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WORKSHOP MANUAL

2007MY N-SERIES

ENGINE
4JJ1
SECTION 6

Isuzu Motors Limited Service Marketing Department

ENGINE MECHANICAL (4JJ1)

6A-1

ENGINE
ENGINE MECHANICAL (4JJ1) TABLE OF CONTENTS
ISUZU DIESEL ENGINE (4JJ1) . . . . . . . . . . . . . . 6A-3 Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6A-3 Work procedure . . . . . . . . . . . . . . . . . . . . . . . . . 6A-3 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6A-14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-16 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18 Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-20 Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . 6A-21 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-26 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-27 Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-28 Service Precautions . . . . . . . . . . . . . . . . . . . . . 6A-28 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-28 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31 Torque specifications . . . . . . . . . . . . . . . . . . . . 6A-33 Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . 6A-34 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-34 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-34 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-37 Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . . 6A-38 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-38 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-40 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-40 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-41 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-42 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-45 Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . 6A-46 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-46 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-46 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-48 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-50 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-52 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-53 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-54 Valve Stem Seal and Valve Spring . . . . . . . . . . . 6A-55 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-56 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-57 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-58 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59 Head Disassembly . . . . . . . . . . . . . . . . . . . . . . 6A-64 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-66 Head Reassembly . . . . . . . . . . . . . . . . . . . . . . 6A-70 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-72 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-80 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-80 Piston and Connecting Rod . . . . . . . . . . . . . . . . 6A-82 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-82 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-82 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-83 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-87 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-88 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-90 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-90 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-91 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-91 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-91 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-93 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-93 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-95 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-95 Gear Case Assembly . . . . . . . . . . . . . . . . . . . . . 6A-96 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-96 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-96 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-97 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-98 Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . . 6A-99 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-99 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-99 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-100 Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-102 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-102 Crankshaft Rear Oil Seal . . . . . . . . . . . . . . . . . 6A-103 Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-103 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-103 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-104

6A-2

ENGINE MECHANICAL (4JJ1)

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

ENGINE MECHANICAL (4JJ1)

6A-3

ISUZU DIESEL ENGINE (4JJ1)


Service Precautions
Matters that maintenance require attention in terms of 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 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.

To prevent damage to the engine and ensure reliability of 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.

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.

6A-4

ENGINE MECHANICAL (4JJ1)

How to read the model

LNW71BMF000101

Legend 1. Engine Model (Stamped) 2. Engine Number (Stamped) Explanation of functions and operations

3. Front

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

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

ENGINE MECHANICAL (4JJ1)


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 injection nozzle harness assembly. Remove the leak off hose. Remove the cylinder head cover. Rotate the crankshaft and make the No.1 cylinder compression top dead center (TDC). Check TDC using a mirror etc.
1 2

6A-5

LNW76ASH001101

Legend 1. Crankshaft Damper Pulley 2. Mirror 3. TDC Mark 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 Exhaust valve NOTE: Adjust while cold. 2. Adjustment of valve clearance 0.15 (0.006) 0.15 (0.006)

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.

Loosen each adjusting screw of the rocker arm completely.

469#$)50!%

Legend 1. Screwdriver 2. Ring Spanner 3. Valve Clearance Adjust Nut Wrench Special tool Valve clearance adjust nut wrench: 5-8840-2822-0 Legend 1. Camshaft Assembly (EX) 2. Camshaft Assembly (IN) 3. Intake Rocker Arm 4. Exhaust Rocker Arm Tightening torque: Rocker arm adjustment Screw nut 18 Nm (1.8 kgm/ 13 lb ft) Adjustment table Cylinder No. Valve arrangement No. 1 cylinder Compression TDC No. 4 cylinder Compression TDC IN 1 EX IN 2 EX IN

LNW71BSH001201

3 EX IN

4 EX

If the No.1 cylinder is the compression TDC, adjust a valve clearance with { mark given on the table and if the No. 4 cylinder is the compression TDC, adjust that with mark. Install the cylinder head cover. Refer to Cylinder Head Cover. Install the leak off hose. Install the fuel injector harness assembly.

ENGINE MECHANICAL (4JJ1)


Compression pressure inspection Warm up the engine. Remove a minus terminal of the battery. 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) Install the minus terminal of the battery. Turn on the starter to emit foreign matter within the cylinders. Install an adapter and the gauge of the compression gauge with the special tool.

6A-7

Turn on the starter to inspect compression pressure. Measure each cylinder one by one. NOTE: To keep engine speed at 200 rpm or more, use fully charged batteries. Remove the compression gauge with the special tool. Remove the minus terminal of the batteries. Install the glow plugs. Install the minus terminal of the batteries. 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.

Trouble Shooting

LNW76ASH001201

Compression gauge: 5-8840-2675-0 Gauge adapter: 5-8840-2815-0 Engine does not turn over Condition Condition Starter motor does not rotate Possible Cause Possible Cause Dead or weak battery Incomplete circuit Starter motor brushes stuck, worn, or broken Starter motor internal damage Starter motor not meshed with flywheel Ring gear abrasion Magnetic switch (starter motor) not properly adjusted Correction Charge battery Replace battery Connect Repair Replace brushes Repair motor Replace ring gear Adjust Correction

6A-8

ENGINE MECHANICAL (4JJ1)


Condition Possible Cause Dead or weak battery Insufficient contact pressure between starter motor brushes and commutator Armature (starter motor) stuck Engine internal damage (Seizure) Correction Charge battery Replace battery Adjust pressure

Starter motor pinion meshed with ring gear but does not rotate

Repair armature Repair engine

Engine turns over but does not start Condition Fuel is not delivered to fuel supply pump Possible Cause Air in fuel system Air entering fuel pipe Empty fuel tank Clogged strainer (fuel suction) Clogged fuel pipe Feed pump malfunction Use of wrong fuel for prevailing temperatures Clogged fuel filter Fuel is delivered to fuel supply pump Loose injection pipe connections Loose or connectors broken electrical Correction Bleed air from fuel system Replace pipe and bleed air from fuel system Replenish fuel Clean or replace strainer Clean or replace pipe Replace pump Drain existing fuel and replace with appropriate fuel Replace filter Tighten connections Tighten and/or replace connectors Replace sensor System diagnosis Bleed air from fuel system Repair pump electrical Tighten and/or replace connectors Replace filter System diagnosis

Bad rotational sensor Engine control system malfunction Insufficient or unstable fuel delivery volume Air in fuel system Feed pump malfunction Loose or connectors broken

Clogged fuel filter Engine control system malfunction Excessive black exhaust smoke Condition Bad injection timing Bad fuel injector condition Possible Cause Engine control system malfunction Carbon deposit at nozzle tip Sticking nozzle Engine control system malfunction

Correction System diagnosis Clean fuel injector assembly Replace fuel injector assembly System diagnosis

ENGINE MECHANICAL (4JJ1)


Condition Insufficient compression pressure Possible Cause Excessive valve clearance Sticking valve stem (valve open) Damaged valve spring Valve seat abrasion Compression leakage damaged piston ring Damaged gasket Piston scoring Fuel condition Water in fuel Poor fuel quality Poor engine aspiration Malfunction detected by engine control system EGR valve and/or intake throttle valve malfunction Clogged intake pipes Clogged air cleaner element Defective sensor Engine control system malfunction Intake throttle valve sticking EGR valve sticking Exhaust brake valve sticking Engine control system malfunction Turbocharger malfunction Damaged turbocharger blade Rough turbocharger shaft rotation Oil leakage from oil seal Broken actuator Defective booster sensor Excessive white exhaust smoke Condition Bad injection timing Malfunction detected by engine control system Insufficient compression pressure Possible Cause Engine control system malfunction Defective sensor Control unit malfunction Engine control system malfunction Excessive valve clearance Sticking valve stem (valve open) Damaged valve spring Valve seat abrasion Compression leakage damaged piston ring Damaged gasket Piston scoring Fuel condition Water in fuel due to Correction System diagnosis Replace sensor Replace unit System diagnosis Adjust clearance Repair or replace valve Replace spring Repair valve seat Replace piston ring Replace gasket Replace piston due to Correction Adjust clearance Repair or replace valve Replace spring Repair valve seat Replace piston ring Replace gasket Replace piston

6A-9

Drain existing fuel and replace with new fuel Drain existing fuel and replace with new fuel Clean or replace pipes Clean or replace element Replace sensor System diagnosis Repair or replace valve Repair or replace valve Repair or replace valve System diagnosis Replace turbocharger Replace turbocharger Replace turbocharger Replace turbocharger Replace sensor

Drain existing fuel and replace with new fuel

6A-10

ENGINE MECHANICAL (4JJ1)


Condition Possible Cause Worn or damaged piston ring(s) Defective valve stem oil seal Defective turbocharger oil seal Clogged turbocharger oil return pipe Correction Replace ring(s) Replace oil seal Replace turbocharger Repair pipe

Excessive oil consumption

Engine knocking Condition Bad timing Malfunction detected by engine control system Fuel condition Poor engine aspiration Engine break-down Possible Cause Engine control system malfunction Defective sensor Control unit malfunction Engine control system malfunction Poor quality fuel Clogged intake pipes Engine control system malfunction Foreign material in cylinders Scored pistons and/or bearings Abnormal engine rotation Condition Engine speed cannot be increased Engine speed unstable Possible Cause Defective control unit Engine control system malfunction Defective control unit Engine control system malfunction Clogged fuel filter element Defective fuel injector(s) Water in fuel Air in fuel system Exhaust brake valve sticking Turbocharger malfunction Damaged turbocharger blade Rough turbocharger shaft rotation Broken actuator Defective booster sensor Abnormal battery charging Condition No charging Possible Cause Open or shorted wiring and/or connectors Defective generator Defective battery Correction Repair or replace wiring and/or connectors Repair or replace generator Replace battery Replace unit System diagnosis Replace unit System diagnosis Replace element Replace fuel injector assembly Drain existing fuel and replace with new fuel Bleed air from fuel system Repair or replace valve Replace turbocharger Replace turbocharger Replace turbocharger Replace sensor Correction Correction System diagnosis Replace sensor Replace unit System diagnosis Drain existing fuel and replace with new fuel Clean or replace pipes System diagnosis Engine overhaul Replace pistons and/or bearings

ENGINE MECHANICAL (4JJ1)


Condition Insufficient charging Possible Cause Open or shorted wiring and/or connectors Defective generator Loose generator drive belt Defective battery Excessive charging Shorted wiring Defective generator Defective battery Turbocharger Troubleshooting Condition Engine has less than normal power Possible Cause Air leakage from intake pipe rubber hose Air leakage from intake cover Clogged intercooler cooling section Clogged air cleaner element Intake throttle valve stuck Turbine and (Interference) housing contact Repair Repair Clean Clean or replace Repair or replace Replace Clean or repair Correction Correction

6A-11

Repair or replace wiring and/or connectors Repair or replace generator Adjust belt tension or replace belt Replace battery Repair or replace wiring Repair or replace generator Replace battery

Excessive carbon deposit near turbine exhaust port that interferes with turbine Rough turbine shaft rotation Damaged turbine blade Blue exhaust smoke Oil leakage from turbocharger oil seal Clogged turbocharger oil return pipe Clogged passages Noisy turbocharger operation center housing oil

Repair or replace Repair or replace Repair or replace Repair Repair or replace Change engine oil Repair Repair or replace Replace Repair or replace Change engine oil Repair Repair

Engine oil deterioration Gas leakage from intake or exhaust system Turbine and (Interference) housing contact

Damaged turbine blade Turbine shaft bearing abrasion or scoring Excessive rotating part wear Engine oil deterioration Clogged turbocharger oil feed pipe Low engine oil pressure Main Data and specifications Item Type

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

6A-12

ENGINE MECHANICAL (4JJ1)


Item Engine model 4JJ1 Direct injection type Liner less mm (in) cc (cu.in) MPa (psi)/rpm rpm Intake mm (in) Exhaust 4-95.4 (3.76) 104.9 (4.13) 2999 (183) 17.5 3 (435)/200 700 25 0.15 (0.006) (cold) 0.15 (0.006) (cold) Compressed ignition 1-3-4-2 Pressure delivery type Gear type L (qts) 10 (10.6) Full flow filter (cartridge type) Built-in-type, water cooling Water cooling type Corrugated fin (pressure type) Centrifugal, belt drive type Wax-type units C (F) L (qts) 85 (185) 10 (10.6) (incl. radiator) Fuel supply pump common rail type Electronic control injector 6-hole Into the fuel tank type AC type V-A 24 - 50 , 24 - 80 IC Engage magnet type Reduction type V-kW 24 - 4.0, 24 - 4.5 Glow plug

Combustion chamber type Cylinder liner type Number of cylinders -cylinder bore X strokes Displacement Compression ratio Compression pressure Idling speed Valve clearance Ignition type Injection order Lubricating system Lubricating type Oil pump type Volume of lubricating oil Oil filter type Oil cooling type Cooling system Cooling type Radiator type Water pump type Thermostat type Thermostat valve-opening temperature Volume of coolant Fuel system Injection pump type Injection nozzle type Fuel pump type Charging system Generator type Power output Regulator type Starting system Starter type Power output Preheat system type

ENGINE MECHANICAL (4JJ1)


Item Glow plug standard voltage/electric current Special Tools Illustration Tool Number/ Description V-A Engine model 4JJ1 23 - 3.5

6A-13

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


5884028220

5-8840-2675-0 Compression gauge

#&&" $%#

5-8840-2815-0 Compression gauge adapter


#&&" &#

6A-14

ENGINE MECHANICAL (4JJ1)

Engine Assembly
Removal
NOTE: Instructions for engine removal Be sure to lock the vehicle's wheels in a fixed position. Use an engine hoisting attachment that can adequately sustain the engine's weight. Do not get underneath the engine while the engine is being lifted. Do not insert fingers into any location where they may be caught. 1. 2. 3. 4. Detach the negative cable from the battery. Drain the coolant. Remove the starter. Remove the front exhaust pipe.
2 1

LNW76ASH000201

7. Remove the air intake pipe with the hoses. Disconnect the hose from the intercooler side. Remove the air intake pipe with the hoses from the turbocharger side. Do not disconnect the hoses from the air intake pipe.

