EGR cooler removal (4JJ1 without DPD)

1. Component views

EGR cooler (Euro4 specifications)

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Part name

1. Nut and bolt

2. EGR pipe adapter
3. Bolt
4. EGR cooler
5. Bolt
6. Bolt
7. EGR pipe adapter

Tightening torque
 1: 27 N・m { 2.8 kgf・m / 20 lb・ft }

3: 27 N・m { 2.8 kgf・m / 20 lb・ft }

5: 27 N・m { 2.8 kgf・m / 20 lb・ft }

6: 27 N・m { 2.8 kgf・m / 20 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 the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
The ECM may malfunction if the battery cable is disconnected within 1 minute.
If the battery cable is disconnected, perform the following settings after connecting the battery

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negative terminal.

Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function

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.

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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. Engine cover removal

1) Remove the engine cover from the engine.

 Legend

1. Engine cover

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6. Intake air duct removal

1) Remove the intake hose and intake air duct as a set from the turbocharger and intercooler.

7. Air cleaner removal

1) Disconnect the connector from the MAF and IAT sensor.

2) Disconnect the connector from the barometric pressure sensor.

3) Disconnect the blow-by hose from the air cleaner.

4) Disconnect the vacuum hose from the air cleaner.

5) Disconnect the intake pipe from the turbocharger.

6) Remove the air cleaner from the vehicle.

Legend

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1. Air cleaner
2. MAF and IAT sensor
3. Vacuum hose
4. Blow-by hose
5. Intake pipe
6. Barometric pressure sensor

8. Vacuum pipe removal

1. RHD models

1) Remove the vacuum hose from the turbocharger and vacuum pipe.

2) Remove the vacuum pipe from the cylinder head cover.

2. LHD models

1) Remove the vacuum hose from the turbocharger and vacuum pipe.

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2) Remove the vacuum pipe as a set with the harness bracket from the cylinder head cover.
Legend

1. Harness bracket

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9. Water pipe removal

1) Remove the water pipe from the following parts.

Water outlet pipe

Cylinder head
Turbocharger

Euro4 specifications

10. EGR cooler water hose disconnect

1. Euro4 specifications

1) Disconnect the EGR cooler water feed hose from the EGR cooler.

2) Disconnect the EGR cooler water return hose from the EGR cooler.
 Legend

1. EGR cooler water return hose

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2. EGR cooler water feed hose

11. Exhaust manifold heat protector removal

1. Euro4 specifications

1) Remove the exhaust manifold heat protector from the exhaust manifold and EGR cooler.
12. EGR cooler removal

1. Euro4 specifications

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1) Remove the EGR cooler and gasket from the cylinder head and exhaust manifold.

2) Remove the EGR pipe adapter and gasket from the EGR cooler.

Legend

1. EGR cooler
2. Exhaust manifold
3. EGR pipe adapter
EGR cooler inspection (4JJ1 without DPD)

1. EGR cooler inspection

1) Inspect the EGR cooler for carbon build up.

Note
Clean the EGR cooler if there is any carbon accumulation.

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EGR cooler installation (4JJ1 without DPD)

1. Component views

EGR cooler (Euro4 specifications)

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Part name

1. Nut and bolt

2. EGR pipe adapter
3. Bolt
4. EGR cooler
5. Bolt
6. Bolt
7. EGR pipe adapter

Tightening torque
 1: 27 N・m { 2.8 kgf・m / 20 lb・ft }

3: 27 N・m { 2.8 kgf・m / 20 lb・ft }

5: 27 N・m { 2.8 kgf・m / 20 lb・ft }

6: 27 N・m { 2.8 kgf・m / 20 lb・ft }

2. EGR cooler installation

1. Euro4 specifications

1) Temporarily tighten the EGR pipe adapter and gasket to the EGR cooler in the order shown in the diagram.

Caution
Do not reuse the gasket.

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2) Final tighten the EGR pipe adapter to the EGR cooler in the order shown in the diagram.

Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft }

 3) Temporarily tighten the EGR cooler and gasket to the cylinder head and exhaust manifold in the order shown in
the diagram.

Caution
Do not reuse the gasket.

