Двигатель isuzu 4jj1 мануал

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Summary of Contents for Isuzu 4JJ1-TC

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WORKSHOP MANUAL

2011MY UC SERIES

ENGINE

4JJ1 MODEL

SECTION 6

Isuzu Motors Limited

E-Solutions &

Service Marketing Dept.

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ENGINE MECHANICAL (4JJ1) 6A-1

SECTION 6A

ENGINE MECHANICAL (4JJ1)

TABLE OF CONTENTS

ISUZU DIESEL ENGINE (4JJ1) ……………………. 6A-3

Service Precautions …………………………………. 6A-3

Trouble Shooting……………………………………… 6A-8

Main Data and Specifications…………………….. 6A-13

Special Tools…………………………………………… 6A-14

Engine Assembly………………………………………… 6A-15

Removal …………………………………………………. 6A-15

Installation ………………………………………………. 6A-17

Special Tools…………………………………………… 6A-19Engine Mount …………………………………………….. 6A-20

Components……………………………………………. 6A-20

Removal …………………………………………………. 6A-21

Installation ………………………………………………. 6A-21

Torque Specifications……………………………….. 6A-22

Special Tools…………………………………………… 6A-22

Cylinder Head Cover …………………………………… 6A-23

Components……………………………………………. 6A-23

Removal …………………………………………………. 6A-24

Installation ………………………………………………. 6A-25

Intake Manifold…………………………………………… 6A-26

Components……………………………………………. 6A-26

Removal …………………………………………………. 6A-27

Installation ………………………………………………. 6A-28

Torque Specifications……………………………….. 6A-30

Turbocharger and Exhaust Manifold ……………… 6A-31

Components……………………………………………. 6A-31

Removal …………………………………………………. 6A-32

Inspection……………………………………………….. 6A-34

Installation ………………………………………………. 6A-35

Torque Specifications……………………………….. 6A-38

Timing Gear Train ………………………………………. 6A-39

Components……………………………………………. 6A-39

Removal …………………………………………………. 6A-40

Disassembly……………………………………………. 6A-42

Reassembly…………………………………………….. 6A-42

Inspection……………………………………………….. 6A-43

Installation ………………………………………………. 6A-44

Torque Specifications……………………………….. 6A-47

Camshaft Assembly ……………………………………. 6A-48

Components……………………………………………. 6A-48

Removal …………………………………………………. 6A-49

Disassembly……………………………………………. 6A-50

Reassembly ……………………………………………. 6A-52

Installation ………………………………………………. 6A-53

Torque Specifications……………………………….. 6A-55

Special Tools…………………………………………… 6A-55

Valve Stem Seal and Valve Spring ……………….. 6A-56

Components……………………………………………. 6A-56

Removal …………………………………………………. 6A-57

Inspection……………………………………………….. 6A-58Installation ………………………………………………. 6A-59

Special Tools…………………………………………… 6A-60

Cylinder Head…………………………………………….. 6A-61

Components……………………………………………. 6A-61

Removal …………………………………………………. 6A-61

Disassembly……………………………………………. 6A-69

Inspection……………………………………………….. 6A-71

Reassembly ……………………………………………. 6A-76

Installation ………………………………………………. 6A-77

Torque Specifications……………………………….. 6A-88

Special Tools…………………………………………… 6A-88

Piston and Connecting Rod………………………….. 6A-89

Components……………………………………………. 6A-89

Removal …………………………………………………. 6A-89

Disassembly……………………………………………. 6A-90

Reassembly ……………………………………………. 6A-94

Installation ………………………………………………. 6A-95

Torque Specifications……………………………….. 6A-97

Special Tools…………………………………………… 6A-97

Flywheel ……………………………………………………. 6A-98

Components……………………………………………. 6A-98

Removal …………………………………………………. 6A-98

Inspection………………………………………………..6A-100

Installation ………………………………………………. 6A-100

Torque Specifications………………………………..6A-102

Special Tools……………………………………………6A-102

Gear Case Assembly …………………………………..6A-103

Components…………………………………………….6A-103

Removal ………………………………………………….6A-104

Installation ………………………………………………. 6A-105

Torque Specifications………………………………..6A-107

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6A-2 ENGINE MECHANICAL (4JJ1)

Crankshaft Front Oil Seal……………………………..6A-108

Components…………………………………………….6A-108

Removal ………………………………………………….6A-108

Installation ……………………………………………….6A-109

Torque Specifications………………………………..6A-110

Special Tools……………………………………………6A-110

Crankshaft Rear Oil Seal ……………………………..6A-111

Components…………………………………………….6A-111

Removal ………………………………………………….6A-112

Installation ……………………………………………….6A-112

Special Tools……………………………………………6A-113

Crankshaft………………………………………………….6A-114

Components…………………………………………….6A-114

Removal ………………………………………………….6A-115

Disassembly…………………………………………….6A-116

Reassembly……………………………………………..6A-116

Inspection………………………………………………..6A-116

Installation ……………………………………………….6A-120

Torque Specifications………………………………..6A-123

Cylinder Block …………………………………………….6A-124

Components…………………………………………….6A-124

Removal ………………………………………………….6A-124

Inspection………………………………………………..6A-125

Installation ……………………………………………….6A-126

Lubrication System………………………………………6A-128

Service Precautions ………………………………….6A-128

Functional Check ……………………………………..6A-129

Oil Filter Cartridge ……………………………………….6A-131

Components…………………………………………….6A-131

Removal ………………………………………………….6A-131

Installation ……………………………………………….6A-131

Special Tools……………………………………………6A-132

Oil Filter Assembly and Oil Cooler …………………6A-133

Components…………………………………………….6A-133

Removal ………………………………………………….6A-133

Installation ……………………………………………….6A-135

Crank Case and Oil Pan……………………………….6A-137

Components…………………………………………….6A-137

Removal ………………………………………………….6A-138

Disassembly…………………………………………….6A-139

Reassembly……………………………………………..6A-139

Installation ……………………………………………….6A-140

Torque Specifications………………………………..6A-142

Oil Pump ……………………………………………………6A-143

Components…………………………………………….6A-143

Removal ………………………………………………….6A-143

Disassembly…………………………………………….6A-145

Reassembly …………………………………………….6A-145

Inspection………………………………………………..6A-145

Installation ………………………………………………. 6A-146

Oil Pressure SW …………………………………………6A-149

Components…………………………………………….6A-149

Removal ………………………………………………….6A-150

Inspection………………………………………………..6A-150

Installation ………………………………………………. 6A-150

Circuit check…………………………………………….6A-150

Air Cleaner Element …………………………………….6A-151

Removal ………………………………………………….6A-151

Cleaning ………………………………………………….6A-151

Installation ………………………………………………. 6A-151

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ENGINE MECHANICAL (4JJ1) 6A-3

ISUZU DIESEL ENGINE (4JJ1)

Service Precautions

Matters that require attention in terms of

maintenance

To prevent damage to the engine and ensure reliabilityof its performance, pay attention to the following in

maintaining the engine:

• When lifting up or supporting the 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 pump strainer, it can

damage the oil pan and the oil strainer.

• When the air duct or air cleaner is 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 maintaining the engine, never fail to 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 oil to the sliding contact surfaces of

the engine before reassembling it. This ensures

adequate lubrication when the engine is first

started.

• When valve train parts, pistons, piston rings,

connecting rods, connecting rod bearings or

crankshaft journal bearings are removed, put them

in order and keep them.

• When installing them, put them back in the same

location they were removed from.

• Gaskets, oil seals, O-rings, etc. must be replaced

with new ones when the engine is reassembled.

• As for parts where a liquid gasket is used, 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 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 assembling or installing parts, fasten them

with the prescribed tightening torque so that they

are installed properly.

Matters that require attention in specifically dealing

with this engine.

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 the service procedure, wash the

fuel line and the surrounding area.

• Perform the service procedures with clean hands.

Do not wear work gloves.

• Immediately after removing the fuel hose and/or

fuel pipe, carefully tape vinyl bags over theexposed ends of the hose or pipe.

•

If parts are to be replaced (fuel hose, fuel pipe,

etc.) do not open the new part packaging until

installation.

Work procedure

• The fuel opening must be quickly sealed when

removing the fuel pipe, injection pipe, fuel injector,

fuel supply pump, and fuel rail.

•

The eyebolts and gasket must be stored in a cleanparts box with a lid to prevent adhesion of foreign

matter.

• Fuel leakage could cause fires. Therefore, after

finishing the work, wipe off the fuel that has leaked

out and make sure there is no fuel leakage after

starting the engine.

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6A-4 ENGINE MECHANICAL (4JJ1)

How to read the model

RTW56ALF001501

Legend

1. Engine Model (Stamped)

2. Engine Number (Stamped)

3. Front

Explanation of functions and operations

Electronic engine controlWith 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 4valves per cylinder. The angular tightening method of

the cylinder head bolt further increases reliability and

durability.

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ENGINE MECHANICAL (4JJ1) 6A-5

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, whileinjection timing or fuel injection quantity is controlled

under every possible driving condition.

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. Inspection of valve clearance

• Remove the fuel injector harness assembly.

• Remove the leak off hose.

• Remove the cylinder head cover.

• Rotate the crankshaft to make the No.1

cylinder meet the compression top dead center

(TDC).

RTW76ASH001301

Legend

1. TDC

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6A-6 ENGINE MECHANICAL (4JJ1)

• Insert a 0.15 mm (0.006 in) thickness 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)

Intake valve 0.15 (0.006)

Exhaust valve 0.15 (0.006)

Note:

Adjust while cold.

2. Adjustment of valve clearance

• Loosen each adjusting screw of the rocker arm

completely.

RTW56ASH003701

Legend

1. Screwdriver

2. Ring Spanner

3. Valve Clearance Adjust Nut Wrench

Special tool

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

• Insert a 0.15 mm (0.006 in) thickness 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.

LHW71BSH001201

Legend

1. Cam; Exhaust

2. Cam; Intake

3. Roller; Intake

4. Roller; Exhaust

Tightening torque:

Rocker arm adjustment screw nut

18 N⋅⋅⋅⋅m (1.8 kg⋅⋅⋅⋅m / 13 lb ft)

Adjustment table

Cylinder No. 1 2 3 4

Valve

arrangementIN EX IN EX IN EX IN EX

No. 1 cylinder

Compression

TDC

No. 4 cylinder

Compression

TDC

× × × ×

• If the No.1 cylinder is the compression TDC, adjusta valve clearance with mark given on the table

and if the No. 4 cylinder is the compression TDC,

adjust that with × mark.

• Install the cylinder head cover.

Refer to «Cylinder Head Cover.»

• Install the leak off hose.

• Install the fuel injector harness assembly.

Compression pressure inspection

• Warm up the engine.

• Disconnect the negative battery cable.

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ENGINE MECHANICAL (4JJ1) 6A-7

• Remove the all glow 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)

• Connect the negative battery cable.

• Turn on the starter to emit foreign matter within the

cylinders.

• Install an adapter and a gauge of a compression

gauge of the special tool.

RTW56ASH003801

Compression gauge: 5-8840-2675-0

Gauge adapter: 5-8840-2815-0

• Turn on the starter to inspect compression

pressure.

Compression pressure MPa(psi)/200rpm

Standard 2.84 − 3.24 (412 − 469)

Limit 1.96 (284)

Differences among

the cylinders 294 kPa (43)

• Measure each cylinder one by one.

Note:

To keep engine speed at 200 rpm or more, use fully

charged batteries.

• Remove a compression gauge of the special tool.

• Disconnect the negative battery cable.

• Install the glow plugs.

• Connect the negative battery cable.

A list of defective phenomena

• Engine does not turn over.

• Engine turns over but does not start.

• Excessive black exhaust smoke.

• Excessive white exhaust smoke.

• Engine knocking.

• Abnormal engine rotation.

• Abnormal battery charging.

• Turbocharger trouble shooting.

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6A-8 ENGINE MECHANICAL (4JJ1)

Trouble Shooting

Engine does not turn over

Condition Possible Cause Correction

Dead or weak battery Charge battery

Replace battery

Incomplete circuit Connector wiring and/or connectorsRepair

Starter motor brushes stuck, worn,

or broken

Replace brushes

Starter motor does not rotate

Starter motor internal damage Repair motor

Ring gear abrasion Replace ring gearStarter motor not meshed with

flywheelMagnetic switch (starter motor) not

properly adjusted

Adjust magnetic switch

Dead or weak battery Charge battery

Replace battery

Insufficient contact pressurebetween starter motor brushes and

commutator

Adjust pressure

Armature (starter motor) stuck Repair armature

Starter motor pinion meshed with

ring gear but does not rotate

Engine internal damage (Seizure) Repair engine

Engine turns over but does not start

Condition 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 strainer (fuel suction) Clean or replace strainer

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

Fuel is not delivered to fuel supply

pump

Clogged fuel filter Replace filter

Loose injection pipe connections Tighten connections

Loose or broken electricalconnectors

Tighten and/or replace connectors

Bad rotational sensor Replace sensor

Fuel is delivered to fuel supply

pump

Engine control system malfunction System diagnosis

Air in fuel system Bleed air from fuel system

Feed pump malfunction Repair pump

Loose or broken electrical

connectors

Tighten and/or replace connectors

Clogged fuel filter Replace filter

Insufficient or unstable fuel delivery

volume

Engine control system malfunction System diagnosis

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ENGINE MECHANICAL (4JJ1) 6A-11

Abnormal engine rotation

Condition Possible Cause Correction

Defective control unit Replace unitEngine speed cannot be increased

Engine control system malfunction System diagnosis

Defective control unit Replace unit

Engine control system malfunction System diagnosis

Clogged fuel filter element Replace element

Defective fuel injector(s) Replace fuel injector assembly

Water in fuel Drain existing fuel and replace with

new fuel

Engine speed unstable

Air in fuel system Bleed air from fuel system

Damaged turbocharger fan Replace turbocharger

Rough turbocharger shaft rotation Replace turbocharger

Turbocharger malfunction

Broken actuator Replace turbocharger

Abnormal battery charging

Condition Possible Cause Correction

Open or shorted wiring and/or

connectors

Repair or replace wiring and/or

connectors

Defective generator Repair or replace generator

No charging

Defective battery Replace battery

Open or shorted wiring and/or

connectors

Repair or replace wiring and/or

connectors

Defective generator Repair or replace generator

Loose generator drive belt Adjust belt tension or replace belt

Insufficient charging

Defective battery Replace battery

Shorted wiring Repair or replace wiring

Defective generator Repair or replace generator

Excessive charging

Defective battery Replace battery

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6A-12 ENGINE MECHANICAL (4JJ1)

Turbocharger Troubleshooting

Condition Possible Cause Correction

Air leakage from intake pipe rubber

hose

Repair rubber hose

Air leakage from intake cover Repair intake cover

Clogged intercooler cooling section Clean cooling section

Clogged air cleaner element Clean or replace element

Intake throttle valve stuck Repair or replace throttle valve

Turbine and housing contact

(Interference)

Replace turbine and/or housing

Excessive carbon deposit near

turbine exhaust port that interferes

with turbine

Clean or repair exhaust port and/or

turbine

Rough turbine shaft rotation Repair or replace turbine shaft

Engine has less than normal power

Damaged turbine blade Repair or replace turbine blade

Oil leakage from turbocharger oilseal

Repair or replace oil seal

Clogged turbocharger oil return

pipe

Repair pipe

Clogged center housing oil

passages

Repair or replace center housing

Blue exhaust smoke

Engine oil deterioration Change engine oil

Gas leakage from intake or

exhaust system

Repair intake or exhaust system

Turbine and housing contact

(Interference)

Repair or replace turbine and/or

housingDamaged turbine blade Replace turbine blade

Noisy turbocharger operation

Turbine shaft bearing abrasion or

scoring

Repair or replace bearing

Engine oil deterioration Change engine oil

Clogged turbocharger oil feed pipe Repair pipe

Excessive rotating part wear

Low engine oil pressure Repair

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ENGINE MECHANICAL (4JJ1) 6A-13

Main Data and Specifications

Item Engine model 4JJ1

Type Diesel/4-cycle/water cooling-type in-line DOHC

Combustion chamber type Direct injection type

Cylinder liner type

Liner less

Number of cylinders -cylinder

bore × strokes

mm (in) 4-95.4(3.76) × 104.9(4.13)

Displacement cc (cu.in) 2999 (183)

Compression ratio 17.5

Compression pressure MPa (psi)/rpm 3 (435)/200

Idling speed rpm 700 ± 25

Valve clearance Intake 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 Gear type

Volume of lubricating oil L (qts) 8.0 (8.5)

Oil filter type 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 °C (°F) 85 (185)

Volume of coolant L (qts) M/T8.7 (9.2) A/T 8.6 (9.1) (incl. radiator)

Fuel system

Injection pump type Fuel supply pump fuel rail type

Fuel injector type Electronic control injector

6-hole

Fuel pump type Into the fuel tank type

Charging system

Generator type AC type

Power output V-A 12 — 110

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ENGINE MECHANICAL (4JJ1) 6A-15

Engine Assembly

Removal

1. Disconnect the negative battery cable.

2. Remove the engine hood.

3. Drain the coolant.

4. Remove the starter motor.

5. Remove the transmission assembly.

Refer to removal procedure for “TRANSMISSION”

in this manual.

6. Disconnect the ECM harness connector.

7. Remove the ECM.

8. Remove the air cleaner.

• Disconnect the MAF sensor harness connector.

• Remove the intake pipe with the lid of air

cleaner box.

• Remove the air cleaner box.

RTW56ASH003901

Legend

1. ECM Harness Connector

2. ECM

3. Air Cleaner Box

9. Remove the clip (1) and clip (2)

RTW86ASH001601

Legend

1. Clip

2. Clip

10. Remove the intake hose (intercooler — intake

throttle).

11. Remove the intake hose (turbocharger —

intercooler).

Remove the harness connector.

RTW56ASH004001

Legend

1. Intake Hose (intercooler — intake throttle)

2. Intake Hose (turbocharger — intercooler)

12. Remove the radiator upper hose.

13. Remove the engine harness clip (1).

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6A-16 ENGINE MECHANICAL (4JJ1)

RTW76ASH001401

14. Remove the breather hose and lower hose of the

radiator.

15. Remove the fan guide.

16. Remove the drive belt.

17. Remove the fan assembly.

18. Remove the radiator.

19. Remove the A/C compressor.

RTW76ASH000701

Legend

1. A/C Compressor Bracket

2. A/C Compressor

• Disconnect the connector.

• Disconnect the A/C generator harness.

• Disconnect the terminal B cable and harness

connector from the generator.

20. Remove the power steering pump.

• Remove the bracket of power steering oil hose

(1).

LTW56ASH000101

21. Remove the harness of engine, battery and earth

(1).

RTW86ASH002001

Legend

1. Earth

22. Remove the connector of the shift on the fly (4×4).

23. Remove the vacuum hose of brake master-vac.

24. Remove the front exhaust pipe.

25. Disconnect the fuel hose on the feed and return

sides.

26. Install the engine hanger (special tool 5-8840-

2823-0).

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ENGINE MECHANICAL (4JJ1) 6A-17

RTW56ASH004301

Legend

1. Engine Hanger (Front Side)

RTW56ASH004401

Legend

1. Engine Hanger (Rear Side)

27. Hang wire on the engine hanger and hoist to lift

up the engine slightly.28. Remove the engine mount.

• Remove the fastening bolts for the engine mount

on the engine side.

29. Remove the engine assembly.

• Hoist the engine slightly to provide space to

remove the catalytic converter.

Installation

Notice:

Be absolutely sure that each harness is reconnected to

its original position.

1. Install the engine assembly.

• Hang wire on the engine hanger and hoist to lift up

the engine.

• Operate a hoist slowly to move the engine to the

place where it is to be installed.

• Make the transmission side lower and operate a

hoist slowly, pulling it backward to the engine.

2. Install the engine mount.

Tightening torque: 48 N⋅⋅⋅⋅m (4.9kg⋅⋅⋅⋅m / 35 lb ft)

3. Remove the engine hanger.

4. Install the catalytic converter.

Tightening torque: 27 N⋅⋅⋅⋅m (2.8kg⋅⋅⋅⋅m / 20 lb ft)

5. Install the front exhaust pipe.

Tightening torque: 67 N⋅⋅⋅⋅m (6.8kg⋅⋅⋅⋅m / 49 lb ft)

6. Install the fuel hose on the feed and return sides.

7. Install the vacuum hose of brake master-vac.

8. Install the connector of the shift on the fly (4×4).

9. Install the harness of engine, battery and earth (1).

RTW86ASH002001

10.Install the power steering pump.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5kg⋅⋅⋅⋅m / 18 lb ft)

• Install the bracket of power steering oil hose.

11.Install the A/C compressor.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5kg⋅⋅⋅⋅m / 18 lb ft)

• Install the connector.

12.Install the A/C generator harness.

• Install the terminal B cable and the harness

connector to the generator.

13.Install the radiator.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5kg⋅⋅⋅⋅m / 18 lb ft)

14.Install the fan assembly.

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

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6A-18 ENGINE MECHANICAL (4JJ1)

15.Install the drive belt.

Refer to removal procedure for “DRIVE BELT” in

this manual.

16.Install the fan guide.

17.Install the breather hose and lower hose of the

radiator.

18.Install the engine harness clip (1).

RTW76ASH001401

19.Install the radiator upper hose.

20.Install the intake hose (turbocharger -intercooler).

• Install the harness connector.

21.Install the intake hose (intercooler — intake throttle).

RTW56ASH004001

22.Install the air cleaner.

• Install the intake pipe with the lid of air cleaner

box.

• Install the air cleaner box.

• Connect the MAF sensor harness connector.

23. Install the clip (1) and clip (2)

RTW86ASH001601

24.Install the ECM.

25.Connect the ECM harness connector.

26.Install the transmission assembly.

Refer to installation procedure for

“TRANSMISSION”.

27.Install the starter motor.

Tightening torque: 94 N⋅⋅⋅⋅m (9.6kg⋅⋅⋅⋅m / 69 lb ft)

28.Replenish the coolant.

29.Install the engine hood.

Tightening torque: 10 N⋅⋅⋅⋅m (1.0kg⋅⋅⋅⋅m / 87 lb in)

30.Connect the negative battery cable.

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ENGINE MECHANICAL (4JJ1) 6A-19

Special Tools

ILLUSTRATIONPART NO.

PART NAME

5-8840-2823-0

Engine hanger

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6A-20 ENGINE MECHANICAL (4JJ1)

Engine Mount

Components

RTW86ALF000301

Legend

1. Nut2. Bolt (L = 80 mm / 3.15 in)

3. Bolt (L = 30 mm / 1.18 in)

4. Bolt (L = 25 mm / 0.98 in)

5. Bolt (L = 30 mm / 1.18 in)

6. Engine Foot RH

7. Engine Mount RH

8. Bolt (L = 25 mm / 0.98 in)

9. Bolt (L = 45 mm / 1.77 in)10. Bolt (L = 30 mm / 1.18 in)

11. Bolt (L = 40 mm / 1.57 in)

12. Bolt (L = 20 mm / 0.79 in)

13. Bolt (L = 100 mm / 3.94 in)

14. Engine Foot LH

15. Engine Mount LH

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ENGINE MECHANICAL (4JJ1) 6A-21

Removal

1. Remove the engine hood.

2. Remove the engine cover.

3. Set the hoist and the engine hanger of the special

tool (special tool 5-8840-2823-0).

4. Remove the engine mount.

• Before removing the engine mount, hang the

engine with a hoist.

• Remove the bolts of the engine mount.

• Hoist the engine assembly slightly to remove the

engine mount.

RTW56ASH022401

Installation

1. Install the engine mount and tighten up with the

specified torque.

Tightening torque: 52 N⋅⋅⋅⋅m (5.3 kg⋅⋅⋅⋅m / 38 lb ft)

2. Remove the engine hanger.

3. Install the engine cover.

4. Install the engine hood.

• Check if nothing is wrong with the engine

mount by starting the engine.

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ENGINE MECHANICAL (4JJ1) 6A-23

Cylinder Head Cover

Components

RTWB6ALF000101

Legend

1. Oil Filler Cap2. Oil Filler Cap Gasket

3. Cylinder Head Cover

4. Bolt

5. Nozzle Seal Cover6. Head Cover Gasket

7. Nut

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ENGINE MECHANICAL (4JJ1) 6A-25

9. Remove the cam end gaskets (1).

• Remove the liquid gasket that has adhered to

cylinder head completely.

RTW56ASH020501

Installation

1. Install the nozzle seal cover.

• Insert from the lower side of cylinder head

cover.

• Apply soapy water or engine oil to the surface

of cylinder head cover side.

• Insert the nozzle seal cover as far as it will go.

