Print-Toyota Service Information 11/3/17, 6(15 pm

Print Exit

1GD-FTV EMISSION CONTROL EGR VALVE REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after
parts are removed, installed, or replaced during the EGR valve removal/installation are shown below.
Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Effects/Inoperative
Necessary Procedures Link
Procedure when not Performed
Replacement of diesel
Perform initialization - ( )
throttle body assembly
Replacement of electric
EGR control valve Perform initialization - ( )
assembly

CAUTION:

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.

PROCEDURE

1.DRAIN ENGINE COOLANT

Click hereEngine / Hybrid System>1GD-FTV COOLING>COOLANT>REPLACEMENT

2.REMOVE DIESEL THROTTLE BODY ASSEMBLY 26100G

Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>DIESEL THROTTLE BODY>REMOVAL

3.REMOVE NO. 2 WATER BY-PASS PIPE 16278

CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.

https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MMT9.html?PUB_TYPE=RM&MODE=1 Page 1 of 13
Print-Toyota Service Information 11/3/17, 6(15 pm

a.

*1 Water Hose Sub-assembly

*2 No. 13 Water By-pass Hose
*3 No. 15 Water By-pass Hose
*4 Heater Hose
*5 No. 16 Water By-pass Hose

w/ Viscous Heater:
Slide the clamp and disconnect the No. 2 water by-pass pipe from the water hose sub-assembly.

b. w/o Viscous Heater:

Slide the clamp and disconnect the No. 2 water by-pass pipe from the No. 13 water by-pass hose.

c. Slide the clamp and disconnect the No. 15 water by-pass hose from the water by-pass pipe.

d. Slide the 2 clamps and disconnect the 2 heater hoses from the No. 2 water by-pass pipe.

e. Slide the clamp and disconnect the No. 16 water by-pass hose from the No. 1 EGR cooler.

f. Remove the 4 bolts and No. 2 water by-pass pipe from the cylinder head cover sub-assembly, No. 3 water
by-pass pipe sub-assembly and No. 2 engine cover bracket.

4.REMOVE GAS FILTER 23265C

a.

Disconnect the 2 vacuum hoses from the turbo pressure sensor and intake manifold.

https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MMT9.html?PUB_TYPE=RM&MODE=1 Page 2 of 13
Print-Toyota Service Information 11/3/17, 6(15 pm

b. Remove the gas filter from the gas filter bracket.

5.REMOVE TURBO PRESSURE SENSOR 89421C

a.

Disconnect the connector from the turbo pressure sensor.

b. Remove the bolt and turbo pressure sensor from the No. 3 water by-pass pipe sub-assembly.

6.REMOVE NO. 2 HOSE TO HOSE TUBE 44763C

a.

Slide the clamp to disconnect the union to connector tube hose from the No. 1 hose to hose tube.

b. Slide the clamp to disconnect the union to check valve hose from the vacuum pump assembly.

c. Remove the 2 bolts and No. 2 hose to hose tube from the cylinder head cover sub-assembly and hose
bracket.

7.REMOVE NO. 2 ENGINE COVER BRACKET 12632

https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MMT9.html?PUB_TYPE=RM&MODE=1 Page 3 of 13
Print-Toyota Service Information 11/3/17, 6(15 pm

a.

Remove the 2 bolts and No. 2 engine cover bracket from the No. 3 water by-pass pipe sub-assembly and
No. 2 EGR valve assembly.

8.DISCONNECT FUEL FILTER ASSEMBLY 23300

a.

Disconnect the clamp and slide the lead wire as shown in the illustration to remove it.

b.

Disconnect the fuel filter assembly from the fuel filter support.

9.DISCONNECT ENGINE WIRE 82121

https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MMT9.html?PUB_TYPE=RM&MODE=1 Page 4 of 13
Print-Toyota Service Information 11/3/17, 6(15 pm

a.

Detach the 2 clamps and disconnect the 2 connectors from the turbocharger sub-assembly.

b.

w/ DPF:
i. Disconnect the connector from the differential pressure sensor.

ii. Disconnect the 3 connectors from the 3 exhaust gas temperature sensors

iii. Disconnect the connector from the exhaust fuel addition injector assembly.

iv. Disconnect the connector from the camshaft position sensor.

v. Disconnect the 4 connectors from the 4 injector assemblies.

vi. Disconnect the connector from the electric EGR control valve assembly.

vii. Disconnect the connector from the glow plug connector.

viii. Disconnect the connector from the sensor wire of common rail assembly.

ix. Detach the 2 clamps and remove the bolt.

https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MMT9.html?PUB_TYPE=RM&MODE=1 Page 5 of 13
Print-Toyota Service Information 11/3/17, 6(15 pm

c.

w/o DPF:
i. Disconnect the connector from the camshaft position sensor.

ii. Disconnect the 4 connectors from the 4 injector assemblies.

iii. Disconnect the connector from the electric EGR control valve assembly.

iv. Disconnect the connector from the glow plug connector.

v. Disconnect the connector from the sensor wire of common rail assembly.

vi. Detach the clamp and remove the bolt.

d.

