 18 ft.*lbf}
| 3. INSTALL NO. 1 EGR COOLER WITH NO. 2 EGR VALVE ASSEMBLY |
Temporarily install the No. 1 EGR cooler with No. 2 EGR valve assembly to the intake manifold with the 4 bolts.
Tighten the 4 bolts in the order shown in the illustration.
- Torque:
- 21 N*m{214 kgf*cm, 15 ft.*lbf}
- NOTICE:
- Make sure to tighten the bolts in the order.
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| 4. INSTALL VACUUM CONTROL VALVE SET |
Install the vacuum control valve set to the intake manifold with the 2 bolts.
- Torque:
- 10 N*m{102 kgf*cm, 7 ft.*lbf}
Connect the 2 vacuum hoses to the No. 2 vacuum transmitting pipe sub-assembly and No. 2 EGR valve assembly.
Connect the connector to the vacuum control valve set.
Connect the engine wire bracket with the bolt.
- Torque:
- 13 N*m{131 kgf*cm, 9 ft.*lbf}
| 5. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY |
Using an E8 "TORX" socket wrench, install 2 new stud bolts to the exhaust manifold.
- Torque:
- 10 N*m{102 kgf*cm, 7 ft.*lbf}
Install 2 new gaskets and the No. 1 EGR pipe sub-assembly to the exhaust manifold and EGR valve adapter with 4 new nuts.
- Torque:
- 29 N*m{296 kgf*cm, 21 ft.*lbf}
Connect the No. 1 EGR pipe sub-assembly to the vacuum transmitting pipe sub-assembly with the bolt.
- Torque:
- 10 N*m{102 kgf*cm, 7 ft.*lbf}
| 6. CONNECT NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY |
Connect the No. 4 water by-pass pipe sub-assembly to the intake manifold with the 2 bolts.
- Torque:
- 10 N*m{102 kgf*cm, 7 ft.*lbf}
Connect the water hose to the No. 2 EGR valve assembly, and slide the clamp to secure the hose.
Connect the No. 7 water by-pass hose to the No. 1 EGR cooler, and slide the clamp to secure the hose.
| 7. INSTALL NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY |
Install the No. 3 water by-pass pipe sub-assembly to the No. 1 EGR cooler with the 2 bolts.
- Torque:
- 10 N*m{102 kgf*cm, 7 ft.*lbf}
Connect the No. 8 water by-pass hose to the No. 3 water by-pass pipe sub-assembly, and slide the clamp to secure the hose.
Connect the No. 4 fuel hose to the No. 3 water by-pass pipe sub-assembly.
| 8. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY |
Install a new gasket and the electric EGR control valve assembly to the No. 2 EGR valve assembly with the 2 bolts.
- Torque:
- 25 N*m{255 kgf*cm, 18 ft.*lbf}
Connect the No. 9 water by-pass hose to the electric EGR control valve assembly, and slide the clamp to secure the hose.
Attach the clamp and connect the connector to the common rail assembly.
| 9. INSTALL NO. 2 EGR PIPE |
Install 2 new gaskets and No. 2 EGR pipe to the electric EGR control valve assembly and the intake manifold with the 4 nuts.
- Torque:
- 29 N*m{296 kgf*cm, 21 ft.*lbf}
| 10. INSTALL EGR VALVE BRACKET |
Install the EGR valve bracket to the electric EGR control valve assembly and intake manifold with the bolt and nut.
- Torque:
- 21 N*m{214 kgf*cm, 15 ft.*lbf}
| 11. CONNECT ENGINE WIRE |
Connect the 2 connectors to the vacuum control valve sets.
Attach the clamp and install the bolt.
- Torque:
- 13 N*m{133 kgf*cm, 9 ft.*lbf}
Attach the clamp and connect the 2 connectors to the vane pump assembly.
Attach the clamp and install the bolt.
- Torque:
- 13 N*m{133 kgf*cm, 10 ft.*lbf}
Connect the connector to the sensor wire of the common rail assembly.
Connect the connector to the glow plug connector.
Connect the connector to the electric EGR control valve assembly.
Connect the 4 connectors to the 4 injector assemblies.
Connect the connector to the camshaft position sensor.
Connect the connector to the exhaust fuel addition injector assembly.
Connect the 3 connectors to the 3 exhaust gas temperature sensors.
Connect the connector to the differential pressure sensor.
Attach the 2 clamps and connect the 2 connectors to the turbocharger sub-assembly.
| 12. CONNECT VANE PUMP OIL RESERVOIR SUB-ASSEMBLY |
Connect the vane pump oil reservoir sub-assembly to the body with the 3 bolts.
- Torque:
- 8.0 N*m{82 kgf*cm, 71 in.*lbf}
| 13. CONNECT UREA TANK FILLER PIPE ASSEMBLY (w/ Urea SCR System) |
Connect the urea tank filler pipe assembly to the body with the 2 bolts.
- Torque:
- 5.5 N*m{56 kgf*cm, 49 in.*lbf}
| 14. INSTALL NO. 2 ENGINE COVER BRACKET |
Install the No. 2 engine cover bracket to the No. 3 water by-pass pipe sub-assembly and No. 2 EGR valve assembly with the 2 bolts.