2. Install the cam end gaskets.

• Apply the liquid gasket (ThreeBond TB-1207B

or equivalent) and mount.

RTW56ASH020601

Legend

1. Cam End Gasket

2. Apply The Liquid Gasket

3. 2.0 — 3.0 mm (0.079 — 0.118 in)

• Apply attaching cam end gasket.

Apply the liquid gasket (ThreeBond TB-1207B

or equivalent).

RTW56ASH022701

Legend

1. 3.0 — 5.0 mm (0.118 — 0.197 in)

2. 3.0 — 5.0 mm (0.118 — 0.197 in)

3. Install the cylinder head cover.

Tightening torque: 10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)

• Tighten the nut and bolts in order shown in the

illustration.

RTW56ASH004801

4. Install the blow-by hose.

5. Install the leak-off hose and the fuel injector

connector.

6. Install the harness bracket to the cylinder head

cover.

7. Install the intake air duct.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

8. Install the engine cover.

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6A-26 ENGINE MECHANICAL (4JJ1)

Intake Manifold

Components

RTW76ALF000201

Legend

1. Intake Duct2. Throttle Assembly

3. Intake Manifold Gasket

4. Intake Manifold5. EGR Valve Assembly Gasket

6. EGR Valve Assembly

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ENGINE MECHANICAL (4JJ1) 6A-27

Removal

1. Remove the engine cover.

2. Disconnect the connectors.

• Fuel Injector

• Throttle Assembly

• EGR Valve

• Glow Plug

• Barometric Sensor

• A/C Compressor Connector

3. Remove the A/C belt.

4. Remove the A/C compressor.

5. Remove the A/C compressor bracket.

6. Remove the intake air duct (Standard output).

RTW56ASH024801

Legend

1. A/C Compressor Bracket

2. Intake Air Duct

3. A/C Compressor

7. Remove the injector leak-off hoses (1).

RTW56ASH024301

8. Remove the engine oil level gauge guide tube.

9. Remove the EGR valve.

RTW66ASH003001

10. Remove the injection pipes.

• Remove sequentially from No.1 cylinder.

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6A-28 ENGINE MECHANICAL (4JJ1)

11. Disconnect the vacuum hose of swirl control valve

(1).

RTW66ASH003101

12. Remove the throttle assembly and gasket.

RTW56ASH005201

Legend

1. Throttle Assembly

2. Intake Manifold

13. Remove the intake manifold.

RTW56ASH018001

14. Remove the intake manifold gasket.

Installation

1. Install the intake manifold gasket.

2. Install the intake manifold.

• Tighten the nuts and bolts in the order

described in the drawing.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

RTW56ASH018001

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ENGINE MECHANICAL (4JJ1) 6A-29

3. Install the throttle assembly and gasket.

• Tighten the bolts to the specified torque.

Tightening torque: 10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)

4. Install the vacuum hose of swirl control valve.

5. Install the injection pipe (fuel rail — fuel injector).

• It installs sequentially from No. 4 cylinder.

Tightening torque: 29 N⋅⋅⋅⋅m (3.0 kg⋅⋅⋅⋅m / 22 lb ft)

6. Install the EGR valve.

• Tighten the nuts to the specified torque.

Tightening torque: 27 N⋅⋅⋅⋅m (2.8 kg⋅⋅⋅⋅m / 20 lb ft)

7. Install the engine oil level guide tube.

Tighten the nuts to the specified torque.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

8. Connect the connector of other parts.

• Fuel Injector

• Throttle Assembly• EGR Valve

• Glow Plug

• Barometric Sensor

• A/C Compressor Connector

9. Install the leak-off hoses.

RTW56ASH024301

Legend

1. Injector Leek-off Hose

10. Install the intake air duct.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

11.Install the A/C compressor bracket.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

12.Install the A/C compressor and A/C compressor

connector.

Tightening torque: 44 N⋅⋅⋅⋅m (4.5 kg⋅⋅⋅⋅m / 33 lb ft)

13. Install the A/C belt.

Check the A/C belt tension.

• Depress (2) or (4) the A/C belt mid-portion with

98 N (10 kg / 22 lb) force.

• Measure frequency of the specified section (1)

or (3) using a frequency meter.

A/C Belt tension position (1)

Deflection mm(in) Frequency (Hz)

New 9-12 (0.35-0.47) 159-189

Reuse 12-14 (0.47-0.55) 137-155

A/C Belt tension position (3)

Deflection mm(in) Frequency (Hz)

New 5-7 (0.2-0.28) 256-310

Reuse 7-9 (0.28-0.35) 220-252

RTW86ASH001801

Legend

1. Position

2. Deflection

3. Position

4. Deflection

5. Compressor

6. Compressor belt

7. Crank pulley

14. Install the engine cover.

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6A-30 ENGINE MECHANICAL (4JJ1)

Torque Specifications

RTW76AMF000101

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ENGINE MECHANICAL (4JJ1) 6A-31

Turbocharger and Exhaust Manifold

Components

RTW56ALF002101

Legend

1. Turbocharger Assembly2. Exhaust Manifold

3. Heat Protector

4. Catalyst Converter

5. Oil Feed Pipe

6. Oil Return Pipe7. Intake Hose for Intercooler and Intake Throttle

8. Intake Duct for Turbocharger and Air Cleaner

9. Intake Hose for Turbocharger and Intercooler

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6A-32 ENGINE MECHANICAL (4JJ1)

Removal

1. Loosen the radiator drain plug to drain coolant.

2. Remove the engine cover.

3. Remove the intake hose from the intercooler and

intake throttle.

4. Remove the intake hose from the turbocharger

and the intercooler.

5. Remove the air intake duct from the turbocharger

and the air cleaner.

6. Remove the EGR cooler.

Refer to “EGR Cooler” in EXHAUST SYSTEM

Section.

7. Remove the oil feed pipe.

8. Remove the oil return pipe.

• Loosen clamps (1) of A/T oil cooler pipe.

RTW56ASH025101

9. Remove the water feed and return pipe.

RTW56ASH005401

Legend

1. Oil Feed Pipe

2. EGR Cooler

3. Water Feed Pipe

4. Water Return Pipe

5. Oil Return Pipe

10. Remove the front exhaust pipe.

RTW56ASH018301

Legend

1. Gasket

2. Front Exhaust Pipe (4×2 High Ride Suspention,

4×4)

3. Gasket4. Front Exhaust Pipe (4×2 Except High Ride

Suspention)

11. Disconnect the front propeller shaft flange (1)

(Front Diff Side, 4×4 only).

RTW76ASH002301

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ENGINE MECHANICAL (4JJ1) 6A-33

12. Remove the catalyst converter.

RTW56ALH000201

13. Remove the turbocharger from the exhaust

manifold.

RTW56ASH005501

Legend

1. Exhaust Manifold

2. Gasket

3. Turbocharger

14. Remove the exhaust manifold.

• Remove the 8 nuts from the exhaust manifold.

RTW56ASH005601

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6A-34 ENGINE MECHANICAL (4JJ1)

Inspection

• Inspection of the exhaust manifold. Inspect the

plane surface of the plane on which the

manifold and the cylinder head are to be

installed.

Manifold installation plane surface mm (in)

Standard 0.3 (0.01) or lower

Limit 0.5 (0.02)

Note:

If the plane surface exceeds the limit, replace it.

LNW21BSH022301

• Check a crack in the exhaust manifold visually.

Carefully inspect the turbocharger for abrasion and/or

excessive wear. Make any necessary adjustments,

repairs, and/or part replacements.

Wheel shaft axial play

Use a dial gauge to measure the wheel axle shaft play

when a force of 12 N (1.2 kg / 2.6 lb) is alternately

applied to both sides of the compressor wheel.

Axial play mm (in)

Standard 0.03 − 0.06 (0.0012 − 0.0024)

Limit 0.09 (0.0035)

LNW21BSH022201

Wheel shaft and bearing clearance

Use a dial gauge to measure the clearance between the

wheel shaft and the bearing.

Clearance mm (in)

Standard 0.056 − 0.127 (0.0022 − 0.0050)

Limit 0.14 (0.0055)

LNW21BSH022301

Legend

1. Oil Outlet

2. Oil Intake

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6A-36 ENGINE MECHANICAL (4JJ1)

2. Install the gasket and turbocharger to the exhaust

manifold. Tighten the nuts to the specified torque.

Tightening torque: 27 N⋅⋅⋅⋅m (2.8 kg⋅⋅⋅⋅m / 20 lb ft)

RTW56ASH005501

Legend

1. Exhaust Manifold

2. Gasket

3. Turbocharger

3. Install the catalyst converter.

Tighten the nuts to the specified torque.

Tightening torque: 27 N⋅⋅⋅⋅m (2.8 kg⋅⋅⋅⋅m / 20 lb ft)

4. Connect the front propeller shaft flange (Front Diff Side, 4×4 only).

5. Install the front exhaust pipe.

Tighten the nuts to the specified torque.

Tightening torque

Exhaust Manifold Side: 67 N⋅⋅⋅⋅m (6.8 kg⋅⋅⋅⋅m / 49 lb ft)

Exhaust Pipe Side: 43 N⋅⋅⋅⋅m (4.4 kg⋅⋅⋅⋅m / 32lb ft)

6. Install the water feed pipe to the turbocharger (1).

• Tighten the joint bolts to the specified torque.

Tightening torque: 54 N⋅⋅⋅⋅m (5.5 kg⋅⋅⋅⋅m / 40 lb ft)

• Install the pipe bracket and tighten the bolts to

the specified torque.

Tightening torque: 10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)

• Install the rubber hoses between the water

return pipes and the thermostat housing.

RTW56ASH019101

7. Install the water return pipe. Tighten the joint bolt

to the specified torque.

Tightening torque: 54 N⋅⋅⋅⋅m (5.5 kg⋅⋅⋅⋅m / 40 lb ft)

RTW56ASH019001

8. Install the turbocharger oil feed pipe to the top of

the turbocharger. Tighten the joint bolts to the

specified torque.

Tightening torque (Turbo charger side):

22.5 N⋅⋅⋅⋅m (2.3 kg⋅⋅⋅⋅m / 17 lb ft)

Tightening torque (Oil cooler side):

22.5 N⋅⋅⋅⋅m (2.3 kg⋅⋅⋅⋅m / 17 lb ft)

• Install the pipe bracket and tighten the bolts to

the specified torque.

Tightening torque: (Clip)

10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)

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ENGINE MECHANICAL (4JJ1) 6A-37

RTW96ASH000101

Legend

1. Oil Feed Pipe

2. Clip

3. For Dia 8.00 mm (0.31 in)

4. For Dia 10.00 mm (0.39 in)

5. Oil Return Pipe

9. Tighten the oil return pipe bolts and nuts to the

specified torque.

Tightening torque (Turbocharger side):

10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)

Tightening torque (Crank case side):25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

10.Install the EGR cooler.

• Refer to “EGR Cooler” in EXHAUST SYSTEM

section.

11. Install the heat protector.

• Refer to “EGR Cooler” in EXHAUST SYSTEM

section.

12. Install the intake hose between the intercooler and

the intake throttle .

13. Install the intake hose between the turbocharger

and the intercooler .14. Install the intake duct between the turbocharger

and the air cleaner .

Tightening torque: 4 N⋅⋅⋅⋅m (0.4 kg⋅⋅⋅⋅m / 35 lb in)

15.Replenish the coolant.

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6A-38 ENGINE MECHANICAL (4JJ1)

Torque Specifications

RTW86ALF000701

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ENGINE MECHANICAL (4JJ1) 6A-39

Timing Gear Train

Components

RTW56ALF001101

Legend

1. Oil Pump Gear2. Crankshaft Gear

3. Idle Gear D

4. Exhaust Camshaft Gear

5. Intake Camshaft Gear

6. Idle Gear D Sprocket

7. Timing Chain

8. Injection Pump Sprocket9. Injection Pump Gear

10. Idle Gear A

11. Vacuum Pump Gear

12. Power Steering Oil Pump Gear

13. Idle Gear C

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6A-40 ENGINE MECHANICAL (4JJ1)

Removal

1. Partially drain the engine coolant.

2. Remove the radiator upper hose.

RTW56FSH000101

3. Remove the fan guide.

RTW46BSH000101

Legend

1. Fan Guide2. Clips

3. Lower Fan Guide

4. Fan Shroud

4. Remove the cooling fan and fan pulley.

RTW56ASH025401

5. Remove the A/C compressor drive belt and fan

belt.

6. Remove the crank pulley.

Note:

Do not reuse the crank pulley bolt.

7. Remove the power steering pump with hose.

RTW56ASH021101

Legend

1. Power Steering Pump

2. Nut

• Disconnect the bracket (1) of power steering oil

hose.

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ENGINE MECHANICAL (4JJ1) 6A-41

LTW56ASH000101

8. Remove the vacuum pump.

• Remove the vacuum pipe bracket and vacuum

pipe.

• Remove the oil pipe (feed side and return side)

of vacuum pump.

RTWB6ASH000801

9. Remove the front cover.

RTWB6ASH001001

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

11. Remove the idle gear A and idle gear A flange, idle

gear A shaft.

RTW56ASH011301

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ENGINE MECHANICAL (4JJ1) 6A-43

• Align the sub gear pin with the hole in the right

side of the idle gear A spring. Press the sub-

gear into place.

RTW56ASH022001

Legend

1. Snap Ring

2. Sub-gear

3. Spring

4. Idle Gear A

• Use a pair of snap ring pliers to snuggly install

the snap ring.

Inspection1. Measurement of idle gear backlash

• Apply a dial gauge on the teeth of the idle 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 measurement exceeds the limit, replace

the idle gear.

Backlash of the idle gear mm (in)

Standard 0.10 − 0.17 (0.004 − 0.007)

Limit 0.30 (0.01)

• Measure backlash of the idle gear before

removing the idle gear A.

2. Measurement of end clearance of the idle gear.

• Insert a thickness gauge between the idle gear

and the thrust collar to measure a clearance.

• If the measurement exceeds the limit, replace

either the idle gear or the thrust collar.

End clearance of the idle gear mm (in)

Standard 0.060 − 0.135 (0.002 − 0.005)

Limit 0.20 (0.008)

• Measure an end clearance of the idle gear

before removing the idle gear B.

3. External diameter of the idle gear shaft.

• Use a micrometer to measure an external

diameter of each idle gear shaft.

• If the measurement exceeds the limit, replace

the shaft.

External diameter of the idle gear A shaft mm (in)

Standard 44.950 − 44.975 (1.7697 − 1.7707)

Limit 44.80 (1.764)

External diameter of the idle gear C shaft mm (in)

Standard 24.959 − 24.980 (0.9826 − 0.9835)

Limit 24.80 (0.976)

RTW56ASH021601

4. Clearance between the idle gear and the idle gear

shaft

• Measure an inside diameter of the idle gear

bush to calculate a clearance between the idle

gear and the idle gear shaft.

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6A-44 ENGINE MECHANICAL (4JJ1)

• If the measurement exceeds the limit, 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

mm (in)

Standard 0.020 − 0.062 (0.0008 − 0.0024)

Limit 0.200 (0.0079)

LNW21BSH003601

Installation

1. Install the crankshaft gear.

2. Install the idle gear C.

• Apply engine oil over the part where the gear of

the idle gear shaft is to be put together.

• Apply engine oil to the bolt screw thread and

seat, and temporarily tighten together with the

flange (tighten fully in later process).

RTW56ASH011401

3. Install the idle gear A.

4. Tighten sub gear setting bolt.

• Use the M6 bolts and lever to turn sub gear to

right direction until it aligns with the M6 bolt

hole between idle gear A and sub gear.

• Tighten the M6 bolt to a suitable torque to

prevent the sub gear from moving.

RTW56ASH011501

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ENGINE MECHANICAL (4JJ1) 6A-45

• Align the oil hole of the cylinder body (2) with

the oil hole of the idle gear A shaft (3).

• Install the flange so that the front mark (1) face

toward the front.

• Install the idle gear A and idle gear A flange,

idle gear A shaft at the position shown in the

figure.

• Apply engine oil over the part where the gear of

the idle gear shaft is to be put together.

• Apply engine oil to the bolt screw thread and

seat, and temporarily tighten together with the

flange (tighten fully in later process).

LNW81BSH000401

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

timing mark.

RTW56ALH000301

5. Tighten the bolts of idle gear A and idle 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 / 43 lb ft)

RTW56ASH011701

Legend

1. Idle Gear A Bolt

2. Idle Gear C Bolt

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6A-46 ENGINE MECHANICAL (4JJ1)

6. Remove the M6 bolt from the idle gear A.

7. Install the gear case cover.

• Apply the liquid gasket (ThreeBond TB-1207B

or equivalent).

RTW56ASH020101

Legend

1. Apply the liquid gasket

• Install the gasket in slot of the gear case cover.

• Tighten the bolts to the specified torque.

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

RTW56ASH012101

8. Install the vacuum pump.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

• Install the oil pipe (feed side and return side) of

vacuum pump.

• Install the vacuum pipe bracket and vacuum

pipe.

9. Install the power steering pump.

• Tighten the nuts to the specified torque.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

• Connect the bracket (1) of power steering oil

hose.

LTW56ASH000101

10. Install the crank pulley.

• Please use new crank pulley bolt.

• Tighten the bolt to the specified torque.

Tightening torque: 294 N⋅⋅⋅⋅m (30.0 kg⋅⋅⋅⋅m / 217 lb ft)

11. Install the A/C compressor drive belt and fan belt.

Refer to drive belt tension check procedure for

Heating and air conditioning and Engine cooling in

this manual.

12. Install the cooling fan.

13. Install the fan guide.

14. Install the radiator upper hose.

15. Replenish the engine coolant.

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ENGINE MECHANICAL (4JJ1) 6A-47

Torque Specifications

LNW76ALF000601

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ENGINE MECHANICAL (4JJ1) 6A-49

Removal

1. Rotate the crankshaft to make the No. 1 cylinder

meet the compression TDC.

RTW76ASH001301

Legend

1. TDC

2. Remove the engine cover.

3. Remove the cylinder head cover.

Refer to «Cylinder Head Cover».

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

RTW56ASH007101

5. Remove the baffle plate (1).

RTW56ASH006301

6. Remove the camshaft bearing cap and camshaft.

• Check the engraved making on the camshaft

bearing caps.

RTW56ASH018401

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6A-50 ENGINE MECHANICAL (4JJ1)

RTW56ASH013801

Disassembly1. Remove the sub gear assembly.

• Clamp the camshaft in a vise. Insert soft metal

protectors (aluminum) between the vise

surfaces and the camshaft.

• Use 5-8840-2591-0 to turn sub gear to right

direction to remove the M5 bolt.

RTW56ASH006801

• Use a pair of snap ring pliers to remove the

scissor gear assembly.

Note:

Take care not to damage the camshaft cams and

journals.

RTW56ASH006401

2. Remove the camshaft gear.

• Use a press (1) and socket (2) to remove the

camshaft gear (3).

RTW56ASH006501

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ENGINE MECHANICAL (4JJ1) 6A-51

3. Remove the dowel pin.

4. Inspect the camshaft visually.

• Check if the journal and cam parts of the

camshaft are worn or damaged, if so, replace

it.

LNW21BSH020201

5. Inspect an end clearance of the camshaft.

• Use a thickness gauge to measure an end

clearance of the camshaft gear and the

camshaft bracket.

• If the measurement exceeds the limit, replace

the camshaft gear or the camshaft.

End clearance of the camshaft mm (in)Standard 0.050 − 0.170 (0.003 − 0.007)

Limit 0.25 (0.010)

Note:

Measure an end clearance of the camshaft before

disassembling.

RTW56ASH013901

6. Check if the cam lobe is worn.

• Use a micrometer to measure the height of the

cam lobe.

• If the height of the cam lobe is at the 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)

LNW21BSH020401

7. Check if the camshaft journal is worn.

• Use a micrometer to measure wear which is

not even with a diameter of the camshaft

journal.

• If the measured uneven wear exceeds the limit,

replace the camshaft.

External diameter of the camshaft journal part

mm (in)

Standard 29.909 − 29.930

(1.1775 − 1.1783)

Limit 29.809 (1.1736)

Partial wear of the camshaft journal part mm (in)

Limit 0.05 (0.0020)

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6A-52 ENGINE MECHANICAL (4JJ1)

LNW21BSH020501

8. Check if the camshaft is runout.

• Place the camshaft on a V block to measure a

runout with a dial gauge.

• Rotate the camshaft slowly to measure how

much the dial indicator shook. If it exceeds the

limit, replace the camshaft.

Runout of the camshaft mm (in)

Limit 0.05 (0.0020)

LNW21BSH020601

9. Measure a camshaft journal oil clearance.

a. Measure an inside diameter of the camshaft

bearing with a dial gauge.

b. Read the difference 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 mm (in)

Standard0.070 − 0.112

(0.0028 − 0.0044)

Limit 0.15 (0.0059)

RTW86ASH000101

Reassembly

1. Install the dowel pin.

2. Install the camshaft gear.

• Align the knock pin with the slot in the camshaft

gear. Use a press to install the camshaft gear

to the camshaft.

RTW56ASH006601

Legend

1. Camshaft

2. Dowel Pin

3. Camshaft Gear

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ENGINE MECHANICAL (4JJ1) 6A-53

3. Install the sub gear assembly.

• Clamp the camshaft in a vise. Insert soft 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.

• Align the sub gear pin (2) with the hole in the

right side of the camshaft gear damper spring

(3). Press the sub-gear into place.

RTW56ASH006701

Legend

1. Snap Ring

2. Sub-gear

3. Damper Spring

4. Camshaft Gear

• Use a pair of snap ring pliers to snuggly install

the snap ring.

4. Tighten sub gear setting bolt.

• Use 5-8840-2591-0 to turn sub gear to right

direction until it aligns with the M5 bolt hole

between camshaft driven gear and sub gear.

• Tighten the M5 bolt to a suitable torque to

prevent the sub-gear from moving.

RTW56ASH006801

Installation

1. Check the crankshaft to make the No. 1 cylinder

meet the compression TDC.

RTW76ASH001301

Legend

1. TDC

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6A-54 ENGINE MECHANICAL (4JJ1)

2. Install the camshaft assembly.

• Align timing mark on intake camshaft and

exhaust camshaft to idle gear D.

RTW56ASH007001

Legend

1. Exhaust Camshaft Gear

2. Intake Camshaft Gear

3. Idle Gear D

3. Camshaft bearing caps, tighten ten bolts on one

side bank to the specified torque.

• Apply engine oil to camshaft journal and

bearing surface of camshaft bearing caps.

RTW56ASH018401

4. Check that the alignment marks (camshaft bearing

cap and camshaft) are aligned.

RTW56ASH006901

Legend

1. Align mark on intake camshaft and exhaust

camshaft to mark of bearing cap

• Apply engine oil over the screw part and 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 bolt of fixing sub gear.

6. Adjustment of valve clearance.

• Refer to installation procedure for inspection /

adjustment of valve clearance in this manual.

7. Install the baffle plate. Tighten the bolts to the

specified torque.

Tightening torque: 10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)

8. Install the cylinder head cover.

Refer to «Cylinder Head Cover».

9. Install the engine cover.

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6A-56 ENGINE MECHANICAL (4JJ1)

Valve Stem Seal and Valve Spring

Components

RTW56ALF001301

Legend

1. Exhaust Rocker Arm Shaft Assembly2. Bolt (Long)

3. Bolt (Short)

4. Intake Rocker Arm Shaft Assembly

5. Fuel Injector Assembly

6. Bolt

7. Fuel Injector Clamp

8. Pin9. Spring Lower Seat

10. Valve Stem Oil Seal

11. Valve Spring

12. Spring Upper Seat

13. Split Collar

14. Valve Stem End Cap

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ENGINE MECHANICAL (4JJ1) 6A-57

Removal

1. Remove the cylinder head.

Refer to “Cylinder Head”.

2. Remove the valve stem end cap.

3. Remove the split collar.

• Use a replacer to compress the valve spring to

remove the split collar.

Special tool

Valve spring replacer: 5-8840-2818-0 (1)

Pivot assembly: 5-8840-2819-0 (2)

RTW56ASH012301

4. Remove the spring upper seat.

• Remove the special tool to remove the upper

seat.

5. Remove the valve spring.

• Put the removed valve springs in order by

cylinder number.

6. Remove the valve stem oil seal.

• Use pliers to remove the oil seal.

RTW56ASH012401

Note:

Do not use the removed oil seal again.

7. Remove the spring lower seat.

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6A-58 ENGINE MECHANICAL (4JJ1)

Inspection

Inspect the valve spring

Note:

Check the valve spring visually and if there is clear

damage or wear, replace it.1. Free length

• Measure free length of the spring and if it is

shorter than the prescribed limit, replace the

spring.

