ENGINE UNIT DISASSEMBLY

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.


  1. REMOVE CAMSHAFT POSITION SENSOR

    A015CJR

    1. Disconnect the sensor connector.

    2. Remove the bolt and sensor.

  2. REMOVE CRANKSHAFT POSITION SENSOR

    A015B82

    1. Disconnect the sensor wire harness clamp.

    2. Remove the bolt and sensor.

  3. DISCONNECT NO. 1 OIL COOLER HOSE

    A015BCRE01
    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

    A015BCNE02

    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)


    1. A0155DM

      Remove the 2 bolts and timing gear cover spacer.

  7. REMOVE OIL FILTER CAP WITH ELEMENT


    1. A015AKI

      Remove the oil filter drain plug.

    2. A015A6BE04

      Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.

    3. Remove the O-ring from the oil filter drain plug and install it to the drain pipe.

    4. A015691E01

      Install the oil filter drain pipe to the oil filter cap and drain the engine oil.

    5. Remove the oil filter drain pipe.

    6. Apply a light coat of engine oil to a new O-ring, and install it to the oil filter drain plug.

    7. A015AKI

      Install the oil filter drain plug to the oil filter cap.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }
    8. A015CT2E01

      Using SST, remove the oil filter cap.

      SST
      09228-06501

      Tech Tips

      Use a container to catch the draining oil. After the oil filter cap is loosened approximately 4 turns and the cap ribs are vertical, engine oil drains from the gap between the oil filter cap and oil pan.

    9. A015AAWE05

      Remove the oil filter element and O-ring from the oil filter cap.

      Note

      Be sure to remove the cap O-ring by hand, without using any tools, to prevent damage to the cap O-ring groove.

  8. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY


    1. A0155E5

      Disconnect the oil pressure sender gauge connector.

    2. Remove the oil pressure sender gauge.

  9. REMOVE OIL COOLER ASSEMBLY


    1. A0156HU

      Remove the 2 bolts, 2 nuts and oil cooler.

    2. A015DHH

      Remove the 2 O-rings and oil cooler gasket.

  10. REMOVE OIL COOLER RELIEF VALVE ASSEMBLY


    1. A0157PW

      Remove the oil cooler relief valve and gasket.

  11. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY


    1. A015E4T

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

    2. A015CNA

      Remove the 2 O-rings.

  12. REMOVE ENGINE OIL LEVEL SENSOR


    1. A01587A

      Remove the 4 bolts and engine oil level sensor.

    2. Remove the gasket.

  13. REMOVE OIL PAN DRAIN PLUG


    1. A0158R9

      Remove the oil pan drain plug and gasket.

  14. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A0156L3

      Remove the 10 bolts and 2 nuts.

    2. A015D2G

      Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

      Note

      Be careful not to damage the contact surfaces of the No. 1 and No. 2 oil pans.

  15. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A015DAB

      Remove the 2 bolts and oil strainer.

    2. Remove the O-ring from the oil strainer.

  16. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY


    1. A015A12E02

      Remove the 20 bolts, 2 nuts and oil reflector plate.

      Note

      If the oil reflector plate is deformed, replace it.

      Tech Tips

      Be sure to clean the bolts and stud bolts, and check the threads for cracks or other damage.

    2. A0158AK

      Remove the No. 1 oil pan by prying between the No. 1 oil pan and cylinder block with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder block and oil pan.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A015970

      Remove the 3 O-rings.

    4. A015BZW

      Remove the cylinder block oil hole gasket.

  17. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A0159QB

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

  18. REMOVE INLET OIL PUMP PIPE


    1. A0158HS

      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


    1. A01593Q

      Remove the 4 bolts and oil regulator.

  20. REMOVE REAR ENGINE OIL SEAL RETAINER


    1. A0158TD

      Remove the 10 bolts.

    2. Remove the oil seal retainer by prying between the oil seal retainer and cylinder block with a screwdriver.

      Tech Tips

      Tape the screwdriver tip before use.

  21. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A015BGG

      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


    1. A0157AY

      Remove the 4 bolts and oil pump.

