Aux.

Emission Control Devices (4HL1) 1H-1

Engine
Aux. Emission Control Devices
(4HL1)
Table of Contents
EGR.................................................................................1H-2
removal.......................................................................1H-2
inspection....................................................................1H-5
installation..................................................................1H-6
Supplementary Information..........................................1H-11
1H-2 Aux. Emission Control Devices (4HL1)

EGR

removal 1. Component views

EGR

Part name 13. Bolt

14. Gasket
1. EGR water pipe
15. EGR cooler
2. Bolt
3. Bolt Tightening torque
4. EGR cooler duct B
5. Bolt 2: 23.5 N・m { 2.4 kgf・m / 17 lb・ft }
6. Gasket 3: 50 N・m { 5.1 kgf・m / 37 lb・ft }
7. Bolt and nut
8. EGR valve 5: 28.4 N・m { 2.9 kgf・m / 21 lb・ft }
9. Gasket 7: 23.5 N・m { 2.4 kgf・m / 17 lb・ft }
10. Gasket
11. Nut 11: 25.5 N・m { 2.6 kgf・m / 19 lb・ft }
12. EGR cooler duct A 13: 28.4 N・m { 2.9 kgf・m / 21 lb・ft }
 Aux. Emission Control Devices (4HL1) 1H-3
2. Preliminary and post procedures 2. Air bleeding plug
1. Preliminary procedures 2) Loosen the radiator side drain plug, and drain the
1) Disconnect the battery cable from the battery engine coolant into a pan.
negative terminal.
Caution：
・ For 4HL1 engine models, do not disconnect
the battery cable within 1 minute after turning
OFF the ignition switch.
・ The ECM may malfunction if the battery cable
is disconnected within 1 minute.
2) Raise the vehicle.
3) Tilt the cab.
3. 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 Legend
with a thick cloth after the engine coolant has 1. Drain plug
cooled, and turn it slowly to release pressure
before removing it. 3) Loosen the drain plug on the cylinder block side,
1) Remove the radiator cap from the radiator. and drain the engine coolant into a pan.

Caution： 4) Drain engine coolant from the radiator reserve tank.

・ The radiator cap opens and closes using a 5) Tighten the drain plug on the cylinder block side.
double action mechanism. 6) Tighten the radiator side drain plug.
・ Do not damage the radiator cap or filler neck.
Caution：
・ Wait until the sound of pressure being
released from the radiator can no longer be ・ Do not start the engine without engine coolant
heard. in the radiator.
・ Doing so might cause overheating and prevent
the engine from running.
4. Water rubber hose removal
1) Remove the 2 water rubber hoses from the EGR
cooler and EGR water pipe.
5. EGR removal
1) Disconnect the connector from the EGR valve.
2) Remove EGR cooler duct A from the following
parts.
・ EGR cooler
・ Turbocharger

Legend
1. Radiator cap
1H-4 Aux. Emission Control Devices (4HL1)

Legend Legend
1. Turbocharger 1. EGR cooler duct B
2. EGR cooler duct A
3. EGR cooler 5) Remove the EGR valve from the inlet cover.

3) Remove the EGR cooler from EGR cooler duct B.

Legend
1. EGR valve
Legend
1. EGR cooler

4) Remove EGR cooler duct B from the cylinder head

and EGR valve.
 Aux. Emission Control Devices (4HL1) 1H-5

inspection
1. EGR inspection
1) Inspect the EGR cooler for carbon build up.
Note：
・ Clean the EGR cooler if there is any carbon
accumulation.
2) Inspect the EGR valve for carbon build up.
Note：
・ Clean the EGR valve if there is any carbon
accumulation.
1H-6 Aux. Emission Control Devices (4HL1)

installation 1. Component views

EGR

Part name
Tightening torque
1. EGR water pipe
2: 23.5 N・m { 2.4 kgf・m / 17 lb・ft }
2. Bolt
3. Bolt 3: 50 N・m { 5.1 kgf・m / 37 lb・ft }
4. EGR cooler duct B
5: 28.4 N・m { 2.9 kgf・m / 21 lb・ft }
5. Bolt
6. Gasket 7: 23.5 N・m { 2.4 kgf・m / 17 lb・ft }
7. Bolt and nut 11: 25.5 N・m { 2.6 kgf・m / 19 lb・ft }
8. EGR valve
9. Gasket 13: 28.4 N・m { 2.9 kgf・m / 21 lb・ft }
10. Gasket 2. EGR installation
11. Nut
12. EGR cooler duct A Caution：
13. Bolt ・ Do not reuse the gasket.
14. Gasket ・ If the procedures or methods for assembling
15. EGR cooler the EGR device are mistaken, it can lead to
 Aux. Emission Control Devices (4HL1) 1H-7

cracks in the pipe or gas leaks. Always follow Legend

the procedures. 1. EGR cooler duct B
・ Even when disassembling only a portion of the
EGR-related parts, loosen all the EGR-related 3) Temporarily install the EGR cooler and gasket to
parts once, replace the gaskets with new ones, EGR cooler duct B.
and then temporarily tighten in the following
order before performing final tightening.
・ For temporary tightening, tighten until the bolt
seating surface is seated.
1) Temporarily tighten the EGR valve and gasket to
the inlet cover.

