ENGINE UNIT DISASSEMBLY

CAUTION / NOTICE / HINT

CAUTION:

When replacing an injector (including interchanging injectors between cylinders), common rail, cylinder head, or intake manifold, replace the corresponding injection pipes with a new one.

PROCEDURE


  1. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  2. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  3. DISCONNECT NO. 1 OIL COOLER HOSE

    B001YLTE02
    Text in Illustration
    *1 No. 1 Oil Cooler Hose
    *2 No. 2 Oil Cooler Hose

  4. DISCONNECT NO. 2 OIL COOLER HOSE

  5. REMOVE CRANKSHAFT PULLEY

    Note

    B001YM8E04

    This procedure is intended for removal/installation of the crankshaft pulley only. Do not use this procedure for removal/installation of the flywheel or the drive plate and ring gear.

    Text in Illustration
    *1 Service Hole
    *2 Protrusion

    1. Install the 2 bolts to the bolt holes of the crankshaft rear side.

    2. Using a bar, turn the crankshaft until the crankshaft pulley service hole is a little to the left of bottom dead center.

    3. Install a 14 mm x 1.5 pitch service bolt with a length of 70 mm or more to the crankshaft pulley service hole, and hold the crankshaft using the timing chain cover protrusion.

    4. Remove the 3 bolts and crankshaft pulley.

      Note

      If the crankshaft pulley cannot be removed, temporarily install a bolt to the crankshaft so that the pulley does not fall, and lightly tap the outer edge of the mass damper with a plastic-faced hammer to remove the pulley. Do not tap the pulley V-ribbed belt ribs, as the crankshaft may be damaged.

  6. REMOVE TIMING GEAR COVER SPACER (w/ Intercooler)

    Click here

  7. REMOVE OIL FILTER CAP WITH ELEMENT

    Click here

  8. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

    Click here

  9. REMOVE OIL COOLER ASSEMBLY

    Click here

  10. REMOVE OIL COOLER RELIEF VALVE ASSEMBLY


    1. A01X7PL

      Remove the oil cooler relief valve and gasket.

  11. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY


    1. A01X3RW

      Remove the 3 bolts, 2 nuts and oil filter bracket.

    2. B001X14

      Remove the 2 O-rings.

  12. REMOVE ENGINE OIL LEVEL SENSOR

    Click here

  13. REMOVE OIL PAN DRAIN PLUG


    1. B001Y63

      Remove the oil pan drain plug and gasket.

  14. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  15. REMOVE OIL STRAINER SUB-ASSEMBLY

    Click here

  16. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY

    Click here

  17. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01X3AY

      Remove the 5 bolts and No. 1 oil pan baffle plate.

  18. REMOVE INLET OIL PUMP PIPE


    1. A01X2NF

      Remove the 3 bolts and inlet oil pump pipe.

    2. Remove the O-ring from the inlet oil pump pipe.

  19. REMOVE OIL REGULATOR ASSEMBLY

    Click here

  20. REMOVE REAR ENGINE OIL SEAL RETAINER

    Click here

  21. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A01X26C

      Place the oil seal retainer on wooden blocks.

    2. Using a screwdriver and hammer, tap out the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  22. REMOVE OIL PUMP ASSEMBLY

    Click here

  23. REMOVE SCAVENGING PUMP ASSEMBLY

    Click here

  24. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    A01X03D

  25. REMOVE OIL FILLER CAP GASKET

  26. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH (w/o DPF)

    Click here

  27. REMOVE NOZZLE HOLDER GASKET RH (w/o DPF)

    Click here

  28. REMOVE NOZZLE HOLDER SEAL RH (w/o DPF)

    Click here

  29. REMOVE CYLINDER HEAD COVER INSULATOR RH (w/ DPF)

  30. REMOVE FUEL INJECTOR RH (w/ DPF)

    Click here

  31. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH (w/ DPF)


    1. A01X6QW

      Remove the 19 bolts, 4 nozzle holder clamp seats and cylinder head cover RH.

      Text in Illustration
      B001XPG Bolt
      B001WGT Nozzle Holder Clamp Seat

    2. Remove the cylinder head cover gasket RH and No. 3 cylinder head cover gasket from the cylinder head cover RH.

  32. REMOVE NO. 2 FUEL PUMP BRACKET (w/ DPF)


    1. A01X0B1

      Remove the bolt and No. 2 fuel pump bracket.

