2003 D4D Egr Clean

[Sam29]

Does anybody know the part number of gasket used for 03 2.0 D-4D?

And where to get them?

Cheers.

[taxigeoff]

... do we need any gasket when cleaning and returning egr vavle...

Yes, all gaskets are non-reusable parts.

Did mine a couple of weeks ago and you do not need a new gasket.

[Sam29]

... do we need any gasket when cleaning and returning egr vavle...

Yes, all gaskets are non-reusable parts.

Did mine a couple of weeks ago and you do not need a new gasket.

thanks mate, is there a gasket? If yes how many?

Is it metalic one?

cheers.

[Thermal]

Did mine a couple of weeks ago and you do not need a new gasket.

Excuse me, but that is not true.

Gaskets should only be used once, even if they still look OK.

The material they are made of changes shape and property when they are installed and torqued to the prescribed value.

Gaskets are cheap and reusing them is false economics.!

[taxigeoff]

... do we need any gasket when cleaning and returning egr vavle...

Yes, all gaskets are non-reusable parts.

Did mine a couple of weeks ago and you do not need a new gasket.

thanks mate, is there a gasket? If yes how many?

Is it metalic one?

cheers.

Just 1 and yes it is metalic. You can see the gasket on the 4th picture

[Sam29]

Thanks mate.

[Sam29]

Very useful post, Thanks to OP.

I have cleaned my EGR valve so thought to share the photos. (sorry for poor quality, as its camera phone.)

Close up

After removing EGR valve

Egr Valve close up

Big opening close up

Small opening close up

After cleaning

Big opening after cleaning

Most difficult and tricky one = small opening

~Merry Xmas and Ciao!

[alexandm]

Does anybody know the part number of gasket used for 03 2.0 D-4D?

And where to get them?

Cheers.

Toyota P/N: 25628-27010

Cheers.

[LeeW]

My 2003 T3X D4D had the engine warning light come on earlier this week, so my wife took it too the local Toyota dealers and they hooked it up and came up with code P0488. The light had gone off by this point but they said that if it re-occured then we'd need a new EGR valve. The quote was £310 fitted!

Anyway since the light had gone off we continued and it came back on yesterday, also the car went into 'limp' mode. So this morning armed with a can of carb cleaner (from Halfords) and a toothbrush (my daughters)and the info gleaned from this thread I set about cleaning the EGR. I got it off ok - although a little daunting at first its really quite straight forwards once you get the air box off.

The cleaner from Halfords worked great and 10minutes later it was clean as a whistle. So I refitted the valve and all the rest of the gubbins and fired her up - still got the engine light on! Anyway I remember reading somewhere that I needed to pull an ECU fuse to clear the fault, so I pulled 21 & 26 the ECU-B & EFI 20. Restarted and power is restored. Everything looks good - hopefully my problem is sorted.

Thanks everyone for contributing to this thread - you've saved me a packet.

Cheers

Lee

[toyota oldham]

Many many thanks for an excellent informative piece about the EGR valve. I had been struggling unbelievably with a sticking valve and the only advice I recieved was to replace it. After finding your article I removed the offending article, squirted it liberally with carb cleaner and then gave it an hour in an ultrasound bath my son had bought for clearing his bike carbs (£90). To say it made a difference would be making the biggest of understatements!! It is like a new car - and diesel consumption has dropped from 47 to 57 mpg!!! Thanks again - Steve L

[rmbaqa]

Thanks everybody for a very informative discussion.

My Avensis D4D 2.0 2004, twice lost power on a speed of about 40-50 mile per hours. On both ocasions it longed for about 35-45 seconds and i could see some black smoke from my rear view mirror.

My car has done around 132 k miles, one of my friends was saying that its a typical sign when your turbo is dying, Can it also be a sticking EGR valve?

Please comment.

Many Thanks

[Jim_80]

Hi - Could somebody who has done this repair tell me where they bought a replacement gasket for the EGR valve? I'm having a hard time finding one; none of the usual suspects seem to stock them. Much appreciated. Thanks.

*Edit* I've answered my own question. The main dealers will order them for you. Cost about nine pounds each.

[Sam29]

Hi - Could somebody who has done this repair tell me where they bought a replacement gasket for the EGR valve? I'm having a hard time finding one; none of the usual suspects seem to stock them. Much appreciated. Thanks.

*Edit* I've answered my own question. The main dealers will order them for you. Cost about nine pounds each.

You dont need to replace them, as they are metallic one, and after cleaning they go back.

[Jim_80]

Hi - Could somebody who has done this repair tell me where they bought a replacement gasket for the EGR valve? I'm having a hard time finding one; none of the usual suspects seem to stock them. Much appreciated. Thanks.

*Edit* I've answered my own question. The main dealers will order them for you. Cost about nine pounds each.

You dont need to replace them, as they are metallic one, and after cleaning they go back.

Well... it's your funeral. But I've ordered a new gasket. ;)

[Geralt]

reviving old thread (but very informative at the same time). When you are cleaning the egr do you also clean the intake and outlet (i mean the holes that egr is fitting onto like in the picture:

[cmia]

the fuel filter is on the right of the egr valve.

you just unscrew and remove.

[Geralt]

Thanks CMIA, but i was asking about those holes:

Also whats the story with the gasket. Replace it or the one thats there is ok?

[cmia]

I guess you can try and clean the EGR holes on the engine block.

Best way would probably clean them is by using a cloth with diesel on it.

Stick in and turn.

I have never cleaned the ports, the valve and spring in the EGR valve blocks up with carbon.

If the gasket is not bent,

clean with diesel, and join back.

[Geralt]

thanks cmia

I did so but instead of using diesel on parts mentioned i used that crburattor cleaner. Hope it wont do any damage. And of course i had to drop one nut in the engine block so ittook me an hour to find it. Anyways took it now for a spin and no black smoke comming out of it on heavy acceleration so I'm happy. Cant tell about mpg as i only done it today. Thank you everyone for all the info

[Doddy01]

this tutorial helped me out loads cleaned egr valve black smoke gone and power back to how it was cheers

[Geralt]

Okay wierd thing has happened. I've cleaned the egr on saturday. Was working fine on saturday. Drove the car to shop on Sunday. Fine as well. Today as I tried to start it in the morning it bearly got going. I had to keep the key turned good while before it started (no acceleration used). The temperature outside was around 2 degress. Maybe it was just a hickup but if not could anything go wrong while I was cleaning that egr that would have impact on the engine starting. Must admit that once started it was going fine and no power losses nor other effects.

[dps10_0]

Brilliant!! My 2005 2.0 D4D was losing power when it reached operating temperature. This was dangerous because it always seemed to happen when I was pulling onto the motorway. Stripped out the air box, fuel filter etc and followed this guide to clean the egr valve. Gave the car a good service while i was at it - engine flush the works! The result??

Car is now pulling like a steam train!! So far so good.....

[Geralt]

not bad eh? BTW that starting issue was a one time thing. She starts like a beauty. But sill gives some smoke when i press the pedal bit harder tho ( but not as much as it used to)

[BALIKBAYAN]

Impressive 70mpg!!!

[fungus]

Thanks a lot for this great tutorial. Had a problem with loss of power when car is warm, and people in this forum suggested MAP sensor, EGR and SCVs. I used your pictures to clean the Egr, and everything went back to normal:-) Or, maybe it even respond better than before. Very saticfied!

Erik