Engine 4JJ1

WORKSHOP MANUAL 2007MY N-SERIES

ENGINE 4JJ1 SECTION 6

Isuzu Motors Limited Service Marketing Department

ENGINE MECHANICAL (4JJ1)

6A-1

ENGINE ENGINE MECHANICAL (4JJ1) TABLE OF CONTENTS ISUZU DIESEL DIESEL ENGINE (4JJ1) (4JJ1) . . . . . . . . . . . . . . 6A-3 Service Service Precautions Precautions . . . . . . . . . . . . . . . . . . . . . . 6A-3 Work procedure . . . . . . . . . . . . . . . . . . . . . . . . . 6A-3 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Engine Assembly Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6A-14 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-16 Special Tools Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18 Engine Mount Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-20 Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . 6A-21 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23 Intake Manifold Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-26 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-27 Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-28 Service Service Precautions Precautions . . . . . . . . . . . . . . . . . . . . . 6A-28 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-28 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31 Torque specifica specifications tions . . . . . . . . . . . . . . . . . . . . 6A-33 Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . 6A-34 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-34 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-34 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-37 Timing Timing Gear Train Train . . . . . . . . . . . . . . . . . . . . . . . . 6A-38 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-38 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-38 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-40 Reassembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-40 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-41 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-42 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-45 Camshaft Camshaft Assembly Assembly . . . . . . . . . . . . . . . . . . . . . . 6A-46 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-46 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-46 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-48 Reassembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-50

Installatio Installation n . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-52 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-53 Special Tools Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-54 Valve Stem Stem Seal and Valve Spring Spring . . . . . . . . . . . 6A-55 Components. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-56 Installatio Installation n . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-57 Special Tools Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-58 Cylinder Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59 Components. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59 Head Disassem Disassembly bly . . . . . . . . . . . . . . . . . . . . . . 6A-64 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-66 Head Reassembly . . . . . . . . . . . . . . . . . . . . . .6A-70 Installatio Installation n . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-72 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-80 Special Tools Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-80 Piston and and Connecting Connecting Rod . . . . . . . . . . . . . . . . 6A-82 Components. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-82 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-82 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6A-83 Reassembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-87 Installatio Installation n . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-88 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-90 Special Tools Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-90 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-91 Components. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-91 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-91 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-93 Installatio Installation n . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-93 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-95 Special Tools Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-95 Gear Case Case Assembly Assembly . . . . . . . . . . . . . . . . . . . . . 6A-96 Components. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-96 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-96 Installatio Installation n . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-97 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-98 Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . . 6A-99 Components. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-99 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-99 Installatio Installation n . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-100 Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-102 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . .6A-102 Crankshaft Crankshaft Rear Rear Oil Seal . . . . . . . . . . . . . . . . . 6A-103 Components. . . . . . . . . . . . . . . . . . . . . . . . . .6A-103 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-103 Installatio Installation n . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-104

6A-2


Special Tools Tools . . . . . . . . . . . . . . . . . . . . . . . . . 6A-104 Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-105 Components. . . . . . . . . . . . . . . . . . . . . . . . . .6A-105 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-105 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .6A-106 Reassembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-106 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-107 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-112 Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-114 Cylinder Cylinder Block Block . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115 6A-115 Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115 6A-115 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-117 Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-118 Lubrication System . . . . . . . . . . . . . . . . . . . . . . 6A-119 Service Precauti Precautions ons . . . . . . . . . . . . . . . . . . . . 6A-119 6A-119 Functional Functional Check Check . . . . . . . . . . . . . . . . . . . . . . 6A-120 Oil Filter Element. . . . . . . . . . . . . . . . . . . . . . . .6A-121 Components. . . . . . . . . . . . . . . . . . . . . . . . . .6A-121 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-121 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-121 Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-122 Oil Filter Filter Assembly Assembly and Oil Cooler . . . . . . . . . . 6A-123 Components. . . . . . . . . . . . . . . . . . . . . . . . . .6A-123 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-123 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .6A-124 Reassembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-124 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-124 Crank Case Case and Oil Pan Pan . . . . . . . . . . . . . . . . . . 6A-126 Components. . . . . . . . . . . . . . . . . . . . . . . . . .6A-126 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-126 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .6A-128 Reassembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-128 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-128 Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-130 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-131 Components. . . . . . . . . . . . . . . . . . . . . . . . . .6A-131 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-131 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .6A-133 Reassembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-133 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-133 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-135 Oil Pressure SW . . . . . . . . . . . . . . . . . . . . . . . .6A-137 Components. . . . . . . . . . . . . . . . . . . . . . . . . .6A-137 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-137 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-137 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-138 Circuit check. . . . . . . . . . . . . . . . . . . . . . . . . .6A-138 Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . 6A-139 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-139 Cleaning Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-139 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-139


6A-3

ISUZU DIESEL ENGINE (4JJ1) Service Precautions Matters that maintenance

require

Matters that require attention in specifically dealing with this engine. attention

in

terms

of

To prevent damage to the engine and ensure reliability of its performance, pay attention to the following in maintaining the engine: • When liftin lifting g up or supportin supporting g the engine, engine, do not apply a jack on the oil pan. When taking down the engine on the ground, do not make the bearing surface of the oil pan touch the ground directly. Use a wooden frame, for example, to support the engine with the engine foot and the flywheel housing. Because there is only a small clearance between the oil pan and the oil p ump strainer, it can damage the oil pan and the oil strainer. • When the the air duct duct or air air cleaner cleaner is removed, removed, cover the air intake opening to prevent foreign matter from getting into the cylinder. If it gets contaminated, it can considerably damage the cylinder and others while the engine is operating. • When maintain maintaining ing the engine, engine, never fail to to remove remove the battery earth cable. If not, it may damage the wire harness or electrical parts. If you need electricity on for the purpose of inspection, for instance, watch out for short circuits and others. • Apply engine engine oil oil to the the sliding sliding contact contact surfaces surfaces of the engine before reassembling it. This ensures adequate lubrication when the engine is first started. • When valve valve train train parts, parts, pistons, pistons, piston piston rings, connecting rods, connecting rod bearings or crankshaft journal bearings are removed, put them in order and keep them. • When install installing ing them, them, put them back back in the same same location they were removed from. • Gaskets, Gaskets, oil seals, O-rings, O-rings, etc. etc. must be replaced replaced with new ones when the engine is reassembled. • As for parts parts where where a liquid liquid gasket gasket is is used, used, remove remove an old liquid gasket completely and clean it up thoroughly so that no oil, water or dust is clinging to them. Then, apply the designated liquid gasket to each place anew before assembly. • Surfaces Surfaces covered covered with liquid gasket must be assembled within 5 minutes of gasket application. If more than 5 minutes has elapsed, remove the existing liquid gasket and apply a new liquid gasket. • When assembli assembling ng or insta installing lling parts, parts, fasten them with the prescribed tightening torque so that they are installed properly. properly.

Holes or clearances in the fuel system, which serve as a passage of fuel, including the inside of the injector, are made with extreme precision. For this reason, they are highly sensitive to foreign matter and if it gets in, it can lead to an accident on the road, for instance; thus, make sure that foreign matter is prevented from getting in. When servicing the fuel system, every precaution must be taken to prevent the entry of foreign material into the system. • Before beginning beginning the the service service procedure, procedure, wash wash the the fuel line and the surrounding area. • Perform the service service procedures procedures with with clean clean hands. hands. Do not wear work gloves. • Immediately Immediately after after removing removing the fuel hose and/or and/or fuel pipe, carefully tape vinyl bags over the exposed ends of the hose or pipe. • If parts parts are are to be be replaced replaced (fuel (fuel hose, hose, fuel fuel pipe, pipe, etc.) do not open the new part packaging until installation.

Work procedure • The fuel fuel opening opening must must be quickly quickly sealed sealed when when removing the fuel pipe, injection pipe, fuel injector, fuel supply pump, and fuel rail. • The eyebolts eyebolts and gasket gasket must must be stored in a clean clean parts box with a lid to prevent adhesion of foreign matter. • Fuel leakage leakage could could cause cause fires. fires. Therefore, Therefore, after after finishing the work, wipe off the fuel that has leaked out and make sure there is no fuel leakage after starting the engine.

6A-4


How to read the model

Legend 1. Engine Engine Model Model (St (Stamp amped) ed) 2. Engine Engine Number Number (Stam (Stamped) ped) Explanation of functions and operations

Electronic engine control With the control unit, the range from injection to air intake/exhaust, including fuel injection quantity, injection timing, intake air restriction, EGR, and idling rpm, is controlled. Piston The piston is aluminum-alloy and a thermal flow piston with a strut cast, while the combustion chamber is a round reentrant type. Cylinder head The cylinder head is aluminum-alloy and there are 4 valves per cylinder. The angular tightening method of the cylinder head bolt further increases reliability and durability.

3. Front

EGR system Based upon data, including water temperature, engine speeds or engine loads, it is controlled via Engine Control Module (ECM) to purify exhaust by recycling part of it. Its main components include an EGR valve, an EGR cooler and various sensors. Connecting rod cap bolt The angular tightening method of the connecting rod cap bolt further increases reliability and durability. Fuel rail-type electronic control injection system The fuel rail-type electronic control injection system is composed of a fuel supply pump that sets the target pressure of high-pressure fuel and supply it, a fuel rail that measures such high-pressure fuel and a fuel injector that turns it into a fine spray and injects it. Each is controlled via ECM based upon various signals, while injection timing or fuel injection quantity is controlled under every possible driving condition.


6A-5

Fuel injector The fuel injector is a 6-hole nozzle that adjusts fuel injection quantity or injection timing by opening or closing an electromagnetic valve on the head of the fuel injector. ECM corrects the dispersion of fuel injection quantity between fuel injector according to ID code data in memory. At the replacement of fuel injector, ID code data should be stored in ECM. Fuel filter with sedimenter It is a fuel filter with sedimenter that gets rid of water by making use of the difference in specific gravity between light oil and water, which comes with an indicator that notifies you that it is filled with water. Preheating system The preheating system consists of the ECM, the glow relay, glow plugs and the glow indicator lamp. The preheating system is operated when the engine coolant temperature is low, and makes the engine easy to start. Lubrication system It is an oil filter with full-flow bypass, which uses a water-cool oil cooler and oil jet to cool the piston. Functional inspection Inspection/adjustment of valve clearance 1. Inspec Inspectio tion n of valve valve clearanc clearance e • Remove Remove the injectio injection n nozzle nozzle harness harness assembl assembly y.

Legend 1. Cranks Crankshaf haftt Damper Damper Pulle Pulley y 2. Mirror rror 3. TDC Ma Mark • Insert Insert a 0.15 0.15 mm (0.006 (0.006 in) thick thicknes ness s gauge gauge between the roller of the rocker arm and the camshaft to tighten up the adjusting screw of the rocker arm. When the movement of the thickness gauge becomes tight, fasten the adjusting screw nut of the rocker arm. Valve clearance mm (in)

• Remove Remove the leak leak off off hose. hose. • Remove Remove the the cylin cylinder der head head cover cover..

Intake valve

0.15 (0.006)

• Rotate Rotate the the crankshaf crankshaftt and make the No.1 No.1 cylinder compression top dead center (TDC).

Exhaust valve

0.15 (0.006)

• Check Check TDC TDC using using a mirror mirror etc. etc.

NOTE: Adjust while cold. 2. Adjustm Adjustment ent of valve valve cleara clearance nce

6A-6


• Loosen each adjusting adjusting screw screw of of the rocker arm completely.

• Insert Insert a 0.15 0.15 mm (0.006 (0.006 in) in) thickne thickness ss gauge gauge between the roller of the rocker arm and the camshaft to tighten up the adjusting screw of the rocker arm. When the movement of the thickness gauge becomes tight, fasten the adjusting screw nut of the rocker arm.

Legend 1. Scre Screwd wdri rive ver r 2. Ring Ring Spann panner er 3. Valve Clearance Clearance Adjust Adjust Nut Nut Wrench Wrench Special tool Valve clearance adjust nut wrench: 5-8840-2822-0

Legend 1. Camshaf Camshaftt Assem Assembly bly (EX) 2. Camsha Camshaft ft Assem Assembly bly (IN) (IN) 3. Inta Intake ke Rock Rocker er Arm Arm 4. Exha Exhaust ust Roc Rocke kerr Arm Tightening torque: Rocker arm adjustment Screw nut 18 N⋅m (1.8 kg⋅m/ 13 lb ft) Adjustment table Cylinder No.

1

2

Valve arrangement

IN

EX

IN

No. 1 cylinder Compression TDC







No. 4 cylinder Compression TDC

3 EX

IN

4 EX

IN

EX



×

×

×

• If the No.1 cylinde cylinderr is the compressi compression on TDC, TDC, adjust a valve clearance with  mark given on the table and if the No. 4 cylinder is the compression TDC, adjust that with × mark. • Instal Installl the cylin cylinder der head head cover cover.. Refer to “Cylinder Head Cover”. • Instal Installl the the leak leak off off hose. hose. • Install Install the fuel injecto injectorr harness harness assembly assembly..

ENGINE MECHANICAL (4JJ1) Compression pressure inspection

6A-7

• Warm up the engin engine. e.

• Turn on the the starter starter to to inspect inspect compress compression ion pressure.

• Remove Remove a minus minus terminal terminal of the the battery battery..

• Measure Measure each each cyli cylinde nderr one by by one. one.

• Remove Remove the all glow glow plugs. plugs. NOTE: When the harness connector is removed, ECM judges that it broke down and DTC is recorded. Upon completion of measurement, never fail to clear the memory of the ECM. (For how to clear the memory of the ECM, refer to “ENGINE CONTROL SYSTEM” Section)

NOTE: To keep engine speed at 200 rpm or more, use fully charged batteries. • Remove the compress compression ion gauge gauge with with the the special special tool. • Remove the minus minus terminal terminal of the the batteries. batteries. • Insta Install ll the the glo glow w plug plugs. s. • Install Install the the minus minus terminal terminal of the batteries. batteries.

• Install Install the minus terminal terminal of the the battery battery.. • Turn Turn on the starter starter to emit foreign foreign matter matter within within the cylinders. • Instal Installl an adapter adapter and and the gaug gauge e compression gauge with the special tool.

of

A list of defective phenomena • Engine Engine does does not turn turn over over..

the

• Engine Engine turns turns over over but does does not not start. start. • Excessi Excessive ve black black exhaus exhaustt smoke. smoke. • Excessi Excessive ve whit white e exhaus exhaustt smoke. smoke. • Engin Engine e knoc knockin king. g. • Abnorma Abnormall engi engine ne rotati rotation. on. • Abnorma Abnormall batte battery ry charging charging.. • Turboc Turbocharg harger er troubl trouble e shooti shooting. ng.

Trouble Shooting

Compression gauge: 5-8840-2675-0 Gauge adapter: 5-8840-2815-0 Engine does not turn over Condition

Possible Cause

Correction

Condition

Possible Cause

Correction

Starter motor does not rotate

Dead or weak battery

Charge battery Replace battery

Incomplete circuit

Connect Repair

Starter motor brushes stuck, worn, or broken

Replace brushes

Starter motor internal damage

Repair motor

Ring gear abrasion

Replace ring gear

Magnetic switch (starter motor) not properly adjusted

Adjust

Starter motor not meshed with flywheel

6A-8

ENGINE MECHANICAL (4JJ1) Condition

Starter motor pinion meshed with ring gear but does not rotate

Possible Cause

Correction

Dead or weak battery

Charge battery Replace battery

Insufficient contact pressure between starter motor brushes and commutator

Adjust pressure

Armature (starter motor) stuck

Repair armature

Engi Engine ne inte intern rnal al dama damage ge (Sei (Seizu zure re))

Repa Repair ir engi engine ne

Engine turns over but does not start Condition Fuel is not delivered to fuel supply pump

Fuel is delivered to fuel supply pump

Insufficient or unstable fuel delivery volume

Possible Cause

Correction

Air in fuel system

Bleed air from fuel system

Air entering fuel pipe

Replace pipe and bleed air from fuel system

Empty fuel tank

Replenish fuel

Clogged str strainer ner (f (fuel su suction) on)

Clean or or re replace st strai rainer

Clogged fuel pipe

Clean or replace pipe

Feed pump malfunction

Replace pump

Use of wrong fuel for prevailing temperatures

Drain existing fuel and replace with appropriate fuel

Clogged fuel filter

Replace filter

Loos Loose e inj injec ecti tion on pipe pipe conn connec ecti tion ons s

Tight ighten en conn connec ecti tion ons s

Loose or connectors

Tighten and/or replace connectors

broken

electrical

Bad rotational sensor

Replace sensor

Engi Engine ne contr control ol syst system em malfu malfunc ncti tion on

Syste System m dia diagno gnosi sis s

Air in fuel system


Feed pump malfunction Loose or connectors

broken

Repair pump electrical

Tighten and/or replace connectors

Clogged fuel filter

Replace filter



Excessive black exhaust smoke Condition

Possible Cause

Correction

Bad injection timing

Engine control system malfunction

System diagnosis

Bad fuel injector condition

Carbon deposit at nozzle tip

Clean fuel injector assembly

Sticking nozzle

Replace fuel injector assembly



ENGINE MECHANICAL (4JJ1) Condition Insufficient compression pressure

Possible Cause

Fuel condition

Poor engine aspiration Malfunction detected by engine control system EGR valve and/or intake throttle valve malfunction

Turbocharger malfunction

Correction

Excessive valve clearance

Adjust clearance

Stick tickin ing g valv valve e ste stem m (val (valve ve open open))

Repa Repair ir or repl replac ace e valv valve e

Damaged valve spring

Replace spring

Valve seat abrasion

Repair valve seat

Compression leakage damaged piston ring

6A-9

due

to

Replace piston ring

Damaged gasket

Replace gasket

Piston scoring

Replace piston

Water in fuel

Drain existing fuel and replace with new fuel

Poor fuel quality


Clogged intake pipes

Clean or replace pipes

Clogged air cleaner element

Clean or replace el element

Defective sensor

Replace sensor

Engin Engine e con contr trol ol syst system em malf malfunc unctio tion n

Syst System em diag diagnos nosis is

Intake throttle valve sticking

Repair or or replace valve

EGR valve sticking

Repair or replace valve

Exhaust br brake va valve st sticking

Repair or or re replace va valve



Damaged turbocharger blade

Replace turbocharger

Roug Rough h turbo turboch charg arger er shaf shaftt rota rotati tion on

Repl Replac ace e turbo turboch char arger ger

Oil leakage from oil seal


Broken actuator


Defective booster sensor

Replace sensor

Excessive white exhaust smoke Condition

Possible Cause

Correction

Bad injection timing


System diagnosis

Malfunction detected by engine control system

Defective sensor

Replace sensor

Control unit malfunction

Replace unit



Excessive valve clearance

Adjust clearance

Stick tickin ing g valv valve e ste stem m (val (valve ve open open))

Repa Repair ir or repl replac ace e valv valve e

Damaged valve spring

Replace spring

Valve seat abrasion

Repair valve seat

Insufficient compression pressure

Compression leakage damaged piston ring

Fuel condition

due

to

Replace piston ring

Damaged gasket

Replace gasket

Piston scoring

Replace piston

Water in fuel


6A-10

ENGINE MECHANICAL (4JJ1) Condition

Excessive oil consumption

Possible Cause

Correction

Worn or damaged piston ring(s)

Replace ring(s)

Defective valve stem oil seal

Replace oil seal

Defective tur turbo boc charger oil oil se seal

Repl eplace ace tu turboc rbocha harg rge er

Clogged turbocharger oil return pipe

Repair pipe

Engine knocking Condition

Possible Cause

Correction

Bad timing


System diagnosis

Malfunction detected by engine control system

Defective sensor

Replace sensor

Control unit malfunction

Replace unit


Syst System em diag diagno nosi sis s

Fuel condition

Poor quality fuel


Poor engine aspiration

Clogged intake pipes

Clean or replace pipes



Foreign material in cylinders

Engine overhaul

Scor Scored ed pis pisto tons ns an and/or d/or bea beari ring ngs s

Rep Replac lace pis pistons tons an and/or d/or bea beari ring ngs s

Engine break-down

Abnormal engine rotation Condition Engine speed cannot be increased Engine speed unstable

Possible Cause Defective control unit

Replace unit



Defective control unit

Replace unit



Clogged fuel filter element

Replace element

Defective fu fuel injector(s)

Replace fu fuel injector as assembly

Water in fuel


Air in fuel system Turbocharger malfunction

Correction


Exhaust br brake va valve st sticking

Repair or or re replace va valve

Damaged turbocharger blade


Roug Rough h turboc turbocha harg rger er shaf shaftt rota rotati tion on

Replac Replace e tur turbo boch charg arger er

Broken actuator


Defective booster sensor

Replace sensor

Abnormal battery charging Condition No charging

Possible Cause

Correction

Open or shorted wiring and/or Repair or replace wiring and/or connectors connectors Defective generator

Repair or replace generator

Defective battery

Replace battery

ENGINE MECHANICAL MECHANICA L (4JJ1) Condition

Possible Cause

Insufficient charging

Open or or sh shorted connectors

Excessive charging

6A-11

Correction

wi wiring

an and/or Repair or replace wiring and/or connectors

Defective generator


Loose generator drive belt

Adjust belt tension or replace belt

Defective battery

Replace battery

Shorted wiring

Repair or replace wiring

Defective generator


Defective battery

Replace battery

Turbocharger Troubleshooting Condition

Possible Cause

Engine Engine has has less less than normal normal powe powerr

Air leakag leakage e from intak intake e pipe rubbe rubber r Repair hose Air leakage from intake cover

Repair

Clog Clogge ged d int inter ercoo cooler ler cool coolin ing g sec secti tion on

Clea Clean n

Clogged air cleaner element

Clean or replace

Intake throttle valve stuck

Repair or replace

Turbine and (Interference)

Blue exhaust smoke

Noisy isy tur turbo boc charger operati ation

Excessive rotating part wear

Correction

housing

contact

Replace

Excessive carbon deposit near turbine exhaust port that interferes with turbine

Clean or repair

Rough turbine shaft rotation

Repair or replace

Damaged turbine blade

Repair or replace

Oil le leakage fr from tu turbocharger oi oil seal

Repair or replace

Clogged turbocharger oil return pipe

Repair

Clogged passages

Repair or replace

center

housing

oil

Engine oil deterioration

Change engine oil

Gas lea leak kage fr from in intake or or ex exhaust system

Repair

Turbine and (Interference)

Repair or replace

housing

contact

Damaged turbine blade

Replace

Turbine shaft bearing abrasion or scoring

Repair or replace

Engine oil deterioration

Change engine oil

Clog Clogge ged d turb turboc ocha harg rger er oil oil fee feed d pipe pipe

Repa Repair ir

Low engine oil pressure

Repair

Main Data and specifications

Item Type

Engine model 4JJ1 Diesel/4-cycle/water cooling-type in-line DOHC

6A-12

ENGINE MECHANICAL (4JJ1) Item

Engine model 4JJ1

Combustion chamber type

Direct injection type

Cylinder liner type

Liner less

Number of cylinders -cylinder

mm (in)

4-95.4 (3.76) × 104.9 (4.13)

bore X strokes Displacement

cc (cu.in)

Compression ratio

2999 (183) 17.5

Compression pressure

MPa (psi)/rpm

Idling speed

rpm

Valve clearance

Intake

3 (435)/200 700 ± 25 0.15 (0.006) (cold)

mm (in) Exhaust

0.15 (0.006) (cold)

Ignition type

Compressed ignition

Injection order

1-3-4-2

Lubricating system Lubricating type

Pressure delivery type

Oil pump type Volume of lubricating oil

Gear type L (qts)

Oil filter type

10 (10.6) Full flow filter (cartridge type)

Oil cooling type

Built-in-type, water cooling

Cooling system Cooling type

Water cooling type

Radiator type

Corrugated fin (pressure type)

Water pump type

Centrifugal, belt drive type

Thermostat type

Wax-type units

Thermostat valve-opening temperature Volume of coolant

°C (°F)

85 (185)

L (qts)

10 (10.6) (incl. radiator)

Fuel system Injection pump type

Fuel supply pump common rail type

Injection nozzle type

Electronic control injector 6-hole

Fuel pump type

Into the fuel tank type

Charging system Generator type Power output

AC type V-A

Regulator type

IC

Starting system

Engage magnet type

Starter type Power output Preheat system type

24 - 50 , 24 - 80

Reduction type V-kW

24 - 4.0, 24 - 4.5 Glow plug

ENGINE MECHANICAL (4JJ1) Item Glow plug standard voltage/electric current Special Tools Illustration

Tool Number/ De Description

5-8840-2822-0 Valve clearance adjust nut wrench 5884028220

5-8840-2675-0 Compression gauge

5-8840-2815-0 Compression gauge adapter

Engine model 4JJ1 V-A

23 - 3.5

6A-13

6A-14


Engine Assembly Removal NOTE: Instructions for engine removal • Be sure to lock lock the vehicle's vehicle's wheels wheels in a fixed fixed position. • Use an an engine engine hoisting hoisting attachment attachment that that can can adequately sustain the engine's weight. • Do not get underneath underneath the engine engine while while the the engine engine is being lifted. • Do not insert fingers fingers into any any location location where where they they may be caught. 1. Detach Detach the negative negative cable cable from from the battery battery.. 2. Drai Drain n the coo coola lant. nt. 3. Remove Remove the starte starter. r. 4. Remove Remove the the front front exhaust exhaust pipe pipe.. 7. Remove Remove the air air intake intake pipe pipe with with the hoses. • Disconnect Disconnect the hose hose from from the intercooler intercooler side. • Remove the air air intake intake pipe pipe with with the hoses from the turbocharger side. • Do not disconnect disconnect the the hoses from the the air intake intake pipe.

5. Remove the transmiss transmission ion assembly assembly.. • Refer Refer to Tran Transmi smissi ssion on sectio section. n. 6. Disconn Disconnect ect the the air intake intake hose. hose. • Disconnect Disconnect the the PCV PCV hose (1) from from the air intake intake hose (2). • Disconnect Disconnect the air air intake intake hose hose (2) (2) from the turbocharger side. • Do not disconnect disconnect the the air intake intake hose from the the air cleaner side.

8. Disconnect Disconnect the the two connectors connectors from from the ECM. 9. Remove Remove the air air intake intake pipe pipe with with the hoses. • Discon Disconnect nect the the connec connector tor from from the boost boost sensor. • Disconnect Disconnect the hose hose from from the intercooler intercooler side. • Remove the air air intake intake pipe pipe with with the hoses from the intake throttle valve. • Do not disconnect disconnect the the hoses from the the air intake intake pipe.


6A-15

NOTE: The bracket on the right side of the engine(1) is used as an engine hanger when the engine is lifted.

10. Disconnect Disconnect the radiator radiator upper upper hose. • Disconnect Disconnect the hose hose from the the radiator radiator side. 11. Detach Detach the the A/C compressor compressor.. • Detach Detach the the A/C compre compresso ssorr drive drive belt. belt. • Detach Detach the the compre compresso ssorr compressor bracket.

from from

the

16. Remove the cooling cooling fan assembly assembly.. A/C A/C

• Remove Remove the the cooling cooling fan fan and the fan fan clutch clutch.. 17. Disconnect Disconnect the power steering steering pump. pump.

• Fix the the compresso compressorr and hose in in an appropri appropriate ate position with wire etc.

• Disconnect Disconnect the power power steerin steering g pump with its hose attached from the engine side.

12. Disconnect Disconnect the the engine engine ground ground cable from the the frame.

• Fix the the pump pump and hose hose in in an approp appropriat riate e position with wire etc.

13. Discon Disconnec nectt the vacuum vacuum hose. hose. • Disconnect Disconnect the hose(1) hose(1) from the vacuum vacuum pump side(2).

18. Disconnect Disconnect the the heater heater hose (1) from from the heater pipe (2).

19. Instal Installl an engine engine hanger hanger (1). (1). 14. Disconnect Disconnect the radiator radiator lower hose. • Discon Disconnec nectt the hose hose from the the engine engine side. side. 15. Disconnect Disconnect the fan fan guide guide bracket. • Remo Remove ve the the bol bolts ts(3 (3). ).

Special tool Engine Hanger: 5-8840-2823-0 • Install Install the engine engine hanger hanger to to the rear rear left left side of the engine.

6A-16


NOTE: The FR engine hanger is not used for this engine.

• Fit hoist hoist wire wire to the the engine engine hanger hanger and hoist hoist the engine. • Operate Operate the hoist and move move the engine into the the installation position. 2. Fit the engine engine mounts. mounts. • Align the engine engine mounts mounts to the engine engine mounting mounting cross member holes, and once fitted , tighten to the specified torque. Tightening torque: Front independent suspension model 122 N⋅m (12.4 kg ⋅m / 90 lb ft)

Front rigid suspension model 94 N⋅m (9.6 kg⋅m / 68 lb ft) 3. Fit Fit the the fuel fuel hos hose. e.

20. 20. Engine Engine Moun Mounts ts • Before removing removing the engine engine mounts, mounts, lift the engine with a hoist. • Remove Remove the the mounting mounting nuts nuts from from side side of the the engine mount's chassis. 21. Disconn Disconnect ect the the fuel fuel hose. hose. • Disconnect Disconnect the hose hose from from fuel fuel filter filter side. side.

4. Fit the the heater heater hose to the heater pipe. 5. Fit the the power power steeri steering ng pump. pump. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft) 6. Fit the the radiat radiator or lower lower hose hose.. 7. Fit the vacuum vacuum hose. hose. • Connec Connectt the hose(1) hose(1) to to the vacuu vacuum m pump (2). (2).

22. 22. Engi Engine ne Asse Assemb mbly ly • Operate the hoist hoist slowly slowly,, and raise raise the engine until it is above and protruding from the chassis frame.

Installation 1. Fit the the engin engine e assembl assembly y.


6A-17

11. Fit the fan guide. guide.

8. Attach the engine engine earth earth cable cable to the frame. frame. 9. Fit the the A/C A/C compre compresso ssor. r. • Fit the the A/C compressor compressor,, and tighten tighten to the specified torque. Tightening torque: 51 N ⋅m (5.2 kg⋅m / 38 lb ft) • Attach Attach the drive belt, and adjust the belt's belt's tension with the tension pulley adjustment belt. • Refer to "Drive "Drive Belt" Belt" section section in the "Cooling "Cooling System" chapter for details concerning belt tension adjustment.

12. Fit the the radiat radiator or upper upper hose. hose. 13. Fit the the air intak intake e pipe and and hose. hose. • Fit the the pipe and the the hose between between the intake intake throttle valve and the int ercooler. • Connect Connect the the boost boost sensor connector connector.. • Use new clips. clips. Tighten Tighten the clip clip according according to to the marking. Tightening torque: 6 N⋅m (0.6 kg⋅m / 52 lb in)

• By hand, hand, press press the center center part part of the the belt belt with a force of 98N (10kg / 142psi), and check with a scale that the degree of deflection is within the specified range. Also, check that the belt is not damaged. A/C Compressor Belt Degree of Deflection: (5.5 - 7.3 mm / 0.2165 - 0.2874 in) (new belt) (7.6 - 9.2 mm / 0.2992 - 0.3622 in) (used belt) • After adjusting adjusting belt tension, tension, tighten tighten the tension tension pulley's lock nut. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft) 10. Fit the cooling cooling fan Assembly Assembly. • Tighten Tighten the the fan clutch clutch to to the fan fan pulley pulley at the the specified torque. Tightening torque: 8 N ⋅m (0.8 kg⋅m / 69 lb in)

14. Connect the ECM ECM harness harness connecto connector. r. 15. Fit the the air intak intake e pipe and and hose. hose. • Fit the the pipe pipe and and the the hose hose betwee between n the turbocharger and the int ercooler. • Connect Connect the the boost boost sensor connector connector.. • Use new clips. clips. Tighten Tighten the clip clip according according to to the marking. Tightening torque: 6 N⋅m (0.6 kg⋅m / 52 lb in)

6A-18

ENGINE MECHANICAL (4JJ1) 17. Remove Remove the the engine engine hanger hanger.. • Remove the engine engine hanger from the the rear rear left left side of the engine. 18. Fit the transmi transmission ssion assembly assembly.. • Refer Refer to to remova removall "TRANSMISSION".

proce procedure dure

19. Install Install the front front exhaust exhaust pipe pipe and gaskets gaskets.. a. Tighte Tighten n tempora temporarily rily.. b. Tighte Tighten n turboch turbocharge argerr side. side. Tightening torque: 67 N ⋅m (6.8 kg⋅m / 48 lb ft) c. Tighte ighten n the the clam clamp. p. Tightening torque: 41 N ⋅m (4.2 kg⋅m / 30 lb ft) d. Tighte Tighten n DPD side. side. Tightening torque: 67 N ⋅m (6.8 kg⋅m / 49 lb ft) 16. Fit the the air air intake intake hose hose (2). (2). • Fit the the hose hose between between the the air clea cleaner ner and and turbocharger. • Fit the the PCV hose hose (1) (1) to the air inta intake ke hose. hose.

20. Fit the starte starter. r. Tightening torque:127 N⋅m (13.0 kg⋅m / 94 lb ft) 21. Repleni Replenish sh the the coolan coolant. t. 22. Reattach Reattach the negative negative cable cable to the battery battery..

Special Tools Illustration

Tool Nu Number/ De Description

5-8840-2823-0 Engine Hanger

5884028230

for


Engine Mount Components

Legend 1. Engi Engine ne Mou Mount nt

Removal 1. Remove Remove the engin engine e assembly assembly.. • Refer Refer to “Engi “Engine ne Assemb Assembly“. ly“. 2. Remove Remove the the engi engine ne mount mount.. • Before removing removing the the engine engine mount, hang the engine with a hoist. • Remove Remove the nuts fastened to the engine foot and engine mount. • Remove Remove the nuts fastened fastened to the engine engine mount mount on the chassis frame side. • Hoist the engine engine assembly assembly slightly slightly to remove remove the engine mount.

6A-19

6A-20


Installation 1. Install Install the engine engine mount mount and tighten tighten up up with the the specified torque. The nuts on the chassis frame side Tightening torque: Front independent suspension model 122 N⋅m (12.4 kg⋅m / 90 lb ft)

Front rigid suspension model 94 N⋅m (9.6 kg⋅m / 68 lb ft) The nuts on the engine foot side Tightening torque: 82 N ⋅m (8.4 kg⋅m / 61 lb ft) 2. Install Install the engine engine assembly assembly.. • Refer Refer to to “Engin “Engine e Assem Assembly bly“. “.

Torque Specifications


Cylinder Head Cover Components

Legend 1. Oil Oil Fil Fille lerr Cap Cap 2. Oil Filler Filler Cap Gasket Gasket 3. Engi Engine ne Cov Cover er 4. Cylind Cylinder er Head Head Cover Cover 5. Bolt

Removal 1. Remove Remove the the engine engine cover cover.. • Remove Remove the oil filler filler cap before before removin removing g the engine cover.

6. 7. 8. 9.

Head Head Cover Cover Mounti Mounting ng Rubber Rubber Oil Oil Sea Seal Head Head Cove Coverr Gaske Gaskett Nut

6A-21

6A-22

ENGINE MECHANICAL (4JJ1) NOTE: Do not reuse the leak-off hose clips (1).

2. Remove the fuel injector injector connector connector (2) and the leak-off hose(1). 3. Discon Disconnec nectt the blow-b blow-by y hose. hose. 4. Remove Remove the cylinder cylinder head head cover cover..