  33. REMOVE CYLINDER HEAD COVER INSULATOR LH (w/ DPF)

  34. REMOVE FUEL INJECTOR LH (w/ DPF)

    Click here

  35. REMOVE OIL SEPARATOR ASSEMBLY

    Click here

  36. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (w/ DPF)


    1. A01X7PI

      Remove the 18 bolts, 4 nozzle holder clamp seats and cylinder head cover LH.

      Text in Illustration
      B001XPG Bolt
      B001WGT Nozzle Holder Clamp Seat

    2. Remove the cylinder head cover gasket LH and No. 4 cylinder head cover gasket from the cylinder head cover LH.

  37. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (w/o DPF)

    Click here

  38. REMOVE NOZZLE HOLDER GASKET LH (w/o DPF)

    Click here

  39. REMOVE NOZZLE HOLDER SEAL LH (w/o DPF)

    Click here

  40. REMOVE FUEL INJECTOR RH (w/o DPF)

    Click here

  41. REMOVE FUEL INJECTOR LH (w/o DPF)

    Click here

  42. REMOVE WATER PUMP ASSEMBLY

    Click here

  43. REMOVE TIMING CHAIN COVER PLATE

    Click here

  44. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. B001XFXE02
      Text in Illustration
      *1 Nut

      Remove the 4 nuts and 16 bolts.

    2. Using a screwdriver, remove the timing chain cover by prying between the timing chain cover and timing gear case.

      Tech Tips

      Tape the screwdriver tip before use.

      B001X66
    3. B001ZOP

      Remove the O-ring from the timing gear case.

  45. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. B001ZCAE05
      Text in Illustration
      *1 Wooden Block

      Place the timing chain cover on wooden blocks.

    2. Using a screwdriver and wooden block, pry out the oil seal.

      Note

      Do not damage the surface of the oil seal press fit hole.

      Tech Tips

      Tape the screwdriver tip before use.

  46. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the 2 crankshaft pulley set bolts to the crankshaft.

    2. Turn the crankshaft clockwise to set the No. 1 cylinder to TDC.

    3. With the crankshaft key 45° counterclockwise from the top position, check that the timing marks of the RH and LH camshaft timing gears are aligned. If not as specified, turn the crankshaft 1 revolution (360°) and align the timing marks as shown below.

      B00202ME05
      Text in Illustration
      *1 Key - -
      *a Top - -

    4. Remove the 2 crankshaft pulley set bolts.

  47. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. B001Y05

      Using a T30 "TORX" wrench, remove the 2 screws and crankshaft position sensor plate.

  48. REMOVE PUMP DRIVE SHAFT GEAR


    1. B001YCTE01

      Using SST, hold the pump drive shaft gear.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    2. Remove the 4 bolts and pump drive shaft gear.

  49. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. Push the tensioner slipper away from the tensioner, and move the stopper plate clockwise to release the lock as shown in A.

    2. Push down the tensioner slipper and move the stopper plate counterclockwise to set the lock as shown in B.

    3. Push the tensioner slipper away from the tensioner, and insert a hexagon wrench into the stopper plate hole as shown in C.

      B001YBIE02
      Text in Illustration
      *1 Stopper Plate - -
    4. B001W1S

      Remove the 2 bolts and No. 1 chain tensioner.

  50. REMOVE NO. 1 CHAIN TENSIONER SLIPPER

    B001XAX

  51. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B001XUH

      Remove the 2 bolts and No. 1 chain vibration damper.

  52. REMOVE NO. 1 CAMSHAFT TIMING SPROCKET AND NO. 1 TIMING CHAIN

    B001Z4M

  53. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. Push the tensioner slipper away from the tensioner, and move the stopper plate clockwise to release the lock as shown in A.

    2. Push up the tensioner slipper and move the stopper plate counterclockwise to set the lock as shown in B.

    3. Push the tensioner slipper away from the tensioner, and insert a hexagon wrench into the stopper plate hole as shown in C.

      B001VRYE02
      Text in Illustration
      *1 Stopper Plate - -
    4. B001Z8I

      Remove the 2 bolts and No. 2 chain tensioner.

  54. REMOVE NO. 2 CHAIN TENSIONER SLIPPER

    B001ZYT

  55. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. B001WGZ

      Remove the 2 bolts and No. 2 chain vibration damper.

  56. REMOVE NO. 2 CAMSHAFT TIMING SPROCKET AND NO. 2 TIMING CHAIN


    1. B001WY1E04

      Using SST, hold the No. 2 camshaft timing sprocket.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    2. Remove the 4 bolts, No. 2 camshaft timing sprocket and No. 2 timing chain.

