Toyota Prius: Egr Cooler

• Removal
• Installation

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 pipe with cooler sub-assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Replacement of inverter with converter assembly	ECU configuration	-
	Resolver learning	DTCs are stored Slight vibration at a Toyota Prius vehicle speed of 5 km/h (3 mph) or less Shock or vibration during acceleration
Gas leaks from exhaust system is repaired	Inspection after repair	Poor idle, etc. Engine start function, etc.

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

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HINT:

When the cable is disconnected/reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	DRAIN ENGINE COOLANT	-	-		-
2	INVERTER WITH CONVERTER ASSEMBLY	G9200	-	-	-
3	EGR PIPE ASSEMBLY	25610	-	-	-
4	WATER BY-PASS HOSE	16261	-	-	-
5	INLET HEATER WATER HOSE	87245	-	-	-
6	NO. 4 WATER BY-PASS HOSE	16281N	-	-	-
7	EGR VALVE ASSEMBLY WITH EGR PIPE WITH COOLER SUB-ASSEMBLY	-		-	-
8	NO. 1 EGR COOLER GASKET	25685	-	-	-

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Non-reusable part

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Procedure		Part Name Code
9	NO. 6 WATER BY-PASS HOSE	16283	-	-	-
10	EGR PIPE WITH COOLER SUB-ASSEMBLY	25601L		-	-
11	EGR VALVE GASKET	25627	-	-	-

*1	EGR VALVE ASSEMBLY	-	-
●	Non-reusable part	-	-

PROCEDURE

1. DRAIN ENGINE COOLANT (for Engine)

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2. REMOVE INVERTER WITH CONVERTER ASSEMBLY

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3. REMOVE EGR PIPE ASSEMBLY

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4. DISCONNECT WATER BY-PASS HOSE

5. DISCONNECT INLET HEATER WATER HOSE

6. DISCONNECT NO. 4 WATER BY-PASS HOSE

7. REMOVE EGR VALVE ASSEMBLY WITH EGR PIPE WITH COOLER SUB-ASSEMBLY

	Bolt		Nut
	Remove in this Direction	-	-

(1) Disconnect the EGR valve assembly connector.

(2) Remove the 2 nuts and disconnect the EGR pipe with cooler sub-assembly from the exhaust manifold (TWC: Front Catalyst).

(3) Remove the bolt and 2 nuts and disconnect the EGR pipe with cooler sub-assembly with the EGR valve assembly from the cylinder head sub-assembly and camshaft housing sub-assembly.

(4) Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the cylinder head sub-assembly and camshaft housing sub-assembly.

HINT:

If a stud bolt is deformed or the threads are damaged, replace it.

(5) Remove the EGR pipe with cooler sub-assembly with the EGR valve assembly.

8. REMOVE NO. 1 EGR COOLER GASKET

9. DISCONNECT NO. 6 WATER BY-PASS HOSE

10. REMOVE EGR PIPE WITH COOLER SUB-ASSEMBLY

(1) Remove the 2 nuts and EGR pipe with cooler sub-assembly from the EGR valve assembly.

(2) Using an E8 "TORX" socket wrench, remove the 3 stud bolts from the EGR pipe with cooler sub-assembly.

HINT:

If a stud bolt is deformed or the threads are damaged, replace it.

11. REMOVE EGR VALVE GASKET

Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	EGR VALVE GASKET	25627	-	-	-
2	EGR PIPE WITH COOLER SUB-ASSEMBLY	25601L		-	-
3	NO. 6 WATER BY-PASS HOSE	16283		-	-

*1	EGR VALVE ASSEMBLY	-	-
	N*m (kgf*cm, ft.*lbf): Specified torque	●	Non-reusable part

Procedure		Part Name Code
4	NO. 1 EGR COOLER GASKET	25685	-	-	-
5	EGR VALVE ASSEMBLY WITH EGR PIPE WITH COOLER SUB-ASSEMBLY	-		-	-
6	NO. 4 WATER BY-PASS HOSE	16281N		-	-
7	INLET HEATER WATER HOSE	87245		-	-
8	WATER BY-PASS HOSE	16261		-	-
9	EGR PIPE ASSEMBLY	25610		-	-
10	INVERTER WITH CONVERTER ASSEMBLY	G9200	-	-	-
11	ADD ENGINE COOLANT (for Engine)	-	-		-
12	INSPECT FOR COOLANT LEAK (for Engine)	-		-	-
13	INSPECT FOR EXHAUST GAS LEAK	-	-	-

N*m (kgf*cm, ft.*lbf): Specified torque

●

Non-reusable part

PROCEDURE

1. INSTALL EGR VALVE GASKET

2. INSTALL EGR PIPE WITH COOLER SUB-ASSEMBLY

(1) Using an E8 "TORX" socket wrench, install the 3 stud bolts to the EGR pipe with cooler sub-assembly.