Free length of the valve spring mm (in)

Inlet / Exhaust

Standard 49.04 (1.93)

Limit 48.15 (1.90)

LNW21BSH017001

2. Valve spring squareness.

• Use a surface plate and a square to measure

the valve spring squareness.

If the measured value exceeds the specified

limit, the valve spring must be replaced.

Valve spring squareness mm (in)

Limit 2.1 (0.083)

LNW21BSH017101

3. Tension

• Use a spring tester to compress the spring to

the installation height. Measure tension of the

compressed spring. If the measurement is

lower than the limit, replace the spring.

Tension of the valve spring N (kg / lb)

Inlet / Exhaust

Installation length mm (in) 37.80 (1.488)

Standard 213 (21.7 / 47.8)

Limit 188 (19.2 / 42.3)

LNW21BSH056701

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ENGINE MECHANICAL (4JJ1) 6A-59

Installation

1. Install the spring lower seat.

2. Install the valve stem oil seal.

• Apply engine oil over the peripheral part of 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: 5-8840-2882-0

RTW56ASH013701

3. Install the valve spring.

4. Install the spring upper seat.

5. Install the split collar.

• Use a replacer to compress the valve spring

and install the split collar.

Special tool

Valve spring replacer: 5-8840-2818-0 (1)

Pivot assembly: 5-8840-2819-0 (2)

RTW56ASH012301

Note:

Move it up and down to check if it moves smoothly.

6. Install the valve stem end cap.

7. Install the cylinder head.

Refer to “Cylinder Head”.

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6A-60 ENGINE MECHANICAL (4JJ1)

Special Tools

ILLUSTRATIONPART NO.

PART NAME

5-8840-2818-0

Valve spring replacer

5-8840-2819-0

Pivot assembly

5-8840-2882-0

Valve stem seal installer

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ENGINE MECHANICAL (4JJ1) 6A-61

Cylinder Head

Components

RTW56ALF001001

Legend

1. Fuel Injector Clamp2. Fuel Injector Assembly

3. Glow Plug

4. Intake and Exhaust Valves

5. Cylinder Head6. Timing Chain Tension Lever

7. Timing Chain Guide

8. Timing Chain Tensioner

Note:

To avoid electric shock;

Set the switch to the ‘OFF’ position and disconnect the

negative battery cable before checking or repairing the

fuel injector, wiring or/and connectors.

Removal

1. Remove the engine head cover.

2. Drain the engine coolant.

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6A-62 ENGINE MECHANICAL (4JJ1)

3. Remove the radiator upper hose.

RTW56FSH000101

4. Remove the fan guide.

RTW46BSH000101

Legend

1. Upper Fan Guide

2. Clips

3. Lower Fan guide

4. Fan Shroud

5. Remove the cooling Fan.

RTW56ASH025401

6. Rotate the crankshaft to make the No.1 cylinder

meet the compression top dead center (TDC).

RTW76ASH001301

Legend

1. TDC

7. Remove the A/C compressor drive belt.

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ENGINE MECHANICAL (4JJ1) 6A-63

8. Remove the A/C compressor adjust pulley.

RTW56ASH010601

Legend

1. Bolt

2. Nut

9. Remove the battery.

10. Disconnect the A/C compressor connector and

A/C compressor with hose.

11. Remove the A/C compressor bracket.

RTW56ASH024201

Legend

1. A/C Compressor Bracket

2. Intake Duct

3. A/C Compressor

12. Remove the intake hose and duct.

RTW56ASH022501

Legend

1. Intake Hose for Intercooler and Intake Throttle

2. Intake Duct for Turbocharger and Air Cleaner

3. Intake Hose for Turbocharger and Intercooler

13. Disconnect the fuel injector connectors (2).

14. Remove the fuel leak off hoses (1).

RTW76ASH000101

Note:

Do not reuse the fuel leak off hose clips.

15. Disconnect each connectors.

• Glow Plug

• EGR Valve

• Throttle Assembly

• Barometric Sensor

• Water temperature sensor

• Camshaft Position sensor

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6A-64 ENGINE MECHANICAL (4JJ1)

16. Remove the harness bracket.

17. Remove the cylinder head cover.

Refer to “Cylinder Head Cover”.

18. Remove the EGR cooler heat protector.

19. Remove the EGR cooler water pipe.

20. Remove the EGR cooler.

21. Loosen the nuts of catalyst converter and

turbocharger.

RTW56ASH006201

Legend

1. Catalyst Converter

2. Turbocharger

22. Remove the exhaust front pipe.

RTW56ASH007701

Legend

1. Exhaust Front Pipe (4×2 High Ride Suspension,

4×4)

2. Exhaust Front Pipe (4×2 Except High Ride

Suspension)

23. Disconnect the Front drive shaft (1). (4×4)

RTW76ASH002301

24. Remove the catalyst converter.

RTW56ALH000201

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ENGINE MECHANICAL (4JJ1) 6A-65

25. Remove the A/T oil cooler pipe brackets (A/T).

RTW56ASH025101

Legend

1. A/T Oil Cooler Pipe Bracket

26. Remove the turbocharger water return pipe and

hose.

RTW56ASH019001

27. Remove the turbocharger water feed pipe (1) and

hose.

RTW56ASH019101

28. Remove the turbocharger engine oil feed pipe.

29. Remove the engine oil level gauge guide tube.

30. Remove the fuel return pipe and hose (1).

RTW56ASH019201

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6A-66 ENGINE MECHANICAL (4JJ1)

31. Remove the fuel injection pipe clip.

32. Remove the fuel injection pipe.

33. Remove the vacuum hose (1).

RTW66ASH003101

34. Remove the timing chain cover lower.

35. Remove the timing chain cover upper.

RTWB6ASH000301

Legend

1. Timing Chain Cover Upper2. Timing Chain Cover Lower

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

RTW56ASH008401

37. Remove the glow plugs (1).

RTW56ASH019301

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ENGINE MECHANICAL (4JJ1) 6A-67

38.Remove the cylinder head cover.

Refer to “Cylinder Head Cover”.

39. Install the lock bolt for camshaft scissor gear.

RTW56ASH007101

40. Remove the fuel injector assembly.

41. Remove the baffle plate.

42. Remove the camshaft bearing caps.

RTW56ASH018401

43.Remove the camshaft.

44. Remove the rocker arm shaft assembly.

Note:

Keep the removed rocker arm shaft assembly properly

so that they may be put back to the original place.

RTW56ASH012201

Legend

1. Exhaust Rocker Arm Shaft Assembly

2. Bolt (Long)

3. Bolt (Short)

4. Intake Rocker Arm Shaft Assembly

5. Front

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6A-68 ENGINE MECHANICAL (4JJ1)

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.

Note:

Remember the original position.

45. Remove the timing chain tensioner.

RTW56CSH003701

Legend

1. Timing Chain Tensioner

2. Gasket

3. Nut

46. Remove the idle gear D.

• Timing chain is dropped behind.

RTW56ASH022101

47. Remove the timing chain tension lever pivot.

RTW56ASH019401

48. Remove the timing chain from supply pump

sprocket.

49. Remove the chain guide bolts from cylinder head.

RTW56ASH019501

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ENGINE MECHANICAL (4JJ1) 6A-69

50. Remove the cylinder head gear case nuts (1) and

bolts (2).

RTW56ASH020801

51. Remove the cylinder head bolt (1).

RTW56ASH008501

Note:

Do not reuse the cylinder head bolt.

52. Remove the cylinder head assembly.

• Loosen the cylinder head bolts in the order

described in the drawing.

• Remove the cylinder head gasket.

Note:

Replace the head gasket with a new one once it is

removed.

RTW56ASH008601

Disassembly

1. Remove the throttle assembly.

• Refer to procedure for Intake Manifold in this

manual.

2. Remove the intake manifold assembly.

• Refer to procedure for Intake Manifold in this

manual.

3. Remove the turbocharger.

• Refer to “Turbocharger and Exhaust Manifold”.

4. Remove the exhaust manifold assembly.

• Refer to procedure for Turbocharger and

Exhaust Manifold in this manual.

5. Remove the water outlet pipe.

6. Remove the valve stem end cap.

Refer to procedure for valve stem and valve in thismanual.

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6A-70 ENGINE MECHANICAL (4JJ1)

7. Remove the split collar.

• Use a replacer to compress the valve spring to

remove the split collar.

Special tool

Valve spring replacer: 5-8840-2818-0 (1)

Pivot assembly: 5-8840-2819-0 (2)

RTW56ASH012301

8. Remove the spring upper seat.

• Remove the special tool to remove the upper

seat.

9. Remove the valve spring.

• Put the removed valve springs in order by

cylinder number.

10. Remove the intake and exhaust valve.

• Sort the removed valves according to cylinders

by using tags others.

LNW21BSH016801

11. Remove the valve stem oil seal.

• Refer to procedure for valve stem and valve in

this manual.

12. Remove the spring lower seat.

13. Remove the valve guide.

• Use the valve guide replacer to press out the

valve guides from the bottom side of the

cylinder head.

Special tool

Valve guide remover and installer:

5-8840-2816-0

RTW56ASH008701

14. Remove the cam end gaskets (1).

RTW56ASH020501

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ENGINE MECHANICAL (4JJ1) 6A-71

15. Remove the oil seals.

RTW56ASH008801

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 edge and a thickness gauge to

measure the four sides and the two diagonals of

the cylinder head lower face.

2. The cylinder head lower surface warpage is more

than the limit, it should be replaced.

RTW56ASH008901

Cylinder Head Lower Face Warpage mm (in)

Standard 0.05 (0.002) or less

Limit 0.20 (0.0079)

Note:

The cylinder head lower face cannot be regrind.

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6A-72 ENGINE MECHANICAL (4JJ1)

011RY00013

Cylinder Head Height (H) (Reference) mm (in)

Standard 143.4 (5.646)

RTW56ASH017401

Manifold Fitting Face Warpage

Use a straight edge and a feeler 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 Grinding Allowance 0.40 (0.016)

RTW56ASH017501

Exhaust Manifold Warpage

Use a straight edge and a feeler gauge to measure the

manifold cylinder head fitting face warpage.

If the measured values exceed the specified limit, the

manifold must be replaced.

Exhasut Manifold Warpage mm (in)

Standard 0.05 (0.002) or less

Limit 0.20 (0.008)

027RY00002

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ENGINE MECHANICAL (4JJ1) 6A-73

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

Standard6.955 – 6.970

(0.2738 – 0.2744)

6.947 – 6.962

(0.2735 – 0.2741)

Limit6.935

(0.2730)

6.920

(0.2724)

011LX027

Valve Stem and Valve Guide Clearance

1. Measure the valve stem outside diameter.

Refer to the item “Valve Stem Outside Diameter”.

2. Use a caliper calibrator or a 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

Standard0.030 – 0.060

(0.0012 – 0.0024)

0.038 – 0.068

(0.0015 – 0.0027)

Limit0.200

(0.008)

0.250

(0.0098)

011RY00023

Valve ThicknessMeasure 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 and Exhasut Valve Thickness mm (in)

Standard 1.32 (0.052)

Limit 1.1 (0.043)

014RY00020

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6A-74 ENGINE MECHANICAL (4JJ1)

Valve Depression

1. Install the valve (1) to the cylinder head (2).

2. Use a depth gauge or a straight edge with 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 1.8 (0.07)

Limit 2.5 (0.098)

014RY00021

Valve Contact Width

1. Check the valve contact faces for roughness and

unevenness. Make smooth the valve contact

surfaces.

2. Measure the valve contact width.

If the measured value exceeds the specified limit,

the valve seat insert must be replaced.

Valve Contact Width mm (in)

Intake Exhaust

Standard 1.4 (0.055) 1.4 (0.055)

Limit 2.2 (0.087) 2.5 (0.098)

014RY00027

Repair of the seat surface• Remove carbon from the surface of the valve

insert seat.

• Use a seat cutter to minimize the scratch and

other roughness, thereby returning the contact

width to the standard value.

LNW71BSH013501

Legend

1. 90°

2. 50°

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.

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ENGINE MECHANICAL (4JJ1) 6A-75

LNW21BSH056101

• Attach compound in the valve insert seat.

• Insert the valve into the valve guide.

• 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.

Note:

Remove compound completely after grinding.

LNW21BSH031801

Remove the valve seat insert

• Arc-weld the entire inner diameter of the valve seat

insert.

• Cool the valve seat insert for two to three minutes.

Contraction due to cooling makes it easier to

remove the valve seat insert.• Remove the valve seat insert, using a screw

driver . Be sure not to harm the cylinder head.

LNW21BSH056001

Legend

1. Arc-Weld

2. Valve Seat Insert

3. Screw Driver

Install the valve seat insert

• Carefully place a washer (the outer diameter is

smaller than the valve seat insert) on the valve

seat insert.

• Use the press to apply pressure 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 valveand hit it lightly to grind it, and confirm that it has even

contact all round.

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6A-76 ENGINE MECHANICAL (4JJ1)

LNW21BSH018601

Legend

1. Attach Compound

2. Valve Seat

3. Press

Reassembly

1. Install the oil seal.

• Install on the surface of the injection pipe insert.

• Hammer it in so that the seal does not incline.

Note:

Be sure not to harm the lip.

Special tool

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

RTW56ASH008801

RTW56ASH009101

Legend

1. Cylinder Head

2. Oil Seal Installer

2. Install the valve guide.

• Hammer in the valve guide from the upper

surface of the cylinder head, using the valve

guide installer.

Special tool

Valve guide remover and installer:

5-8840-2816-0

Note:

When replacing the valve guide, it must be replacedtogether with the valve.

RTW56ASH009001

• Height from the upper surface of the cylinder

head to the edge surface of the valve guide

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ENGINE MECHANICAL (4JJ1) 6A-77

RTW56ASH023001

Legend

1. 12.6 ± 0.1 mm (0.50 ± 0.0039 in)

2. Cylinder Head

3. Install the valve spring lower seat.

4. Install the valve stem oil seal.

• Refer to procedure for valve stem and valve in

this manual.

5. Install the intake and exhaust valve.

• Apply engine oil on the valve stem part and

install the valve.

6. Install the valve spring, the valve spring upper seat

and the split collar.• Refer to procedure for valve stem and valve in

this manual.

7. Install the rocker arm and shaft assembly.

• Refer to procedure for valve stem and valve in

this manual.

8. Install the exhaust manifold assembly.

• Refer to procedure for Turbocharger and

Exhaust Manifold in this manual.

9. Install the turbocharger.

• Refer to procedure for Turbocharger and

Exhaust Manifold in this manual.

10. Install the intake manifold assembly.

• Refer to procedure for Intake Manifold in this

manual.

11. Install the throttle assembly.

• Refer to procedure for Intake Manifold in this

manual.

Installation

1. Select the cylinder head gasket.

Cylinder Head Gasket Selection

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.

011LX011

1. Use a dial indicator to measure the piston

projection amount.

2. Refer to the illustration for the piston head

projection measuring positions. All measuring

positions should be as close as possible to the

cylinder block.

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ENGINE MECHANICAL (4JJ1) 6A-79

8. Apply liquid gasket (ThreeBond 1207B or

equivalent) at the two locations.

RTW56ASH020901

Legend

1. 2 — 3 mm (0.079 — 0.118 in)

2. 3 — 4 mm (0.118 — 0.157 in)

9. Install the cylinder head within 5 minutes

application of the liquid gasket.

10. Install the cylinder head.

• Wipe the cylinder head lower face.

• Install the cylinder head, adjusting the dowel of

the cylinder block.11. Install the cylinder head bolt.

• Please use new cylinder head bolt.

• Use a torque wrench and angle gauge 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°-75° (degrees)

4th step = 60°-75° (degrees)

Note: Do not reuse cylinder head bolt.

RTW56ASH009701

Special tool

Angle gauge: 5-8840-0266-0

12. Install the cylinder head gear case bolt and nut.

• Tighten up with the prescribed torque according

to the order given on the figure.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

LNW81BSH000701

13. Install the water by pass pipe.

Apply 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)

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6A-80 ENGINE MECHANICAL (4JJ1)

14. Install the vacuum hose (1).

RTW66ASH003101

15. Install the rocker arm shaft assembly.

• Apply the engine oil.

• Attach the rocker arm shaft assembly in

sequence from No.1 to No.4.

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

RTW56ASH012201

Legend

1. Exhaust Rocker Arm Shaft Assembly

2. Bolt (Long)

3. Bolt (Short)

4. Intake Rocker Arm Shaft Assembly

5. Front

16. Install the chain guide bolt from cylinder head.

Tighten the bolt to the specified torque.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

RTW56ASH019501

17. Install the tension lever.

18. Rotate the crankshaft to make the No.1 cylinder

meet the compression top dead center (TDC).

RTW76ASH001301

Legend

1. TDC

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ENGINE MECHANICAL (4JJ1) 6A-81

19. Install the timing chain with idle gear D.

• Apply the engine oil bolt thread and seat.

Tightening torque : 59 N⋅⋅⋅⋅m (6.0 kg⋅⋅⋅⋅m / 43 lb ft)

RTW56ASH021801

• Align the timing marks at two locations as

shown.

RTW56ASH020301

Legend

1. Timing Chain

2. Timing Mark

3. Blue Link

4. Yellow Link

20. Install the timing chain tension lever pivot.

Tighten the bolt to the specified torque.

Tightening torque: 27 N⋅⋅⋅⋅m (2.8 kg⋅⋅⋅⋅m / 20 lb ft)

RTW56ASH019401

21. Attach the hook of the timing chain tensioner.

• Hold the latch (3) depressed. Insert the plunger

(2). Attach the hook (5) to the pin (1) to hold the

plunger in place.

RTW56CSH004401

22. Install the timing chain tensioner (1) and the

gasket (2).

Tighten the nuts (3) to the specified torque.

Tightening torque: 10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)

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ENGINE MECHANICAL (4JJ1) 6A-83

26. Align mark on camshaft to mark on camshaft

bearing cap.

• Align mark (1) on intake camshaft and exhaust

camshaft to mark of bearing cap.

RTW56ASH006901

27. Remove the lock bolt from the camshaft gear.

28. Turn the crank pulley two rotation (720°CA).

• Align mark on camshaft to mark on camshaft

bearing cap.

RTW56ASH020701

Legend

1. Exhaust Camshaft Gear

2. Intake Camshaft Gear

3. Idle Gear D

29. Apply liquid gasket (ThreeBond TB-1207C or

equivalent) to timing chain cover upper (1).

• Attach cover within 5minutes after the

application of gasket.

LNW71BSH013801

Legend

1. Liquid gasket

2. 2 – 2.5 mm (0.079 – 0.098 in)

3. 2 – 2.5 mm (0.079 – 00.98 in)

30. Install the timing chain cover upper (1).

Tighten the bolt to the specified torque.

• Apply loctite #262 or equivalent to the bolt and

stud threads of cylinder side head side (2).

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

RTW76CSH001201

31. Apply liquid gasket (ThreeBond TB-1207C or

equivalent) to the timing chain cover lower (1).

• Attach the cover within 5 minutes of applying

the liquid gasket.

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6A-84 ENGINE MECHANICAL (4JJ1)

RTWB6ASH000401

Legend

1. Liquid gasket

2. 2 – 2.5 mm (0.079 – 0.098 in)

3. 2 – 2.5 mm (0.079 – 00.98 in)

32. Install the timing chain cover lower.

Tighten the bolts and nuts to the specified torque.

Tightening torque: 10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)

33. Inspection / adjustment of valve clearance.

• Refer to procedure for Service Precautions in

this manual.

34. Install the fuel injector.• Refer to procedure for Fuel System in this

manual.

35. Install the baffle cover.

• Refer to procedure for Camshaft Assembly in

this manual.

36. Install the cam end gasket.

• Apply the liquid gasket (ThreeBond TB-1207B

or equivalent).

RTW56ASH020601

Legend

1. Cam End Gasket

2. 2.0 — 3.0 mm (0.078 — 0.118 in)

37. Install the cylinder head cover.

Refer to procedure for Cylinder Head Cover in this

manual.

38. Install the glow plug.

Tighten the glow plug to the specified torque.

Tightening torque: 18 N⋅⋅⋅⋅m (1.8 kg⋅⋅⋅⋅m / 13 lb ft)

39. Install the glow plug connector.

Tighten the nut to the specified torque.Tightening torque: 2 N⋅⋅⋅⋅m (0.2 kg⋅⋅⋅⋅m / 17 lb in)

RTW56ASH010201

Legend

1. Glow Plug Connector

2. Nut

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6A-86 ENGINE MECHANICAL (4JJ1)

49. Install the turbocharger engine oil return pipe (1).

Tighten the bolt and nut to the specified torque.

Tightening torque:

nut: 25 N⋅⋅⋅⋅m (2.6 kg⋅⋅⋅⋅m / 19 lb ft)

bolt: 10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)

RTW56ASH010701

50. Install the turbocharger engine oil feed pipe and

clip.

Tighten the bolt to the specified torque.

Tightening torque:

pipe: 22.5 N⋅⋅⋅⋅m (2.3 kg⋅⋅⋅⋅m / 17 lb ft)

Tightening torque:clip: 10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)

RTW96ASH000301

Legend

1. Oil Feed Pipe

2. Clip

3. For Dia 8.00 mm (0.31 in)

4. For Dia 10.00 mm (0.39 in)

51. Install the turbocharger water feed pipe.

RTW56ASH019101

Legend

1. Turbocharger Water Feed Pipe

52. Install the turbocharger water return pipe.

RTW56ASH019001

Legend

1. Turbocharger Water Return Pipe

53 Install the A/T oil cooler pipe bracket.

Refer to procedure for automatic transmission in

this manual.

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ENGINE MECHANICAL (4JJ1) 6A-87

54. Install the catalyst converter.

Refer to procedure for Turbocharger and Exhaust

Manifold in this manual.

55. Connect the front drive shaft. (4×4)

Refer to procedure for front propeller shaft in this

manual.

56. Install the exhaust front pipe.

• Refer to procedure for “Exhaust System” in this

manual.

57. Install the EGR cooler.

• Refer to procedure for “Exhaust System” in this

manual.

58. Install the EGR cooler water pipe.

• Refer to procedure for “Exhaust System” in this

manual.

59. Install the EGR cooler heat protector.

• Refer to procedure for “Exhaust System” in this

manual.

60. Install the cooling fan.

• Refer to procedure for “Engine Cooling” in this

manual.

61.Install the A/C drive belt.

• Refer to procedure for “Intake Manifold” in this

manual.

62. Install the radiator fan shroud. Upper and lower.

63. Install the radiator upper hose.

• Refer to procedure for engine cooling in this

manual.

64. Install the harness bracket.

65. Install the fuel leak off hoses (1), and the fuel

injector connectors (2).

RTW76ASH000101

Note:

Do not reuse the leak off pipe ASM. (1) and clips (2).

RTW86ASH000701

Legend

1. Leak off pipe ASM.

2. Clip

66. Install the intake hose.

RTW56ASH022501

Legend

1. Intake Hose for Intercooler and Intake Throttle

2. Intake Duct for Turbocharger and Air Cleaner

3. Intake Hose for Turbocharger and Intercooler

67. Install the engine head cover.

68. Replenish the coolant.

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ENGINE MECHANICAL (4JJ1) 6A-89

Piston and Connecting Rod

Components

RTWA86ALF000601

Legend

1. Snap Ring2. Piston Pin

3. Piston Ring

4. Piston5. Connecting Rod

6. Bearing

Removal

1. Demount the engine assembly.

Refer to “Engine Assembly”.

2. Remove the cylinder head cover.

Refer to “Cylinder Head Cover”.

3. Remove the camshaft assembly.

Refer to “Camshaft Assembly”.

4. Remove the cylinder head.

Refer to “Cylinder Head”.

5. Remove the gear case assembly.

Refer to “Gear Case Assembly”.

6. Remove the oil pan.

Refer to “Oil Pan” .

7. Remove the connecting rod cap.

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6A-90 ENGINE MECHANICAL (4JJ1)

Note:

Sort the removed bearings according to cylinders by

using tags.

LNW21BSH004901

8. Remove the piston and connecting rod.

• Remove carbon on the upper side of the

cylinder block with a scraper.

• Pull out the piston and connecting rod towards

the cylinder head.

Note:

Be sure not to damage the oil jet and cylinder block

when pushing out the connecting rod.

9. Remove the connecting rod 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 the piston ring.

• Use ring pliers to remove the piston 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.

LNW21BSH005101

2. Remove the snap ring.

3. Remove the piston pin.

Note:

Sort the disassembled piston pins, pistons and

connecting rods together in the same order as the

cylinders.

LNW21BSH005201

4. Remove the connecting rods from the piston.

5. Clean the piston.

• Carefully clean carbon that is adhered to 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.