5. Remove Remove the nozzle nozzle seal seal cover cover from the cylinder cylinder head cover. • Remove Remove from from the lower lower side side of cylind cylinder er head head cover. 6. Remove Remove the the cam end end gasket gasket (1). (1). • Remove the liquid liquid gasket gasket that has has adhered adhered to cylinder head completely.


6A-23

• Apply Apply attachi attaching ng cam end end gasket. gasket. Apply Apply the liquid gasket (ThreeBond TB-1207B or equivalent).

Installation 1. Install Install the the nozzle nozzle seal seal cover cover.. • Insert from the lever side of cylinder cylinder head cover. • Apply soapy water or engine engine oil oil to the surface surface of cylinder head cover side. • Insert the nozzle nozzle seal seal cover cover as far far as it will will go. 2. Instal Installl the cam cam end end gasket. gasket. • Apply the liquid gasket gasket (ThreeBond (ThreeBond TB-1207B TB-1207B or equivalent) and mount.

Legend 1. 3.0 - 5.0 5.0 mm (0.1 (0.118 - 0.197 0.197 in) in) 2. 3.0 - 5.0 5.0 mm (0.1 (0.118 - 0.197 0.197 in) in) 3. Install Install the the cylinder cylinder head cover. cover. • Tighten Tighten the bolts and a nut nut in order order shown shown in the illustration. Tightening torque: 10 N ⋅m (1.0 kg⋅m / 87 lb in)

4. Install Install the the blowblow-by by hose. hose. Legend 1. Cam Cam End Gask Gasket et 2. Apply Apply The The Liqui Liquid d Gaske Gaskett 3. 2.0 to 3.0 3.0 mm (0.079 (0.079 to 0.118 0.118 in)

5. Install Install the leak-of leak-offf hose and and the fuel fuel injector injector connector. 6. Instal Installl the engin engine e cover cover. • Install Install the oil oil filler filler cap after install installing ing the the engine engine cover.

6A-24


Intake Manifold Components

Legend 1. Intake Intake Manif Manifold old Gask Gasket et 2. Inta Intake ke Mani Manifo fold ld 3. EGR Valv Valve e Assembl Assembly y Gasket Gasket

Removal 1. Remove Remove the the engine engine cove coverr. • Remove the oil oil filler filler cap before removing removing the engine cover.

4. EGR Valve alve Assem Assembly bly 5. Intake Intake Throttl Throttle e Assembly Assembly Gasket Gasket 6. Intake Intake Throt Throttle tle Assem Assembly bly


6A-25

6. Remove the the intake intake throttle throttle connecto connector(2) r(2) and the EGR valve connector(1).

2. Remove Remove the air air intake intake pipe pipe with the hoses. hoses. • Discon Disconnec nectt the connec connector tor from from the boos boostt sensor.

7. Remove the injection injection pipe (No.1 (No.1 to 4).

• Disconnect Disconnect the hose hose from from the intercooler intercooler side. • Remove Remove the air intake intake pipe with with the the hoses hoses from from the intake throttle valve. • Do not not disconnect disconnect the hoses hoses from from the air intake intake pipe.

8. Remove the intake intake manifold manifold and gasket. gasket. • Remove the intake intake manifold manifold with with the the EGR valve and the intake throttle. 9. Remove the EGR EGR valve valve (2) from the the intake intake manifold (1). 3. Remove Remove the the A/C compre compresso ssorr. • Remo Remove ve the the A/C belt belt.. • Discon Disconnec nectt connector.

the

A/C

compr compress essor or

4. Remove Remove the A/C compress compressor or bracket. bracket. 5. Remove Remove the engine engine oil oil level level guide guide tube. tube.

harness harness

6A-26


10. Remove the intake intake throttle throttle (3) from from the intake intake manifold (1).

6. Install Install the the engine engine level level guide tube. 7. Install Install the the A/C compressor compressor bracket. bracket. 8. Instal Installl the A/C compres compressor sor.. • Inst Instal alll the the A/C A/C belt belt.. 9. Install Install the intake intake air pipe and and hose. hose. • Fit the the pipe and the hose between between the intake intake throttle valve and the intercooler. • Use new new clips. clips. Tighten Tighten the clip clip according according to the the marking. Tightening torque: 6 N ⋅m (0.6 kg⋅m / 52 lb in)

Installation 1. Install Install the EGR EGR valve valve to the intake intake manifold. manifold. Tightening torque: 27 N ⋅m (2.8 kg⋅m / 20 lb ft) 2. Install Install the intake intake throttle throttle to the intake intake manifold manifold.. Tightening torque: 10 N ⋅m (1.0 kg⋅m / 87 lb in) 3. Insta Install ll the intake intake manif manifold. old. a. Install Install the gasket gasket and the the intake intake manifold manifold and tighten tempor arily. arily. b. Tighten Tighten the bolts and nuts nuts in the the order described in the drawing. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft)

4. Install Install the injection injection pipe pipe (No.1 (No.1 to 4). 4). 5. Connect Connect the intake intake throttle throttle connector connector and and EGR valve connector.

10. Connect Connect the boost sensor connector connector.. 11. Install Install the engine engine cover. cover. • Install Install the oil oil filler filler cap after after instal installing ling the the engine engine cover.

ENGINE MECHANICAL (4JJ1) Torque Specifications

6A-27

6A-28


Turbocharger Service Precautions • The turbochar turbocharger ger is a high precision precision componen componentt and cannot be disassembled (spins at approx. 100,000 rpm). If any damage whatsoever, such as dents and scratches, is discovered on the turbo charger's fins or housing, the entire turbo charger must be replaced.

• While carrying carrying out maintenance, maintenance, take appropriate appropriate measures to prevent foreign materials from entering into the turbine housing, compressor housing, or oil inlets/outlets. • After servicing servicing the the turbocharge turbocharger, r, pour clean clean engine engine oil (3-5 cc) into the pipe connecting port before installing the oil pipe.

Components

Legend 1. Turbo Turbochar charger ger Assembl Assembly y 2. Oil Oil Fee Feed d Pipe Pipe 3. Turb Turboc ochar harger ger Duct Duct 4. Exhau Exhaust st Adapt Adaptor or

5. Water ater Fee Feed d Pipe Pipe 6. Water ater Ret Retur urn n Pipe Pipe 7. Oil Oil Ret Retur urn n Pip Pipe e

ENGINE MECHANICAL (4JJ1) Removal

6A-29

6. Remove Remove the the heat prote protecto ctorr (1).

1. Drain Drain the coolant coolant.. 2. Remove the front front exhaust exhaust pipe and and exhaust exhaust brake. brake.

7. Remove Remove the the oil oil feed feed pipe. pipe. 8. Remove Remove the the water water return return pipe. pipe. 9. Remove Remove the the oil oil return return pipe pipe..

3. Remove Remove the the followi following ng parts. parts.

10. Remove the turbochar turbocharger ger assembly assembly from the the exhaust manifold.

a. Inle Inlett hose hose (5) (5) b. PCV PCV hos hose e (2) (2) c. Air Air duc ductt (1) (1) d. Right Right side side nois noise e cover cover (6) (6) e. Fan guide guide bracke brackett (3) (3) f. Water Water feed pipe pipe and and VGS vacuum vacuum hose hose (4)

Inspection Visual and noise inspection 4. Remove Remove the the AC genera generator tor.. • Discon Disconnec nectt the generat generator or termina terminals. ls. 5. Remove the turbocharger.

exhaust exhaust

adapter

• Remove Remove the the adapt adapter's er's brack bracket et (3). (3). • Remove Remove the exhaus exhaustt adapte adapterr (2). (2).

from

the

The turbine housing outlet's adaptor and the compressor housing inlet's rubber hose must be removed before a visual inspection on the turbocharger can take place. The turbocharger can not be disassembled or adjusted. • Check the turbocha turbocharger rger for for abnormal abnormal noise during operation.

6A-30


• Check the compressor compressor cover cover and and turbine turbine housing housing for scratches and/or cracks caused by contact with the fin. • Check the inner inner surface surface of the the housing housing for for oil leakage. • Check the turbine turbine exhaust exhaust port port for excessive excessive carbon deposits that may interfere with the fin. • Turn the turbine turbine shaft shaft by by hand hand and check check for for dragging or sticking conditions. • Move the the shaft shaft and check check for for excessive excessive clearance clearance in axial and radial directions. Axial play on the wheel shaft • Use a dial gauge gauge to measure measure the axial axial play play on the wheel shaft. • Alternately Alternately,, apply a force of of approximate approximately ly 12 N (1.2 kg / 2.6 lb) to the compressor wheel end. Axial Play

mm (in) Standard Limit

0.03 - 0.08 (0.0012-0.0031) 0.09(0.0035)

Legend 1. Oil Oil Outl Outlet et Port Port 2. Oil Oil Inl Inlet et Port Port Waste gate operation (EURO 3 Specification) 1. Remove Remove the hose hose from the waste gate gate actuator actuator.. 2. Install Install the pressure pressure gauge gauge (general (general tool). Refer Refer to the illustration.

Clearance between wheel shaft and bearing • Use a dial gauge to measure measure the the clearance clearance between wheel shaft and bearing. Clearance

mm (in) Standard Limit

0.08 - 0.1 (0.0031-0.0039) 0.17(0.0067)

Legend 1. Waste Waste Gate Actuato Actuator r 2. Waste aste Gat Gate e Hose Hose 3. Pressure Pressure Gauge Gauge (General (General Tool) 3. Use the the pressure pressure gauge pump to apply pressure pressure (load) to the waste gate actuator (the engine must be off).


6A-31

4. Note the the pressure pressure at which which the control control rod moves 2 mm (0.078 in). This pressure must be within the specified limit.

Control rod pressure range:

kPa (mmHg / psi)

143 - 154 (1068 - 1158 / 20.7 - 22.4) Actuator operation (EURO 4 Specification) 1. Install Install a vacuum vacuum pump (2) to the the actuator actuator (1) as shown in the illustration.

2. Install Install the the oil oil return return pipe. pipe. • Install Install the O-rings into both both sides sides of the oil oil return pipe, and tighten the bolt to the specified torque. Tightening torque Turbocharger side: Crank case side:

10 N⋅m (1.0 kg⋅m / 87 lb ⋅in) 25 N⋅m (2.5 kg⋅m / 18 lb ⋅ft)

3. Install Install the the water water return return pipe. pipe. • Tighten Tighten the water return pipe's eye bolt bolt to the specified torque. 2. Operate Operate the vacuum pump and and apply apply vacuum vacuum pressure to the actuator.

Tighte Tightenin ning g torque torque:: 23 N⋅m (2.3 kg⋅m / 17 lb ⋅ft) 4. Install Install the the oil oil feed feed pipe. pipe.

Working vacuum pressure

kPa (mmHg / psi)

Refer eferen ence ce

44 (330 (330 / 6.38 6.38))

3. Place a vernier caliper caliper on the end end of the the control rod of actuator. Release the vacuum pressure and check the control rod moves. Measure the length of the control rod moving.

• Install Install the eye eye bolt to the oil feed feed pipe on the top top of turbocharger, and tighten the bolt to the specified torque. Tighte Tightenin ning g torque torque:: 39 N⋅m (4.0 kg⋅m / 29 lb ⋅ft) 5. Install Install the exhaust exhaust adapter adapter to the turbocharge turbocharger, r, and tighten to the specified torque. Tighte Tightenin ning g torque torque:: 27 N⋅m (2.8kg⋅m / 20 lb ⋅ft) 6. Fit the heat heat protector protector and and tighten tighten with the bolt. Tighte Tightenin ning g torque torque:: 10 N⋅m (1.0 kg⋅m / 87 lb ⋅in)

Standard length

7 mm (0.28 in)

Installation 1. Install Install the the turbocharg turbocharger er assembly assembly.. • Install Install the gaskets gaskets and turbocha turbocharger rger assembly assembly,, and tighten to the specified torque. Tightening torque Nut 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft) Bolt 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)

6A-32

ENGINE MECHANICAL (4JJ1) c. Tighte ighten n the the clam clamp. p. Tightening torque: 41 N ⋅m (4.2 kg⋅m / 30 lb ft) d. Tight Tighten en DPD DPD sid side. e. Tightening torque: 67 N ⋅m (6.8 kg⋅m / 49 lb ft) 10. Repleni Replenish sh the the coolan coolant. t.

Legend 1. Heat Heat Protector Protector;; Turboch Turbocharg arger er 2. Exhaus Exhaustt Adap Adapte terr 3. Exhaust Exhaust Adapter Adapter Bracket Bracket 7. Instal Installl the AC gener generato atorr. 8. Instal Installl the followi following ng parts. parts. a. Water feed pipe pipe and VGS vacuum vacuum hose hose (4) b. Fan guide guide bracket bracket (3) c. Right Right side side noise noise cover cover (6) (6) d. Air Air duc ductt (1) (1) e. PCV PCV hos hose e (2) (2) f. Inl Inlet hose hose (5) (5)

9. Install Install the front front exhaust exhaust pipe pipe and gaskets. gaskets. a. Tighte Tighten n temporar temporarily ily.. b. Tighte Tighten n turboch turbocharg arger er side. side. Tightening torque: 67 N ⋅m (6.8 kg⋅m / 48 lb ft)

ENGINE MECHANICAL (4JJ1) Torque specifications

6A-33

6A-34


Exhaust Manifold Components

Legend 1. EGR EGR Cool Cooler er 2. Heat Heat Protect Protector; or; EGR EGR Coole Cooler r 3. Heat Heat Protecto Protector; r; Exhaust Exhaust Manifo Manifold ld 4. Gask Gasket et

Removal 1. Drai Drain n the coo coola lant. nt. 2. Remove the turbocha turbocharger rger assembl assembly y. Refer to "Turbocharger".

5. 6. 7. 8.

Exha Exhaust ust Mani Manifo fold ld Gask asket Turbocha urbocharger rger Assembl Assembly y Gask asket

ENGINE MECHANICAL (4JJ1) 3. Remove the EGR cooler heat protecto protector. r.

Limit

6A-35

0.5 (0.02)

NOTE: If the plane surface exceeds the limit, replace it.

4. Remove Remove the the EGR EGR coole cooler. r. • Discon Disconnec nectt the rubber rubber hoses hoses of of the water water pipe(IN, OUT) from the EGR cooler. • Remove Remove the the EGR cooler cooler and and the gaske gaskett from from the exhaust manifold. 5. Remove the exhaust exhaust manifold manifold heat heat protector protector..

• Check a crack crack in the the exhaust exhaust manifold manifold visually visually.. Carefully inspect the turbocharger for abrasion and/or excessive wear. Make any necessary adjustments, repairs, and/or part replacements.

Installation 1. Install Install the the exhaust exhaust manif manifold old.. • Put the gasket in to instal installl the exhaust exhaust manifold. manifold. • Tighten Tighten in order described described in in the drawing. drawing. Tightening torque: 52 N ⋅m (5.3 kg⋅m / 38 lb ft)

6. Remove Remove the the exhaust exhaust manif manifold. old. • Remove Remove the the exhaus exhaustt manifol manifold d and gasket gasket..

Inspection • Inspec Inspectio tion n of the exhau exhaust st manifo manifold. ld. Inspect the plane surface of the plane on which the manifold and the cylinder head are to be installed. 2. Install Install the exhaust exhaust manifold manifold heat protector protector.. Manifold installation plane surface Standard

mm (in)

0.3 (0.01) or lower

Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18lb ft) 3. Instal Installl the EGR EGR cooler cooler..

6A-36


a. Put the gasket gasket in in to install install the EGR cooler cooler.. b. Temporary emporary tighteni tightening ng order order.. 1 → 2 → 3 → 4 → 5 → 6 c. Fully Fully tighte tightenin ning g order order.. 3 → 4 → 5 → 1 → 2 → 6 Tightening torque Bolt, Nut (1 - 5) : 27 N ⋅m (2.8 kg ⋅m / 20 lb ft) Bolt (6) : 52 N ⋅m (5.3 kg⋅m / 38 lb ft)

4. Connect Connect the rubber rubber hoses hoses to the water water pipe(IN, pipe(IN, OUT) of the EGR cooler. 5. Install Install the EGR cooler cooler heat heat protector protector.. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft) 6. Instal Installl the turbochar turbocharger ger.. Refer to “Turbocharger”. 7. Replen Replenish ish the coolant coolant..


6A-37

6A-38


Timing Gear Train Components

Legend 1. Oil Oil Pum Pump p Gea Gear r 2. Cran Cranks ksha haft ft Gear Gear 3. Idle Idle Gear Gear D 4. Exhaust Exhaust Camsha Camshaft ft Gear 5. Intake Intake Camsha Camshaft ft Gear 6. Idle Idle Gear Gear D Sproc Sprocket ket 7. Timi Timing ng Chai Chain n

Removal 1. Drain Drain the the engine engine coolant coolant.. 2. Remove Remove the the radiator radiator upper upper hose hose..

8. 9. 10. 10. 11. 12. 13. 13.

Injecti Injection on Pump Pump Sproc Sprocket ket Injecti Injection on Pump Gear Gear Idle Idle Gear Gear A Vacuum acuum Pump Pump Gear Gear Power Power Steeri Steering ng Oil Pump Pump Gear Gear Idle Idle Gear Gear C

ENGINE MECHANICAL (4JJ1) 3. Remove Remove the the fan guid guide e bracket bracket..

Legend 1. Fan Guide Guide Bracket Bracket(RH (RH)) 2. Fan Guide Guide Bracket Bracket(LH (LH)) 3. Bolt

9. Remove the cover cover of the the gear gear case cover(1). cover(1).

10. Remove Remove the gear gear case case cover cover.

4. Remove Remove the cooling cooling fan fan and fan pulley. pulley.

11. Install Install the M6 M6 bolt to the idle gear A.

5. Remove Remove the A/C compressor compressor drive drive belt belt and fan fan belt. 6. Remove Remove the the crank crank pulley pulley.. NOTE: Do not reuse the crank pulley bolt and washer. 7. Remove Remove the power power steering steering pump with with hose. hose. 8. Remove Remove the the vacuu vacuum m pump. pump. • Remove Remove the the vacuum vacuum pipe pipe bracket bracket and vacuu vacuum m pipe. • Remove Remove the oil pipe pipe (feed (feed side and return return side) side) of vacuum pump.

6A-39

6A-40


12. Remove the idle idle gear A and idle gear A flange, flange, idle idle gear A shaft.

13. Remove the idle gear C and and idle gear gear C shaft. shaft.

14. Remove Remove the the crankshaf crankshaftt gear gear..

Disassembly 1. Remove Remove the scissor scissor gear assembl assembly y. • Clamp the vise. vise. Insert Insert soft metal protectors protectors (aluminum) between the vise and component. Use snap ring pliers to remove the scissor gear assembly.

Legend 1. Snap Snap Ring Ring 2. SubSub-ge gear ar 3. Spring ing 4. Idle dle Ge Gear A

Reassembly 1. Install Install the scissor scissor gear assembly assembly..

ENGINE MECHANICAL (4JJ1) • Clamp the vise. vise. Insert Insert soft soft metal metal protectors protectors (aluminum) between the vise and component. Press against the pin on the left side of the idle gear A spring to make a gap on the right side of the spring. Push the spring into place. • Align the sub sub gear pin with with the the hole in the right side of the idle gear A spring. Press the subgear into place.

6A-41

• If the the measurement measurement exceeds exceeds the limit, replace either the idle gear o r the thrust collar.

End clearance of the idle gear

mm (in)

Standard

0.080 - 0.155 (0.003 - 0.006)

Limit

0.20 (0.008)

• Measure an end end clearance clearance of the the idle idle gear gear before removing the idle gear B. 3. External diameter diameter of the the idle idle gear shaft. shaft. • Use a micro micromet meter er to measu measure re an externa externall diameter of each idle gear shaft. • If the the measurement measurement exceeds exceeds the limit, replace replace the shaft.

Extern External al diam diamete eterr of of the the idle idle gear gear A sha shaft ft Standa ndard

44. 44.950 - 44.9 4.975 (1 (1.7697 697 - 1.7 1.7707)

Limit

44.80 (1.764)

Extern External al dia diame mete terr of the the idle idle gea gearr C shaf shaftt Legend 1. Snap Snap Ring Ring 2. SubSub-ge gear ar 3. Spring ing 4. Idle Idle Gea Gear A

mm (in) (in)

mm (in) (in)

Standa ndard

24. 24.959 - 24 24.980 (0 (0.9826 - 0.9 0.9835 835)

Limit

24.80 (0.976)

• Use snap snap ring ring pliers pliers to snugly install install the snap ring.

Inspection 1. Measurement Measurement of idle idle gear backlash backlash • Apply a dial dial gauge gauge on the the teeth teeth of the idle idle gear gear to be measured and move the gear to right and left lightly to read how much the dial gauge shook (never fail to fix the gear). • If the the measurement measurement exceeds the limit, limit, replace replace the idle gear.

Backlash of the idle gear

mm (in)

Standard

0.10 - 0.17 (0.004 - 0.006)

Limit

0.30 (0.01)

• Measur Measure e backlas backlash h of the idle idle gear gear before before removing the idle gear A. 2. Measurement Measurement of end clearance clearance of of the idle idle gear. gear. • Insert a thickness thickness gauge between between the idle gear and the thrust collar to measure a clearance.

4. Clearance Clearance between between the idle gear gear and the the idle gear shaft • Measur Measure e an inside inside diamet diameter er of the the idle gear gear bush to calculate a clearance between the idle gear and the idle gear shaft.

6A-42


• If the the measurement measurement exceeds exceeds the limit, replace replace either the idle gear or the shaft.

Clearance between the idle gear A and the shaft

mm (in)

Standard

0.025 - 0.075 (0.0010 - 0.0030)

Limit

0.200 (0.0079)

Clearance between the idle gear C and the shaft

• Apply engine oil to the bolt bolt screw screw thread thread and seat, and temporarily tighten together with the flange (tighten fully in later process).

mm (in)

Standard

0.020 - 0.062 (0.0008 - 0.0024)

Limit

0.200 (0.0079)

3. Instal Installl the the idle idle gear gear A. A. 4. Tight Tighten en sub gear gear settin setting g bolt. bolt. • Use the the M6 bolts and lever lever to to turn sub gear gear to right direction until it aligns with the M6 bolt hole between idle gear A and sub gear. • Tighten Tighten the the M6 bolt to a suitab suitable le torque torque to prevent the sub gear from moving.

Installation 1. Install Install the crankshaft crankshaft gear. gear. 2. Instal Installl the the idle idle gear gear C. C. • Apply engine engine oil oil over over the part where the gear gear of the idle gear shaft is to be put together.

• Apply engine engine oil over over the part where the gear gear of the idle gear shaft is to be put together. • Install Install the idle gear A and idle idle gear A flange, flange, idle gear A shaft at the position shown in the figure. • Apply engine oil to the bolt bolt screw screw thread thread and seat, and temporarily tighten together with the flange (tighten fully in later process).

ENGINE MECHANICAL (4JJ1) • Align the oil oil hole hole of the the cylinder cylinder body (2) (2) with with the oil hole of the idle gear A shaft (3). Install the flange so that the front mark (1) face toward the front.

6A-43

• Attach, Attach, aligning aligning with with the gear crank: crank: idle idle A and and timing mark.

5. Tighten Tighten the bolts bolts of of idle gear gear A and idle idle gear gear C to the specified torque. Tightening torque: idle gear A: 32 N ⋅m (3.3 kg⋅m / 24 lb ft) idle gear C: 59 N ⋅m (6.0 kg⋅m / 44 lb ft)

6A-44


Legend 1. Idle Idle Gear Gear A Bol Boltt 2. Idle Idle Gear Gear C Bolt Bolt 6. Remove the M6 bolt from from the idle gear gear A. 7. Instal Installl the gear gear case case cover cover. • Apply the liquid liquid gasket (ThreeBond (ThreeBond TB-1207B or equivalent).

8. Instal Installl the vacuum vacuum pump pump.. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft) • Install Install the oil pipe pipe (feed (feed side and return return side) side) of vacuum pump. • Install Install the the vacuum vacuum pipe pipe bracket bracket and and vacuum vacuum pipe. 9. Install Install the the power power steering steering pump. pump. • Tighten Tighten the the nut nut to the specifi specified ed torque. torque. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft) 10. Install Install the cover of the gear case case cover cover 11. Install Install the the crank crank pulley pulley.. Tightening torque: 294 N⋅m (30 kg⋅m / 217 lb ft) 12. Install Install the A/C A/C compressor compressor drive drive belt belt and fan belt.Refer to drive belt tension check procedure for Heating and air conditioning and Engine cooling in this manual. 13. Instal Installl the cool cooling ing fan. fan. 14. Instal Installl the fan guide guide bracket bracket.. 15. Install Install the the radiator radiator upper hose. 16. Repleni Replenish sh the engine engine coola coolant. nt.

Legend 1. Apply Apply the the liqui liquid d gasket gasket • Install Install the gasket gasket in slot slot of the the gear case cover cover.. • Tighten Tighten the the bolts bolts to to the specified specified torque. torque. Tightening torque: 8 N ⋅m (0.8 kg ⋅m / 69 lb in)


6A-45

6A-46


Camshaft Assembly Components

Legend 1. Snap Snap Ring ing 2. Sub Sub Ge Gear 3. Knoc Knock k Pin Pin 4. Damp Damper er Sprin pring g

Removal 1. Rotate Rotate the crankshaf crankshaftt to make make the No.1 No.1 cylinder cylinder compression TDC. • Check Check TDC TDC usin using g a mirror mirror etc. etc.

5. Camsha Camshaft ft Gear Gear and Camsh Camshaft aft 6. Cam Cap 7. Bolt


6A-47

4. Remove Remove the the baffle baffle plat plate. e.

Legend 1. Cranks Crankshaf haftt Damper Damper Pull Pulley ey 2. Mirror ror 3. TDC Ma Mark

Legend 1. Baff Baffle le Pla Plate te 5. Remove the camshaft camshaft bearing bearing cap cap and camshaf camshaft. t.

2. Remove Remove the cylinder cylinder head head cover cover.. Refer to "Cylinder Head Cover".

• Check the engrave engraved d making making on the camshaf camshaftt bearing caps.

3. Install Install the M5 M5 lock bolt bolt of fixing fixing sub sub gear. gear.

1E 2E 3E 4E

1I

5E 2I 3I 4I 5I

RTW56ASH018401

6A-48


2. Remove Remove the the camshaf camshaftt gear. gear.

Disassembly 1. Remove the sub gear gear assembly assembly..

• Use a press and socket socket to remove remove the the camshaft camshaft gear.

• Clamp the camshaft camshaft in a vise. Insert soft metal protectors (aluminum) between the vise surfaces and the camshaft.

1

• Use a camshaft camshaft gear gear tool (5-8840-2591-0 (5-8840-2591-0)) to turn sub gear to right direction to remove the M5 bolt.

2 3

RTW56ASH006501

Legend 1. Press 2. Socke cket 3. Cams Camsha haft ft Gear Gear 3. Remove Remove the dowel dowel pin. pin. 4. Inspect Inspect the camshaft camshaft visually visually.. • Use snap snap ring ring pliers pliers to remove the scissor scissor gear assembly. NOTE: Take care not to damage the camshaft cams and journals.

ENGINE MECHANICAL (4JJ1) • Check if the the journal journal and cam cam parts parts of of the the camshaft are worn or damaged, if so, replace it.

6A-49

• Use a micrometer micrometer to to measure measure the the height height of the the cam lobe. • If the height height of of the cam cam lobe is at the the limit limit or less, replace the camshaft.

Height of the cam lobe

mm (in) Inlet

Exhaust

Standard

40.6 (1.60)

40.6 (1.60)

Limit

39.6 (1.56)

39.6 (1.56)

5. Inspect Inspect an end end clearance clearance of the camshaft. camshaft. • Use a thic thickne kness ss gauge gauge to measu measure re an end end clearance of the camshaft gear and the camshaft bracket. • If the the measurement measurement exceeds the limit, limit, replace replace the camshaft gear or the cam shaft.

End clearance of the camshaft

mm (in)

Standard

0.050 - 0.170 (0.002 - 0.007)

Limit

0.25 (0.009)

NOTE: Measure an end clearance of the camshaft before disassembling.

7. Check if the camshaft camshaft journal journal is is worn. worn. • Use a micrometer micrometer to measure wear which which is is not even with a diameter of the camshaft journal. • If the measured measured uneven uneven wear wear exceeds exceeds the the limit, limit, replace the camshaft.

External diameter of the camshaft journal part Standard

29.9 9.909 - 29.930 930 (1.1 1.1775 - 1.17 .1783)

Limit

29.809 (1.1736)

Part Partia iall wea wearr of of the the cam camsh shaf aftt jou journ rnal al par partt Limit

RTW56ASH013901

6. Check Check if the the cam cam lobe is is worn. worn.

mm (in)

mm (in) (in)

0.05 (0.0019)

6A-50

ENGINE MECHANICAL (4JJ1) b. Read the the difference difference between between the inside diameter of the camshaft bearing and the diameter of the camshaft journal. If the measured oil clearance exceeds the limit, replace the camshaft bearing.

Clearance of the journal part Standard

0.030 - 0.112 (0.0012 - 0.0044 )

Limit

0.15 (0.0059 )

8. Check Check if the the camsh camshaft aft is is bent. bent. • Place the camshaf camshaftt on a V block to measure measure a bend with a dial gauge. • Rotate Rotate the camshaft camshaft slowly slowly to measure measure how how much the dial indicator shook. If it exceeds the limit, replace the camshaft.

Bent of the camshaft Limit

mm (in) 0.05 (0.0019 )

Reassembly 1. Instal Installl the the dowel dowel pin. pin. 2. Instal Installl the camsha camshaft ft gear gear.

9. Measure a camshaft camshaft journal journal oil clearance clearance.. a. Measure an inside inside diameter diameter of the camshaft camshaft bearing with a dial gauge.

mm (in)

ENGINE MECHANICAL (4JJ1) • Align the knock knock pin pin with with the slot slot in the camshaft camshaft gear. Use a press to install the camshaft gear to the camshaft.

Legend 1. Cams Camsha hafft 2. Dowe Dowell Pi Pin 3. Cams Camshaf haftt Gear Gear

6A-51

• Align the the sub gear pin pin (2) with the hole hole in the the right side of the camshaft gear spring (3). Press the sub-gear into place.

Legend 1. Snap Snap Ring Ring 2. Sub Sub Ge Gear 3. Sprin ring 4. Cams Camshaf haftt Gear Gear

3. Install Install the the sub gear assembly assembly. • Clamp the camshaf camshaftt in a vise. Insert Insert soft soft metal metal protectors (aluminum) between the vise surfaces and the camshaft. Press against the pin on the left side of the camshaft gear spring (3) to make a gap on the right side of the spring. Push the spring into place.

• Use snap snap ring pliers to snugly snugly install install the snap snap ring.

4. Tight Tighten en sub gear gear settin setting g bolt. bolt. • Use a camshaft camshaft gear gear tool tool (5-8840-259 (5-8840-2591-0) 1-0) to to turn sub gear to right direction until it aligns with the M5 bolt hole between camshaft driven gear and sub gear.

6A-52


• Tighten Tighten the the M5 bolt bolt to to a suitabl suitable e torque torque to prevent the sub gear from moving.

1

2

3 RTW56ASH007001

Installation 1. Rotate Rotate the crankshaf crankshaftt to make make the No.1 No.1 cylinder cylinder compression TDC. • Check Check TDC TDC usin using g a mirror mirror etc. etc.

Legend 1. Exhaus Exhaustt Camsh Camshaft aft Gear Gear 2. Intake Intake Camsha Camshaft ft Gear Gear 3. Idle dle Ge Gear D 3. Camshaft Camshaft bearing bearing caps, caps, tighten tighten ten bolts on on one side bank to the specified torque. • Apply Apply engine engine oil to to camshaf camshaftt journal journal and and bearing surface of camshaft bearing caps.

1E 2E 3E 4E

1I

5E 2I 3I 4I 5I

Legend 1. Cranks Crankshaf haftt Damper Damper Pulle Pulley y 2. Mirror rror 3. TDC TDC Ma Mark 2. Install Install the the camshaft camshaft assembly assembly. • Align timing mark on intake intake camshaft camshaft and exhaust camshaft to idle gear D.

RTW56ASH018401

ENGINE MECHANICAL (4JJ1) 4. Check that that the alignmen alignmentt marks marks (camshaft (camshaft bearing bearing cap and camshaft) (1) are aligned.

6A-53

• Apply engine oil over over the screw part and tighten tighten up the bearing cap with the prescribed torque. Tightening torque: 18 N ⋅m (1.8kg⋅m / 13 lb ft) 5. Remove the M5 lock lock bolt of of fixing sub gear. gear. 6. Adjustm Adjustment ent of valve valve cleara clearance nce.. Refer to installation procedure for inspection / adjustment of valve clearance in this manual. 7. Install Install the the baffle baffle plate plate.. Tighten the bolts to the specified torque. Tightening torque: 10 N ⋅m (1.0 kg⋅m/87 lb in) 8. Install Install the the cylinder cylinder head cover. cover. Refer to "Cylinder Head Cover".


6A-54




5-8840-2591-0 Camshaft gear tool


6A-55

Valve Stem Seal and Valve Spring Components

Legend 1. Exhaust Exhaust Rocke Rockerr Arm Shaft Shaft Assembly Assembly 2. Bolt Bolt (Lon (Long) g) 3. Bolt Bolt (Sh (Shor ort) t) 4. Intake Intake Rocke Rockerr Arm Shaft Shaft Assembly Assembly 5. Fuel Inject Injector or Asse Assembl mbly y 6. Fuel Inject Injector or Clam Clamp p Bolt Bolt 7. Fuel Inject Injector or Clamp Clamp

Removal 1. Remove Remove the cylinde cylinderr head assembly assembly. Refer to "Cylinder Head". 2. Remove Remove the the valve valve stem stem end cap. cap. 3. Remove Remove the the split split collar collar..

8. 9. 10. 11. 12. 13. 13. 14.

Pin Spring pring Lowe Lowerr Seat Seat Valve alve Stem Stem Oil Seal Valve alve Sprin Spring g Sprin Spring g Uppe Upperr Seat Seat Split plit Coll Collar ar Valve alve Stem Stem End Cap Cap

• To prevent prevent the valve from falling falling into the the cylinder, move the piston to TDC.

6A-56


• Use a replacer replacer to compress compress the valve spring to remove the split collar. Special tool

NOTE: Do not reuse the oil seal. 7. Remove Remove the the spring spring lower lower seat. seat.

Valve spring replacer: 5-8840-2818-0 Pivot: 5-8840-2819-0

Inspection Inspect the valve spring NOTE: Check the valve spring visually and if there is clear damage or wear, replace it. 1. Free Free leng length th • Measure free length of the the spring spring and if it is shorter than the prescribed limit, replace the spring.

Free Free leng length th of the the val valve ve spri spring ng IN / EX EX

mm (in) (in)

Standard

49.04 (1.93) / 57.57 (2.27)

Limit

48.15 (1.89) / 56.52 (2.23)

Legend 1. Valve alve spring spring replace replacer r 2. Pivot 4. Remove Remove the the spring spring upper upper seat. seat. • Remove the special special tool to remove remove the the upper upper seat. 5. Remove Remove the valve valve sprin spring. g. Put the removed valve springs in order by cylinder number. 6. Remove Remove the the valve valve stem stem oil seal. seal. • Use plie pliers rs to remove remove the the oil seal. seal.

2. Valve alve spring spring squarene squareness. ss. • Use a surfa surface ce plate plate and and a square square to measu measure re the valve spring squareness.If the measured value exceeds the specified limit, the valve spring must be replaced.