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4) Final tighten the EGR cooler to the cylinder head and exhaust manifold in the order shown in the diagram.

Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft }

3. Exhaust manifold heat protector installation

1. Euro4 specifications

1) Install the exhaust manifold heat protector to the exhaust manifold and EGR cooler.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

 cardiagn.com
4. EGR cooler water hose connect

1. Euro4 specifications

1) Connect the EGR cooler water return hose to the EGR cooler.

2) Connect the EGR cooler water feed hose to the EGR cooler.
 Legend

1. EGR cooler water return hose

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2. EGR cooler water feed hose

5. Water pipe installation

1) Install the water pipe to the following parts.

Water outlet pipe

Cylinder head
Turbocharger

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in } Bolt, nut

Euro4 specifications

6. Vacuum pipe installation

1. RHD models

1) Install the vacuum pipe to the cylinder head cover.

 Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2) Install the vacuum hose to the turbocharger and vacuum pipe.

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2. LHD models

1) Install the vacuum pipe as a set with the harness bracket to the cylinder head cover.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

 Legend

1. Harness bracket

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2) Install the vacuum hose to the turbocharger and vacuum pipe.

7. Air cleaner installation

1) Install the air cleaner to the vehicle.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

Legend

1. Air cleaner

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2. MAF and IAT sensor
3. Vacuum hose
4. Blow-by hose
5. Intake pipe
6. Barometric pressure sensor

2) Referring to the diagram, connect the intake pipe to the turbocharger by aligning the alignment marks.

Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in }

Legend

1. Alignment mark

3) Connect the blow-by hose to the air cleaner.

4) Connect the vacuum hose to the air cleaner.

5) Connect the connector to the barometric pressure sensor.

 6) Connect the connector to the MAF and IAT sensor.

8. Intake air duct installation

1) Install the intake hose and intake air duct as a set to the turbocharger and intercooler.

Caution
Referring to the diagram, face the threaded portion of the clamp toward the engine front.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Nut, bolt

Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in } Clamp (Turbocharger side)

Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in } Clamp (Intercooler side)

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9. Engine cover installation

1) Install the engine cover to the engine.

Legend

1. Engine cover
10. Underguard installation

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

11. Preliminary and post procedures

1. Post procedures

1) Connect the battery cable to the battery negative terminal.

2) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

3) Close the engine hood.

12. Coolant filling

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1) Fill with engine coolant up to the radiator filler neck.

Note
Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

Caution
Fill slowly to prevent air from entering the system.

2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator
with engine coolant.

Note
Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant
lowers.

Caution
Repeat the operation until the coolant level no longer drops.

3) Add engine coolant up to the MAX line of the radiator reserve tank.
Legend

1. Radiator reserve tank

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2. MAX line
3. MIN line

4) Install the radiator cap to the radiator.

5) Start and idle the engine.

Caution
Idle the engine for 5 minutes or more.

6) Stop the engine.

7) Remove the radiator cap from the radiator.

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.

8) Fill with engine coolant up to the radiator filler neck.

Note
If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.

9) Install the radiator cap to the radiator.

10) Start the engine.

11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant
temperature gauge reaches the center.

12) With the engine running, check that the thermostat valve is open.

Note
 Touch the radiator upper hose, and confirm that it has become warm.
If it has not become warm, go back to Step 11.

Caution
Do not try determining it by using only an engine coolant temperature gauge.

13) Idle the engine for 5 minutes.

14) Stop the engine.

15) Remove the radiator cap from the radiator.

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.

16) Fill with engine coolant up to the radiator filler neck.

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Note
Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

17) Add engine coolant up to the MAX line of the radiator reserve tank.

18) Install the radiator cap to the radiator.

19) Repeat steps 10 to 18 until the coolant level no longer lowers.

Caution
If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.
EGR pipe removal (4JJ1 without DPD)

1. Component views

EGR pipe (Euro2 specifications)

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Part name

1. Nut
2. EGR pipe
3. Bolt
4. Gasket
5. Gasket

Tightening torque

1: 27 N・m { 2.8 kgf・m / 20 lb・ft }

 3: 27 N・m { 2.8 kgf・m / 20 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 the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
The ECM may malfunction if the battery cable is disconnected within 1 minute.
If the battery cable is disconnected, perform the following settings after connecting the battery
negative terminal.

Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function

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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

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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. Engine cover removal

1) Remove the engine cover from the engine.

Legend

1. Engine cover

6. Air cleaner removal

 1) Disconnect the connector from the MAF and IAT sensor.

2) Disconnect the connector from the barometric pressure sensor.

3) Disconnect the blow-by hose from the air cleaner.

4) Disconnect the vacuum hose from the air cleaner.

5) Disconnect the intake pipe from the turbocharger.

6) Remove the air cleaner from the vehicle.

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Legend

1. Air cleaner
2. MAF and IAT sensor
3. Vacuum hose
4. Blow-by hose
5. Intake pipe
6. Barometric pressure sensor

7. Intake air duct removal

1) Remove the intake hose and intake air duct as a set from the turbocharger and intercooler.
8. Vacuum pipe removal

1. RHD models

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1) Remove the vacuum hose from the turbocharger and vacuum pipe.

2) Remove the vacuum pipe from the cylinder head cover.

2. LHD models

1) Remove the vacuum hose from the turbocharger and vacuum pipe.

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2) Remove the vacuum pipe as a set with the harness bracket from the cylinder head cover.
 Legend

1. Harness bracket

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9. Turbocharger water hose disconnect

1) Disconnect the turbocharger water feed hose from the water feed and return pipe.

Without EGR and Euro2 specifications

Legend

1. Turbocharger water feed hose

2. Turbocharger water return hose

10. Exhaust manifold heat protector removal

1) Remove the exhaust manifold heat protector from the exhaust manifold and bracket.

Euro2 specifications
11. EGR pipe removal

1. Euro2 specifications

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1) Remove the EGR pipe and gasket from the inlet manifold and exhaust manifold.
EGR pipe inspection (4JJ1 without DPD)

1. EGR pipe inspection

1) Inspect the EGR pipe for carbon accumulation.

Note
Clean the EGR pipe if there is any carbon accumulation.

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EGR pipe installation (4JJ1 without DPD)

1. Component views

EGR pipe (Euro2 specifications)

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Part name

1. Nut
2. EGR pipe
3. Bolt
4. Gasket
5. Gasket

Tightening torque

1: 27 N・m { 2.8 kgf・m / 20 lb・ft }

 3: 27 N・m { 2.8 kgf・m / 20 lb・ft }

2. EGR pipe installation

1. Euro2 specifications

1) Install the EGR pipe and gasket to the inlet manifold and exhaust manifold.

Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft }

Caution
Do not reuse the gasket.

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3. Exhaust manifold heat protector installation

1) Install the exhaust manifold heat protector to the exhaust manifold and bracket.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Euro2 specifications
4. Turbocharger water hose connect

1) Connect the turbocharger water feed hose to the water feed and return pipe.

Without EGR and Euro2 specifications

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Legend

1. Turbocharger water feed hose

2. Turbocharger water return hose

5. Vacuum pipe installation

1. RHD models

1) Install the vacuum pipe to the cylinder head cover.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2) Install the vacuum hose to the turbocharger and vacuum pipe.

 2. LHD models

1) Install the vacuum pipe as a set with the harness bracket to the cylinder head cover.

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Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Legend

1. Harness bracket

2) Install the vacuum hose to the turbocharger and vacuum pipe.

6. Intake air duct installation

1) Install the intake hose and intake air duct as a set to the turbocharger and intercooler.

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Caution
Referring to the diagram, face the threaded portion of the clamp toward the engine front.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Nut, bolt

Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in } Clamp (Turbocharger side)

Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in } Clamp (Intercooler side)

7. Air cleaner installation

1) Install the air cleaner to the vehicle.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

Legend

1. Air cleaner

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2. MAF and IAT sensor
3. Vacuum hose
4. Blow-by hose
5. Intake pipe
6. Barometric pressure sensor

2) Referring to the diagram, connect the intake pipe to the turbocharger by aligning the alignment marks.

Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in }

Legend

1. Alignment mark

3) Connect the blow-by hose to the air cleaner.