LNW76ASH000101

5. Remove the transmission assembly. Refer to Transmission section. 6. Disconnect the air intake hose. Disconnect the PCV hose (1) from the air intake hose (2). Disconnect the air intake hose (2) from the turbocharger side. Do not disconnect the air intake hose from the air cleaner side.

LNW76ASH000301

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

ENGINE MECHANICAL (4JJ1)

6A-15

NOTE: The bracket on the right side of the engine(1) is used as an engine hanger when the engine is lifted.
2 1 3

LNW76ASH000501

10. Disconnect the radiator upper hose. Disconnect the hose from the radiator side. 11. Detach the A/C compressor. Detach the A/C compressor drive belt. Detach the compressor from the A/C compressor bracket. Fix the compressor and hose in an appropriate position with wire etc. 12. Disconnect the engine ground cable from the frame. 13. Disconnect the vacuum hose. Disconnect the hose(1) from the vacuum pump side(2).

LNW76ASH000701

16. Remove the cooling fan assembly. Remove the cooling fan and the fan clutch. 17. Disconnect the power steering pump. Disconnect the power steering pump with its hose attached from the engine side. Fix the pump and hose in an appropriate position with wire etc. 18. Disconnect the heater hose (1) from the heater pipe (2).
1

2
LNW76ASH000601

LNW76ASH000801

14. Disconnect the radiator lower hose. Disconnect the hose from the engine side. 15. Disconnect the fan guide bracket. Remove the bolts(3).

19. Install an engine hanger (1). Special tool Engine Hanger: 5-8840-2823-0 Install the engine hanger to the rear left side of the engine.

6A-16

ENGINE MECHANICAL (4JJ1)


Fit hoist wire to the engine hanger and hoist the engine. Operate the hoist and move the engine into the installation position. 2. Fit the engine mounts. Align the engine mounts to the engine mounting cross member holes, and once fitted , tighten to the specified torque. Tightening torque: Front independent suspension model 122 Nm (12.4 kgm / 90 lb ft) Front rigid suspension model 94 Nm (9.6 kgm / 68 lb ft) 3. Fit the fuel hose.
LNW76ASH000901

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

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

LNW76ASH001001

4. Fit the heater hose to the heater pipe. 5. Fit the power steering pump. Tightening torque: 25 Nm (2.5 kgm / 18 lb ft) 6. Fit the radiator lower hose. 7. Fit the vacuum hose. Connect the hose(1) to the vacuum pump (2).

LNW76ASH001001

22. Engine Assembly Operate the hoist slowly, and raise the engine until it is above and protruding from the chassis frame.

Installation
1. Fit the engine assembly.

ENGINE MECHANICAL (4JJ1)


11. Fit the fan guide.
2 2 1

6A-17

1 3

LNW76ASH000601

8. Attach the engine earth cable to the frame. 9. Fit the A/C compressor. Fit the A/C compressor, and tighten to the specified torque. Tightening torque: 51 Nm (5.2 kgm / 38 lb ft) Attach the drive belt, and adjust the belt's tension with the tension pulley adjustment belt. Refer to "Drive Belt" section in the "Cooling System" chapter for details concerning belt tension adjustment. By hand, press the center part of the belt with a force of 98N (10kg / 142psi), and check with a scale that the degree of deflection is within the specified range. Also, check that the belt is not damaged. A/C Compressor Belt Degree of Deflection: (5.5 - 7.3 mm / 0.2165 - 0.2874 in) (new belt) (7.6 - 9.2 mm / 0.2992 - 0.3622 in) (used belt) After adjusting belt tension, tighten the tension pulley's lock nut. Tightening torque: 25 Nm (2.5 kgm / 18 lb ft) 10. Fit the cooling fan Assembly. Tighten the fan clutch to the fan pulley at the specified torque. Tightening torque: 8 Nm (0.8 kgm / 69 lb in)

LNW76ASH000701

12. Fit the radiator upper hose. 13. Fit the air intake pipe and hose. Fit the pipe and the hose between the intake throttle valve and the intercooler. Connect the boost sensor connector. Use new clips. Tighten the clip according to the marking. Tightening torque: 6 Nm (0.6 kgm / 52 lb in)

LNW76ASH000501

14. Connect the ECM harness connector. 15. Fit the air intake pipe and hose. Fit the pipe and the hose between the turbocharger and the intercooler. Connect the boost sensor connector. Use new clips. Tighten the clip according to the marking. Tightening torque: 6 Nm (0.6 kgm / 52 lb in)

6A-18

ENGINE MECHANICAL (4JJ1)


17. Remove the engine hanger. Remove the engine hanger from the rear left side of the engine. 18. Fit the transmission assembly. Refer to removal procedure for "TRANSMISSION". 19. Install the front exhaust pipe and gaskets. a. Tighten temporarily. b. Tighten turbocharger side. Tightening torque: 67 Nm (6.8 kgm / 48 lb ft) c. Tighten the clamp. Tightening torque: 41 Nm (4.2 kgm / 30 lb ft) d. Tighten DPD side. Tightening torque: 67 Nm (6.8 kgm / 49 lb ft)
LNW76ASH000301

16. Fit the air intake hose (2). Fit the hose between the air cleaner and turbocharger. Fit the PCV hose (1) to the air intake hose.

2 1

LNW76ASH000101

20. Fit the starter. Tightening torque:127 Nm (13.0 kgm / 94 lb ft) 21. Replenish the coolant. 22. Reattach the negative cable to the battery.
LNW76ASH000201

Special Tools
Illustration Tool Number/ Description

5-8840-2823-0 Engine Hanger

5884028230

ENGINE MECHANICAL (4JJ1)

6A-19

Engine Mount
Components

LNW76AMF000101

Legend 1. Engine Mount

Removal
1. Remove the engine assembly. Refer to Engine Assembly. 2. Remove the engine mount. Before removing the engine mount, hang the engine with a hoist. Remove the nuts fastened to the engine foot and engine mount. Remove the nuts fastened to the engine mount on the chassis frame side. Hoist the engine assembly slightly to remove the engine mount.

LNW46ASH002501

6A-20

ENGINE MECHANICAL (4JJ1)

Installation
1. Install the engine mount and tighten up with the specified torque. The nuts on the chassis frame side Tightening torque: Front independent suspension model 122 Nm (12.4 kgm / 90 lb ft) Front rigid suspension model 94 Nm (9.6 kgm / 68 lb ft) The nuts on the engine foot side Tightening torque: 82 Nm (8.4 kgm / 61 lb ft)
LNW76ASH001501

2. Install the engine assembly. Refer to Engine Assembly.

Torque Specifications

51 (5.2/ 38)

40 (4.1 / 30) 94 (9.6/69)

LNW76AMF000201

ENGINE MECHANICAL (4JJ1)

6A-21

Cylinder Head Cover


Components
1 2

4 9 6 5 6

LNW71BLF000401

Legend 1. Oil Filler Cap 2. Oil Filler Cap Gasket 3. Engine Cover 4. Cylinder Head Cover 5. Bolt

6. 7. 8. 9.

Head Cover Mounting Rubber Oil Seal Head Cover Gasket Nut

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

6A-22

ENGINE MECHANICAL (4JJ1)


NOTE: Do not reuse the leak-off hose clips (1).

LNW76ASH002201

2. Remove the fuel injector connector (2) and the leak-off hose(1). 3. Disconnect the blow-by hose. 4. Remove the cylinder head cover.


LNW76ASH002101

469%$)50

LNW71BSH000401

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

ENGINE MECHANICAL (4JJ1)




6A-23

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

 

469#$)50 #

Installation
1. Install the nozzle seal cover. Insert from the lever 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 gasket. Apply the liquid gasket (ThreeBond TB-1207B or equivalent) and mount.
! 12  3 11 10 2 9

469#$)50 %

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. Tighten the bolts and a nut in order shown in the illustration. Tightening torque: 10 Nm (1.0 kgm / 87 lb in)

13

14

1 15

LNW76ASH001701 469#$)50 $

Legend 1. Cam End Gasket 2. Apply The Liquid Gasket 3. 2.0 to 3.0 mm (0.079 to 0.118 in)

4. Install the blow-by hose. 5. Install the leak-off hose and the fuel injector connector. 6. Install the engine cover. Install the oil filler cap after installing the engine cover.

6A-24

ENGINE MECHANICAL (4JJ1)

Intake Manifold
Components

1 2

3 4

LNW71BLF000101

Legend 1. Intake Manifold Gasket 2. Intake Manifold 3. EGR Valve Assembly Gasket

4. EGR Valve Assembly 5. Intake Throttle Assembly Gasket 6. Intake Throttle Assembly

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

ENGINE MECHANICAL (4JJ1)

6A-25

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

LNW76ASH002201

2
LNW71BSH001101

2. Remove the air intake pipe with the hoses. Disconnect the connector from the boost sensor. Disconnect the hose from the intercooler side. Remove the air intake pipe with the hoses from the intake throttle valve. Do not disconnect the hoses from the air intake pipe.

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


1

LNW71DSH000101

LNW76ASH000501

8. Remove the intake manifold and gasket. Remove the intake manifold with the EGR valve and the intake throttle. 9. Remove the EGR valve (2) from the intake manifold (1).

3. Remove the A/C compressor. Remove the A/C belt. Disconnect the A/C compressor connector. 4. Remove the A/C compressor bracket. 5. Remove the engine oil level guide tube.

harness

6A-26

ENGINE MECHANICAL (4JJ1)


6. Install the engine level guide tube. 7. Install the A/C compressor bracket. 8. Install the A/C compressor. Install the A/C belt. 9. Install the intake air pipe and hose. Fit the pipe and the hose between the intake throttle valve and the intercooler. Use new clips. Tighten the clip according to the marking. Tightening torque: 6 Nm (0.6 kgm / 52 lb in)

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

3
LNW71BSH001001

Installation
1. Install the EGR valve to the intake manifold. Tightening torque: 27 Nm (2.8 kgm / 20 lb ft) 2. Install the intake throttle to the intake manifold. Tightening torque: 10 Nm (1.0 kgm / 87 lb in) 3. Install the intake manifold. a. Install the gasket and the intake manifold and tighten temporarily. b. Tighten the bolts and nuts in the order described in the drawing. Tightening torque: 25 Nm (2.5 kgm / 18 lb ft)

LNW76ASH000501

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

3 8

5 1

4 2

6 10

LNW71BSH000901

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

ENGINE MECHANICAL (4JJ1) Torque Specifications

6A-27

25(2.5/18)

27(2.8/20)

27(2.8/20)

25(2.5/18)

25(2.5/18)

10(1.0/87lbin)

LNW76ALF000101

6A-28

ENGINE MECHANICAL (4JJ1)

Turbocharger
Service Precautions
The turbocharger is a high precision component and cannot be disassembled (spins at approx. 100,000 rpm). If any damage whatsoever, such as dents and scratches, is discovered on the turbo charger's fins or housing, the entire turbo charger must be replaced. While carrying out maintenance, take appropriate measures to prevent foreign materials from entering into the turbine housing, compressor housing, or oil inlets/outlets. After servicing the turbocharger, pour clean engine oil (3-5 cc) into the pipe connecting port before installing the oil pipe.

Components

1 2 5

LNW71JLF000101

Legend 1. Turbocharger Assembly 2. Oil Feed Pipe 3. Turbocharger Duct 4. Exhaust Adaptor

5. Water Feed Pipe 6. Water Return Pipe 7. Oil Return Pipe

ENGINE MECHANICAL (4JJ1) Removal


1. Drain the coolant. 2. Remove the front exhaust pipe and exhaust brake. 6. Remove the heat protector (1).
1

6A-29

LNW71JSH000301

LNW76ASH000101

3. Remove the following parts. a. Inlet hose (5) b. PCV hose (2) c. Air duct (1) d. Right side noise cover (6) e. Fan guide bracket (3) f. Water feed pipe and VGS vacuum hose (4)

7. 8. 9. 10.