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6A-92 ENGINE MECHANICAL (4JJ1)

LNW76ASH001401

Legend

1. Grade

2. Front Mark Cut

8. Inspect the piston ring.

• Insert the piston ring horizontally (in the position

it would assume if it were installed to the

piston) into the cylinder block.

LNW21BSH009301

• Push the piston ring into the cylinder bore until

it reaches the measuring point 1 or 2 where the

cylinder block 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 2 120 mm (4.7 in).

LNW61ASH004401

LNW61ASH004501

• Use a thickness gauge to measure the piston

ring gap.

If the measured value exceeds the specified

limit, the piston ring must be replaced.

Piston ring gap mm (in)

Standard

1st compression ring 0.27 — 0.51

(0.0106 – 0.0201)

2nd compression ring 0.42 – 0.66

(0.0165 – 0.0260)

Oil ring 0.27 – 0.56

(0.0106 – 0.0220)

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ENGINE MECHANICAL (4JJ1) 6A-93

Measure the clearance between the piston ring

groove and the piston.

• Remove carbon in the piston ring groove.

• Put the piston ring in the piston ring groove, use

a thickness gauge to measure the gap between

them.

• If the clearance between the 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)

∗ Measurement is impossible

LNW21BSH009501

9. Inspect the piston pin.

• Visually inspect the piston pin for cracks,

scratches and other damage, and replace it if

necessary.• Use a micrometer to measure the outer

diameter of the piston pin. If the measured

value exceeds the limit, replace the piston pin.

Piston pin outer diameter mm (in)

Standard 33.995 – 34.000 (1.33838 – 1.33858)

LNW21BSH009601

• Inspect to make sure that there is a resistance

to the extent which the piston can push the

piston pin lightly in normal temperatures.

• If it feels a large looseness or instability in

normal temperatures, replace the piston or

piston pin.

LNW21BSH009701

•

Measure the bush of the small edge of theconnecting rod. If the clearance of the bush inner

diameter and the pin diameter exceeds the limit,

replace the bush or connecting rod assembly, and

the pin.

Piston pin and connecting rod small end bushing

clearance mm (in)

Standard 0.008 — 0.020 (0.0003 — 0.0008)

Limit 0.05 (0.0020)

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6A-94 ENGINE MECHANICAL (4JJ1)

LNW21BSH009801

10. Measure the clearance between the piston 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,

measure the clearance. If the clearance

exceeds the limit, replace the piston and the

piston pin.

Piston pin and piston pin hole clearance mm (in)

Standard 0.008 — 0.019 (0.0003 — 0.0007)

11. Measure the connecting rod alignment.

• Use a connecting rod aligner to measure the

torsion and parallel level of the big end hole

and the small end hole. If the measured value

exceeds the limit, replace it.

Connecting rod alignment

(par length of 100 mm (3.94 in)) mm (in)

Standard Limit

Distortion 0.08 (0.003) or less 0.20 (0.008)

Parallelism 0.05 (0.002) or less 1.50 (0.060)

LNW21BSH010401

12. Measure the bearing oil clearance.

• Install the bearing to the connecting rod big

end.

• Tighten the connectingrod cap to the two step

of angular tightening method.

• Use an inside dial indicator to measure the

connecting rod bearing inside diameter. After

engine oil shall be applied tobolt mating

surfaces and thread portions.

Connecting rod bearing cap bolt torque:

N⋅m (kg⋅m / lb ft)

1st step 29.4 (3.0 / 22)

2nd step 45 deg

If the clearance between the measured bearing

inside diameter and the crankpin exceeds the

specified limit, the bearing and/or the crankshaft

must be replaced.

Crankpin and bearing clearance mm (in)

Standard 0.029 — 0.083 (0.0011 — 0.0033)

Reassembly

1. Install the piston.2. Install the connecting rod.

• Install it so that the front mark of the head of

the piston, and the connecting rod forging mark

(projecting) on the connecting rod, both face in

the same direction.

• Install the snap ring of one side.

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ENGINE MECHANICAL (4JJ1) 6A-95

LNW46ASH004601

Legend

1. Front Mark

2. Forging Mark (Projecting)

3. Apply enough engine oil on the piston pin, push it

in the piston and the connecting rod small edge.

4. Use snap ring pliers to install the snap ring.

Note:

Make sure that the snap ring is installed in the ring

groove properly. Make sure that the connecting rod

moves smoothly.

015R100001

5. Use ring pliers to install the piston ring.

• Install the piston rings in the order shown in the

illustration.

• Install 2nd and 1st compression rings in this

order so that the laser marks face upward.

• Insert the expander coil into the oil ring groove

so that there is no gap on either side of the

expander coil before installing the oil ring.

RTW56ASH023201

Legend

1. Compression Ring 1st

2. Compression Ring 2nd

3. Oil Ring

4. Expander

Installation

1. Install the connecting rod bearing.

• Install the bearing on the connecting rod, andapply engine oil on the bearing.

2. Install the piston and connecting rod assembly.

• Apply enough engine oil on the piston ring, ring

groove and piston side surface.

• With the piston front mark cut facing forward,

use the piston ring compressor to insert the

piston in the cylinder block.

Note:

• Be sure not to make the connecting rod touch

the oil jet when pushing in the piston.

• Be sure not to harm the inside of the cylinder

block when pushing in the piston.

Special tool

Piston ring compressor: 5-8840-9018-0

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6A-96 ENGINE MECHANICAL (4JJ1)

015LX096

3. Install the connecting rod cap.

• Install the bearing on the connecting rod cap

and apply engine oil.

• Install the cap, matching the numbers (1, 2, 3,

and 4) of the caps and connecting rods.

015R100007

• Install the connecting rod cap, and tighten bolt

at the specified torque in the order as shown inthe diagram.

Apply engine oil to the threaded portion of the

tightening bolts and seat surface and tighten

them at the specified torques.

LNW71BSH015201

Tightening torque:1st step = 29.4 N⋅⋅⋅⋅m (3.0 kg⋅⋅⋅⋅m / 22 lb ft)

2nd step = 45°- 60° (degrees)

Special tool

Angle gauge: 5-8840-0266-0

Note:

Make sure that the crankshaft smoothly rotates.

LNW71BSH013401

4. Install the oil pan.

Refer to “Oil Pan”.

5. Install the gear case assembly.

Refer to “Gear Case Assembly”.

6. Install the cylinder head.

Refer to “Cylinder Head”.

7. Install the camshaft assembly.

Refer to “Camshaft Assembly”.

8. Install the cylinder head cover.

Refer to “Cylinder Head Cover”.

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6A-98 ENGINE MECHANICAL (4JJ1)

Flywheel

Components

RTW56ALF001701

Legend

1. Flywheel Assembly and Pilot Bearing2. Driven Plate

3. Pressure Plate Assembly

4. Release Bearing5. Shift Fork

6. Transmission Assembly

Removal

1. Remove the transmission assembly.

Refer to «transmission assembly removal and

installation».

2. Remove the clutch pressure plate.

• Remove the pressure plate installation bolts in

the order shown in the drawing.

• Remove the pressure plate from the flywheel.

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ENGINE MECHANICAL (4JJ1) 6A-99

RTW56ASH014201

3. Remove the driven plate.

• Remove the driven plate from the flywheel

along with the clutch aligner.

• Install the crankshaft stopper in the starter

installation part of the rear plate.

Note:

Make sure that the stopper is applied with the ring gear

and installed properly.

Special tool

Crankshaft stopper: 5-8840-0214-0

4. Remove the pilot bearing.

• Remove the pilot bearing from the flywheel.

015RY00018

Special tool

Pilot Bearing Remover: 5-8840-2000-0

Sliding Hammer: 5-8840-0019-0

5. Remove the flywheel.

• Gradually loosen the flywheel installation bolts

in the order shown in the drawing so that the

flywheel does not rotate.

• After loosening the bolts, remove the stopper

and remove the flywheel.

• In the case of A/T car, after loosening the

flywheel installation bolts, remove the washer,

flexible plate, flywheel and sleeve in this order.

015RY00001

6. Remove the ring gear.

• Put a bar on the ring gear and hit it with a

hammer to remove it.

LNW21BSH012001

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6A-100 ENGINE MECHANICAL (4JJ1)

Inspection

1. Visual inspection

• Inspect the flywheel friction surface for cracks

and damages, and replace it if it has

abnormality.

• Inspect the tooth part of the ring gear, replace

the ring gear if it has damage or serious wear.

2. Measurement of the friction surface

• Measure the depth of the friction surface of the

flywheel (1).

• Adjust it if the measured value is within the

standard value and the limit.

• If the measured value exceeds the limit,

replace the flywheel.

Depth of the friction surface of the flywheel mm (in)

Standard 18 (0.7087)

Limit 19 (0.7480)

Depth = From the pressure installation surface

to the friction surface.

RTW86ASH000801

3. Flywheel installation bolts.

• There is no damage in appearance.

• Exchange for a new part if damage is

extensive.

Installation

1. Install the ring gear.

• Heat the ring gear evenly with a gas burner to

invite thermal expansion. Do not allow the

temperature of the gas burner to exceed 200°C

(392°F).

• Install the ring gear when it is sufficiently

heated. The ring gear must be installed with the

chamfer facing the clutch.

Note:

• Install the ring gear so that the side with a

pattern faces forward.

• Shrink fit the ring gear to the flywheel.

Make sure that flywheel and ring gear adhesion

is complete.

LNW21BSH01201

2. Install the pilot bearing.

• Place the crankshaft pilot bearing right angle

across the crankshaft bearing installation hole.

• Tap around the edges of the crankshaft pilot

bearing outer races with a brass hammer to

drive the bearing into the crankshaft bearing

installation hole.Special tool

Pilot Bearing Installer: 5-8522-0024-0

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ENGINE MECHANICAL (4JJ1) 6A-101

015RY00010

3. Install the flywheel.

• Install the flywheel of the crankshaft, tighten

them in the order shown in the illustration.

• Apply molybdenum disulfide on the screw part

and setting face of the bolt.

• Install the crankshaft stopper on the starter

installation part of the rear plate.

Tightening torque:

1st step = 59 N⋅⋅⋅⋅m (6.0 kg⋅⋅⋅⋅m / 43 lb ft)

2nd step = 60° — 90° (degrees)

Special tool

Crankshaft stopper: 5-8840-0214-0

015RY00001

4. Install the driven plate.

• Use a clutch aligner to install the driven plate

on the flywheel.

LNW21BSH002601

Legend

1. Clutch Aligner

5. Install the clutch pressure plate.

• Install the pressure plate on the flywheel so that

the installation hole of the pressure plate

matches with the dowel pins of the flywheel.

• Tighten the pressure plate in the order shown

in the illustration.

Tightening torque: 18 N⋅⋅⋅⋅m (1.8 kg⋅⋅⋅⋅m / 13 lb ft)

RTW56ASH023301

6. Install the transmission assembly.

Refer to removal procedure for “TRANSMISSION”.

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6A-102 ENGINE MECHANICAL (4JJ1)

Torque Specifications

Special Tools

ILLUSTRATIONPART NO.

PART NAMEILLUSTRATION

PART NO.

PART NAME

5-8840-0214-0

Crankshaft stopper

5-8522-0024-0

Pilot Bearing Installer

5-8840-2000-0

Pilot Bearing Remover

5-8840-0019-0

Sliding Hammer

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ENGINE MECHANICAL (4JJ1) 6A-103

Gear Case Assembly

Components

RTWB6ALF000301

Legend

1. Adjust Plate2. Generator

3. Gear Case Bracket

4. Gasket5. Gear Case Assembly

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6A-104 ENGINE MECHANICAL (4JJ1)

Removal

1. Remove the engine assembly.

Refer to removal procedure for “Engine Assembly”

in this manual.

2. Remove the cylinder head.

Refer to removal procedure for “Cylinder Head” in

this manual.

3. Remove the adjustment bracket of generator.

4. Remove the vacuum pump and pipe.

Refer to removal procedure for “Brake” in this

manual.

5. Remove the power steering pump.

Refer to removal procedure for “Power Steering” in

this manual.

6. Remove the water pump.

Refer to removal procedure for “Water Pump” in

this manual.

7. Remove the fuel supply pump.

Refer to removal procedure for “Fuel Supply

Pump” in this manual.

8. Remove the crankshaft pulley.

Refer to removal procedure for “Crankshaft Front

Oil Seal” in this manual.

9. Remove the gear case cover.

Refer to removal procedure for “Gear Case Cover”

in this manual.

10. Remove the idle gear A and idle gear A shaft, idle

gear C and idle gear C shaft.

Refer to removal procedure for “Timing Gear

Train” in this manual.

RTW56ASH011401

RTW56ASH011301

11. Remove the oil pump.

Refer to removal procedure for “Oil Pump” in this

manual.

12. Remove the gear case bracket.

RTWB6ASH000601

Legend

1. Gear Case Bracket

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ENGINE MECHANICAL (4JJ1) 6A-105

13. Remove the timing gear case (1) and gasket (2).

RTW76ASH001201

Note:

Do not remove the bolts (8) when maintaining.

RTW86ASH001001

Legend

1. Gear Case Assembly

2. Bolt L = 25 mm (0.98 in)

3. Bolt L = 60 mm (2.36 in)4. Bolt L = 45 mm (1.77 in)

5. Bolt L = 35 mm (1.38 in)

6. Bolt L = 16 mm (0.63 in)

7. Bolt L = 20 mm (0.79 in)

8. Bolt

Installation

1. Install the packing of the timing gear case.

• Apply liquid gasket (ThreeBond 1207B or

equivalent) on the joint (1) of the cylinder block

and the crank case.

RTW86ASH001301

2. Install the timing gear case.

• Install the timing gear case to match with the

dowel pins, install bolts in the order shown in

the illustration.

Note:

Do not remove the bolts (8) when maintaining.

RTW86ASH001001

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6A-106 ENGINE MECHANICAL (4JJ1)

Legend

1. Gear Case Assembly

2. Bolt L = 25 mm (0.98 in)

3. Bolt L = 60 mm (2.36 in)

4. Bolt L = 45 mm (1.77 in)

5. Bolt L = 35 mm (1.38 in)

6. Bolt L = 16 mm (0.63 in)

7. Bolt L = 20 mm (0.79 in)

8. Bolt

• Tighten the bolts to the specified torque.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

• Tighten them in the order shown in the

illustration.

3. Install the gear case bracket.

Temporarily tighten with the bolts and nuts (Gear

case side).

Temporarily tighten with the bolt (Cylinder body

side).

Fully tighten the nuts and bolts (Gear case side).

Fully tighten the bolt (Cylinder body side).

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb⋅⋅⋅⋅ft)

RTWB6ASH000601

Legend1. Gear Case Bracket

4. Install the oil pump.

Refer to installation procedure for “Oil Pump” in

this manual.

5. Install the idle gear C shaft and idle gear C, idle

gear A shaft and idle gear A.

Refer to installation procedure for “Timing Gear

Train” in this manual.

6. Install the gear case cover.

Refer to removal procedure for “Gear Case Cover”

in this manual.

7. Install the crankshaft pulley.

Refer to removal procedure for “Crankshaft Front

Oil Seal” in this manual.

8. Install the fuel supply pump.

Refer to installation procedure for “Fuel Supply

Pump” in this manual.

9. Install the water pump.

Refer to installation procedure for “Water Pump” in

this manual.

10.Install the power steering pump.

Refer to removal procedure for “Power Steering” in

this manual.

11. Install the vacuum pump and pipe.

Refer to removal procedure for “Brake” in this

manual.

12. Install the adjustment bracket of generator.

Tighten the bolts to the specified torque.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

13. Install the cylinder head.

Refer to installation procedure for “Cylinder Head”

in this manual.

14. Install the engine assembly.

Refer to installation procedure for “Engine

Assembly” in this manual.

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ENGINE MECHANICAL (4JJ1) 6A-107

Torque Specifications

RTWB6ALF000401

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6A-108 ENGINE MECHANICAL (4JJ1)

Crankshaft Front Oil Seal

Components

RTWB6AMF000601

Legend

1. Bolt

2. Washer

3. Crankshaft Damper Pulley

4. Crankshaft Front Oil Seal

Removal

1. Remove the fan assembly.

• Remove the fan assembly unscrewing four

mounting nuts.

RTW56ASH025401

2. Remove the fan belt.

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ENGINE MECHANICAL (4JJ1) 6A-109

3. Remove the crankshaft pulley.

Note:

Do not reuse the bolt and the washer.

RTW86ASH000201

4. Remove the crankshaft front oil seal.

• Remove only the oil seal with a screwdriver or

the like, avoiding damage to the oil seal contact

surface on the front cover and the shaft.

Installation

1. Install the crankshaft front oil seal.

• Use the special tool to install the front oil seal.

Front Oil SealInstaller: 5-8840-2821-0 (1)

RTW56ASH016501

• Apply engine oil to the lip of the oil seal.

• With the seal pressed in check the dimension

of the oil seal section.

Standard Dimension = 1.5 mm (0.06 in)

RTW96ASH000401

Legend

1. 1.5 mm (0.06 in)

2. Install the crankshaft damper pulley.

• Install the crankshaft pulley aligning with the

key on the crankshaft.

• Hold the flywheel ring gear stationary to prevent

the crankshaft from turning when tightening the

damper pulley bolt.

Tightening torque: 294 N⋅⋅⋅⋅m (30 kg⋅⋅⋅⋅m / 217 lb ft)

• Take care not to damage the crankshaft

damper pulley boss.

RTW86ASH000201

3. Install the fan belt.

• Refer to “Engine Cooling”

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ENGINE MECHANICAL (4JJ1) 6A-111

Crankshaft Rear Oil Seal

Components

RTW56ALF002501

Legend

1. Crankshaft Rear Oil Seal2. Flywheel

3. Driven Plate

4. Clutch Pressure Plate5. Transmission Assembly

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6A-112 ENGINE MECHANICAL (4JJ1)

Removal

1. Remove the flywheel.

Refer to «Flywheel».

• With the oil seal pushed in deep, install the

special tool as shown in the illustration and

remove the oil seal.

Oil Seal Remover: 5-8840-2360-0

015LV002

Installation

1. Install the crankshaft rear oil seal.

• Use an oil seal install to install the crankshaft

rear oil seal.

Oil Seal Installer: 5-8840-2359-0

RTW56ASH022901

2. Install the flywheel.

Refer to «Flywheel».

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ENGINE MECHANICAL (4JJ1) 6A-113

Special Tools

ILLUSTRATIONPART NO.

PART NAME

5-8840-2359-0Oil seal installer

5-8840-2360-0

Oil seal remover

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6A-114 ENGINE MECHANICAL (4JJ1)

Crankshaft

Components

RTW56ALF002601

Legend

1. Upper Bearing2. Thrust Bearing

3. Gear

4. Crankshaft5. Lower Bearing

6. Bearing Cap

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ENGINE MECHANICAL (4JJ1) 6A-115

Removal

1. Demount the engine assembly.

Refer to «Engine Assembly».

2. Remove the cylinder head cover.

Refer to «Cylinder Head Cover».

3. Remove the camshaft.

Refer to «Camshaft Assembly».

4. Remove the cylinder head.

Refer to «Cylinder Head».

5. Remove the fuel supply pump and fuel rail.

Refer to «Fuel Supply Pump» and «Fuel Rail» in the

fuel system section.

6. Remove the front cover.

Refer to «Front Cover».

7. Remove the crankshaft rear oil seal.

Refer to «Crankshaft Rear Oil Seal».

8. Remove the water pump.

Refer to «Water Pump» in Cooling System Section.

9. Remove the timing gear train.

Refer to «Timing Gear Train».

10.Remove the oil pump.

Refer to «Oil Pump».

11. Remove the gear case assembly.

Refer to “Gear Case Assembly”.

12. Disconnect the crankshaft position (CKP) sensor

connector.

13. Remove the CKP sensor.

LNW71ASH001701

14. Remove the crankshaft gear.

901R100008

15. Remove the crank case.

Refer to «Crank Case and Oil Pan».

16.Remove pistons and connecting rods.

Refer to «Piston and Connecting Rod».

17. Remove the bearing cap.

• Loosen the crankshaft bearing cap bolts in

numerical order a little at a time.

LNW81HSH000101

18.Remove the lower crankshaft bearings.

19.Remove the crankshaft assembly.

20.Remove the thrust bearing.

21.Remove the upper crankshaft bearings.

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6A-116 ENGINE MECHANICAL (4JJ1)

Disassembly

1. Remove the crank angle sensor rotor (1).

• Confirm that the pin (2) is not removed.

RTW76ASH001501

Reassembly

1. Install the crank angle sensor rotor.

• Attach by making a rotor tooth’s running out

side into a front side.

• Align the hole (2) and the pin (3) to install.

• Apply Loctite #262 or the equivalent to the 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)

RTW86ASH001201

Legend

1. Crank Angle Sensor Rotor2. Hole

3. Pin

Inspection

1. Thrust clearance

• Measure the crankshaft end play at the center

journal of the crankshaft.

• Do this before removing the crankshaft bearing

caps. If the measured value exceeds the

specified limit, the crankshaft thrust bearing

must be replaced.

Axial play of the crankshaft mm (in)

Standard 0.040 – 0.201 (0.0016 – 0.0079)

Note:

Measure the thrust clearance before dismounting.

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ENGINE MECHANICAL (4JJ1) 6A-117

015RY00002

2. Main bearing clearance

• Remove the crank case.

Set out disassembled main bearings in the

order of the numbers.

• Remove the crankshaft. Remove the main

bearings.

• Clean the crankshaft journal and upper and

lower bearings.

• Check the bearings for damage or excessive

wear.

If you find damage or excessive wear, replace

the bearings in pairs.

• Place the upper bearings and the crankshaft 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 on the crankshaft journal as

shown.

•

Place the lower bearings at original positions onthe bearing cap.

015RY00012

• Install the bearing cap and tighten bolts to the

specified tightening torque.

• Tighten the bearing cap in the sequence shown

using a torque wrench and an angle gauge.

LNW81BSH001701

Tightening torque: 166 N⋅⋅⋅⋅m (16.9 kg⋅⋅⋅⋅m / 122 lb ft)

Note:

Do not turn the crankshaft after you have tightened thebearing cap.

• Loosen the bolts and gently remove the bearing

cap.

• Measure the widest part of the Plastigage

flattened by tightening the bearing cap to

determine the clearance.

Journal oil clearance mm (in)

Standard 0.030 — 0.054 (0.0012 — 0.0021)

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6A-118 ENGINE MECHANICAL (4JJ1)

LNW21BSH024401

• If the journal oil clearance exceeds the limit,

replace the main bearings altogether or the

crankshaft.

• Remove the Plastigage from the bearings and

the crankshaft.

Inspection of the crankshaft

• Check the crankshaft journal and crank pin

surfaces for wear and damage. Check the oil

seal contact surface for excessive wear and

damage.

• Check the oil port for clogging.

3. Crankshaft 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 mm (in)

Standard 0.05 or less (0.0020 or less)

015LX061

4. Measure the journal and the crankpin diameters

and uneven wear.

• Measure outer diameters of the journal and the

pin and calculate differences between the

maximum and the minimum values. Take

measurements at four positions for both the

journal and the pin.

LNW21BSH024601

Crankshaft outside diameter mm (in)

Standard

Journal69.917 – 69.932

(2.7526 – 2.7532)

Pin52.915 – 52.930

(2.0833 – 2.0839)

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ENGINE MECHANICAL (4JJ1) 6A-119

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 bearing selection is based on themeasured diameters of the crankshaft journals

and the bearing inserts.

• Match the crankshaft bearing housing grade

marks and the crankshaft journal grade marks

in the table below to determine the correct

crankshaft bearing size.

• Crankshaft bearing housing grade marks 1, 2

or 3 are stamped on the rear right hand side of

the cylinder block.

RTW56ASH017101

Legend

1. No.1

2. No.2

3. No.3

4. No.4

5. No.5

• The crankshaft journal grade marks (1 or -, 2 or—, 3 or —) are stamped on each crankshaft

journal web.

The crankshaft 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.

RTW86ASH000901

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.

RTW56ASH017301

Legend

1. Lot No.

2. Size Code

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6A-120 ENGINE MECHANICAL (4JJ1)

Bearing Selection Table

mm (in)

CrankshaftBearing Housing

Crankshaft Journal

GradeMark

DiamaeterGradeMark

Diamaeter

CrankshaftBearing

Size Codeand Color

1 or- 69.927-69.932(2.7530-2.7532)

2 or- —

69.922-69.927(2.7528-2.7530)

4YELLOW

1

73.992-74.000

(2.9131-2.9134)

3 or- — —

69.917-69.922(2.7526-2.7528)

5RED

1 or-

69.927-69.932(2.7530-2.7532)

2BLACK

2 or- —

69.922-69.927(2.7528-2.7530)

3BLUE

2

73.983-73.991

(2.9127-2.9130)

3 or- — —

69.917-69.922(2.7526-2.7528)

4YELLOW

1 or-

69.927-69.932(2.7530-2.7532)

1GREEN

2 or- —

69.922-69.927(2.7528-2.7530)

3

73.975-73.982

(2.9124-2.9127)

3 or- — —

69.917-69.922(2.7526-2.7528)

2BLACK

Installation

1. Install the crankshaft upper bearing.

• The crankshaft upper bearings have an oil hole

and an oil groove. The lower bearings do not.

