Timing gear case removal (4JJ3 with DPD)

Part name

Tightening torque

1: 25 N・m { 2.5 kgf・m / 18 lb・ft }

3: 40 N・m { 4.1 kgf・m / 30 lb・ft }

5: 51 N・m { 5.2 kgf・m / 38 lb・ft }

7: 25 N・m { 2.5 kgf・m / 18 lb・ft }

8: 25 N・m { 2.5 kgf・m / 18 lb・ft }

12: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Refer to "1.Engine 1B.Mechanical(4JJ3 with DPD) cylinder head removal".

1) Remove the vacuum pipe as a set with the vacuum hose from the timing gear case and vacuum pump.

2) Remove the vacuum pump oil pipe from the vacuum pump and cylinder block.

3) Remove the vacuum pump from the gear case cover.

1) Remove the fuel feed pipe from the fuel supply pump and common rail (fuel rail).

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1) Remove the fuel leak-off pipe from the fuel supply pump and common rail (fuel rail).

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1) Install the special tool to the starter installation section of the rear plate.

SST: 5-8840-0214-0 - crankshaft stopper

2) Remove the crankshaft pulley from the crankshaft.

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1) Remove the oil filter and gasket from the oil cooler.

1) Remove the tension pulley from the generator bracket.

2) Remove the generator lower bracket from the cylinder block and timing gear case.

1) Remove the water pump and gasket from the timing gear case.

1) Disconnect the power steering oil pump and power steering oil hose as a set from the timing gear case.

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2) Remove the power steering oil hose from the bracket.

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1) Remove the cover from the gear case cover.

2) Remove the gear case cover from the timing gear case.

1) Remove the oil pump from the timing gear case.

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1) Apply the dial gauge to the idle gear tooth to be measured, and gently move the gear left and right to measure the fluctuation of the dial gauge.

Standard: 0.10 to 0.17 mm { 0.0039 to 0.0067 in }

Limit: 0.30 mm { 0.0118 in }

2) Measure the idle gear axial direction clearance using a feeler gauge.

Axial direction clearance of the idle gear.

Idle gear	Standard value	Limit
A	0.055 to 0.130 mm { 0.0022 to 0.0051 in }	0.20 mm { 0.0079 in }
D	0.090 to 0.155 mm { 0.0035 to 0.0061 in }

3) Turn the crankshaft in the forward direction (clockwise) to align the marks with idle gear A and the supply pump gear removal or installation position.

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4) Install the M6 bolt for securing the sub gear to idle gear A.

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5) Remove the supply pump gear from the fuel supply pump using a gear puller.

1) Remove the flange from idle gear A.

2) Remove idle gear A from the idle gear A shaft.

3) Remove the idle gear A shaft from the timing gear case.

4) Remove the crank gear from the crankshaft.

5) Remove idle gear D from the idle gear shaft.

6) Remove the idle gear D shaft from the camshaft brackets.

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1) Disconnect the connector from the fuel supply pump.

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2) Remove the fuel supply pump from the timing gear case.

3) Remove the O-ring from the fuel supply pump.

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1) Remove the timing gear case bracket from the timing gear case and cylinder block.

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2) Remove the flange bolt from the timing gear case.

3) Remove the timing gear case and gasket from the cylinder block.

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