Valve spring squareness IN / EX Limit

mm (in)

2.1 (0.083) / 2.5 (0.098)


6A-57

Installation 1. Install Install the the spring spring lower lower seat. seat. 2. Install Install the the valve valve stem stem oil seal. • Apply engine oil over over the peripheral peripheral part part of the the valve guide and install the oil seal by using a valve stem seal installer. NOTE: After installing the valve stem oil seal, check if it is inserted nice and deep and the oil seal is not tilted or the garter spring has not come off. Special tool Valve stem seal installer: 5-8840-2817-0

3. Tensi ension on • Use a spring spring tester tester to to compress compress the the spring spring to to the installation height. Measure tension of the compressed spring. If the measurement is lower than the limit, replace the spring. Installation lengt ngth mm mm (in)

Tension of the valve spring

37. 37.80 (1 (1.488) 88)

N (kg / lb) Inlet / Exhaust

Standard

213 (21.7 / 157) / 409 (41.7 / 301)

Limit

188 (19.2 / 138) / 370 (37.7 / 272)

3. Instal Installl the valve valve spri spring. ng. 4. Instal Installl the sprin spring g upper upper seat. seat. 5. Instal Installl the split split colla collarr. • Apply compressed compressed air air over over the cylinder cylinder from from the glow plug holes to keep the valve at the home position. • Use a replacer replacer to compress compress the the valve valve spring spring and install the s plit collar. Special tool Valve spring replacer: 5-8840-2818-0 Pivot: 5-8840-2819-0

6A-58

ENGINE MECHANICAL (4JJ1) NOTE: Move it up and down to check if it moves smoothly. smoothly. 6. Instal Installl the valve valve stem stem end cap. cap. 7. Install Install the cylinder cylinder head assembly assembly.. Refer to "Cylinder Head".

Legend 1. Valve alve spring spring replace replacer r 2. Pivot



5-8840-2818-0 Valve spring replacer

5884028180

5-8840-2819-0 Pivot assembly

5884028190

5-8840-2817-0 Valve stem seal installer


Cylinder Head Components

Legend 1. Timin Timing g Chain Tens Tensione ioner r 2. Glow Glow Plug Plug 3. Intake Intake and and Exhaus Exhaustt Valv Valves es 4. Fuel Inject Injector or Asse Assembl mbly y NOTE: To avoid electric shock; Set the switch to the 'OFF' position and disconnect battery negative cable before checking or repairing the fuel injector, wiring or/and connectors.

Removal 1. Drain Drain the the engine engine coola coolant. nt.

5. 6. 7. 8.

Fuel Injecto Injectorr Clamp Clamp Cyli Cylind nder er Head Head Timin Timing g Chai Chain n Guide Guide Timing Timing Chain Chain Tension Lever

2. Remove Remove the the turboch turbocharg arger er.. Refer to “Turbocharger“.

6A-59

6A-60


3. Remove the EGR cooler heat protecto protector. r.

7. Remove Remove the the LH noise noise cover cover.. 4. Remove Remove the EGR cool cooler er..

8. Remove Remove the the radiato radiatorr upper hose hose..

5. Remove the water water by by pass pass pipe pipe (1). (1).

9. Remove Remove the A/C compress compressor or drive drive belt. belt. 10. Remove Remove the the A/C compress compressor or.. • Remove Remove the the compr compress essor or compressor bracket.

from from

the the

A/C

• Fix the the compressor compressor and hose hose in an appropriate appropriate position with wire etc. 11. Remove Remove the A/C A/C compressor compressor bracket. bracket. 12. Remove Remove the A/C compressor compressor adjust adjust pulley pulley..

6. Remove the air air intake intake pipe pipe with the hoses. hoses. • Disconn Disconnect ect the the connect connector or from from the boost boost sensor. • Disconnect Disconnect the hose hose from from the intercooler intercooler side. side. • Remove the air air intake intake pipe pipe with with the hoses from the intake throttle valve. • Do not disconnect disconnect the hoses hoses from the air intake intake pipe.

Legend 1. Bolt 2. Nut 13. Remove Remove the cylinder cylinder head head cover cover.. Refer to “Cylinder Head Cover“. 14. Remove Remove the oil level level gauge tube.

ENGINE MECHANICAL (4JJ1) 15. Remove Remove the injectio injection n pipes (NO.1 to 4).

6A-61

19. Remove the harness harness connector connector of camshaft camshaft position sensor (1), water temperature sensor (2).

16. Discon Disconnec nectt the heater heater hose. hose. • Disconnect Disconnect the heater heater hose from the cylinde cylinder r block side. 17. Remove Remove the fan guide guide bracket bracket (LH).

20. Remove the timing chain cover. cover. a. Remove Remove the the lower lower cover cover (2). (2). b. Remove Remove the upper upper cove coverr (1). (1).

18. Remove Remove the noise noise shield shield cover cover (1) from from the lower lower timing chain cover.

21. Remove Remove the fuel fuel inject injector or.. Refer to “Fuel Injector“ in “FUEL SYSTEM“ section. 22. Remove the glow glow plug plug connecto connector. r. 23. Remove Remove the the glow glow plug plug .

6A-62


24. Install Install M5 bolts bolts to the the sub gear gear of the camshaft. camshaft.

26. Remove Remove the the camshaft camshaft bearing bearing cap. cap.

1E 2E 3E 4E

1I

5E 2I 3I 4I 5I

RTW56ASH018401

25. Remove Remove the the baffle baffle plate plate (1). (1).

27. Remove Remove the camsha camshaft. ft.

ENGINE MECHANICAL (4JJ1) 28. Remove Remove the timing timing chain chain tensioner tensioner (1) (1) and gasket gasket (2).

29. Remove Remove the the idle idle gear gear D. • Timing iming chain chain is droppe dropped d behind. behind.

6A-63

30. Remove the timing timing chain chain tension tension lever pivot. pivot.

31. Remove the timing timing chain chain from the supply supply pump pump sprocket. 32. Remove the chain chain guide guide bolt from the the cylinder cylinder head.

33. Remove the rocker rocker arm shaft assembly assembly. NOTE: Keep the removed rocker arm shaft assembly properly so that they may be put back to the original place.

6A-64


Legend 1. Exhaust Exhaust Rocke Rockerr Arm Shaft Shaft Assembly Assembly 2. Bolt Bolt (Lon (Long) g) 3. Bolt Bolt (Sh (Shor ort) t) 4. Intake Intake Rocke Rockerr Arm Shaft Shaft Assembly Assembly 5. Front NOTE: Pay full attention so as not to drop the parts in the gear case of the front part of the cylinder head or a hole into which oil pours back in the front.

36. Remove Remove the cylinde cylinderr head assembly assembly. • Remove the cylinde cylinderr head assembly assembly with with the the exhaust manifold and the intake manifold. • Remove Remove the the cylin cylinder der head head gask gasket. et. NOTE: Replace the head gasket with a new one once it is removed.

Head Disassembly 1. Remove Remove the intake intake manifold manifold assembly assembly..

34. Remove the cylinder cylinder head head gear case bolts bolts (2) and nuts (1).

2. Remove Remove the exhaust exhaust manifold manifold assembly assembly.. 3. Remove Remove the the water water outlet outlet pipe. pipe. 4. Remove Remove the the valve valve stem stem cap. cap. 5. Remove Remove the the split split collar collar.. • Use a replacer replacer to compress compress the valve spring to remove the split collar. Special tool Valve spring replacer: 5-8840-2818-0 Pivot: 5-8840-2819-0

35. Remove the cylinder cylinder head head bolts bolts.. • Loosen the cylinde cylinderr head bolts in the the order order described in the drawing. NOTE: Do not reuse the cylinder head bolts.


6A-65

9. Remove Remove the the valve valve stem oil oil seal. seal.

Legend 1. Valve alve spring spring repla replacer cer 2. Pivot 6. Remove Remove the the spring spring upper upper seat seat 7. Remove Remove the the valve valve spring spring.. • Put the the remove removed d valve valve spring springs s in order order by cylinder number. 8. Remove Remove the intake intake and exhaust exhaust valve. valve. • Put the removed removed valves in order order by by cylinder cylinder number.

10. Remove Remove the the spring spring lower lower seat. seat. 11. Remove Remove the valv valve e guide. guide. • Use the the valve valve guide replacer replacer to press press out out the valve guides from the bottom side of the cylinder head. Special tool Valve guide remover and installer: 5-8840-2816-0

6A-66


12. Remove Remove the the cam cam end gaske gaskett (1).

2. The cylinder cylinder head head lower lower surface surface warpage warpage is more more than the limit, it should be replaced.

13. Remove Remove the oil seal. seal. Cylinder Head Lower Face Wa Warpage

mm (i (in)

Standard

0.05 (0.002) or less

Limit

0.20 (0.0079)

NOTE: The cylinder head lower face cannot be reground.

Inspection Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. Cylinder Head Lower Face Warpage 1. Use a straight straight edge and a thickne thickness ss gauge gauge to measure the four sides and the two diagonals of the cylinder head lower face. Cylin ylinde derr Hea Head d He Height ight (H) (H) (Re (Refe fere renc nce) e) Standard

mm (in) (in)

143.4 (5.646)


6A-67

Exhaust Manifold Warpage Use a straight edge and a thickness gauge to measure the manifold cylinder head fitting face warpage.If the measured values exceed the specified limit, the manifold must be replaced.

Exhaust Manifold Warpage

mm (in)

Standard

0.05 (0.002) or less

Limit

0.20 (0.008)

Manifold Fitting Face Warpage Use a straight edge and a thickness gauge to measure the manifold cylinder head fitting face warpage.Regrind the manifold cylinder head fitting surfaces if the measured values are greater than the specified limit but less than the maximum grinding allowance.If the measured values exceed the maximum grinding allowance, the cylinder head must be replaced.

Manifold Fitting Face Warpage

mm (in)

Standard

0.05 (0.002) or less

Limit

0.20 (0.008)

Maximum Gr Grinding Al Allowance

0.40 (0 (0.016)

Valve Stem Cap Make the necessary part replacements.If excessive wear or damage is discovered during inspection. Valve Stem Outside Diameter Measure the valve stem diameter at three points.If the measured value is less than the specified limit, the valve and the valve guide must be replaced as a set.

Valve Stem Outside Diameter

mm (in)

Intake Valve

Exhaust Valve

Standard

6.955 - 6.970 (0.2738 - 0.2744)

6.939 - 6.949 (0.2732 - 0.2736)

Limit

6.935 (0.2730)

6.920 (0.2724)

6A-68

ENGINE MECHANICAL (4JJ1) Valve Thickness Measure the valve thickness.If the measured value is less than the specified limit, the valve and the valve guide must be replaced as a set.

Intake an and Ex Exhaust Va Valve Th Thickness

mm (i (in)

Standard

1.3 (0.051)

Limit

1.1 (0.045)

Valve Stem and Valve Guide Clearance 1. Measure the valve valve stem outside outside diameter diameter.Refe .Referr to the item "Valve Stem Outside Diameter". 2. Use a caliper caliper calibrato calibratorr or a telescoping telescoping gauge to measure the valve guide inside diameter. If the measured values exceed the specified limit, the valve and the valve guide must be replaced as a set.

Valve Stem Clearance

mm (in)

Intake Valve

Exhaust Valve

Standard

0.030 - 0.060 (0.0012 - 0.0023)

0.038 - 0.068 (0.0015 - 0.0027)

Limit

0.200 (0.008)

0.250 (0.0098)

Valve Depression 1. Install Install the valve valve (1) to the cylinde cylinderr head (2). (2). 2. Use a depth depth gauge gauge or a straight straight edge edge with steel steel rule to measure the valve depression from the cylinder head lower surface. If the measured value exceeds the specified limit, the valve seat insert must be replaced.

Valve Depression

mm (in)

Standard

0.5 (0.02)

Limit

2.5 (0.098)


6A-69

• Use a seat cutter cutter to minimize minimize the scratch scratch and other other roughness (15/45/75 degree-blade), thereby returning the contact width to the standard value.

Valve Contact Width 1. Check the the valve contact contact faces faces for roughnes roughness s and unevenness. Make smooth the valve contact surfaces. 2. Measure Measure the the valve valve contac contactt width. width. If the measured value exceeds the specified limit, the valve seat insert must be replaced.

Valve Contact Width

NOTE: Remove only scratches and roughness, and do not cut the surface too much. Use the free adjustment valve cutter pilot. Do not let the valve cutter pilot waver inside the valve guide.

mm (in) Intake

Exhaust

Standard

2.26 (0.089)

2.12 (0.083)

Limit

2.2 (0.087)

2.5 (0.078)

Valve Seat Angle

Degree 45

• Attach compound compound in the valve insert seat. • Insert Insert the the valve valve into into the valve valve guide guide.. Repair of the seat surface • Remove Remove carbon carbon from from the surfa surface ce of the valve valve insert seat.

• Attach compound compound on the valve valve seat seat surface, surface, rotate rotate the valve and hit it lightly to grind it, and confirm that it has even contact all round.

6A-70


NOTE: Remove compound completely after grinding.

Install the valve seat insert • Carefully Carefully place place a washer (the outer outer diameter diameter is smaller than the valve seat insert) on the valve seat insert. • Use the the press press to apply pressure pressure gradually gradually on the washer, thereby pushing the valve seat insert. NOTE: Do not apply too much pressure with the press. Attach compound on the valve seat surface, rotate the valve and hit it lightly to grind it, and confirm that it has even contact all round.

Replace the valve seat insert. Remove the valve seat insert • Arc-weld Arc-weld the entire entire inner inner diameter diameter of the valve seat seat insert. • Cool the the valve valve seat insert for two to three three minutes. minutes. Contraction due to cooling makes it easier to remove the valve seat insert. • Remove the valve valve seat seat insert, insert, using using a screw screw driver driver.. Be sure not to harm the cylinder head.

Legend 1. Washer 2. Valve alve Seat Seat Insert Insert 3. Press

Head Reassembly 1. Insta Install ll the the oil oil seal seal.. • Install Install on the the surface surface of the the injection injection pipe pipe insert. insert. • Hammer it in so so that the seal seal does not incline. incline. NOTE: Be sure not to harm the Lip. Special tool Injection pipe oil seal installer: 5-8840-2820-0

Legend 1. ArcArc-We Weld ld 2. Valve alve Seat Seat Inse Insert rt 3. Scre Screw w Driv Driver er


6A-71

Height from the upper surface of the cylinder head to the edge surface of the valve guide; NOTE: When replacing the valve guide, it must be replaced together with the valve.

Legend 1. Cyli Cylinde nderr Head Head 2. Injection Injection Pipe Pipe Oil Oil Seal Seal Install Installer er 2. Instal Installl the valv valve e guide. guide. • Hammer Hammer in the valve valve guide from the upper upper surface of the cylinder head, using the valve guide installer. installer. Special tool Valve guide remover and installer: 5-8840-2816-0

Legend 1. 12.6 ± 0.1 mm (0.50 ± 0.0039 in) 2. Cyli Cylind nder er Head Head 3. Install Install the valve spring lower seat. 4. Install Install the the valve valve stem stem oil seal. • Apply engine oil over over the peripheral peripheral part part of the the valve guide and install the oil seal by using a valve stem seal installer.

6A-72


NOTE: After installing the valve stem oil seal, check if it is inserted nice and deep and the oil seal is not tilted or the garter spring has not come off. Special tool Valve stem seal installer: 5-8840-2817-0

5. Install Install the intake intake and exhaust exhaust valve. • Apply Apply engine engine oil on on the valve valve stem stem part part and install the valve.

• Use a replacer replacer to compress compress the valve spring and install the split collar. Special tool Valve spring replacer: 5-8840-2818-0 Pivot: 5-8840-2819-0

Legend 1. Valve alve spring spring repl replace acer r 2. Pivot NOTE: Move it up and down to check if it moves smoothly. smoothly. 9. Instal Installl the valve valve stem stem end cap. cap. 10. Install Install the exhaust exhaust manifol manifold d assembly assembly.. Refer to “Exhaust Manifold”. 11. Install Install the intake intake manifold manifold assembly assembly.. Refer to “Intake Manifold”.

Installation 1. Select Select the cylind cylinder er head head gasket. gasket.

6. Instal Installl the valv valve e spring spring.. 7. Install Install the the valve valve spring spring upper upper seat. seat. 8. Insta Install ll the spli splitt collar collar.. • Apply compressed compressed air air over over the cylinder cylinder from from the glow plug holes to keep the valve at the home position.


6A-73

Cylinder Head Gasket Selection

4. Obtain the maximum maximum value value in the four four cylinders. cylinders.

Cylinder head gasket is determined by the piston head projection from the cylinder body upper surface, in order to improve engine performance. Three types of gasket are provided with difference of thickness. Select the appropriate one out of three grades of gasket, according to the following procedure. Before measurement, clear off carbon from the piston head and cylinder body surface and also clean the place where the gasket was installed.

5. Determine Determine the gasket grade required required to the maximum value described above in accordance with the following table.

Cylinder Head Gasket Combination mm(in)

1. Use a dial dial indicato indicatorr to measure measure the the piston piston projection amount. 2. Refer to the illustr illustration ation for for the piston head head projection measuring positions. All measuring positions should be as close as possible to the cylinder block.

3. Measure Measure the points points 1, 2, 2, 3, 4 and obtain obtain two differences 1-2 and 3-4 on each cylinder. Calculate the average value of the piston head projection on each cylinder.

6A-74

ENGINE MECHANICAL (4JJ1) • Use a torqu torque e wrench wrench and and angle angle gauge gauge to to tighten the head bolts in the order described in the drawing. Tightening torque: 1st step = 70 N ⋅m (7.1 kg⋅m / 51 lb ft) 2nd step = 70 N ⋅m (7.1 kg⋅m / 51 lb ft) 3rd step = 60 ° (degrees) 4th step = 60 ° (degrees)

RTW56ASH009501

NOTE: Difference of each piston projection must be equal or within 0.05 mm (0.002 in). 6. Select Select the the gear case case gasket. gasket. • This should should be of the same same grade grade as cylinder cylinder gasket is chosen. 7. Apply liquid liquid gasket gasket (ThreeBond (ThreeBond equivalent) at the two locations .

1207B

or Special tool Angle gauge: 5-8840-0266-0 11. Install Install the cylinder cylinder head gear gear case bolts bolts (2) and nuts (1). • Tighten Tighten the the bolts bolts and nuts to the specified specified torque. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft)

8. Install Install the cylinder cylinder head gasket and gear case gasket within 5 minutes of application of the liquid gasket. 9. Install Install the cylinder cylinder head assembly assembly. • Wipe the the cylinder cylinder head assembly assembly lower face. • Install Install the cylinder cylinder head head assembly assembly,, adjusting adjusting the dowel of the cylinder block. 10. Install Install the the cylind cylinder er head head bolt. bolt. • Please Please use use new cylind cylinder er head head bolt. bolt.

12. Install Install the rocker rocker arm arm shaft shaft assembly assembly.. • Apply Apply the the eng engin ine e oil. oil.

ENGINE MECHANICAL (4JJ1) • Attach Attach the the rocker rocker arm shaf shaftt assembl assembly y in sequence from No.1 to No.4.

6A-75

16. Rotate Rotate the crankshaft crankshaft to make the No.1 No.1 cylinder cylinder compression top dead center (TDC).

Tightening torque: 21 N ⋅m (2.1 kg⋅m / 15 lb ft)

Legend 1. Exhaust Exhaust Rocke Rockerr Arm Shaft Shaft Assembly Assembly 2. Bolt Bolt (Lon (Long) g) 3. Bolt Bolt (Sh (Shor ort) t) 4. Intake Intake Rocke Rockerr Arm Shaft Shaft Assembly Assembly 5. Front 13. Install Install the water water by pass pass pipe.Apply pipe.Apply soapy soapy water to the O-ring.Tighten the bolt to the specified torque. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft) 14. Install Install the chain guide guide bolt bolt from cylinder cylinder head.Tighten the bolt to the specified torque. Tightening torque: 25 N ⋅m (2.5 kg⋅m/18 lb ft)

15. Instal Installl the tension tension lever lever..

Legend 1. Cranks Crankshaf haftt Damper Damper Pulle Pulley y 2. Mirror rror 3. TDC Ma Mark 17. Install Install the timing timing chain chain with with idle gear D. • Apply the engine engine oil bolt bolt thread thread and seat. seat. Tightening torque: 59 N ⋅m (6.0 kg⋅m/43 lb ft)

6A-76


• Align Align the timin timing g marks marks at two loca locatio tions ns as shown.

Legend 1. Timi Timing ng Chai Chain n 2. Timin iming g Mark Mark 3. Blue Blue Link Link 4. Yello ellow w Link Link

19. Hold Hold the latch(3 latch(3)) depresse depressed. d. Insert the plunger(2). Attach the hook(4) to the pin(1) to hold the plunger in place.

20. Install Install the timing timing chain chain tensioner tensioner (1) and gasket gasket (2). Tighten the bolt to the specified torque. Tightening torque: 10 N ⋅m (1.0 kg⋅m / 87 lb in)

18. Install Install the timing timing chain tension tension lever lever pivot.Tighten pivot.Tighten the bolt to the specified torque. Tightening torque: 27 N ⋅m (2.8 kg⋅m / 20 lb ft)

21. Unlock Unlock the the tensio tensioner ner hook. hook. • Press Press the plac place e of the arrow arrow in the the figure. figure. • The hook hook is open opened. ed. The The plunger plunger pushes pushes the the tension lever.


22. Install Install the the camshaft camshaft assembly assembly.. • Align Align timing timing mark mark on intake intake camsh camshaft aft and and exhaust camshaft to idle gear D.

1

6A-77

24. Align mark mark (1) on camshaft camshaft to mark mark on camshaf camshaftt bearing cap. • Align mark on intake intake camshaf camshaftt and exhaust exhaust camshaft to mark of bearing cap.

2

3 RTW56ASH007001

Legend 1. Exhaust Exhaust Camsha Camshaft ft Gear Gear 2. Intake Intake Camsha Camshaft ft Gear Gear 3. Idle Idle Gea Gear D 23. Install Install the the camshaft camshaft bearing cap. • Apply engine oil to to all of the the cylinder cylinder head journals. Tightening torque: 18 N ⋅m (1.8 kg⋅m / 13 lb ft)

25. Remove the M5 lock lock bolt from from the camshaf camshaftt Gear. Gear. 26. Turn Turn the crank crank pulley pulley two two rotation rotation (720°CA) • Align mark on on camshaft camshaft to mark mark on camshaft camshaft bearing cap.

6A-78

ENGINE MECHANICAL (4JJ1) 31. Instal Installl the noise noise cover cover.. Refer to procedure for fuel system in this manual. 32. Inspection Inspection and and adjustment adjustment of of valve clearan clearance. ce. Refer to procedure for service precautions in this manual. 33. Install Install the fuel injecto injector. r.Refer Refer to procedur procedure e for fuel system in this manual. 34. Install Install the baffle baffle cover cover.Refer to procedure procedure for for camshaft in this manual. 35. Instal Installl the cam cam end end gasket. gasket. • Apply the liquid gasket (ThreeBond (ThreeBond TB-1207B TB-1207B or equivalent).

Legend 1. Exhaust Exhaust Camsha Camshaft ft Gear 2. Intake Intake Camsha Camshaft ft Gear 3. Idle Idle Gear Gear D

Legend 1. Cam Cam End End Gask Gasket et 2. 2.0 to to 3.0 mm mm (0.078 (0.078 to 0.1 0.118 in) 36. Install Install the cylinder cylinder head head cover. cover. Refer to “Cylinder Head Cover”. 37. Install Install the glow plug. Tighten Tighten the the glow plug plug to the specified torque. Tightening torque: 18 N ⋅m (1.8 kg⋅m / 13 lb ft) Legend 1. Timi Timing ng Chai Chain n 2. Timin iming g Mark Mark 3. Dark Dark Plat Plate e 4. Yello ellow w Pla Plate te

38. Install Install the glow glow plug connector connector.. Tighten Tighten the nuts nuts to the specified torque. Tightening torque: 2 N ⋅m (0.2 kg⋅m / 17 lb in) 39. Install Install the the fuel fuel injecti injection on pipe. pipe. Attachment order No.2 →No.1→No.3→No.4

27. Apply liquid liquid gasket gasket to timing timing chain cover cover upper. upper. Refer to procedure for fuel system in this manual.

40. Tighten Tighten the fuel fuel injector injector clamp clamp bolt to the specifi specified ed torque.

28. Install Install the timing chain cover upper upper.. Refer to procedure for fuel system in this manual.


29. Apply liquid liquid gasket gasket to timing timing chain cover cover lower. lower. Refer to procedure for fuel system in this manual.


30. Install Install the timing timing chain chain cover cover lower lower.. Refer to procedure for fuel system in this manual.

42. Install Install the fuel injectio injection n pipe clip .Tighten .Tighten the the nut to the specified torque.

41. Tighten Tighten the injecti injection on pipe to the specified specified torque. torque.

Tightening torque: 8 N ⋅m (0.8 kg⋅m / 69 lb in)

ENGINE MECHANICAL (4JJ1) 43. Install Install the engine oil level level gauge gauge guide. guide. • Apply engine oil oil to the the O-ring. O-ring. Tighten Tighten the the bolt bolt to the specified torque. Tightening torque: 25 N ⋅m (2.6 kg⋅m / 19 lb ft) 44. Install Install the A/C compress compressor or bracket.Ti bracket.Tighten ghten the bolt bolt to the specified torque.

52. Instal Installl the coolin cooling g fan. fan. Refer to procedure for Engine cooling in this manual. 53. Instal Installl the A/C A/C drive drive belt. belt. Refer to Procedure for Intake Manifold in this manual. 54. Instal Installl the fan fan guide guide bracket. bracket.


55. Install Install the the radiator radiator upper hose.

45. Install Install the A/C compresso compressorr adjust pulley pulley.. Tighten Tighten the bolt (1) and nut (2) to the specified torque.

56. Install Install the Turbocharg Turbocharger. er. Refer to “Turbocharger“.

Tightening torque: bolt 25 N ⋅m (2.6 kg⋅m/19 lb ft) (Dry)

57. Repleni Replenish sh the the coola coolant. nt.

Tightening torque: nut 41 N⋅m (4.2 kg ⋅m/30 lb ft)

46. Install Install the A/C A/C compressor compressor and connector connector.. Tighten the bolt to the specified torque. Tightening torque: 44 N ⋅m (4.5 kg ⋅m / 33 lb ft) 47. Connect Connect each each connec connector tor.. • Barom Baromet etric ric Senso Sensor r • EGR Va Valve • Glow plug • Water Water temper temperatur ature e sens sensor or • Camsha Camshaft ft Positio Position n sens sensor or • Thro Thrott ttle le Asse Assembl mbly y 48. Install Install the the exhaust exhaust front pipe. Refer to procedure for exhaust system in this manual. 49. Instal Installl the EGR EGR cooler cooler.. Refer to procedure for exhaust system in this manual. 50. Install Install the the EGR cooler water pipe. Refer to procedure for exhaust system in this manual. 51. Install Install the EGR cooler cooler heat heat protector protector.. Refer to procedure for exhaust system in this manual.

6A-79

6A-80





5-8840-2820-0 Injection pipe oil seal installer

Illustration


5-8840-2816-0 Valve guide remover and installer

ENGINE MECHANICAL (4JJ1) Illustration


5-8840-2817-0 Valve stem seal installer

5-8840-2818-0 Valve spring replacer

5884028180

5-8840-2819-0 Pivot

5884028190

5-8840-0266-0 Angle gauge

6A-81

6A-82


Piston and Connecting Rod Components

3

1

4

2 1 5

6

RTW56ALF001601

Legend 1. Pisto Piston n Pin Snap Snap Ring Ring 2. Pist Piston on Pin Pin 3. Pist Piston on Ring Ring

Removal 1. Demoun Demountt the engine engine assembl assembly y. Refer to "Engine Assembly". 2. Remove the cylind cylinder er head head cover cover.. Refer to "Cylinder Head Cover". 3. Remove the camshaft camshaft assembly assembly. Refer to "Camshaft Assembly". 4. Remove Remove the the cylin cylinder der head head.. Refer to "Cylinder Head".

4. Pis Piston 5. Conn Connec ecti ting ng Rod Rod 6. Beari aring

5. Remove Remove the gear case case assembly assembly.. Refer to "Gear Case Assembly". 6. Remove Remove the oil pan. pan. Refer to "Oil Pan and Crank Case" . 7. Remove Remove the the connecti connecting ng rod cap. cap. NOTE: Sort the removed bearings according to cylinders by using tags.


8. Remove Remove the piston and connect connecting ing rod. rod. • Remove Remove carbo carbon n on the the upper upper side side of the cylinder block with a scraper. • Pull out the the piston piston and and connecting connecting rod towards towards the cylinder head. NOTE: Be sure not to damage the oil jet and cylinder block when pushing out the connecting rod.

6A-83

2. Remove Remove the snap ring. ring. 3. Remove Remove the piston piston pin. NOTE: Sort the disassembled piston pins, pistons and connecting rods together in the same order as the cylinders.

9. Remove Remove the the connectin connecting g rod bearing. bearing. NOTE: Sort the bearings in the order of cylinders when reusing them so that they are not confused with the bearings of other cylinders.

Disassembly 1. Remove Remove the the pist piston on ring. ring. • Use ring ring pliers pliers to remov remove e the piston piston ring. ring. NOTE: Sort the piston rings in the same order as the cylinders when reusing them so that they are not confused with the pistons and piston rings of other cylinders. 4. Remove the connecting connecting rods from from the piston. piston. 5. Pis Piston • Carefully Carefully clean clean carbon that is adhered adhered to the the head of the piston and the groove of the piston ring. NOTE: Do not use a wire brush to clean the piston because it scratches the piston. Visually inspect the piston for cracks, burns and other excessive wear, and replace it if there is any abnormality.

6A-84


6. Measure the gap between between the the piston piston and the inner inner diameter of the cylinder bore. Inner diameter of the cylinder block.

• Measurement Measurement position position (from (from the the bottom bottom surface surface of the piston) 11.00 mm (0.43 in).

• Use a cylinder cylinder bore bore dial dial indicato indicatorr to measure the cylinder block inner diameter both in the thrust and radial directions in the designated position. • Measurement Measurement position position (from (from the upper surface surface of the cylinder block) 20 mm (0.79 in) • Measure the cylinder cylinder block block inner inner diameter diameter based on the average value of the actual measurement values on 2 positions.

Cylinder block inner diameter

mm (in)

95.421 - 95.450 (3.75673 - 3.75787)

Legend 1. 11 mm mm (0. (0.43 43 in) in)

Gap between the piston and the inner diameter of the cylinder block Standard

mm (in)

0.082 - 0.100 (0 (0.0032 - 0. 0.0039)

NOTE: If it is found that the gap between the cylinder block inner diameter and the piston exceeds the standard value, replace the piston or cylinder block. 7. Piston Piston replace replacement ment Legend 1. 20 mm (0.79 (0.79 in) in) 2. Radial dial 3. Thru Thrus st

• The head head of the the piston piston has has a marking marking of grade grade A, B or C. The mark shows the grade of the piston. • If oversize oversize pistons pistons are installed, installed, rebore the cylinder block. Refer to "Cylinder Block".

Piston outside diameter • Use a micro micromet meter er to measu measure re the outs outside ide diameter of the piston in the right angle to the piston pin in the designated position.

Piston Grade (Service Part)

mm (in)

A

95.340 - 95.369 (3.75354 - 3.75469)

B

95.350 - 95.379 (3.75394 - 3.75508)

C

95.360 - 95.389 (3.75433 - 3.75547)


6A-85

• Push the the piston piston ring ring into into the cylinder cylinder bore bore until until it reaches the measuring point 1 or 2 where the cylinder liner bore is the smallest.Do not allow the piston ring to slant to one side or the other. It must be perfectly horizontal. Measuring Point 1 10 mm (0.4 in) or Measuring Point 2 20 mm (0.8 in)

Legend 1. Grade 2. Fron Frontt Mark Mark Cut Cut 8. Inspec Inspectt the the pisto piston n ring. ring. • Insert the piston piston ring ring horizontal horizontally ly (in the position position it would assume if it were installed to the piston) into the cylinder liner.

• Use a thickness thickness gauge to measure measure the piston piston ring gap. If the measured value exceeds the specified limit, the piston ring must be replaced.

Piston ring gap

mm (in) Standard

Limit

1st compression ring

0.27 - 0.51 (0.0106 - 0.0200)

1.50 (0.059)

2nd compression ring

0.42 - 0.66 (0.0165 - 0.0260)

1.50 (0.059)

6A-86

ENGINE MECHANICAL (4JJ1) 0.27 - 0.56 (0.0106 - 0.220)

Oil ring

1.50 (0.059)

Measure the clearance between the piston ring groove and the piston. • Remove Remove carbon carbon in in the pisto piston n ring groov groove. e. • Put the piston ring in the piston piston ring ring groove, groove, use a thickness gauge to measure the gap between them. • If the the clearance clearance between between the piston piston ring groove and the piston exceeds the limit, replace the piston and the piston ring.

Piston ring and piston ring groove clearance

mm (in)

Standard

Limit

1st compression ring

—*

—*

2nd compression ring

0.05 - 0.09 (0.0020 - 0.0035)

1.50 (0.059)

Oil ring

0.03 - 0.07 (0.0012- 0.0028)

1.50 (0.059)

• Inspect Inspect to make make sure that there there is a resistance resistance to the extent which the piston can push the piston pin lightly in normal temperatures. • If it feels a large loosene looseness ss or instab instability ility in normal temperatures, replace the piston or piston pin.

*Measurement is impossible

9. Inspec Inspectt the the piston piston pin. pin. • Visually Visually inspect inspect the piston piston pin for for cracks, cracks, scratches and other damages, and replace it if necessary. • Use a micr micromet ometer er to meas measure ure the the outer outer diameter of the piston pin. If the measured value exceeds the limit, replace the piston pin.

Piston pin outer diameter

mm (in)

Stand tandar ard d

33.9 33.995 95 - 34.0 34.000 00 (1.3 (1.338 3838 38 - 1.33 1.3385 858) 8)

Limit

33.970 (1.33740)

• Measure Measure the the bush bush of the small small edge of the connecting rod. If the clearance of the bush inner diameter and the pin diameter exceeds the limit, replace the bush or connecting rod assembly, assembly, and the pin.

Piston pin and connecting rod small end bushing clearance

mm (in)

Standard

0.008 - 0.020 (0 (0.0003 - 0.0008)

Limit

0.05 (0.0020)


10. Measure Measure the clearance clearance between between the piston and and the piston pin. • Apply engine oil on the piston pin. Use your finger to push it in the piston hole and rotate it. If the pin smoothly rotates without instability, the clearance is normal. If there is instability, instability, measure the clearance. If the clearance exceeds the limit, replace the piston and the piston pin.

12. Measure the bearing oil clearance. clearance. • Install Install the bearing to the the connecting connecting rod big big end. • Tighten Tighten the the bearing bearing cap cap to the two two step step of angular tightening method. • Use an inside inside dial indicator indicator to to measure measure the the connecting rod bearing inside d iameter.

Conn Connec ecti ting ng rod rod bea beari ring ng cap cap bol boltt tor torqu que: e: Pis Piston ton pin pin and and pis pisto ton n pin pin hole hole clear learan ance ce

mm (in (in))

Standard

0.008 - 0.019 (0 (0.0003 - 0.0007)

Limit

0.04 (0.0016)

11. Measure Measure the connecti connecting ng rod alignment. alignment. • Use a connecting connecting rod aligner aligner to measure measure the torsion and parallel level of the big end hole and the small end hole. If the measured value value exceeds the limit, replace it.