•

Carefully wipe any foreign material from theupper bearing.

• Locate the position mark applied 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 block bearing fitting surfaces.

015LX125

2. Install the crankshaft assembly.

Apply an ample coat of engine oil to the crankshaft

journals and the crankshaft bearing surfaces

before installing the crankshaft.

LNW71BSH003801

3. Install the thrust bearing.

• Apply an ample coat of engine oil to the thrust

bearings before installation. Install the thrustbearings to the crankshaft No.3 journal front

and rear.

• The thrust bearing oil grooves must be facing

the sliding faces.

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ENGINE MECHANICAL (4JJ1) 6A-121

LNW71BSH003901

4. Install the lower crankshaft bearing.

• Before the crankshaft bearing installation,

select the appropriate bearings in accordance

with the description in CRANK BEARING

SELECTION of INSPECTION AND REPAIR.

5. Install the bearing cap.

• Install the bearing caps with the bearing cap

head arrow mark facing the front of the engine.

The bearing cap numbers must be facing up.

LNW81BSH001801

• Tighten the crankshaft bearing cap bolts to the

specified torque a little at time in the sequence

shown in the illustration.

Crankshaft Bearing Cap Torque N⋅m (kg⋅m / lb ft)

166 (16.9 / 122)

Check to see the crankshaft turns smoothly by

rotating it manually.

Note:

Confirm that the crankshaft turns smoothly.

LNW81BSH001701

6. Install pistons and connecting rods.

Refer to «Piston and Connecting Rod».

7. Install the crank case.

Refer to «Crank Case and Oil Pan».

8. Install the crankshaft gear.

RTW56ASH017001

9. Install the gear case assembly.

Refer to «Gear Case Assembly».

10.Install the oil pump.

Refer to «Oil Pump».

11.Install the timing gear train.

Refer to «Timing Gear Train».

12.Install the water pump.

Refer to «Water Pump» in Cooling System Section.

13.Install the front cover.

Refer to «Timing Gear Train».

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ENGINE MECHANICAL (4JJ1) 6A-123

Torque Specifications

RTW76AMF000301

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6A-124 ENGINE MECHANICAL (4JJ1)

Cylinder Block

Components

RTW76ASF000101

Legend

1. Cylinder Block

Removal

1. Demount the engine assembly.

Refer to «Engine Assembly».

2. Remove the cylinder head cover.

Refer to «Cylinder Head Cover».

3. Remove the camshaft assembly.

Refer to «Camshaft Assembly».

4. Remove the cylinder head.

Refer to «Cylinder Head».

5. Remove the fuel supply pump and fuel rail

assembly.

Refer to «Fuel Supply Pump» and «Fuel Rail

Assembly» in FUEL SYSTEM Section.

6. Remove the oil filter assembly and oil cooler.

Refer to “Oil Filter Assembly and Oil Cooler”.

7. Remove the crankshaft front oil seal.

Refer to «Crankshaft Front Oil Seal».

8. Remove the crankshaft rear oil seal.

Refer to «Crankshaft Rear Oil Seal».

9. Remove the oil pan.

Refer to «Oil Pan».

10. Remove the water pump.

Refer to «Water Pump» in Cooling System Section.

11. Remove the front cover.

Refer to «Front Cover».

12. Remove the timing gear train.

Refer to «Timing Gear Train».

13. Remove the oil pump.

Refer to «Oil Pump».

14. Remove pistons and connecting rods.

Refer to «Piston and Connecting Rod».

15. Remove the crankshaft.

Refer to «Crankshaft».

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ENGINE MECHANICAL (4JJ1) 6A-125

16. Remove the piston cooling pipe.

RTW76ASH001101

Inspection

1. Carefully remove water stains or other foreign

matters on the surface of the cylinder block.

• Be careful not to damage the cylinder block.

2. Carefully remove the liquid gasket on the

crankcase mounting surface.

3. Clean up the cylinder block.

4. Visually inspect the cylinder block.

• Conduct color check and hydraulic (or

pneumatic) test and if you find a crack or other

damage, replace the cylinder block.

RTW76ASH000801

5. Cylinder block wear measurement.

• Use a cylinder indicator to measure the cylinder

bore at measuring point (1) in the thrust (2-2)

and axial (3-3) directions of the crankshaft.

• Measuring Point (1): 20 mm (0.79 in)

If the measured value exceeds the specified

limit, the cylinder block must be replaced.

012RY00010

Cylinder block bore diameter mm (in)

Standard 95.421 − 95.450 (3.7567 − 3.7579)

Limit 95.48 (3.7590)

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6A-126 ENGINE MECHANICAL (4JJ1)

6. Cylinder block upper face warpage.

• Use a straight edge (1) and a thickness gauge

(2) to measure the four sides and the two

diagonals of the cylinder block upper face.

• If the measured values exceeds the limit, the

cylinder block must be replaced.

Cylinder block upper face warpage mm (in)

Standard 0.05 or less (0.002 or less)

Limit 0.20 (0.008)

012R100001

Cylinder block height (H) (Reference) mm (in)

Standard 259.945 – 260.055 (10.2340 – 10.2384)

LNW71BSH002101

Installation

1. Install the piston cooling pipe.

• Align the dowel pin of the piston 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)

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.

RTW76ASH001101

2. Install the crankshaft.

Refer to «Crankshaft».

3. Install pistons and connecting rods.

Refer to «Piston and Connecting Rod».

4. Install the oil pump.

Refer to «Oil Pump».

5. Install the timing gear train.

Refer to «Timing Gear Train».

6. Install the front cover.

Refer to «Front Cover».

7. Install the water pump.

Refer to «Water Pump» in Cooling System Section.

8. Install the oil pan.

Refer to «Oil Pan».

9. Install the crankshaft rear oil seal.

Refer to «Crankshaft Rear Oil Seal».

10. Install the crankshaft front oil seal.

Refer to «Crankshaft Front Oil Seal».

11. Install the oil filter assembly and oil cooler.

Refer to «Oil Filter Assembly and Oil Cooler».

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6A-128 ENGINE MECHANICAL (4JJ1)

Lubrication System

Service Precautions

• During each disassembly, remove the old 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 or insufficient coating 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 and end of the application 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

LNW76ALF000201

1. Oil Pump Relief Valve Operating Pressure: 490 – 686 kPa (5.0 – 7.0 kg/cm2 / 71 – 100 psi)

2. Oil Cooler Relief Valve Opening Pressure: 176 – 216 kPa (1.8 – 2.2 kg/cm2 / 26 – 31 psi)

3. Oil Filter Relief Valve Opening Pressure: 80 – 120 kPa (0.8 – 1.2 kg/cm2 / 11 – 17 psi)

4. Oil Pressure Switch Operating Pressure: 29.4 – 49.0 kPa (0.3 – 0.5 kg/cm2 / 4.3 – 7.1 psi)

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

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ENGINE MECHANICAL (4JJ1) 6A-129

Functional Check

Oil pressure check

1. Check whether the engine oil is contaminated with

dirt, light oil, or water. If contaminated with dirt,

light oil, or water (after examining the cause andtaking the appropriate measures for light oil or

water contamination), replace the oil.

2. Check the engine oil level. The oil level should be

between the two holes of the level gauge. If the oil

level is insufficient, replenish it.

3. Remove the oil pressure switch on the nipple.

4. Install the oil pressure gauge on the nipple.

RTW56ASH015501

Legend

1. Oil Pressure Switch

5. Warm the engine.

6. Measure the oil pressure, to check whether it is

more than 400 kPa (4 kg/cm2 / 58 psi) at 3600

rpm.

7. Stop the engine.

8. Remove the oil pressure gauge.

9. Install the oil pressure switch.10. Start the engine and check for oil leakage.

Engine oil

• 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 betweenthe 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.

RTW56ASH015601

RTW86ASH001401

Legend

1. Lower Limit

2. Upper Limit

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6A-130 ENGINE MECHANICAL (4JJ1)

Replenished engine oil L (lmp·gal)

Condition 4 x 2 4 x 4 Notes

With oil filter

replacement7 (1.54) 7.5 (1.65)

Drained from DRAIN BOLT,

after that fill up to upper level

Without oil filter

replacement6.4 (1.41) 6.9 (1.52)

Drained from DRAIN BOLT,

after that fill up to upper level

Engine dry 8 (1.76) 8 (1.76) Fill up to upper level

Note:

Because it is the value of the aim, confirmation is with a

premise in a level gauge.

Engine oil leakage

• In the lift up condition, confirm that there are no

leaks from the cylinder head cover and oil pan.

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ENGINE MECHANICAL (4JJ1) 6A-131

Oil Filter Cartridge

Components

RTW56ASF000101

Legend

1. Oil Filter Cartridge

Removal

1. Place a tray under the oil filter cartridge.

2. Remove the oil filter cartridge using the oil filter

wrench.

Special tool

Oil filter wrench: 5-8840-0203-0 (1)

RTW56ASH012501

Installation

1. Install the oil filter cartridge.

• Apply grease or engine oil to the seal in the

cartridge and install it using the oil filter wrench.

• Tighten the cartridge using the specified torque.

Tightening torque: 20 N·m (2.0 kg·m / 14 lb ft)

Or

After it comes in contact with the oil seal,

tighten it through an additional turn of 1 and

1/4.

Special tool

Oil filter wrench: 5-8840-0203-0

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6A-132 ENGINE MECHANICAL (4JJ1)

Special Tools

ILLUSTRATIONPART NO.

PART NAME

5-8840-0203-0

Oil filter wrench

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6A-134 ENGINE MECHANICAL (4JJ1)

6. Remove the water intake pipe.

RTW56ASH012601

Legend

1. Water Intake Pipe

2. Bracket

3. Bracket

4. Bolt

7. Remove the oil cooler.

RTW66ASH009101

Installation

1. Install the oil filter and cooler.

• Install the O-ring on the oil filter and cooler,

apply grease.

• Apply the liquid gasket and mount within 5

minutes. Apply liquid gasket (ThreeBond TB-

1207C or equivalent) to the flange surface

groove (cylinder block). Bead diameter must

be between 2 and 3 mm (0.079 and 0.118 in).

Refer to the illustration for the offset position

(no more than 1 mm (0.039 in)).

RTW56ASH013101

Legend

1. Liquid Gasket

2. O-ring

• Align the oil filter and cooler holes with the

cylinder block studs. Install the oil cooler to the

cylinder clock.

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ENGINE MECHANICAL (4JJ1) 6A-135

RTW56ASH013201

Legend

1. Bolt 45 mm (1.77 in)

2. Bolt 110 mm (4.33 in)

3. Bolt 70 mm (2.76 in)

4. Nut

• Tighten the bolts to the specified torque in the

order shown in the illustration.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

RTW56ASH013301

2. Install the water intake pipe.

a. Temporarily tighten the bolt (6).

b. Install the O-ring (2) to the water intake pipe

(7).

c. Apply soapy water to the O-ring (2) and install

the water intake pipe (7).

• Take care not to twist the O-ring.

d. Temporarily tighten the bolts.

Temporary tightening order: 1→3→4→5

e. Tighten the bolts to the specified torque.

Fully tightening order: 3→4→1→5→6

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

RTW76ASH001701

3. Install the water bypass pipe (1).

• After applying soapy water to O-ring, set it on

bypass 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)

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6A-136 ENGINE MECHANICAL (4JJ1)

RTW56ASH008401

Note:

Installing with the surface of the oil cooler (1) and water

bypass pipe (3) at an angle will cause coolant leaks.

RTW86ASH001701

Legend

1. Oilcooler

2. Gasket

3. Water bypas pipe

4. Install the bracket of generator.

Tighten the bolts to the specified torque.

Tightening torque: 51 N⋅⋅⋅⋅m (5.2 kg⋅⋅⋅⋅m / 38 lb ft)

5. Install the adjustment bracket of generator.

Tighten the bolts to the specified torque.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

6. Install the generator.

Refer to Installation procedure for generator in this

manual.

7. Install the exhaust manifold.

Refer to Installation procedure for turbocharger

and exhaust manifold in this manual.

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ENGINE MECHANICAL (4JJ1) 6A-139

7. Remove the cylinder head.

Refer to “Cylinder Head”.

8. Remove the timing gear case.

Refer to “Timing Gear Case”.

9. Remove the retainer.

RTW76ASH002001

Legend

1. Retainer

2. Bolt

10. Remove the crank case.

LNW71HSH001201

Legend

1. O-ring

2. Crank Case

Note:

Take care not to damage the O-ring.

Disassembly

1. Remove the oil strainer.

RTWB6ASH000901

Legend

1. Gasket

2. Oil Strainer

3. Bolt

4. Crank Case

Reassembly

Install the oil strainer.

• Install the gasket on the strainer.• Tighten the bolts to the specified torque.

Tightening torque: 22 N⋅⋅⋅⋅m (2.2 kg⋅⋅⋅⋅m / 16 lb ft)

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6A-140 ENGINE MECHANICAL (4JJ1)

Installation

1. Install the crank case.

• Apply the liquid gasket (ThreeBond TB-1207C

or equivalent) and mount within 5 minutes.

Note:

Adjust the amount of liquid gasket when applying it near the O-ring to prevent from protrusion.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

LNW81BSH000601

Legend

1. 2.0 — 3.0 mm (0.079 — 0.118 in)

2. 4.0 — 5.0 mm (0.157 — 0.197 in)

2. Install the oil 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)

RTW56ASH015201

Legend

1. 2.0 mm (0.079 in)

2. 3.0 mm (0.118 in)

3. Install the retainer.

• Apply the liquid gasket (ThreeBond TB-1207C

or equivalent) and mount within 5 minutes.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

LNW71HSH001001

Legend

1. 1 — 1.5 mm (0.039 — 0.059 in)

2. 1 — 1.5 mm (0.039 — 0.059 in)

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ENGINE MECHANICAL (4JJ1) 6A-141

RTW76ASH002001

Legend

1. Retainer

2. Bolt

4. Install the timing gear case.

Refer to “Gear Case Assembly”.

5. Install the cylinder head.

Refer to “Cylinder Head”.

6. Install the rear plate.

• Tighten the bolts to the specified torque.

Tightening torque: 82 N⋅⋅⋅⋅m (8.4 kg⋅⋅⋅⋅m / 61 lb ft)

7. Install the flywheel.

Refer to “Flywheel”.

8. Connect the earth terminal of crank case side.

Note:

Do not allow the caulked portion of the terminal to

interfere with nearby parts.

9. Install the oil level gage guide tube.

• Apply the engine oil to the O-ring.

• Tighten the bolts to the specified torque.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

10. Install the engine assembly.

Refer to “Engine Assembly”.

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6A-142 ENGINE MECHANICAL (4JJ1)

Torque Specifications

RTWB6AMF000501

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ENGINE MECHANICAL (4JJ1) 6A-143

Oil Pump

Components

RTW66AMF000701

Legend

1. Bolt 2. Oil Pump Assembly

Removal

1. Drain the engine coolant.

2. Remove the radiator upper hose.

3. Remove the upper fan shroud.

4. Remove the fan and fan clutch.

• Loosen the fan clutch nuts.

• Remove the fan together with the fan clutch.

Take care not to damage the radiator core.

5. Remove the fan drive belt and pulley.

• Loosen the tension adjust bolt on the generator

and A/C.

• Remove the fan drive belt with the fan pulley.

6. Remove the lower fan shroud.

7. Disconnect the power steering pump.

• Disconnect the bracket of the power steering oil

hose clip (1).LTW56ASH000101

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6A-144 ENGINE MECHANICAL (4JJ1)

8. Remove the vacuum pump.

• Remove the vacuum pipe bracket and vacuum

pipe.

• Remove the oil pipe (feed side and return side)

of vacuum pump.

9. Remove the crank pulley.

10. Remove the front cover.

RTWB6ASH001001

11. Remove the oil pump (1).

RTW86ASH001101

Disassembly

1. Remove the spring pin.

2. Remove the spring seat.

3. Remove the spring.

4. Remove the valve.

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ENGINE MECHANICAL (4JJ1) 6A-145

Reassembly

1. Install the valve.

2. Install the spring.

3. Install the spring seat.

4. Install the spring pin.

RTW56ASH015901

Legend

1. Spring Pin

2. Spring Seat

3. Spring

4. Valve

Inspection

NOTE:

Think to match direction of ditch of gear when

assembling it.

1. Measure the clearance between the driven

gear/drive gear shaft and the bush.

• Measure the outside diameter of the driven

gear shaft using a micrometer.

Outside diameter of the driven gear shaft/drive

gear shaft mm (in)

Standard 15.989 — 16.000 (0.62949 — 0.62992)

Limit 15.900 (0.62598)

RTW56ASH025601

• Measure the inside diameter of the bushes of

the cylinder block using the dial gauge.

• If the clearance between the driven gear

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)

RTW56ASH014701

2. Measure the clearance between the gear side

surface and the gear side surface of the oil pump

housing.

• Measure the width size the driven gear/drive

gear.

Width size the driven gear/drive gear mm (in)

Standard 14.5 (0.5709)

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6A-146 ENGINE MECHANICAL (4JJ1)

RTW56ASH025501

• Measure the Depth size of the gear case

housing surface and the oil pump housing gear

case side.

Depth size the gear case housing surface and the oil

pump housing gear case side

mm (in)

Standard 14.500 — 14.527 (0.5709 — 0.5719)

RTW56ASH014801

Clearance between the gear side surface and the

gear side surface of the oil pump housing mm (in)

Standard 0.063 — 0.027 (0.0025 — 0.0011)

Limit 0.20 (0.0079)

Installation

1. Install the oil pump.

• Apply engine oil to the oil pump attachment

gearbox.

• Tighten the bolts to the specified torque.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

• Installed pump gear should be smooth to

rotate.

2. Install the gear case cover.

• Apply the liquid gasket (Threebond TB-1207B

or equivalent) mount within 5 minutes.

RTW56ASH020101

Legend

1. Apply the liquid gasket in area

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ENGINE MECHANICAL (4JJ1) 6A-147

• Install the packing in the slot of the gear case

cover.

• Tighten the bolts to the specified torque.

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

RTW56ASH012101

3. Install the crank pulley.

• Tighten the bolts to the specified torque.

Tightening torque: 294 N⋅⋅⋅⋅m (30.0 kg⋅⋅⋅⋅m / 217 lb ft)

4. Install the vacuum pump.

• Tighten the nuts to the specified torque.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

•

Install the oil pipe (feed side and return side) of vacuum pump.

• Install the vacuum pipe bracket and vacuum

pipe.

5. Install the power steering pump.

• Tighten the nuts to the specified torque.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

• Install the bracket of power steering oil hose

clip (1).

LTW56ASH000101

6. Install the lower fan shroud.

7. Install the fan drive belt and pulley.

• Install the fan drive belt with the fan pulley.

8. Install the fan and fan clutch.

• Tighten the bolts to the specified torque.

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

9. Adjust the drive belt of generator and A/C

compressor.

• Apply tension to the fan drive belt by moving

the generator.

• Depress (2) the Generator drive belt mid-

portion with 98 N⋅m (10 kg/22 lb) force.• Depress (4) or (6) the A/C belt mid-portion with

98 N⋅m (10 kg/22 lb) force.

• Measure frequency of the specified parts (1)

and (3), or (5) using a frequency meter.

Generator drive belt tension position (1)

Deflection mm(in) Frequency (Hz)

New 4-6 (0.16-0.24) 210-234

Reuse 6-8 (0.24-0.31) 179-193

A/C Belt tension position (3)

Deflection mm(in) Frequency (Hz)

New 9-12 (0.35-0.47) 159-189

Reuse 12-14 (0.47-0.55) 137-155

A/C Belt tension position (5)

Deflection mm(in) Frequency (Hz)

New 5-7 (0.2-0.28) 256-310

Reuse 7-9 (0.28-0.35) 220-252

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6A-148 ENGINE MECHANICAL (4JJ1)

RTW86ASH002101

Legend

1. Position

2. Deflection

3. Position

4. Deflection

5. Position

6. Deflection

7. Compressor

8. Compressor belt

9. Crank pulley

10. Generator belt

11. Generator

10. Install the upper fan shroud.

11. Install the radiator upper hose.

12. Replenish the engine coolant.

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ENGINE MECHANICAL (4JJ1) 6A-149

Oil Pressure SW

Components

RTW76AMF000401

Legend

1. Cylinder Block

2. Gasket

3. Nipple; Oil Pressure Warning SW

4. Oil Pressure SW

5. Nipple; Oil Gallery

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6A-150 ENGINE MECHANICAL (4JJ1)

Removal

1. Remove the oil pressure SW.

2. Remove the nipple; oil gallery.

3. Remove the nipple; oil pressure warning SW and

gasket.

Inspection

Check the continuity between the switch terminal and

the body grounding in a no-load condition.

If there is no connectivity, replace with normal parts.

LNW21HSH003301

Installation1. Install the nipple; oil gallery, oil pressure warning

SW and gasket.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb⋅⋅⋅⋅ft)

2. Install the Nipple.

Tightening torque: 15 N⋅⋅⋅⋅m (1.5 kg⋅⋅⋅⋅m / 11 lb⋅⋅⋅⋅ft)

3. Install the oil pressure SW.

Tightening torque: 15 N⋅⋅⋅⋅m (1.5 kg⋅⋅⋅⋅m / 11 lb⋅⋅⋅⋅ft)

Circuit check

1. Turn the ignition switch ON.

2. Disconnect the oil pressure switch connector, and

inspect that the oil pressure warning light turns off

at the time of the disconnection.

If it does not turn off, inspect the circuit between

the meter and the oil pressure switch. Repair any

open circuit.

LNW71HSH002101

3. Disconnect the oil pressure switch connector, and

inspect that the oil pressure warning light lights

when the harness side connector is connected to

the ground.

If it does not light, inspect the circuit between the

meter and the oil pressure switch. Repair any open

circuit.

LNW21HSH003401

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ENGINE MECHANICAL (4JJ1) 6A-151

Air Cleaner Element

Removal

1. Remove the air cleaner cover fixing clip.

2. Remove the air cleaner element assembly.

Cleaning

Dry type element

• Rotate the element with your hand while applying

compressed air to the inside of the element. This

will blow the dust free.

Compressed air pressure kPa (kg/cm2 /psi)

392 − 490 (4 − 5/57 − 71)

LNW46ASH003201

Installation

1. Install the air cleaner element assembly.

2. Install the air cleaner cover.

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MEMO

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ENGINE COOLING (4JJ1) 6B-1

SECTION 6B

ENGINE COOLING (4JJ1)

TABLE OF CONTENTS

Main Data and Specifications……………………….. 6B-2

General Description…………………………………….. 6B-3

Coolant Flow …………………………………………… 6B-3

Water Pump……………………………………………. 6B-4

Thermostat……………………………………………… 6B-4

Radiator………………………………………………….. 6B-5

Antifreeze Solution …………………………………… 6B-5

Diagnosis…………………………………………………… 6B-6

Draining and Refilling Cooling System …………… 6B-7Water Pump ………………………………………………. 6B-8

Removal …………………………………………………. 6B-8

Inspection and Repair ………………………………. 6B-9

Installation………………………………………………. 6B-9

Thermostat ………………………………………………… 6B-11

Removal …………………………………………………. 6B-11

Inspection and Repair ………………………………. 6B-11

Operating Test of Thermostat ……………………. 6B-11

Installation ………………………………………………. 6B-12

Radiator…………………………………………………….. 6B-13

Radiator and Associated Parts…………………… 6B-13

Removal …………………………………………………. 6B-14

Inspection and Repair ………………………………. 6B-15

Radiator Cap…………………………………………… 6B-15

Radiator Core………………………………………….. 6B-15

Flushing the Radiator ……………………………….. 6B-15

Cooling System Leakage Check………………… 6B-15

Installation ………………………………………………. 6B-16Engine Coolant Change ……………………………. 6B-16

Fan Clutch with Cooling Fan ………………………… 6B-17

Inspection and Repair ………………………………. 6B-17

Special Tools…………………………………………… 6B-18

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6B-2 ENGINE COOLING (4JJ1)

Main Data and Specifications

DescriptionItem

M/T A/T

Cooling system

Water pump type

Pump to crankshaft speed ratio (To 1)

Delivery volume lit (US/UK gal)/min

Pump speed at 5600 rpm

Water temperature at 30°C (86°F)

Pump bearing type

Thermostat type

Valve initial opening temperature °C (°F)

Valve full opening temperature °C (°F)

Valve lift at fully open position mm (in)

Engine coolant forced circulation

Centrifugal impeller type

1.25

240 (63.1/53.3)

Double row shaft

Wax pellet with jiggle valve

85 (185)

100 (212)

10 (0.39)

Radiator Tube type corrugated

Heat radiation capacity kW (kcal/h) 93 (80.2)

Heat radiation area m2 (ft

2) 11.63 (125.2)

Radiator front area m2 (ft

2) 0.28 (3)

Radiator dry weight kg (lb) 5.3 (11.7) 5.4 (11.9)

Radiator cap valve opening pressure kPa (kg/cm2/psi) 93.3 — 122.7 (0.95 — 1.25/13.5 — 17.8)

Engine coolant capacity lit (U.S pint) 4.0 (8.5) 4.0 (8.5)

Engine coolant total capacity lit (U.S pint) 8.7 (18.4) 8.6 (18.2)

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ENGINE COOLING (4JJ1) 6B-3

General Description

Coolant Flow

RTW76BLF000201

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 the 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 the specified value. All of the

coolant is now circulating through the radiator for effective engine cooling.