Remove the oil feed pipe. Remove the water return pipe. Remove the oil return pipe. Remove the turbocharger assembly from the exhaust manifold.

LNW71JSH000101

Inspection
Visual and noise inspection
LNW71BSH000101

4. Remove the AC generator. Disconnect the generator terminals. 5. Remove the exhaust adapter from turbocharger. Remove the adapter's bracket (3). Remove the exhaust adapter (2).

the

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

6A-30

ENGINE MECHANICAL (4JJ1)

Check the compressor cover and turbine housing for scratches and/or cracks caused by contact with the fin. Check the inner surface of the housing for oil leakage. Check the turbine exhaust port for excessive carbon deposits that may interfere with the fin. Turn the turbine shaft by hand and check for dragging or sticking conditions. Move the shaft and check for excessive clearance in axial and radial directions. Axial play on the wheel shaft Use a dial gauge to measure the axial play on the wheel shaft. Alternately, apply a force of approximately 12 N (1.2 kg / 2.6 lb) to the compressor wheel end. Axial Play Standard Limit 0.03 - 0.08 (0.0012-0.0031) 0.09(0.0035) mm (in)

LNW71JSH000501

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

LNW71JSH000401

Clearance between wheel shaft and bearing Use a dial gauge to measure the clearance between wheel shaft and bearing. Clearance Standard Limit 0.08 - 0.1 (0.0031-0.0039) 0.17(0.0067) mm (in) Legend 1. Waste Gate Actuator 2. Waste Gate Hose 3. Pressure Gauge (General Tool)

LNW21BSH022401

3. Use the pressure gauge pump to apply pressure (load) to the waste gate actuator (the engine must be off).

ENGINE MECHANICAL (4JJ1)


4. Note the pressure at which the control rod moves 2 mm (0.078 in). This pressure must be within the specified limit. Control rod pressure range: kPa (mmHg / psi)

6A-31

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

2 1
LNW71JSH000101

2. Install the oil return pipe. Install the O-rings into both sides of the oil return pipe, and tighten the bolt to the specified torque. Tightening torque Turbocharger side: Crank case side: 10 Nm (1.0 kgm / 87 lbin) 25 Nm (2.5 kgm / 18 lbft)

LNW71JSH000201

3. Install the water return pipe. Tighten the water return pipe's eye bolt to the specified torque. Tightening torque: 23 Nm (2.3 kgm / 17 lbft) 4. Install the oil feed pipe. Install the eye bolt to the oil feed pipe on the top of turbocharger, and tighten the bolt to the specified torque. Tightening torque: 39 Nm (4.0 kgm / 29 lbft) 5. Install the exhaust adapter to the turbocharger, and tighten to the specified torque. Tightening torque: 27 Nm (2.8kgm / 20 lbft) 6. Fit the heat protector and tighten with the bolt. Tightening torque: 10 Nm (1.0 kgm / 87 lbin)

2. Operate the vacuum pump and apply vacuum pressure to the actuator. Working vacuum pressure Reference kPa (mmHg / psi)

44 (330 / 6.38)

3. Place a vernier caliper on the end of the control rod of actuator. Release the vacuum pressure and check the control rod moves. Measure the length of the control rod moving. Standard length 7 mm (0.28 in)

Installation
1. Install the turbocharger assembly. Install the gaskets and turbocharger assembly, and tighten to the specified torque. Tightening torque Nut 25 Nm (2.5 kgm / 18 lbft) Bolt 27 Nm (2.8 kgm / 20 lbft)

6A-32

ENGINE MECHANICAL (4JJ1)


c. Tighten the clamp.
1

Tightening torque: 41 Nm (4.2 kgm / 30 lb ft) d. Tighten DPD side.


2

Tightening torque: 67 Nm (6.8 kgm / 49 lb ft) 10. Replenish the coolant.

LNW71JSH000301

Legend 1. Heat Protector; Turbocharger 2. Exhaust Adapter 3. Exhaust Adapter Bracket 7. Install the AC generator. 8. Install the following parts. a. Water feed pipe and VGS vacuum hose (4) b. Fan guide bracket (3) c. Right side noise cover (6) d. Air duct (1) e. PCV hose (2) f. Inlet hose (5)

LNW71BSH000101

9. Install the front exhaust pipe and gaskets. a. Tighten temporarily. b. Tighten turbocharger side. Tightening torque: 67 Nm (6.8 kgm / 48 lb ft)

ENGINE MECHANICAL (4JJ1) Torque specifications

6A-33

10 (1.0/87 lbin)

10 (1.0/87 lbin) 22.5 (2.2/16)

27 (2.8/20) 25 (2.5/1.8)

27 (2.8/20)

25 (2.5/1.8)

10 (1.0/87 lbin) 25 (2.5/1.8)

LNW76ALF001001

6A-34

ENGINE MECHANICAL (4JJ1)

Exhaust Manifold
Components

1 2

3 4 5 6

LNW71BLF000601

Legend 1. EGR Cooler 2. Heat Protector; EGR Cooler 3. Heat Protector; Exhaust Manifold 4. Gasket

5. 6. 7. 8.

Exhaust Manifold Gasket Turbocharger Assembly Gasket

Removal
1. Drain the coolant. 2. Remove the turbocharger assembly. Refer to "Turbocharger".

ENGINE MECHANICAL (4JJ1)


3. Remove the EGR cooler heat protector. Limit 0.5 (0.02)

6A-35

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

LNW71FSH000101

4. Remove the EGR cooler. Disconnect the rubber hoses of the water pipe(IN, OUT) from the EGR cooler. Remove the EGR cooler and the gasket from the exhaust manifold. 5. Remove the exhaust manifold heat protector.

LNW21BSH006601

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.

Installation
1. Install the exhaust manifold. Put the gasket in to install the exhaust manifold. Tighten in order described in the drawing. Tightening torque: 52 Nm (5.3 kgm / 38 lb ft)

7
LNW71BSH000701

6. Remove the exhaust manifold. Remove the exhaust manifold and gasket.

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 Standard mm (in)
LNW71BSH000801

2. Install the exhaust manifold heat protector. 0.3 (0.01) or lower Tightening torque: 25 Nm (2.5 kgm / 18lb ft) 3. Install the EGR cooler.

6A-36

ENGINE MECHANICAL (4JJ1)

a. Put the gasket in to install the EGR cooler. b. Temporary tightening order. 123456 c. Fully tightening order. 345126 Tightening torque Bolt, Nut (1 - 5) : 27 Nm (2.8 kgm / 20 lb ft) Bolt (6) : 52 Nm (5.3 kgm / 38 lb ft)

6 1 2 3 4 5

LNW71FSH000201

4. Connect the rubber hoses to the water pipe(IN, OUT) of the EGR cooler. 5. Install the EGR cooler heat protector. Tightening torque: 25 Nm (2.5 kgm / 18 lb ft) 6. Install the turbocharger. Refer to Turbocharger. 7. Replenish the coolant.

ENGINE MECHANICAL (4JJ1) Torque Specifications

6A-37

52(5.3/38)

27(2.8/20)

27(2.8/20)

25(2.5/18)

25(2.5/18)

52(5.3/38)

LNW76ALF000701

6A-38

ENGINE MECHANICAL (4JJ1)

Timing Gear Train


Components

5 6

8 9

10

11

12 1 13
RTW56ALF001101

Legend 1. Oil Pump Gear 2. Crankshaft Gear 3. Idle Gear D 4. Exhaust Camshaft Gear 5. Intake Camshaft Gear 6. Idle Gear D Sprocket 7. Timing Chain

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

Injection Pump Sprocket Injection Pump Gear Idle Gear A Vacuum Pump Gear Power Steering Oil Pump Gear Idle Gear C

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

ENGINE MECHANICAL (4JJ1)


3. Remove the fan guide bracket.
2 1 3

6A-39

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

LNW76ASH000701

LNW76ASH003201

Legend 1. Fan Guide Bracket(RH) 2. Fan Guide Bracket(LH) 3. Bolt 4. Remove the cooling fan and fan pulley.

10. Remove the gear case cover.

469#$)50'%

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

469#$)50 #"

5. Remove the A/C compressor drive belt and fan belt. 6. Remove the crank pulley. NOTE: Do not reuse the crank pulley bolt and washer. 7. Remove the power steering pump with hose. 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.

6A-40

ENGINE MECHANICAL (4JJ1)


14. Remove the crankshaft gear.

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

469#$)50 # 469#$)50!

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

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

" !


469#$)50"

469#$)50 

Legend 1. Snap Ring 2. Sub-gear 3. Spring 4. Idle Gear A

Reassembly
1. Install the scissor gear assembly.

ENGINE MECHANICAL (4JJ1)


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

6A-41

If the measurement exceeds the limit, replace either the idle gear or the thrust collar. End clearance of the idle gear Standard Limit mm (in) 0.20 (0.008)

0.080 - 0.155 (0.003 - 0.006)

" !

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 Standard Limit 44.80 (1.764) mm (in)

44.950 - 44.975 (1.7697 - 1.7707)

External diameter of the idle gear C shaft


469#$)50 

mm (in)

Standard Limit

24.959 - 24.980 (0.9826 - 0.9835) 24.80 (0.976)

Legend 1. Snap Ring 2. Sub-gear 3. Spring 4. Idle Gear A Use snap ring pliers to snugly install the snap ring.

Inspection
1. 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 Standard Limit mm (in) 0.10 - 0.17 (0.004 - 0.006) 0.30 (0.01)
469#$)50 $

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.

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.

6A-42

ENGINE MECHANICAL (4JJ1)


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

If the measurement exceeds the limit, replace either the idle gear or the shaft. Clearance between the idle gear A and the shaft Standard Limit 0.200 (0.0079) mm (in)

0.025 - 0.075 (0.0010 - 0.0030)

Clearance between the idle gear C and the shaft Standard Limit 0.200 (0.0079)

mm (in)

0.020 - 0.062 (0.0008 - 0.0024)

469#$)50"

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.

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.

469#$)50#

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

ENGINE MECHANICAL (4JJ1)


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.

6A-43

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

3
LNW71BSH000501

RTW56ALH000301

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

6A-44

ENGINE MECHANICAL (4JJ1)

469#$)50%

469#$)50 

Legend 1. Idle Gear A Bolt 2. Idle Gear C Bolt 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).


8. Install the vacuum pump. Tightening torque: 25 Nm (2.5 kgm / 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 nut to the specified torque. Tightening torque: 25 Nm (2.5 kgm / 18 lb ft) 10. Install the cover of the gear case cover 11. Install the crank pulley. Tightening torque: 294 Nm (30 kgm / 217 lb ft) 12. 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. 13. Install the cooling fan. 14. Install the fan guide bracket. 15. Install the radiator upper hose. 16. Replenish the engine coolant.

469#$)50 

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 Nm (0.8 kgm / 69 lb in)

ENGINE MECHANICAL (4JJ1) Torque Specifications

6A-45

130 (13.3 / 96.2)

8 (0.8 / 69lb in)

294 (30 / 217) 32 (3.3 / 24)

59 (6.0 / 43)

LNW76ALF000601

6A-46

ENGINE MECHANICAL (4JJ1)

Camshaft Assembly
Components

7 6

5 4 2 1 3

RTW56ALF000901

Legend 1. Snap Ring 2. Sub Gear 3. Knock Pin 4. Damper Spring

5. Camshaft Gear and Camshaft 6. Cam Cap 7. Bolt

Removal
1. Rotate the crankshaft to make the No.1 cylinder compression TDC. Check TDC using a mirror etc.

ENGINE MECHANICAL (4JJ1)


4. Remove the baffle plate.
1 2 

6A-47

LNW76ASH001101

Legend 1. Crankshaft Damper Pulley 2. Mirror 3. TDC Mark 2. Remove the cylinder head cover. Refer to "Cylinder Head Cover". 3. Install the M5 lock bolt of fixing sub gear.

469#$)50$!

Legend 1. Baffle Plate 5. Remove the camshaft bearing cap and camshaft. Check the engraved making on the camshaft bearing caps.

1E 2E 3E 1I 2I 3I 4I 5I 4E 5E

RTW56ASH018401

469#$)50%

6A-48

ENGINE MECHANICAL (4JJ1)

469#$)50!&

LNW76ASH002501

Disassembly
1. Remove the sub gear assembly. Clamp the camshaft in a vise. Insert soft metal protectors (aluminum) between the vise surfaces and the camshaft. Use a camshaft gear tool (5-8840-2591-0) to turn sub gear to right direction to remove the M5 bolt.

2. Remove the camshaft gear. Use a press and socket to remove the camshaft gear.

2 3

RTW56ASH006501

Legend 1. Press 2. Socket 3. Camshaft Gear 3. Remove the dowel pin. 4. Inspect the camshaft visually.

LNW76ASH002601

Use snap ring pliers to remove the scissor gear assembly. NOTE: Take care not to damage the camshaft cams and journals.

ENGINE MECHANICAL (4JJ1)


Check if the journal and cam parts of the camshaft are worn or damaged, if so, replace it.