  23. REMOVE SCAVENGING PUMP ASSEMBLY


    1. A01593V

      Remove the 4 bolts and scavenging pump.

  24. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    A0156J6

  25. REMOVE OIL FILLER CAP GASKET

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


    1. A015CK9

      Remove the 18 bolts, cylinder head cover and gasket.

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


    1. A015CGN

      Using a small screwdriver and hammer, remove the 4 nozzle holder gaskets.

      Tech Tips

      Tape the screwdriver tip before use.

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


    1. A015BTY

      Using a small screwdriver, remove the 4 holder seals by prying the portion between each holder seal and the cutout part of the cylinder head cover.

      Tech Tips

      Tape the screwdriver tip before use.

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

  30. REMOVE FUEL INJECTOR RH (w/ DPF)


    1. A015611

      Remove the 4 bolts, 4 washers, 4 nozzle holder clamps and 4 injectors.

      Tech Tips

      Arrange the injectors, holder clamps, washers and bolts in the correct order.

    2. Remove the O-ring from each injector.

    3. Remove the 4 injection nozzle seats from the cylinder head.

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


    1. A015CFS

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

      Text in Illustration
      A015DIT Bolt
      A015CC1 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. A015APQ

      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)


    1. A0157BA

      Remove the 4 bolts, 4 washers, 4 nozzle holder clamps and 4 injectors.

      Tech Tips

      Arrange the injectors, holder clamps, washers and bolts in the correct order.

    2. Remove the O-ring from each injector.

    3. Remove the 4 injection nozzle seats from the cylinder head.

  35. REMOVE OIL SEPARATOR ASSEMBLY


    1. A0157GO

      Remove the 3 bolts, oil separator and gasket.

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


    1. A015D3Z

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

      Text in Illustration
      A015DIT Bolt
      A015CC1 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)


    1. A015DOO

      Remove the 17 bolts, cylinder head cover and gasket.

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


    1. A015CGN

      Using a small screwdriver and hammer, remove the 4 nozzle holder gaskets.

      Tech Tips

      Tape the screwdriver tip before use.

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


    1. A0158R5

      Using a small screwdriver, remove the 4 holder seals by prying the portion between each holder seal and the cutout part of the cylinder head cover.

      Tech Tips

      Tape the screwdriver tip before use.

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


    1. A015DUS

      Remove the union bolt, 4 hollow screws, 5 gaskets and nozzle leakage pipe.

      Text in Illustration
      A015CC1 Union Bolt

      Note


      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

    2. A01575P

      Remove the 4 bolts, 4 washers, 4 nozzle holder clamps and 4 injectors.

      Tech Tips

      Arrange the injectors, holder clamps, washers and bolts in the correct order.

    3. Remove the O-ring from each injector.

    4. Remove the 4 injection nozzle seats from the cylinder head.

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


    1. A015CZW

      Remove the union bolt, 4 hollow screws, 5 gaskets and No. 2 nozzle leakage pipe.

      Text in Illustration
      A015CC1 Union Bolt

      Note


      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

    2. A015AEN

      Remove the 4 bolts, 4 washers, 4 nozzle holder clamps and 4 injectors.

      Tech Tips

      Arrange the injectors, holder clamps, washers and bolts in the correct order.

    3. Remove the O-ring from each injector.

    4. Remove the 4 injection nozzle seats from the cylinder head.

  42. REMOVE WATER PUMP ASSEMBLY


    1. A0158CT

      Remove the 9 bolts, 2 nuts, water pump and gasket.

  43. REMOVE TIMING CHAIN COVER PLATE

    A0156F8

    1. Remove the 4 bolts, cover plate and gasket.

  44. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A0157BME02
      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.

      A015DZK
    3. A0157K4

      Remove the O-ring from the timing gear case.

  45. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A0157T3E02
      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.

      A0157BOE02
      Text in Illustration
      *1 Key - -
      *a Top - -

    4. Remove the 2 crankshaft pulley set bolts.

  47. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A015AJD

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

  48. REMOVE PUMP DRIVE SHAFT GEAR


    1. A015E0QE01

      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.