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6B-4 ENGINE COOLING (4JJ1)

Water Pump

RTW56BSF000101

A centrifugal type water pump forcefully circulates the

coolant through the cooling system.

The water pump is not a disassembled type.

Thermostat

RTW56BSF000201

A wax pellet type thermostat is used.

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ENGINE COOLING (4JJ1) 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 / cm2

/ 13.5 — 17.8 psi)

pressure. (No oil cooler provided for M/T)

RTW56BSH000301

Antifreeze Solution

NOTE:

Antifreeze solution + Water = Total cooling system

capacity.

Total Cooling System Capacity Lit(US / UK gal) (US pint)

M/T 8.7 (2.3/1.9) (18.4)

A/T 8.6 (2.3/1.9) (18.2)

See section 0B MAINTENANCE AND LUBRICATION .

F06RW005

NOTE:

To maintain the corrosion resistance of the aluminum

radiator, water and antifreeze must be combined in a

1:1 solution (50% antifreeze and 50% water).

RTW76BSH000201

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ENGINE COOLING (4JJ1) 6B-7

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 the reserve tank when theengine 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 free from oil.

Replace the EC if excessively dirty.

1. Remove the radiator skid plate.

2. Completely drain the cooling system by opening

the drain plug at the bottom of the radiator.

RTW56BSH000301

3. Remove the radiator cap.

WARNING:To avoid the danger of being burned, do notremove the cap while the engine and radiator arestill hot. Scalding fluid and steam can be blown outunder pressure.

4. Disconnect all hoses from the EC reserve tank.

Scrub and clean the inside of the reserve tank with

soap and water. Flush it well with clean water,

then drain it. Install the reserve tank and hoses.

5. Refill the cooling system with the EC using a

solution that is at least 50 percent antifreeze.

Procedure for filling with coolant (in case of full change).

• Make sure that the engine is cool.

• Open radiator cap and pour coolant up to filler

neck.

• Pour coolant into reservoir tank up to “MAX» line.

• Tighten radiator cap and start the engine. After

idling for 2 to 3 minutes, stop the engine and

reopen the radiator cap. If the water level is lower,

replenish.

WARNING:When the coolant is heated to a high temperature,be sure not to loosen or remove the radiator cap.

Otherwise you might get scalded by hot vapor orboiling water. To open the radiator cap, put a pieceof thick cloth on the cap and loosen the cap slowlyto reduce the pressure when the coolant hasbecome cooler.

• After tightening the radiator cap, warm up the

engine at about 2000 rpm. Set heater adjustment

to the highest temperature position, and let the

coolant circulate also into heater water system.

• Check to see the thermostat has opened through

the needle position of the water thermometer,

conduct a 5–minute idling again and stop theengine.

• When the engine has been cooled, check filler

neck for water level and replenish if required.

Should extreme shortage of coolant be found,

check the cooling system and reservoir tank hose

for leakage.

• Pour coolant into the reservoir tank up to “MAX»

line.

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6B-8 ENGINE COOLING (4JJ1)

Water Pump

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 the engine cover.

2. Radiator Upper Hose

a. Partially drain the engine coolant.

b. Remove the radiator upper hose.

RTW56FSH000101

3. Water Outlet Pipe

a. Disconnect the turbocharger-cooling pipe from

the outlet pipe.

b. Loosen the fixing bolt and remove the water

outlet bolt.

4. Upper Fan Shroud

5. Fan and Fan Clutch

a. Loosen the fan clutch nuts.

b. Remove the fan together with the fan clutch.

Take care not to damage the radiator core.

6. Fan Drive Belt and Pulley

a. Loosen the tension adjust bolt on the

generator.

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

RTW56ASH025401

7. Water Pump

a. Remove the water pump bolts and nuts.

b. Remove the water pump.

RTW56BSH000201

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ENGINE COOLING (4JJ1) 6B-9

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 in the water pump body.

• Coolant leakage from the sealed unit.

• Excessive radial play or abnormal noise in the fan

center when rotated by hand.

• Excessive thrust play in the fan center (Standard

play: less than 0.2 mm (0.0079 in)).

• Cracks or corrosion in the impeller.

Installation

1. Water Pump

RTW56BSH000201

a. Install the water pump with a new gasket.

b. Tighten bolts and nuts to specified torque.

Water Pump Nut/Bolt Torque:

25 N·m (2.5 kg·m /18 lb ft)

2. Fan Drive Belt and Pulley and Fan and Fan Clutch.

RTW56ASH025401

a. Install the fan drive belt and fan pulley and fan

and fan clutch.

b. Tighten the nuts to specified torque.

Fan Clutch Nut Torque: 8 N·m (0.8 kg·m /69 lb in)

c. Apply tension to the fan drive belt by moving

the generator.

d. Apply a force of 98 N (10 kg/22 lb) to the drive

belt mid-portion to check the drive belt

deflection.

Fan Drive Belt Deflection

mm (in) Frequency (Hz)

New belt 4 — 6 (0.16 – 0.24) 210- 234

Reuse belt 6 — 8 (0.24 – 0.31) 179 — 193

3. Upper Fan Shroud

4. Water Outlet Pipe.

a. Install the water outlet pipe to the thermostat

housing.

b. Tighten the outlet pipe bolt to specified torque.

Outlet Pipe Bolt Torque:

25 N·m (2.5 kg·m /18 lb ft)

c. Connect the turbocharger-cooling pipe to outlet

pipe.

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6B-10 ENGINE COOLING (4JJ1)

5. Radiator Upper Hose.

RTW56FSH000101

a. Connect the radiator upper hose to the water

outlet pipe.

b. The knob of clamp shall be directed to

horizontal.

c. Replenish the engine coolant.

6. Install the engine cover.

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ENGINE COOLING (4JJ1) 6B-11

Thermostat

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 the engine cover.

2. Radiator Upper Hose

a. Partially drain the engine coolant.

b. Remove the radiator upper hose.

c. Remove the engine harness clip.

RTW56FSH000101

3. Water Outlet Pipe

a. Disconnect the turbocharger-cooling pipe from

outlet pipe.

b. Loosen the fixing bolt and remove the water

outlet bolt.

4. Thermostat

Remove the thermostat from the thermostat

housing.

Take care not to damage the thermostat.

RTW56BSH000101

Legend

1. Front

2. Thermostat

3. Jiggle Valve

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 submerge the thermostat in water.

2. Heat the water.Stir the water constantly to avoid

direct heat being applied to the thermostat.

3. Check the thermostat initial opening temperature.

Thermostat Initial Opening Temperature °C (°F)

85 (185)

4. Check the thermostat full opening temperature.

Thermostat Full Opening Temperature °C (°F)

100 (212)

Valve Lift At Fully Open Position mm (in)

10 (0.39)

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ENGINE COOLING (4JJ1) 6B-13

Radiator

Radiator and Associated Parts

RTW76BLF000101

Legend

1. Reserve Tank Hose

2. Reserve Tank

3. Radiator Hose

4. Fan Guide; Lower

5. Fan Guide

6. Radiator Assembly

7. Drain Plug

8. Radiator Cap

9. Bracket

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6B-14 ENGINE COOLING (4JJ1)

Removal

1. Disconnect battery ground cable.

2. Loosen a drain plug to drain EC.

3. Disconnect oil cooler hose on automatic

transmission (A/T).

4. Remove the engine cover.5. Disconnect radiator inlet hose and outlet hose

from the engine.

RTW56BSH000301

6. Remove upper fan guide (1), clips (2) on both

sides and the bottom lock, then remove lower fan

guide (3) with fan shroud (4).

PTW46BSH000101

Legend

1. Upper Fan Guide

2. Clips

3. Lower Fan Guide

4. Fan Shroud

7. Disconnect the reserve tank hose (1) fromradiator.

8. Remove bracket (9).

RTW76BMH000101

Legend

1. Reserve Tank Hose

2. Reserve Tank

3. Radiator Hose

4. Fan Shroud

5. Fan Guide

6. Radiator Assembly

7. Drain Plug

8. Radiator Cap

9. Bracket

9. Lift up and remove the radiator assembly with

hose, taking care not to damage the radiator core

with a fan blade.

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ENGINE COOLING (4JJ1) 6B-15

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)

110RS006

Radiator Core

1. A bent fin may result in reduced ventilation 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, bugs and other foreign 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 / cm2 / 28.5 psi) with a cap tester:

• Leakage from the radiator.

• Leakage from the coolant pump.

• Leakage from the water hoses.

• Check the rubber hoses for swelling.

110RS005

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6B-16 ENGINE COOLING (4JJ1)

Installation

1. Install radiator assembly (6) with hose, taking care

not to damage the radiator core with a fan blade.

2. Support the radiator upper tank with the bracket

(9) and secure the radiator.

3. Connect reserve tank hose (1).4. Install lower fan guide (4).

5. Connect radiator inlet hose and outlet hose (3) to

the engine.

6. Install the engine cover.

7. Connect oil cooler hose to automatic transmission.

8. Connect battery ground cable.

RTW76BMH000101

Legend

1. Reserve Tank Hose

2. Reserve Tank

3. Radiator Hose

4. Fan Shroud

5. Fan Guide

6. Radiator Assembly

7. Drain Plug

8. Radiator Cap

9. Bracket

9. Pour engine coolant up to filler neck of radiator,

and up to MAX mark of reserve tank.

Important operation (in case of 100% engine

coolant change) procedure for filling with engine

coolant.

RTW76BSH000101

Engine coolant change

Refer to change procedure for Draining and Refilling

Cooling System in this section.

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6B-18 ENGINE COOLING (4JJ1)

Special Tools

ILLUSTRATIONPART NO.

PART NAME

5-8840-0277-0

Cap tester

5-8840-2603-0

Adapter

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FUEL SYSTEM (4JJ1) 6C-1

SECTION 6C

FUEL SYSTEM (4JJ1)

TABLE OF CONTENTS

Fuel System ………………………………………………. 6C-2

Service Precautions …………………………………. 6C-2

Trouble Shooting……………………………………… 6C-8

Fuel System Check ………………………………….. 6C-10

Fuel Filter Assembly……………………………………. 6C-12

Components……………………………………………. 6C-12

Removal …………………………………………………. 6C-12

Installation ………………………………………………. 6C-12

Fuel Filter Element ……………………………………… 6C-13Removal …………………………………………………. 6C-13

Installation ………………………………………………. 6C-13

Fuel Injector……………………………………………….. 6C-14

Components……………………………………………. 6C-14

Removal …………………………………………………. 6C-15

Installation ………………………………………………. 6C-15

Torque Specifications……………………………….. 6C-18

Fuel Rail Pressure Sensor …………………………… 6C-19

Removal …………………………………………………. 6C-19

Installation ………………………………………………. 6C-19

Fuel Pressure Limiter ………………………………….. 6C-20Removal …………………………………………………. 6C-20

Installation ………………………………………………. 6C-20

Fuel Rail Assembly……………………………………… 6C-21

Components……………………………………………. 6C-21

Removal …………………………………………………. 6C-22

Disassembly……………………………………………. 6C-24

Reassembly…………………………………………….. 6C-24

Installation ………………………………………………. 6C-24

Torque Specifications……………………………….. 6C-26

Fuel Supply Pump ………………………………………. 6C-27

Components……………………………………………. 6C-27Removal …………………………………………………. 6C-28

Installation ………………………………………………. 6C-33

Torque Specifications……………………………….. 6C-38

Fuel Rail Pressure (FRP) Regulator/Suction

Control Valve (SCV) ………………………………… 6C-39

Components……………………………………………. 6C-39

Removal …………………………………………………. 6C-40

Installation ………………………………………………. 6C-41

Fuel Sedimenter Switch ………………………………. 6C-43

Inspection……………………………………………….. 6C-43

Fuel Tank and Fuel Cooler…………………………… 6C-44

Fuel Tank and Associated Parts ………………… 6C-44

Removal …………………………………………………. 6C-45

Installation ………………………………………………. 6C-45

Fuel Gauge Unit …………………………………………. 6C-46

Fuel Gauge Unit and Associated Parts……….. 6C-46

Removal …………………………………………………. 6C-47

Installation ………………………………………………. 6C-47

Special Tool ……………………………………………. 6C-47Fuel Tube/Quick-Connector Fittings ……………… 6C-48

Precautions …………………………………………….. 6C-48

Cautions During Work………………………………. 6C-48

Removal …………………………………………………. 6C-48

Reuse of Quick-Connector………………………… 6C-49

Assembling Advice…………………………………… 6C-49

Filler Neck …………………………………………………. 6C-50

Removal …………………………………………………. 6C-50

Installation ………………………………………………. 6C-50

Fuel Filler Cap……………………………………………. 6C-51

General Description …………………………………. 6C-51Inspection……………………………………………….. 6C-51

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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 the service procedure, wash the

fuel line and the surrounding area.

• Perform the service procedures with clean hands.

Do not wear work gloves.

• Immediately after removing the fuel hose and/or

fuel pipe, carefully tape vinyl bags over the

exposed ends of the hose or pipe.

• If parts are to be replaced (fuel hose, fuel pipe,

etc.) do not open the new part packaging until

installation.

Discard gaskets and O-rings and replace them with newones.

Work procedure

• The fuel opening must be quickly sealed when

removing the fuel pipe, injection pipe, fuel injector,

fuel supply pump, and fuel rail.

• The eyebolts and gasket must be stored in a clean

parts box with a lid to prevent adhesion of foreign

matter.

• Fuel leakage could cause fires. Therefore, after

finishing the work, wipe off the fuel that has leaked

out and make sure there is no fuel leakage after

starting the engine.

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FUEL SYSTEM (4JJ1) 6C-3

Explanations on functions and operation

Fuel system diagram

RTW76CMF000101

Legend

1. Fuel Rail

2. Fuel Pressure Limiter

3. Leak Off Pipe

4. Fuel Injector

5.

Fuel Return Pipe

6. Fuel Cooler

7.

Fuel Tank

8. Fuel Pump and Sender Assembly

9. Fuel Filler Cap

10. Check Valve

11. Fuel Feed Pipe

12. One Way Valve

13. Fuel Filter With Sedimenter

14. Switch; Clogging Monitoring

15. Fuel Supply Pump

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6C-4 FUEL SYSTEM (4JJ1)

Fuel rail assembly

RTW76CLF000601

Legend

1. Fuel Pressure Limiter 2. Fuel Rail Pressure Sensor

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FUEL SYSTEM (4JJ1) 6C-5

Fuel supply pump

RTW56CLF000301

Legend

1. Fuel Temperature Sensor

2. Fuel Rail Pressure (FRP) Regulator / Suction

Control Valve (SCV)

3. High Pressure Pipe

4. Camshaft Key

5. Camshaft Nut

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6C-6 FUEL SYSTEM (4JJ1)

Fuel injector

RTW76CMH000201

Legend

1. Terminal

2. Fuel Injector ID Code

3. Two Dimensional Barcode

4.

Parts Number

5. Port for Mounting the Injection Pipe

6. O-ring

Fuel filter

RTW76CSH001001

Legend

1. Element

2. Air Bleeding Plug

3. Switch; Clogging Monitoring

4. Sensor; Water

5. Drain Plug

Functional check

Air bleeding

1. Ignition switch is turned to the ON position for 15

seconds.

2. Ignition switch is turned to the OFF position.

3. The above operation is repeated 5 times.

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

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:

1. Draining with fuel filter drain plug.a. Set a container at the tip of the plastic hose.

b. Loosen the air bleeding plug and the drain plug.

c. Discharge the water.

d. Tighten the drain plug after discharging the

water.

e. Tighten the air bleeding plug to the specified

torque.

Tightening torque: 3 N⋅m(0.3 kg⋅m/26 lb in)

f. Ignition switch is turned ON for 15 seconds

check for fuel leakage.

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FUEL SYSTEM (4JJ1) 6C-7

g. Check that the warning lamp in the meter is off.

2. Draining with drain plug in engine room.

a. With the engine off, open the engine hood and

loosen the drain plug (1) located on the left

hand side of the engine room. (3-4 turns)

b. Turn the starter switch to the “ON” position for

10 seconds, and then turn the starter switch to

the “OFF” position for 10 seconds. Then, once

again turn the starter switch to the “ON”

position for 10 seconds.

c. Tighten the drain plug firmly.

d. After starting the engine, check that there is no

fuel leakage from the drain plug. Also check

that the water separator indicator has turned

off.

RTW76CSH001301

NOTE:

• If the water separator requires frequent draining,

have the fuel tank drained at your ISUZU Dealer.

• Be sure to stop the engine when draining the fuel

tank.

• Confirm that there are no combustible materials

under the drain hose, and use a receptacle to

catch the drained water.

Fuel Pump Functional Check

1. Turn the starter switch to “ON” position.

2. Touch the under portion of the fuel tank (1) by the

hand as shown in the following figure within 12

seconds.

RTW56CSH004001

3. Make sure a vibration by the Fuel Pump is

detected.

Fuel Pump stops within 12 seconds of turning the

starter switch to the “ON” position.

When the check is repeated, return the starter

switch to the “LOCK” position for 10 – 15 seconds

and perform procedures 1 – 3.WARNING: FUEL PUMP FUNCTIONAL CHECKMUST BE CONDUCTED UNDER THE FOLLOWINGCONDITIONS TO AVOID INJURY.

•••• APPLY THE PARKING BRAKE.

•••• STOP THE ENGINE.

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6C-8 FUEL SYSTEM (4JJ1)

Trouble Shooting

Problems with starting

Condition Possible Cause Correction

Problems with starting Fuel tank is empty Fill the tank.

Air has entered the fuel system. Bleed the air.Fuel line or fuel cooler is clogged or

damaged. Connection to the fuel line

is loose.

Repair or replace the fuel line and

fuel cooler. Re-tighten the

connection.

Fuel filter element is clogged. Replace the cartridge.

Fault in the feed pump Replace the fuel supply pump.

Regulating valve is open. Replace

Sticking of the fuel injector Replace the fuel injector.

Defective engine control system Diagnose the engine control system.

Hunting during idling

Condition Possible Cause Correction

Hunting during idling Air has entered the fuel system. 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 filter element is clogged. Replace the fuel filter element

(cartridge).

Sticking of the fuel injector Replace the fuel injector.

Defective engine control system Diagnose the engine control system.

Insufficient horsepower

Condition Possible Cause Correction

Insufficient horsepower Air has entered the fuel system. Bleed air from the fuel system.

Leakage or clogging of the fuel

system

Repair or replace the fuel system.

Water mixes in the fuel system Replace the fuel.

Fuel filter element is clogged. Replace the element or the

cartridge.Sticking of the fuel injector Replace the fuel injector.

Defective engine control system Diagnose the engine control system.

Maximum engine speed is too low

Condition Possible Cause Correction

Maximum engine speed is too low Fuel line, fuel cooler is clogged or

damaged.

Repair or replace the fuel line, fuel

cooler.

Defective engine control system Diagnose the engine control system.

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FUEL SYSTEM (4JJ1) 6C-9

Engine does not stop

Condition Possible Cause Correction

Engine does not stop Defective engine control system Diagnose the engine control system.

Exhaust gas is blue or black

Condition Possible Cause Correction

Exhaust gas is blue or black. Reduction in injection-valve opening

pressure or defective atomizing

status

Replace the fuel injector.

Engine control system malfunction System diagnosis.

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FUEL SYSTEM (4JJ1) 6C-11

Step Action Value(s) Yes No

6 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

• Fuel pump and sender malfunction

• Clogged fuel cap hole

• Water

Is the action complete?

Go to Step 7

7 Bleed the air from the fuel pipe again. Refer to

Fuel System Air Bleeding in this section.

Is the action complete?

Verify repair

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6C-12 FUEL SYSTEM (4JJ1)

Fuel Filter Assembly

Components

RTW86CSF000101

Legend

1. Fuel Sedimenter Connector

2. Bolt

3. Harness Connector

4. Fuel Hose

5. Water Drain Hose

6. Fuel Filter Assembly

Removal

1. Remove the water drain hose.

2. Remove the fuel sedimenter connector.

3. Disconnect the harness connector.

4. Remove the feed hose and the return hose from

the fuel filter and plug it so that the fuel does not

flow out.

5. Remove the bolts for mounting the fuel filter.

6. Remove the fuel filter assembly.

Installation

1. Install the fuel filter assembly.

2. Install the bolts for mounting the fuel filter.

3. Install the feed hose and the return hose.

4. Connect the harness connector.

5. Install the fuel sedimenter connector.

6. Install the water drain hose.

7. Bleed out the air.

• Refer to «Fuel System».

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FUEL SYSTEM (4JJ1) 6C-13

Fuel Filter Element

Removal

1. Detach the drain hose on the lower part of the fuel

filter or the drain plug, loosen the air bleed plug,

and drain the fuel from the fuel filter.

2. Detach the water-in-fuel switch harness and water

drain hose.

3. Turn the element case counterclockwise to detach,

and remove the filter element.

4. Replace the O-ring and confirm the snap-fit

position, and fit a new filter element inside the

element case.

Note:

It is strongly advisable to use the ISUZU genuine fuel

filter for replacement.

RTW86CSH000101

Legend

1. Gasket

2. Element

3. O-ring

4. Sedimenter Sensor

Installation

1. Apply a light coat of new diesel oil to the O-ring

and gasket.

2. Turn the element case clockwise until it is

completely seated against the upper cover. Then

check that the drain hose is in its correct position,

and then use a filter wrench and tighten to the

specified torque.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

3. Use a clip to fix the drain hose at the base of the

fuel filter, and fit the water-in-fuel switch harness.

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6C-14 FUEL SYSTEM (4JJ1)

Fuel Injector

Components

RTW76CLF000101

Legend

1. Cylinder Head Cover2. Fuel Injector Clamp

3. Fuel Injector Clamp Bolt

4. Fuel Injector5. Fuel Injection Pipe

6. Fuel Injection Pipe Clip

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FUEL SYSTEM (4JJ1) 6C-15

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 foreignmaterial into the fuel system or fuel injector during the

removal and installation procedure.

Note: To avoid electric shock;

Set the switch to the ‘OFF’ position and disconnect the

negative battery cable before checking or repairing the

fuel injector, wiring or/and connectors.

Removal

1. Remove the cylinder head cover.

Refer to the removal procedure for the cylinder

head cover in this manual.Remove the attachment bolt of the engine oil level

gauge guide tube.

2. Remove the fuel injection pipe and clip.

3. Loosen the fuel injector clamp fixing bolts and

remove the fuel injector.

If the fuel injector is difficult to remove, use the

remover. Use a screwdriver to force the fuel

injector clamp off the fuel injector.

Note: Cover the areas exposed during parts removal to

prevent the entry of foreign material into the fuel

system.4. Mark each fuel injector with the number of 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: Do not tamper with the electromagnetic portion of

the fuel injector. Reduced electromagnetic function will

result in injector failure.

Note: After replacement of the fuel injector, perform the

following procedure.

• All fuel injectors are replaced:

Remove the fuel injector ID code label on thecylinder head cover.

• Any fuel injector(s) is replaced:

Black out the replaced cylinder of the fuel injector

ID code on the fuel injector ID code label with a

marking pen or equivalent.

Installation

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

injector.

Note: Do not reuse the leak off pipe (2) and clips (3).

RTW66CSH000101

Legend

1. Fuel Injector

2. Leak Off Pipe

3. Clip

4. O-ring

5. Gasket

2. Install the fuel injector clamps. Refer to the

illustration.