6A-49

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 Inlet Standard Limit 40.6 (1.60) 39.6 (1.56) mm (in) Exhaust 40.6 (1.60) 39.6 (1.56)

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 Standard Limit mm (in) 0.25 (0.009)

0.050 - 0.170 (0.002 - 0.007)

LNW21BSH020401

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

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 Standard Limit 29.809 (1.1736) mm (in)

29.909 - 29.930 (1.1775 - 1.1783)

Partial wear of the camshaft journal part Limit

mm (in)

0.05 (0.0019)

RTW56ASH013901

6. Check if the cam lobe is worn.

6A-50

ENGINE MECHANICAL (4JJ1)


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 Standard Limit mm (in) 0.030 - 0.112 (0.0012 - 0.0044 ) 0.15 (0.0059 )

LNW21BSH020501

8. Check if the camshaft is bent. Place the camshaft on a V block to measure a bend with a dial gauge. Rotate the camshaft slowly to measure how much the dial indicator shook. If it exceeds the limit, replace the camshaft. Bent of the camshaft Limit mm (in) 0.05 (0.0019 )
LNW21BSH054601

Reassembly
1. Install the dowel pin. 2. Install the camshaft gear.

LNW21BSH020601

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

ENGINE MECHANICAL (4JJ1)


Align the knock pin with the slot in the camshaft gear. Use a press to install the camshaft gear to the camshaft.

6A-51

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

2 3

469#$)50$$

LNW76ASH002401

Legend 1. Camshaft 2. Dowel Pin 3. Camshaft Gear 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.

Legend 1. Snap Ring 2. Sub Gear 3. Spring 4. Camshaft Gear Use snap ring pliers to snugly install the snap ring.

LNW76ASH002501

4. Tighten sub gear setting bolt. Use a camshaft gear tool (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.

6A-52

ENGINE MECHANICAL (4JJ1)

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

3
RTW56ASH007001

LNW76ASH002601

Installation
1. Rotate the crankshaft to make the No.1 cylinder compression TDC. Check TDC using a mirror etc.

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.

2
1E 2E

3
1I 2I 3I 4I 5I

3E 4E 5E

LNW76ASH001101

Legend 1. Crankshaft Damper Pulley 2. Mirror 3. TDC Mark 2. Install the camshaft assembly. Align timing mark on intake camshaft and exhaust camshaft to idle gear D.

RTW56ASH018401

ENGINE MECHANICAL (4JJ1)


4. Check that the alignment marks (camshaft bearing cap and camshaft) (1) are aligned.

6A-53

Apply engine oil over the screw part and tighten up the bearing cap with the prescribed torque. Tightening torque: 18 Nm (1.8kgm / 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 Nm (1.0 kgm/87 lb in) 8. Install the cylinder head cover. Refer to "Cylinder Head Cover".

469#$)50$'

Torque Specifications
Nm(kgm/lb ft)

18 (1.8/13)

10 (1.0kgm/87lb in)

Lubricate with engine oil

RTW56AMF001701

6A-54

ENGINE MECHANICAL (4JJ1)

Special Tools
Illustration Tool Number/ Description

5-8840-2591-0 Camshaft gear tool

ENGINE MECHANICAL (4JJ1)

6A-55

Valve Stem Seal and Valve Spring


Components
2 3 4 5 6

3 2

7 8

14 13 12 11 10 9

RTW56ALF001301

Legend 1. Exhaust Rocker Arm Shaft Assembly 2. Bolt (Long) 3. Bolt (Short) 4. Intake Rocker Arm Shaft Assembly 5. Fuel Injector Assembly 6. Fuel Injector Clamp Bolt 7. Fuel Injector Clamp

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

Pin Spring Lower Seat Valve Stem Oil Seal Valve Spring Spring Upper Seat Split Collar Valve Stem End Cap

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

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

6A-56

ENGINE MECHANICAL (4JJ1)


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

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

Inspection
Inspect the valve spring NOTE: Check the valve spring visually and if there is clear damage or wear, replace it. 1. Free 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 IN / EX Standard Limit mm (in)

49.04 (1.93) / 57.57 (2.27) 48.15 (1.89) / 56.52 (2.23)


469#$)50 !

Legend 1. Valve spring replacer 2. Pivot 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.

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 IN / EX Limit mm (in)

2.1 (0.083) / 2.5 (0.098)

469#$)50 "

ENGINE MECHANICAL (4JJ1) Installation

6A-57

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: 5-8840-2817-0

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. Installation length mm (in) 37.80 (1.488)

Tension of the valve spring Standard Limit

N (kg / lb) Inlet / Exhaust 213 (21.7 / 157) / 409 (41.7 / 301) 188 (19.2 / 138) / 370 (37.7 / 272)
469#$)50!%

3. Install the valve spring. 4. Install the spring upper seat. 5. Install the split collar. Apply compressed air over the cylinder from the glow plug holes to keep the valve at the home position. Use a replacer to compress the valve spring and install the split collar. Special tool Valve spring replacer: 5-8840-2818-0 Pivot: 5-8840-2819-0

LNW21BSH056701

6A-58

ENGINE MECHANICAL (4JJ1)


NOTE: Move it up and down to check if it moves smoothly. 6. Install the valve stem end cap. 7. Install the cylinder head assembly. Refer to "Cylinder Head".


469#$)50 !

Legend 1. Valve spring replacer 2. Pivot

Special Tools
Illustration Tool Number/ Description

5-8840-2818-0 Valve spring replacer

5884028180

5-8840-2819-0 Pivot assembly

5884028190

5-8840-2817-0 Valve stem seal installer

#&&" &%

ENGINE MECHANICAL (4JJ1)

6A-59

Cylinder Head
Components

3 4 6 7 5

8
LNW71BLF000901

Legend 1. Timing Chain Tensioner 2. Glow Plug 3. Intake and Exhaust Valves 4. Fuel Injector Assembly NOTE: To avoid electric shock; Set the switch to the 'OFF' position and disconnect battery negative cable before checking or repairing the fuel injector, wiring or/and connectors.

5. 6. 7. 8.

Fuel Injector Clamp Cylinder Head Timing Chain Guide Timing Chain Tension Lever

2. Remove the turbocharger. Refer to Turbocharger.

Removal
1. Drain the engine coolant.

6A-60

ENGINE MECHANICAL (4JJ1)

3. Remove the EGR cooler heat protector.

LNW76ASH000501 LNW71FSH000101

4. Remove the EGR cooler. 5. Remove the water by pass pipe (1).

Remove the LH noise cover. Remove the radiator upper hose. Remove the A/C compressor drive belt. Remove the A/C compressor. Remove the compressor from the A/C compressor bracket. Fix the compressor and hose in an appropriate position with wire etc. 11. Remove the A/C compressor bracket. 12. Remove the A/C compressor adjust pulley.

7. 8. 9. 10.


469#$)50&"

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

1
LNW76CSH001101

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

ENGINE MECHANICAL (4JJ1)


15. Remove the injection pipes (NO.1 to 4).
1

6A-61

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

LNW71DSH000101

16. Disconnect the heater hose. Disconnect the heater hose from the cylinder block side. 17. Remove the fan guide bracket (LH). 18. Remove the noise shield cover (1) from the lower timing chain cover.

LNW76CSH001801

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

 2

LNW76CSH001001

469#$+50"

21. Remove the fuel injector. Refer to Fuel Injector in FUEL SYSTEM section. 22. Remove the glow plug connector. 23. Remove the glow plug .

6A-62

ENGINE MECHANICAL (4JJ1)


26. Remove the camshaft bearing cap.

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

1E 2E 3E 1I 2I 3I 4I 5I 4E 5E

469#$)50%

RTW56ASH018401

25. Remove the baffle plate (1).

27. Remove the camshaft.

469#$)50$!

469#$)50!&

ENGINE MECHANICAL (4JJ1)


28. Remove the timing chain tensioner (1) and gasket (2).

6A-63

30. Remove the timing chain tension lever pivot.

2 1
469#$)50'" LNW71BSH001401

29. Remove the idle gear D. Timing chain is dropped behind.

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

469#$)50  469#$)50'#

33. 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.

6A-64

ENGINE MECHANICAL (4JJ1)

! ! $  "  " & #  % !

'

!

%

$

&

"

469#$)50 

469#$)50&$

Legend 1. Exhaust Rocker Arm Shaft Assembly 2. Bolt (Long) 3. Bolt (Short) 4. Intake Rocker Arm Shaft Assembly 5. Front NOTE: Pay full attention so as not to drop the parts in the gear case of the front part of the cylinder head or a hole into which oil pours back in the front. 34. Remove the cylinder head gear case bolts (2) and nuts (1).

36. Remove the cylinder head assembly. Remove the cylinder head assembly with the exhaust manifold and the intake manifold. Remove the cylinder head gasket. NOTE: Replace the head gasket with a new one once it is removed.

Head Disassembly
1. 2. 3. 4. 5. Remove the intake manifold assembly. Remove the exhaust manifold assembly. Remove the water outlet pipe. Remove the valve stem cap. 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 Pivot: 5-8840-2819-0

469#$)50 &

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

ENGINE MECHANICAL (4JJ1)


9. Remove the valve stem oil seal.

6A-65


469#$)50 ! 469#$)50 "

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

10. Remove the spring lower seat. 11. 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

469#$)50&% LNW21BSH016801

6A-66

ENGINE MECHANICAL (4JJ1)


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

12. Remove the cam end gasket (1).




469#$)50 #

13. Remove the oil seal. Cylinder Head Lower Face Warpage Standard Limit

469#$)50&'

mm (in)

0.05 (0.002) or less 0.20 (0.0079)

NOTE: The cylinder head lower face cannot be reground.

469#$)50&&

A E C B D F

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.

LNW61ASH003901

Cylinder Head Height (H) (Reference) Standard

mm (in)

143.4 (5.646)

ENGINE MECHANICAL (4JJ1)


Exhaust Manifold Warpage

6A-67

Use a straight edge and a thickness gauge to measure the manifold cylinder head fitting face warpage.If the measured values exceed the specified limit, the manifold must be replaced. Exhaust Manifold Warpage
0

mm (in) 0.05 (0.002) or less 0.20 (0.008)

Standard Limit

469#$)50%"

Manifold Fitting Face Warpage Use a straight edge and a thickness gauge to measure the manifold cylinder head fitting face warpage.Regrind the manifold cylinder head fitting surfaces if the measured values are greater than the specified limit but less than the maximum grinding allowance.If the measured values exceed the maximum grinding allowance, the cylinder head must be replaced. Manifold Fitting Face Warpage Standard Limit Maximum Grinding Allowance mm (in) 0.05 (0.002) or less 0.20 (0.008) 0.40 (0.016) Valve Stem Cap Make the necessary part replacements.If excessive wear or damage is discovered during inspection. Valve Stem Outside Diameter Measure the valve stem diameter at three points.If the measured value is less than the specified limit, the valve and the valve guide must be replaced as a set. Valve Stem Outside Diameter Intake Valve Standard Limit 6.955 - 6.970 (0.2738 - 0.2744) 6.935 (0.2730) mm (in) Exhaust Valve 6.939 - 6.949 (0.2732 - 0.2736) 6.920 (0.2724)
LNW21BSH001601

469#$)50%#

6A-68

ENGINE MECHANICAL (4JJ1)


Valve Thickness Measure the valve thickness.If the measured value is less than the specified limit, the valve and the valve guide must be replaced as a set. Intake and Exhaust Valve Thickness Standard Limit mm (in)

1.3 (0.051) 1.1 (0.045)

LNW21BSH017301

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.
LNW21BSH017801

Valve Stem Clearance Intake Valve Standard Limit 0.030 - 0.060 (0.0012 - 0.0023) 0.200 (0.008)

mm (in) Exhaust Valve 0.038 - 0.068 (0.0015 - 0.0027) 0.250 (0.0098)

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 Standard Limit mm (in) 0.5 (0.02) 2.5 (0.098)

LNW61ASH004001

ENGINE MECHANICAL (4JJ1)

6A-69

Use a seat cutter to minimize the scratch and other roughness (15/45/75 degree-blade), thereby returning the contact width to the standard value.
2 150 90 30

LNW61ASH004101

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 Intake Standard Limit 2.26 (0.089) 2.2 (0.087) mm (in) Exhaust 2.12 (0.083) 2.5 (0.078) Valve Seat Angle 45 Degree
LNW21BSH018201

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.

LNW21BSH056101 LNW61ASH004201

Repair of the seat surface Remove carbon from the surface of the valve insert seat.

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.

6A-70

ENGINE MECHANICAL (4JJ1)


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 valve and hit it lightly to grind it, and confirm that it has even contact all round.

NOTE: Remove compound completely after grinding.

3 1

LNW21BSH031801

Replace the valve seat insert. 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.

LNW21BSH018601

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

Head Reassembly
3

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
LNW21BSH056001

Legend 1. Arc-Weld 2. Valve Seat Insert 3. Screw Driver

ENGINE MECHANICAL (4JJ1)

6A-71

469#$)50&&

469#$)50'

Height from the upper surface of the cylinder head to the edge surface of the valve guide;


NOTE: When replacing the valve guide, it must be replaced together with the valve.