  57. REMOVE FUEL SUPPLY PUMP DRIVE GEAR NUT


    1. Using SST, hold the idle gear.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

    2. Remove the nut.

      B001XUCE04
      Text in Illustration
      *A w/ Intercooler *B w/o Intercooler

  58. REMOVE IDLE GEAR ASSEMBLY


    1. B001YVH

      w/ Intercooler:

      Using an 8 mm x 1.25 pitch service bolt with a length of 15 mm or more, fix the idle gear in place.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    2. B001Z1KE04
      Text in Illustration
      *A w/ Intercooler
      *B w/o Intercooler

      Remove the 2 bolts, idle gear thrust plate and idle gear.

  59. SEPARATE SUB IDLE GEAR, IDLE GEAR SPRING AND IDLE GEAR (w/ Intercooler)


    1. A01X2J8

      Hold the idle gear in a vise between aluminum plates.

      Note

      Be careful not to damage the gears.

    2. B001YU9E01

      Using SST, hole the idle gear, and remove the bolt and sub idle gear.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )
    3. A01XC33

      Remove the idle gear spring from the idle gear.

  60. REMOVE NO. 1 IDLE GEAR SHAFT

    B001Z32

  61. REMOVE FUEL SUPPLY PUMP DRIVE GEAR


    1. B00202SE02

      Using SST, remove the fuel supply pump drive gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05031 )

  62. INSPECT RADIAL BALL BEARING


    1. A01XAGW

      Turn the bearing, and check that the bearing moves smoothly and quietly.

      If it moves roughly or noisily, replace the radial ball bearing.

  63. REMOVE RADIAL BALL BEARING

    B001YV2E01

    Tech Tips

    It is not necessary to remove the bearing unless it is being replaced.


    1. Using SST, remove the radial ball bearing.

      SST
      09950-00020
      09950-00030
      09950-60010   ( 09951-00580 )
      09950-40011   ( 09957-04010 )

  64. SEPARATE FUEL SUPPLY PUMP DRIVE GEAR AND FUEL SUPPLY PUMP SHAFT SPROCKET


    1. A01X5H8

      Hold the fuel supply pump shaft sprocket in a vise between aluminum plates.

      Note

      Be careful not to damage the gears.

    2. Remove the 4 bolts and separate the fuel supply pump drive gear and fuel supply pump shaft sprocket.

  65. REMOVE STRAIGHT PIN

    Tech Tips

    It is not necessary to remove the straight pin unless it is being replaced.

    A01WYW0

    1. Remove the straight pin.

  66. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. B001WXP

      Using a 6 mm hexagon wrench, remove the hexagon bolt. Then remove the 2 nuts and fuel supply pump.

    2. Remove the O-ring.

  67. REMOVE V-BANK SILENCER

    B001XGZ

  68. REMOVE TIMING GEAR CASE SUB-ASSEMBLY


    1. B001YQHE02
      Text in Illustration
      *1 Nut

      Remove the 22 bolts, 2 nuts and timing gear case shown in the illustration.

    2. B001ZZ8

      Remove the 2 O-rings and timing gear case gasket.

  69. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE (w/ Intercooler)

    A01X9LE

  70. DISCONNECT NO. 3 VACUUM TRANSMITTING HOSE (w/ Intercooler)

    A01X24H

  71. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ Intercooler)


    1. A01X7GC

      Remove the 2 bolts and No. 1 vacuum transmitting pipe.

  72. REMOVE NO. 2 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ Intercooler)


    1. A01X85E

      Remove the 3 bolts and No. 2 vacuum transmitting pipe.

  73. REMOVE NO. 2 TIMING GEAR CASE INSULATOR (w/ Intercooler)

    A01X968

  74. REMOVE NO. 1 AND NO. 2 CAMSHAFTS


    1. B001X5L

      Using a 6 mm x 1.0 pitch service bolt with a length of 16 mm or more, fix the No. 1 camshaft in place.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. B001ZSK

      Loosen the 2 union bolts.

    3. B001Y2AE02

      Uniformly loosen and remove the 20 bolts in the sequence shown in the illustration.

    4. B001VUM

      Remove the 2 union bolts and No. 1 and No. 2 oil feed pipes.

    5. B001WQI

      Remove the 8 No. 3 camshaft bearing caps and No. 1 camshaft bearing cap.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

    6. B001W9F

      Remove the No. 1 and No. 2 camshafts.

  75. REMOVE NO. 2 CAMSHAFT BEARING CAP

    B001ZYR

  76. REMOVE NO. 1 VALVE ROCKER ARM


    1. B001WME

      Remove the 16 No. 1 valve rocker arms.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  77. REMOVE NO. 1 VALVE LASH ADJUSTER ASSEMBLY


    1. B001XJ4

      Remove the 16 No. 1 valve lash adjusters.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  78. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH


    1. B001ZLAE02

      Uniformly loosen and remove the 10 bolts and 10 spacers in the sequence shown in the illustration. Then remove the cylinder head.