Connecting rod alignment (par length of 100 mm (3.94 in))

6A-87

mm (in) (in)

1st step

29.4 (3.0 / 22)

2nd step

45 deg

If the clearance between the measured bearing inside diameter and the crank pin exceeds the specified limit, the bearing and/or the crankshaft must be replaced.

Crank pin and bearing clearance

mm (in)

Standard

0.029 - 0.083 (0 (0.0011 - 0.0026)

Limit

0.10 (0.0039)

mm (in)

Standard

Limit

Distortion

0.08 (0 (0.003) or or le less

0.20 (0 (0.008)

Parallelism

0.05 (0 (0.002) or or le less

1.50 (0 (0.006)

Reassembly 1. Instal Installl the the piston piston.. 2. Install Install the the connect connecting ing rod. rod. • Install Install it so that that the front mark mark of the the head of the piston, and the connecting rod forging mark (projecting) on the connecting rod, both face in the same direction. • Instal Installl the snap snap ring ring of of one side. side.

6A-88

ENGINE MECHANICAL (4JJ1) • Insert the expander expander coil into into the the oil ring groove groove so that there is no gap on either side of the expander coil before installing the oil ring.

Legend 1. Fron Frontt Mark Mark 2. Forging Forging Mark Mark (Proj (Project ecting ing)) 3. Apply enough enough engine engine oil on the piston piston pin, pin, push itit in the piston and the connecting rod small edge. 4. Use snap snap ring pliers pliers to to install install the snap snap ring. ring. NOTE: Make sure that the snap ring is installed in the ring groove properly. Make sure that the connecting rod moves smoothly. smoothly.

Legend 1. Compres Compression sion Ring Ring 1st 1st 2. Compres Compression sion Ring Ring 2nd 2nd 3. Oil Oil Ring Ring 4. Exp Expande ander r

Installation 1. Install Install the the connecting connecting rod bearing. bearing. • Install Install the bearing bearing on the the connecting connecting rod, and apply engine oil on the bearing. 2. Install Install the piston piston and connectin connecting g rod assembly assembly.. • Apply enough engine oil on on the piston piston ring, ring, ring groove and piston side surface. • Dislocate Dislocate the piston ring end gap gap so that that (1) (1) is 1st ring, (3) is 2nd ring and (2) is oil ring, as shown in the drawing. • With the the piston piston front front mark mark cut cut facing facing forward, forward, use the piston ring compressor to insert the piston in the cylinder liner. NOTE: • Be sure not to make the the connecting connecting rod touch touch the oil jet when pushing in the piston. • Be sure not to harm the the inside inside of the cylinder cylinder block when pushing in the piston.

5. Use ring ring pliers pliers to install install the the piston ring. • Install Install the piston piston rings in the order shown shown in in the illustration. • Install Install 2nd and 1st 1st compressio compression n rings in this this order so that the marks "2N" and "N" face upward.

ENGINE MECHANICAL (4JJ1) Special tool Piston ring compressor: 5-8840-9018-0

4. Install Install the oil pan. pan. Refer to "Oil Pan and Crank Case". 3. Instal Installl the connec connectin ting g rod cap. cap. • Install Install the the bearing bearing on the connect connecting ing rod rod cap and apply engine oil. • Install Install the cap, matching matching the numbers numbers (1, 2, 3, and 4) of the caps and connecting rods.

5. Install Install the gear case assembly assembly. Refer to "Gear Case Assembly". 6. Install Install the the cylin cylinder der head. head. Refer to "Cylinder Head". 7. Install Install the the camshaft camshaft assembly assembly.. Refer to "Camshaft Assembly". 8. Install Install the the cylinder cylinder head cover. cover. Refer to "Cylinder Head Cover".

• Apply engine oil on on the screw part and the the setting face of the tightening bolt and tighten it with the designated torque. Tightening torque: 1st step = 29.4 N ⋅m (3.0 kg⋅m / 22 lb ft) 2nd step = 45 ° (degrees) Special tool Angle gauge: 5-8840-0266-0 NOTE: Make sure that the crankshaft smoothly rotates.

6A-89

6A-90





5-8840-9018-0 Piston ring compressor



Flywheel Components

Legend 1. Pressur Pressure e Plate Plate Assembl Assembly y 2. Driv Driven en Plate Plate 3. Pilo Pilott Beari Bearing ng 4. Washer 5. Flyw Flywhe heel el

Removal 1. Remove Remove the starte starterr. 2. Remove Remove the transmission transmission assembly assembly.. Refer to "transmission assembly removal and installation". 3. Remove Remove the the clutch clutch pressure pressure plate. plate. • Remove Remove the pressure pressure plate installatio installation n bolts bolts in the order shown in the drawing. • Remove Remove the pressure pressure plate plate from from the the flywheel. flywheel.

6. 7. 8. 9.

Beari Bearing ng Sto Stoppe pper r Flyw Flywhe heel el Hous Housin ing g Flywhe Flywheel el (Smooth (Smoother er E) E) Flex Flexib ible le Plate Plate

6A-91

6A-92

ENGINE MECHANICAL (4JJ1) • In the case of A/T car, car, after after loosening loosening the flywheel installation bolts, remove the washer, flexible plate, flywheel and sleeve in this order.

4. Remove Remove the driven driven plate plate.. • Remove the driven plate from the flywheel flywheel along with the clutch aligner (1). 5. Install Install the crankshaf crankshaftt stopper stopper in the starter starter installation part of the flywheel housing.

7. Remove Remove the the pilot pilot bear bearing. ing. • Remove the pilot pilot bearing bearing from the the flywheel flywheel..

NOTE: Make sure that the stopper is applied with the ring gear and installed pro perly. perly. Special tool Crankshaft stopper: 5-8840-0214-0

Special tool Pilot Bearing Remover: 5-8840-2000-0 Sliding Hammer: 5-8840-0019-0 8. Remove Remove the the ring ring gear gear.. • Put a bar bar on the the ring ring gear gear and hit hit it with with a hammer to remove it. 6. Remove Remove the flywhe flywheel. el. • Gradually Gradually loosen loosen the flywheel flywheel installat installation ion bolts bolts in the order shown in the drawing so that the flywheel does not rotate. • After loosening loosening the the bolts, bolts, remove remove the stopper stopper and remove the flywheel.


6A-93

Depth = From the pressure installation surface to the friction surface.

Inspection

3. Flywheel Flywheel installatio installation n bolts. bolts.

1. Visual Visual inspect inspection ion

• There There is no damage damage in appe appearan arance. ce.

• Inspect Inspect the flywheel flywheel frictio friction n surface surface for for cracks cracks and damages, and replace it if it has abnormality. • Inspect Inspect the tooth part of of the ring gear gear,, replace replace the ring gear if it ha s damage or serious wear. 2. Measurement Measurement of the the friction friction surface surface

• Exchange Exchange for for a new new part part if damag damage e is extensive.

Installation 1. Install Install the the pilot pilot bear bearing ing

• Measure Measure the depth of of the frictio friction n surface surface of the flywheel.

• Place the crankshaf crankshaftt pilot pilot bearing bearing right angle across the crankshaft bearing installation hole.

• Adjust it if the measured measured value is within within the the standard value and the limit.

• Tap around around the edges edges of the the crankshaf crankshaftt pilot bearing outer races with a brass hammer to drive the bearing into the crankshaft bearing installation hole.

• If the the measured measured value value exceeds exceeds the limit, limit, replace replace the flywheel.

2. Install Install the the ring ring gear gear.. Dept Depth h of the the fric fricti tion on surf surfac ace e of the the flyw flywhee heell Standard

12 (0.4724)

Limit

13 (0.5118)

mm (in) (in)

• Heat the ring ring gear gear evenly evenly with with a gas burner burner to to invite thermal expansion. Do not allow the temperature of the gas burner to exceed 200 °C (390°F). • Install Install the ring gear gear when when it is suffici sufficiently ently heated. The ring gear must be installed with the chamfer facing the clutch. NOTE: • Install Install the ring ring gear so that the side side with a pattern pattern faces forward. • Shrink fit the the ring gear to the flywheel flywheel.Make .Make sure that flywheel and ring gear adhesion is complete.

6A-94


3. Instal Installl the the flywh flywheel eel.. • Install Install the flywheel flywheel of the cranksha crankshaft, ft, tighten tighten them in the order shown in the illustration. • Apply molybdenum molybdenum disulfide disulfide on the screw part and setting face of the bolt. • Install Install the crankshaft crankshaft stopper on the the starter starter installation part of the flywheel housing. Tightening torque: 1st step = 59 N ⋅m (6.0 kg⋅m / 43 lb ft)

Legend 1. Clutc Clutch h Ali Align gner er 5. Install Install the clutch clutch pressure pressure plate. plate. • Install Install the pressure pressure plate on the flywheel flywheel so that that the installation hole of the pressure plate matches with the dowel pins of the flywheel. • Tighten Tighten the the pressure pressure plate plate in the order order shown shown in the drawing. Tightening torque: 51N ⋅m (5.2 kg⋅m / 38 lb ft)

2nd step = 60 ° - 90° (degrees) Special tool Crankshaft stopper: 5-8840-0214-0

6. Install Install the transmission transmission assembly assembly.. Refer to "transmission assembly removal and installation". 4. Instal Installl the driven driven plat plate. e. • Use a clutch clutch aligner aligner to install install the driven driven plate plate on the flywheel.

7. Instal Installl the starte starterr. Tightening torque: 127 N⋅m (13 kg⋅m / 94 lb ft)




5-8840-2230-0 Crankshaft stopper


6A-95

6A-96


Gear Case Assembly Components

Legend 1. Adju Adjust st Pla Plate te 2. Gene Genera rato tor r

Removal 1. Remove Remove the the engine engine assembl assembly y. Refer to “Engine Assembly”. 2. Remove Remove the the cylin cylinder der head head.. Refer to “Cylinder Head”. 3. Remove the adjustment adjustment bracket bracket of generato generator. r. 4. Remove Remove the the vacuum vacuum pump pump and pipe. pipe. Refer to removal procedure for brake in this manual.

3. Gask asket 4. Gear Gear Cas Case e Assem Assembl bly y

5. Remove Remove the the power power steering steering pump. pump. Refer to removal procedure for power steering in this manual. 6. Remove Remove the water water pump. pump. Refer to removal procedure for water pump in this manual. 7. Remove Remove the the fuel supp supply ly pump. pump. Refer to removal procedure for fuel supply pump in this manual.


6A-97

8. Remove Remove the the crankshaf crankshaftt pulley pulley.. Refer to removal procedure for crankshaft front oil seal in this manual.

• Install Install the timing gear case case to match with the the dowel pins, install bolts them in the ord er shown in the illustration.

9. Remove Remove the the gear gear case cover cover.. Refer to removal procedure for gear case cover in this manual.

• Do not remove remove the the bolts(1 bolts(11) 1) when mainta maintaining. ining.

10. Remove Remove the idle idle gear A and and idle gear gear A shaft, shaft, idle gear C and idle gear C shaft. Refer to “Timing Gear Train”. 11. Remove Remove the the oil oil pump. pump. Refer to “Oil Pump”. 12. Remove Remove the timing timing gear case (1) and gasket gasket (2).

Installation 1. Install Install the gasket of the timing gear case. case. • Apply Apply liqui liquid d gasket gasket (Three (ThreeBond Bond 1207 1207B B or equivalent) on the joint (1) of the cylinder block and the crank case.

Legend 1. Gear Gear Case Case Ass Assem embl bly y 2. Bolt Bolt L = 20 mm mm (0.79 (0.79 in) 3. Bolt Bolt L = 60 mm mm (2.36 (2.36 in) 4. Bolt Bolt L = 45 mm mm (1.77 (1.77 in) 5. Bolt Bolt L = 35 mm mm (1.38 (1.38 in) 6. Bolt Bolt L = 16 mm mm (0.63 (0.63 in) 7. Bolt Bolt L = 20 mm mm (0.79 (0.79 in) 8. Bolt Bolt L = 25 mm mm (0.98 (0.98 in) 9. Nut 10. UP 10. Bolt • Tighten Tighten the bolts bolts and nuts to the specified specified torque. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft) 3. Install Install the oil pump. pump. Refer to “Oil Pump”. 4. Install Install the idle idle gear C shaft shaft and idle idle gear C, idle idle gear A shaft and idle gear A. Refer to “Timing Gear Train”. 5. Instal Installl the gear gear case cove cover. r. Refer to removal procedure for gear case cover in this manual. 6. Install Install the the crankshaft crankshaft pulley. pulley. Refer to removal procedure for crankshaft front oil seal in this manual. 7. Install Install the the fuel supp supply ly pump. pump. Refer to installation procedure for fuel supply pump in this manual. 8. Instal Installl the water water pump. pump. Refer to installation procedure for water pump in this manual.

2. Instal Installl the timin timing g gear case. case.

6A-98


9. Install Install the the power power steerin steering g pump. pump. Refer to removal procedure for power steering in this manual. 10. Install Install the the vacuum vacuum pump pump and and pipe. pipe. Refer to removal procedure for brake in this manual.


11. Install Install the adjustment adjustment bracket bracket of generator generator.. Tighten the bolts to the specified torque. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft) 12. Instal Installl the cylind cylinder er head. head. Refer to “Cylinder Head”. 13. Install Install the engine engine assembly assembly.. Refer to “Engine Assembly”.


Crankshaft Front Oil Seal Components

Legend 1. Bolt 2. Washer 3. Cranks Crankshaf haftt Damper Damper Pull Pulley ey 4. Cranks Crankshaf haftt Front Front Oil Oil Seal Seal

Removal 1. Remove Remove the radiato radiator. r. Refer to “Radiator“ in ENGINE COOLING section. 2. Remove Remove the the fan assem assembly bly.. • Remove Remove the the fan assemb assembly ly unscrew unscrewing ing four four mounting nuts.

5. Gear Gear Case Case Cove Cover r 6. Slin Slinge ger r 7. Cran Cranks ksha haft ft Gea Gear r

6A-99

6A-100


3. Remove Remove the fan belt. belt. 4. Remove the crankshaft crankshaft pulley. pulley. NOTE: Do not reuse the crankshaft pulley bolt and the washer. 5. Remove the crankshaf crankshaftt front front oil seal. • Use the the special special tool to remove remove the front front oil oil seal. seal.

• Tight Tighten en the the bolt as as far as itit will will go. Special tool Oil seal and slinger installer: 5-8840-2855-0

The length from the surface of the crankshaft gear to the surface of the slinger:

Special tool Remover: 5-8840-0027-0

5.8 - 6.2 mm (0.228 - 0.244 in)

• Put a rod rod and a woode wooden n piece piece etc. etc. as shown shown in in the illustration. And pull the rod to the front slowly, slowly, and remove the crankshaft front oil seal.

Legend 1. Rod 2. Remo Remove ver r 3. Wood Wooden en Pie Piece ce 6. Remove Remove the the gear gear case cove coverr. 7. Remove Remove the slinge slingerr. • Remove the slinger slinger with a screwdriv screwdriver er etc. etc. avoiding damage to the surface of the crankshaft gear.

Legend 1. Bolt 2. Washer 3. Slinge Slingerr Instal Installe ler r 4. Sli Slinger ger 5. Cran Cranks ksha haft ft Gear Gear 6. Cran Cranks ksha haft ft 2. Instal Installl the gear gear case case cover cover. 3. Install Install the crankshaft crankshaft front front oil oil seal. seal. • Use the the special tool to install install the front front oil seal. Use only one of the special tools when the oil seal is installed.

NOTE: The slinger does not need to be replaced if there are no scratches nor damages.

Special tool

Installation

The length from the surface of the crankshaft gear to the surface of the oil seal:

1. Instal Installl the the sling slinger er..

Oil seal and slinger installer: 5-8840-2855-0

• Use the the special special tool tool to install install the slinger slinger.. 14.75 - 15.25 mm (0.581 - 0.600 in)


Legend 1. Bolt 2. Washer 3. Front Front Oil Oil Seal Seal Insta Installe ller r 4. Gear Gear Cas Case e Cov Cover er 5. Front Front Oil Oil Sea Seall 6. Sli Slinger ger 7. Cran Cranks ksha haft ft Gear Gear 8. Cran Cranks ksha haft ft • Apply Apply engin engine e oil to to the lip lip of the oil oil seal. seal. 4. Install Install the cranksha crankshaft ft damper damper pulley pulley.. • Install Install the crankshaft crankshaft pulley pulley aligning aligning with with the key on the crankshaft. • Hold the flywheel flywheel ring ring gear gear stationary stationary to prevent prevent the crankshaft from turning when tightening the damper pulley bolt. • Tighten ighten in the seque sequence nce show shown. n. • Take care care not to damage damage the the crankshaf crankshaftt damper pulley boss. Tightening torque: 294 N⋅m (30 kg⋅m/217 lb ft) 5. Instal Installl the the fan fan belt. belt. Refer to "Engine Cooling" 6. Instal Installl the radiat radiator or.. Refer to “Radiator“ in ENGINE COOLING section.

6A-101

6A-102



Special Tool Illustration


5-8840-0027-0 Remover

5-8840-2855-0 Oil seal and slinger installer


Crankshaft Rear Oil Seal Components

Legend 1. Starte arter r 2. Trans Transmis missio sion n Assemb Assembly ly 3. Clutch Clutch Pressure Pressure Plate Plate 4. Driv Driven en Pla Plate te

Removal 1. Remove Remove the flywhe flywheel. el. Refer to "Flywheel". • With the oil oil seal seal pushed pushed in deep, install install the special tool as shown in the illustration and remove the oil seal.Oil Seal Remover: 5-88402360-0

5. 6. 7. 8.

Flyw Flywh heel eel Cranks Crankshaf haftt Rear Rear Oil Seal Seal Trans Transmis mission sion Assembl Assembly y Flex Flexib ible le Plate Plate

6A-103

6A-104

ENGINE MECHANICAL (4JJ1) • Use an oil seal seal install install to install install the cranksha crankshaft ft rear oil seal. Oil Seal Installer: 5-8840-2359-0

Installation 1. Install Install the crankshaft crankshaft rear rear oil seal.



5-8840-2359-0 Oil seal installer

5-8840-2360-0 Oil seal remover

2. Instal Installl the the flywh flywheel eel.. Refer to "Flywheel".


6A-105

Crankshaft Components

Legend 1. Upper Upper Beari Bearing ng 2. Thrust Thrust Beari Bearing ng 3. Gear

Removal 1. Demount Demount the the engine engine assembly assembly.. Refer to "Engine Assembly". 2. Remove Remove the cylinder cylinder head head cover cover.. Refer to "Cylinder Head Cover". 3. Remove Remove the camsha camshaft. ft. Refer to "Camshaft Assembly". 4. Remove Remove the the cylin cylinder der head. head. Refer to "Cylinder Head".

4. Cran Cranks ksha haft ft 5. Lower Lower Beari Bearing ng 6. Bear Bearin ing g Cap Cap

5. Remove the fuel fuel supply supply pump and common common rail. rail. Refer to "Fuel Supply Pump and Common Rail" in the fuel system section. 6. Remove Remove the the front front cove coverr. Refer to "Front Cover". 7. Remove the cranksha crankshaft ft rear rear oil oil seal. seal. Refer to "Crankshaft Rear Oil Seal".

6A-106


8. Remove Remove the water water pump. pump. Refer to "Water Pump" in the Cooling System Section. 9. Remove Remove the the timing timing gear gear train train.. Refer to "Timing Gear Train". 10. Remove Remove the oil pump. pump. Refer to "Oil Pump".

18. Remove Remove the the thrust thrust bearing bearing.. 19. Remove Remove the upper crankshaft crankshaft bearings. bearings.

Disassembly 1. Remove Remove the crank crank angle angle sensor sensor rotor rotor..

11. Remove the gear gear case assembly assembly.. Refer to "Gear Case Assembly". 12. Remove the crankshaft crankshaft gear. gear.

Legend 1. Crank Crank Angle Angle Sensor Sensor Roto Rotor r 2. Bolt 13. Remove Remove the crank crank case. case. Refer to "Crank Case and Oil Pan". 14. Remove pistons pistons and connecting connecting rods. Refer to "Pistons and Connecting Rods". 15. Remove Remove the bearing bearing cap. cap. • Loosen the cranksha crankshaft ft bearing bearing cap bolts bolts in numerical order a little at a time.

Reassembly 1. Install Install the the crank crank angle angle sensor sensor rotor rotor • Attach Attach by makin making g a rotor tooth' tooth's s running running out out side into a front side. • Apply Loctite Loctite #262 or the equivale equivalent nt to the bolt bolt threads (if a new bolt is used, Loctite application is not required). Tightening torque: 12 N ⋅m (1.2 kg⋅m / 104 lb in)

16. Remove the lower lower crankshaft crankshaft bearings. bearings. 17. Remove the cranksha crankshaft ft assembly assembly..


Legend 1. Crank Crank Angle Angle Senso Sensorr Rotor Rotor 2. Bolt

6A-107

2. Main bearin bearing g clear clearanc ance e • Remove the crankcase.Set crankcase.Set out disassembled disassembled main bearings in the order of the numbers. • Remove Remove the the cranksha crankshaft. ft. Remo Remove ve the main main bearings.

Inspection

• Clean the cranksha crankshaft ft journal journal and upper upper and lower bearings.

1. Thrus Thrustt cleara clearanc nce e • Measure Measure the crankshaft crankshaft end play play at the center journal of the crankshaft. • Do this this before before removing removing the crankshaf crankshaftt bearing bearing caps. If the measured value exceeds the specified limit, the crankshaft thrust bearing must be replaced.

Axial play of the crankshaft Standard

mm (in) 0.10 (0.004)

NOTE: Measure the thrust clearance before dismounting.

• Check the bearings bearings for damage or excessi excessive ve wear. If you find damage or excessive wear, replace the bearings in pairs. • Place the upper upper bearings bearings and and the crankshaft crankshaft on on the cylinder block. Install the crankshaft so that it is horizontal. NOTE: Turn the crankshaft about 30 degrees to allow the bearings to settle in. • Place Plastigage Plastigage on the cranksha crankshaft ft journal journal as shown.

6A-108


• Place the the lower lower bearings bearings at original original positions positions on the bearing cap.

• Install Install the bearing cap and and tighten tighten bolts bolts to the specified tightening torque. • Tighten Tighten the the bearing bearing cap in the sequence sequence shown using a torque wrench and an angle gauge.

#1,#2, #2,#4,# 4,#5

0.030 030 - 0.0 0.054 (0 (0.0012 012 - 0.0021) 21)

#3

0.042 - 0.066 (0.0016 - 0.0026)

• If the journal journal oil clearance clearance exceeds exceeds the the limit, limit, replace the main bearings altogether or the crankshaft. • Remove the Plastiga Plastigage ge from from the the bearings bearings and the crankshaft. Inspection of the crankshaft • Check the crankshaf crankshaftt journal journal and crank crank pin surfaces for wear and damage. Check the oil seal contact surface for excessive wear and damage. • Check Check the the oil port for clog cloggin ging. g. 3. Cranks Crankshaf haftt run-out run-out Carefully set the crankshaft on the V block. Slowly turn the crankshaft to measure the run-out. If the crankshaft run-out exceeds the limit, replace the crankshaft.

Crankshaft run-out Standard Tightening torque: 166 N ⋅m (16.9 kg ⋅m / 122 lb ft) NOTE: Do not turn the crankshaft after you have tightened the bearing cap. • Loosen the bolts bolts and and gently gently remove remove the the bearing bearing cap. • Measure Measure the the widest widest part part of the the Plasti Plastigag gage e flattened by tightening the bearing cap to determine the clearance.

Journal oil clearance

mm (in)

mm (in) 0.05 or less (0.0020 or less)


6A-109

NOTE: Tufftriding (soft nitriding treatment) is applied to enhance strength of the crankshaft. Therefore, you should not polish the surface of the crankshaft. Crankshaft bearing selection • Crankshaft Crankshaft bearing bearing selectio selection n is based based on the measured diameters of the crankshaft journals and the bearing inserts. • Match the crankshaf crankshaftt bearing bearing housing housing grade grade marks and the crankshaft journal grade marks in the table below to determine the correct crankshaft bearing size. • Crankshaft Crankshaft bearing bearing housing housing grade grade marks marks 1, 1, 2 or 3 are stamped on the rear right hand side of the cylinder body b ody..

4. Measure Measure the journal journal and and the crank pin pin diameters diameters and uneven wear. • Measure Measure outer outer diameters diameters of the the journal journal and and the the pin and calculate differences between the maximum and the minimum values. Take measurements at four positions for both the journal and the pin.

Legend 1. No.1 2. No.2 3. No.3 4. No.4 5. No.5

Crankshaft Outside Diameter

mm (in)

Standard

Limit

Journal

69.917 - 69.932 (2.7526 - 2.7532)

69.91 (2.7524)

Pin

52.915 - 52.930 (2.0833 - 2.0839)

52.9 (2.083)

• The cranksha crankshaft ft journal journal grade marks (1 or -, 2 or --, 3 or ---) are stamped on each crankshaft journal web. The crankshaft journal journal and bearing clearance must be the same for each position after installation of the crankshaft and the crankshaft bearings. NOTE: The crankshaft journal mark No. 4 is stamped on crankshaft No. 4 journal web front side or rear side.

6A-110 6A-110


Legend 1. No.1 2. No.2 3. No.3 4. No.4 5. No.5 NOTE: Be careful about difference in the shape of the bearings when installing them.

ENGINE MECHANICAL MECHANIC AL (4JJ1)

3

73.97573.982 (2.91242.9127)

1 or -

69.92769.932 (2.75302.7532)

2 or - -

69.92269.927 (2.75282.7530)

3 or - - -

69.91769.922 (2.75262.7528)

6A-111 6A-111

1

2

Bearing Selection Table (#3) mm (in) Crankshaft Bearing Housing Legend 1. Lot No No 2. Size Size Code ode

Grade Mark

Diameter

Bearing Selection Table (#1, #2, #4, #5)

Crankshaft Journal Grade Mark

Diameter

1 or -

69.92769.932 (2.75302.7532)

2 or --

69.92269.927 (2.75282.7530)

3 or - - -

69.91769.922 (2.75262.7528)

3

1 or -

69.92769.932 (2.75302.7532)

0

2 or - -

69.92269.927 (2.75282.7530)

1

3 or - - -

69.91769.922 (2.75262.7528)

2

mm (in) Crankshaft Bearing Housing Grade Mark

1

2

Diameter

73.99274.000 (2.91312.9134)

73.98373.991 (2.91272.9130)

Crankshaft Journal

Crankshaft Bearing Size Code

Grade Mark

Diameter

1 or -

69.92769.932 (2.75302.7532)

2 or --

69.92269.927 (2.75282.7530)

3 or - - -

69.91769.922 (2.75262.7528)

1 or -

69.92769.932 (2.75302.7532)

2

2 or - -

69.92269.927 (2.75282.7530)

3

3 or - - -

69.91769.922 (2.75262.7528)

4

1

73.99274.000 (2.91312.9134)

4

5

2

73.98373.991 (2.91272.9130)

Crankshaft Bearing Size Code

2

6A-112 6A-112

3


73.97573.982 (2.91242.9127)

1 or -

69.92769.932 (2.75302.7532)

2 or - -

69.92269.927 (2.75282.7530)

3 or - - -

69.91769.922 (2.75262.7528)

9

2. Install Install the crankshaf crankshaftt assembly assembly.Apply .Apply an an ample coat of engine oil to the crankshaft journals and the crankshaft bearing surfaces before installing the crankshaft.

0

Installation 1. Install Install the the crankshaf crankshaftt upper upper bearing. bearing. • The crankshaf crankshaftt upper upper bearings bearings have have an oil hole hole and an oil groove. The lower bearings do not. • Carefully Carefully wipe wipe any any foreign foreign material material from from the upper bearing. • Locate Locate the the positi position on mark mark applie applied d at disassembly if the removed upper bearings are to be reused. NOTE: Do not apply engine oil to the bearing back faces and the cylinder body bearing fitting surfaces.

3. Instal Installl the thrus thrustt bearing bearing.. • Apply an an ample ample coat of engine engine oil to the thrust bearings before installation. Install the thrust bearings to the crankshaft center journal. • The thrust thrust bearing oil grooves must be facing facing the sliding faces.

4. Install Install the the lower lower crankshaf crankshaftt bearing. bearing. • Before the cranksh crankshaft aft bearing bearing installa installation, tion, select the appropriate bearings in accordance with the description in CRANK BEARING SELECTION of INSPECTION INSPE CTION AND REPAIR. 5. Instal Installl the bearing bearing cap. cap.

ENGINE MECHANICAL MECHANICA L (4JJ1) • Install Install the bearing bearing caps caps with with the bearing bearing cap head arrow mark facing the front of the engine. The bearing cap numbers must be facing up.

6A-113

8. Install Install the the crankshaf crankshaftt gear gear..

9. Install Install the gear case assembly assembly. Refer to "Gear Case Assembly". • Tighten Tighten the crankshaft crankshaft bearing bearing cap cap bolts bolts to the the specified torque a little at time in the sequence shown in the illustration.

Crank ankshaf haft Bea Bearin ring Cap Torque

N⋅m (kg⋅m / lb ft)

166 (16.9 / 122) Check to see the crankshaft turns smoothly by rotating it manually. manually. NOTE: Confirm that the crankshaft turns smoothly.

10. Instal Installl the the oil oil pump. pump. Refer to "Oil Pump". 11. Install Install the timing gear train. train. Refer to "Timing Gear train". 12. Instal Installl the the water water pump. pump. Refer to "Water Pump" in the Cooling System Section. 13. Instal Installl the front front cover cover.. Refer to "Front Cover". 14. Install Install the crankshaft crankshaft rear rear oil oil seal. seal. Refer to "Crankshaft Rear Oil Seal". 15. Install Install the fuel fuel supply supply pump and common common rail. rail. Refer to "Fuel Supply Pump and Common Rail". 16. Instal Installl the cylin cylinder der head. head. Refer to "Cylinder Head". 17. Install Install the the camshaft camshaft assembly assembly.. Refer to "Camshaft Assembly". 18. Install Install the the cylinder cylinder head cover. cover. Refer to "Cylinder Head Cover". 19. Mount the the engine engine assembly assembly on on the chassis. chassis. Refer to "Engine Assembly".

6. Install Install pistons pistons and connecti connecting ng rods. rods. Refer to "Pistons and Connecting Rods". 7. Instal Installl the crank crank case. case. Refer to "Crank Case and Oil Pan".

6A-114 6A-114



ENGINE MECHANICAL MECHANICA L (4JJ1)

6A-115

Cylinder Block Components

Legend 1. Cyli Cylinde nderr Blo Block ck

Removal 1. Demount Demount the the engine engine assembly assembly.. Refer to "Engine Assembly". 2. Remove Remove the cylinder cylinder head head cover cover.. Refer to "Cylinder Head Cover". 3. Remove Remove the camshaft camshaft assembly assembly.. Refer to "Camshaft Assembly".

13. Remove Remove the oil pump. pump. Refer to "Oil Pump". 14. Remove pistons and connect connecting ing rods. rods. Refer to "Pistons and Connecting Rods". 15. Remove Remove the the cranksh crankshaft aft.. Refer to "Crankshaft" 16. Remove the piston piston cooling cooling pipe. pipe.

4. Remove Remove the the cylin cylinder der head. head. Refer to "Cylinder Head". 5. Remove Remove the fuel fuel supply supply pump and fuel rail assembly. Refer to "Fuel Supply Pump” and “Fuel Rail Assembly" in FUEL SYSTEM section. 6. Remove Remove the oil filter filter assembly assembly and oil oil cooler. cooler. Refer to "Oil Filter Assembly and Oil Cooler". 7. Remove Remove the crankshaft crankshaft front front oil oil seal. seal. Refer to "Crankshaft Front Oil Seal". 8. Remove Remove the crankshaft crankshaft rear oil oil seal. seal. Refer to "Crankshaft Rear Oil Seal". 9. Remove Remove the oil pan. pan. Refer to "Oil Pan". 10. Remove Remove the the wate waterr pump. pump. Refer to "Water Pump" in the Cooling System Section. 11. Remove Remove the the front front cover cover. Refer to "Front Cover". 12. Remove Remove the the timing timing gear gear train. train. Refer to "Timing Gear Train".

Inspection 1. Carefully Carefully remove remove water water stains stains or other other foreign foreign matters on the surface of the cylinder block.

6A-116 6A-116


• Be careful careful not to to damage damage the the cylinder cylinder block. block. 2. Carefully Carefully remove remove the the liquid liquid crankcase mounting surface.

gasket gasket

on the

3. Clean Clean up the the cylind cylinder er block block..

Standard dard

95.421 421 - 95. 95.450 (3.756 7567 - 3.7579 579)

Limit

95.48 (3.7590)

6. Cylind Cylinder er Reborin Reboring. g.

4. Visually Visually inspec inspectt the cylinder cylinder block. block. • Conduc Conductt color color check check and hydra hydraulic ulic (or (or pneumatic) test and if you find a crack or other damage, replace the cylinder block.

• Select oversize oversize pistons pistons to fit fit the largest largest cylinder cylinder bore (previously measured). • At a point point 11 11 mm (0.43 in) in) above above the lower edge of the piston skirt, measure the piston diameter at a right angle to the piston pin. Calculate the additional cylinder boring required for each cylinder.

5. Cylinder Cylinder block wear measurement. measurement. • Use a cylind cylinder er indicator indicator to measure measure the cylinder cylinder bore at measuring point (1) in the thrust (2-2) and axial (3-3) directions of the crankshaft. • Measuri Measuring ng Point Point (1): (1): 20 mm mm (0.79 (0.79 in). If the measured value exceeds the specified limit, the cylinder block must be replaced or rebored.

Legend 1. 11 mm mm (0. (0.43 43 in) in) • Formula Boring inside diameter = D + C - H ± E D = Piston outside diameter (Measured Oversize Piston) C = Piston and cylinder bore clearance 0.082 - 0.100 mm (0.0032 - 0.0039 in) H = Honing allowance 0.03 mm (0.0012 in) or less E = Boring machine error

Piston size

mm (in)

Stand andard ard

95.340 - 95.389 389 (3 (3.75 .7535 - 3.7555)

Overs Oversiz ize(0 e(0.2 .25) 5)

95.59 95.590 0 - 95.63 95.639 9 (3.76 (3.7634 34 - 3.7 3.765 653) 3)


95.84 95.840 0 - 95.88 95.889 9 (3.77 (3.7732 32 - 3.7 3.775 752) 2)


96.09 96.090 0 - 96.13 96.139 9 (3.78 (3.7831 31 - 3.7 3.785 850) 0)

• Bore and and hone hone the the cylinders cylinders individually individually as required. • Once Once again, again, measure measure each each cylin cylinder der bore. bore. Cylinder block bore diameter

mm (in)

Each cylinder bore remainder

mm (in)


6A-117

Installation

0.02 (0.0008) or less.

1. Install Install the the piston piston cooling cooling pipe. pipe. 7. Cylinder Cylinder block block upper face warpage. warpage. • Use a straig straight ht edge edge (1) and a thick thicknes ness s gauge gauge (2) to measure the four sides and the two diagonals of the cylinder body upper face. • If the the measured measured values exceeds exceeds the limit, the cylinder body must be replaced.