469#$)50'

Legend 1. Cylinder Head 2. Injection Pipe 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

469#$)50 !

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. Apply engine oil over the peripheral part of the valve guide and install the oil seal by using a valve stem seal installer.

6A-72

ENGINE MECHANICAL (4JJ1)


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

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


469#$)50!% 469#$)50 !

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

Legend 1. Valve spring replacer 2. Pivot NOTE: Move it up and down to check if it moves smoothly. 9. Install the valve stem end cap. 10. Install the exhaust manifold assembly. Refer to Exhaust Manifold. 11. Install the intake manifold assembly. Refer to Intake Manifold.

Installation
1. Select the cylinder head gasket.

LNW21BSH018801

6. Install the valve spring. 7. Install the valve spring upper seat. 8. Install the split collar. Apply compressed air over the cylinder from the glow plug holes to keep the valve at the home position.

ENGINE MECHANICAL (4JJ1)


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.

6A-73

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

LNW61ASH004301

Cylinder Head Gasket Combination mm(in)

LNW21BSH068001

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.

Gasket Grade Mark Piston Projection Gasket Thickness A B C 0.067-0.117 (0.0026-0.0046) 0.117-0.167 (0.0046-0.0066) 0.167-0.217 (0.0066-0.0085) 0.95 (0.0374) 1.00 (0.0394) 1.05 (0.0413)

RTW76ASH000301
"

469!$)50%

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

6A-74

ENGINE MECHANICAL (4JJ1)


Use a torque wrench and angle gauge to tighten the head bolts in the order described in the drawing. Tightening torque: 1st step = 70 Nm (7.1 kgm / 51 lb ft) 2nd step = 70 Nm (7.1 kgm / 51 lb ft) 3rd step = 60 (degrees) 4th step = 60 (degrees)

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!

'

"

&

$

RTW56ASH009501

NOTE: Difference of each piston projection must be equal or within 0.05 mm (0.002 in). 6. Select the gear case gasket. This should be of the same grade as cylinder gasket is chosen. 7. Apply liquid gasket (ThreeBond 1207B or equivalent) at the two locations .

&

"





#

469#$)50'%

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

469#$)50 '

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

469#$)50 &

12. Install the rocker arm shaft assembly. Apply the engine oil.

ENGINE MECHANICAL (4JJ1)


Attach the rocker arm shaft assembly in sequence from No.1 to No.4. Tightening torque: 21 Nm (2.1 kgm / 15 lb ft)
! !  " 1 2

6A-75

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

LNW76ASH001101 469#$)50 

Legend 1. Exhaust Rocker Arm Shaft Assembly 2. Bolt (Long) 3. Bolt (Short) 4. Intake Rocker Arm Shaft Assembly 5. Front 13. Install the water by pass pipe.Apply soapy water to the O-ring.Tighten the bolt to the specified torque. Tightening torque: 25 Nm (2.5 kgm / 18 lb ft) 14. Install the chain guide bolt from cylinder head.Tighten the bolt to the specified torque. Tightening torque: 25 Nm (2.5 kgm/18 lb ft)

Legend 1. Crankshaft Damper Pulley 2. Mirror 3. TDC Mark 17. Install the timing chain with idle gear D. Apply the engine oil bolt thread and seat. Tightening torque: 59 Nm (6.0 kgm/43 lb ft)

469#$)50 &

469#$)50'#

15. Install the tension lever.

6A-76

ENGINE MECHANICAL (4JJ1)


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

Align the timing marks at two locations as shown.


 !

"

469#$)50 ! LNW71BSH001501

Legend 1. Timing Chain 2. Timing Mark 3. Blue Link 4. Yellow Link 18. Install the timing chain tension lever pivot.Tighten the bolt to the specified torque. Tightening torque: 27 Nm (2.8 kgm / 20 lb ft)

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

2 1
LNW71BSH001401

469#$)50'"

21. Unlock the tensioner hook. Press the place of the arrow in the figure. The hook is opened. The plunger pushes the tension lever.

ENGINE MECHANICAL (4JJ1)

6A-77

469#$)50 "

469#$)50!&

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

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

3
RTW56ASH007001

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

469#$)50$'

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

6A-78

ENGINE MECHANICAL (4JJ1)


31. Install the noise cover. Refer to procedure for fuel system in this manual. 32. Inspection and adjustment of valve clearance. Refer to procedure for service precautions in this manual. 33. Install the fuel injector.Refer to procedure for fuel system in this manual. 34. Install the baffle cover.Refer to procedure for camshaft in this manual. 35. Install the cam end gasket. Apply the liquid gasket (ThreeBond TB-1207B or equivalent).
! !
469#$)50 %

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


!

469#$)50 $

Legend 1. Cam End Gasket 2. 2.0 to 3.0 mm (0.078 to 0.118 in) 36. Install the cylinder head cover. Refer to Cylinder Head Cover. 37. Install the glow plug. Tighten the glow plug to the specified torque.
"
469#$)50 !

Legend 1. Timing Chain 2. Timing Mark 3. Dark Plate 4. Yellow Plate 27. Apply liquid gasket to timing chain cover upper. Refer to procedure for fuel system in this manual. 28. Install the timing chain cover upper. Refer to procedure for fuel system in this manual. 29. Apply liquid gasket to timing chain cover lower. Refer to procedure for fuel system in this manual. 30. Install the timing chain cover lower. Refer to procedure for fuel system in this manual.

Tightening torque: 18 Nm (1.8 kgm / 13 lb ft) 38. Install the glow plug connector. Tighten the nuts to the specified torque. Tightening torque: 2 Nm (0.2 kgm / 17 lb in) 39. Install the fuel injection pipe. Attachment order No.2No.1No.3No.4 40. Tighten the fuel injector clamp bolt to the specified torque. Tightening torque: 26 Nm (2.7 kgm / 20 lb ft) 41. Tighten the injection pipe to the specified torque. Tightening torque: 30 Nm (3.1 kgm / 22 lb ft) 42. Install the fuel injection pipe clip .Tighten the nut to the specified torque. Tightening torque: 8 Nm (0.8 kgm / 69 lb in)

ENGINE MECHANICAL (4JJ1)


43. Install the engine oil level gauge guide. Apply engine oil to the O-ring. Tighten the bolt to the specified torque. Tightening torque: 25 Nm (2.6 kgm / 19 lb ft) 44. Install the A/C compressor bracket.Tighten the bolt to the specified torque. Tightening torque: 25 Nm (2.6 kgm / 19 lb ft) 45. Install the A/C compressor adjust pulley. Tighten the bolt (1) and nut (2) to the specified torque. Tightening torque: bolt 25 Nm (2.6 kgm/19 lb ft) (Dry) Tightening torque: nut 41 Nm (4.2 kgm/30 lb ft)

6A-79

52. Install the cooling fan. Refer to procedure for Engine cooling in this manual. 53. Install the A/C drive belt. Refer to Procedure for Intake Manifold in this manual. 54. Install the fan guide bracket. 55. Install the radiator upper hose. 56. Install the Turbocharger. Refer to Turbocharger. 57. Replenish the coolant.

1
LNW76CSH001101

46. Install the A/C compressor and connector. Tighten the bolt to the specified torque. Tightening torque: 44 Nm (4.5 kgm / 33 lb ft) 47. Connect each connector. Barometric Sensor EGR Valve Glow plug Water temperature sensor Camshaft Position sensor Throttle Assembly 48. Install the exhaust front pipe. Refer to procedure for exhaust system manual. 49. Install the EGR cooler. Refer to procedure for exhaust system manual. 50. Install the EGR cooler water pipe. Refer to procedure for exhaust system manual. 51. Install the EGR cooler heat protector. Refer to procedure for exhaust system manual.

in this

in this

in this

in this

6A-80

ENGINE MECHANICAL (4JJ1)

Torque Specifications

25(2.5/18)

70(7.1/51) 70(7.1/51) 60 60

18(1.8/13)

2(0.2/17lb in) 25(2.5/18) 10(1.0/87lb in)

26(2.7/20)

25(2.5/18)

27(2.8/20)

LNW76ALF000801

Special Tools
Illustration Tool Number/ Description Illustration Tool Number/ Description

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


#&&" &  #&&" &$

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

ENGINE MECHANICAL (4JJ1)


Illustration Tool Number/ Description

6A-81

5-8840-2817-0 Valve stem seal installer

#&&" &%

5-8840-2818-0 Valve spring replacer

5884028180

5-8840-2819-0 Pivot

5884028190

5-8840-0266-0 Angle gauge

6A-82

ENGINE MECHANICAL (4JJ1)

Piston and Connecting Rod


Components

2 1 5

RTW56ALF001601

Legend 1. Piston Pin Snap Ring 2. Piston Pin 3. Piston Ring

4. Piston 5. 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 and Crank Case" . 7. Remove the connecting rod cap. NOTE: Sort the removed bearings according to cylinders by using tags.

ENGINE MECHANICAL (4JJ1)

6A-83

LNW21BSH004901

LNW21BSH005101

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.

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.

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.

LNW21BSH005201

4. Remove the connecting rods from the piston. 5. 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.

6A-84

ENGINE MECHANICAL (4JJ1)


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

6. Measure the gap between the piston and the inner diameter of the cylinder bore. Inner diameter of the cylinder block. Use a cylinder bore dial indicator to measure the cylinder block inner diameter both in the thrust and radial directions in the designated position. Measurement position (from the upper surface of the cylinder block) 20 mm (0.79 in) Measure the cylinder block inner diameter based on the average value of the actual measurement values on 2 positions. Cylinder block inner diameter 95.421 - 95.450 (3.75673 - 3.75787) mm (in)

469#$)50 !

Legend 1. 11 mm (0.43 in)


1

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

mm (in)

2 3 2 3

0.082 - 0.100 (0.0032 - 0.0039)

NOTE: If it is found that the gap between the cylinder block inner diameter and the piston exceeds the standard value, replace the piston or cylinder block.
LNW21BSH039801

Legend 1. 20 mm (0.79 in) 2. Radial 3. Thrust Piston outside diameter Use a micrometer to measure the outside diameter of the piston in the right angle to the piston pin in the designated position.

7. Piston replacement The head of the piston has a marking of grade A, B or C. The mark shows the grade of the piston. If oversize pistons are installed, rebore the cylinder block. Refer to "Cylinder Block". Piston Grade (Service Part) A B C mm (in)

95.340 - 95.369 (3.75354 - 3.75469) 95.350 - 95.379 (3.75394 - 3.75508) 95.360 - 95.389 (3.75433 - 3.75547)

ENGINE MECHANICAL (4JJ1)

6A-85

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

2
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 liner.

LNW61ASH004401

LNW21BSH034801

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 Standard 1st compression ring 2nd compression ring 0.27 - 0.51 (0.0106 - 0.0200) 0.42 - 0.66 (0.0165 - 0.0260) mm (in) Limit 1.50 (0.059) 1.50 (0.059)

6A-86

ENGINE MECHANICAL (4JJ1)


Oil ring 0.27 - 0.56 (0.0106 - 0.220) 1.50 (0.059)

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 Standard 1st compression ring 2nd compression ring Oil ring * 0.05 - 0.09 (0.0020 - 0.0035) 0.03 - 0.07 (0.0012- 0.0028) mm (in) Limit * 1.50 (0.059) 1.50 (0.059)
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.

*Measurement is impossible

LNW21BSH009701 LNW21BSH009501

9. Inspect the piston pin. Visually inspect the piston pin for cracks, scratches and other damages, 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 Standard Limit 33.970 (1.33740) mm (in)

Measure the bush of the small edge of the connecting rod. If the clearance of the bush inner diameter and the pin diameter exceeds the limit, replace the bush or connecting rod assembly, and the pin. Piston pin and connecting rod small end bushing clearance Standard Limit 0.05 (0.0020) mm (in)

0.008 - 0.020 (0.0003 - 0.0008)

33.995 - 34.000 (1.33838 - 1.33858)

ENGINE MECHANICAL (4JJ1)

6A-87

LNW21BSH009801

LNW21BSH010401

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 Standard Limit 0.04 (0.0016) mm (in)

12. Measure the bearing oil clearance. Install the bearing to the connecting rod big end. Tighten the bearing cap to the two step of angular tightening method. Use an inside dial indicator to measure the connecting rod bearing inside diameter. Connecting rod bearing cap bolt torque: 1st step 2nd step mm (in)

29.4 (3.0 / 22) 45 deg

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)) Standard Distortion Parallelism 0.08 (0.003) or less 0.05 (0.002) or less

If the clearance between the measured bearing inside diameter and the crank pin exceeds the specified limit, the bearing and/or the crankshaft must be replaced. Crank pin and bearing clearance Standard Limit 0.10 (0.0039) mm (in)

0.029 - 0.083 (0.0011 - 0.0026)

mm (in) Limit 0.20 (0.008) 1.50 (0.006)

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.