Legend
1. EGR cooler

4) Temporarily tighten EGR cooler duct A and the

gasket to the following parts.
・ EGR cooler
Legend ・ Turbocharger

1. EGR valve

2) Temporarily tighten the following parts to the

cylinder head and EGR valve.
・ EGR cooler duct B
・ Gasket

Legend
1. Turbocharger
2. EGR cooler duct A
3. EGR cooler

5) Final tighten the following parts in the order shown

in the diagram.
1H-8 Aux. Emission Control Devices (4HL1)
・ EGR cooler Tightening torque: 50 N・m { 5.1 kgf・m / 37 lb・ft } 3
・ EGR valve
Tightening torque: 28.4 N・m { 2.9 kgf・m / 21 lb・ft }
・ EGR cooler duct A
4, 6
・ EGR cooler duct B
Tightening torque: 23.5 N・m { 2.4 kgf・m / 17 lb・ft } Note：
1, 2 ・ The number after the tightening torque
indicates the diagram number.
Tightening torque: 25.5 N・m { 2.6 kgf・m / 19 lb・ft }
5
 Aux. Emission Control Devices (4HL1) 1H-9

6) Connect the connector to the EGR valve.

3. Water rubber hose installation
1) Install the 2 water rubber hoses to the EGR cooler
and EGR water pipe.
4. Preliminary and post procedures
1. Post procedures
1) Lower the cab.
2) Connect the battery cable to the battery negative
terminal.
5. Coolant filling
1) Remove the air bleeding plug from the water outlet
pipe.

Legend
1. Radiator cap
2. Air bleeding plug

2) Fill the radiator with engine coolant.

Caution：
・ Fill slowly to prevent air from entering the
system.
3) Install the air bleeding plug to the water outlet pipe.
1H-10 Aux. Emission Control Devices (4HL1)
4) Press the radiator upper hose manually several Note：
times to discharge the air from the hose. ・ Perform with the engine running.
Caution： 16) Touch the radiator upper hose, and confirm that the
・ Repeat the operation until the coolant level no coolant in the hose has become warm.
longer drops.
Caution：
5) Install the radiator cap to the radiator. ・ If the radiator upper hose has not become
6) Add engine coolant up to the MAX line of the warm, raise engine speed to continue warm
radiator reserve tank. up.
・ Do not try determining by using only an engine
coolant temperature gauge and the hot air
coming out from the heater.
17) Idle the engine for 5 minutes.
18) Stop the engine.
19) Turn the radiator cap to the left while pushing down
to remove 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.
Caution：
Legend
・ Wait until the sound of pressure being
1. Radiator reserve tank released from the radiator can no longer be
2. MAX line heard.
3. MIN line
20) Fill the radiator with engine coolant.
7) Start and idle the engine for 5 minutes or more. 21) Install the radiator cap to the radiator.
8) Stop the engine. 22) Repeat steps 15 to 24 until the engine coolant level
9) Remove the radiator cap from the radiator. no longer lowers.
10) Fill the radiator with engine coolant. Caution：
11) Install the radiator cap to the radiator. ・ If the engine coolant level of the radiator
reserve tank has lowered the next morning,
12) Turn OFF the heater fan switch. add up to the MAX line.
13) Start the engine.
14) Raise the engine speed.
Note：
・ Increase the engine speed to around 2000 rpm
and run the engine for 5 minutes once the
needle of the engine coolant temperature
gauge reaches the center.
・ If there is a warm up switch, turn ON the warm
up switch, and then increase the engine speed
up to approx. 2000 rpm after the warm up
switch is turned OFF.
15) Check if the thermostat valve is open.
 Aux. Emission Control Devices (4HL1) 1H-11

Supplementary Information
1. Component views

EGR

Part name 14. Gasket

15. EGR cooler
1. EGR water pipe
2. Bolt Tightening torque
3. Bolt
4. EGR cooler duct B 2: 23.5 N・m { 2.4 kgf・m / 17 lb・ft }
5. Bolt 3: 50 N・m { 5.1 kgf・m / 37 lb・ft }
6. Gasket
7. Bolt and nut 5: 28.4 N・m { 2.9 kgf・m / 21 lb・ft }
8. EGR valve 7: 23.5 N・m { 2.4 kgf・m / 17 lb・ft }
9. Gasket
10. Gasket 11: 25.5 N・m { 2.6 kgf・m / 19 lb・ft }
11. Nut 13: 28.4 N・m { 2.9 kgf・m / 21 lb・ft }
12. EGR cooler duct A
13. Bolt