• Align the the dowel dowel pin pin of the piston piston cooling cooling pipe with the pin hole on the cylinder block and tighten with the relief valve. Tightening torque: Relief valve 30 N ⋅m (3.1 kg⋅m / 22 lb ft) bolts M8 25 N ⋅m (2.5 kg ⋅m / 18 lb ft)

Cylinder block upper face warpage

mm (in)

Standard

0.05 or less (0.002 or less)

Limit

0.20 (0.079)

Cylinder body height (H) (Reference) Stand tandar ard d

mm (in)

262. 262.94 945 5 - 263. 263.05 055 5 (10. (10.35 352 2 - 10.3 10.356 56))

bolts M6 8 N⋅m (0.8 kg⋅m / 69 lb in) NOTE: Be careful not to deform or damage the piston cooling pipe nozzle.

2. Instal Installl the crank cranksha shaft. ft. Refer to "Crankshaft". 3. Install Install pistons pistons and connect connecting ing rods. rods. Refer to "Pistons and Connecting Rods". 4. Instal Installl the the oil oil pump. pump. Refer to "Oil Pump". 5. Instal Installl the timin timing g gear train train.. Refer to "Timing Gear Train". 6. Instal Installl the fron frontt cover cover.. Refer to "Front Cover". 7. Instal Installl the water water pump. pump. Refer to "Water Pump" in the Cooling System Section. 8. Install Install the oil pan.Re pan.Refer fer to "Oil Pan". Pan". 9. Install Install the the crankshaft crankshaft rear oil oil seal. seal. Refer to "Crankshaft Rear Oil Seal". 10. Install Install the crankshaft crankshaft front front oil oil seal. seal. Refer to "Crankshaft Front Oil Seal". 11. Install Install the oil filter filter assembly and and oil cooler. cooler. Refer to "Oil Filter Assembly and Oil Cooler".

6A-118 6A-118


12. Install Install the fuel fuel supply pump pump and fuel fuel rail assembly assembly.. Refer to "Fuel Supply Pump” and “Fuel Rail Assembly" in FUEL SYSTEM section. 13. Instal Installl the cylin cylinder der head. head. Refer to "Cylinder Head".


14. Install Install the the camshaft camshaft assembly assembly. Refer to "Camshaft Assembly". 15. Install Install the cylinder cylinder head head cover. cover. Refer to "Cylinder Head Cover". 16. Mount the engine engine assembly assembly on the chassis. chassis. Refer to "Engine Assembly”.


6A-119

Lubrication System Service Precautions • During each disassem disassembly bly,, remove the old old gasket gasket adhering to each part and mating part completely using a scraper at the location, where the fluid gasket is to be used, clean the traces of oil, moisture, and dirt completely using waste cotton and apply the specified new fluid gasket at each location.

• Avoid excessive excessive or insufficien insufficientt coating coating volume. volume. Note that seizure may occur in case of excessive coating due to clogging of the oil gallery and oil jet, and oil and water leakage may occur if the coating is insufficient. • Always, the start start and end of the applicat application ion should should be overlapped. Explanations on functions and operation The lubrication system uses the filter element combined with a full flow bypass, water-cooled oil cooler, and oil jet for piston cooling.

Lubricating system diagram

Legend 1. Oil Pump Relief Valve Operating Operating Pressur Pressure: e: 490 2 686 kPa (5.0 - 7.0 kg/cm / 71 - 100 psi)

2. Oil Cooler Cooler Relief Relief Valve Valve Opening Opening Pressure: Pressure: 176 176 2 216 kPa (1.8 - 2.2 kg/cm / 26 - 31 psi)

6A-120


3. Oil Filter Filter Relief Relief Valve Valve Opening Opening Pressure: Pressure: 80 80 120 kPa (0.8 - 1.2 kg/cm 2 / 11 - 17 psi) 4. Oil Pressure Pressure Switch Switch Operatin Operating g Pressure: Pressure: 29.4 29.4 2 49.0 kPa (0.3 - 0.5 kg/cm / 4.3 - 7.1 psi)

5. Regulating Regulating Valve: Valve: 176 176 - 216 kPa kPa (1.8 - 2.2 kg/ cm2 / 26 - 31 psi)

Functional Check

Engine oil

Oil pressure check

Ensure the car is on level ground. Before starting the engine or when 30 minutes or more have elapsed after stopping the engine, check the engine oil volume using the level gauge. The volume is appropriate if the engine oil is between the upper and lower limits of the level gauge. Replenish the engine oil, if level is below the lower limit. Also, check for contamination of the engine oil.

1. Check whether whether the engine engine oil is is contaminat contaminated ed with dirt, light oil, or water. If contaminated with dirt, light oil, or water (after examining the cause and taking the appropriate measures for light oil or water contamination), replace the oil. 2. Check the the engine engine oil level. level. The oil oil level level should be between the two holes of the level gauge. If the oil level is insufficient, replenish it. 3. Remove the oil pressur pressure e switch switch on the nipple. nipple. 4. Install Install the oil oil pressure pressure gauge gauge on the the nipple. nipple. 5. Warm Warm the the engi engine ne.. 6. Measure the oil pressur pressure, e, to check check whether whether it is more than 400 kPa (4 kg/cm 2 / 58 psi) at 3600 rpm. 7. Stop top the the engi engine ne..

ADD

FULL

8. Remove Remove the the oil press pressure ure gauge gauge.. 9. Install Install the the oil oil pressure pressure switch. switch.

1

10. Start Start the engine engine and check for for oil leakage. leakage.

2

RTW56ASH015701

Legend 1. Lowe Lowerr Lim Limit it 2. Uppe Upperr Lim Limit it Engine oil leakage • In the lift up up condition, condition, confirm confirm that there are no leaks from the cylinder head cover and oil pan.


Oil Filter Element Components

Legend 1. Oil Oil Cool Cooler er 2. Oil Oil Filt Filter er Elem Element ent 3. Gask asket 4. Plate 5. Spring ing

Removal 1. Place a tray under the oil oil filter filter.. 2. Remove Remove the drain drain plug, plug, and oil oil in the filter is is drained. 3. Remove Remove the center center bolt, bolt, and remove remove the the element element in the case. NOTE: Do not reuse the two O-rings and the gasket.

Installation 1. Instal Installl the oil filte filterr element element.. • Apply grease(Besco grease(Besco L2, L3 or equivalen equivalent) t) or engine oil to the O-rings and the gasket. • Tighten Tighten the the bolt bolt and the drain drain plug plug using using the specified torque. Tightening torque: Center bolt 44 N ⋅m (4.5 kg⋅m / 33 lb ft) Drain plug 24 N ⋅m (2.4 kg⋅m / 17 lb ft)

6. 7. 8. 9. 10. 10.

Cent Center er Bolt Bolt O-rin -ring g O-rin -ring g Drai Drain n Plug Plug Oil Oil Filt Filter er Case Case

6A-121

6A-122




Oil Filter Assembly and Oil Cooler Components

Legend 1. Oil Filter Filter Assembly Assembly and and Oil Cooler Cooler 2. Wate Waterr By Pas Pass s Pipe Pipe

Removal 1. Remove Remove the the turboch turbocharg arger er.. Refer to “Turbocharger”. 2. Remove Remove the the exhaust exhaust manif manifold. old. Refer to “Exhaust Manifold”.

3. Wate Waterr Intak Intake e Pipe Pipe

3. Remove the water water by by pass pass pipe pipe (1).

6A-123

6A-124


4. Remove Remove the water water intak intake e pipe (1). (1).

Disassembly 1. Remove Remove the element mounting nuts(1). nuts(1).

Legend 1. Wate Waterr Intak Intake e Pipe Pipe 2. Bra Bracket 3. Bra Bracket 4. Bolt

2. Remove Remove the the elem element ent (1). 3. Remove Remove the gasket gasket (2). (2).

5. Remove the oil cooler and oil oil filter filter..

Reassembly 1. Install Install the the gasket gasket on on the element. element. 2. Instal Installl the the elem element ent.. 3. Tighten Tighten the element element fixing fixing nuts nuts using the the specified specified torque. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft)

Installation 1. Install Install the oil filter filter and and cooler cooler.. • Install Install the O-ring O-ring on on the oil filter and and cooler cooler,, apply grease.

ENGINE MECHANICAL (4JJ1) • Apply the liquid liquid gasket and mount mount within within 5 minutes. Apply liquid gasket (ThreeBond TB1207C or equivalent) to the flange surface groove (cylinder block). Bead diameter must be between 2 and 3 mm (0.008 and 0.012 in). Refer to the illustration for the offset position (no more than 1 mm (0.004 in)).

6A-125

• Tighten Tighten the bolts bolts to the specifi specified ed torque torque in the order shown in the illustration. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft)

2. Install Install the water intake intake pipe. pipe.

Legend 1. Liqu Liquid id Gask Gasket et 2. O-ring ring • Align the oil oil filter filter and cooler cooler holes with the cylinder block studs. Install the oil cooler to the cylinder clock.

• After applying applying soapy soapy water water to O-ring, O-ring, set it on water intake pipe and insert into the oil cooler.Tighten the bolts to the specified torque. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft) 3. Install Install the water by pass pass pipe. • After applying applying soapy soapy water water to O-ring, O-ring, set it on by pass pipe and insert into the cylinder head.Tighten the bolts to the specified torque. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft) 4. Install Install the bracket of generato generator. r. Tighten the bolts to the specified torque. Tightening torque: 51 N ⋅m (5.2 kg⋅m / 38 lb ft) 5. Install Install the adjustmen adjustmentt bracket bracket of generator generator.. Tighten the bolts to the specified torque. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft) 6. Install Install the the genera generator tor.. Refer to Installation procedure for generator in this manual. 7. Install Install the the exhaust exhaust manif manifold old.. Refer to Installation procedure for turbocharger and exhaust manifold in this manual.

Legend 1. Bolt Bolt 35 35 mm mm X 11 2. Bolt Bolt 70 mm X 4 3. Bolt Bolt 90 mm X 2 4. Nut X 2

6A-126


Crank Case and Oil Pan Components

Legend 1. Flyw Flywhee heell Housi Housing ng 2. Cyli Cylind nder er Block Block 3. Oil Oil Strai trainer ner

Removal 1. Remove the engine assembly assembly.. Refer to “Engine Assembly“. 2. Remove the oil level gauge guide guide tube. tube. 3. Remove Remove the the heater heater pipe pipe and hose. hose.

4. Cran Crank k Case Case 5. Oil Pan Pan

ENGINE MECHANICAL (4JJ1) 4. Remove Remove the oil pan. pan.

5. Remove Remove the flywhe flywheel. el. Refer to “Flywheel”. 6. Remove Remove the flywh flywheel eel housin housing. g.

9. Remove Remove the the reta retaine inerr.

Legend 1. Ret Retaine ainer r 2. Bolt 10. Remove Remove the the crank crank case. case.

Legend 1. Bolt 2. Bolt 3. Nut 7. Remove Remove the the cylin cylinder der head. head. Refer to “Cylinder Head”. 8. Remove Remove the the timing timing gear gear case. case. Refer to “Timing Gear Case”.

Legend 1. O-ri -ring 2. Cran Crank k Case Case NOTE: Take care not to damage an O-ring.

6A-127

6A-128


Disassembly 1. Remove Remove the the oil oil strain strainer er..

Legend 2. Oil Oil Strai trainer ner 3. Bolt 4. Cran Crank k Case Case

Legend 1. 2.0 - 3.0 3.0 mm (0.079 (0.079 - 0.1 0.118 18 in) 2. 4.0 - 5.0 mm mm (0.157 (0.157 - 0.17 0.179 9 in) 2. Instal Installl the the oil oil pan. pan. Apply the liquid gasket (ThreeBond TB-1207B or equivalent)and mount within 5 minutes. Tightening torque: 22 N ⋅m (2.2 kg⋅m / 16 lb ft)

Reassembly Install the oil strainer. • Install Install the the packing packing on the straine strainer. r. • Tighten Tighten the the bolts bolts to the specified specified torque. torque. Tightening torque: 22 N ⋅m (2.2 kg⋅m / 16 lb ft)

Installation 1. Instal Installl the the crank crank case. case. • Apply the liquid liquid gasket (ThreeBond (ThreeBond TB-1207C TB-1207C or equivalent) and mount within 5 minutes. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft)

Legend 1. 2.0 2.0 mm (0.07 (0.079 9 in) in) 2. 3.0 3.0 mm (0.1 (0.118 18 in) in) 3. Instal Installl the retain retainer er.. • Apply the liquid gasket (ThreeBond (ThreeBond TB-1207C TB-1207C or equivalent) and mount within 5 minutes. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft)


6A-129

4. Install Install the heater pipe and hose. hose.

Legend 1. 2 - 2.5 2.5 mm (0.07 (0.079 9 - 0.098 0.098 in) 2. 2 - 2.5 2.5 mm (0.07 (0.079 9 - 0.098 0.098 in)

5. Install Install the the timing timing gear gear case. case. Refer to “Timing Gear Case”. 6. Install Install the the cylin cylinder der head. head. Refer to “Cylinder Head”. 7. Install Install the the Flywheel Flywheel housin housing. g. • Tighten Tighten the the bolts bolts to to the specified specified torque. torque. Tightening torque: Bolt (1) : 106 N ⋅m (10.8 kg⋅m / 78 lb ft) Bolt (2) : 82 N ⋅m (8.4 kg⋅m / 61 lb ft) Bolt (1) : 51 N ⋅m (5.2 kg⋅m / 38 lb ft)

Legend 1. Ret Retaine ainer r 2. Bolt

8. Install Install the flywhe flywheel. el. Refer to “Flywheel”. 9. Install Install the oil level level gage gage guide guide tube. tube. • Apply Apply the the engine engine oil oil to the the O-rin O-ring. g. • Tighten Tighten the the bolts bolts to to the specified specified torque. torque. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft)

6A-130


10. Install Install the the engine engine assembly assembly.. Refer to “Engine Assembly“.



Oil Pump Components

Legend 1. Bolt

Removal 1. Drain Drain the the engine engine coola coolant. nt. 2. Remove Remove the the radiato radiatorr upper upper hose. hose.

2. Oil Pump Assembly

6A-131

6A-132


3. Remove Remove the the fan guide guide brac bracket ket..

Legend 1. Fan Guide Guide Brac Bracket ket (RH) 2. Fan Guide Guide Brac Bracket ket (LH) (LH) 3. Bolt 4. Remove Remove the the fan and and fan clut clutch. ch. • Loosen Loosen the the fan fan clutch clutch nuts nuts.. • Remove the fan together together with the fan fan clutch. clutch. Take care not to damage the radiator core. 5. Remove the fan drive belt belt and and pulley pulley. • Loosen the tension tension adjust bolt on the the generator generator and A/C. • Remove the fan drive belt with with the fan pulley pulley.. 6. Disconnect Disconnect the power power steering steering pump. pump. 7. Remove Remove the vacuum vacuum pump pump.. • Remove the vacuum vacuum pipe bracket bracket and vacuum pipe. • Remove the oil oil pipe (feed side side and return side) of vacuum pump.

8. Remove Remove the the noise noise cover cover (1). (1).

9. Remove Remove the the crank crank pulley pulley.. NOTE: Do not reuse the crank pulley bolt and washer. 10. Remove Remove the cover cover of the gear gear case cover(1). cover(1).

ENGINE MECHANICAL (4JJ1) 11. Remove Remove the gear case case cover cover..

12. Remove Remove the oil pump. pump.

6A-133

4. Install Install the the sprin spring g pin. pin.

Legend 1. Sprin pring g Pin Pin 2. Sprin pring g Seat Seat 3. Sprin ring 4. Valve

Inspection NOTE: Think to match direction of ditch of gear when assembling it. 1. Measure Measure the clearance clearance between between the driven driven gear/ gear/ drive gear shaft and the bush. • Measure the outside outside diameter diameter of the driven driven gear shaft using a micrometer.

Legend 1. Oil Pu Pump

Disassembly 1. Remove Remove the spring spring pin. pin. 2. Remove Remove the the sprin spring g seat. seat. 3. Remov Remove e the spr sprin ing. g. 4. Remov Remove e the val valve ve..

Reassembly 1. Instal Installl the the valve. valve. 2. Instal Installl the the spring. spring. 3. Instal Installl the spring spring seat. seat.

Outside diameter of the driven gear shaft/ drive gear shaft

mm (in)

Standar ndard d

15.9 15.989 89 - 16.0 16.000 00 (0. (0.62 6294 949 9 - 0.6 0.629 2992 92))

Limit

15.900 (0.62598)

6A-134

ENGINE MECHANICAL (4JJ1) • Measure the width width size size the the driven driven gear/driv gear/drive e gear.

• Measure the inside inside diameter diameter of the bushes bushes of the cylinder block using the dial gauge. • If the clearance clearance between between the the driven driven gear gear shaft/ shaft/ drive gear shaft and bush exceeds the limit, replace the oil pump assembly.

Clearance between the driven gear shaft/ drive gear shaft and bush

mm (in)

Standard

0.04 - 0.07 (0.0016 - 0.0028)

Limit

0.20 (0.0079)

2. Measure the clearance clearance between between the gear side side surface and the gear side surface of the oil pump housing.

• Measure Measure the the Depth Depth size size of the gear gear case case housing surface and the oil pump housing gear case side.

Depth size the gear case housing surface Stand andard

mm (in)

14.5 4.500 - 14.52 .527 (0 (0.5709 - 0.5 0.57 719) 19)

Clearance between the gear side surface and the gear side surface of the oil pump housing

mm (in)

Standard

0.065 - 0.109 (0 (0.0026 - 0.0043)

Limit

0.20 (0.0079)

ENGINE MECHANICAL (4JJ1) Installation 1. Instal Installl the the oil oil pump. pump.

6A-135

• Tighten Tighten the the bolts bolts to to the specified specified torque. torque. Tightening torque: 8 N⋅m (0.8 kg⋅m / 69 lb in)

• Apply engine engine oil to the the oil pump attachm attachment ent gearbox. • Tighten Tighten the the bolts bolts to the specified specified torque. torque. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft)

3. Install Install the cover cover of the the gear case case cover. cover. 4. Instal Installl the crank crank pulley pulley.. • Tighten Tighten the the bolts bolts to to the specified specified torque. torque. Tightening torque: 294 N ⋅m (30 kg⋅m / 217 lb ft) Legend 1. Oil Pu Pump • Installed Installed pump pump gear gear should should be smooth to rotate. rotate. 2. Instal Installl the gear gear case cover cover.. • Apply the liquid gasket (Threebond (Threebond TB-1207B TB-1207B or equivalent) mount within 5 minutes.

5. Instal Installl the nois noise e cover cover.. • Tighten Tighten the the bolts bolts to to the specified specified torque. torque. Tightening torque: 10 N ⋅m (1.0 kg⋅m / 87 lb in) 6. Instal Installl the vacuum vacuum pump pump.. • Tighten Tighten the the nuts nuts to the specifi specified ed torque. torque. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft) • Install Install the oil oil pipe (feed (feed side side and return return side) side) of vacuum pump. • Install Install the vacuum pipe bracket bracket and vacuum pipe. 7. Install Install the the power power steering steering pump. • Tighten Tighten the the nuts nuts to the specifi specified ed torque. torque. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft) 8. Install Install the fan fan drive drive belt and and pulley. pulley. • Install Install the fan fan drive belt with with the fan fan pulley pulley. 9. Install Install the the fan fan and and fan fan clutch. clutch. • Tighten Tighten the the bolts bolts to to the specified specified torque. torque. Tightening torque: 8 N⋅m (0.8 kg⋅m / 69 lb in) 10. Adjust the drive drive belt belt of generato generatorr and A/C A/C compressor.

Legend 1. Apply Apply The Liqui Liquid d Gasket Gasket in Area Area • Install Install the the gasket gasket in the the slot slot of the the gear gear case case cover.

• Apply tension tension to the fan fan drive drive belt belt by moving the generator.

6A-136


• Apply a force of 98 N (10 kg / 22 lb) to the drive belt mid portion to check the drive belt deflection.

Generator drive belt deflection New belt

5 - 6 (0.20 - 0.24)

Reuse belt

7 - 8 (0.28 - 0.32)

A/C compressor drive belt deflection New belt

6 - 7 (0.24 - 0.28)

Reuse belt

8 - 9 (0.32 - 0.35)

11. Install Install the the fan guide bracket. bracket. 12. Install Install the the radiato radiatorr upper upper hose. hose. 13. Replen Replenish ish the the engine engine coolant. coolant.

mm (in)

mm (in)


Oil Pressure SW Components

Legend 1. Oil Oil Pres Pressu sure re SW 2. Gask asket

Removal 1. Remove Remove the the oil press pressure ure SW. SW. 2. Remove Remove the nipple; nipple; oil pressure pressure warning warning SW and gasket.

Installation 1. Install Install the nipple; nipple; oil oil pressure pressure warning warning SW and gasket. Tightening torque: 25 N ⋅m (2.5 kg⋅m/18 lb ft) 2. Install Install the the oil oil pressure pressure SW. SW. Tightening torque: 15 N ⋅m (1.5 kg⋅m/11 lb ft)

3. Nipple Nipple;; Oil Pressur Pressure e Warning Warning SW

6A-137

6A-138


Inspection Check the continuity between the switch terminal and the body grounding in a no-load condition.If there is no connectivity, connectivity, replace with normal parts.

Circuit check 1. Turn Turn the start starter er switch switch to to ON. 2. Disconnect Disconnect the the oil pressure pressure switch switch connector connector,, and confirm that the oil pressure-warning lamp lights when the connector on the harness side is grounded. If the warning lamp does not light up, check the circuit between the meter and the oil pressure switch, and repair the disconnected locations.


Air Cleaner Element Removal 1. Remove Remove the air air cleaner cleaner cover cover fixing fixing bolt. bolt. 2. Remove Remove the air cleaner element element assembly assembly..

Cleaning Dry type element • Rotate Rotate the element element with your hand hand while while applyin applying g compressed air to the inside of the element. This will blow the dust free.

Compressed air pressure

kPa (kg/cm2 /psi)

690 (7 / 100)

Installation 1. Install Install the air air cleaner cleaner element element assembly assembly.. 2. Install Install the the air air cleaner cleaner cover. cover.

6A-139

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ENGINE COOLING (4JJ1)

ENGINE ENGINE COOLING (4JJ1) TABLE OF CONTENTS Main Data and Specifications . . . . . . . . . . . . . . . . 6B-2 Main Data and Specifications. . . . . . . . . . . . . . . 6B-2 General General Description Description . . . . . . . . . . . . . . . . . . . . . . 6B-3 Diagnosis Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-7 Diagnosis Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-7 Draining and Refilling Cooling System . . . . . . . . . 6B-8 Draining and Refilling Cooling System. . . . . . . . 6B-8 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-9 Removal and Installation . . . . . . . . . . . . . . . . . . 6B-9 Thermostat Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-11 6B-11 Removal and Installation . . . . . . . . . . . . . . . . . 6B-11 Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13 Removal and Installation . . . . . . . . . . . . . . . . . 6B-13 Radiator Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-15 Radiator Core. . . . . . . . . . . . . . . . . . . . . . . . . . 6B-15 Flushing the Radiator . . . . . . . . . . . . . . . . . . . . 6B-15 Cooling Cooling System Leakage Leakage Check . . . . . . . . . . . 6B-15 Engine coolant coolant change change . . . . . . . . . . . . . . . . . . 6B-17 Fan Clutch Clutch with Cooling Cooling Fan. . . . . . . . . . . . . . . . 6B-18 Inspection Inspection and Repair Repair . . . . . . . . . . . . . . . . . . . 6B-18 Special Tools Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-19

6B-1

6B-2


Main Data and Specifications Main Data and Specifications Description

Item

M/T

Cooling system

Smoother

Engine coolant forced circulation

Water pump type

Centrifugal impeller type

Pump to crankshaft speed ratio

(To 1)

Delivery volume

lit (US/UK gal)/min

1.25 240 (63.1/53.3)

Pump speed at 5600 rpm Water temperature at 30°C (86°F) Pump bearing type

Double row shaft

Thermostat type

Wax pellet with jiggle valve

Valve initial opening temperature

°C (°F)

85 (185)

Valve full opening temperature

°C (°F)

100 (212)

Valve lift at fully open position

mm (in)

10 (0.39)

Radiator

Tube type corrugated

Heat radiation capacity

kW

91.2

Heat radiation area

m2 (ft2)

10.9 (117.3)

Radiator front area

m2 (ft2)

0.242 (2.6)

Radiator dry weight

N (kg/lb)

Radiator cap valve opening pressure

kPa (psi)

Engine coolant capacity

lit (U.S pint)

6.7 (7.1)

Engine coolant total capacity

lit (U.S pint)

10 (10.6)

125.5 (12.8 / 28.2)

128.5 (13.1 / 28.9)

93.3 – 122.7 (13.5 – 17.8)

ENGINE COOLING (4JJ1) General Description Coolant Flow

The engine cooling system consists of the radiator, the water pump, the cooling fan, and the thermostat. To quickly increase cold engine coolant temperature for smooth engine operation, the coolant is circulated by the water pump and thermostat through the bypass pipe and back to the cylinder body. The coolant does not circulate through the radiator. When the coolant temperature reaches specified value, the thermostat will begin to open and a gradually increasing amount of coolant will circulate through the radiator. The thermostat will be fully open when the coolant temperature reaches specified value. All of the coolant is now circulating through the radiator for effective engine cooling.

6B-3

6B-4


Water Pump

RTW56BSF000101

A centrifugal type water pump forcefully circulates the coolant through the cooling system. The water pump is not disassembled type. Thermostat

RTW56BSF000201

A wax pellet type thermostat is used.


6B-5

Radiator The radiator is a tube type with corrugated fins. In order to raise the boiling point of the coolant, the radiator is fitted with a cap in which the valve is operated at 93.3 – 122.7 kPa (0.95 – 1.25 kg / cm 2 / 13.5 – 17.8 psi) pressure. (No oil cooler provided for M/T)

Freezing temperature guideline

Mix ratio Liter Liter (qts) (qts)

Concentration of engine coolant

Engine coolant

Tap water

-18°C (-0.4°F)

3.5 (3.7)

6.5 (6.9)

35%

-25°C (-13°F)

4.2 (4.4)

5.8 (6.1)

42%

-35°C (-31°F)

5.0 (5.3)

5.0 (5.3)

50%

-40°C (-40°F)

5.3 (5.6)

4.7 (5.0)

53%

2. Engine coolant coolant density density measurement measurement Methods for measuring specific gravity • Measure Measure the the speci specific fic grav gravity ity and and the temperature of the cooling water using an antifreeze specific gravity meter and thermometer. Take precautionary measures as the boiled cooling water may gush out at high temperatures if the cap is removed. • Use a deep contain container er to suit the the height height of of the specific gravity meter. Engine Coolant 1. About the engine engine coolant concentration concentration • Take the concentratio concentration n correspondin corresponding g to the the minimum temperature because the freezing temperature varies according to the concentration of the engine coolant. • Use only only genuin genuine e Isuzu Isuzu engine engine coola coolant. nt. • Use engine engine coolant coolant with with a mix mix ratio in the range range of 30 to 60% because over heating is likely to occur if the ratio is greater than 60% and corrosion prevention is inadequate if the ratio is less than 30%.

Legend 1. Anti-Freeze Anti-Freeze Specific Specific Gravity Gravity Meter Meter 2. Radi Radiat ator or • Fix the the temperatur temperature e of the cooling cooling water being measured in the range of 0 to 50 ° C (32 (32 to to 122 ° F).

6B-6


• Measure the temperature temperature and specifi specific c gravity gravity and determine the concentration from the table given below.

Coolant scooping method • Measure the concentration concentration using the coolant coolant scoop.


6B-7

Diagnosis Diagnosis Condition Engine overheating

Possible Cause

Correction

Low Engine Coolant level

Replenish

Thermo meter unit faulty

Replace

Faulty thermostat

Replace

Faulty Engine Coolant temperature sensor

Repair or replace

Clogged radiator

Clean or replace

Faulty radiator cap

Replace

Low engine oil level or use of improper engine oil

Replenish or change oil

Clogged exhaust system

Clean ex exhaust sy system or or re replace faulty parts

Faul Faulty ty Thro Thrott ttlle Pos Posit itio ion n sen senso sorr

Repl Repla ace thro thrott ttle le valv valve e ass assem embl bly y

Open or shorted Throttle Position sensor circuit

Repair or replace

Damaged cylinder head gasket

Replace

Engine overcooling

Faulty thermostat

Replace

Engine slow to warm–up

Faulty thermostat

Replace

Thermo unit faulty

Replace

6B-8


Draining and Refilling Cooling System Draining and Refilling Cooling System Before draining the cooling system, inspect the system and perform any necessary service to ensure that it is clean, does not leak and is in proper working order. The engine coolant (EC) level should be between the "MIN" and "MAX" lines of reserve tank when the engine is cold. If low, check for leakage and add EC up to the "MAX" line. There should not be any excessive deposit of rust or scales around the radiator cap or radiator filler hole, and the EC should also be fr ee from oil.Replace the EC if excessively dirty.

• Press the radiator radiator upper hose(1) hose(1) 2 to 3 times times as shown in the illustration. If the coolant level is down caused by the air was bled, poor the coolant again.

1. Completely Completely drain drain the cooling cooling system system by opening opening the drain plug at the bottom of the radiator. 2. Remove Remove the radi radiator ator cap. cap. WARNING: To avoid the danger of being burned, do not remove the cap while the engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure. 3. Disconnect Disconnect all all hoses hoses from the the EC reserve reserve tank. tank. Scrub and clean the inside of the reserve tank with soap and water. water. Flush it well with clean water, water, then drain it. Install the reserve tank and and hoses. 4. Refill the cooling cooling system system with with the EC. Procedure for filling with coolant (in case of full change) • Confir Confirm m that the the engin engine e has cool cooled. ed. • Open the the radiator radiator cap cap and the reserve reserve tank tank cap. cap. • Unscrew Unscrew the air air bleedi bleeding ng bolt(2 bolt(2). ). • Pour Pour the coola coolant nt up to the the fille fillerr neck. neck.

• Pour the the coolan coolantt up to the the "MAX" "MAX" line line in the reserve tank. • Tighten Tighten the air air bleeding bleeding bolt firmly firmly.. • Close the radiato radiatorr cap and and the reserve tank cap cap and start the engine. Stop the engine after running for about 2 to 3 minutes at the idling rpm. Open the radiator cap again and replenish if the water level is low. WARNING: Do not loosen or remove the radiator cap when the temperature of the cooling water is high. Steam or boiling water will gush out and you may be burnt. To open the radiator cap, cover the cap with a thick cloth when the cooling water is cool, release the pressure by slowly turning the cap, and then remove the cap. • After tightening tightening the radiator radiator cap, warm up up the engine by running it at about 2000 rpm. • When the the pointer pointer of of the thermometer thermometer crosses crosses the median and the thermostat has activated, run at idling rpm for another 5 minutes, then stop the engine and leave it as-is. • After the engine engine has cooled cooled down down sufficient sufficiently ly,, check the water level in the filler neck part and replenish if necessary. If the level is extremely low, check for leaks in the cooling water conduit system and reserve tank hose.


6B-9

Water Pump Removal and Installation

b. Remove the fan drive belt belt with the the fan pulley pulley..

Read this Section carefully before performing any removal and installation procedure. This Section gives you important points as well as the order of operation. Be sure that you understand everything in this Section before you begin. Removal 1. Remove Remove the the engine engine cover cover.. 2. Radiat Radiator or Upper Upper Hose a. Partially Partially drain the engine coolant. coolant. b. Remove Remove the the radiato radiatorr upper upper hose. hose. 3. Water Water Out Outle lett Pipe Pipe a. Disconnect Disconnect the turbocharg turbocharger-coo er-cooling ling pipe pipe from from the outlet pipe. b. Loosen the fixing fixing bolt bolt and remove the water water outlet bolt. 4. Fan Fan guid guide e brac bracke kett

7. Wate Waterr Pum Pump p a. Remove the water water pump pump bolts bolts and and nuts. nuts. b. Remove Remove the water water pump. pump.

Legend 1. Fan Gui Guide de Brac Bracke kett RH 2. Fan Gui Guide de Brac Bracke kett LH 3. Bolt 5. Fan and Fan Clut Clutch ch a. Loosen Loosen the the fan fan clutch clutch nuts nuts.. b. Remove Remove the fan fan together together with with the fan fan clutch. clutch. Take care not to d amage the radiator core. 6. Fan Drive Drive Belt Belt and and Pulle Pulley y a. Loosen the tension tension adjust adjust bolt on the generator generator..

RTW56BSH000201

Inspection and Repair The water pump is not disassembled type.Make necessary parts replacement if extreme wear or damage is found during inspection. Should any of the following problems occur, the entire water pump assembly must be replaced. • Cracks Cracks in in the wate waterr pump pump body body. • Coolant Coolant leaka leakage ge from from the seale sealed d unit. unit. • Excessive Excessive radial radial play play or abnorma abnormall noise noise in the the fan fan center when rotated by hand. • Excessive Excessive thrust thrust play in the fan center center (Standa (Standard rd play: less than 0.2 mm (0.0078 in)).

6B-10


• Cracks Cracks or corro corrosion sion in in the impel impeller ler..

d. Apply a force force of 98 N (10 kg/22 kg/22 lb) to the drive drive belt mid-portion to check the drive belt deflection.

Installation 1. Water ater Pump Pump

Fan Drive Belt Deflection

mm (in)

New belt

5 - 6 (0.20 – 0.24)

Reuse belt

7 - 8 (0.28 – 0.32)

3. Fan Fan guide guide brack bracket et 4. Water Water Outlet Outlet Pipe. Pipe. a. Install Install the water outlet outlet pipe pipe to the the thermostat thermostat housing. b. Tighten Tighten the outlet outlet pipe pipe bolt to to specified specified torque. torque. Outlet Pipe Bolt Torque: 25 N⋅m (2.5 kg⋅m /18 lb ft) c. Connect Connect the turbocharger-c turbocharger-cooling ooling pipe to to outlet outlet pipe. 5. Radiat Radiator or Uppe Upperr Hose Hose.. RTW56BSH000201

a. Install Install the water water pump pump with with a new new gasket. gasket. b. Tighten Tighten bolts bolts and nuts nuts to specifi specified ed torque. torque. Water Pump Bolt/Nut Torque: 25 N⋅m (2.5 kg⋅m /18 lb ft) 2. Fan Drive Drive Belt and Pulley Pulley and Fan Fan and Fan Fan Clutch. Clutch.

a. Install Install the fan fan drive belt belt and fan fan pulley pulley and fan fan and fan clutch. b. Tighten Tighten the the nuts nuts to specified specified torque. torque. Fan Clutch Nut Torque: 8 N ⋅m (0.8 kg⋅m /69 lb in) c. Apply tension tension to the fan drive drive belt belt by moving moving the generator.

a. Connect Connect the radiator radiator upper hose hose to the the water water outlet pipe. b. The knob knob of clamp shall be directed directed to horizontal. c. Replen Replenish ish the the engine engine cool coolant ant.. 6. Instal Installl the engin engine e cover cover.


6B-11

Thermostat Removal and Installation Read this Section carefully before performing any removal and installation procedure. This Section gives you important points as well as the order of operation. Be sure that you understand everything in this Section before you begin.

2. Heat the water water.St .Stir ir the water water constantly constantly to avoid avoid direct heat being applied to the thermostat. 3. Check the thermostat thermostat initial initial opening opening temperature. temperature.

Thermostat Initial Opening Temperature:

°C (°F)

85 (185) Removal 1. Remove Remove the the engine engine cover cover..