6A-88

ENGINE MECHANICAL (4JJ1)


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.

1 ! 

2 " 

!
LNW41BSH003701

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. Legend 1. Compression Ring 1st 2. Compression Ring 2nd 3. Oil Ring 4. Expander

"
469#$)50 ! 

Installation
1. Install the connecting rod bearing. Install the bearing on the connecting rod, and apply 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. Dislocate the piston ring end gap so that (1) is 1st ring, (3) is 2nd ring and (2) is oil ring, as shown in the drawing. With the piston front mark cut facing forward, use the piston ring compressor to insert the piston in the cylinder liner. 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.

LNW61ASH004601

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 marks "2N" and "N" face upward.

ENGINE MECHANICAL (4JJ1)


Special tool Piston ring compressor: 5-8840-9018-0

6A-89

LNW21BSH011401 LNW21BSH072201

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.

4. Install the oil pan. Refer to "Oil Pan and Crank Case". 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".

LNW61ASH004801

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

6A-90

ENGINE MECHANICAL (4JJ1)

Torque Specifications
Nm(kgm/lb ft)

1st STEP 29.4(3.0/22)

2nd STEP 45 Lubricate with engine oil


RTW56AMF001801

Special Tools
Illustration Tool Number/ Description

5-8840-9018-0 Piston ring compressor

#&&"'&

5-8840-0266-0 Angle gauge

ENGINE MECHANICAL (4JJ1)

6A-91

Flywheel
Components

5 3 2 1 4

10 8 9

LNW71BMF000601

Legend 1. Pressure Plate Assembly 2. Driven Plate 3. Pilot Bearing 4. Washer 5. Flywheel

6. 7. 8. 9.

Bearing Stopper Flywheel Housing Flywheel (Smoother E) Flexible Plate

Removal
1. Remove the starter. 2. Remove the transmission assembly. Refer to "transmission assembly removal and installation". 3. 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.

6A-92

ENGINE MECHANICAL (4JJ1)


In the case of A/T car, after loosening the flywheel installation bolts, remove the washer, flexible plate, flywheel and sleeve in this order.

3 10 8

7 9 4

4 1 6

7 2 5

2
LNW21BSH002501

4. Remove the driven plate. Remove the driven plate from the flywheel along with the clutch aligner (1). 5. Install the crankshaft stopper in the starter installation part of the flywheel housing. NOTE: Make sure that the stopper is applied with the ring gear and installed properly. Special tool Crankshaft stopper: 5-8840-0214-0

LNW21BSH072801

7. Remove the pilot bearing. Remove the pilot bearing from the flywheel.

2 3

LNW21BSH029301

LNW21BSH007701

Special tool Pilot Bearing Remover: 5-8840-2000-0 Sliding Hammer: 5-8840-0019-0 8. Remove the ring gear. Put a bar on the ring gear and hit it with a hammer to remove it.

6. 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.

ENGINE MECHANICAL (4JJ1)

6A-93

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

LNW21BSH012001 LNW21BSH011901

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. 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 Standard Limit 12 (0.4724) 13 (0.5118) mm (in)

3. Flywheel installation bolts. There is no damage in appearance. Exchange for a new part if damage is extensive.

Installation
1. 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. 2. 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 200C (390F). 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.

6A-94

ENGINE MECHANICAL (4JJ1)

LNW21BSH012101

LNW21BSH002601

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 flywheel housing. Tightening torque: 1st step = 59 Nm (6.0 kgm / 43 lb ft) 2nd step = 60 - 90 (degrees) Special tool Crankshaft stopper: 5-8840-0214-0

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 drawing. Tightening torque: 51Nm (5.2 kgm / 38 lb ft)

9 1 5 3

3 10 8
8

7 9 4

4 2

2
LNW21BSH002501

LNW71BSH001301

4. Install the driven plate. Use a clutch aligner to install the driven plate on the flywheel.

6. Install the transmission assembly. Refer to "transmission assembly removal and installation". 7. Install the starter. Tightening torque: 127 Nm (13 kgm / 94 lb ft)

ENGINE MECHANICAL (4JJ1) Torque Specifications

6A-95

59(6.0/43)

60

to 90

51(5.2/38)

59(6.0/43)

60

to 90

LNW76AMF000301

Special Tools
Illustration Tool Number/ Description

5-8840-2230-0 Crankshaft stopper

#&&"

!

5-8840-0266-0 Angle gauge

6A-96

ENGINE MECHANICAL (4JJ1)

Gear Case Assembly


Components

3 4

LNW76ALF000301

Legend 1. Adjust Plate 2. Generator

3. Gasket 4. Gear Case Assembly

Removal
1. Remove the engine assembly. Refer to Engine Assembly. 2. Remove the cylinder head. Refer to Cylinder Head. 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.

ENGINE MECHANICAL (4JJ1)


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 Timing Gear Train. 11. Remove the oil pump. Refer to Oil Pump. 12. Remove the timing gear case (1) and gasket (2).

6A-97

Install the timing gear case to match with the dowel pins, install bolts them in the order shown in the illustration. Do not remove the bolts(11) when maintaining.
11 11 3 10 5 2 4 2 1 11

2 2 6 4 7 2

2 8

2 2

2 2 9 2 9

LNW76ASH002701


469%$)50 

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

Legend 1. Gear Case Assembly 2. Bolt L = 20 mm (0.79 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 L = 25 mm (0.98 in) 9. Nut 10. UP 10. Bolt Tighten the bolts and nuts to the specified torque. Tightening torque: 25 Nm (2.5 kgm / 18 lb ft) 3. Install the oil pump. Refer to Oil Pump. 4. Install the idle gear C shaft and idle gear C, idle gear A shaft and idle gear A. Refer to Timing Gear Train. 5. Install the gear case cover. Refer to removal procedure for gear case cover in this manual. 6. Install the crankshaft pulley. Refer to removal procedure for crankshaft front oil seal in this manual. 7. Install the fuel supply pump. Refer to installation procedure for fuel supply pump in this manual. 8. Install the water pump. Refer to installation procedure for water pump in this manual.

469#$)50$!

2. Install the timing gear case.

6A-98

ENGINE MECHANICAL (4JJ1)


11. Install the adjustment bracket of generator. Tighten the bolts to the specified torque. Tightening torque: 25 Nm (2.5 kgm / 18 lb ft) 12. Install the cylinder head. Refer to Cylinder Head. 13. Install the engine assembly. Refer to Engine Assembly.

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

Torque Specifications

25 (2.5/18) 25 (2.5/18) 51 (5.2/38)

25 (2.5/18)

LNW76ALF000401

ENGINE MECHANICAL (4JJ1)

6A-99

Crankshaft Front Oil Seal


Components
7 6

2 1

LNW76AMF000401

Legend 1. Bolt 2. Washer 3. Crankshaft Damper Pulley 4. Crankshaft Front Oil Seal

5. Gear Case Cover 6. Slinger 7. Crankshaft Gear

Removal
1. Remove the radiator. Refer to Radiator in ENGINE COOLING section. 2. Remove the fan assembly. Remove the fan assembly unscrewing four mounting nuts.

LNW61BSH003601

6A-100

ENGINE MECHANICAL (4JJ1)


Tighten the bolt as far as it will go. Special tool Oil seal and slinger installer: 5-8840-2855-0 The length from the surface of the crankshaft gear to the surface of the slinger: 5.8 - 6.2 mm (0.228 - 0.244 in)

3. Remove the fan belt. 4. Remove the crankshaft pulley. NOTE: Do not reuse the crankshaft pulley bolt and the washer. 5. Remove the crankshaft front oil seal. Use the special tool to remove the front oil seal. Special tool Remover: 5-8840-0027-0 Put a rod and a wooden piece etc. as shown in the illustration. And pull the rod to the front slowly, and remove the crankshaft front oil seal.

3 2 1

3
LNW76ASH002901

LNW76ASH002801

Legend 1. Rod 2. Remover 3. Wooden Piece 6. Remove the gear case cover. 7. Remove the slinger. Remove the slinger with a screwdriver etc. avoiding damage to the surface of the crankshaft gear. NOTE: The slinger does not need to be replaced if there are no scratches nor damages.

Legend 1. Bolt 2. Washer 3. Slinger Installer 4. Slinger 5. Crankshaft Gear 6. Crankshaft 2. Install the gear case cover. 3. Install the crankshaft front oil seal. Use the special tool to install the front oil seal. Use only one of the special tools when the oil seal is installed. Special tool Oil seal and slinger installer: 5-8840-2855-0 The length from the surface of the crankshaft gear to the surface of the oil seal: 14.75 - 15.25 mm (0.581 - 0.600 in)

Installation
1. Install the slinger. Use the special tool to install the slinger.

ENGINE MECHANICAL (4JJ1)


4 2 1 3 5 6 7 8

6A-101

LNW76ASH003001

Legend 1. Bolt 2. Washer 3. Front Oil Seal Installer 4. Gear Case Cover 5. Front Oil Seal 6. Slinger 7. Crankshaft Gear 8. Crankshaft Apply engine oil to the lip of the oil seal. 4. 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. Tighten in the sequence shown. Take care not to damage the crankshaft damper pulley boss. Tightening torque: 294 Nm (30 kgm/217 lb ft) 5. Install the fan belt. Refer to "Engine Cooling" 6. Install the radiator. Refer to Radiator in ENGINE COOLING section.

6A-102

ENGINE MECHANICAL (4JJ1)

Torque Specifications

294(30/217)

LNW76AMF000501

Special Tool
Illustration Tool Number/ Description

5-8840-0027-0 Remover

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


#&&" &##

ENGINE MECHANICAL (4JJ1)

6A-103

Crankshaft Rear Oil Seal


Components

6 3 4 5

LNW71BLF000501

Legend 1. Starter 2. Transmission Assembly 3. Clutch Pressure Plate 4. Driven Plate

5. 6. 7. 8.

Flywheel Crankshaft Rear Oil Seal Transmission Assembly Flexible Plate

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: 5-88402360-0

6A-104

ENGINE MECHANICAL (4JJ1)


Use an oil seal install to install the crankshaft rear oil seal. Oil Seal Installer: 5-8840-2359-0

12.50.3mm (0.490.01in)

LNW76ASH002301

Installation
1. Install the crankshaft rear oil seal. 2. Install the flywheel. Refer to "Flywheel".

RTW56ASH022901

Special Tools
Illustration Tool Number/ Description

5-8840-2359-0 Oil seal installer

5-8840-2360-0 Oil seal remover

ENGINE MECHANICAL (4JJ1)

6A-105

Crankshaft
Components

RTW56ALF002601

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

4. Crankshaft 5. Lower Bearing 6. Bearing Cap

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 common rail. Refer to "Fuel Supply Pump and Common 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".

6A-106

ENGINE MECHANICAL (4JJ1)


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

8. Remove the water pump. Refer to "Water Pump" in the 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. Remove the crankshaft gear.

Disassembly
1. Remove the crank angle sensor rotor.

469#$)50$&

Legend 1. Crank Angle Sensor Rotor 2. Bolt


LNW61ASH005501

13. Remove the crank case. Refer to "Crank Case and Oil Pan". 14. Remove pistons and connecting rods. Refer to "Pistons and Connecting Rods". 15. Remove the bearing cap. Loosen the crankshaft bearing cap bolts in numerical order a little at a time.

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

10

8 9

LNW21BSH037601

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

ENGINE MECHANICAL (4JJ1)




6A-107

469#$)50$%

LNW61ASH005701

Legend 1. Crank Angle Sensor Rotor 2. Bolt

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 Standard 0.10 (0.004) mm (in)

2. Main bearing clearance Remove the crankcase.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.

NOTE: Measure the thrust clearance before dismounting.

6A-108

ENGINE MECHANICAL (4JJ1)


#1,#2,#4,#5 #3 0.030 - 0.054 (0.0012 - 0.0021) 0.042 - 0.066 (0.0016 - 0.0026)

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

LNW61ASH005801

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.

LNW21BSH024401

10

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) 0.05 or less (0.0020 or less)

LNW21BSH038701

Standard

Tightening torque: 166 Nm (16.9 kgm / 122 lb ft) NOTE: Do not turn the crankshaft after you have tightened the bearing 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)

ENGINE MECHANICAL (4JJ1)

6A-109

NOTE: Tufftriding (soft nitriding treatment) is applied to enhance strength of the crankshaft. Therefore, you should not polish the surface of the crankshaft. Crankshaft bearing selection Crankshaft bearing selection is based on the measured 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 body.
LNW21BSH024501

4. Measure the journal and the crank pin 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.

LNW76ASH003101

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.

LNW21BSH024601

Crankshaft Outside Diameter Standard Journal Pin 69.917 - 69.932 (2.7526 - 2.7532) 52.915 - 52.930 (2.0833 - 2.0839)

mm (in) Limit 69.91 (2.7524) 52.9 (2.083)

6A-110

ENGINE MECHANICAL (4JJ1)

"

469#$)50% 

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

ENGINE MECHANICAL (4JJ1)


1 or 73.97573.982 (2.91242.9127) 69.92769.932 (2.75302.7532) 69.92269.927 (2.75282.7530) 69.91769.922 (2.75262.7528)

6A-111

2 or --

3 or ---

Bearing Selection Table (#3) mm (in)


469#$)50%!