HINT:

If a stud bolt is deformed or the threads are damaged, replace it.

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

(2) Install the EGR pipe with cooler sub-assembly to the EGR valve assembly with the 2 nuts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

3. CONNECT NO. 6 WATER BY-PASS HOSE

*a	0 to 4 mm (0 to 0.157 in.)	*b	LH
*c	Front of the Toyota Prius vehicle	*d	180 deg

(1) Connect the No. 6 water by-pass hose to the EGR pipe with cooler sub-assembly and slide the clip to secure it.

HINT:

Engage the clip within the area shown in the illustration.

4. INSTALL NO. 1 EGR COOLER GASKET

5. INSTALL EGR VALVE ASSEMBLY WITH EGR PIPE WITH COOLER SUB-ASSEMBLY

*a	Stud Bolt (A)	*b	Stud Bolt (B)
*c	48 mm (1.890 in.)	*d	26 mm (1.024 in.)
*e	13 mm (0.512 in.)	*f	29 mm (1.142 in.)
*g	14 mm (0.551 in.)	*h	13 mm (0.512 in.)
	Bolt		Nut
	Installation in this Direction	-	-

(1) Set the EGR pipe with cooler sub-assembly with the EGR valve assembly to the engine assembly.

(2) Using an E8 "TORX" socket wrench, install the stud bolt (A) and stud bolt (B) to the cylinder head sub-assembly and camshaft housing sub-assembly.

HINT:

If a stud bolt is deformed or the threads are damaged, replace it.

Torque:

9.5 N·m {97 kgf·cm, 84 in·lbf}

(3) Temporarily install the EGR pipe with cooler sub-assembly with the EGR valve assembly to the cylinder head sub-assembly and camshaft housing sub-assembly with the bolt and 2 nuts.

(4) Temporarily install the EGR pipe with cooler sub-assembly to the exhaust manifold (TWC: Front Catalyst) with 2 new nuts.

(5) Tighten the bolt and 2 nuts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(6) Tighten the 2 nuts.

Torque:

26 N·m {265 kgf·cm, 19 ft·lbf}

(7) Connect the EGR valve assembly connector.

6. CONNECT NO. 4 WATER BY-PASS HOSE

*a	Up	*b	LH
*c	Paint Mark	*d	180 deg
*e	0 to 4 mm (0 to 0.157 in.)	-	-

(1) Connect the No. 4 water by-pass hose to the EGR pipe with cooler sub-assembly and slide the clip to secure it.

HINT:

Engage the clip within the area shown in the illustration.

7. CONNECT INLET HEATER WATER HOSE

*a	Up	*b	LH
*c	Paint Mark	*d	120 deg

(1) Connect the inlet heater water hose to the EGR pipe with cooler sub-assembly and slide the clip to secure it.

HINT:

Engage the clip within the area shown in the illustration.

8. CONNECT WATER BY-PASS HOSE

*a	0 to 4 mm (0 to 0.157 in.)	*b	UP
*c	LH	*d	180 deg
*e	Paint Mark	-	-

(1) Connect the water by-pass hose to the EGR valve assembly and slide the clip to secure it.

HINT:

Engage the clip within the area shown in the illustration.

9. INSTALL EGR PIPE ASSEMBLY

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10. INSTALL INVERTER WITH CONVERTER ASSEMBLY

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11. ADD ENGINE COOLANT (for Engine)

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12. INSPECT FOR COOLANT LEAK (for Engine)

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13. INSPECT FOR EXHAUST GAS LEAK

(a) If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

HINT:

Perform "Inspection After Repairs" after repairing or replacing the exhaust system.

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