      Note


      • Be careful not to drop washers into the cylinder head.

      • Head warpage or cracking could result from removing bolts in an incorrect order.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  79. REMOVE NO. 1 CYLINDER HEAD GASKET

  80. REMOVE NO. 3 AND NO. 4 CAMSHAFTS


    1. B001X5L

      Using a 6 mm x 1.0 pitch service bolt with a length of 16 mm or more, fix the No. 4 camshaft in place.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. B001Z1W

      Loosen the 2 union bolts.

    3. B001ZP4E02

      Uniformly loosen and remove the 20 bolts in the sequence shown in the illustration.

    4. B001YZF

      Remove the 2 union bolts and No. 3 and No. 4 oil feed pipes.

    5. B001VK9

      Remove the 8 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

    6. B001W9E

      Remove the No. 3 and No. 4 camshafts.

  81. REMOVE NO. 5 CAMSHAFT BEARING CAP

    B001WTI

  82. REMOVE NO. 2 VALVE ROCKER ARM


    1. B001X9L

      Remove the 16 No. 2 valve rocker arms.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  83. REMOVE NO. 2 VALVE LASH ADJUSTER ASSEMBLY


    1. B001Y5C

      Remove the 16 No. 2 valve lash adjusters.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  84. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH


    1. B001Z0OE02

      Uniformly loosen and remove the 10 bolts and 10 spacers in the sequence shown in the illustration. Then remove the cylinder head.

      Note


      • Be careful not to drop washers into the cylinder head.

      • Head warpage or cracking could result from removing bolts in an incorrect order.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  85. REMOVE NO. 2 CYLINDER HEAD GASKET

  86. REPLACE STUD BOLT

    Tech Tips

    B001Y8NE02
    *1 20 mm (0.787 in.)
    *2 42 mm (1.65 in.)
    *3 13 mm (0.512 in.)

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


    1. Intake Pipe:


      1. Using an E8 "TORX" wrench, replace the 4 stud bolts.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. No. 3 Intake Manifold:


      1. Using an E8 "TORX" wrench, replace the 2 stud bolts labeled A.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
        B001XGPE01

      2. Using an E6 "TORX" wrench, replace the 2 stud bolts labeled B.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      3. Using an E6 "TORX" wrench, replace the stud bolt labeled C.

        Torque:
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    3. Oil Filter Bracket:


      1. B001ZDOE02
        *1 20 mm (0.787 in.)
        *2 42 mm (1.65 in.)
        *3 13 mm (0.512 in.)

        Using an E8 "TORX" wrench, replace the 2 stud bolts.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    4. No. 1 Oil Pan:


      1. B001YRFE01

        Using an E8 "TORX" wrench, replace the 2 stud bolts labeled A.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      2. Using an E7 "TORX" wrench, replace the 2 stud bolts labeled B.

        Torque:
        5.2 N*m  { 53 kgf*cm, 46 in.*lbf }

    5. Timing Chain Cover:


      1. B001Y75E02

        Using an E7 "TORX" wrench, replace the 2 stud bolts labeled A.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      2. Replace the 2 stud bolts labeled B.

        Torque:
        12 N*m  { 120 kgf*cm, 9 ft.*lbf }

    6. Timing Gear Case:


      1. B001XTCE01
        *1 54 mm (2.13 in.)
        *2 27 mm (1.06 in.)
        *3 12 mm (0.472 in.)

        Using an E7 "TORX" wrench, replace the 4 stud bolts.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
      2. B001VQ1E01
        *1 16 mm (0.630 in.)
        *2 40 mm (1.57 in.)
        *3 12 mm (0.472 in.)

        Remove the 2 stud bolts.

      3. Remove the adhesive from the threads of the timing gear case.

      4. Apply adhesive to 2 or more threads of the 2 stud bolts.

      5. Install the 2 stud bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  87. REPLACE STRAIGHT SCREW PLUG

    Tech Tips

    A01XAWT

    If water or oil leaks from the straight screw plug or the plug is corroded, replace it.


    1. No. 1 Oil Pan:


      1. Using a 10 mm hexagon wrench, replace the straight screw plug and/or gasket.

        Torque:
        50 N*m  { 510 kgf*cm, 37 ft.*lbf }
      2. A01X07U

        Using a 14 mm hexagon wrench, replace the straight screw plug and/or gasket.