Crankshaft Bearing Housing Grade Mark Diameter

Legend 1. Lot No 2. Size Code Bearing Selection Table (#1, #2, #4, #5) mm (in) Crankshaft Bearing Housing Grade Mark Diameter Crankshaft Journal Crankshaft Bearing Grade Size Code Diameter Mark 1 or 73.99274.000 (2.91312.9134) 69.92769.932 (2.75302.7532) 69.92269.927 (2.75282.7530) 69.91769.922 (2.75262.7528) 69.92769.932 (2.75302.7532) 69.92269.927 (2.75282.7530) 69.91769.922 (2.75262.7528)

Crankshaft Journal Crankshaft Bearing Grade Size Code Diameter Mark 1 or 69.92769.932 (2.75302.7532) 69.92269.927 (2.75282.7530) 69.91769.922 (2.75262.7528) 69.92769.932 (2.75302.7532) 69.92269.927 (2.75282.7530) 69.91769.922 (2.75262.7528)

73.99274.000 (2.91312.9134)

2 or --

3 or --4 1 or 73.98373.991 (2.91272.9130)

2 or --

3 or ---

2 or --

1 or 73.98373.991 (2.91272.9130)

3 or ---

2 or --

3 or ---

6A-112

ENGINE MECHANICAL (4JJ1)


1 or 73.97573.982 (2.91242.9127) 69.92769.932 (2.75302.7532) 69.92269.927 (2.75282.7530) 69.91769.922 (2.75262.7528) 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.

2 or --

3 or ---

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 the upper 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 body bearing fitting surfaces.

LNW61ASH006101

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

LNW21BSH038301

LNW21BSH037401

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.

ENGINE MECHANICAL (4JJ1)


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. 8. Install the crankshaft gear.

6A-113

469#$)50% LNW21BSH038601

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

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 the Cooling System Section. 13. Install the front cover. Refer to "Front Cover". 14. Install the crankshaft rear oil seal. Refer to "Crankshaft Rear Oil Seal". 15. Install the fuel supply pump and common rail. Refer to "Fuel Supply Pump and Common Rail". 16. Install the cylinder head. Refer to "Cylinder Head". 17. Install the camshaft assembly. Refer to "Camshaft Assembly". 18. Install the cylinder head cover. Refer to "Cylinder Head Cover". 19. Mount the engine assembly on the chassis. Refer to "Engine Assembly".

10

LNW21BSH038701

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

6A-114

ENGINE MECHANICAL (4JJ1)

Torque Specifications
166(16.9/122) Nm(kgm/lb ft)

12Nm(1.2kgm/104 lb in)

RTW56AMF001301

ENGINE MECHANICAL (4JJ1)

6A-115

Cylinder Block
Components


469%$)5.

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 the 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 "Pistons and Connecting Rods". 15. Remove the crankshaft. Refer to "Crankshaft" 16. Remove the piston cooling pipe.

469%$)50

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

6A-116

ENGINE MECHANICAL (4JJ1)


Standard Limit 95.421 - 95.450 (3.7567 - 3.7579) 95.48 (3.7590)

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.

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

469%$)50&

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 or rebored.

469#$)50 !

Legend 1. 11 mm (0.43 in) Formula Boring inside diameter = D + C - H E D = Piston outside diameter (Measured Oversize Piston) C = Piston and cylinder bore clearance 0.082 - 0.100 mm (0.0032 - 0.0039 in) H = Honing allowance 0.03 mm (0.0012 in) or less E = Boring machine error Piston size mm (in) 95.340 - 95.389 (3.7535 - 3.7555) 95.590 - 95.639 (3.7634 - 3.7653) 95.840 - 95.889 (3.7732 - 3.7752) 96.090 - 96.139 (3.7831 - 3.7850)

2 3 2 3

Standard Oversize(0.25) Oversize(0.50) Oversize(0.75)

LNW21BSH039801

Bore and hone the cylinders individually as required. Once again, measure each cylinder bore. Each cylinder bore remainder mm (in)

Cylinder block bore diameter

mm (in)

ENGINE MECHANICAL (4JJ1)


0.02 (0.0008) or less. 7. 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 body upper face. If the measured values exceeds the limit, the cylinder body must be replaced. Cylinder block upper face warpage Standard Limit 0.20 (0.079) mm (in)

6A-117

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 Nm (3.1 kgm / 22 lb ft) bolts M8 25 Nm (2.5 kgm / 18 lb ft) bolts M6 8 Nm (0.8 kgm / 69 lb in) NOTE: Be careful not to deform or damage the piston cooling pipe nozzle.

0.05 or less (0.002 or less)

LNW61ASH006501

469%$)50

Cylinder body height (H) (Reference) Standard

mm (in)

262.945 - 263.055 (10.352 - 10.356)

2. Install the crankshaft. Refer to "Crankshaft". 3. Install pistons and connecting rods. Refer to "Pistons and Connecting Rods". 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 the 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".

LNW71BSH000301

6A-118

ENGINE MECHANICAL (4JJ1)


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

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

Torque Specifications
30 (3.1/22) 25 (2.5/18) 8 (0.8/69lb in)

LNW71BSF000301

ENGINE MECHANICAL (4JJ1)

6A-119

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

4. Oil Press. SW

Warning Lamp

Oil Gallery
Oil Filter & Cooler Assembly 5. Regulating Valve Idler Gear Shaft Piston Cooling Jet Timing Gear Oil Pump Rocker Arm Oil Strainer Connecting Rod Bearing Crankshaft Bearing Camshaft Bearing Turbocharger Vacuum Pump

Oil Filter

3. Relief Valve

Oil Cooler 2. Relief Valve 1. Relief Valve

Timing Chain Oil Jet

Oil Pan

LNW76ALF000201

Legend 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)

6A-120

ENGINE MECHANICAL (4JJ1)


5. Regulating Valve: 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)

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 and taking 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. 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 between the upper and lower limits of the level gauge. Replenish the engine oil, if level is below the lower limit. Also, check for contamination of the engine oil.

ADD

FULL

RTW56ASH015701

Legend 1. Lower Limit 2. Upper Limit Engine oil leakage In the lift up condition, confirm that there are no leaks from the cylinder head cover and oil pan.

ENGINE MECHANICAL (4JJ1)

6A-121

Oil Filter Element


Components

1 2 3

6 4 5

7 8 9

10
LNW71HSF000101

Legend 1. Oil Cooler 2. Oil Filter Element 3. Gasket 4. Plate 5. Spring

6. 7. 8. 9. 10.

Center Bolt O-ring O-ring Drain Plug Oil Filter Case

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

Installation
1. Install the oil filter element. Apply grease(Besco L2, L3 or equivalent) or engine oil to the O-rings and the gasket. Tighten the bolt and the drain plug using the specified torque. Tightening torque: Center bolt 44 Nm (4.5 kgm / 33 lb ft) Drain plug 24 Nm (2.4 kgm / 17 lb ft)

6A-122

ENGINE MECHANICAL (4JJ1)

Torque Specifications

44(4.5/33)

25(2.5/18)
LNW76ASF000101

ENGINE MECHANICAL (4JJ1)

6A-123

Oil Filter Assembly and Oil Cooler


Components

2 1

LNW71HMF000101

Legend 1. Oil Filter Assembly and Oil Cooler 2. Water By Pass Pipe

3. Water Intake Pipe

Removal
1. Remove the turbocharger. Refer to Turbocharger. 2. Remove the exhaust manifold. Refer to Exhaust Manifold.

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


469#$)50&"

6A-124

ENGINE MECHANICAL (4JJ1) Disassembly


1. Remove the element mounting nuts(1).

4. Remove the water intake pipe (1).

" !

469#$)50 $

Legend 1. Water Intake Pipe 2. Bracket 3. Bracket 4. Bolt 5. Remove the oil cooler and oil filter.

469#$)50 '

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

469#$)50!

LNW71HSH000101

Reassembly
1. Install the gasket on the element. 2. Install the element. 3. Tighten the element fixing nuts using the specified torque. Tightening torque: 25 Nm (2.5 kgm / 18 lb ft)

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

ENGINE MECHANICAL (4JJ1)


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

6A-125

Tighten the bolts to the specified torque in the order shown in the illustration. Tightening torque: 25 Nm (2.5 kgm / 18 lb ft)

4 1 3

10 1 11

12 2 22 22 20 17 16 15 14 13

19

18

LNW76ASH002001

2
LNW76ASH001801

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.

2. Install the water intake pipe. After applying soapy water to O-ring, set it on water intake pipe and insert into the oil cooler.Tighten the bolts to the specified torque. Tightening torque: 25 Nm (2.5 kgm / 18 lb ft) 3. Install the water by pass pipe. After applying soapy water to O-ring, set it on by pass pipe and insert into the cylinder head.Tighten the bolts to the specified torque. Tightening torque: 25 Nm (2.5 kgm / 18 lb ft) 4. Install the bracket of generator. Tighten the bolts to the specified torque.

1 1

Tightening torque: 51 Nm (5.2 kgm / 38 lb ft) 5. Install the adjustment bracket of generator. Tighten the bolts to the specified torque.
2

Tightening torque: 25 Nm (2.5 kgm / 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.

LNW76ASH001901

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

6A-126

ENGINE MECHANICAL (4JJ1)

Crank Case and Oil Pan


Components

LNW76ALF000501

Legend 1. Flywheel Housing 2. Cylinder Block 3. Oil Strainer

4. Crank Case 5. Oil Pan

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

ENGINE MECHANICAL (4JJ1)


4. Remove the oil pan. 9. Remove the retainer.

6A-127

LNW76ASH001301

469%$)50 

5. Remove the flywheel. Refer to Flywheel. 6. Remove the flywheel housing.

Legend 1. Retainer 2. Bolt 10. Remove the crank case.

3 

LNW71BSH001601

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

469#$)50 '

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

6A-128

ENGINE MECHANICAL (4JJ1)

Disassembly
1. Remove the oil strainer.
!

" 

469#$)50#!

469$$)50' 

Legend 2. Oil Strainer 3. Bolt 4. Crank Case

Legend 1. 2.0 - 3.0 mm (0.079 - 0.118 in) 2. 4.0 - 5.0 mm (0.157 - 0.179 in) 2. Install the oil pan. Apply the liquid gasket (ThreeBond TB-1207B or equivalent)and mount within 5 minutes. Tightening torque: 22 Nm (2.2 kgm / 16 lb ft)

Reassembly
Install the oil strainer. Install the packing on the strainer. Tighten the bolts to the specified torque. Tightening torque: 22 Nm (2.2 kgm / 16 lb ft)

Installation
1. Install the crank case. Apply the liquid gasket (ThreeBond TB-1207C or equivalent) and mount within 5 minutes. Tightening torque: 25 Nm (2.5 kgm / 18 lb ft)


469#$)50# 

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 Nm (2.5 kgm / 18 lb ft)

ENGINE MECHANICAL (4JJ1)


4. Install the heater pipe and hose.

6A-129

469#$)50%%

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

LNW76ASH001301

5. Install the timing gear case. Refer to Timing Gear Case. 6. Install the cylinder head. Refer to Cylinder Head. 7. Install the Flywheel housing. Tighten the bolts to the specified torque. Tightening torque: Bolt (1) : 106 Nm (10.8 kgm / 78 lb ft) Bolt (2) : 82 Nm (8.4 kgm / 61 lb ft)


Bolt (1) : 51 Nm (5.2 kgm / 38 lb ft)

469%$)50 

Legend 1. Retainer 2. Bolt


2

LNW71BSH001601

8. Install the flywheel. Refer to Flywheel. 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 Nm (2.5 kgm / 18 lb ft)

6A-130

ENGINE MECHANICAL (4JJ1)

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

Torque Specifications

106(10.8/78) 25(2.5/18) 51(5.2/38)

25(2.5/18)

82(8.4/61)

25(2.5/18)

22(2.2/16) 44(4.5/33)

LNW76ALF000901

ENGINE MECHANICAL (4JJ1)

6A-131

Oil Pump
Components

2 1

RTW66AMF000701

Legend 1. Bolt

2. Oil Pump Assembly

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

6A-132

ENGINE MECHANICAL (4JJ1)


8. Remove the noise cover (1).

3. Remove the fan guide bracket.


2 1 3

LNW76ASH000701

469#$+50"

Legend 1. Fan Guide Bracket (RH) 2. Fan Guide Bracket (LH) 3. Bolt 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. Disconnect the power steering pump. 7. 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. NOTE: Do not reuse the crank pulley bolt and washer. 10. Remove the cover of the gear case cover(1).

LNW76ASH003201

ENGINE MECHANICAL (4JJ1)


11. Remove the gear case cover. 4. Install the spring pin.

6A-133

! 

