How to Remove and Clean Toyota Yaris D4D EGR Valve

toyota yaris d4d egr removal guide
EGR valves are designed to allow a small amount of exhaust gas back into the combustion chamber, this in theory increases efficiency and reduces pollution.

Blocked and sticky EGR valves in diesels can cause all sorts of running problems which will vary depending on if your valve is sticky, stuck closed or even stuck open. Problems known to be related to EGR valves include:
  • rough idling
  • hesitation
  • stalling
  • knocking
  • lower mpg
  • black smoke from exhaust

On some vehicles the EGR valve is hard to access which can make cleaning a pain. Luckily on the Toyota Yaris D4D 1.4 diesel 2003 it is very easy to remove, this whole job can be completed in 20 minutes or less even for a complete novice mechanic.

Tools required:
  • 13mm socket and extender
  • Brake or carb cleaner (WD40 is also acceptable)
  • Cleaning rag
The EGR valve is located on the front-ride hand side of the block as circled below.
toyota yaris 1.4 d4d egr valve

Remove vacuum hose circled by pulling and then undo the 3 bolts circled. That is it!

 This particular Toyota Yaris EGR valve was not actually very 'coked up' at all.
toyota yaris d4d egr valve

 Just give it a good spray with your cleaner of choice and then get the rag in there to get all the carbon deposits cleaned out.

Fitting is the reverse of removal, torque the bolts in sequence and be careful not to over-tighten and don't forget the metal gasket.


  1. Well that looks easy. Will now do it myself now that I can see what to do. Thanks for the very informative post.

  2. So what's the torque and the sequence for putting it back together?

    1. Sorry by sequence I just meant working your way around the bolts increasing the torque on each one as you go rather than torquing one right up with the others loose.

  3. This fix didn't work for me, but what did work was removing and cleaning the part that has 5 bolts where the dip stick is that is connected to the thick air pipe. Here's the link and how to solve the problem, my Yaris is literally a different car now, it purrs likema kitten, better on mileage ( almost a 100 mile improvement on my last fill up ), much much quick ( 90mph effortless ) and it also heats up inside quicker-

    1. Hey, thanks for your contribution. Good fix.

    2. You're welcome Pug Addicts :)

      Unfortunately I've just had to scrap my 2003 Yaris, but I did get nearly 100,000 miles out of it. I've bought a 2008 1.4 D4D, and I'm convinced it has the same problem, as it's quite sluggish when going up the gears. Thing is, the engine layout isn't as simple as the 2003 one. I think I know where the EGR is and the other connecting part I had the main issue with, but I'm a bit scared to start pulling it to bits on my own. I'm gonna have to get a mechanic to do it...