        Torque:
        86 N*m  { 877 kgf*cm, 63 ft.*lbf }

    2. Oil Filter Bracket:


      1. A01XAU4

        Using a 10 mm hexagon wrench, replace the straight screw plug and/or gasket.

        Torque:
        50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    3. Timing Gear Case:


      1. A01X1C2

        Using a 10 mm hexagon wrench, replace the straight screw plug and/or gasket.

        Torque:
        40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  88. REPLACE CYLINDER BLOCK STRAIGHT SCREW PLUG

    Tech Tips

    If water leaks from the straight screw plug or the plug is corroded, replace it.


    1. A01X4K1

      Replace the 2 straight screw plugs and 2 gaskets.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
      Text in Illustration
      B001WGT Front

  89. REPLACE RING PIN

    Tech Tips

    It is not necessary to remove the ring pin unless it is being replaced.


    1. No. 1 and No. 2 Intake Manifold:


      1. B001XRJE02
        Text in Illustration
        *a 4.4 to 5.6 mm

        Replace the ring pin.

        Standard protrusion
        4.4 to 5.6 mm (0.173 to 0.222 in.)

    2. Cylinder Head:


      1. B001WL2E02
        Text in Illustration
        *a RH
        *b LH
        *c 4.4 to 5.6 mm

        Replace the ring pin.

        Standard protrusion
        4.4 to 5.6 mm (0.173 to 0.222 in.)

    3. V-ribbed Belt Tensioner:


      1. B001W2LE02
        Text in Illustration
        *a 4.7 to 5.7 mm

        Replace the ring pin.

        Standard protrusion
        4.7 to 5.7 mm (0.185 to 0.224 in.)

    4. Timing Chain Case:


      1. B001Z18E02
        Text in Illustration
        *a 4.7 to 5.7 mm

        Replace the ring pin.

        Standard protrusion
        4.7 to 5.7 mm (0.185 to 0.224 in.)

    5. Timing Gear Case:


      1. B001WD9E04
        Text in Illustration
        *a 5.2 to 5.7 mm

        Replace the ring pin.

        Standard protrusion
        5.2 to 5.7 mm (0.205 to 0.224 in.)

    6. Cylinder Head RH:


      1. Replace the ring pin.

        B001YYWE01
        Standard protrusion
        2.5 to 3.5 mm (0.0984 to 0.138 in.)
        Text in Illustration
        *a No. 2 Camshaft Bearing Cap
        *b Cylinder Head RH
        *c 2.5 to 3.5 mm

    7. Cylinder Head LH:


      1. Replace the ring pin.

        B001YYWE01
        Standard protrusion
        2.5 to 3.5 mm (0.0984 to 0.138 in.)
        Text in Illustration
        *a No. 5 Camshaft Bearing Cap
        *b Cylinder Head LH
        *c 2.5 to 3.5 mm

  90. REPLACE CHAIN TENSIONER STRAIGHT PIN

    Tech Tips

    It is not necessary to remove the straight pin unless it is being replaced.


    1. B001XNOE02
      Text in Illustration
      *a 18 to 20 mm

      Replace the straight pin.

      Standard protrusion
      18 to 20 mm (0.709 to 0.787 in.)

  91. REPLACE TIMING GEAR COVER SET STRAIGHT PIN

    Tech Tips

    It is not necessary to remove the straight pin unless it is being replaced.


    1. B001ZVOE02
      Text in Illustration
      *a 5.0 to 7.5 mm

      Replace the straight pin.

      Standard protrusion
      5.0 to 7.5 mm (0.197 to 0.295 in.)

  92. REPLACE HOLE PLUG (w/o Intercooler)

    Tech Tips

    It is not necessary to remove a hole plug unless it is being replaced.


    1. Remove the hole plug from the No. 4 camshaft.

    2. B001W62E03
      Text in Illustration
      *1 No. 4 Camshaft
      *2 Hole Plug

      Using a 12 mm steel bar and hammer, tap in the hole plug as shown in the illustration.

  93. REPLACE TIGHT PLUG (w/o Intercooler)

    Note

    If oil leaks from a tight plug or a plug is corroded, replace it.


    1. Remove the tight plug from the timing chain cover.

    2. Apply adhesive to a new tight plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. B001YIWE02
      Text in Illustration
      *a 0.2 to 0.5 mm

      Using SST and a hammer, tap in the tight plug as shown in the illustration.

      SST
      09950-60010   ( 09951-00550 )
      09950-70010   ( 09951-07100 )
      Standard depth
      0.2 to 0.5 mm (0.00787 to 0.0197 in.)