Detach the clamp and disconnect the connector from the power steering oil pressure switch.

e. Detach the clamp and remove the bolt.

f. Disconnect the connector from the vacuum control valve set.

https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MMT9.html?PUB_TYPE=RM&MODE=1 Page 6 of 13
Print-Toyota Service Information 11/3/17, 6(15 pm

10.REMOVE EGR VALVE BRACKET 25625

CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.

a.

Remove the bolt, nut and EGR valve bracket from the electric EGR control valve assembly and intake
manifold.

11.REMOVE NO. 2 EGR PIPE 25612

CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.

a.

Remove the bolt, 4 nuts and No. 2 EGR pipe from the electric EGR control valve assembly and intake
manifold.

b. Remove the 2 gaskets.

12.REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY 25800

CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.

https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MMT9.html?PUB_TYPE=RM&MODE=1 Page 7 of 13
Print-Toyota Service Information 11/3/17, 6(15 pm

a.

Detach the clamp and disconnect the connector from the common rail assembly.

b.

Slide the clamp and disconnect the No. 9 water by-pass hose from the electric EGR control valve assembly.

c. Remove the 2 bolts and electric EGR control valve assembly.

d. Remove the gasket.

13.REMOVE NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY 16206B

CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.

a.

Disconnect the No. 4 fuel hose from the No. 3 water by-pass pipe sub-assembly.

https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MMT9.html?PUB_TYPE=RM&MODE=1 Page 8 of 13
Print-Toyota Service Information 11/3/17, 6(15 pm

b.

Slide the clamp and disconnect the No. 8 water by-pass hose from the No. 3 water by-pass pipe sub-
assembly.

c. Remove the 2 bolts and No. 3 water by-pass pipe sub-assembly from the No. 1 EGR cooler.

14.DISCONNECT NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY 16209

CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.

a.

*A for Cold Area Specification Vehicle

*B except Cold Area Specification Vehicle

Slide the clamp and disconnect the No. 7 water by-pass hose from the No. 1 EGR cooler.

b. Slide the clamp and disconnect the water hose from the No. 2 EGR valve assembly.

https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MMT9.html?PUB_TYPE=RM&MODE=1 Page 9 of 13
Print-Toyota Service Information 11/3/17, 6(15 pm

c. Remove the 2 bolts and disconnect the No. 4 water by-pass pipe sub-assembly from the intake manifold.

15.REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY 25601

CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.

a.

Remove the bolt and disconnect the No. 1 EGR pipe sub-assembly from the vacuum transmitting pipe sub-
assembly.

b.

Remove the 4 nuts and the No. 1 EGR pipe from the exhaust manifold and EGR valve adapter.

c. Remove the 2 gaskets.

d.

Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.

16.REMOVE VACUUM CONTROL VALVE SET 25804

https://toyotamanuals.com.au/docs/hilux-service-repair-manual…anual/repair/contents/RM100000000MMT9.html?PUB_TYPE=RM&MODE=1 Page 10 of 13
Print-Toyota Service Information 11/3/17, 6(15 pm

a.

Remove the bolt and engine wire bracket.

b.

Disconnect the 2 vacuum hoses from the No. 2 vacuum transmitting pipe sub-assembly and No. 2 EGR
valve assembly.

c.

Remove the 2 bolts and vacuum control valve set from the intake manifold.

17.REMOVE NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY

CAUTION:
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
engine is hot.

https://toyotamanuals.com.au/docs/hilux-service-repair-manual…anual/repair/contents/RM100000000MMT9.html?PUB_TYPE=RM&MODE=1 Page 11 of 13
Print-Toyota Service Information 11/3/17, 6(15 pm

a.

Remove the 4 bolts and No. 1 EGR cooler and No. 2 EGR valve assembly from the intake manifold.

18.REMOVE EGR VALVE ADAPTER 25624

a.

Remove the 2 bolts and EGR valve adapter from the No. 2 EGR valve assembly.

b. Remove the gasket.

19.REMOVE NO. 2 EGR VALVE ASSEMBLY 25630

a.

Remove the 4 bolts and No. 2 EGR valve assembly from the No. 1 EGR cooler.

b. Remove the gasket.

https://toyotamanuals.com.au/docs/hilux-service-repair-manual…anual/repair/contents/RM100000000MMT9.html?PUB_TYPE=RM&MODE=1 Page 12 of 13
Print-Toyota Service Information 11/3/17, 6(15 pm

c.

Using an E8 "TORX" socket wrench, remove the 4 stud bolts from the No. 2 EGR valve assembly.

© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.

https://toyotamanuals.com.au/docs/hilux-service-repair-manual…anual/repair/contents/RM100000000MMT9.html?PUB_TYPE=RM&MODE=1 Page 13 of 13