Toyota Avalon (XX50): Egr Valve

Components

COMPONENTS

ILLUSTRATION

*1	NO. 1 EGR PIPE SUB-ASSEMBLY	*2	EGR VALVE ASSEMBLY
*3	EGR VALVE BRACKET	*4	EGR INLET GASKET
*5	EGR VALVE ADAPTER GASKET	*6	EGR VALVE GASKET
*7	NO. 8 WATER BY-PASS HOSE	*8	NO. 4 WATER BY-PASS HOSE
*9	FUEL PIPE SUB-ASSEMBLY	*10	ENGINE WIRE
*11	NO. 1 FUEL VAPOR FEED HOSE	*12	NO. 2 FUEL VAPOR FEED HOSE
*13	EGR COOLER ASSEMBLY	-	-
	N*m (kgf*cm, ft.*lbf): Specified torque	●	Non-reusable part

Inspection

INSPECTION

PROCEDURE

1. INSPECT EGR VALVE ASSEMBLY

(a) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition 1 (EGA+) - 2 (EGA-) 20°C (68°F) 3.1 to 3.7 Ω 3 (EGB-) - 4 (EGB+) If the result is not as specified, replace the EGR valve assembly.

*a Component without wire harness connected (EGR Valve Assembly)

Installation

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. INSTALL EGR VALVE ASSEMBLY

HINT:

Perform "Inspection After Repair" after replacing the EGR valve assembly.

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(a) Using an 8 mm socket wrench, install the EGR valve assembly to the EGR valve bracket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Align and fit the hole of the EGR valve bracket to the pin of the camshaft housing.

*a Pin *b Hole

(c) Using the 8 mm socket wrench, install the EGR valve assembly with the EGR valve bracket to the camshaft housing with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Using the 8 mm socket wrench, connect the fuel pipe sub-assembly to the EGR valve bracket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(e) Connect the No. 4 water by-pass hose and No. 8 water by-pass hose to the EGR valve assembly and slide the 2 clips to secure them.

2. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

(a) Install a new EGR inlet gasket to the intake manifold.

(b) Install a new EGR valve adapter gasket to the No. 1 EGR pipe sub-assembly.

(c) Using an 8 mm socket wrench, install the No. 1 EGR pipe sub-assembly to the intake manifold and EGR valve assembly with the 4 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

3. CONNECT EGR COOLER ASSEMBLY

(a) Install a new EGR valve gasket to the EGR valve assembly. NOTICE: Make sure that the claws of the EGR valve gasket are toward the EGR valve assembly side.

*a Claw

(b) Connect the EGR cooler assembly to the EGR valve assembly with the 2 bolts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

4. CONNECT ENGINE WIRE

(a) Engage the 2 wire harness clamps to connect the engine wire.

(b) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(c) Connect the EGR valve assembly connector.

(d) Engage the 3 hose clamps to connect the No. 1 fuel vapor feed hose and No. 2 fuel vapor feed hose.

*1 No. 1 Fuel Vapor Feed Hose *2 No. 2 Fuel Vapor Feed Hose

5. ADD ENGINE COOLANT (for Engine)

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6. INSPECT FOR COOLANT LEAK (for Engine)

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7. INSPECT FOR EXHAUST GAS LEAK

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8. PERFORM INITIALIZATION

(a) Perform "Inspection After Repair" after replacing the EGR valve assembly.

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Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during EGR valve assembly removal/installation are shown below.

NOTICE:

This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. DRAIN ENGINE COOLANT (for Engine)

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2. DISCONNECT ENGINE WIRE

(a) Disengage the 3 hose clamps and disconnect the No. 1 fuel vapor feed hose and No. 2 fuel vapor feed hose.

*1 No. 1 Fuel Vapor Feed Hose *2 No. 2 Fuel Vapor Feed Hose

(b) Disconnect the EGR valve assembly connector.

(c) Remove the bolt.

(d) Disengage the 2 wire harness clamps and disconnect the engine wire.

3. DISCONNECT EGR COOLER ASSEMBLY

(a) Remove the 2 bolts and disconnect the EGR cooler assembly from the EGR valve assembly.

(b) Remove the EGR valve gasket from the EGR valve assembly.

4. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

(a) Using an 8 mm socket wrench, remove the 4 bolts and No. 1 EGR pipe sub-assembly from the intake manifold and EGR valve assembly.

(b) Remove the EGR valve adapter gasket from the No. 1 EGR pipe sub-assembly.

(c) Remove the EGR inlet gasket from the intake manifold.

5. REMOVE EGR VALVE ASSEMBLY

(a) Slide the 2 clips and disconnect the No. 4 water by-pass hose and No. 8 water by-pass hose from the EGR valve assembly.

*1 No. 4 Water By-pass Hose *2 No. 8 Water By-pass Hose

(b) Using an 8 mm socket wrench, remove the bolt and disconnect the fuel pipe sub-assembly from the EGR valve bracket.

(c) Using the 8 mm socket wrench, remove the bolt.

(d) Remove the EGR valve assembly with the EGR valve bracket from the camshaft housing vertically.

*a Pin *b Hole

(e) Using the 8 mm socket wrench, remove the bolt and EGR valve assembly from the EGR valve bracket.