Egr Cooler Installation

Install a new O-ring to the EGR cooler.

Temporarily install the No. 2 EGR valve assembly, No. 1 EGR pipe, 2 new gaskets, 2 bolts and 2 nuts to the EGR cooler.

Install a new gasket to the No. 1 EGR pipe.

Install a new gasket to the EGR cooler.

Temporarily install the EGR cooler assembly with the 2 bolts and 2 nuts (^*1).

Temporarily install the 4 bolts (^*2).

Tighten the 2 bolts and 2 nuts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Tighten the 2 bolts to the exhaust manifold.

Torque:

16 N*m{163 kgf*cm, 12 ft.*lbf}

Tighten the 2 bolts to the cylinder head.

Torque:

24 N*m{245 kgf*cm, 18 ft.*lbf}

Tighten the 2 bolts and 2 nuts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Connect the vacuum hose.

Temporarily install the No. 1 manifold stay.

Temporarily install a new turbine outlet elbow gasket and exhaust manifold converter with the 3 nuts.

Temporarily install the 2 bolts and nut.

Tighten the 3 nuts (Pushing the manifold converter against the No. 1 manifold stay).

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Tighten the 2 bolts and nut.

Torque:

56 N*m{571 kgf*cm, 41 ft.*lbf}

Temporarily install the No. 2 exhaust manifold stay with the 2 bolts and nut.

Tighten the 2 bolts (Pushing the No. 2 exhaust manifold stay against the manual transmission).

Torque:

56 N*m{571 kgf*cm, 41 ft.*lbf}

Tighten the nut.

Torque:

56 N*m{571 kgf*cm, 41 ft.*lbf}

Using pliers, slide the clip to install the No. 1 and No. 2 vacuum transmitting hose assembly.

HINT:

Make sure that the paint marks on the No. 1 and No. 2 vacuum transmitting hose assemblies and No. 1 and No. 2 vacuum pipes are aligned.

Using vernier calipers, measure the free length of the compression springs.

Minimum length:

38.5 mm (1.516 in.)

Fully insert 2 new gaskets to the exhaust manifold converter and front exhaust pipe assembly by hand.

NOTICE:

1. Be careful with the installation direction of the gasket.
   
2. Do not reuse the gasket.
   
3. Do not damage the gasket.
   
4. To ensure a proper seal, do not use the tail exhaust pipe to force the gasket onto the front exhaust pipe.
   

   HINT:

   Using a plastic hammer, uniformly strike the gasket so that the gasket and front exhaust pipe are properly fit.

Install the front exhaust pipe assembly.

Install the 2 bolts and 2 compression springs.

Torque:

43 N*m{439 kgf*cm, 32 ft.*lbf}

NOTICE:

After installation, check that the clearance is almost the same at any point between the flanges of the tail exhaust pipe assembly and front exhaust pipe assembly.

Install the 2 bolts and 2 compression springs.

Torque:

43 N*m{439 kgf*cm, 32 ft.*lbf}

NOTICE:

After installation, check that the clearance is almost the same at any point between the flanges of the exhaust manifold converter and front exhaust pipe assembly.

Tighten all the plugs.

Torque:

for cylinder block drain cock plug:

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

Add engine coolant.

Specified capacity:

8.9 liters (9.4 US qts, 7.8 lmp. qts)

HINT:

1. The coolant reserve tanks of 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 that consists of a combination of low phosphates and organic acids).
   

1. Contact your TOYOTA dealer for further details.
   

Slowly pour coolant into the radiator reservoir until it reaches the FULL line.

Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level is low, add coolant.

Install the radiator cap.

Bleed air from the cooling system.

NOTICE:

Before starting the engine, turn the A/C switch off.

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

   HINT:

   The thermostat open timing can be confirmed by squeezing the inlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.

   NOTICE:

   When squeezing the radiator hose:

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

2. Maintain the engine speed at 2,000 to 2,500 rpm.
   

3. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air from the system.
   

   NOTICE:

   When squeezing the radiator hoses:

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

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

CAUTION:

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

Check the coolant level in the reserve tank.
If the coolant level is low, add coolant to the reserve tank FULL line.

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

Warm up the engine.

Using a radiator cap tester, increase the pressure inside the radiator to 177 kPa (1.8 kgf/cm, 26 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 cylinder head.

Install the inlet air cleaner with the bolt and clip.

Torque:

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

Install the side cover with the 2 clips.

Install the intake duct seal with the 11 clips.

Install the No. 1 engine cover.