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ENGINE UNIT DISASSEMBLY

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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.

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PROCEDURE


  1. Click here

    REMOVE CAMSHAFT POSITION SENSOR

    Click here

  2. Click here

    REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  3. Click here

    DISCONNECT NO. 1 OIL COOLER HOSE

    Table 1. Text in Illustration
    *1 No. 1 Oil Cooler Hose
    *2 No. 2 Oil Cooler Hose
  4. Click here

    DISCONNECT NO. 2 OIL COOLER HOSE

  5. Click here

    REMOVE CRANKSHAFT PULLEY

    B001YM8E04
    Note:

    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.

    Table 2. 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. Click here

    REMOVE TIMING GEAR COVER SPACER (w/ Intercooler)

    Click here

  7. Click here

    REMOVE OIL FILTER CAP WITH ELEMENT

    Click here

  8. Click here

    REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

    Click here

  9. Click here

    REMOVE OIL COOLER ASSEMBLY

    Click here

  10. Click here

    REMOVE OIL COOLER RELIEF VALVE ASSEMBLY


    1. A01X7PL

      Remove the oil cooler relief valve and gasket.

  11. Click here

    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. Click here

    REMOVE ENGINE OIL LEVEL SENSOR

    Click here

  13. Click here

    REMOVE OIL PAN DRAIN PLUG


    1. B001Y63

      Remove the oil pan drain plug and gasket.

  14. Click here

    REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  15. Click here

    REMOVE OIL STRAINER SUB-ASSEMBLY

    Click here

  16. Click here

    REMOVE NO. 1 OIL PAN SUB-ASSEMBLY

    Click here

  17. Click here

    REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01X3AY

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

  18. Click here

    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. Click here

    REMOVE OIL REGULATOR ASSEMBLY

    Click here

  20. Click here

    REMOVE REAR ENGINE OIL SEAL RETAINER

    Click here

  21. Click here

    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.

      Tip:

      Tape the screwdriver tip before use.

  22. Click here

    REMOVE OIL PUMP ASSEMBLY

    Click here

  23. Click here

    REMOVE SCAVENGING PUMP ASSEMBLY

    Click here

  24. Click here

    REMOVE OIL FILLER CAP SUB-ASSEMBLY

  25. Click here

    REMOVE OIL FILLER CAP GASKET

  26. Click here

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

    Click here

  27. Click here

    REMOVE NOZZLE HOLDER GASKET RH (w/o DPF)

    Click here

  28. Click here

    REMOVE NOZZLE HOLDER SEAL RH (w/o DPF)

    Click here

  29. Click here

    REMOVE CYLINDER HEAD COVER INSULATOR RH (w/ DPF)

  30. Click here

    REMOVE FUEL INJECTOR RH (w/ DPF)

    Click here

  31. Click here

    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.

      Table 3. 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. Click here

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


    1. A01X0B1

      Remove the bolt and No. 2 fuel pump bracket.

  33. Click here

    REMOVE CYLINDER HEAD COVER INSULATOR LH (w/ DPF)

  34. Click here

    REMOVE FUEL INJECTOR LH (w/ DPF)

    Click here

  35. Click here

    REMOVE OIL SEPARATOR ASSEMBLY

    Click here

  36. Click here

    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.

      Table 4. 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. Click here

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

    Click here

  38. Click here

    REMOVE NOZZLE HOLDER GASKET LH (w/o DPF)

    Click here

  39. Click here

    REMOVE NOZZLE HOLDER SEAL LH (w/o DPF)

    Click here

  40. Click here

    REMOVE FUEL INJECTOR RH (w/o DPF)

    Click here

  41. Click here

    REMOVE FUEL INJECTOR LH (w/o DPF)

    Click here

  42. Click here

    REMOVE WATER PUMP ASSEMBLY

    Click here

  43. Click here

    REMOVE TIMING CHAIN COVER PLATE

    Click here

  44. Click here

    REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. B001XFXE02

      Remove the 4 nuts and 16 bolts.

      Table 5. Text in Illustration
      *1 Nut

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

      B001X66
      Tip:

      Tape the screwdriver tip before use.

    3. B001ZOP

      Remove the O-ring from the timing gear case.

  45. Click here

    REMOVE FRONT CRANKSHAFT OIL SEAL


    1. B001ZCAE05

      Place the timing chain cover on wooden blocks.

      Table 6. Text in Illustration
      *1 Wooden Block

    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.

      Tip:

      Tape the screwdriver tip before use.

  46. Click here

    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. B00202ME05

      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.