4. Check the the thermostat thermostat full full opening opening temperatu temperature. re.

2. Radiat Radiator or Upper Upper Hose a. Partially Partially drain the engine coolant. coolant.

Thermostat Full Opening Temperature:

b. Remove Remove the the radiato radiatorr upper upper hose. hose.

°C (°F)

100 (212)

c. Remove Remove the the engine engine harne harness ss clip. clip. 3. Water Water Out Outle lett Pipe Pipe a. Disconnect Disconnect the turbocharg turbocharger-coo er-cooling ling pipe pipe from from outlet pipe.

Valve Lift At Fully Open Position: 10 (0.39)

b. Loosen the fixing fixing bolt bolt and remove the water water outlet bolt. 4. Ther Thermo most stat at Remove the thermostat from the thermostat housing. Take care not to damage the thermostat.

Legend 1. Agita Agitati ting ng Rod Rod 2. Ther Thermo mome mete ter r 3. Wood Wooden en Pie Piece ce Legend 1. Jigg Jiggle le Valve alve 2. Ther Thermo most stat at Inspection and Repair Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. Operating Test of Thermostat 1. Completely Completely submerge submerge the thermost thermostat at in water. water.

mm (in)

6B-12


Installation 1. Ther Thermo most stat at Install the thermostat. Mount the jiggle valve with the valve facing engine front.

Legend 1. Jigg Jiggle le Valve alve 2. Ther Thermo most stat at 2. Water Water Outlet Outlet Pipe. Pipe. a. Install Install the water water outlet outlet pipe with with a new gasket to to the thermostat housing. b. Tighten Tighten the outlet outlet pipe pipe bolt to to specified specified torque. torque. Outlet Pipe Bolt Torque: 25 N⋅m (2.5 kg⋅m /18 lb ft) c. Connect Connect the turbocha turbocharger-co rger-cooling oling pipe pipe to outlet pipe. d. Instal Installl the engine engine harnes harness s clip. clip. 3. Radiat Radiator or Upper Upper Hose. Hose. a. Connect Connect the radiator radiator upper hose hose to the the water outlet pipe. b. The knob of the clamp clamp should should be directed directed to the horizontal side. c. Replen Replenish ish the the engin engine e coolant coolant.. 4. Instal Installl the engin engine e cover cover.


Radiator Removal and Installation Radiator and Associated Parts

Legend 1. Reserv Reserve e Tank Tank Hose Hose 2. Radi Radiat ator or Uppe Upperr Hose Hose 3. Radiat Radiator or & Inter Intercoo cooler ler Removal 1. Disconnect Disconnect battery ground cable. 2. Loosen the drain drain plug to to drain the the engine engine coolant. coolant. • After draining draining the the coolant, coolant, tighte tighten n the drain plug.

4. Fan Fan Gui Guide de 5. Radiat Radiator or Lower Lower Hose Hose

6B-13

6B-14


Legend 1. Radiat Radiator or Drain Drain Plug Plug 3. Remove the air air intake intake pipe pipe with the hoses. hoses. • Disconnect Disconnect the hose hose from from the intercooler intercooler side. side. • Remove the air air intake intake pipe pipe with with the hoses from the turbocharger side.

6. Remove Remove the radiator radiator upper upper hose hose on the the radiator radiator side. 7. Remove Remove the radiator radiator lower hose on on the radiator radiator side. 8. Remove Remove the coolant coolant reserve reserve tank tank hose hose from the the radiator side. 9. Remove Remove the the fan guide guide brack bracket. et.

• Do not disconnect disconnect the hoses hoses from the air intake intake pipe.

4. Disconnect Disconnect the ECM harness connector connector.. 5. Remove the air air intake intake pipe pipe with the hoses. hoses. • Disconn Disconnect ect the the connect connector or from from the boost boost sensor. • Disconnect Disconnect the hose hose from from the intercooler intercooler side. side. • Remove the air air intake intake pipe pipe with with the hoses from the intake throttle valve. • Do not disconnect disconnect the hoses hoses from the air intake intake pipe.

Legend 1. Fan Guide Guide Bracket Bracket RH 2. Fan Fan Guide Guide Brac Bracke kett LH 3. Bolt 10. Remove Remove the the inter inter cooler cooler..


6B-15

11. Take care to avoid avoid damage damage to the radiator radiator core from the fan blade, and remove the brackets on the right and left sides of the radiator. Simultaneously remove the radiator.

Radiator Core

Inspection and Repair Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.

Radiator Cap Measure the valve opening pressure of the pressurizing valve with a radiator filler cap tester.Replace the cap if the valve opening pressure is outside the standard range. Valve opening pressure: 93.3 – 122.7 kPa (0.95 – 1.25 kg / cm2 / 13.5 – 17.8 psi) Cap tester: 5-8840-0277-0 Adapter: 5-8840-2603-0 Check the condition of the vacuum valve in the center of the valve seat side of the cap. If considerable rust or dirt is found, or if the valve seat cannot be moved by hand, clean or replace the cap. Valve opening vacuum: 1.96 – 4.91 kPa (0.02 – 0.05 kg / cm2 / 0.28 – 0.71 psi)

1. A bent fin may may result result in reduced reduced ventilati ventilation on and overheating may occur. All bent fins must be straightened. Pay close attention to the base of the fin when it is being straightened. 2. Remove all dust, dust, bugs and and other other foreign material. material.

Flushing the Radiator Thoroughly wash the inside of the radiator and the engine coolant passages with cold water and mild detergent. Remove all signs of scale and rust.

Cooling System Leakage Check Use a radiator cap tester to force air into the radiator through the filler neck at the specified pressure of 196 kPa (2.0 kg / cm 2 / 28.5 psi) with a cap tester: • Leakage Leakage from the radiator radiator.. • Leakage Leakage from the coolant coolant pump. pump. • Leakage Leakage from the water water hoses hoses.. • Check Check the rubb rubber er hoses hoses for swel swellin ling. g.

6B-16

ENGINE COOLING (4JJ1) 6. Mount Mount the radia radiator tor upper upper hose. hose. 7. Pour engine engine coolant coolant up to to filler filler neck of radiator radiator,, and up to MAX mark of reserve tank. Important operation (in case of 100% engine coolant change) procedure for filling with engine coolant. • Confir Confirm m that the the engin engine e has coole cooled. d. • Open the the radiator radiator cap and and the reserve tank cap. • Unscrew Unscrew the air air bleed bleeding ing bolt( bolt(2). 2). • Pour the the coolan coolantt up to the the filler filler neck. neck. • Press the radiator radiator upper hose(1) 2 to 3 times as shown in the illustration. If the coolant level is down caused by the air was bled, poor the coolant again.

Installation 1. Ensure that that no damage damage occurs occurs to the the radiator radiator core because of the fan brade.Mount the brackets on the left and right sides of the radiator on the frame according to the figure. Tightening Torque: 26 N ⋅m (2.6 kg⋅m /19 lb ft)

• Pour the the cooling cooling water water up to the "MAX" line line in the reserve tank. • Tighten Tighten the the air air bleeding bleeding bolt firmly firmly.. • Close the radiator radiator cap and and the reserve tank cap and start the engine. Stop the engine after running for about 2 to 3 minutes at the idling rpm. Open the radiator cap again and replenish if the water level is low.

Legend 1. Flan Flange ge nut nut 2. Rubbe bber 3. Stud tud Bolt Bolt 4. Bra Bracket 5. Bracket Bracket on the Radi Radiator ator Side Side 6. Washer 2. Instal Installl the interc intercool ooler er.. 3. Instal Installl the fan fan guide guide bracket bracket.. 4. Mount the the reserve reserve tank hose hose of the coolant coolant on the radiator. 5. Mount Mount the radiat radiator or lower lower hose. hose.

WARNING: Do not loosen or remove the radiator cap when the temperature of the cooling water is high. Steam or boiling water will gush out and you may be burnt. To open the radiator cap, cover the cap with a thick cloth when the cooling water is cool, release the pressure by slowly turning the cap, and then remove the cap. • After tightening tightening the the radiator radiator cap, cap, warm warm up the the engine by running it at about 2000 rpm. • When the pointer pointer of the the thermomet thermometer er crosses crosses the median and the thermostat has activated, run at idling rpm for another 5 minutes, then stop the engine and leave it as-is.

ENGINE COOLING (4JJ1) • After the engine engine has cooled cooled down down sufficient sufficiently ly,, check the water level in the filler neck part and replenish if necessary. If the level is extremely low, check for leaks in the cooling water conduit system and reserve tank hose.

Legend 1. Rese Reserv rve e Tan Tank k 2. MAX Line Line (Uppe (Upperr Limit Limit)) 3. MIN Line Line (Lowe (Lowerr Limit Limit))

Engine coolant change Refer to change procedure for Draining and Refilling Cooling System in this section.

6B-17

6B-18


Fan Clutch with Cooling Fan Inspection and Repair Make necessary correction or parts replacement if wear, damage or any other abnormal condition are found through inspection. Visually inspect for damage, leak (silicon grease) or other abnormal conditions. 1. Inspec Inspectio tion n (on-veh (on-vehicl icle) e) a. Turn the fan clutch by hand when in a low temperature condition before starting the engine, and confirm that it can be turned readily.

2. Inspec Inspectio tion n (in (in unit) unit) Warm up the bimetal of the fan clutch by using the heat gun until the temperature gets to about 85°C(185°F) when measured with the thermistor. Then confirm that the fan clutch can be turned with considerable effort (clutch torque). If the fan clutch rotates more readily at this time, this indicates that the silicone grease is leaking internally. Replace the fan clutch with a new one.

b. Start Start the the engine engine to warm warm it up until until the temperature at the fan clutch portion gets to around 85°C(185°F). Then stop the engine and confirm that the fan clutch can be turned with considerable effort (clutch torque) when turned by hand. If the fan clutch rotates more readily, however, this indicates that the silicone grease is leaking internally. Replace the fan clutch with a new one.

3. Clearance Clearance between between fan and and fan guide The clearance in three places must be 3mm(0.118 in) or more.

ENGINE COOLING (4JJ1) Special Tools Illustration


5-8840-02770-0 Cap tester

5-8840-2603-0 Adapter

6B-19

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FUEL SYSTEM (4JJ1)

ENGINE FUEL SYSTEM (4JJ1) TABLE OF CONTENTS Fuel System System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-2 Service Service Precautions Precautions . . . . . . . . . . . . . . . . . . . . . . 6C-2 Work procedure . . . . . . . . . . . . . . . . . . . . . . . . .6C-2 Fuel System Check . . . . . . . . . . . . . . . . . . . . . .6C-7 Fuel Filter Assembly . . . . . . . . . . . . . . . . . . . . . . .6C-9 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-9 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-9 Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . .6C-10 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-10 Fuel Injector Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-12 Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-12 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-14 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6C-16 Fuel Pressure Pressure Sensor . . . . . . . . . . . . . . . . . . . . . 6C-17 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17 Fuel Pressure Limiter . . . . . . . . . . . . . . . . . . . . .6C-18 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-18 Fuel Rail Rail Assembly Assembly . . . . . . . . . . . . . . . . . . . . . . . 6C-19 Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-19 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-19 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-21 Reassembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-22 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6C-23 Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . . .6C-24 Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-24 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-28 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6C-33 Fuel Sedimenter Sedimenter Switch Switch . . . . . . . . . . . . . . . . . . . 6C-34 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-34 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-35 Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-35 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-35 Mounting Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-36 Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . .6C-37 Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-37 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-37 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-38 Mounting Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-39 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6C-39

6C-1

6C-2

FUEL SYSTEM (4JJ1)

Fuel System Service Precautions Parts of the fuel system such as the internal part of the fuel injector, and holes and clearances that form passages for fuel are finished to a very high degree of accuracy. They are therefore highly sensitive to foreign matter and the entry of foreign matter could cause damage to the fuel passage. Therefore, effective measures should be taken to prevent the entry of foreign matter. If a water removal agent is used in the fuel then it will absorb moisture in the light oil and may cause rust. Therefore, do not use a water removal agent in the fuel tank. When servicing the fuel system, every precaution must be taken to prevent the entry of foreign material into the system. • Before beginning beginning the the service service procedure, procedure, wash wash the the fuel line and the surrounding area. • Perform the service service procedures procedures with with clean clean hands. hands. Do not wear work gloves. • Immediately Immediately after removing removing the fuel hose hose and/or and/or fuel pipe, carefully tape vinyl bags over the exposed ends of the hose or pipe.

Legend 1. Fue Fuel Rai Raill 2. Press Pressure ure Lim Limit iter er 3. Leak Leak Off Off Pipe Pipe 4. Fuel Fuel Inje Inject ctor or 5. Fuel Fuel Retu Return rn Pipe Pipe 6. Fuel Fuel Fee Feed d Pipe Pipe

• If parts parts are are to be replaced replaced (fuel (fuel hose, hose, fuel fuel pipe, pipe, etc.) do not open the new part packaging until installation. Discard gaskets and O-rings and replace them with new ones.

Work procedure • The fuel fuel opening opening must must be quickly quickly sealed sealed when when removing the fuel pipe, injection pipe, fuel injector, fuel supply pump, and fuel rail. • The eyebolt eyebolts s and gasket must be stored in a clean clean parts box with a lid to prevent adhesion of foreign matter. • Fuel leakage could cause fires. Therefore, Therefore, after after finishing the work, wipe off the fuel that has leaked out and make sure there is no fuel leakage after starting the engine. Explanations on functions and operation Fuel system diagram

7. 8. 9. 10. 11.

Fuel Fuel Tank ank Prim Primin ing g Pump Pump Fuel Fuel Filter Filter With With Sedime Sedimente nter r Recirc Recirculat ulation ion valve valve Fuel Fuel Supp Supply ly Pump

FUEL SYSTEM (4JJ1) Fuel Rail Assembly

Legend 1. Pressure Limiter

2. Fuel Rail Pressure Sensor

6C-3

6C-4

FUEL SYSTEM (4JJ1)

Fuel Supply Pump

Legend 1. Fuel Fuel Temp Tempera eratur ture e Sensor Sensor 2. Suctio Suction n Contro Controll Valv Valve e 3. High High Pres Pressu sure re Pipe Pipe

4. Cams Camsha haft ft Key Key 5. Cams Camsha haft ft Nut Nut

FUEL SYSTEM (4JJ1) Fuel Injector

6C-5

Fuel Filter

Legend 1. Ele Elemen ment 2. Case 3. Drai Drain n Plug Plug 4. Switc Switch h Conne Connecto ctor r Functional Check Air Bleeding Legend 1. Termi ermina nall 2. Fuel Inject Injector or ID ID Code Code 3. Two Two Dimensi Dimensiona onall Barcode Barcode 4. Part Parts s Numb Number er 5. Part for Mountin Mounting g the the Injection Injection Pipe 6. O-ring ring

1. Before Before star starting ting the the engine engine a. Fit a tray tray below below the fuel fuel filter filter (below (below the the air bleed plug). b. Loosen the plug plug adequately adequately and operate operate the the priming pump more than 20 times until the fuel near the plug overflows. c. Tighten Tighten the plug, and and operate operate the priming pump more than 10 times until it is filled with fuel. d. Tighten Tighten the plug plug firmly firmly and wipe wipe the fuel fuel in the surrounded area. Operate the priming pump (10 to 15 times) till it is filled with fuel and then send fuel to the engine. 2. After After start starting ing the the engin engine e a. Start Start the engine engine by rotating rotating the starter starter without without depressing the accelerator pedal. b. After starti starting, ng, maintain maintain the idling rotati rotation on for 5 seconds. c. Slowly rotate rotate the idling idling control knob clockwis clockwise e and maintain it for 3 minutes. d. Fully depress depress the accelerator accelerator pedal and increase the rotations to maximum.(Repeat this operation several times) e. Rotate Rotate the idling idling knob knob countercloc counterclockwise kwise and return to idling more.

6C-6

FUEL SYSTEM (4JJ1)

NOTE: If the air bleeding work is insufficient then it could lead to faults in the engine. Therefore, the procedures after starting the engine should always be implemented. Water drain

• Disch Discharg arge e the wat water er.. • Tighten Tighten the drain plug plug after after discharging discharging the the water. water. • Tighten Tighten the the air bleeding bleeding plug plug to the the specified specified torque. Tightening Tightening torque : 7.5 N⋅m (0.7 (0.7 kg⋅m/26 m/26 lb in) in)

A warning lamp will light up if water above the specified volume collects in the sedimenter. In such cases, drain out the water by performing the following operations:

• Ignition Ignition switch switch is turned turned ON for 15 seconds seconds check check for fuel leakage. • Check that the the warning warning lamp lamp in the meter meter is off.

• Set a contai container ner at the tip tip of the the plastic plastic hose. hose. • Loosen the air air bleeding bleeding plug plug and the the drain drain plug.

Trouble Shooting

Problems with starting Condition Problems with starting

Possible Cause

Correction

Fuel tank is empty

Fill the tank.

Air has entered the fuel system.

Bleed the air.

Fuel line is clogged or damaged. Connection to the fuel line is loose.

Repair or replace the fuel line. Retighten the connection.

Fuel fifilter el element is is cl clogged.

Replace th the ca cartridge.

Fault in the feed pump

Replace the fuel supply pump.

Regulating valve is open.

Replace

Sticking of of the fuel injector

Replace th the fu fuel injector.

Defe Defect ctiv ive e engi engine ne cont contro roll syst system em

Diag Diagno nose se system.

the the

engi engine ne

cont contro roll

Hunting during idling Condition Hunting during idling

Possible Cause

Correction


Bleed air from the fuel system.

Leakage or clogging of the fuel system

Repair or replace the fuel system.

Drops of water have entered the fuel system.

Replace the fuel.

Fuel Fuel fil filter ter elem elemen entt is clog clogge ged. d.

Repl Replac ace e the fuel fuel fil filter ter elem elemen entt kit. kit.





the the

engi engine ne

cont contro roll

Insufficient horsepower Condition Insufficient horsepower

Possible Cause

Correction


Bleed air from the fuel system.

Leakage or clogging of the fuel system

Repair or replace the fuel system.

Water mi mixes in in th the fu fuel sy system

Replace th the fu fuel.

Fuel fifilter el element is is cl clogged.

Replace th the el element ki kit.





the the

engi engine ne

cont contro roll

FUEL SYSTEM (4JJ1)

6C-7

Maximum engine speed is too low Condition

Possible Cause

Maxi Maximu mum m eng engin ine e spee speed d is too too low low

Correction

Fuel Fuel line line is clog clogge ged d or dama damage ged. d.

Repa Repair ir or repl replac ace e the the fuel fuel line line..



the the

engi engine ne

cont contro roll

Engine does not stop Condition

Possible Cause

Engine does not stop

Defective engine control system

Correction Diagnose system.

the

engine

control

Exhaust gas is blue or black Condition

Possible Cause

Exhaust gas is blue or black.

Correction

Reduction in injection-valve opening pressure or defective atomizing status

Replace the fuel injector.

Engin Engine e cont contro roll sys syste tem m mal malfu func nctio tion n

Syst System em diagn diagnos osis is..

Fuel System Check

• Clog Clogged ged fuel fuel fil filte ter r

Description

• Fuel pipe malfunction malfunction (Crushing, (Crushing, clogging, disconnection, etc.)

Conforms to a fuel leak. Engine acceleration raises fuel pressure and which increases the leak. Leak could be in the following pipes and locations. • Between Between inje injector ctors s and fuel fuel rail. rail. • Between Between fuel fuel rail rail and fuel fuel supply supply pump. pump. • Between Between fuel supply pump and and fuel fuel filter filter.. • Between Between fuel fuel filter filter and and fuel fuel tank. tank. • Between Between pressu pressure re limite limiterr and fuel tank tank.. • Between Between injector injector over flow flow and leak leak off off pipe. pipe. Diagnostic Aids Check the following items. • Air in the fuel fuel line line Step

Action

• Fuel Fuel tank tank mal malfu func ncti tion on • Injec Injecto torr malfu malfunc ncti tion on • Fuel supply supply pump pump malfun malfuncti ction on • Pressure Pressure limite limiterr malfu malfunct nction ion An intermittent may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for poor connections or a damaged harness. Inspect the ECM harness and connector for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. ECU may set a DTC, if there is adequate air in fuel line. Schematic Reference: Engine Controls Schematics Value(s)

Yes

No

Go to Step 2

Add fuel and go to Step 2

Go to Step 7

Go to Step 3

Go to Step 4

—

Check the fuel quantity. quantity. 1

breakage, breakage,

— Was a problem found? Check the fuel quality. quality.

2

1.

Disc Discha harg rge e the the fue fuell fro from m fuel fuel tank tank

2.

Repl Replen enis ish h the tank tank wit with h speci specifi fied ed fuel fuel

3.

Bleed Bleed the the air air fro from m the the fuel fuel syst system em

4.

Start art th the en engin gine

—

Could the engine be started? 3

Bleed the air from fuel system. Refer to Fuel System Air Bleeding in this section. Is the action complete?

—

6C-8 Step

4

FUEL SYSTEM (4JJ1) Action Check the main fuel filter for clogging. Clean, repair, or replace as required. Notice: Replacement of a fuel filter is checking to a dealer.

Value(s)

5

6

7

Is the action complete?

—

Go to Step 6

—

Go to Step 7

—

Verify repair

—

—

Is the action complete? Rebleed the air from the fuel pipe. Refer to Fuel System Air Bleeding in this section.

Go to Step 5

—

Is the action complete? Check the fuel tank. If a problem is found, clean, repair, or replace as necessary. • Foreign material (Clogged suction port) • Bent or cracked suction pipe • Fuel tank distortion • Fuel tank improper installation • Clogged fuel cap hole • Water

No

—

Is the action complete? Check the fuel line for damage and leakage. Clean, repair, or replace as required. • Crushed areas • Breakage • Cracks • Loose connections

Yes

—

FUEL SYSTEM (4JJ1)

Fuel Filter Assembly Components

Legend 1. Bolt 2. Fuel Fuel Feed Feed Hose Hose

Removal 1. Disconnect Disconnect the sedimen sedimenter ter harness harness connector connector.. 2. Remove the feed hose and and the return return hose hose from the fuel filter and plug it so that the fuel does not flow out. 3. Remove the bolts bolts for mounting mounting the the fuel filter filter.. 4. Remove Remove the fuel filter assembly assembly..

Installation 1. Install Install the fuel filter filter assembly assembly.. 2. Install Install the bolts bolts for mounting mounting the fuel fuel filter. filter. 3. Install Install the feed hose hose and the return return hose. hose. 4. Connect Connect the sedimente sedimenterr harness connector connector.. 5. Bleed Bleed out the air. air. • Refe Referr to "Fue "Fuell Syste System". m".

3. Fuel Fuel Retu Return rn Hos Hose e 4. Sedimen Sedimenter ter Harnes Harness s Connecto Connector r

6C-9

6C-10

FUEL SYSTEM (4JJ1)

Fuel Filter Element Removal 1. Remove the fuel fuel in in the element case.

5. If foreign foreign material material is attache attached d on the surface surface of the the body inner circumference, wipe it with clean cloth.

a. Loosen the drain drain plug plug at the the bottom bottom of of the element case. b. When the air breather breather of of the body body is loosene loosened, d, the is run out from the drain plug. 2. Remove the harness harness of the the water water warning warning switch. switch. 3. Remove the element element case case from the body body by rotating the case in a counterclockwise direction, using a socket (width of double socket: 29mm(a)). After removing the case, confirm that the float at the inside bottom can move up and down smoothly. If foreign materials, sludge or other dirty materials are deposited at the bottom of the case, remove it clearly. 4. Remove the O-ring O-ring of the body body by pulling pulling out out the element downward.

Legend 1. Cap 2. Air Air ble bleed eder er 3. Filt Filter er body body 4. O-ring ring 5. Fuel Fuel filter filter elemen elementt 6. Elem Elemen entt case case 7. O-ring ring 8. Drai Drain n plug plug 9. Wirin Wiring g conne connect ctor or

Installation 1. Place the the O-ring, O-ring, packaged packaged with with the element element kit, into the groove on the outer circumference of the body. Careful handling of the O-ring is needed to prevent being damaged by the threaded area of the body. 2. Apply a thin layer layer of fresh fresh diesel diesel fuel fuel on the gaskets, inside and outside of the element, and then insert the gasket until it hits the end. NOTE: Be careful not to insert any foreign materials into the four holes (clean side) next to the inside gasket.

FUEL SYSTEM (4JJ1)

6C-11

5. Tighten Tighten the drain plug plug of the the element element case, case, and reconnect the connector of the water warning switch. Tightening torque: 0.4 N⋅m (0. (0.04 04 kg⋅m / 3.47 3.47 lb in) in) 6. After starting starting the the engine, engine, check check each section section for for no looseness.

Legend 1. Salie Salient nt for for soc socke kett 2. Float 3. Outsi Outside de gask gasket et 4. Insid Inside e gaske gaskett 5. Clea Clean n sid side e hol hole e 6. Elem Elemen entt kit kit 7. O-ri O-ring ng gro grove ve 3. Apply a thin thin layer layer of fresh fresh diesel diesel fuel on on the inner inner circumference of the element case (or the O-ring section at the body side). Turn the element in a clockwise direction until it hits to the body carefully. Biting with the O-ring must be avoided. No hitting of the element to the case means that the element does not have compete insertion. Turn the element and push it in again. 4. Tighten Tighten the element element case with with a torque torque wrench. wrench. Tightening Tightening torque: 33 N⋅m (3.4 (3.4 kg⋅m / 25 25 lb ft) ft)

6C-12

FUEL SYSTEM (4JJ1)

Fuel Injector Components

Legend 1. Cylind Cylinder er Head Head Cove Cover r 2. Fuel Fuel Inje Injecto ctorr Clamp Clamp 3. Fuel Fuel Inject Injector or Clamp Clamp Bolt The fuel system consists of many tiny holes and spaces that allow the movement of fuel from one place to another. These holes and spaces are milled to extremely high precision. This is especially true of the fuel injector. The fuel injector is very sensitive to foreign material. Foreign material will result in fuel system breakdown. Exercise great care not to allow the entry of foreign material into the fuel system or fuel injector during the removal and installation procedure.

4. Fuel Fuel Inje Inject ctor or 5. Fuel Fuel Inject Injection ion Pipe Pipe 6. Fuel Fuel Inject Injection ion Pipe Pipe Clip Clip NOTE: To avoid electric shock: Set the switch to the 'OFF' position and disconnect the battery negative cable before checking or repairing the fuel injector, wiring or/ and connectors.

Removal 1. Remove Remove the cylinder cylinder head head cover cover.. Refer to “Cylinder Head Cover” in ENGINE MECHANICAL section.

FUEL SYSTEM (4JJ1) 2. Remove Remove the injection injection pipe sleeve sleeve nut (1) from the injector.

6C-13

4. Mark each each fuel injector injector with with the number number of the the cylinder from which it was removed. Store the fuel injector in a safe place. Position the fuel injector so that the nozzle is protected. NOTE: • If a fuel fuel injector injector is replaced, replaced, cross off off the replaced replaced injector ID codes on the label with a marking pen etc. • If all fuel injectors injectors are replaced replaced,, remove the fuel fuel injector ID code label from the engine cover.

3. Remove Remove the inject injector or.. NOTE: Do not reuse the clip, gasket and bolt.

Legend 1. 1st Cyli Cylinder nder Inje Injecto ctorr ID Code Code 2. 2nd Cylin Cylinder der Injec Injector tor ID Code Code 3. 3rd Cyli Cylinde nderr Injecto Injectorr ID Code Code 4. 4th Cylin Cylinder der Injec Injector tor ID Code Code 5. Engi Engine ne Cov Cover er 6. Inject Injector or ID ID Code Code Label Label

Legend 1. Fuel Fuel Inje Inject ctor or 2. Leak Leak Off Off Pip Pipe e 3. Clip 4. Gask asket 5. Washer NOTE: • Do not not tamper tamper with with the the electromag electromagnetic netic portion portion of the fuel injector. Reduced electromagnetic function will result in injector failure.

6C-14

FUEL SYSTEM (4JJ1)

Installation 1. Install Install the new new gasket gasket and O-ring O-ring to each fuel injector.

4. Temporarily emporarily tighten tighten the clamp bolts. bolts. 5. Apply a thin thin coat of of engine oil to the the outer surface surface of the fuel injector side sleeve nuts. 6. Install Install the fuel fuel injector injector pipes to the the position position shown shown in the illustration. 7. Use a spanner spanner to careful carefully ly tighten tighten the sleeve sleeve nuts nuts until the fuel injector pipes contact the fuel injector and fuel rail. 8. Tighten Tighten the fuel fuel injector injector pipe clips clips to the the specified specified torque. Tightening Tightening torque: 8 N⋅m (0. (0.8 8 kg⋅m / 69 69 lb in) in)

Legend 1. Fuel Fuel Inje Inject ctor or 2. Leak Leak Off Off Pipe Pipe 3. Clip 4. Gask Gasket et 5. Washer 2. Install Install the fuel fuel injector injector clamps. clamps. Refer Refer to the the illustration. • Apply Engine oil to to the threads threads and seating seating surfaces of the clamp bolts.

Legend 1. Fuel Fuel Inje Inject ctor or 2. Pipe Pipe Clip Clip 9. Tighten Tighten the injecti injection on pipes to to the specified specified torque. torque. Tightening torque ⋅ Injector Injector Side: Side: 30 N⋅m (3.1 (3.1 kg⋅m / 22 22 lb ft) ft) Fuel rail side: side: 25 N⋅m (2.5 (2.5 kg⋅m / 18 18 lb ft) ft)

Legend 1. Fuel Fuel Inje Inject ctor or 2. Fuel Fuel Inject Injector or Clamp Clamp Bolt 3. Fuel Fuel Inje Injecto ctorr Clamp Clamp 3. Install Install the fuel fuel injector injector clamps clamps to the cylinder cylinder head. head.

FUEL SYSTEM (4JJ1)

Legend 1. Cla Clamp Bol Boltt 2. Slee Sleeve ve Nut Nut 10. Tighten Tighten the fuel injector injector clamp bolts bolts to the specified torque. Tightening Tightening torque: 26 N⋅m (2. (2.7 7 kg⋅m / 20 lb ft) ft) 11. Tighten Tighten the engine engine oil level level gauge guide guide tube. tube. Tightening Tightening torque: 25 25 N⋅m (25 (25 kg⋅m / 18 18 lb ft) ft) 12. Install Install the the cylinder cylinder head cover cover.. Refer to “Cylinder Head Cover” in ENGINE MECHANICAL section. 13. Program the Fuel Injector Injector ID Codes • Refer to “Program “Programming” ming” in ENGINE ENGINE CONTROL CONTROL SYSTEM section.

Legend 1. Fuel Inject Injector or ID ID Code Code 2. Fuel Fuel Inje Inject ctor or

6C-15

6C-16

FUEL SYSTEM (4JJ1)


FUEL SYSTEM (4JJ1)

6C-17

Fuel Pressure Sensor Removal 1. Disconnect Disconnect the the fuel pressure pressure sensor sensor harness harness connector (1).

Installation 1. Install Install the fuel pressure pressure sensor sensor.. Tightening Tightening torque: 98 N⋅m (10. (10.0 0 kg⋅m/72 m/72 lb ft) ft) 2. Connect the connector.

2. Remove Remove the fuel pressure pressure sensor sensor.. NOTE: Cover the areas exposed during parts removal to prevent the entry of foreign material into the fuel system.

Legend 1. Fuel Fuel Rail Rail 2. Fuel Rail Rail Press Pressure ure Sens Sensor or 3. Fuel Pressur Pressure e Limi Limiter ter

fuel fuel

pressure pressure

sensor

harness harness

6C-18

FUEL SYSTEM (4JJ1)

Fuel Pressure Limiter Removal 1. Remove the leak leak off off pipe and hose hose (1). NOTE: Cover the areas exposed during parts removal to prevent the entry of foreign material into the fuel system.

2. Remove the fuel fuel pressur pressure e limiter limiter.. NOTE: Cover the areas exposed during parts removal to prevent the entry of foreign material into the fuel system.

Legend 1. Fue Fuel Rai Raill 2. Fuel Fuel Rail Rail Pressu Pressure re Senso Sensor r 3. Fuel Fuel Press Pressure ure Limite Limiterr

Installation 1. Install Install the the fuel fuel pressure pressure limiter. limiter. Tightening Tightening torque: 172 N⋅m (17 (17.5 .5 kg⋅m/127 m/127 lb ft) 2. Install Install the fuel fuel leak off off pipe and hose hose (1) using using the mounting eyebolt using the specified torque. Tightening Tightening torque: 10 N⋅m (1.0 (1.0 kg⋅m/87 m/87 lb in) in)

FUEL SYSTEM (4JJ1)

6C-19

Fuel Rail Assembly Components

Legend 1. Injecti Injection on Pipe Pipe (#1 (#1 to #4) 2. Fuel Feed Feed Pipe Pipe Assembl Assembly y 3. Injecti Injection on Pipe Pipe Clip Clip 4. Fuel Fuel Rail Rail Parts of the fuel system such as the internal part of the fuel injector, holes and clearances that form passages for fuel are finished to a very high degree of accuracy. They are therefore highly sensitive to foreign matter and the entry of foreign matter could cause damage to the fuel passage. Therefore, effective measures should be taken to prevent the entry of foreign matter.

5. Fuel Fuel Rai Raill Brack Bracket et 6. Space pace Rubb Rubber er 7. Fuel Fuel Leak Leak Off Off Pipe Pipe

Removal 1. Remove the air air intake intake pipe pipe with the hoses. hoses. • Discon Disconnec nectt the conne connecto ctorr from the the boost boost sensor. • Disconnect Disconnect the hose hose from from the intercooler intercooler side. • Remove the air air intake intake pipe pipe with with the hoses from the intake throttle valve. • Do not disconnect disconnect the hoses from from the the air intake intake pipe.

6C-20

FUEL SYSTEM (4JJ1)

2. Remove the noise noise cover left side. • Disconnect Disconnect the dropping dropping register register connector connector and and remove the noise cover. 3. Disconnect Disconnect the the fuel rail rail pressure pressure sensor sensor harness harness connector (1).

6. Remove Remove the leak leak off off pipe and hose hose (1). (1). NOTE: Cover the areas exposed during parts removal to prevent the entry of foreign material into the fuel system.

4. Remove the engine engine oil oil level gage guide guide tube. tube. 5. Remove Remove the the fuel fuel hose hose (1). (1). NOTE: Cover the areas exposed during parts removal to prevent the entry of foreign material into the fuel system.

7. Remove Remove the fuel fuel feed pipe pipe assembly assembly (1) for for supply pump. NOTE: Cover the areas exposed during parts removal to prevent the entry of foreign material into the fuel system.

FUEL SYSTEM (4JJ1)

8. Disconnect Disconnect the the injection injection pipe pipe sleeve nut nut (1). NOTE: Cover the areas exposed during parts removal to prevent the entry of foreign material into the fuel system.

6C-21

Legend 1. Fuel Fuel Rai Rail 2. Fuel Fuel Rai Raill Brack Bracket et 3. Space pace Rubb Rubber er

Disassembly 1. Remove the fuel fuel pressure pressure limiter limiter. 2. Remove Remove the press pressure ure sensor sensor..

9. Remove the fuel fuel rail and fuel fuel rail bracket. bracket. NOTE: • Do not grasp the the pressure pressure sensor sensor,, during during the fuel fuel rail removal procedure. • Take care care not to damage damage the the connector connector unit unit of the pressure sensor.

