Cylinder head
Part name
Tightening torque
2: 25 N・m { 2.5 kgf・m / 18 lb・ft }
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4-1: 70 N・m { 7.1 kgf・m / 52 lb・ft }
4-2: 70 N・m { 7.1 kgf・m / 52 lb・ft }
4-3: 60 to 75 °
4-4: 60 to 75 °
1) Open the engine hood.
2) Disconnect the battery cable from the battery negative terminal.
Caution
3) Raise the vehicle.
1) Remove the drain plug from the oil pan, and drain the engine oil to a pan.
2) Install the drain plug to the oil pan.
Caution
Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft }
1) Remove the cowl panel from vehicle.
Refer to "1.Engine 1G.Exhaust(4JJ3 with DPD) DPD removal".
1) Disconnect the battery ground cable from the frame.
2) Disconnect the battery cable from the battery.
3) Remove the battery bracket from the frame.
4) Remove the battery from vehicle.
Legend
1) Remove the radiator upper hose from the thermostat and radiator.
Legend
1) Disconnect the radiator reserve tank hose from the radiator.
2) Remove the radiator reserve tank from the fan guide.
1) Remove the fan shroud from the fan guide.
2) Remove the fan guide from the radiator.
Legend
1) Remove the cooling fan and cooling fan clutch as a set from the water pump.
2) Remove the fan pulley from the water pump.
1) Loosen the tension pulley lock nut.
2) Loosen the tension pulley adjust bolt.
3) Remove the A/C compressor drive belt from the following parts.
Legend
1) Loosen the tension pulley lock nut.
2) Loosen the tension pulley adjust bolt.
3) Remove the A/C compressor drive belt from the following parts.
Legend
1) Loosen the tension pulley lock nut.
2) Loosen the tension pulley adjust bolt.
3) Remove the cooling fan belt from the following parts.
MT models
Legend
AT models
Legend
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) Disconnect the connector from charge air cooler temperature sensor 2.
2) Disconnect the air intake hose from the intercooler.
3) Remove the intake air duct from the intake throttle valve.
1) Disconnect the A/C compressor from the A/C compressor bracket.
Legend
1) Remove the A/C compressor bracket from the cylinder head.
1) Remove the oil level gauge from the oil level gauge guide tube.
2) Remove the oil level gauge guide tube from the crankcase.
Caution
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.
Legend
3) Remove the injector leak-off pipe from the injector.
Caution
Legend
1) Disconnect the PCV hose from the cylinder head cover.
2) Disconnect the harness clip from the cylinder head cover.
RHD
LHD
3) Remove the harness bracket from the cylinder head cover.
Note
Models with urethane covers
Legend
4) Remove the cylinder head cover from the cylinder head.
Caution
5) Remove the oil seal from the lower side of the cylinder head cover.
1) Disconnect the fuel feed hose from the fuel supply pump.
2) Disconnect the fuel return hose from the fuel leak-off pipe.
Legend
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) Disconnect the connector from the swirl control solenoid valve.
2) Disconnect the vacuum hose from swirl control solenoid valve.
3) Remove the swirl control solenoid valve and bracket as a set from the inlet manifold.
1) Remove the harness bracket from the inlet manifold.
Legend
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) Remove the clip from the injection pipe.
2) Remove the injection pipes from the injector and common rail (fuel rail).
Caution
Legend
1) Remove the injector clamp from the injector.
2) Remove the injector from the cylinder head.
Note
Caution
3) Remove the gasket from the injector.
4) Remove the O-ring from the injector.
Caution
Legend
1) Remove the tension pulley from the cylinder head.
1) Remove the EGR cooler bypass pipe and gasket from the exhaust manifold and inlet manifold.
Caution
1) Remove the EGR gas pressure pipe from the exhaust manifold and EGR gas pressure pipe bracket.
Caution
Legend
Legend
2) Remove the EGR gas pressure pipe bracket from the cylinder head.
1) Remove the water pipe from the following parts.
1) Disconnect the radiator lower hose from the water intake pipe.
Legend
1) Remove the water intake pipe and water hose as a set from the oil filter and oil cooler.
Caution
1) Disconnect the connector from the intake throttle valve.
2) Remove the following parts from the inlet manifold.
Caution
Legend
1) Disconnect the heater pipe from the inlet manifold.
1) Disconnect the water hose from the water outlet pipe.
2) Remove the thermostat from the thermostat housing.
Caution
Legend
1) Disconnect the connector from the glow plug.
Legend
2) Remove the glow plug from the cylinder head.
Legend
1) Rotate the crankshaft in the forward direction (clockwise) to align the No. 1 cylinder piston to compression top dead center.
Legend
2) Remove the baffle plate from the cylinder head.
1) Remove the idle pulley from the timing chain upper cover.
2) Disconnect the connector from the CMP sensor.
Legend
3) Remove the timing chain upper cover from the cylinder head.
Legend
1) Remove the noise cover from the timing chain lower cover.
2) Remove the timing chain lower cover from the gear case cover.
1) Rotate the crankshaft in the forward direction (clockwise) to align the No. 1 cylinder piston to compression top dead center.
Legend
2) Align the marks of the camshaft upper bracket and camshaft.
Legend
3) Remove the oil feed pipe from the timing chain tensioner.
Caution
4) Remove the timing chain tensioner and gasket from the cylinder head.
Caution
Legend
5) Remove the timing chain lever pivot from the timing chain tension lever.
6) Remove the idle gear D shaft bolt and sleeve from idle gear D and sprocket.
7) Remove the timing chain and sprocket as a set from idle gear D.
Legend
8) Remove the timing chain from the supply pump sprocket by lowering the timing chain and sprocket.
9) Take the timing chain tension lever out from the cylinder head.
10) Remove the timing chain guide from the cylinder head and cylinder block.
Legend
1) Use the M5 lock bolt to secure the camshaft gear.
2) Remove the following parts as a set from the cylinder head.
Legend
1) Install special tool to the cylinder head.
SST: 5-8840-2886-0 - rear engine hanger
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2) Install the wire to the engine hanger and hoist.
3) Remove the nuts and bolts from between cylinder head and timing gear case.
Legend
4) Loosen the cylinder head bolts in the order shown in the diagram.
Caution
5) Remove the cylinder head from the cylinder block.
6) Remove the cylinder head gasket and timing gear case gasket from the cylinder head.
Caution