      Table 7. Text in Illustration
      *1 Key - -
      *a Top - -

    4. Remove the 2 crankshaft pulley set bolts.

  47. Click here

    REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. B001Y05

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

  48. Click here

    REMOVE PUMP DRIVE SHAFT GEAR


    1. B001YCTE01

      Using SST, hold the pump drive shaft gear.

      09960-10010 09962-01000 09963-01000

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

  49. Click here

    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. B001YBIE02

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

      Table 8. Text in Illustration
      *1 Stopper Plate - -
    4. B001W1S

      Remove the 2 bolts and No. 1 chain tensioner.

  50. Click here

    REMOVE NO. 1 CHAIN TENSIONER SLIPPER

  51. Click here

    REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B001XUH

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

  52. Click here

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

  53. Click here

    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. B001VRYE02

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

      Table 9. Text in Illustration
      *1 Stopper Plate - -
    4. B001Z8I

      Remove the 2 bolts and No. 2 chain tensioner.

  54. Click here

    REMOVE NO. 2 CHAIN TENSIONER SLIPPER

  55. Click here

    REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. B001WGZ

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

  56. Click here

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


    1. B001WY1E03

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

      09960-10010 09962-01000 09963-01000

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

  57. Click here

    REMOVE FUEL SUPPLY PUMP DRIVE GEAR NUT


    1. Using SST, hold the idle gear.

      09960-10010 09962-01000 09963-00700
    2. B001XUCE04

      Remove the nut.

      Table 10. Text in Illustration
      *A w/ Intercooler *B w/o Intercooler
  58. Click here

    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.

      13 N*m 133 kgf*cm 10 ft.*lbf
    2. B001Z1KE04

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

      Table 11. Text in Illustration
      *A w/ Intercooler
      *B w/o Intercooler
  59. Click here

    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.

      09960-10010 09962-01000 09963-00700
    3. A01XC33

      Remove the idle gear spring from the idle gear.

  60. Click here

    REMOVE NO. 1 IDLE GEAR SHAFT

  61. Click here

    REMOVE FUEL SUPPLY PUMP DRIVE GEAR


    1. B00202SE02

      Using SST, remove the fuel supply pump drive gear.

      09950-50013 09951-05010 09952-05010 09953-05020 09954-05031
  62. Click here

    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. Click here

    REMOVE RADIAL BALL BEARING

    Tip:

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


    1. Using SST, remove the radial ball bearing.

      09950-00020
      09950-00030
      09950-60010 09951-00580
      09950-40011 09957-04010
  64. Click here

    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. Click here

    REMOVE STRAIGHT PIN

    A01WYW0
    Tip:

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


    1. Remove the straight pin.

  66. Click here

    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. Click here

    REMOVE V-BANK SILENCER

  68. Click here

    REMOVE TIMING GEAR CASE SUB-ASSEMBLY


    1. B001YQHE02

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

      Table 12. Text in Illustration
      *1 Nut
    2. B001ZZ8

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

  69. Click here

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

  70. Click here

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

  71. Click here

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


    1. A01X7GC

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

  72. Click here

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


    1. A01X85E

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

  73. Click here

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

  74. Click here

    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.

      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.

      Tip:

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

    6. B001W9F

      Remove the No. 1 and No. 2 camshafts.

  75. Click here

    REMOVE NO. 2 CAMSHAFT BEARING CAP

  76. Click here

    REMOVE NO. 1 VALVE ROCKER ARM


    1. B001WME

      Remove the 16 No. 1 valve rocker arms.

      Tip:

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

  77. Click here

    REMOVE NO. 1 VALVE LASH ADJUSTER ASSEMBLY


    1. B001XJ4

      Remove the 16 No. 1 valve lash adjusters.

      Tip:

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

  78. Click here

    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.

      Tip:

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

  79. Click here

    REMOVE NO. 1 CYLINDER HEAD GASKET

  80. Click here

    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.

      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.

      Tip:

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

    6. B001W9E

      Remove the No. 3 and No. 4 camshafts.

  81. Click here

    REMOVE NO. 5 CAMSHAFT BEARING CAP

  82. Click here

    REMOVE NO. 2 VALVE ROCKER ARM


    1. B001X9L

      Remove the 16 No. 2 valve rocker arms.

      Tip:

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

  83. Click here

    REMOVE NO. 2 VALVE LASH ADJUSTER ASSEMBLY


    1. B001Y5C

      Remove the 16 No. 2 valve lash adjusters.

      Tip:

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

  84. Click here

    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.

      Tip:

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

  85. Click here

    REMOVE NO. 2 CYLINDER HEAD GASKET

  86. Click here

    REPLACE STUD BOLT

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

    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.