Legend 1. Fuel Fuel Rai Rail 2. Fuel Rail Rail Pressu Pressure re Senso Sensor r 3. Fuel Pressure Pressure Limite Limiter r

Reassembly 1. Install Install the fuel pressure pressure limiter limiter.. Tightening Tightening torque: 172 N⋅m (17. (17.5 5 kg⋅m/127 m/127 lb ft)

6C-22

FUEL SYSTEM (4JJ1)

2. Install Install the the fuel fuel pressure pressure sensor. sensor. Tightenin Tightening g torque: torque: 98 N⋅m (10 (10.0 .0 kg⋅m/72 m/72 lb ft) ft)

4. Install Install the fuel fuel feed pipe pipe assembly assembly (1) for for supply pump and tighten the bolts to the specified torque. Tightening torque: 44 N ⋅m (4.5 kg⋅m/33 lb ft)

Installation 1. Tighten Tighten the space space rubber, rubber, fuel fuel rail bracket bracket and fuel fuel rail using the specified mounting torque. Tightening torque: 25 N ⋅m (2.5 kg⋅m/18 lb ft)

5. Tighten Tighten the the fuel leak off off pipe (1) using using the mounting eyebolt using the specified torque. Tightening torque: 10 N ⋅m (1.0 kg⋅m/87 lb in)

Legend 1. Fue Fuel Rai Raill 2. Fuel Fuel Rail Rail Bra Brack cket et 3. Spac Space e Rubbe Rubber r 2. Tighten Tighten the fuel fuel pipe using using the the mounting mounting sleeve sleeve nut (1) and the specified torque. Tightening torque: 25N⋅m (2.5 kg⋅m/18 lb ft)

3. Connect Connect the fuel rail rail pressure pressure sensor sensor harness harness connector.

FUEL SYSTEM (4JJ1) 6. Instal Installl the fuel hose (1). (1).

6C-23

• Fit the the pipe and the the hose between between the intake intake throttle valve and the int ercooler. • Connect Connect the the boost boost sensor connector connector.. • Use new clips. clips. Tighten Tighten the clip clip according according to to the marking. Tightening torque: 6 N⋅m (0.6 kg⋅m / 52 lb in)

7. Tighten Tighten the engine oil oil level level gage guide guide tube tube and tighten the mounting bolt to the specified torque. Tightening torque: 25N ⋅m (2.5 kg⋅m/18 lb ft) 8. Install Install the the noise noise cover cover left left side. side. 9. Install Install the dropping dropping register register connector connector.. 10. Fit the the air intake intake pipe pipe and hose. hose.


11. Install Install the boost boost sensor sensor connector connector..

6C-24

FUEL SYSTEM (4JJ1)

Fuel Supply Pump Components

Legend 1. Fuel Fuel Feed Feed Pipe Pipe Assembl Assembly y 2. Inject Injection ion Pipe Pipe Slee Sleeve ve Nut Nut 3. Spac Space e Rubb Rubber er A 4. Bra Bracket 5. Spac Space e Rubb Rubber er B 6. Fuel Fuel Suppl Supply y Pump Pump The fuel system consists of many tiny holes and spaces that allow the movement of fuel from one place to another. These holes and spaces are milled to extremely high precision. This is especially true of the fuel injector. The fuel injector is very sensitive to foreign material. Foreign material will result in fuel system breakdown. Exercise great care not to allow the entry of foreign material into the fuel system or fuel injector during the removal and installation procedure.

Removal 1. Partially Partially drain the engine engine coolant. coolant. Refer Refer to drain drain procedure for engine cooling in this manual. 2. Remove Remove the the radiator radiator upper upper hose hose..

7. 8. 9. 10. 10. 11.

Nois Noise e Cov Cover er Timing iming Chain Chain Cover Cover Lower Lower Nut Sproc procke kett Fuel Fuel Supply Supply Pump Gear

FUEL SYSTEM (4JJ1) 3. Remove Remove the fan guide. guide.

Legend 1. Fan Guid Guide e Brac Bracke kett 2. Fan Guid Guide e Brac Bracke kett 3. Bolt

6C-25

6. Remove the A/C compress compressor or adjust adjust pulley pulley..

Legend 1. Bolt 2. Nut 7. Disconnect Disconnect the A/C compressor compressor..

4. Remove Remove the the cooli cooling ng Fan. Fan.

8. Remove the A/C A/C compress compressor or bracket. bracket. 9. Remove the the fuel rail rail assembly assembly.. Refer to to removal removal procedure for Fuel rail assembly in this manual. 10. Remove the cylinder cylinder head head cover cover.. Refer to removal procedure for Fuel rail assembly in this manual. 11. Disconnect Disconnect the connector connector of supply supply pump. pump. 12. Remove Remove the the noise noise cove cover. r.

5. Remove Remove the A/C compress compressor or drive drive belt. belt.

Legend 1. Nois Noise e Cov Cover er

6C-26

FUEL SYSTEM (4JJ1)

13. Remove the the timing chain chain cover cover assembly assembly. Upper & lower.

Legend 1. Timin Timing g Chain Chain Cover Cover Upper Upper 2. Timin Timing g Chain Chain Cover Cover Lower Lower.

Legend 1. Align mark on intake camshaft camshaft and exhaust exhaust camshaft to mark of bearing cap 15. 15. Loos Loosen en the the nut. nut.

14. Align the the timing timing marks at 3 locations locations as shown. shown.

Legend 1. Nut Legend 1. Cranks Crankshaf haftt Damper Damper Pulle Pulley y 2. Mirror rror 3. TDC TDC Ma Mark

FUEL SYSTEM (4JJ1)

6C-27

16. Remove Remove the timing timing chain tennsioner tennsioner..

19. Timing Timing chain chain in moved moved upward upwards. s.

Legend 1. Timing Timing Chain Tennsioner ennsioner.. 2. Gask asket

20. Paint the the alignment alignment mark. mark. Between Between idle gear A and supply pump gear.

17. Remove Remove the timing timing chain chain tension tension lever lever pivot. pivot. 18. Remove Remove the the nut and and sprocke sprocket. t.

Legend 1. Tension ension Leve Leverr Pivot Pivot 2. Sproc procke kett 3. Nut

6C-28

FUEL SYSTEM (4JJ1)

21. Use a gear gear puller puller to remove remove the fuel supply supply pump pump gear.

22. Remove the supply supply pump pump and supply pump bracket with spacer rubber.

23. Remove Remove the supply pump and O-ring. O-ring.

Legend 1. O-ring ring 2. Supp Supply ly Pump Pump

NOTE: • Do not not hold the high high pressure pressure pipe, pipe, during during the the supply pump removal procedure. • Do not grasp the high high pressure pressure pipe, pipe, when when moving moving the supply pump from one location to another.

Installation 1. Install Install the O-ring to the fuel supply supply pump. pump. 2. Install Install the fuel fuel supply supply pump. Apply Apply soapy soapy water to the O-rings before attaching. NOTE: Take care not to twist the O-ring. 3. Install Install the the fuel fuel supply supply pump pump bracket. bracket. Temporarily tighten with the bolts and nuts (Gear case side). Temporarily tighten with the bolts (Cylinder body side). Fully tighten the bolts and nuts (Gear case side). Fully tighten the bolts (Cylinder body side). Tightening torque: 25 N ⋅m (2.5 kg⋅m /18 lb ft)

Legend 1. Supp Supply ly pump pump 2. Spac Space e Rubb Rubber er B 3. Suppl Supply y Pump Pump Brack Bracket et 4. Spac Space e Rubb Rubber er A

FUEL SYSTEM (4JJ1)

Legend 1. Fuel Fuel Supp Supply ly Pump Pump 2. Space pace Rubbe Rubberr B 3. Fuel Supply Supply Pump Bracket Bracket 4. Space pace Rubbe Rubberr A 4. Confirm Confirm that the supply supply pump pump camshaft camshaft key key is turned to the right and is horizontal.

6C-29

6. Install Install the timing timing chain chain to the each each sprocket sprocket and install the fuel supply pump sprocket to the pump shaft. a. Align the the camshaft camshaft sprocket sprocket timing timing mark (1) with the bright plate timing chain link (2). b. Align the fuel fuel supply supply pump pump sprocket sprocket timing timing mark (3) with the yellow plate timing chain link (4). c. Install Install the fuel fuel supply supply pump pump sprocket sprocket to the the fuel pump shaft by aligning the dowel pin that is attached to the gear. d. Hand-tighten Hand-tighten the fuel fuel supply supply pump shaft nut.

5. Install Install the fuel fuel supply supply pump to the pump pump shaft. shaft. a. Align the fuel pump gear timing mark (1) with the idle gear A paint marks (2). b. Ensure Ensure that that the pump pump must must be bit bit with with maingear(3)of the idle gear A. Depress the pump gear when it is bitted with scissors gear (4) of the idle gear A.

Legend 1. Timin iming g Mark Mark 2. Dark Dark Plat Plate e 2. Timin iming g Mark Mark 2. Yello ellow w Plat Plate e

6C-30

FUEL SYSTEM (4JJ1)

7. Install Install the timing timing chain chain tension lever lever pivot. pivot. Handtighten the pivot bolt. Confirm that the tension lever moves smoothly. 8. Attach the hook hook of the timing chain chain tensioner tensioner.. • Hold Hold the latch( latch(3) 3) depress depressed. ed. Insert Insert the the plunger(2). Attach the hook (4) to the pin (1) to hold the plunger in place.

11. Tighten Tighten the nut nut (1) to the specifie specified d torque. Tightening torque: 130 N⋅m (13.3 kg ⋅m / 96 lb ft)

9. Install Install the gasket gasket (2) and the timing timing chain chain tensioner tensioner (1). Tighten the nut to the specified torque. Tightening torque: 10 N ⋅m (1.0 kg⋅m/ 87 lb in)

12. Tighten Tighten the timing timing chain chain tension tension lever lever pivot bolt bolt to the specified torque Tightening torque: 27 N ⋅m (2.8 kg⋅m / 20 lb ft) 13. Turn Turn the crank crank pulley pulley two rotati rotations ons (720°CA).

10. Unlock Unlock the the tension tensioner er hook. hook. • Press Press the place place of the arrow arrow in the figu figure. re. • The hook hook is opened opened.. The plung plunger er pushes pushes the the tension lever.

FUEL SYSTEM (4JJ1)

6C-31

14. Check the mark mark (1) on the intake intake camshaft camshaft and and exhaust camshaft to the mark of camshaft bearing cap.

18. Apply liquid liquid gasket gasket (ThreeBond (ThreeBond TB-1207C TB-1207C or equivalent) to the timing chain cover lower (1). 15. Install Install the the cylinder cylinder head cover cover.. Refer to “Cylinder Head Cover”.

• Attach the cover cover within 5 minutes minutes of applying applying the liquid gasket.

16. Apply liquid liquid gasket (ThreeBond (ThreeBond TB-1207C TB-1207C or or equivalent) to the timing chain cover upper (1). • Attach Attach the cover within within 5 minutes minutes of applying applying the liquid gasket.

19. Install Install the timing timing chain chain cover lower lower (1). Tighten Tighten the the bolts (2) and nuts (3) to the specified torque. Tightening torque: 10 N ⋅m (1.0 kg⋅m / 87 lb in)

17. Install Install the timing chain cover upper (1). (1). Tighten the bolt to the specified torque. • Apply Loctite Loctite #262 or equivale equivalent nt to the bolt bolt and and stud threads of cylinder head side (2). Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft)

6C-32

FUEL SYSTEM (4JJ1) 25. Install Install the A/C compress compressor or adjust pulley pulley..

20. Install Install the noise noise cover (1). (1). Tighten Tighten the bolts bolts to the the specified torque. Tightening torque: 10 N ⋅m (1.0 kg⋅m / 87 lb in)

Legend 1. Bolt 2. Nut Tighten the bolt and nut to the specified torque. Bolt Tightening torque: 25 N⋅m (2.5 kg⋅m/18 lb ft) Nut Tightening torque: 25 N ⋅m (2.5 kg⋅m/18 lb ft) 26. Install Install the A/C compress compressor or drive drive belt. Refer to the drive belt tension check procedure for Heating and air conditioning in this manual. 27. Instal Installl the cool cooling ing fan. fan. 28. Instal Installl the the fan fan guide. guide. 29. Install Install the the radiator radiator upper hose. 30. Repleni Replenish sh the engine engine coola coolant. nt. 31. Start Start the the engine engine and and let idle.

21. Install Install the connector connector of supply pump. 22. Install Install the the fuel fuel rail assembly assembly.. • Refer to the the Install Install procedure procedure for for Fuel Fuel rail rail assembly in this manual. 23. Install Install the A/C A/C compressor compressor bracket. bracket. Tighten Tighten the the bolts to the specified torque. Tightening torque: 25 N ⋅m (2.5 kg⋅m / 18 lb ft) 24. Install Install the A/C compressor compressor.. Tighten the bolts to the specified torque. Tightening torque: 44 N ⋅m (4.5 kg⋅m / 33 lb ft)

IMPORTANT: In order for the ECM to learn the characteristics of the fuel supply pump, let the engine idle until warn-up. If fuel system DTC's are stored in the meantime, clear the DTC and warn-up the engine again.

FUEL SYSTEM (4JJ1) Torque Specifications

6C-33

6C-34

FUEL SYSTEM (4JJ1)

Fuel Sedimenter Switch Inspection 1. Check that that there is is continuity continuity between between the switch switch connector terminals when the float in the fuel sedimenter is above the water drain line. 2. Turn on the ignition ignition switch, switch, remove remove the fuel sedimenter connector, and connect the terminals of the connectors on the harness side. Confirm that the sedimenter warning lamp lights up. If abnormalities are detected during the check, replace the CASE – KIT (with switch) and carry out repairs in case of defective connections between circuits or short circuits.

Legend 1. Sen Sensor 2. Connec Connector tor on The The Vehic Vehicle le Side 3. Harn Harnes ess s 4. Drai Drain n Plug Plug

FUEL SYSTEM (4JJ1)

6C-35

Fuel Tank Components

Legend 1. Fuel gauge gauge unit unit conn connect ector or 2. Brea Breath ther er hos hose e 3. Fuel Fuel feed feed hose hose

Removal 1. Loosen Loosen the the fuel fuel fille fillerr cap. cap. 2. Drain the fuel fuel through through the drain drain plug. plug. 3. After draining draining the the fuel tighten tighten the the drain plug plug to its specified torque. Tight Tighteni ening ng torqu torque: e: 20 N⋅m (2.0 kg⋅m / 14 lb ft) 4. Remove Remove the connector connector from from the fuel fuel gauge unit. 5. Remove Remove the the breat breather her hose. hose.

4. Fuel Fuel ret retur urn n hose hose 5. Band 6. Fuel Fuel tank ank

6. Remove Remove the the fuel fuel feed feed hose. hose. 7. Remove Remove the the fuel retur return n hose. hose. • Use a stopcock stopcock to preven preventt fuel from spilling spilling,, point it upwards and tie it to the frame. 8. Remove the band band for mounting mounting the the fuel tank tank and remove the tip of the band on the frame side. 9. Pull the the fuel fuel tank tank to the outside. outside.

6C-36

FUEL SYSTEM (4JJ1)

NOTE: If the fuel tank can not be removed, remove the bracket and lower the fuel tank downwards.

• Put fuel fuel into the fuel fuel tank tank and tighten tighten the fuel fuel filler cap. • Connec Connectt the batte battery ry ground ground cabl cable. e. • After After starti starting ng the engin engine, e, check check the hose hose connections to make sure that there are not any fuel leaks. 6. Connect Connect the connector connector to the fuel fuel gauge gauge unit.

Mounting 1. Mount Mount the the fuel fuel tank tank.. NOTE: If you removed the bracket when removing the fuel tank, attach the bracket to the frame and tighten it to its specified torque. Tighte ighteni ning ng torqu torque: e: 55 N⋅m (5.6 kg⋅m / 41lb ft) Also, when placing the t he fuel tank on o n the bracket, make sure the rubber that is attached to fuel tank contacts the bracket. 2. Mount the the band onto onto the fuel fuel tank and and tighten tighten the mounting nut to its tightening torque. Tight Tighteni ening ng torque torque:: 12 N⋅m (1.2 kg⋅m / 104 lb in) 3. Mount Mount the the fuel fuel return return hose hose.. 4. Mount Mount the the fuel fuel feed feed hose. hose. • Put the the hose hose onto the the pipe pipe at leas leastt 25 mm (0.9843 in). 5. Mount Mount the the breath breather er hose. hose.

FUEL SYSTEM (4JJ1)

Fuel Gauge Unit Components

Legend 1. Fuel gauge unit connector

Removal 1. Remove the the wiring wiring connector connector from from the fuel fuel gauge unit. 2. Remove Remove the mounting mounting screw screw and remove the fuel fuel gauge unit. NOTE: When removing and attaching the fuel gauge unit, take caution with respect to interference with surrounding objects; do not deform the arm. Also, after removing the fuel gauge unit, place a seal so that foreign materials do not get into the tank.

2. Fuel gauge unit

6C-37

6C-38

FUEL SYSTEM (4JJ1)

Inspection The fuel tank unit changes its internal resistance based on the position of the float (height of liquid) and moves the needle of the f uel meter.

a b

1. While moving moving the the float from from E to F, F, inspect inspect the resistance value between connector terminals 1 J28 - 2 J-28. 2. Confirm Confirm that the the low fuel fuel light light turns turns on when when the float is in the "E" position. If there are any abnormalities found with the inspection, replace with a part that works correctly.

325.2mm / 12.80in (Fuel tank capacity 63L / 13.86Imp.gal) 379.7mm / 14.95in (Fuel tank capacity 75L / 16.5Imp.gal, 100L / 22Imp.gal) 284.8mm / 11.21in (Fuel tank capacity 63L / 13.86Imp.gal) 336.1mm / 13.23in (Fuel tank capacity 75L / 16.5Imp.gal, 100L / 22Imp.gal)

FUEL SYSTEM (4JJ1) c d

6C-39

175.1mm / 6.89in (Fuel tank capacity 63L / 13.86Imp.gal) 207.7mm / 8.18in (Fuel tank capacity 75L / 16.5Imp.gal, 100L / 22Imp.gal) 76.7mm / 3.02in (Fuel tank capacity 63L / 13.86Imp.gal) 75.8mm / 2.98in (Fuel tank capacity 75L / 16.5Imp.gal, 100L / 22Imp.gal)

Float Position

Standard resistance volume (Ω)

F (FULL stopper)

2.5

1 /2

33.0

Warning lamp lighting point

87.0

E (EMPTY stopper)

98.3

Mounting

1. Mount Mount the fuel fuel gaug gauge e unit. unit.

Perform the removal process backwards for mounting.

2. Connect the wiring wiring connector connector to to the fuel fuel gauge gauge unit.


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ENGINE ELECTRICAL (4JJ1)

ENGINE ENGINE ELECTRICAL (4JJ1) TABLE OF CONTENTS Charging System. . . . . . . . . . . . . . . . . . . . . . . . . .6D-2 Servicing Cautions . . . . . . . . . . . . . . . . . . . . . . . 6D-2 Important Generator Components and Function6D-2 Troubleshoo Troubleshooting ting . . . . . . . . . . . . . . . . . . . . . . . . . 6D-3 Diagnosis Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D-4 Unit Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-6 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-6 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-6 Inspection Inspection and Repair Repair . . . . . . . . . . . . . . . . . . . . 6D-8 Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . .6D-8 Stator Stator Coil Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D-9 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-9 Rectifier Rectifier Assembly Assembly . . . . . . . . . . . . . . . . . . . . . . 6D-10 Rectifier Rectifier Assembly Assembly . . . . . . . . . . . . . . . . . . . . . . 6D-11 6D-11 Reassembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D-12 Final Assembly. . . . . . . . . . . . . . . . . . . . . . . . .6D-12 Starter Starter Motor Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D-14 Starting Circuit Diagram . . . . . . . . . . . . . . . . . .6D-14 . 6D-14 Removal and Installation . . . . . . . . . . . . . . . . .6D-14 Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6D-15 Inspection Inspection and Repair Repair . . . . . . . . . . . . . . . . . . . 6D-19 Reassembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D-22 Magnetic Switch. . . . . . . . . . . . . . . . . . . . . . . .6D-24 Pre-Heating System . . . . . . . . . . . . . . . . . . . . . .6D-26 Inspection Inspection and Repair Repair . . . . . . . . . . . . . . . . . . . 6D-26

6D-1

6D-2


Charging System Servicing Cautions • Battery polarity polarity is important. important. If If the battery cables are reversed, the generator diodes will be destroyed. • Do not remove the battery battery cables cables or the charging charging circuit wiring when the engine is running. • Confirm Confirm that the terminal terminal wires wires are are connected connected to the proper terminals by checking the terminal numbers (the number on the terminal wire and the terminal must be the same). • Disconnect Disconnect the the battery battery negativ negative e cable (-) before before inspecting the generator. • Do not open or close the battery battery relay relay switch switch when when the engine is running. • Disconnect Disconnect the battery battery negative negative cable cable (-) when using external equipment (Quick-Charge) to charge the bat tery. tery.

• When steam steam cleanin cleaning g or washing the engine, engine, do not allow steam or water to come in direct contact with the battery and other electrical system components. • Be sure sure to read read the item item on belt tension tension adjustment adjustment before beginning the procedure.

Important Function

Generator

Components

and

• The generator generator uses uses a built-in built-in solid-s solid-state tate IC IC voltage voltage regulator. The regulator and other important components together with their connections are shown in the illustration. • The voltage voltage regula regulator tor is instal installed led to the the rear cover assembly of the generator together with the brush holder and the rectifier. The generator requires no additional voltage regulation. • 9 diodes diodes are connected connected to the stator stator coil coil to convert AC to DC. The DC voltage is delivered to the generator output terminal.

AC Generator


6D-3

Charging System

B S l i o c r o t o R

Charge lamp L

Charge relay

IG-SW Warnning lamp

Stator coil

B

S

y r e t t a B

L

F IC Regulator P

QOS C/U

SW

E

RTW56DMF000101

Troubleshooting

• Inadeq Inadequa uate te cha charg rgin ing g

Symptoms

• Exces Excessi sive ve char chargi ging ng • Unstab Unstable le chargi charging ng curren currentt

• No cha chargin rging g

• Abnorma Abnormall generat generator or noise noise No charging Possible problem

Countermeasure

Dead battery

Replace

Open or shorted wiring

Repair

Open or shorted ammeter Loose wiring connections One or more generator coils open or shorted

Replace

Bad diode Bad regulator Loose regulator connections

Repair

Inadequate charging Possible problem Dead battery

Countermeasure Replace

6D-4

ENGINE ELECTRICAL (4JJ1) Possible problem

Countermeasure

Open or shorted wiring

Repair

Loose wiring connections Loose generator drive belt

Adjust belt tension

Stator coil intermittent short

Replace

Bad diode Loose battery connections

Repair

Bad regulator

Replace

Loose regulator connections

Repair

Excessive charging Possible problem

Countermeasure

Bad regulator

Replace

Unstable charging current Possible problem

Countermeasure

Open wiring connection or broken wire

Repair


Adjust belt tension

Open or shorted stator coil

Replace

Loose terminal connections

Repair

Bad regulator

Replace

Loose regulator terminal connections

Repair

Abnormal operating noise Possible problem

Countermeasure


Adjust belt tension

Bad bearing

Replace

Loose rotor core or stator core

Repair

Bad diode

Replace

Open or shorted stator coil

Replace

Diagnosis On-vehicle Inspection The charging system warning light tells the vehicle operator of possible problems with the system. When the ignition switch is moved to the ON position, the light turns on. The light turns off immediately after the engine is started. If the light turns on during engine operation, there is a problem with the charging system. Perform the checks described below. 1. Check Check the belt belt (brok (broken en or loose loose). ). 2. Check the harness harness disconnected).

connectors connectors

(loose

or

3. With the engine off, off, turn turn the ignition ignition switch switch to to the ON position. If the warning lamp does not light, remove the harness connector from the generator. Ground the connector L terminal. The lamp should light. If it does not, the bulb is burned out. Replace the bulb. 4. Start Start the engine. engine. If the the warning warning lamp remains remains on, on, the generator must be repaired or replaced.


6D-5

Specifications

Battery power Generator output Rotational direction (Viewed from pulley) Rated speed Maximum speed

Volts

24

Amperes

45 / 50 / 80

—

Clockwise

rpm

5000 12000

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Unit Servicing Components

Legend 1. Pull Pulley ey Nut Nut 2. Pul Pulley 3. Front Front Cove Coverr Asse Assembl mbly y 4. Roto Rotorr Ass Assem embl bly y 5. Stat Stator or Asse Assemb mbly ly

Disassembly 1. Remove Remove the the throu through gh bolts bolts.. 2. Insert a flat-blade flat-blade screwdriver screwdriver between between the front front cover and the stator. Pry the parts apart.

6. 7. 8. 9. 10.

Thro Throug ugh h Bolts Bolts Rear Rear Cover Cover Assembl Assembly y Rect Rectif ifie ier r Ball Ball Bea Beari ring ng Ball Ball Bear Bearin ing g

ENGINE ELECTRICAL (4JJ1) 3. Separate Separate the front front cover/ro cover/rotor tor assembly assembly from from the rear cover/stator assembly. assembly.

8. Remove the bearing bearing retainer retainer and the the bearing. bearing.

9. Remove the B-termina B-terminall nut and M5 M5 nut. 4. Place the front front cover cover and rotor in in a vise. vise. 5. Remove Remove the pulley pulley nut and the pulley pulley.. 6. Remove the rotor rotor from from the front front cover cover..

7. Remove the screw screw from from the front cover cover..

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10. Remove the rear cover from the stator. stator.

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11. Remove the stator stator assembly assembly..

Limit

12. Remove the the rectifier rectifier assembly assembly from the stator stator assembly.

30.7 (1.209)

3. Measure Measure the electrical electrical resista resistance nce between between the slip slip rings. If the resistance is greater than the specified limit (open circuit), repair is required.

Rotor coil resistance at 20 °C (68°F)

Inspection and Repair Repair or replace any parts found to be excessively worn or damaged during the inspection procedure.

Rotor Assembly 1. Check for for dirty or rough slip ring ring surfaces. surfaces. Remove Remove dirt from the surfaces with a clean rag. Use No. 500 or No. 600 sandpaper to smooth the surfaces. 2. Measure the slip ring diameters diameters.. Replace Replace the slip slip ring if the diameter is less than the specified limit.

Slip ring diameter Standard

mm (in) 31.7 (1.248)

Ω

(45 A)

10.5

(50 A)

8.2

(80 A)

10.2

ENGINE ELECTRICAL (4JJ1) 4. Check for for conductivity conductivity between between the slip slip rings rings and the rotor core. If there is continuity, the rotor assembly must be replaced.

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2. Measure the the resistance resistance between between the the stator coil coil and the stator core. If the resistance is less than the specified value, the stator coil must be replaced. Stator coil/core resistance: MIN 1 M Ω

Stator Coil 1. Measure Measure the stator stator coil resistan resistance. ce. If the resist resistance ance is less than the specified value, the stator coil must be replaced.

Stator coil resistance at 20 °C (68°F)

Ω

45 A

0.19

50 A

0.19

80 A

0.07

1

2

LNW76DSH000701

Brushes Measure the brush height. If the height is less than the specified limit, the brushes must be replaced.

Brush height

mm (in)

Standard

25 (0.984)

Limit

6.5 (0.260)

6D-10

ENGINE ELECTRICAL (4JJ1) Rectifier Assembly Measure each of the diode resistances in both directions (anode/cathode and cathode/anode). If any of the diodes have the same resistance in both directions, the rectifier must be replaced.

Tester Wire E U,V, and WN

+

+

——

—

NO conductivity

— Conductivity

Negative side diode check

——

BAT

+

—

+

——

NO conductivity

—

Conductivity

——

U,V, and WN

Positive side diode check


6D-11 6D-11

Rectifier Assembly (45A / 50A)

(80A)

Test circuit Refer to the judgment criteria shown in the Table below.Carefully check Items 1 to 5.If all the items are OK, the IC regulator is normal. Circuit components 1

DC regulated power supply

0 - 30 volts variable with output of 1 ampere or more

2

Lamps (2)

3

Sw S witches (3)

——

4

DC voltmeter

0 to 60 volts, 0.5 grade

5

Pulse generator (Oscillator)

24 volts, 1.8 watts

5 to 30 volt output at a frequency of 1KHz

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Judgment criteria

NO.

Switch 1

Switch 2

1

ON

OFF

Lamp condition Switch Voltmeter 3 reading Lamp 1 Lamp 2 OFF 24V

2

ON

ON

On (dim)

OFF

On or flashing

3

ON

ON

OFF

32V

Off or on (dim)

4

OFF

ON

OFF

24V

On or flashing

5

ON

ON

ON

36V

On

Reassembly Follow the disassembly steps in reverse order to reassemble the generator. Pay close attention to the items below. • Be very careful not to to reverse reverse battery battery polarity polarity.. Reversed battery polarity will destroy the rectifier diodes. • Do not not ground ground the generator generator B-termina B-terminal. l. Heat Heat and fire damage to the harness will result. • If using using a fast fast charge charge procedure procedure,, be sure sure to disconnect the battery positive cable. If you do not, the rectifier diodes will be exposed to high positive voltage that will destroy them. • Be very careful careful to reassemb reassemble le the parts parts to their their original positions. Particular care must be taken with insulated parts. • Carefully Carefully clean clean all insulated insulated parts parts so that they they are completely free of oil and/or grease. • Be sure that B-termina B-terminall twist-typ twist-type e stoppers stoppers (round (round terminal) are securely inserted before tightening the nuts.

Final Assembly 1. Pulley Pulley and and rotor rotor assembly assembly.. • Instal Installl the pulley pulley and and rotor rotor assemb assembly ly a. Carefully Carefully clamp clamp the rotor assembly assembly in a vise. vise.

ON

Remarks Initi itial exc excitati ation che check Full excitation check

OFF

ON

Lamp 1 off or dimly lit when the voltmeter shows less than 24 volts or 32 volts Stator and brush separation check Excess voltage check

b. Tighte Tighten n the the pulle pulley y nut. nut. Tightening torque: 110 N⋅m (11.2 kg⋅m / 81lb ft)

ENGINE ELECTRICAL (4JJ1) c. The rear rear ball bearing is pressed pressed into the wheel wheel eccentric groove.The bearing ring projects from the groove.During installation, rotate the bearing to the point of minimum bearing ring projection.

6D-13

• Insert the the pin from from the outside outside of the rear rear cover. cover. Press the brushes into the holde r. Complete the assembly procedure.

3. Use a bench bench press press to install install the the rear rear cover assembly to the front cover c over assembly. 2. Rear cover and stator stator assembly assembly.. • Use a pair of of long-nose long-nose pliers pliers to connect connect the stator coil leads and the rectifier leads. • Finish Finish the the work work as quickl quickly y as possib possible le to prevent the rectifier from heat transferred by the soldering.

4. Throug Through h bolt bolts. s. • place a guide guide bar through the holes holes in the front front cover and rear cover flange for proper alignment.Install the through bolts. Tightening torque:4N ⋅m(0.4 kg⋅m / 35 lb ⋅ in)

6D-14


Starter Motor Starting Circuit Diagram

3. Instal Installl the E/G E/G oil level level gage. gage. 4. Instal Installl the A/T oil oil level level gage. gage. 5. Reconnect Reconnect the battery battery cable cable at the the starter starter motor and the ground cable at a t the cylinder body. 6. Reconnect Reconnect the battery cable and and the ground ground cable cable at the battery terminals.

Removal and Installation Read this Section carefully before performing any removal and installation procedure. This Section gives you important points as well as the order of operation. Be sure that you understand everything in this Section before you begin. Important Operations - RemovalStarter Motor 1. Disconnect Disconnect the the battery battery cable and and the ground ground cable cable at the battery terminals. 2. Remove Remove the the A/T oil oil level level gage gage.. 3. Remove Remove the the E/G oil oil level level gage gage.. 4. Disconnect Disconnect the magnetic magnetic switch cable at at the terminal bolts. 5. Disconnect Disconnect the the battery cable at the the starter starter motor and the ground cable at the cylinder body. 6. Remove the starter starter motor from the the engine. engine. Important Operations - Installation Follow the removal procedure in the reverse order to perform the installation procedure. Pay careful attention to the important points during the installation procedure. Starter Motor 1. Install Install the starter starter motor to the rear plate. 2. Tighten Tighten the starter starter motor motor bolts bolts to the specified specified torque.

Motor Bolt Torque:

N⋅m (kg⋅m / lb ft) 85 (8.7 / 63)

ENGINE ELECTRICAL (4JJ1) Components 24 V 4.0 kW

Legend 1. Plun Plung ger 2. Dust Dust Cove Cover r 3. Magne Magneti tic c Swit Switch ch 4. Termin erminal al Cover Cover 5. Gear Gear Case ase 6. T0rsi T0rsion on Sprin pring g 7. Dust Dust Cove Cover r 8. Shif Shiftt Lev Lever er 9. Thro Throug ugh h Bol Boltt 10. 10. Rear Rear Cove Cover r 11. Brush Brush Hold Holder er 12. O Ring 13. Yoke oke

14. 14. 15. 15. 16. 16. 17. 17. 18. 18. 19. 19. 20. 20. 21. 21. 22. 22. 23. 23. 24. 25. 25. 26. 26.

Ball Ball Beari Bearing ng Arma Armatu ture re Ball Ball Beari Bearing ng Beari Bearing ng Retai Retaine ner r Pinio Pinion n Shaf Shaftt Ball Ball Beari Bearing ng Clut Clutch ch Ball Ball Beari Bearing ng Retur Return n Spr Sprin ing g Stopp topper er Clip Ball Ball Beari Bearing ng Beari Bearing ng Hold Holder er

6D-15

6D-16


24 V 4.5 kW

Legend 1. Plu Plunger 2. Dust Dust Cove Cover r 3. Magne Magneti tic c Swit Switch ch 4. Termi ermina nall Cover Cover 5. Torsion orsion Spring pring 6. Shif Shiftt Lev Lever er 7. Dust Dust Cove Cover r 8. Gear Gear Case ase 9. Thro Throug ugh h Bolt Bolt 10. 10. Rear Rear Cove Cover r 11. Drain Drain Pipe Pipe 12. Brush Brush Hold Holder er 13. O Ring 14. Yoke 15. O Ring 16. Ball Ball Beari Bearing ng 17. 17. Arma Armatu ture re

18. 19. 20. 21. 22. 22. 23. 24. 25. 26. 27. 28. 28. 29. 30. 31. 31. 32. 33. 34.

Ball Ball Bear Bearin ing g Beari Bearing ng Retai Retainer ner Clip Pini Pinion on Sto Stopp pper er Pini inion Cush Cushio ion n Spri Spring ng Slee Sleeve ve Cover Cover Stoppe topperr Washe Washer r Pini Pinion on Shaf Shaftt Ball Ball Bear Bearin ing g Clutc lutch h Ball Ball Bear Bearin ing g Retu Return rn Spr Spring ing Stopp topper er Clip Ball Ball Bear Bearin ing g Beari Bearing ng Hol Holde der r

ENGINE ELECTRICAL (4JJ1) Important Operations 1. Lead Lead Wire Wire Disconnect the lead wire at the magnetic switch.

6D-17

Remove the torsion spring from the magnetic switch.

3. Thro Throug ugh h Bolt Bolt 2. Magnet Magnetic ic Switc Switch h Assembl Assembly y Remove the magnetic switch bolts, then remove the switch from the shift lever.

