Egr Cooler (W/O Glow Plug Controller) 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}

w/ EGR Cooler:

1. Install a new gasket and electric EGR control valve to the EGR valve adapter 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.

   
   
   
   
   
   
   

   Text in Illustration

   *1	EGR Cooler	*2	New Gasket
   *3	Electric EGR Control Valve	*4	Claw

w/o EGR Cooler:

1. Install a new gasket and the electric EGR control valve.
   

Set a new gasket to the cylinder head.

Temporarily install the electric EGR control valve with No. 2 EGR valve and EGR cooler with the 2 nuts and bolt.

HINT:

Temporarily install the bolt so that the bolt head contacts the EGR cooler.

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

Connect the EGR valve position sensor connector.

Set a new gasket labeled A to the No. 2 intake air connector as shown in the illustration.

Insert the No. 2 intake air connector with the gasket into the electric EGR control valve.

Install a new gasket labeled B to the electric EGR control valve side shown in the illustration.

Set a new gasket labeled C to the intake manifold.

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

Temporarily install the intake air connector and electric EGR control valve with the 3 nuts shown in the illustration.

Tighten the 3 nuts labeled A shown in the illustration.

Torque:

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

Tighten the 3 bolts labeled B shown in the illustration.

Torque:

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

Tighten the bolt labeled C shown in the illustration.

Torque:

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

Tighten the 2 nuts labeled D shown in the illustration.

Torque:

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

Temporarily install the No. 2 intake air connector bracket 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}

w/ EGR Cooler:

1. Install the electric vacuum regulating valve together with the bracket with the 2 bolts.
   

   Torque:

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

2. Connect the 4 vacuum hoses.
   

   NOTICE:

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

3. Connect the connector.
   

w/o EGR Cooler:

1. Install the vacuum switching valve with the bolt.
   

   Torque:

   3.5 N*m{36 kgf*cm, 31 in.*lbf}

2. Install the electric vacuum regulating valve together with the bracket with the 2 bolts.
   

   Torque:

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

3. Connect the 3 vacuum hoses.
   

4. Connect the 2 connectors.
   

Connect the No. 3 water by-pass pipe with wire harness with the 2 bolts.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

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

w/ EGR Cooler:
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.

w/o EGR Cooler:
Install the No. 2 and No. 3 injection pipe clamps with the bolt 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. 1 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 (HILUX_TGN26 RM000004QR1006X.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 (HILUX_TGN26 RM000004QR1006X.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.

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 radiator reservoir.

Standard Capacity:

Item	Specified Condition
for Automatic Transmission	11.1 liters (11.7 US qts, 9.8 Imp. qts)
for Manual Transmission	9.8 liters (10.4 US qts, 8.6 Imp. qts)

NOTICE:

Never use water as a substitute for engine coolant.

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.
   

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, 17 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 F line.
If the coolant level is below the F line, add TOYOTA SLLC to the F line.

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. Hand pump pumping speed: Max. 2 strokes/ sec.
   
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.
   

Check if the engine starts.

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 to ON and turn the intelligent tester on.

Clear the DTCs.

1. w/ EGR Cooler: (HILUX_TGN26 RM000000PDK0SYX.html)
   
2. w/o EGR Cooler: (HILUX_TGN26 RM000000PDK0T9X.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 fifth 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.

1. w/ EGR Cooler: (HILUX_TGN26 RM000000PDK0SYX.html)
   
2. w/o EGR Cooler: (HILUX_TGN26 RM000000PDK0T9X.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.

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 118 kPa (1.2 kgf/cm², 17 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.

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 push the intelligent tester main switch 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.