Idle gear removal (4JJ3 with DPD)

Part name

Tightening torque

2: 8.0 N・m { 0.8 kgf・m / 71 lb・in }

3: 130 N・m { 13.3 kgf・m / 96 lb・ft }

6: 59 N・m { 6.0 kgf・m / 44 lb・ft }

14: 32 N・m { 3.3 kgf・m / 24 lb・ft }

15: 59 N・m { 6.0 kgf・m / 44 lb・ft }

19: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

22-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }

22-2: 180 °

22-3: 60 °

Refer to "1.Engine 1B.Mechanical(4JJ3 with DPD) crankshaft front oil seal removal".

1) Disconnect the B-terminal from the generator.

2) Disconnect the connector from the generator.

3) Remove the upper bracket from the generator and timing gear case.

4) Remove the generator from the lower bracket.

1) Remove the water pipe from the following parts.

Refer to "1.Engine 1Z.Engine Electrical Control(4JJ3 with DPD) exhaust differential pressure sensor removal".

1) Disconnect the following sensor harnesses from the harness bracket.

2) Remove the differential pressure sensor bracket from the cylinder head cover.

3) Remove the harness bracket from the cylinder head cover.

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1) Remove the air duct bracket from the cylinder head cover.

1) Disconnect the connector from the injector.

2) Remove the fuel leak-off hose from the leak-off pipe.

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3) Remove the injector leak-off pipe from the injector.

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1) Disconnect the PCV hose from the cylinder head cover.

2) Disconnect the harness clip from the cylinder head cover.

3) Remove the harness bracket from the cylinder head cover.

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4) Remove the cylinder head cover from the cylinder head.

5) Remove the oil seal from the lower side of the cylinder head cover.

1) Rotate the crankshaft in the forward direction (clockwise) to align the No. 1 cylinder piston to compression top dead center.

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2) Remove the baffle plate from the cylinder head.

1) Remove the idle pulley from the timing chain lower cover.

2) Remove the noise cover from the timing chain lower cover.

3) Remove the timing chain lower cover from the gear case cover.

1) Remove the tension pulley from the cylinder head.

1) Remove the idle pulley from the timing chain upper cover.

2) Disconnect the connector from the CMP sensor.

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3) Remove the timing chain upper cover from the cylinder head.

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1) Remove the oil feed pipe from the timing chain tensioner.

2) Remove the timing chain tensioner and gasket from the cylinder head.

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3) Remove the timing chain lever pivot from the timing chain tension lever.

4) Remove the idle gear D shaft bolt and sleeve from idle gear D and sprocket.

5) Remove the timing chain and sprocket as a set from idle gear D.

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6) Remove the timing chain from the supply pump sprocket by lowering the timing chain and sprocket.

7) Take the timing chain tension lever out from the cylinder head.

8) Remove the timing chain guide from the cylinder head and cylinder block.

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1) Measure the axial direction clearance of the camshaft gear and camshaft bracket using a feeler gauge.

Standard: 0.050 to 0.130 mm { 0.00197 to 0.00512 in }

Limit: 0.250 mm { 0.00984 in }

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

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

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

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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 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 cover from the gear case cover.

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

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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