Rocker arm shaft removal (4JJ3 with DPD)

1. Component views

Rocker arm shaft

Part name

  1. Rocker arm
  2. Spacer
  3. Bolt
  4. Rocker arm shaft
  5. Camshaft bracket
  6. Plate

Tightening torque

3: 14 N・m { 1.4 kgf・m / 124 lb・in } Wet

2. Timing chain removal

Refer to "1.Engine 1B.Mechanical(4JJ3 with DPD) Timing chain removal".

3. EGR cooler bypass control solenoid valve removal

1) Disconnect the connector from the EGR cooler bypass control solenoid valve.

2) Disconnect the vacuum hose from the EGR cooler bypass control solenoid valve.

3) Remove the EGR cooler bypass control solenoid valve and bracket as a set from the inlet manifold.

Legend

  1. EGR cooler bypass control solenoid valve

4. Leak-off pipe removal

1) Remove the harness bracket from the inlet manifold.

Legend

  1. Harness bracket

2) Disconnect the 3 vacuum hoses from the vacuum pipe.

3) Disconnect the 2 leak-off hoses from the leak-off pipe.

4) Remove the leak-off pipe from the inlet manifold.

Legend

  1. Leak-off hose (Injector side)
  2. Leak-off pipe
  3. Vacuum pipe
  4. Vacuum hose (EGR cooler bypass control solenoid valve side)
  5. Leak-off hose (Supply pump side)
  6. Vacuum hose (Vacuum pump side)

5. Injection pipe removal

1) Remove the clip from the injection pipe.

2) Remove the injection pipes from the injector and common rail (fuel rail).

Caution

  • Do not reuse the injection pipe.

Legend

  1. Injection pipe
  2. Clip

6. Baffle plate removal

1) Remove the baffle plate from the cylinder head.

7. Injector removal

1) Remove the injector clamp from the injector.

2) Remove the injector from the cylinder head.

Note

  • If it is difficult to remove the injector, use a remover.
  • Store the removed injectors with the cylinder numbers attached.

Caution

  • Cover the exposed portion to prevent foreign material from getting into the fuel system.
  • Do not damage the injector nozzle.
  • Absolutely never touch the injector solenoids because that can hinder their performance or cause damage.

3) Remove the gasket from the injector.

4) Remove the O-ring from the injector.

Caution

  • Do not reuse the following parts.
  • Clip
  • O-ring
  • Gasket

Legend

  1. Injector
  2. Leak-off pipe
  3. Clip
  4. O-ring
  5. Gasket

8. Camshaftbracket removal

1) Use the M5 lock bolt to secure the camshaft gear.

2) Remove the following parts as a set from the cylinder head.

  • Camshaft bracket
  • Rocker arm shaft
  • Camshaft
  • Idle gear D

Legend

  1. Camshaft bracket
  2. Cylinder head

9. Rocker arm shaft removal

1) Remove the camshaft upper bracket from the camshaft brackets.

Note

  • Check that there are installation position markings on the camshaft upper brackets.

2) Remove the inlet camshaft and exhaust camshaft from the camshaft brackets.

Caution

  • Take measures to prevent the inlet and exhaust sides from becoming mixed up.

Legend

  1. Camshaft upper bracket
  2. Inlet camshaft
  3. Exhaust camshaft

3) Remove the rocker arm shaft from the rocker arms and camshaft brackets.

Caution

  • If reusing the rocker arm, perform the procedures necessary to install it to its original position.

4) Remove the spacer from the rocker arm shaft.

5) Remove the plate from the camshaft bracket.

Legend

  1. Rocker arm
  2. Spacer
  3. Bolt
  4. Rocker arm shaft
  5. Camshaft bracket
  6. Plate
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