- Torque:
- 10 N*m{102 kgf*cm, 7 ft.*lbf}
| 15. INSTALL NO. 3 ENGINE COVER BRACKET |
Install the No. 3 engine cover bracket to the engine cover bracket and No. 2 engine cover bracket with the 2 bolts.
- Torque:
- 21 N*m{214 kgf*cm, 15 ft.*lbf}
| 16. INSTALL DIESEL TURBO PRESSURE SENSOR |
Install the diesel turbo pressure sensor to the No. 3 water by-pass pipe sub-assembly with the bolt.
- Torque:
- 10 N*m{102 kgf*cm, 7 ft.*lbf}
Connect the connector to the diesel turbo pressure sensor.
| 17. INSTALL GAS FILTER |
Install the gas filter to the gas filter bracket.
Connect the 2 vacuum hoses to the turbo pressure sensor and intake manifold.
| 18. INSTALL NO. 2 WATER BY-PASS PIPE |
Install the No. 2 water by-pass pipe to the cylinder head cover sub-assembly, No. 3 water by-pass pipe sub-assembly and No. 2 engine cover bracket with the 3 bolts.
- Torque:
- 10 N*m{102 kgf*cm, 7 ft.*lbf}
Connect the No. 16 water by-pass hose to the No. 1 EGR cooler, and slide the clamp to secure the hose.
Connect the No. 15 water by-pass hose to the water by-pass pipe, and slide the clamp to secure the hose.
Connect the No. 13 water by-pass hose to the water outlet sub-assembly, and slide the clamp to secure the hose.
| 19. INSTALL WATER HOSE SUB-ASSEMBLY |
Connect the 2 water hose sub-assemblies to the No. 2 water pipe, and slide the clamp to secure the hoses.
Connect the 2 water hose sub-assemblies to the air conditioning unit assembly, and slide the clamp to secure the hoses.
w/ Rear Air Conditioning System:
Connect the 2 water hose sub-assemblies to the water pipe, and slide the clamp to secure the hoses.
| 20. INSTALL DIESEL THROTTLE BODY ASSEMBLY |
| 21. ADD ENGINE COOLANT |
- CAUTION:
- Do not remove the radiator reservoir cap sub-assembly, vent plug, radiator drain cock plug while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
- To prevent injury due to contact with an operating fan and generator V belt or cooling fan, keep your hands and clothing away from the fan and generator V belt and cooling fans when working in the engine compartment with the engine running.
- When pressing the radiator hoses, wear protective gloves
- HINT:
- Before starting the engine to warm up the engine, turn the A/C switch off.
Add engine coolant through the radiator reservoir filler opening until the engine coolant reaches the "B" line.
Text in Illustration *a B Line - Standard Capacity:
Item Specified Condition for Manual Transmission except Cold Area Specification Vehicle 10.1 liters (10.7 US qts, 8.9 Imp. qts) for Cold Area Specification Vehicle 11.9 liters (12.6 US qts, 10.5 Imp. qts) for Automatic Transmission except Cold Area Specification Vehicle 10.0 liters (10.6 US qts, 8.8 Imp. qts) for Cold Area Specification Vehicle 11.8 liters (12.5 US qts, 10.4 Imp. qts)
- NOTICE:
- Do not substitute plain water for engine coolant.
- HINT:
- 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 is a combination of low phosphates and organic acids).
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Press the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.
If the coolant level drops below the B line, add engine coolant to the B line.
Install the radiator reservoir cap sub-assembly.
Using a wrench, install the vent plug.
- Torque:
- 2.0 N*m{20 kgf*cm, 18 in.*lbf}
Bleed air from the cooling system.
Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
- NOTICE:
- Immediately after starting the engine, if the radiator reservoir sub-assembly does not have any engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant.
- Do not start the engine when there is no coolant in the radiator reservoir sub-assembly.
- Make sure that the needle does not show an abnormally high temperature.
- If there is not enough coolant, the engine may overheat.
- HINT:
- The thermostat open timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.
Maintain the engine speed at 2000 to 2500 rpm.
Press the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air.
Stop the engine, and wait until the engine coolant cools down to ambient temperature.
Check the coolant level in the radiator reservoir sub-assembly.
If the coolant level is low, add engine coolant to the radiator reservoir sub-assembly full line.
| 22. INSPECT FOR COOLANT LEAK |
- CAUTION:
- Do not remove the radiator reservoir cap sub-assembly while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
- NOTICE:
- Before each inspection, turn the A/C switch off.
Remove the radiator reservoir cap sub-assembly.
Fill the radiator assembly with engine coolant and attach a radiator cap tester.
Warm up the engine.
Using the radiator cap tester, increase the pressure inside the radiator assembly to 118 kPa (1.2 kgf/cm2, 17 psi), and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leaks.
If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block assembly and cylinder head sub-assembly.
Remove the radiator cap tester and install the radiator reservoir cap sub-assembly.