4. Screw 5. Rear Rear Cove Cover r Remove the through bolts, then remove the rear cover.

6D-18


6. Moto Motorr Ass Assem embl bly y Remove the four brushes from the brush holders.

Remove the yoke along with the armature and the brush holder from the gear case. Remove the brushes and commutator carefully so as not to allow them in contact with the adjacent parts.

9. Arm Armatur ature e Remove the brush holder and pull out the armature assembly free from the yoke.

10. 10. Beari Bearing ng Retai Retainer ner 11. Pinion Pinion Assembly Assembly 12. 12. Dust Dust Cove Cover r 13. Shift Shift Lever Lever (4.0 (4.0kW kW only) only) 14. Shift Lever and and Lever Lever pin (4.5kW only) 15. 15. Gear Gear Case Case a. Remove Remove the the bearing bearing retain retainer er.. b. Remove the pinion pinion from the the gear gear case. case.

7. Brus Brush h Hold Holder er 8. Yoke

ENGINE ELECTRICAL (4JJ1) c. Use a screwdriver screwdriver to remove remove the stopper clip. Then disassemble the pinion assembly.

2. Check the commuta commutator tor excessive wear.

mica mica

6D-19

segments segments

for

3. Measure Measure the mica mica segment segment depth. depth.

Mica Segment Depth

mm (in)

Standard

0.5 – 0.8 (0.020 – 0.030)

Limit

0.2 (0.008)

If the mica segment depth is less than the standard but more than the limit, the commutator may be reground. If the mica segment depth is less than the limit, the commutator must be replaced.

Inspection and Repair Make the necessary adjustments, repairs, and part replacement if excessive wear or damage is discovered during inspection. Armature 1. Measure Measure the commut commutato atorr run-out. run-out. Replace the commutator if the measured run-out exceeds the specified limit.

Commutator Run-Out

mm (in)

Standard

0.05 (0.002)

Limit

0.20 (0.079)

Legend 1. Insu Insula lato tor r 2. 0.5 to to 0.8 mm (0.02 (0.020 0 to 0.030 0.030 in) 3. Commut Commutato atorr Segment Segments s 4. Corr Corre ect 5. Inco Incorr rrec ectt 4. Measure the commutato commutatorr outside outside diameter diameter..

Commutator Outside Diameter

mm (in)

Standard

36.5 (1.44)

Limit

35.5 (1.40)

6D-20


If the measured outside diameter is less than the specified limit, the commutator must be replaced.

b. Repair Repair Step Step 1 at differe different nt segments segments of of the armature core. There should be continuity between all segments of the commutator. If there is not, the armature must be replaced.

5. Use a circuit circuit tester to to check the armature armature for grounding. a. Hold one probe of the circuit circuit tester tester against against the the commutator segment. b. Hold the the other other circuit circuit tester tester probe probe against against the armature core. If the circuit tester indicates continuity, the armature is grounded. The armature must be replaced.

Yoke 1. Use a circuit circuit tester tester to check check the the field winding winding ground. a. Hold one one circuit circuit tester tester probe against against the the field field winding end or brush. b. Hold the the other other circuit circuit tester tester probe probe against against the the bare surface of the yoke body. There should should be no continuity. If there is continuity, continuity, the field coil is grounded. The yoke must be replaced.

6. Use the circuit circuit tester to check the armature armature for continuity. a. Hold the the circuit circuit tester tester probes probes against against two commutator segments. 2. Use the circuit circuit tester to to check the the field winding winding continuity. a. Hold one one circuit circuit tester tester probe probe against against the the "M" terminal lead wire.

ENGINE ELECTRICAL (4JJ1) b. Hold the other other circuit circuit tester tester probe probe against against the field winding brush. There should be continuity.If there is no continuity, continuity, the yoke must b e replaced.

Brush and Brush Holder 1. Use a vernier vernier caliper caliper to to measure measure the brush brush length length (four brushes). Replace the brushes as a set if one or more of the brush lengths is less than the specified limit.

6D-21

2. Use a circuit circuit tester to to check the brush brush holder holder insulation. Touch one probe to the holder plate and the other probe to the positive brush holder. There should be no continuity.

Inspect the brushes for excessive wear. If the negative brushes have excessive wear, the entire brush holder assembly must be replaced. If the positive brushes have excessive wear, the entire yoke must be replaced. Overrunning Clutch

Brush Length

mm (in)

Standard

15.5 (0.61)

Limit

12 (0.47)

1. Inspect the overrunnin overrunning g clutch clutch gear teeth teeth for excessive wear and damage. Replace the overrunning clutch if necessary. 2. Rotate Rotate the the pinion pinion clockw clockwise ise.. It should turn smoothly. smoothly. 3. Try to rotate rotate the pinion pinion in the the opposite opposite direction. direction. The pinion should lock.

6D-22


Bearing Inspect the bearings for excessive wear damage.Replace the bearings if necessary.

b. Instal Installl the dust cover cover.. and Dust Cover Bolt Torque:

N⋅m (kg⋅m/lb in)

10.6 (1.08 / 78)

Reassembly Important Operations 1. Magnet Magnetic ic Switc Switch h Assembl Assembly y a. Attach the torsion torsion spring spring to the hole in the magnetic switch as illustrated.

4. Pini Pinion on Ass Assem embl bly y Apply a coat of grease to the reduction gear and install the pinion assembly to the armature shaft.

b. Insert the the shift shift lever into into the plunger plunger hole hole of the the magnetic switch.

5. Brush Brush Holde Holders rs

2. Gea Gear Cas Case e 3. Dust Dust Cove Cover r a. Install Install the magnetic magnetic switch switch assembly assembly in the gear gear case.

a. Install Install the brushes into the the brush holder with raising the spring end of the brush spring. Take care not to damage the commutator face.


6D-23

b. Install Install the the brush holder with alignin aligning g the peripheries of the yoke and the brush holder.

Inspection After Assembly 6. Thro Throug ugh h Bolt Bolt Install the through bolts in the rear cover and tighten them to the specified torque.

Through Bolt Torque:

Use a vernier caliper to measure the pinion shaft thrust play. The pinion shaft thrust play is equal to the pinion shaft end and pinion stopper clearance.

N⋅m (kg⋅m/lb in) Pinion Shaft Thrust Play:

8.1 (0.83 / 69.7)

0.3 - 1.0 (0.012 - 0.039)

7. Lead Lead Wire Wire Connect the lead wire in the magnetic switch and tighten the terminal nut to the specified torque.

Lead Wi Wire Te Terminal Nut Nut Torqu rque: 8.6 (0.88 / 74.9)

N⋅m (kg⋅m/lb m/lb in) in)

mm (in)

6D-24


Magnetic Switch The following tests must be performed with the starter motor fully assembled. The yoke lead wire must be disconnected from the "M" terminal. To prevent coil burning, complete each test as quickly as possible (within three to five seconds). Temporarily connect the solenoid switch between the clutch and the housing and run the following test. Complete each test within three to five seconds. 1. Pull-i Pull-in n Tes Testt Connect the battery negative terminal with the solenoid switch body and the M terminal. When current is applied to the S terminal from the battery positive terminal, the pinion should flutter.

2. Hold-i Hold-in n Maintenan Maintenance ce Test Test Disconnect the lead at the M terminal. The pinion should continue to flutter.

3. Retur Return n Tes Testt Disconnect the battery positive lead at the S terminal. The pinion should return to its home position.


6D-25

6D-26


Pre-Heating System Inspection and Repair Make the necessary adjustments, repairs, and part replacement if excessive wear of damage is discovered during inspection. Visual Check Check the main fuses and glow indicator for damage. Replace the part(s) if required. Glow Relay The glow relay is located in the relay box the engine compartment. Use an ohmmeter to measure the resistance between terminals No.2 and No.3. If the measured value is outside the specified range, the glow relay must be replaced.

Glow Relay Resistance:

Ω

94 - 114

Glow Plug Use a circuit tester to test the glow plugs for continuit y.

Glow Plug Resistance (Reference): Approximately 0.9

Ω

EXHAUST SYSTEM (4JJ1)

ENGINE EXHAUST SYSTEM (4JJ1) TABLE OF CONTENTS Exhaust System System . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-2 Service Service Precautions Precautions . . . . . . . . . . . . . . . . . . . . . . 6F-2 Explanations Explanations on functions functions and operatio operation n . . . . . . 6F-2 Functional Functional check check . . . . . . . . . . . . . . . . . . . . . . . . 6F-3 List of abnormal abnormal phenomena phenomena . . . . . . . . . . . . . . . 6F-3 Trouble Trouble Shooting Shooting . . . . . . . . . . . . . . . . . . . . . . . . 6F-3 Exhaust Silencer Silencer and and Exhaust Pipe Pipe . . . . . . . . . . . 6F-4 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-4 DPD Disassemb Disassembly ly . . . . . . . . . . . . . . . . . . . . . . . 6F-5 DPD Inspection Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 6F-6 DPD Reassembly. Reassembly. . . . . . . . . . . . . . . . . . . . . . . . 6F-6 Installation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-8 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-10 Exhaust Brake Brake System . . . . . . . . . . . . . . . . . . . . 6F-11 6F-11 Service Service Precautions Precautions . . . . . . . . . . . . . . . . . . . . . 6F-11 6F-11 Explanations Explanations on functions functions and operatio operation n . . . . . 6F-11 6F-11 Functional Functional check check . . . . . . . . . . . . . . . . . . . . . . . 6F-11 6F-11 Exhaust Brake. Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12 Components. Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12 Disassembly. Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12 Reassembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-13 Installation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-13 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-14 Exhaust Throttle Throttle . . . . . . . . . . . . . . . . . . . . . . . . . 6F-15 Components. Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-15 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-15 Disassembly. Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16 Reassembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16 Installation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-17 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-18 EGR System System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-19 Service Service Precautions Precautions . . . . . . . . . . . . . . . . . . . . . 6F-19 Explanations Explanations on functions functions and operatio operation n . . . . . 6F-19 EGR Valve Valve and EGR Cooler Cooler . . . . . . . . . . . . . . . . 6F-20 Components. Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-20 Removal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-20 Installation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-21 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-22

6F-1

6F-2


Exhaust System Service Precautions

Explanations on functions and operation

Offset in position of the exhaust system during assembly may sometimes cause vibrations or rattling noise. Therefore, temporarily tighten the bolt until all the parts have been positioned, and sequentially tighten from the engine side to the rear pipe side.

The exhaust brake assembly operates the auxiliary brakes by adjusting the exhaust pressure. The silencer has a built-in catalytic converter and the catalyst is a ceramic monolith (honeycomb). This reduces the CO and HC in the exhaust gas. The rear exhaust pipe has a built-in post silencer. This improves the silencing effect. The main parts consist of the front exhaust pipe, center exhaust pipe, exhaust brake unit, silencer with built-in catalyst, and rear exhaust pipe.

Legend 1. Front Front Exha Exhaust ust Pipe Pipe A 2. Exhaust Exhaust Brake Brake Assem Assembly bly 3. Front Front Exha Exhaust ust Pipe Pipe B 4. DPD(Diesel DPD(Diesel Particul Particulate ate Specification)

Defuser Defuser,,

EURO

4

5. 6. 7. 8. 9.

Exhaust Exhaust Silencer(EU Silencer(EURO RO 3 Specifica Specification) tion) Exhaus Exhaustt Throttl Throttle e Assemb Assembly ly Exhau Exhaust st Sil Silenc encer er Center Center Exhaust Exhaust Pipe Rear Rear Exh Exhau aust st Pip Pipe e

EXHAUST SYSTEM (4JJ1) Functional check

• Check for dents, dents, damage holes or cracks cracks due due to corrosion, and abnormal noise during operation.

• During check or repairs repairs of of the exhaust exhaust system, system, confirm that the clearance between the body and the floor is adequate.

• If CO or or HC value value in in the exhaust exhaust gas increases increases when measuring the exhaust gas (vehicle inspection, etc.), replace the silencer (built-in catalyst).

• Adequate Adequate care should be taken taken to to prevent prevent damage damage due to heating or vibrations in the body panel as it may lead to exhaust gas entering the cabin. • Check for loose loose or damaged damaged connectors connectors and and leakage of exhaust gas.

6F-3

List of abnormal phenomena • Vibration Vibration or rattling rattling noise noise from the exhaust exhaust system. system.

• Check for degradat degradation, ion, cracks cracks or damage damage to to the clamp or rubber.

• Cloggi Clogging ng of the the exhaus exhaustt system. system. • Exhaust Exhaust leakage leakage or noise. noise.

• If the pipe or or silencer silencer is is damaged damaged or has a dent then repair or replace it.

Trouble Shooting Vibration or rattling noise from the exhaust system

Condition

Possible Cause

Correction

Vibration or rattling noise from the Loose or misaligned misaligned components components Match the joints joints and then re-tighten. re-tighten. exhaust system Or,check for damage in the hanger, mounting brackets and clamps. Clogging of the exhaust system

Condition Clog Clogg ging ing of the the exha exhaus ustt syste ystem m

Possible Cause

Correction

The The exha exhaus ustt brak brake e is in the the ON Refer to the Engine Control Systems status. in 6E section, check the electric system and repair if there are abnormalities. Check if the shaft movement in the exhaust brake throttle valve moves is jerky and replace if there is an abnormality. Clogging or deformation exhaust piping.

of

the Repair or replace the exhaust piping.

Exhaust leakage or noise

Condition Exhaust le leakage or or no noise

Possible Cause

Correction

Defect or or mi misalignment in in mo mounting

Match th the jo joints an and th then re re-tighten.

Damage or burn-out of exhaust Replace the damaged parts. piping or silencer Defective components in the Replace the defective parts. exhaust system (clamps, pipes, silencer) Internal damage to silencer

Replace the silencer

6F-4


Exhaust Silencer and Exhaust Pipe Removal 1. Remove Remove the the rear rear exhaust exhaust pipe. pipe. • Remove Remove the the clamp clamp and rear rear exhaust exhaust pipe pipe..

Legend 1. Diffe Different rential ial Pressu Pressure re Pipe (F) (F) 2. Exhaust Exhaust Temperat Temperature ure Sensor (R) 3. Diffe Different rential ial Pressu Pressure re Sensor Sensor 4. Differential Differential Pressure Pressure Hose Hose (F) 5. Differential Differential Pressure Pressure Hose Hose (R) 6. Diffe Different rential ial Pressu Pressure re Pipe (R) 7. Exhaust Exhaust Temperat Temperature ure Sensor (F)

2. Remove Remove the the center center exhaus exhaustt pipe. pipe. 3. Remove Remove the exhaus exhaustt silence silencerr. 4. Remove the exhaust exhaust throttle throttle air pipe. 5. Remove the exhaust exhaust throttle throttle assembly assembly.. 6. Remove the Specification). 7. Remove Remove the the Specification).

exhaust exhaust DPD

silencer(EURO silencer(EURO

assem assembly bly

(EURO (EURO

3 4

• Remove the 2 connectors connectors on on the DPD exhaust exhaust temperature sensor. • Remove the clip clip that that secures secures the the connectors connectors on the DPD exhaust temperature sensor. • Remove the 2 DPD differ differential ential pressure pressure hoses. hoses. • Remove the DPD DPD assembly assembly from the front front pipe. pipe.

NOTE: In the event that the differential pressure sensor assembly must be removed, pay attention to the following points. • Do not not loosen loosen the 4 screws screws used used to tighten the differential pressure sensor. If these screws have been loosened, replace the differential pressure sensor assembly. assembly. • If the differential differential sensor assembl assembly y is dropped, dropped, it cannot be reused.


Legend 1. Senso Sensorr Ass Assemb embly ly 2. Tigh Tighte teni ning ng Screw Screw 8. Remove Remove the the front front exhaust exhaust pipe pipe (B). 9. Remove Remove the the exhaus exhaustt brake. brake. • Remove Remove the the air air hose and and the the exhaust exhaust brake brake assembly. 10. Remove Remove the the front front pipe pipe (A). (A). • Remove Remove the the clamp clamp and and front front pipe pipe..

DPD Disassembly 1. Loosen the the clip (1) from the hose connecting connecting to the the differential pressure pipe and remove the hose. 2. Loosen the the sleeve sleeve nuts (2) (2) and (4) that that secure secure the differential pressure pipe. 3. Remove Remove the clip clip (3) that secure secure the the differentia differentiall pressure pipe. 4. Remove Remove the differentia differentiall pressure pressure pipe.

6F-5

Legend 1. Hose Hose Clip Clip 2. Sleev Sleeve e Nut Nut (Rr) (Rr) 3. Clip 4. Sleev Sleeve e Nut Nut (Ft) (Ft) 5. Disassemble Disassemble the DPD assembly assembly.. • Loosen Loosen the the nuts nuts used used for mountin mounting g the oxidation catalyst section, and detach the oxidation catalyst section. • Loosen the nuts nuts used used for mounting mounting the the filter filter and detach the filter and rear case. NOTE: Do not submit the DPD assembly to high impact or drop the assembly. assembly.

6F-6


4

5

3 1 2

1

2

LNW41GSH000201

Legend 1. Oxidati Oxidation on Cataly Catalyst st Sectio Section n 2. Gask Gasket et 3. Filt Filter er Secti Section on 4. Gask Gasket et 5. Rear Rear Case ase

Legend 1. Filter ter 2. Filt Filter er Case Case 3. If the differe differential ntial pressure pressure sensor sensor assembly assembly has has been replaced, carry out the following steps (on the vehicle). • Without turning turning the engine on, turn turn the key from from "OFF" to "ON".

DPD Inspection 1. Perform an external external appearan appearance ce inspectio inspection n on exhaust pipe related components. • Damage Damage to a body body pane panell caused caused by heat heating ing or vibration can lead to exhaust gas intruding into the cabin. • Inspect Inspect the the connecti connections ons for for damage, and exhaust gas leaks.

LNW41GSH000601

loosenes looseness, s,

• Inspect the clamps clamps and rubber rubber for for deterioratio deterioration, n, cracks, and damage. • Inspect Inspect the the pipe pipe and silenc silencer er for dents dents and and corrosion induced cracks, and if damaged, repair or replace the damaged part(s). 2. Perform an DPD DPD related related inspection. inspection. • Visually Visually inspect inspect the filter filter for erosion, erosion, damage, or blocking. • Light shines shines through through the filter from the the opposite opposite side. If light is transmitted and is visible, replace the filter section. NOTE: Before DPD disassemble, be sure to use a scan tool to check the DPD differential pressure, status, and inspection and servicing details. Refer to the "Engine control" section for details.

• The DPD DPD lamp lamp is turned on, and then then after after 30 seconds turned off. • After After confirm confirming ing that that the DPD DPD lamp has has gone off, turn the key to the "OFF" position and leave for 15 seconds. 4. Check Check the oxidat oxidation ion catalys catalyst. t. • Visually Visually inspect inspect the damage, or plugging.

catalys catalystt

for erosion, erosion,

DPD Reassembly 1. Insert gaskets gaskets in the filter filter section section and the the rear case case and tighten temporarily with bolts and nuts. 2. Insert gasket gaskets s in the filter filter section section and oxidati oxidation on catalyst and tighten temporarily with bolts and nuts. NOTE: Check the mounting location of the filter section and rear case, and the filter section and oxidation catalyst, and tighten each pipe bracket in 2 places by tightening the bolts alternatively. alternatively. 3. Tighten Tighten the bolts bolts and nuts nuts to the specifi specified ed torque. torque. • Tighten Tighten all all of the bolts bolts and nuts nuts twice. twice. Torque : 25 N ⋅m (2.5 kg⋅m / 18 lb ⋅ft)

EXHAUST SYSTEM (4JJ1) NOTE: After tightening all of the bolts and all of the nuts, tighten them all to the same torque (tightening twice)

4

6F-7

7. Insert the the hose for for the differe differential ntial pressure pressure pipe pipe until it reaches the spool and secure with a clip.

5

3

2

1

LNW41GSH000201

Legend 1. Oxidat Oxidation ion Catal Catalyst yst Secti Section on 2. Gask asket 3. Filt Filter er Secti Section on 4. Gask asket 5. Rear Rear Case Case 4. Insert the the protruded protruded section section of the differe differential ntial pressure pipe (only Ft side) into DPF and tighten the sleeve nut (4) by hand. Then, tighten the sleeve nut (Rr) (2) by hand. NOTE: Clean the old anti-seize compound from the sleeve nut and apply new anti-seize compound. 5. Fix the the pipe in place place using using a clip clip (3). (3). Torque: 10 N⋅m (1.0 kg⋅m / 87 lb⋅in) 6. Fully Fully tighte tighten n the sleeve sleeve nuts. nuts. Torque (Ft): 4 5 N⋅m (4.6 kg⋅m / 33 lb⋅ft) Torque (Rr): 35 N ⋅m (3.6 kg⋅m / 26 lb ⋅ft)

Legend 1. Hose Hose Clip Clip 2. Sleev Sleeve e Nut Nut (Rr) (Rr) 3. Clip 4. Sleev Sleeve e Nut Nut (Ft) (Ft) NOTE: If the procedures described above are not followed, the sleeve nut may become loose. Air-tightness check • Once the the engine engine is is warmed warmed up, run run at maxim maximum um non-load RPM. • To ensure ensure there are no gas leakages, leakages, with with the engine revved up, spray soapy water on the pressure hose (1) and sleeve nuts (2) (4) connecting parts.

6F-8

EXHAUST SYSTEM (4JJ1) • Attach Attach the hose hose clips clips (4 locations) locations) securely securely to prevent gas leakage. NOTE: • Do not confus confuse e the front/r front/rear ear direct directions ions.. • Do not not use hoses hoses that that are are cracked cracked.. • Do not overtighten overtighten or or remove remove the differ differential ential sensor assembly's tightening screws. • If there there is a gas leak in in the coupling coupling section, section, a sensor malfunction may occur. Ensure to check for gas leakage after starting the engine.

Legend 1. Hose Hose clip lip 2. Sleev Sleeve e Nut Nut (Rr) (Rr) 3. Clip 4. Sleev Sleeve e Nut Nut (Ft) (Ft)

1

8

7

7

2

2

Installation

6

3

NOTE:

5

4

• A possible possible cause cause of vibration vibration or looseness looseness is the misspositioning of the exhaust system during assembly. Therefore, do not fully tighten the bolts until all the components are positioned, and when positioned, tighten the bolts starting at the engine and working outwards. • Do not re-use gaskets gaskets or nuts nuts that that were removed. removed. 1. Instal Installl the front front exhau exhaust st pipe pipe A. Torque : 67 N ⋅m (6.8 kg ⋅m / 49 lb ⋅ft) NOTE: Tighten the front exhaust pipe so that it is balanced, and make sure there are not any gas leaks. 2. Install Install the exhaust exhaust brake and and front exhaust exhaust pipe pipe B. • Insta Install ll the the air air hose hose.. Torque : 27 N ⋅m (2.8 kg ⋅m / 20 lb ⋅ft) 3. Install Install the DPD DPD assembly assembly to the the front pipe (EURO (EURO 4 Specification). Torque : 22 N ⋅m (2.2 kg ⋅m / 16 lb ⋅ft) 4. Install Install the DPD DPD differenti differential al pressure pressure hose to the differential pressure pipe (EURO 4 Specification). • Insert the front front side side of the differe differential ntial pressure pressure hose into the port of the differential pressure sensor that is marked "F" (white).

LNW41GSH000901

Legend 1. Diffe Different rential ial Pressu Pressure re Sensor Sensor 2. Clip 3. Differ Different ential ial Pressu Pressure re Hose Hose 4. Proper Properly ly Fitt Fitted ed Hoses Hoses 5. Revers Reversely ely Fitted Fitted Hoses Hoses 6. Differ Different ential ial Pressu Pressure re Hose Hose 7. Clip 8. Diffe Different rential ial Pressu Pressure re Sensor Sensor


6F-9

6. Fix the DPD DPD temperature temperature sensor sensor harness harness with with clips clips (EURO 4 Specification). 7. Install Install the exhaust exhaust silencer silencer to to the front front pipe (EURO (EURO 3 Specification). Torque : 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft) 8. Install Install the exhaust exhaust throttle throttle assembly assembly and extension extension pipe. Torque : 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft) 9. Install Install the exhaust exhaust throttle throttle air air hose. hose. 10. Install Install the the center center exhaust pipe. 11. Install Install the rear exhaust exhaust pipe. • Tighten ighten the the cla clamp mp.. Torque : 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)

Legend 1. Nut 2. F; Fron Frontt Mar Mark k 3. Rear Side Side Differenti Differential al Pressure Pressure Hose Hose Spigot Spigot 4. Front Side Side Different Differential ial Pressure Pressure Hose Hose Spigot Spigot 5. Bra Bracket 5. Connect Connect the DPD DPD temperature temperature sensor connectors connectors (EURO 4 Specification). NOTE: Do not confuse the front/rear directions.

Legend 1. Differ Different ential ial pressu pressure re pipe (F) (F) 2. Exhaust temperature temperature sensor sensor 1 (filter (filter inlet) inlet) 3. Differ Different ential ial pressu pressure re sensor sensor 4. Differ Different ential ial pressu pressure re hose (F) 5. Differ Different ential ial pressu pressure re hose (R) 6. Differ Different ential ial pressu pressure re pipe (R) 7. Exhaust temperat temperature ure sensor sensor 2 (catalys (catalystt inlet) inlet)

6F-10




Exhaust Brake System Service Precautions During assembly and mounting, mount the parts appropriately at the specified tightening torque value.


Functional check Operational check • Confirm Confirm the sound of the the valve valve touchin touching g the stopper when the exhaust brake is operated in the idling condition.

6F-11

6F-12


Exhaust Brake Components

Legend 1. Power Chamber Chamber,, Insulator Insulator,, Gasket and and Bearing 2. Lock Nuts Nuts and Clevis Clevis Join Jointt 3. Split Split Pin and washer washer 4. Exhaust Exhaust Brake Brake Valv Valve e

Removal 1. Remove Remove the the vacuum vacuum and and clips. clips. 2. Remo Remove ve the the nut nut.. 3. Remove Remove the exhaust exhaust pipe. pipe. 4. Remove the exhaust exhaust brake assembly assembly.

Disassembly 1. Remove Remove the split split pin. 2. Remove Remove the lock lock nuts. nuts. 3. Remove Remove the the clevi clevis s joint. joint. 4. Remove Remove the the power power chambe chamberr.

Reassembly 1. Mount Mount the the power power chamber chamber..

5. Fron Frontt Exhau Exhaust st Pipe Pipe B 6. Exhaus Exhaustt Brake Brake Assembly Assembly 7. Fron Frontt Exhau Exhaust st Pipe Pipe A

EXHAUST SYSTEM (4JJ1) Tightening torque : 14 N⋅m (1.4kg⋅m / 122lb ⋅in)

6F-13

Unit check • Negative Negative pressure pressure in the the power power chamber chamber caused caused by the vacuum pump. When a pressure of 53.3 to 93.3 kPa (400 to 700 mmHg) is applied, the exhaust brake valve should open or close smoothly.

2. Mount Mount the the lock lock nuts. nuts. 3. After mounting mounting the the clevis joint, joint, tighten tighten the lock lock nuts to the specified torque. Tightening torque : 13N ⋅m (1.3kg⋅m / 113lb ⋅in)

Installation 1. Mount the exhaust exhaust brake assembly assembly. Tightening torque : 17N ⋅m (1.7 kg⋅m / 12 lb⋅ft)

4. Mount Mount the the spli splitt pin. pin.

Inspection Check for damage or degradation in the parts mentioned below. • Exha Exhaus ustt brak brake e val valve ve • Exha Exhaus ustt brak brake e sha shaft ft • Butt Butter erfl fly y valv valve e • Bush • Powe Powerr cham chambe ber r

6F-14


2. Mount the exhaust pipe.

3. Mount the nuts. Tightening torque : 67 N⋅m (6.8kg⋅m / 49lb ⋅ft) 4. Mount the vacuum vacuum hose and and the the clips. clips.



Exhaust Throttle Components

Legend 1. Power Power Chamb Chamber er 2. Gask asket 3. Insu Insula lato tor r 4. Bea Bearing 5. Lock Nuts Nuts and Clevis Clevis Join Jointt 6. Pin Pin and and Spl Split it Pin Pin

Removal 1. Remove Remove the the vacuum vacuum hose and and clip. clip. 2. Remov Remove e the the nut. nut. 3. Remove Remove the the rear exhau exhaust st pipe. pipe. 4. Remove Remove the the center center exhaus exhaustt pipe. pipe. 5. Remove Remove the the exhaust exhaust silencer silencer..

7. 8. 9. 10. 11. 12.

Cover Extensi Extension on Silenc Silencer er Exhau Exhaust st Cent Center er Pipe Pipe DPD (Diesel Particulate Particulate Defuser) Defuser) Exhaust Exhaust Thro Throttl ttle e Body Exhaust Exhaust Thro Throttl ttle e Asembly Asembly

6F-15

6F-16

EXHAUST SYSTEM (4JJ1) Unit inspection • Apply vacuum pressure pressure to the power power chamber chamber using a vacuum pump. The exhaust throttle valve should open and close smoothly when pressure of 75 - 93.3kPa {560 700mmHg} is applied.

6. Remove the exhaust exhaust throttle throttle assembly assembly..

Disassembly 1. Remove Remove the split split pin. 2. Remove Remove the lock lock nut. nut. 3. Remove Remove the the clevi clevis s joint. joint.

NOTE: Do not change the exhaust throttle's adjustment as it may have an affect on DPD performance.

4. Remove Remove the the power power chambe chamberr.

Inspection Inspect the following deterioration, etc. • Exhau Exhaust st thro thrott ttle le valv valve e • Exhau Exhaust st thro thrott ttle le shaf shaftt

parts

for

damage

and

Reassembly 1. Instal Installl the power power chambe chamberr. Tigh Tighte teni ning ng torque torque 14 N⋅m (1.4 kg⋅m / 122 lb⋅in)

• Butt Butter erfl fly y valv valve e • Powe Powerr cham chambe ber r

2. Instal Installl the the lock lock nut. 3. After mounting mounting the the clevis joint, joint, tighten tighten the lock lock nut to specified tightening torque. Tigh Tighte teni ning ng torque torque 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)

EXHAUST SYSTEM (4JJ1) NOTE: Do not adjust or remove the adjusting bolt. Do not remove the lever.

4. Install Install the the rear exhau exhaust st pipe. pipe.

1

2

Tight Tighten enin ing g torq torque ue 50 N⋅m (5.1 kg⋅m / 37 lb ⋅in) LNW41GSH001201

Legend 1. Leve Leverr 2. Adjus Adjusti ting ng bol boltt 4. Instal Installl the split split pin. pin.

Installation 1. Install Install the exhaust exhaust throttle throttle assembly assembly.. Tigh Tighte teni ning ng torque torque 20N 20N⋅m (2.0kg⋅m / 14 lb ⋅in)

2. Install Install the the exhaust exhaust silencer silencer.. 3. Install Install the the exhaust exhaust center pipe.

5. Install Install the the vacuum vacuum hose and clip. clip.

6F-17

6F-18




6F-19

EGR System Service Precautions


Perform EGR related assembly according to the usual procedure of temporarily fitting and then permanently tightening the parts so that unnecessary stresses are not applied on the parts.

Re-circulate a part of the exhaust gas of the EGR system in the intake manifold.Reduce the combustion temperature and inhibit NOx generation since inert gases may be mixed up in the intake sir. An electronic control system is used in this EGR to balance the requirements of operability and low emissions.A DC motor is operated using the control current of the Engine Control Module (ECM) to control the EGR. Refer to the chapter on Engine Control System for details on fault diagnosis of the EGR system.

Legend 1. EGR EGR cool cooler er 2. Engine Engine Contro Controll Module Module (ECM) (ECM)

3. EGR Valve alve DC DC Motor Motor

6F-20


EGR Valve and EGR Cooler Components

Legend 1. EGR EGR Val Valve ve 2. EGR EGR Valv Valve e Gaske Gaskett 3. EGR EGR Cool Cooler er

Removal 1. Drai Drain n the coo coola lant. nt. 2. Remove Remove the the turboch turbocharg arger er.. Refer to “Turbocharger” in ENGINE MECHANICAL section.

4. Heat Heat Protec Protecto tor r 5. EGR EGR Cool Cooler er Gask Gasket et 6. EGR EGR Cool Cooler er Gask Gasket et

EXHAUST SYSTEM (4JJ1) 3. Remove Remove the the heat prote protecto ctorr.

6F-21

b. Tighten Tighten the bolt and and nuts by final final tightening tightening order. Final tightening order : 3 →4→5→1→2→6 Tightening torque : Bolt, Nut 1 to 5 27 N⋅m (2.8 kg⋅m / 20 lb ⋅ft) Bolt 6 52 N⋅m (5.3 kg⋅m / 38 lb ⋅ft)

4. Remove Remove the the EGR EGR coole cooler. r. • Disconnect Disconnect the Water Water pipe pipe rubber rubber hose hose (IN , OUT) and remove the EGR cooler and gasket. 5. Remove Remove the EGR valve. valve.

3. Connect the water water pipe pipe rubber hose (IN,OUT (IN,OUT). ). 4. Install Install the the heat heat protec protector tor Tightening torque : 25 N ⋅m (2.5 kg⋅m / 18 lb ⋅ft) 5. Install Install the turbo turbochar charger ger.. Refer to “Turbocharger” in ENGINE MECHANICAL section. 6. Repleni Replenish sh the the coolan coolant. t.

Installation 1. Instal Installl the EGR valve. valve. Tightening torque : 27 N⋅m (2.8kg⋅m / 20lb ⋅ft) 2. Instal Installl the EGR EGR Cooler Cooler.. a. Install Install the gaskets gaskets and the the EGR cooler. cooler. Temporarily tighten t he bolts and the nuts. Temporary tightening order : 1 →2→3→4→5→6

6F-22



ACCELERATOR CONTROL SYSYEM (4JJ1)

ENGINE ACCELERATOR ACCELERATOR CONTROL SYSYEM (4JJ1) TABLE OF CONTENTS Accelerator Pedal Assembly . . . . . . . . . . . . . . . . . 6H-2 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .6H-2 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6H-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6H-2

6H-1

6H-2

ACCELERATOR CONTROL SYSYEM (4JJ1)

Accelerator Pedal Assembly Components

Legend 1. Nut 2. Conn Connec ecto tor r 3. Control Link and Bracket Bracket Assembly Assembly

Removal

4. Accele Accelerat rator or Pedal Pedal 5. Bolt

Installation

1. Nut to Contorol Contorol Link and Bracket Bracket Assembly Assembly

1. Instal Installl the Harness Harness Conn Connecto ector r

2. Bolt Bolt to Acce Acceler lerator ator Pedal Pedal

2. Instal Instal the the Accelerato Acceleratorr Pedal Pedal Bolt

3. Harness Harness Connector Connector to Accelerator Accelerator Switch Connector and Accelerator Position Sensor

3. Install Install the Control Control Link Link and Bracket Bracket Assembly Assembly

NOTE: Disconnect the battery ground cable when the harness connector is disconnected.

LG4JJ-WE-0761

You are requested to order this manual using the manual number that is shown above.

This manual is applicable for vehicles in all countries except the USA, Canada and Mexico.

All rights rights reserved. reserved. This manual manual may not be reproduced in whole or in part, without the permission in writing of ISUZU MOTORS LIMITED. Issued by

ISUZU MOTORS LIMITED SERVICE MARKETING DEPARTMENT DEPARTMENT Tokyo, Japan First edition August. 2006

No. LG4JJ-WE-0761

Engine 4JJ1

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