This procedure covers the removal and replacement of the EGR cooler on the 2018-2024 Toyota Camry 2.5L I4 engine, including disconnection of exhaust components and coolant lines.

Warnings

Tools required

Parts

• EGR Cooler Assembly × 1 — Use OEM specification
• EGR Cooler Gasket × 1 — Use OEM specification
• Exhaust Flange Gasket × 1 — Use OEM specification
• EGR Pipe Gasket × 1 — Use OEM specification
• Coolant hose clamps (if damaged) × 2 — Use OEM specification

Fluids

• Toyota Super Long Life Coolant (Pink) — 2 qt

Preparation

1. Ensure engine is completely cold (minimum 4 hours after last operation)
2. Disconnect negative battery terminal and wait 90 seconds
3. Remove engine cover by pulling upward on perimeter clips
4. Position drain pans under engine and radiator drain locations
5. Partially drain coolant from radiator drain plug until level is below EGR cooler connections (approximately 2-3 quarts)
6. Apply penetrating oil to all exhaust fasteners and O2 sensor threads, allow to soak 15-30 minutes
7. Remove plastic engine cover and air intake duct for access

Procedure

1. 1

   Remove heat shields
   Remove the exhaust manifold heat shield by removing the mounting bolts. The heat shield may have multiple sections. Remove upper heat shield first, then lower section to expose EGR cooler and exhaust connections.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
2. 2

   Disconnect oxygen sensor
   Disconnect the oxygen sensor electrical connector. Using an oxygen sensor socket or 22mm deep socket, remove the upstream oxygen sensor from the exhaust manifold. Work carefully to avoid damaging threads in manifold.
   ⚠O2 sensor threads are easily damaged. Use proper oxygen sensor socket with cutout for wire. Do not allow sensor to hang by wire.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
3. 3

   Disconnect EGR valve connector
   Locate the EGR valve on top of the EGR cooler assembly. Disconnect the electrical connector from the EGR valve by pressing the release tab and pulling straight out. Move harness aside.
4. 4

   Remove EGR pipe
   Remove the EGR pipe that connects the EGR valve to the intake manifold. Remove the flange bolts at both ends of the pipe. Note the gasket orientation for reinstallation.
   ℹ️The EGR pipe may have carbon buildup. This is normal but note condition for cleaning if reusing.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
5. 5

   Disconnect coolant lines
   Position drain pan directly under EGR cooler. Using pliers, release the spring clamps on both coolant hoses connected to the EGR cooler. Carefully twist and pull hoses off the cooler nipples. Expect coolant drainage.
   ⚠Coolant will drain from hoses and cooler. Ensure drain pan is properly positioned.
6. 6

   Remove exhaust manifold connection
   Locate the exhaust flange connecting the EGR cooler to the exhaust manifold. Remove the two flange bolts. The connection may be seized due to heat cycling. Work bolts evenly and use caution not to break studs.
   ⚠Exhaust studs are highly susceptible to breaking. If stud breaks, manifold removal may be required for extraction.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
7. 7

   Remove EGR cooler mounting bolts
   Remove the mounting bolts securing the EGR cooler assembly to the engine block and cylinder head. There are typically 3-4 mounting bolts depending on configuration. Support the cooler while removing the final bolt.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
8. 8

   Remove EGR cooler assembly
   Carefully maneuver the EGR cooler assembly out of the engine bay. It may require rotation and angling to clear surrounding components. Note the routing path for reinstallation. Inspect the old gasket surfaces and remove all gasket material from mating surfaces on engine and exhaust manifold.
9. 9

   Prepare mating surfaces
   Using a gasket scraper and wire brush, thoroughly clean all gasket mating surfaces on the engine block, cylinder head mounting points, and exhaust manifold flange. Surfaces must be completely clean and flat. Inspect for cracks or damage. Clean coolant hose nipples on engine.
   ⚠Do not gouge or scratch sealing surfaces. Damage will cause leaks.
10. 10

    Install new EGR cooler
    Position new gaskets on all mating surfaces (exhaust flange, EGR pipe connection, and mounting flange). Install the new EGR cooler assembly by reversing removal path. Start all mounting bolts finger-tight before torquing any fasteners.
11. 11

    Torque EGR cooler mounting bolts
    Torque the EGR cooler mounting bolts to specification in a cross-pattern sequence to ensure even seating. Start with the center bolts and work outward.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
12. 12

    Connect exhaust flange
    Install new exhaust flange gasket. Apply anti-seize compound to exhaust flange bolt threads. Install flange bolts and torque to specification in a cross-pattern.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
13. 13

    Reconnect EGR pipe
    Install new EGR pipe gaskets at both flange connections. Apply anti-seize to flange bolt threads. Install EGR pipe and torque flange bolts to specification at both ends.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
14. 14

    Reconnect coolant lines
    Inspect coolant hoses for cracks or damage. Replace if necessary. Push coolant hoses firmly onto EGR cooler nipples until fully seated. Install spring clamps or new hose clamps in correct position over nipple ridges.
15. 15

    Reinstall oxygen sensor and heat shields
    Apply anti-seize compound to oxygen sensor threads only (avoid contaminating sensor tip). Install oxygen sensor and torque to specification. Reconnect oxygen sensor electrical connector. Reinstall heat shields and torque bolts to specification.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Reconnect EGR valve electrical connector ensuring positive locking engagement
2. Reinstall air intake duct and engine cover
3. Refill cooling system with Toyota Super Long Life Coolant to proper level
4. Reconnect negative battery terminal
5. Start engine and allow to reach operating temperature while monitoring for leaks
6. Check coolant level after engine reaches operating temperature and top off as needed

Verification

• With engine at operating temperature, visually inspect all connections for coolant leaks, exhaust leaks, and proper gasket sealing
• Check for exhaust odor in engine bay or visible exhaust smoke from connections
• Verify EGR valve operation using scan tool to command EGR on/off and monitor response
• Inspect coolant level in reservoir after engine cools completely and top off if necessary
• Test drive vehicle and verify no check engine light illumination and normal engine performance
• Re-check all connections after first heat cycle (50-100 miles) for any seepage

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