RTW56CSH000601

Legend

1. Fuel Injector

2. Bolt

3. Fuel Injector Clamp

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6C-16 FUEL SYSTEM (4JJ1)

3. Apply Engine oil to the threads and seating

surfaces of the clamp bolts.

4. Install the fuel injector clamps to the cylinder head.

5. Temporarily tighten the clamp bolts.

6. Apply a thin coat of engine oil to the outer surface

of the fuel injector side sleeve nuts.

7. Temporarily tighten the injector pipe clips (4).

8. Temporarily tighten the sleeve nuts (3).

• Apply engine oil to the threaded portion of

sleeve nuts (3) and the O-ring (2) of the

injector.

• Temporarily tighten manually until the nut does

not turn further.

9. Temporarily tighten the sleeve nuts (5).

• Temporarily tighten manually until the nut does

not turn further.

10. Tighten the injector clamp bolts at the specified

torque.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

11. Tighten the sleeve nuts (5) at the specified torque.

Tightening torque: 29.5 N⋅⋅⋅⋅m (3.0 kg⋅⋅⋅⋅m / 22 lb ft)

12. Tighten the sleeve nuts (3) at the specified torque.

Tightening torque: 29.5 N⋅⋅⋅⋅m (3.0 kg⋅⋅⋅⋅m / 22 lb ft)

13.Tighten the injector pipe clips (4) at the specified

torque.

Tightening torque: 7.8 N⋅⋅⋅⋅m (0.8 kg⋅⋅⋅⋅m / 69 lb in)

RTW86CSH000201

Legend

1. Injector

2. O-ring

3. Sleeve nuts

4. Clip

5. Sleeve nuts

14. Tighten the engine oil level gauge guide tube.

Tightening torque: 25 N⋅⋅⋅⋅

m (2.5 kg⋅⋅⋅⋅

m / 18 lb ft)15. Install the cylinder head cover.

Refer to the install procedure for the cylinder head

cover in this manual.

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FUEL SYSTEM (4JJ1) 6C-17

Record the Fuel Injector ID Code Data fromeach injector housing

1. Remove each fuel injector harness connector.

2. Record all numbers of each cylinder on the

harness connector housing. The correct order for

the fuel injector ID codes of the following

illustration is as follows:

5F 05 00 FB 00 F7 08 F5 19 FF 04 49

RTW76ESH002601

Legend

1. Fuel Injector ID Code

2. Fuel Injector

Programming Fuel Injector ID Codes

1. Install a scan tool.

2. Turn ON the ignition, with the engine OFF.

3. Select Diagnostics > appropriate vehicle

identification > 4JJ1 > Programming > Injector ID

Code.

4. In order to get programming approval, the on-

screen displays a message to user. Get

programming approval from the TIS 2000 using

the following procedure:

a. Connect a scan tool to the terminal that

installed TIS 2000 with the latest software and

the hardware key is plugged into port.

b. Turn ON the scan tool and keep at title screen.

c. Launch the TIS application.

d. Select the Security Access at the main screen.

e. Highlight the «Tech2» on the Diagnostic Tool

Selection screen and click «Next».

f. Click «Close» on the Security Access Enabled

screen.

g. Turn OFF the scan tool.

h. Disconnect the scan tool from the terminal.

5. Reinstall a scan tool to the vehicle.

6. Turn ON the ignition, with the engine OFF.

7. Select Diagnostics > appropriate vehicle

identification > 4JJ1 > Programming > Injector ID

Code.

8. Enter 24 figures of replaced fuel injector ID code.

9. After complete the programming, turn OFF the

ignition for 30 seconds.

10.Start the engine and let idle.

11.Inspect for a proper engine running condition and

for no DTC’s. Refer to the Diagnostic System

Check — Engine Controls if needed.

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6C-18 FUEL SYSTEM (4JJ1)

Torque Specifications

RTW86CLF000101

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FUEL SYSTEM (4JJ1) 6C-19

Fuel Rail Pressure Sensor

Removal

1. Disconnect the fuel pressure sensor harness

connector (1).

LNW76CSH001601

2. Remove the fuel pressure sensor (2).

Note: Cover the areas exposed during parts removal to

prevent the entry of foreign material into the fuel

system.

RTW76CSH000101

Legend

1. Fuel Rail

2. Fuel Rail Pressure Sensor

3. Fuel Pressure Limiter

Installation

1. Install the fuel pressure sensor.

Tightening torque: 98 N·m (10.0 kg·m / 72 lb ft)2. Connect the fuel pressure sensor connector.

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6C-20 FUEL SYSTEM (4JJ1)

Fuel Pressure Limiter

Removal

1. Remove the leak off pipe and hose (1).

Note: Cover the areas exposed during parts removal toprevent the entry of foreign material into the fuel

system.

RTW76CSH000301

2. Remove the fuel pressure limiter.

Note: Cover the areas exposed during part removal to

prevent the entry of foreign material into the fuel

system.

RTW76CSH000101

Legend

1. Fuel Rail

2. Fuel Rail Pressure Sensor

3. Fuel Pressure Limiter

Installation

1. Install the fuel pressure limiter.

Tightening torque: 172 N·m (17.5 kg·m / 127 lb ft)

2. Install the fuel leak off pipe and hose using the

mounting eyebolt using the specified torque.

Tightening torque: 10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)

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FUEL SYSTEM (4JJ1) 6C-21

Fuel Rail Assembly

Components

RTW76CLF000301

Legend

1. Injection Pipe (No.1 to No.4)2. Fuel Feed Pipe Assembly

3. Injection Pipe Clips

4. Fuel Rail5. Fuel Rail Bracket

6. Fuel Leak Off Pipe and Hose

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.

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6C-22 FUEL SYSTEM (4JJ1)

Removal

1. Remove the starter motor.

• Refer to the removal procedure for engine

electrical in this manual.

2. Remove the fuel feed pipe (1) for supply pump.

Note: Cover the areas exposed during parts removal to

prevent the entry of foreign material into the fuel

system.

RTW76CSH000501

3. Remove the fuel hose (1).

Note: Cover the areas exposed during parts removal to

prevent the entry of foreign material into the fuel

system.

RTW76CSH000601

4. Remove the leak off pipe and hose (1).

Note: Cover the areas exposed during parts removal to

prevent the entry of foreign material into the fuel

system.

RTW76CSH000301

5. Disconnect the fuel rail pressure sensor harness

connector (1).

LNW76CSH001601

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FUEL SYSTEM (4JJ1) 6C-23

6. Disconnect the injection pipe sleeve nut (1).

Note: Cover the areas exposed during parts removal to

prevent the entry of foreign material into the fuel

system.

RTW76CSH000701

7. Disconnect the vacuum pipe and swirl control

solenoid valve from the fuel rail bracket.

8. Remove the fuel rail and fuel rail bracket.

Note:

• Do not grasp the pressure sensor, during the

fuel rail removal procedure.

• Take care not to damage the connector unit of

the pressure sensor.

RTW76CSH000801

Legend1. Fuel Rail

2. Fuel Rail Bracket

3. Vacuum Pipe

4. Swirl Control Solenoid Valve

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6C-24 FUEL SYSTEM (4JJ1)

Disassembly

1. Remove the fuel pressure limiter.

2. Remove the pressure sensor.

RTW76CSH000101

Legend

1. Fuel Rail

2. Fuel Rail Pressure Sensor

3. Fuel Pressure Limiter

Reassembly

1. Install the fuel pressure limiter.

Tightening torque: 172 N⋅⋅⋅⋅m (17.5 kg⋅⋅⋅⋅m / 127 lb ft)

2. Install the fuel pressure sensor.

Tightening torque: 98 N⋅⋅⋅⋅m (10.0 kg⋅⋅⋅⋅m / 72 lb ft)

Installation

1. Tighten the fuel rail bracket and fuel rail using the

specified torque.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

2. Tighten the vacuum pipe to the fuel rail bracket

using the specified torque.

Tightening torque: 10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)

3. Tighten the swirl control solenoid valve to the fuel

rail bracket using the specified torque.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

Note:

• Do not grasp the pressure sensor, during the

fuel rail removal procedure.

• Take care not to damage the connector unit of

the pressure sensor.

RTW76CSH000801

Legend

1. Fuel Rail

2. Fuel Rail Bracket

3. Vacuum Pipe

4. Swirl Control Solenoid Valve

4. Tighten the fuel pipe using the mounting sleeve

nut and the specified torque.

Tightening torque: 29.5 N⋅⋅⋅⋅m (3.0 kg⋅⋅⋅⋅m / 22 lb ft)

5. Connect the fuel rail pressure sensor harness

connector.

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FUEL SYSTEM (4JJ1) 6C-25

6. Tighten the fuel leak off pipe and hose (1) using

the mounting eyebolt using the specified torque.

Tightening torque: 20.1 N⋅⋅⋅⋅m (2.0 kg⋅⋅⋅⋅m / 14 lb ft)

RTW76CSH000401

7. Install the fuel hose (1).

RTW76CSH000601

8. Install the fuel feed pipe (1) for supply pump and

tighten the bolts to the specified torque.

Tightening torque: 44.1 N⋅⋅⋅⋅m (4.5 kg⋅⋅⋅⋅m / 33 lb ft)

RTW76CSH000501

9. Install the starter motor.

• Refer to removal procedure for engine

electrical in this manual.

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6C-26 FUEL SYSTEM (4JJ1)

Torque Specifications

RTW86CLF000201

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FUEL SYSTEM (4JJ1) 6C-27

Fuel Supply Pump

Components

RTWB6CLF000101

Legend

1. Fuel Feed Pipe Assembly

2. Injection Pipe Sleeve Nuts

3. Fuel Supply Pump

4. Timing Chain Cover Lower

5. Nut

6. Sprocket

7. Fuel Supply Pump Gear

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.

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6C-28 FUEL SYSTEM (4JJ1)

Removal

1. Partially drain the engine coolant.

Refer to drain procedure for engine cooling in this

manual.

2. Remove the radiator upper hose.

RTW56FSH000101

3. Remove the fan guide.

RTW46BSH000101

Legend

1. Upper Fan Guide

2. Clips

3. Lower Fan Guide

4. Fan Shroud

4. Remove the cooling Fan.

RTW56ASH025401

5. Remove the A/C compressor drive belt.

6. Remove the A/C compressor adjust pulley.

RTW56ASH010601

Legend

1. Bolt

2. Nut

7. Remove the battery.

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6C-30 FUEL SYSTEM (4JJ1)

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

RTW76ASH001301

Legend

1. TDC

RTW56ASH006901

Legend

1. Align mark on intake camshaft and exhaust

camshaft to mark of bearing cap

15. Loosen the nut (1).

RTW56CSH001601

16. Remove the timing chain tensioner.

RTW56CSH003701

Legend

1. Timing Chain Tensioner.

2. Gasket

3. Nuts

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FUEL SYSTEM (4JJ1) 6C-31

17. Remove the timing chain tension lever pivot.

18. Remove the nut and sprocket.

RTW56CSH004101

Legend

1. Tension Lever Pivot

2. Sprocket

3. Nut

19. Timing chain in moved upwards.

RTW56CSH003301

20. Paint the alignment mark.

Between idle gear A and supply pump gear.

RTW56AMH000401

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FUEL SYSTEM (4JJ1) 6C-33

Installation

1. Install the O-ring to the fuel supply pump.

2. Install the fuel supply pump (1).

Apply soapy water to the O-ring before attaching.

Note: Take care not to twist the O-ring.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

RTWB6CSH000101

3. Confirm that the supply pump camshaft key is

turned to the right and is horizontal.

RTW56CSH004301

4. Install the fuel supply pump gear to the pump

shaft.

a. Align the fuel pump gear timing mark (1) with

the idle gear A paint marks (2).

b. Ensure that the pump gear is bitten with main

gear (3) of the idle gear A. Depress the pump

gear when it is bitten with scissors gear (4) of

the idle gear A.

RTW56CSH005101

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6C-34 FUEL SYSTEM (4JJ1)

5. Install the timing chain to the each sprocket and

install the fuel supply pump sprocket to the pump

shaft.

a. Align the camshaft sprocket timing mark (1)

with the dark plate timing chain link (2).

b. Align the fuel supply pump sprocket timing

mark (3) with the yellow plate timing chain link

(4).

c. Install the fuel supply pump sprocket to the fuel

pump shaft by aligning the dowel pin that is

attached to the gear.

d. Hand-tighten the fuel supply pump shaft nut.

RTW56CSH005001

6. Install the timing chain tension lever pivot. Hand-

tighten the pivot bolt.

• Confirm the tension lever moves smoothly.

RTW56ASH019401

7. Attach the hook of the timing chain tensioner.

• Hold the latch (3) depressed. Insert the plunger

(2). Attach the hook (5) to the pin (1) to hold the

plunger in place.

RTW56CSH004401

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FUEL SYSTEM (4JJ1) 6C-35

8. Install the timing chain tensioner.

Tighten the nut to the specified torque.

Tightening torque: 10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)

RTW56CSH001701

Legend

1. Timing Chain Tensioner

2. Gasket

3. Nuts

9. Unlock the tensioner hook.

• Press the place of the arrow in the figure.

• The hook is opened. The plunger pushes the

tension lever.

RTW56ASH020401

10. Tighten the fuel supply pump shaft nut.

Tighten the nut (1) to the specified torque.

Tightening torque: 130 N⋅⋅⋅⋅m (13.3 kg⋅⋅⋅⋅m / 96 lb ft)

RTW56CSH001601

11. Tighten the timing chain tension lever pivot bolt to

the specified torque.

Tightening torque: 27 N⋅⋅⋅⋅m (2.8 kg⋅⋅⋅⋅m / 20 lb ft)

12. Turn the crank pulley two rotations (720°CA).

13. Check mark (1) on intake camshaft and exhaust

camshaft to mark of camshaft bearing cap.

RTW56ASH006901

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6C-36 FUEL SYSTEM (4JJ1)

14. Install the cylinder head cover.

Refer to «Cylinder Head Cover» in ENGINE

MECHANICAL section.

15. Apply liquid gasket (ThreeBond TB-1207C or

equivalent) to timing chain cover upper (1).

• Attach cover within 5minutes after the

application of gasket.

LNW71BSH013801

Legend

1. Liquid Gasket

2. 2.0 – 2.5 mm (0.079 – 0.098 in)

3. 2.0 – 2.5 mm (0.079 – 0.098 in)

16. Install the timing chain cover upper (1).Tighten the bolt to the specified torque.

• Apply Loctite No262 or equivalent to the bolt

and stud threads of cylinder head side (2).

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

RTW76CSH001201

17. Apply liquid gasket (ThreeBond TB-1207C or

equivalent) to the timing chain cover lower (1).

• Attach the cover within 5 minutes of applying

the liquid gasket.

RTWB6ASH000401

Legend

1. Liquid Gasket

2. 2.0 – 2.5 mm (0.079 – 0.098 in)

3. 2.0 – 2.5 mm (0.079 – 0.098 in)

18. Install the timing chain cover lower.

Tighten the nuts and bolts to the specified torque.

Tightening torque: 10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)

19. Connect the connectors.

• Supply pump.

• Camshaft position sensor.

20. Install the fuel rail assembly.

• Refer to the Install procedure for «Fuel rail

assembly» in this manual.

21. Install the A/C compressor bracket.

Tighten the bolts to the specified torque.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)

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FUEL SYSTEM (4JJ1) 6C-37

22. Install the A/C compressor.

RTW56ASH004201

Legend

1. A/C Compressor Bracket

2. Intake Duct

3. A/C Compressor

Tighten the bolts to the specified torque.

Tightening torque: 44 N⋅⋅⋅⋅m (4.5 kg⋅⋅⋅⋅m / 33 lb ft)

23. Install the battery.

24. Install the A/C compressor adjust pulley.

RTW56ASH010601

Legend

1. Bolt

2. Nut

Tighten the nut and bolt 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)

25. Install the A/C compressor drive belt.

Refer to the drive belt tension check procedure forHeating and air conditioning in this manual.

26. Install the cooling fan.

27. Install the fan guide.

28. Install the radiator upper hose.

29. Replenish the engine coolant.

Fuel Supply Pump Relearn Procedure

The ECM goes through a fuel supply pump learn

procedure to fine tune the current supplied to the fuel

rail pressure (FRP) regulator. This learning process in

only performed when the engine is idling.

1. Install the scan tool.

2. Turn ON the ignition, with the engine OFF.

3. Command the Fuel Supply Pump Learn Resetting

with the scan tool.

4. Observe the Fuel Supply Pump Status parameter

with the scan tool. Confirm the scan tool indicates

Not Learned.

5. Start the engine and let idle until engine coolant

temperature (ECT) reads 149°F (65°C) or higher

while observing Fuel Supply Pump Status

parameter with the scan tool. The scan tool

changes status Not Learned > Learned.

6. If the ECM has correctly learned the fuel supply

pump current adjustment, the Fuel Supply Pump

Status parameter on the scan tool will indicate

Learned.

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6C-38 FUEL SYSTEM (4JJ1)

Torque Specifications

RTWB6CLF000201

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FUEL SYSTEM (4JJ1) 6C-39

Fuel Rail Pressure (FRP) Regulator/Suction Control Valve (SCV)

Components

RTWB6CMF000101

Legend

1. Fuel Supply Pump

2. O-ring

3. Fuel Rail Pressure (FRP)

Regulator/SuctionControl Valve (SCV)

4. 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.

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6C-40 FUEL SYSTEM (4JJ1)

Removal

1. Remove engine harness that clip around the

supply pump.

2. Disconnect the connector of fuel rail pressure

(FRP) regulator/suction control valve (SCV).

Note: Be careful not to do damage to connector by

excessive force.

RTW56ESH002901

Legend

1. Fuel Temperature (FT) Sensor

2. Fuel Rail Pressure (FRP) Regulator/Suction

Control Valve (SCV)

3. Remove the fuel hose (1).

Note: Cover the areas exposed during parts removal to

prevent the entry of foreign material into the fuel

system.

RTW76CSH000601

4. Remove the leak off pipe and hose (1).

Note: Cover the areas exposed during parts removal to

prevent the entry of foreign material into the fuel

system.

RTW76CSH000301

5. Remove the fuel rail pressure (FRP)

regulator/suction control valve (SCV).

6. Remove the O-ring(1).

LNW71DSH005001

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FUEL SYSTEM (4JJ1) 6C-41

Installation

1. Install the O-ring(1).

LNW71DSH005001

2. Install the fuel rail pressure (FRP) regulator/suction

control valve (SCV) to the supply pump, and

temporarily tighten two bolts.

Note:

• Be careful so as not to pinch the O-ring during

installation.

• Temporarily tighten by hand until the FRP

regulator adheres the supply pump.

3. Tighten the to fuel rail pressure (FRP)regulator/suction control valve (SCV) the specified

torque.

Tightening torque: 9 N⋅⋅⋅⋅m (0.9 kg⋅⋅⋅⋅m / 78 lb in)

4. Tighten the fuel leak off pipe and hose (1) using

the mounting eyebolt using the specified torque.

Tightening torque: 20.1 N⋅⋅⋅⋅m (2.0 kg⋅⋅⋅⋅m / 14 lb ft)

RTW76CSH000401

5. Install the fuel hose (1).

RTW76CSH000601

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6C-42 FUEL SYSTEM (4JJ1)

6. Connect the connector of fuel rail pressure (FRP)

regulator/suction control valve (SCV).

RTW56ESH002901

Legend

1. Fuel Temperature (FT) Sensor

2. Fuel Rail Pressure (FRP) Regulator/Suction

Control Valve (SCV)

7. Remove engine harness that clip around the

supply pump.

Relearn Procedure

The ECM goes through a fuel supply pump learn

procedure to fine tune the current supplied to the fuelrail pressure (FRP) regulator. This learning process in

only performed when the engine is idling.

1. Install the scan tool.

2. Turn ON the ignition, with the engine OFF.

3. Command the Fuel Supply Pump Learn Resetting

with the scan tool.

4. Observe the Fuel Supply Pump Status parameter

with the scan tool. Confirm the scan tool indicates

Not Learned.

5. Start the engine and let idle until engine coolant

temperature (ECT) reads 149°F (65°C) or higher

while observing Fuel Supply Pump Status

parameter with the scan tool. The scan tool

changes status Not Learned > Learned.

6. If the ECM has correctly learned the fuel supply

pump current adjustment, the Fuel Supply Pump

Status parameter on the scan tool will indicate

Learned.

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FUEL SYSTEM (4JJ1) 6C-43

Fuel Sedimenter Switch

Inspection

1. Check that there is continuity between the switch

connector terminals when the float in the fuel

sedimenter is above the water drain line.

2. Turn on the ignition switch, 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 switch parts and carry out repairs in case of

defective connection between circuits or short circuits.

RTW76CSH001101

Legend

1. Sensor

2. Connector on The Vehicle Side

3. Harness

4. Drain Valve

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6C-44 FUEL SYSTEM (4JJ1)

Fuel Tank and Fuel Cooler

Fuel Tank and Associated Parts

RTW76CLF000701

Legend

1. Bolt; Fuel Tank2. Fuel Tank Band

3. Fuel Tank

4. Fuel Filler Hose and Pipe

5. Fuel Tube/Quick Connector

6. Bracket; Fuel Cooler7. Bolts; Fuel Cooler Bracket

8. Fuel Return Hose

9. Fuel Cooler

10. Bolts; Fuel Cooler

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FUEL SYSTEM (4JJ1) 6C-45

Removal

Note: When repairs to the fuel system have been

completed, start the engine and check the fuel system

for loose connections or leakage. For the fuel system

diagnosis, see Section «Drivability and Emission».

1. Disconnect the battery ground cable.2. Slowly loosen the fuel filler cap.

Note: Be careful that fuel does not spout out because of

change of pressure in the fuel tank.

Note: Cover opening of the filler neck to prevent any

dust entering.

3. Jack up the vehicle.

4. Disconnect the quick connector of the fuel tube at

the fuel cooler way.

5. Remove fuel return hose from the pipe.

6. Remove fixing bolt of the bracket fuel cooler and

remove bracket fuel cooler.

Note: Cover the opening of the pipe to prevent any dust

and fuel leakage.

Note: For remove fuel cooler, Remove bolts of the fuel

cooler and remove fuel cooler.

7. Support underneath of the fuel tank with a lifter.

8. Remove the inner liner of the wheel house at rear

left side.

9. Remove fixing bolt of the filler neck from the body.

10. Disconnect the quick connector of the fuel tube

from the fuel pipe and the evapo tube from evapo joint connector.

Note: Cover the quick connector to prevent any dust

entering and prevent fuel leakage.

Note: Refer to «Fuel Tube/Quick Connector Fittings» in

this section when performing any repairs.

11. Remove fixing bolt of the fuel tank band and

remove the tank band.

12. Disconnect the pump and sender connector on the

fuel pump and remove the harness from the weld

clip on the fuel tank.

13. Lower the fuel tank.

Note: When lowering the fuel tank from the vehicle, do

not scratch the hoses and tubes by contact with other

parts.

Installation

1. Raise the fuel tank.

Note: When raising the fuel tank to the vehicle, do not

scratch the hoses and tubes by contact with other parts.

2. Connect the pump and sender connector to the

fuel pump and install the harness to the weld clip

on the tank.

Note: The connector must be securely connected

against the stopper.

3. Install the tank band and fasten bolt.

Torque: 68 N⋅⋅⋅⋅m (6.9 kg⋅⋅⋅⋅m / 50 lb ft)

Note: The anchor of the tank band must be securely

installed to the guide hole on the frame.

4. Connect the quick connector of the fuel tube to the

fuel pipe and the evapo tube from evapo joint

connector.

Note: Pull off the left checker on the fuel pipe.

Note: Refer to «Fuel Tube/Quick Connector Fittings» in

this section when performing any repairs.

5. Install the filler neck to the body with bolt.

Note: For install the fuel cooler to the bracket with bolt.

Torque: 6.5 N⋅⋅⋅⋅m (0.7 kg⋅⋅⋅⋅m / 61 lb in)

6. Install the bracket to Frame with bolt.

Torque: 48 N⋅⋅⋅⋅m (4.9 kg⋅⋅⋅⋅m / 35 lb ft)

7. Install the fuel return hose at the fuel cooler way.8. Install the quick connector at the fuel cooler way.

9. Install the inner liner of the wheel house at rear left

side.