4) Connect the vacuum hose to the air cleaner.

5) Connect the connector to the barometric pressure sensor.

 6) Connect the connector to the MAF and IAT sensor.

8. Engine cover installation

1) Install the engine cover to the engine.

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Legend

1. Engine cover

9. Underguard installation

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

10. Preliminary and post procedures

1. Post procedures

1) Lower the vehicle.

2) Connect the battery cable to the battery negative terminal.

3) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

4) Close the engine hood.

11. Coolant filling

1) Fill with engine coolant up to the radiator filler neck.

Note
Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.
Caution
Fill slowly to prevent air from entering the system.

2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator
with engine coolant.

Note
Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant
lowers.

Caution
Repeat the operation until the coolant level no longer drops.

3) Add engine coolant up to the MAX line of the radiator reserve tank.

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Legend

1. Radiator reserve tank

2. MAX line
3. MIN line

4) Install the radiator cap to the radiator.

5) Start and idle the engine.

Caution
Idle the engine for 5 minutes or more.

6) Stop the engine.

7) Remove the radiator cap from the radiator.

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.

8) Fill with engine coolant up to the radiator filler neck.

Note
If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.

9) Install the radiator cap to the radiator.

10) Start the engine.

11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant
temperature gauge reaches the center.

12) With the engine running, check that the thermostat valve is open.

Note
Touch the radiator upper hose, and confirm that it has become warm.
If it has not become warm, go back to Step 11.

Caution
Do not try determining it by using only an engine coolant temperature gauge.

13) Idle the engine for 5 minutes.

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14) Stop the engine.

15) Remove the radiator cap from the radiator.

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.

16) Fill with engine coolant up to the radiator filler neck.

Note
Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

17) Add engine coolant up to the MAX line of the radiator reserve tank.

18) Install the radiator cap to the radiator.

19) Repeat steps 10 to 18 until the coolant level no longer lowers.

Caution
If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.
EGR valve removal (4JJ1 without DPD)

1. 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 the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
The ECM may malfunction if the battery cable is disconnected within 1 minute.

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If the battery cable is disconnected, perform the following settings after connecting the battery
negative terminal.

Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function

2. EGR valve disconnect

1. Euro2 and Euro4 specifications

1) Disconnect the connector from the EGR valve.

3. EGR valve removal

1. Euro2 and Euro4 specifications

1) Remove the EGR valve and gasket from the inlet manifold.
EGR valve inspection (4JJ1 without DPD)

1. EGR valve inspection

1) Inspect the EGR valve for carbon build up.

Note
Clean the EGR valve if there is any carbon accumulation.

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EGR valve installation (4JJ1 without DPD)

1. EGR valve installation

1. Euro2 and Euro4 specifications

1) Install the EGR valve and gasket to the inlet manifold.

Caution
Do not reuse the gasket.

Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft } Nut

Tightening torque: 24 N・m { 2.4 kgf・m / 18 lb・ft } Bolt

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2. EGR valve connect

1. Euro2 and Euro4 specifications

1) Connect the connector to the EGR valve.

3. Preliminary and post procedures

1. Post procedures

1) Connect the battery cable to the battery negative terminal.

2) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".
3) Close the engine hood.

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Supplementary Information (4JJ1 without DPD)

1. Component views

EGR pipe (Euro2 specifications)

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Part name

1. Nut
2. EGR pipe
3. Bolt
4. Gasket
5. Gasket

Tightening torque

1: 27 N・m { 2.8 kgf・m / 20 lb・ft }

 3: 27 N・m { 2.8 kgf・m / 20 lb・ft }

EGR cooler (Euro4 specifications)

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Part name

1. Nut and bolt

2. EGR pipe adapter
3. Bolt
4. EGR cooler
5. Bolt
6. Bolt
7. EGR pipe adapter

Tightening torque

1: 27 N・m { 2.8 kgf・m / 20 lb・ft }

3: 27 N・m { 2.8 kgf・m / 20 lb・ft }

5: 27 N・m { 2.8 kgf・m / 20 lb・ft }

6: 27 N・m { 2.8 kgf・m / 20 lb・ft }