How to remove throttle body and EGR valve

[Cornato]

Well after doing so much work on my van these past weeks I've learned to do a few new procedures that I've haven't done before. Andcould not find really detailed instructions with pics on here. This stuff may be basic knowledge, but I know I like pictures and details. It's also about time I contributed to this great forum and help someone else out.

So here it goes...

In this I'll show you how to remove the EGR system and Throttle body on a 1986 2WD CRG TV with a 4YE engine.

To get to the EGR valve easily you'll need to take off the throttle body. And if you're cleaning one you might as well clean another.

First thing is to take of the air intake, the big hose going from air cleaner to throttle body. You can use a phillips head screwdriver, but it's easier to use a 10mm socket. And be gentle they are prone to cracking, so don't give it a reason to.

Ok, so you might as well inspect it and see if it needs replacing while you're at it.

Now you want to disconnect all the vacuum hoses on the throttle body, EGR Modulator and EGR valve. There are 2 coolant hoses underneath the throttle body remove these as well. You should probably label them to remember where they go. And in keeping with the theme, you should probably replace these hoses too as they get hard and brittle and develop cracks and leaks.

http://i1129.photobucket.com/albums/m506/cornato5/DSC02068-1.jpg


Now you need to disconnect the TPS sensor. It is located on the rear of the throttle body. I'm touching it with a screwdriver in the pic below. Now it is held on by a connector that has a wire retainer on it. Be careful not to break the connector and remove the wires first.

Now remember the TPS is calibrated. So mark where the screws are so you can reposition it exactly during reassembly. And yes you have to remove it because carb cleaner will destroy it.

http://i1129.photobucket.com/albums/m506/cornato5/DSC02062.jpg
http://i1129.photobucket.com/albums/m506/cornato5/DSC02067.jpg

To take off the throttle body you need to first remove the throttle cable. It's just one 12mm nut holding it on. Then remove the three 12mm bolts and one 12mm nut in the four corners.

http://i1129.photobucket.com/albums/m506/cornato5/DSC02070.jpg

I went went ahead and took the EGR modulator off in this next pic. Very simple, once the hoses are off it just slides out.

http://i1129.photobucket.com/albums/m506/cornato5/DSC02063-1.jpg

Sometimes the throttle body is very hard to get off as mine was, it needs some persuasion. I took a 2x4 and placed it on the top part of the throttle body that was protruding and gave it one WHACK. Boom goes the dynamite. Easy peezy lemon squeezy.

http://i1129.photobucket.com/albums/m506/cornato5/DSC02063-2.jpg

Great! Now you can clean your throttle body nice and shiny. Mine was terrible and used a can of carb cleaner then soaked it in degreaser and worked it over with a rag and toothbrush and brass wire brush. Be sure to clear out all the channels like EGR etc.

Now you can shoot some carb cleaner in your intake manifold. Try to wipe out whatever you can.

http://i1129.photobucket.com/albums/m506/cornato5/DSC02051.jpg

Now to remove the EGR valve. Slide the EGR modulator holder thing off. And remove two 12mm nut on either side of the valve.

http://i1129.photobucket.com/albums/m506/cornato5/DSC02061.jpghttp://i1129.photobucket.com/albums/m506/cornato5/DSC02060.jpghttp://i1129.photobucket.com/albums/m506/cornato5/DSC02057.jpg

Cool, now trace the EGR valve to where it terminates into the exhaust. Use a 15/16 wrench to free the nut. And the hole thing comes out through the top of the engine.

http://i1129.photobucket.com/albums/m506/cornato5/DSC02049.jpg

Now inspect the EGR valve where it meets the engine block. If it's clogged then clear it out. If not, just shoot the carb cleaner through all the pipes and openings. Use a wire brush if you got one to removed carbon build up. If it's really bad, clean it with your throttle body and soak it.

http://i1129.photobucket.com/albums/m506/cornato5/DSC02050.jpg
http://i1129.photobucket.com/albums/m506/cornato5/DSC02053.jpg

Phew. Ok. Intermission.