10. Remove lifter from the fuel tank.

11. Lower the vehicle.

12. Tighten the filler cap until at least three clicks.

13. Connect the battery ground cable.

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6C-46 FUEL SYSTEM (4JJ1)

Fuel Gauge Unit

Fuel Gauge Unit and Associated Parts

RTW56CLF001701

Legend

1. Fuel Tube/Quick Connector2. Fuel Feed Port

3. Retainer Ring (Fuel Gauge Unit Lock)

4. Connector; Fuel Gauge Unit

5. Fuel Return Port6. Fuel Gauge Unit and Sender Assembly

7. Seal; Fuel Gauge Unit

8. Fuel Tank Assembly

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FUEL SYSTEM (4JJ1) 6C-47

Removal

Note: When repairs to the fuel system have been

completed, start the engine and check the fuel system

for loose connections or leakage. For the fuel system

diagnosis, see Section «Drivability and Emission».

1. Remove the fuel tank assembly. Refer to «FuelTank Removal» in this section.

2. Disconnect the quick connector of the fuel tube

from the fuel gauge unit.

140R100035

3. Remove the retainer ring from the fuel tank with

the removal tool 5-8840-2602-0.

4. Slowly remove the fuel gauge unit from the fuel

tank as no bend float arm.

Note: Cover opening for the fuel gauge unit on the fuel

tank to prevent any dust entering.

5. Discard the fuel gauge unit seal because it cannot

be reused.

Installation

1. Clean the seal surface of the fuel tank and the fuel

gauge unit.

Note: If there is dust on the seal surface, it can cause a

fuel leak.

2. Install the new fuel gauge unit seal to the opening

of the fuel tank along the groove.

3. Slowly install the fuel gauge unit into the fuel tank

so there is no bend in the float arm.

4. Set the flange of the fuel gauge unit on the fuel

gauge unit seal as mating convexity of the fuel

gauge unit and reentrant of the fuel tank.

5. Slowly lock the retainer ring to the fuel tank with

the remover tool 5-8840-2602-0.

6. Connect the quick connector of the fuel tube to the

gauge unit.

Note: Pull off the left checker of the fuel pipe.

Note: Refer to «Fuel Tube/Quick Connector Fittings» in

this section when performing any repairs.

7. Check for leak.

Method of leak check.

1. Plug the end of the quick connector and

breather hose (Pull off the breather hose from

fuel tank) and tighten fuel filler cap until at least

one click is heard.

2. Apply soapy water around the fuel gauge unit

seal area.3 Pressure air into the fuel tank from the end of

the breather pipe at 34.3 kPa (0.35 kg / cm2 / 5

psi) over 15 seconds.

4 Verify that no bubbles from around the fuel

gauge unit seal area.

8. Install the fuel tank assembly.

Note: Refer to «Install the fuel tank» in this section.

Special ToolILLUSTRATION

PART NO.

PART NAME

5-8840-2602-0

Remover: fuel pump

retainer ring

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6C-48 FUEL SYSTEM (4JJ1)

Fuel Tube / Quick — Connector Fittings

Precautions

• Do not light a match or create a flame.

• Keep flames away from your work area to prevent

flammable materials from catching fire.

• Disconnect the battery ground cable to prevent

electrical shorts.

• Pre−treat the piping system or associated parts

from thermal damage or from spattering when

welding or similar heat−generating work.

Cautions During Work

Do not expose the assembly to battery electrolyte or do

not wipe the assembly with a cloth used to wipe off spilt

battery electrolyte.Piping that has been splattered with battery electrolyte

or battery electrolyte soaked cloth that was wiped on the

piping cannot be used.

Removal

1. Open the fuel cap to relieve the fuel pressure in

the tank. Use compressed air to remove any dirt

on the fuel quick connect fittings prior to

disconnecting the fittings. When disconnecting the

fuel pipe, cover the area with a cloth to preventfuel from splashing as the fuel pipe may still have

some pressure in it.

140R100002

2. For removal of the quick connector, hold the quick

connector in one hand, and pull out the connector

with the other hand while pressing the square

release button of the connector, as illustrated.

140R100032

Legend

1. O-ring

2. Port

3. Connector

4. Plastic Tube

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FUEL SYSTEM (4JJ1) 6C-49

Note: Do not use tools of any kind. Only use bare hands

when disconnecting the connector. Use a lubricant (light

oil) and/or push and pull the connector until the pipe is

disconnected.

140R100037

Cover the connectors that were removed with a plastic

bag, to prevent dust or rain water from entering.

140R100028

Reuse of Quick-Connector

• Replace the port and connector if a scratch, dent

or crack is found.

• Remove any dirt build up on the port when

installing the connector. Replace the connector, if

there is any rust, dents or scratches.

• After cleaning the port, insert it straight into the

connector until it clicks. After it clicks, try pulling it

out at 49 N (5 kg / 11 lb) to make sure that it is not

drawn and is securely locked.

140R100036

Assembling AdviceBy applying engine oil or light oil to the pipe, port makes

pipe assembly easier. The pipe assembly should take

place immediately after applying oil (to prevent dust

from sticking to the pipe surface — which may decrease

sealing ability).

Test/Inspection After Assembling

1. Reconnect the battery negative cable.

2. Start the engine and observe the engine idle

speed. The presence of dirt in the fuel system may

affect the fuel injection system.

3. Check for fuel leakage from the connector.

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6C-50 FUEL SYSTEM (4JJ1)

Filler Neck

Removal

1. Remove the fuel tank.

Note: Refer to «Fuel Tank» in this section.2. Put a marking on the following points as the filler

neck assembly is restored.

• Each joint area of the hose (to restore axial

direction and insertion length of the hose)

• Each fasten area of the clamp (to restore axial

direction and position of the clamp)

• Each bolt in the clamp (to restore fasten length

of bolt in the clamp)

• The band clip (to restore position and fasten

length of the band clip)

Note: Cover end of each hose and pipe to prevent anydust entering.

Installation

1. Align each marking and restore the following point.

• Each joint area of the hose (Restore axial

direction and insertion length of the hose)

• Each fasten area of the clamp (Restore axial

direction and position of the clamp)

Tightening torque: 2.5 N·m (0.25 kg⋅⋅⋅⋅m / 21.7 lb in)

Filler neck side except flat deck model.

• Each bolt in the clamp (Restore fasten length of

bolt in the clamp)

Tightening torque: 2.5 N·m (0.25 kg⋅⋅⋅⋅m / 21.7 lb in)

Filler neck side except flat deck model.

• The band clip (Restore position and fasten

length of the band clip)

2. Install the fuel tank.

Note: Refer to «Fuel Tank» in this section.

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FUEL SYSTEM (4JJ1) 6C-51

Fuel Filler Cap

General Description

A vacuum valve and pressure valve are built into the

fuel filler cap which adjusts the fuel pressure in the fuel

tank to prevent fuel tank damage.

RTW56CSH004601

Legend

1. Seal Ring

Inspection

The fuel filler cap must be inspected for seal condition.The fuel filler cap must be replaced if found defective.

Note: A replacement fuel filler cap must be the same as

the original. The fuel filler cap valve was designed

primarily for this application and must be replaced with

the same type or decreased engine performance may

occur.

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MEMO

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ENGINE ELECTRICAL (4JJ1) 6D-1

SECTION 6D

ENGINE ELECTRICAL (4JJ1)

TABLE OF CONTENTS

Charging System………………………………………… 6D-2

Servicing Cautions …………………………………… 6D-2

Important Generator Components and

Function…………………………………………………. 6D-2

Troubleshooting ………………………………………. 6D-5

Diagnosis………………………………………………… 6D-7

Specifications ………………………………………….. 6D-8

Unit Servicing …………………………………………….. 6D-9

Disassembly……………………………………………. 6D-10Inspection and Repair ………………………………. 6D-11

Rotor Assembly ……………………………………. 6D-11

Stator Coil……………………………………………. 6D-12

Brushes ………………………………………………. 6D-12

Rectifier ………………………………………………. 6D-13

Regulator Assembly………………………………. 6D-13

Measuring Procedure ……………………………. 6D-13

Reassembly…………………………………………….. 6D-14

Final Assembly………………………………………… 6D-14

Starter Motor ……………………………………………… 6D-15

Starting Circuit Diagram ……………………………. 6D-15

Removal and Installation…………………………… 6D-15

Important Operations – Removal…………….. 6D-15

Important Operations – Installation………….. 6D-15

Disassembly……………………………………………. 6D-16

Disassembly Steps ……………………………….. 6D-16

Important Operations…………………………….. 6D-17

Inspection and Repair ………………………………. 6D-20

Armature ……………………………………………… 6D-20

Yoke……………………………………………………. 6D-21

Brush and Brush Holder ………………………… 6D-22

Overrunning Clutch……………………………….. 6D-22

Bearing ……………………………………………….. 6D-23

Reassembly…………………………………………….. 6D-24

Reassembly Steps………………………………… 6D-24

Important Operations…………………………….. 6D-25

Inspection After Assembly……………………… 6D-26

Magnetic Switch ………………………………………. 6D-27

Torque Specifications……………………………….. 6D-28

Pre-Heating System ……………………………………. 6D-29

Inspection and Repair ………………………………. 6D-29

Visual Check………………………………………… 6D-29

Glow Relay ………………………………………….. 6D-29

Glow Plug ……………………………………………. 6D-29

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6D-2 ENGINE ELECTRICAL (4JJ1)

Charging System

Servicing Cautions

• Battery polarity is important. If the battery cables

are reversed, the generator diodes will be

destroyed.

• Do not remove the battery cables or the charging

circuit wiring when the engine is running.

• Confirm that the terminal wires are connected to

the proper terminals by checking the terminal

numbers (the number on the terminal wire and the

terminal must be the same).

• Disconnect the battery negative cable (-) before

inspecting the generator.

• Do not open or close the battery relay switch when

the engine is running.

• Disconnect the battery negative cable (-) when

using external equipment (Quick-Charge) to

charge the battery.

• When steam cleaning or washing the engine, do

not allow steam or water to come in direct contact

with the battery and other electrical system

components.

• Be sure to read the item on belt tension

adjustment before beginning the procedure.

Important Generator Componentsand Function

• The generator uses a built-in solid-state IC voltage

regulator. The regulator and other important

components together with their connections are

shown in the illustration.

• The voltage regulator is installed to the rear cover

assembly of the generator together with the brush

holder and the rectifier. The generator requires no

additional voltage regulation.

• 8 diodes are connected to the stator coil to convert

AC to DC. The DC voltage is delivered to the

generator output terminal.

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ENGINE ELECTRICAL (4JJ1) 6D-3

AC Generator

RTW76DMF000101

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6D-4 ENGINE ELECTRICAL (4JJ1)

Charging System

RTW56DMF000101

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ENGINE ELECTRICAL (4JJ1) 6D-5

Troubleshooting

Symptoms

• No charging

• Inadequate charging

• Excessive charging• Unstable charging current

• Abnormal generator noise

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6D-6 ENGINE ELECTRICAL (4JJ1)

No charging

Possible problem Countermeasure

Dead battery Replace

Open or shorted wiring

Open or shorted ammeter

Loose wiring connections

Repair

One or more generator coils open or shorted

Bad diode

Bad regulator

Replace

Loose regulator connections Repair

Inadequate charging

Possible problem Countermeasure

Dead battery Replace

Open or shorted wiring

Loose wiring connectionsRepair

Loose generator drive belt Adjust belt tensionStator coil intermittent short

Bad diodeReplace

Loose battery connections Repair

Bad regulator Replace

Loose regulator connections Repair

Excessive charging

Possible problem Countermeasure

Bad regulator Replace

Unstable charging currentPossible problem Countermeasure

Open wiring connection or broken wire Repair

Loose generator drive belt 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

Loose generator drive belt Adjust belt tension

Bad bearing Replace

Loose rotor core or stator core Repair

Bad diode Replace

Open or shorted stator coil Replace

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ENGINE ELECTRICAL (4JJ1) 6D-7

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 the belt (broken or loose).

2. Check the harness connectors (loose or

disconnected).

3. With the engine off, turn the ignition switch to the

ON position. If the warning lamp does not light,

remove the harness connector from the generator.

Ground the connector IG terminal. The lamp

should light. If it does not, the bulb is burned out.

Replace the bulb.

4. Start the engine. If the warning lamp remains on,

the generator must be repaired or replaced.

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6D-8 ENGINE ELECTRICAL (4JJ1)

Specifications

Battery power Volts 12

Generator output Amperes 110

Rotational direction (Viewed from pulley) Clockwise

Rated speed 5,000

Maximum speed rpm 18,000

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ENGINE ELECTRICAL (4JJ1) 6D-9

Unit Servicing

RTW56DLF000101

Legend

1. Pulley Nut

2. Pulley

3. Front Cover Assembly4. Rotor Assembly

5. Stator

6. Through Bolts

7. Nuts

8. Terminal Insulation Plate

9. Rear Cover Assembly10. Rectifier

11. Brush Holder

12. Regulator Assembly

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6D-10 ENGINE ELECTRICAL (4JJ1)

Disassembly

1. Remove the through bolts.

2. Insert a flat-blade screwdriver between the front

cover and the stator. Pry the parts apart.

3. Separate the front cover/rotor assembly from the

rear cover/stator assembly.

RTW56DSH000301

4. Place the front cover and rotor in a vise.

5. Remove the pulley nut and the pulley.

6. Remove the rotor from the front cover.

RTW56DSH000501

7. Remove the screw from the front cover.

8. Remove the bearing retainer and the bearing.

RTW56DSH000601

9. Remove the B-terminal nut.

10. Remove the rectifier and the brush holder.

11.Remove the rear cover from the stator.

RTW56DSH000401

12.Remove the bolts securing the stator terminal to

the rectifier.

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ENGINE ELECTRICAL (4JJ1) 6D-11

13.Remove the stator.

066RS030

14.Remove the bolts securing the regulator, the

rectifier, and the brush holder. Separate the parts.

066RW025

Inspection and Repair

Repair or replace any parts found to be excessively

worn or damaged during the inspection procedure.

Rotor Assembly

1. Check for dirty or rough slip ring surfaces. 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. Replace the slip

ring if the diameter is less than the specified limit.

Slip ring diameter mm (in)

Standard 27 (1.063)

Limit 26 (1.024)

066RS032

3. Measure the electrical resistance between the slip

rings. If the resistance is greater than the specified

limit (open circuit), repair is required.

Slip ring resistance Ω

Less than 3.75

066RS033

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6D-12 ENGINE ELECTRICAL (4JJ1)

4. Check for conductivity between the slip rings and

the rotor core. If there is continuity, the rotor

assembly must be replaced.

066RS017

Stator Coil

1. Measure the stator coil resistance. If the

resistance is less than the specified value, the

stator coil must be replaced.

Stator coil resistance

0.07Ω at 20°C (68°F)

066RS034

2. Measure the resistance between the stator coil

and the stator core. If the resistance is less than

the specified value, the stator coil must be

replaced.

Stator coil/core resistance MΩ

1

066RS035

Brushes

Measure the brush height. If the height is less than the

specified limit, the brushes must be replaced.

Brush height mm (in)

Standard 18 (0.709)

Limit 5.5 (0.217)

066RW024

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ENGINE ELECTRICAL (4JJ1) 6D-13

Rectifier

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.

066RS036

Regulator Assembly

There are 3 checkpoints (12V batteries, 10 ohms 3W

resistor, 0-50V/0.5V steps, and 300 ohms 12W variable

resistor). Refer to the schematic below.

Measuring Procedure

1. Measure the voltage (BAT) at the V1 checkpoint. A

10-13 volt reading indicates that the BAT battery is

good.

2. Measure the voltage at checkpoints V1 and V2 as

you gradually increase the resistance of the

variable resistor from 0. The voltage at V1 should

change with the voltage at V2. If it does not, the

regulator is damaged and must be replaced.

3. Measure the voltage at checkpoint V3 with the

variable resistor setting fixed. If the measuredvoltage is 14.4 ± 0.3, the regulator is good. If the

measured voltage is outside this range, the

regulator is damaged and must be replaced.

RTW56DMF000301

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ENGINE ELECTRICAL (4JJ1) 6D-15

Starter Motor

Starting Circuit Diagram

RTW46DSH005501

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 the battery cable and the ground cable

at the battery terminals.

2. Remove the A/T oil level gage.

3. Remove the Engine oil level gage.

4. Disconnect the magnetic switch cable at the

terminal bolts.

5. Disconnect the battery cable at the starter motor

and the ground cable at the cylinder body.

6. Remove the starter motor from the 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 the starter motor to the rear plate.

2. Tighten the starter motor bolts to the specified

torque.

Starter Motor Bolt Torque N⋅m (kg⋅m/lb ft)

85 (8.7 / 63)

3. Install the Engine oil level gage.

4. Install the A/T oil level gage.

5. Reconnect the battery cable at the starter motorand the ground cable at the cylinder body.

6. Reconnect the battery cable and the ground cable

at the battery terminals.

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6D-16 ENGINE ELECTRICAL (4JJ1)

Disassembly

RTW460LF000201

Disassembly Steps

1. Lead Wire

2. Bolts

3. Magnetic Switch Assembly

4. Torsion Spring

5. Plunger

6. Dust Cover

7. Magnetic Switch

8. Screw

9. Through Bolts

10. Rear Cover

11. Motor Assembly

12. Brush Holder

13. Yoke

14. Armature

15. Bolt

16. Bearing Retainer

17. Pinion Assembly

18. Pinion Stopper Clip

19. Pinion Stopper

20. Return Spring

21. Pinion Shaft

22. Clutch

23. Dust Cover

24. Shift Lever

25. Gearcase

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ENGINE ELECTRICAL (4JJ1) 6D-17

Important Operations

1. Lead Wire

Disconnect the lead wire at the magnetic switch.

RTW46DSH002601

2. Magnetic Switch Assembly

Remove the magnetic switch bolts, then remove

the switch from the shift lever.

RTW46DSH002701

Remove the torsion spring from the magnetic

switch.

RTW46DSH002801

3. Through Bolts

4. Screw

5. Rear Cover

Remove the through bolts, then remove the rear

cover.

RTW46DSH002901

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6D-18 ENGINE ELECTRICAL (4JJ1)

6. Motor Assembly

Remove the four brushes from the brush holders.

RTW46DSH003001

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.

RTW46DSH003101

7. Brush Holder

8. Yoke

9. Armature

Remove the brush holder and pull out the

armature assembly free from the yoke.

RTW46DSH003201

10. Bearing Retainer

11. Pinion Assembly

12. Dust Cover

13. Shift Lever

14. Gearcase

1) Remove the bearing retainer.

2) Remove the pinion from the gear case.

RTW46DSH003301

3) Use a screwdriver to remove the stopper clip.

Then disassemble the pinion assembly.

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ENGINE ELECTRICAL (4JJ1) 6D-19

RTW46DSH003401

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6D-20 ENGINE ELECTRICAL (4JJ1)

Inspection and Repair

Make the necessary adjustments, repairs, and part

replacement if excessive wear or damage is discovered

during inspection.

Armature

1. Measure the commutator run-out.

Replace the commutator if the measured run-out

exceeds the specified limit.

Commutator Run-Out mm (in)

Standard Limit

0.05 (0.002) 0.25 (0.010)

RTW46DSH003501

2. Check the commutator mica segments for

excessive wear.

3. Measure the mica segment depth.

Mica Segment Depth mm (in)

Standard Limit

0.5 — 0.8 (0.020 — 0.030) 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.

RTW56DSH000701

Legend

1. Insulator

2. 0.5 — 0.8 mm (0.020 — 0.030 in)

3. Commutator Segments

4. Correct

5. Incorrect

4. Measure the commutator outside diameter.

Commutator Outside Diameter mm (in)

Standard Limit

36.5 (1.44) 35.5 (1.40)

If the measured outside diameter is less than the

specified limit, the commutator must be replaced.

HCW51ESH000901

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ENGINE ELECTRICAL (4JJ1) 6D-21

5. Use a circuit tester to check the armature for

grounding.

1) Hold one probe of the circuit tester against the

commutator segment.

2) Hold the other circuit tester probe against the

armature core.

If the circuit tester indicates continuity, the

armature is grounded.

The armature must be replaced.

RTW46DSH003601

6. Use the circuit tester to check the armature for

continuity.

1) Hold the circuit tester probes against two

commutator segments.

2) Repair Step 1 at different segments of the

armature core.

There should be continuity between all segments

of the commutator.

If there is not, the armature must be replaced.

RTW46DSH003701

Yoke

1. Use a circuit tester to check the field winding

ground.

1) Hold one circuit tester probe against the field

winding end or brush.

2) Hold the other circuit tester probe against thebare surface of the yoke body.

There should be no continuity. If there is

continuity, the field coil is grounded. The yoke

must be replaced.

RTW46DSH003801

2. Use the circuit tester to check the field winding

continuity.

1) Hold one circuit tester probe against the “M”

terminal lead wire.

2) Hold the other circuit tester probe against the

field winding brush.

There should be continuity.If there is no continuity,

the yoke must be replaced.

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6D-22 ENGINE ELECTRICAL (4JJ1)

RTW46DSH003901

Brush and Brush Holder1. Use a vernier caliper to measure the brush length

(four brushes).

Replace the brushes as a set if one or more of the

brush lengths is less than the specified limit.

Brush Length mm (in)

Standard Limit

15 (0.59) 12 (0.47)

RTW46DSH004001

2. Use a circuit tester to check the brush holder

insulation.

Touch one probe to the holder plate and the other

probe to the positive brush holder.

There should be no continuity.

RTW46DSH004101

3. 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

1. Inspect the overrunning clutch gear teeth for

excessive wear and damage.

Replace the overrunning clutch if necessary.

2. Rotate the pinion clockwise.

It should turn smoothly.

3. Try to rotate the pinion in the opposite direction.

The pinion should lock.

065RY00035

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ENGINE ELECTRICAL (4JJ1) 6D-23

Bearing

Inspect the bearings for excessive wear and damage.

Replace the bearings if necessary.

RTW46DSH004401

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6D-24 ENGINE ELECTRICAL (4JJ1)

Reassembly

RTW46DLF000601

Reassembly Steps

1. Magnetic Switch Assembly

2. Magnetic Switch

3. Dust Cover

4. Plunger

5. Torsion Spring

6. Shift Lever

7. Gearcase

8. Dust Cover

9. Bolts

10. Pinion Assembly

11. Clutch

12. Pinion Shaft

13. Return Spring

14. Pinion Stopper

15. Pinion Stopper Clip

16. Bearing Retainer

17. Bolt

18. Motor Assembly

19. Armature

20. Yoke

21. Brush Holder

22. Rear Cover

23. Screw

24. Through Bolts

25. Lead Wire

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ENGINE ELECTRICAL (4JJ1) 6D-25

Important Operations

1. Magnetic Switch Assembly

1) Attach the torsion spring to the hole in the

magnetic switch as illustrated.

2) Insert the shift lever into the plunger hole of themagnetic switch.

RTW46DSH005601

2. Gear Case

3. Dust Cover

1) Install the magnetic switch assembly in the

gear case.

2) Install the dust cover.

Dust Cover Bolt Torque N⋅m (kg⋅m/lb in)

8 (0.8 / 69)

RTW46DSH005701

4. Pinion Assembly

Apply a coat of grease to the reduction gear and

install the pinion assembly to the armature shaft.

065RY00041

5. Brush Holders

1) Install the brushes into the brush holder with

raising the spring end of the brush spring.

Take care not to damage the commutator face.

2) Install the brush holder with aligning the

peripheries of the yoke and the brush holder.

RTW46DSH004501

6. Through Bolt

Install the through bolts in the rear cover and

tighten them to the specified torque.

Through Bolt Torque N⋅m (kg⋅m/lb in)

8.1 (0.83 / 69.7)

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6D-26 ENGINE ELECTRICAL (4JJ1)

065RY00044

7. Lead Wire

Connect the lead wire in the magnetic switch and

tighten the terminal nut to the specified torque.

Lead Wire Terminal Nut Torque N⋅m (kg⋅m/lb in)

8.6 (0.88 / 74.9)

RTW46DSH002601

Inspection After Assembly

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.

Pinion Shaft Thrust Play (a) mm (in)0.1 – 2.0 (0.004 – 0.079)

MFW81ESH000201

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ENGINE ELECTRICAL (4JJ1) 6D-27

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 quicklyas 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-in Test

Connect the battery negative terminal with the

solenoid switch body and the M terminal. When

current is applied to the S terminal from the batter y

positive terminal, the pinion should flutter.

RTW46DSH004601

2. Hold-in Maintenance Test

Disconnect the lead at the M terminal. The pinion

should continue to flutter.

RTW46DSH005901

3. Return Test

Disconnect the battery positive lead at the S

terminal.

The pinion should return to its home position.

RTW46DSH004701

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6D-28 ENGINE ELECTRICAL (4JJ1)

Torque Specifications

N⋅⋅⋅⋅m (kg⋅⋅⋅⋅m/lb in)

RTW76DLF000101

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ENGINE ELECTRICAL (4JJ1) 6D-29

Pre-Heating System