        6.0 N*m 61 kgf*cm 53 in.*lbf

    2. No. 3 Intake Manifold:


      1. B001XGPE02

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

        6.0 N*m 61 kgf*cm 53 in.*lbf

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

        5.0 N*m 51 kgf*cm 44 in.*lbf

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

        4.0 N*m 41 kgf*cm 35 in.*lbf

    3. Oil Filter Bracket:


      1. B001ZDOE02
        Table 14.
        *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.

        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.

        6.0 N*m 61 kgf*cm 53 in.*lbf

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

        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.

        6.0 N*m 61 kgf*cm 53 in.*lbf

      2. Replace the 2 stud bolts labeled B.

        12 N*m 120 kgf*cm 9 ft.*lbf

    6. Timing Gear Case:


      1. B001XTCE01
        Table 15.
        *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.

        6.0 N*m 61 kgf*cm 53 in.*lbf
      2. B001VQ1E01
        Table 16.
        *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.

        10 N*m 102 kgf*cm 7 ft.*lbf
  87. Click here

    REPLACE STRAIGHT SCREW PLUG

    A01XAWT
    Tip:

    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.

        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.

        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.

        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.

        40 N*m 408 kgf*cm 30 ft.*lbf
  88. Click here

    REPLACE CYLINDER BLOCK STRAIGHT SCREW PLUG

    Tip:

    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.

      38 N*m 387 kgf*cm 28 ft.*lbf
      Table 17. Text in Illustration
      B001WGT Front
  89. Click here

    REPLACE RING PIN

    Tip:

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


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


      1. B001XRJE03

        Replace the ring pin.

        Standard protrusion
        4.4 to 5.6 mm (0.173 to 0.222 in.)
        Table 18. Text in Illustration
        *a 4.4 to 5.6 mm

    2. Cylinder Head:


      1. B001WL2E02

        Replace the ring pin.

        Standard protrusion
        4.4 to 5.6 mm (0.173 to 0.222 in.)
        Table 19. Text in Illustration
        *a RH
        *b LH
        *c 4.4 to 5.6 mm

    3. V-ribbed Belt Tensioner:


      1. B001W2LE02

        Replace the ring pin.

        Standard protrusion
        4.7 to 5.7 mm (0.185 to 0.224 in.)
        Table 20. Text in Illustration
        *a 4.7 to 5.7 mm

    4. Timing Chain Case:


      1. B001Z18E02

        Replace the ring pin.

        Standard protrusion
        4.7 to 5.7 mm (0.185 to 0.224 in.)
        Table 21. Text in Illustration
        *a 4.7 to 5.7 mm

    5. Timing Gear Case:


      1. B001WD9E04

        Replace the ring pin.

        Standard protrusion
        5.2 to 5.7 mm (0.205 to 0.224 in.)
        Table 22. Text in Illustration
        *a 5.2 to 5.7 mm

    6. Cylinder Head RH:


      1. B001YYWE01

        Replace the ring pin.

        Standard protrusion
        2.5 to 3.5 mm (0.0984 to 0.138 in.)
        Table 23. 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. B001YYWE01

        Replace the ring pin.

        Standard protrusion
        2.5 to 3.5 mm (0.0984 to 0.138 in.)
        Table 24. Text in Illustration
        *a No. 5 Camshaft Bearing Cap
        *b Cylinder Head LH
        *c 2.5 to 3.5 mm
  90. Click here

    REPLACE CHAIN TENSIONER STRAIGHT PIN

    Tip:

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


    1. B001XNOE02

      Replace the straight pin.

      Standard protrusion
      18 to 20 mm (0.709 to 0.787 in.)
      Table 25. Text in Illustration
      *a 18 to 20 mm
  91. Click here

    REPLACE TIMING GEAR COVER SET STRAIGHT PIN

    Tip:

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


    1. B001ZVOE02

      Replace the straight pin.

      Standard protrusion
      5.0 to 7.5 mm (0.197 to 0.295 in.)
      Table 26. Text in Illustration
      *a 5.0 to 7.5 mm
  92. Click here

    REPLACE HOLE PLUG (w/o Intercooler)

    Tip:

    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

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

      Table 27. Text in Illustration
      *1 No. 4 Camshaft
      *2 Hole Plug
  93. Click here

    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

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

      09950-60010 09951-00550
      09950-70010 09951-07100
      Standard depth
      0.2 to 0.5 mm (0.00787 to 0.0197 in.)
      Table 28. Text in Illustration
      *a 0.2 to 0.5 mm