EGR cooler bypass valve removal (4JJ3 with DPD)

1. Component views

EGR cooler bypass valve

Part name

  1. EGR cooler bypass valve
  2. EGR valve
  3. Nut
  4. Bolt
  5. Bolt
  6. EGR valve adapter
  7. Nut and bolt
  8. Bolt

Tightening torque

3: 25 N・m { 2.5 kgf・m / 18 lb・ft }

4: 25 N・m { 2.5 kgf・m / 18 lb・ft }

5: 25 N・m { 2.5 kgf・m / 18 lb・ft }

7: 25 N・m { 2.5 kgf・m / 18 lb・ft }

8: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution

  • After turning OFF the ignition switch (power mode for models with passive entry and start system), do not disconnect the battery cable within 3 minutes.
  • If the battery cable is disconnected within 3 minutes, the vehicle electronic control system may malfunction.
  • If the battery cable is disconnected, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function after connecting the battery negative terminal.

3) Raise the vehicle.

3. Underguard removal

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".

4. Coolant drain

Warning

  • Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
  • When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.

1) Remove the radiator cap from the radiator.

2) Loosen the radiator drain plug, and drain the coolant into a pan.

3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.

Legend

  1. Drain plug

4) Apply LOCTITE 262 or equivalent to the threaded portion of the cylinder block side drain plug.

5) Tighten the drain plug on the cylinder block.

Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }

6) Tighten the radiator drain plug.

5. Starter motor removal

Refer to "1.Engine 1J.Electrical(4JJ3 with DPD) starter motor removal".

6. EGR cooler bypass valve removal

1) Disconnect the connector from the EGR valve.

2) Disconnect the connector from EGR gas temperature sensor 2 (EGR valve side).

Legend

  1. EGR valve
  2. EGR gas temperature sensor 2 (EGR valve side)

3) Disconnect the heater hose from the heater pipe.

4) Disconnect the EGR cooler bypass valve water feed hose from the EGR cooler bypass valve.

5) Disconnect the heater hose from the heater pipe.

Legend

  1. EGR cooler bypass valve cooler water feed hose
  2. Heater hose

6) Disconnect the EGR cooler bypass valve vacuum hose from the EGR cooler bypass valve.

Legend

  1. EGR cooler bypass valve
  2. EGR cooler bypass valve vacuum hose

7) Remove the bracket from the inlet manifold.

8) Disconnect the EGR cooler bypass valve water return hose from the heater pipe.

Legend

  1. EGR cooler bypass valve water return hose
  2. Heater pipe

9) Remove the EGR valve and gasket from the inlet manifold and EGR valve adapter.

Caution

  • Do not reuse the gasket.

10) Remove the clip from injection pipe No. 3 and No. 4.

11) Remove injection pipe No. 4 from the injector and common rail (fuel rail).

Caution

  • Do not reuse the injection pipe.

Legend

  1. Injection pipe No. 3
  2. Injection pipe No. 4
  3. Clip

12) Remove the EGR cooler bypass valve and EGR valve adapter from the inlet manifold.

Caution

  • Do not reuse the gasket.

Legend

  1. EGR valve adapter
  2. Gasket
  3. EGR cooler bypass valve
  4. Gasket

13) Remove the EGR cooler bypass valve water return hose from the EGR cooler bypass valve.

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