      A015DRSE02
      Text in Illustration
      *1 Stopper Plate - -
    4. A0156GR

      Remove the 2 bolts and No. 1 chain tensioner.

  50. REMOVE NO. 1 CHAIN TENSIONER SLIPPER

    A01564K

  51. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A0157D9

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

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

    A0158HA

  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.

      A015DO1E02
      Text in Illustration
      *1 Stopper Plate - -
    4. A0155BH

      Remove the 2 bolts and No. 2 chain tensioner.

  54. REMOVE NO. 2 CHAIN TENSIONER SLIPPER

    A0159DL

  55. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A015943

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

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


    1. A015DE3E01

      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.

      A015CQOE02
      Text in Illustration
      *A w/ Intercooler *B w/o Intercooler

  58. REMOVE IDLE GEAR ASSEMBLY


    1. A015E4V

      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. A015DZSE02
      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. A015BIT

      Hold the idle gear in a vise between aluminum plates.

      Note

      Be careful not to damage the gears.

    2. A0159XGE01

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

      SST
      09960-10010   ( 09962-01000, 09963-00700 )
    3. A015B18

      Remove the idle gear spring from the idle gear.

  60. REMOVE NO. 1 IDLE GEAR SHAFT

    A0155P3

  61. REMOVE FUEL SUPPLY PUMP DRIVE GEAR


    1. A015ACQE01

      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. A015998

      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

    A01563LE01

    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. A015DIK

      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.

    A0158JM

    1. Remove the straight pin.

  66. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. A015AH6

      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

    A0159OE

  68. REMOVE TIMING GEAR CASE SUB-ASSEMBLY


    1. A015BY5E02
      Text in Illustration
      *1 Nut

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

    2. A0155LX

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

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

    A0156ED

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

    A015DO5

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


    1. A015DMC

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

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


    1. A015CZO

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

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

    A015A27

  74. REMOVE NO. 1 AND NO. 2 CAMSHAFTS


    1. A015ATK

      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. A015CNE

      Loosen the 2 union bolts.

    3. A0155JBE01

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

    4. A015BGX

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

    5. A0158S7

      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. A015D13

      Remove the No. 1 and No. 2 camshafts.

  75. REMOVE NO. 2 CAMSHAFT BEARING CAP

    A0157IH

  76. REMOVE NO. 1 VALVE ROCKER ARM


    1. A01590K

      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. A01585A

      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. A015DH8E01

      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. A015ATK

      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. A0158I9

      Loosen the 2 union bolts.

    3. A0157SVE01

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

    4. A015AUW

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

    5. A015B34

      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. A0155KE

      Remove the No. 3 and No. 4 camshafts.

  81. REMOVE NO. 5 CAMSHAFT BEARING CAP

    A0158PF

  82. REMOVE NO. 2 VALVE ROCKER ARM


    1. A0159GD

      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. A01590A

      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. A0158EKE01

      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

    A015CVME02

    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. A015C2JE02

        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 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. A015BP4E02

        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. A015AG3E02

        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. A0158X9E01

        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. A0159G4E01

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

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
      2. A0158TQE01

        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

    A015CW2

    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. A015957

        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. A0157RM

        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. A015563

        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. A0156KC

      Replace the 2 straight screw plugs and 2 gaskets.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
      Text in Illustration
      A015CC1 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. A0157FYE02
        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. A015CT1E02
        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. A015E1IE02
        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. A015BPME02
        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. A0156GCE04
        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. A0155IJE03
        Text in Illustration
        *a No. 2 Camshaft Bearing Cap
        *b Cylinder Head RH
        *c 2.5 to 3.5 mm

        Replace the ring pin.

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

    7. Cylinder Head LH:


      1. A0155IJE04
        Text in Illustration
        *a No. 5 Camshaft Bearing Cap
        *b Cylinder Head LH
        *c 2.5 to 3.5 mm

        Replace the ring pin.

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

  90. REPLACE CHAIN TENSIONER STRAIGHT PIN

    Tech Tips

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


    1. A0155B9E02
      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. A015AZUE02
      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. A0159H5E02
      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. A0156WFE02
      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.)