Now everything should be clean and dry and look like this.

http://i1129.photobucket.com/albums/m506/cornato5/DSC02048.jpg

Perfect. Let us reassemble.

In this part RTV sealant is your best friend. You should buy a replacement gasket for the throttle body and EGR. But if you didn't, go to your parts store and grab this for 8 bucks.

http://i1129.photobucket.com/albums/m506/cornato5/DSC02058.jpg

Scrape your old gasket off and smear this on. Smear this around all your vacuum hose line nipples too. It dries and make a airtight, heat resistant gasket seal.

Tighten everything up, double check for hoses in their right places. And wait about and hour before starting so the RTV can set.

Ok, Thanks for looking. And feel free to add any corrections, comments, questions, or concerns. Happy Tails.

[djshimon]

nice write up, thank you. is there a way to test the egr?

[Cornato]

Well I think in the manual it has a detailed list of procedures to do to test it. Check it out.

http://yotavans.org/community/tips/toyo_manual.html

Just look up the EFI system and it shows how to test.

I didn't. Ha Ha. Lazy.

[joegri]

cornato thanx so much for posting yer "how to". this is a repair that has scared the hell out of me. with the great photos and commentary it seems to be very doable! as of this moment i,m waiting for my parts to arrive and will be doing this job on my primer van. tell me if you think i,m crazy i believe that with a new o2 sensor -new tps - cleaned out egr valve and a good cleaning of the throttle body and new plugs the van should/can get 20 mpg around town!! again thanx for posting this opperation very cool!!

[joegri]

i performed this repair today insatlled a new t p s and cleaned out the egr valve. i hope the tps is set good(gasket settin up). kinda col cuz it was a nice day n took my time. i will post back results after it runs!!

[spacecruisers]

i removed my throttle body today and this is what it looked like:

5252
5253
5254
5255

rock auto has a rebuild service for $100. (https://www.rockauto.com/en/moreinfo.php?pk=6330714&cc=1279784&jsn=423&jsn=423) is that worth it? or am i good enough just trying to clean it with carb cleaner and a rag? I'm ok with spending the money if it means my throttle body is good for another 30 years :)

you can see by all the soot buildup that things were running very rich. replacing the TPS and hoping that fixes it. the hose to the bottom side of the EGR vacuum solenoid modulator was also disconnected and melted a hole in it so I'm replacing that as well.

[JDM VANMAN]

Nice job finding this thread, have you had a chance to read Tim's thread on how to clean and rebuild a throttle body?

Check it out-

http://www.toyotavantech.com/forum/showthread.php?1242-Article-Cleaning-the-Throttle-Body&highlight=Throttle+body+rebuild

Keep us posted!!

Good Luck:thmbup:

JDM

[spacecruisers]

it took me a long time but i did it :LOL2:

i did see Tims thread, i dont currently have the tools to do Tim's re-build job (dremel, tap and die, etc.)
i could buy them, but its also more of a time issue. I've got some other things i need to fix as well that i could work on while waiting for a rebuild.
dont know all the details on the throttle body though so maybe just cleaning it is all it needs.

i'm of the opinion though if somethings worth doing its worth doing right! want to make sure my van runs in tip top shape :dance2:

btw great write up Cornato! this was really nice to have.

[JDM VANMAN]

Yeah I heard that!!! Time keeps on slipping... slipping... slipping....


I just reread that thread in detail....and oh yeah not having all the tools to do the job has stopped me from rebuilding the spare TB that I have too!!!

I've seen on rockauto theY have some items that you can have sent out to be rebuilt but I've never tried it nor have read about anyone on the forum trying it out.:?: If you happen to send it out please keep us posted!!

JDM

[Gambit]

I've got the throttle body off for TPS replacement and figured I should do a cleaning of the EGR valve as well - hard to tell from the photos, but is there a gasket I need to get or be careful with as I remove? Thanks

[whatvan]

Anyone every come up with a part number for the EGR Valve gasket?