"

469#$)50'%

469#$)50#'

12. Remove the oil pump.

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.
469#$)50 

Legend 1. Oil Pump

Outside diameter of the driven gear shaft/ drive gear shaft Standard Limit 15.900 (0.62598)

mm (in)

15.989 - 16.000 (0.62949 - 0.62992)

Disassembly
1. 2. 3. 4. Remove the spring pin. Remove the spring seat. Remove the spring. Remove the valve.

Reassembly
1. Install the valve. 2. Install the spring. 3. Install the spring seat.

6A-134

ENGINE MECHANICAL (4JJ1)


Measure the width size the driven gear/drive gear.

469#$)50 #$

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 Standard Limit 0.20 (0.0079) mm (in)

469#$)50 ##

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 Standard mm (in)

14.500 - 14.527 (0.5709 - 0.5719)

0.04 - 0.07 (0.0016 - 0.0028)

469#$)50"&

469#$)50"%

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

Clearance between the gear side surface and the gear side surface of the oil pump housing Standard Limit 0.20 (0.0079)

mm (in)

0.065 - 0.109 (0.0026 - 0.0043)

ENGINE MECHANICAL (4JJ1) 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 Nm (2.5 kgm / 18 lb ft) Tightening torque: 8 Nm (0.8 kgm / 69 lb in)

6A-135

Tighten the bolts to the specified torque.

469#$)50 

3. Install the cover of the gear case cover. 4. Install the crank pulley. Tighten the bolts to the specified torque.
469#$)50 

Legend 1. Oil Pump 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.


Tightening torque: 294 Nm (30 kgm / 217 lb ft) 5. Install the noise cover. Tighten the bolts to the specified torque. Tightening torque: 10 Nm (1.0 kgm / 87 lb in) 6. Install the vacuum pump. Tighten the nuts to the specified torque. Tightening torque: 25 Nm (2.5 kgm / 18 lb ft) Install the oil pipe (feed side and return side) of vacuum pump. Install the vacuum pipe bracket and vacuum pipe. 7. Install the power steering pump. Tighten the nuts to the specified torque. Tightening torque: 25 Nm (2.5 kgm / 18 lb ft) 8. Install the fan drive belt and pulley. Install the fan drive belt with the fan pulley. 9. Install the fan and fan clutch. Tighten the bolts to the specified torque. Tightening torque: 8 Nm (0.8 kgm / 69 lb in) 10. Adjust the drive belt of generator and A/C compressor. Apply tension to the fan drive belt by moving the generator.

469#$)50 

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

6A-136

ENGINE MECHANICAL (4JJ1)

Apply a force of 98 N (10 kg / 22 lb) to the drive belt mid portion to check the drive belt deflection. Generator drive belt deflection New belt Reuse belt 5 - 6 (0.20 - 0.24) 7 - 8 (0.28 - 0.32) mm (in)

A/C compressor drive belt deflection New belt Reuse belt 6 - 7 (0.24 - 0.28) 8 - 9 (0.32 - 0.35)

mm (in)

11. Install the fan guide bracket. 12. Install the radiator upper hose. 13. Replenish the engine coolant.

ENGINE MECHANICAL (4JJ1)

6A-137

Oil Pressure SW
Components

LNW76AMF000601

Legend 1. Oil Pressure SW 2. Gasket

3. Nipple; Oil Pressure Warning SW

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

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

6A-138

ENGINE MECHANICAL (4JJ1)

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

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

LNW21HSH003401

ENGINE MECHANICAL (4JJ1)

6A-139

Air Cleaner Element


Removal
1. Remove the air cleaner cover fixing bolt. 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 690 (7 / 100) kPa (kg/cm2 /psi)

LNW46ASH003201

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

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ENGINE COOLING (4JJ1)

6B-1

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

6B-2

ENGINE COOLING (4JJ1)

Main Data and Specifications


Main Data and Specifications
Description M/T Smoother Engine coolant forced circulation Centrifugal impeller type (To 1) lit (US/UK gal)/min 1.25 240 (63.1/53.3)

Item Cooling system Water pump type Pump to crankshaft speed ratio Delivery volume Pump speed at 5600 rpm Water temperature at 30C (86F) Pump bearing type Thermostat type Valve initial opening temperature Valve full opening temperature Valve lift at fully open position Radiator Heat radiation capacity Heat radiation area Radiator front area Radiator dry weight Radiator cap valve opening pressure Engine coolant capacity Engine coolant total capacity kW m2 (ft2) m2 (ft2) N (kg/lb) kPa (psi) lit (U.S pint) lit (U.S pint) C (F) C (F) mm (in)

Double row shaft Wax pellet with jiggle valve 85 (185) 100 (212) 10 (0.39) Tube type corrugated 91.2 10.9 (117.3) 0.242 (2.6) 125.5 (12.8 / 28.2) 128.5 (13.1 / 28.9) 93.3 122.7 (13.5 17.8) 6.7 (7.1) 10 (10.6)

ENGINE COOLING (4JJ1) General Description


Coolant Flow

6B-3

Turbocharger EGR Cooler

Cylinder head Thermostat

Reservoir Tank

Radiator

Oil cooler

Cooling fan

Water pump Cylinder block Car heater

RTW76BLF000301

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

6B-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 disassembled type. Thermostat

RTW56BSF000201

A wax pellet type thermostat is used.

ENGINE COOLING (4JJ1)


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) Freezing temperature guideline Mix ratio Liter (qts) Engine coolant 4.2 (4.4) 5.0 (5.3) 5.3 (5.6) Tap water 6.5 (6.9) 5.8 (6.1) 5.0 (5.3) 4.7 (5.0)

6B-5

Concentration of engine coolant 35% 42% 50% 53%

-18C (-0.4F) 3.5 (3.7) -25C (-13F) -35C (-31F) -40C (-40F)

2. Engine coolant density measurement Methods for measuring specific gravity Measure the specific gravity and the temperature of the cooling water using an antifreeze specific gravity meter and thermometer. Take precautionary measures as the boiled cooling water may gush out at high temperatures if the cap is removed.
LNW76BSH002801

Use a deep container to suit the height of the specific gravity meter.

Engine Coolant 1. About the engine coolant concentration Take the concentration corresponding to the minimum temperature because the freezing temperature varies according to the concentration of the engine coolant. Use only genuine Isuzu engine coolant. Use engine coolant with a mix ratio in the range of 30 to 60% because over heating is likely to occur if the ratio is greater than 60% and corrosion prevention is inadequate if the ratio is less than 30%.

ANTIFREEZE CONCENTRATION (%) 0 10 20 30 40 50


LNW46BSH001001

FREEZING TEMPERATURE (C)

-10 -20 -30 -40 -50


LNW46BSH001301

Legend 1. Anti-Freeze Specific Gravity Meter 2. Radiator Fix the temperature of the cooling water being measured in the range of 0 to 50 C (32 to 122 F).

6B-6

ENGINE COOLING (4JJ1)

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

1100 1090 1080 1070 1060 1050 1040 1030 1020 1010 1000

60% 50% 40% 30% 20% 10%

SPECIFIC GRAVITY

0 10 20 30 40 50 60 70 TEMPERATURE (C)

LNW46BMH000101
Coolant scooping method Measure the concentration using the coolant scoop.

ENGINE COOLING (4JJ1)

6B-7

Diagnosis
Diagnosis
Condition Engine overheating Possible Cause Low Engine Coolant level Thermo meter unit faulty Faulty thermostat Faulty Engine Coolant temperature sensor Clogged radiator Faulty radiator cap Low engine oil level or use of improper engine oil Clogged exhaust system Faulty Throttle Position sensor Open or shorted Throttle Position sensor circuit Damaged cylinder head gasket Engine overcooling Engine slow to warmup Faulty thermostat Faulty thermostat Thermo unit faulty Replenish Replace Replace Repair or replace Clean or replace Replace Replenish or change oil Clean exhaust system or replace faulty parts Replace throttle valve assembly Repair or replace Replace Replace Replace Replace Correction

6B-8

ENGINE COOLING (4JJ1)

Draining and Refilling Cooling System


Draining and Refilling Cooling System
Before draining the cooling system, inspect the system and perform any necessary service to ensure that it is clean, does not leak and is in proper working order. The engine coolant (EC) level should be between the "MIN" and "MAX" lines of reserve tank when the engine is cold. If low, check for leakage and add EC up to the "MAX" line. There should not be any excessive deposit of rust or scales around the radiator cap or radiator filler hole, and the EC should also be free from oil.Replace the EC if excessively dirty. 1. Completely drain the cooling system by opening the drain plug at the bottom of the radiator. 2. Remove the radiator cap. WARNING: To avoid the danger of being burned, do not remove the cap while the engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure. 3. Disconnect 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. 4. Refill the cooling system with the EC. Procedure for filling with coolant (in case of full change) Confirm that the engine has cooled. Open the radiator cap and the reserve tank cap. Unscrew the air bleeding bolt(2). Pour the coolant up to the filler neck.
LNW76BSH002901

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

2 1

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

ENGINE COOLING (4JJ1)

6B-9

Water Pump
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. Removal 1. Remove the engine cover. 2. Radiator Upper Hose a. Partially drain the engine coolant. b. Remove the radiator upper hose. 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. Fan guide bracket
2 1 3

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

469#$)50 #"

7. Water Pump a. Remove the water pump bolts and nuts. b. Remove the water pump.

LNW76ASH000701

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

RTW56BSH000201

Inspection and Repair The water pump is not disassembled type.Make necessary parts replacement if extreme wear or damage is found during inspection. Should any of the following problems occur, the entire water pump assembly must be replaced. Cracks 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 (0.0078 in)).

6B-10

ENGINE COOLING (4JJ1)


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 New belt Reuse belt mm (in) 5 - 6 (0.20 0.24) 7 - 8 (0.28 0.32)

Cracks or corrosion in the impeller. Installation 1. Water Pump

3. Fan guide bracket 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 Nm (2.5 kgm /18 lb ft) c. Connect the turbocharger-cooling pipe to outlet pipe. 5. Radiator Upper Hose. 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.

RTW56BSH000201

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

469#$)50 #"

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 Nm (0.8 kgm /69 lb in) c. Apply tension to the fan drive belt by moving the generator.

ENGINE COOLING (4JJ1)

6B-11

Thermostat
Removal and Installation
Read this Section carefully before performing any removal and installation procedure. This Section gives you important points as well as the order of operation. Be sure that you understand everything in this Section before you begin. 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. 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. 4. Check the thermostat full opening temperature. Thermostat Full Opening Temperature: 100 (212) C (F) 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: 85 (185) C (F)

Valve Lift At Fully Open Position: 10 (0.39)

mm (in)

1 2 2

LNW61BSH003501

LNW71CSH000401

Legend 1. Agitating Rod 2. Thermometer 3. Wooden Piece

Legend 1. Jiggle Valve 2. Thermostat 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.

6B-12

ENGINE COOLING (4JJ1)

Installation 1. Thermostat Install the thermostat. Mount the jiggle valve with the valve facing engine front.

1 2 2

LNW71CSH000401

Legend 1. Jiggle Valve 2. Thermostat 2. Water Outlet Pipe. a. Install the water outlet pipe with a new gasket to the thermostat housing. b. Tighten the outlet pipe bolt to specified torque. Outlet Pipe Bolt Torque: 25 Nm (2.5 kgm /18 lb ft) c. Connect the turbocharger-cooling pipe to outlet pipe. d. Install the engine harness clip. 3. Radiator Upper Hose. a. Connect the radiator upper hose to the water outlet pipe. b. The knob of the clamp should be directed to the horizontal side. c. Replenish the engine coolant. 4. Install the engine cover.

ENGINE COOLING (4JJ1)

6B-13

Radiator
Removal and Installation
Radiator and Associated Parts
3 4

5
LNW76BLF001901

Legend 1. Reserve Tank Hose 2. Radiator Upper Hose 3. Radiator & Intercooler Removal 1. Disconnect battery ground cable. 2. Loosen the drain plug to drain the engine coolant. After draining the coolant, tighten the drain plug.

4. Fan Guide 5. Radiator Lower Hose

6B-14

ENGINE COOLING (4JJ1)

LNW46BSH000401

LNW76ASH000501

Legend 1. Radiator Drain Plug 3. Remove the air intake pipe with the hoses. Disconnect the hose from the intercooler side. Remove the air intake pipe with the hoses from the turbocharger side. Do not disconnect the hoses from the air intake pipe.

6. Remove the radiator upper hose on the radiator side. 7. Remove the radiator lower hose on the radiator side. 8. Remove the coolant reserve tank hose from the radiator side. 9. Remove the fan guide bracket.
2 1 3

LNW76ASH000701 LNW76ASH000301

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

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

ENGINE COOLING (4JJ1)


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

6B-15

LNW21BSH000201

Radiator Core
LNW76BSH003001

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

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.

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)

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.

6B-16

ENGINE COOLING (4JJ1)


6. Mount the radiator upper hose. 7. 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. Confirm that the engine has cooled. Open the radiator cap and the reserve tank cap. Unscrew the air bleeding bolt(2). Pour the coolant up to the filler neck. Press the radiator upper hose(1) 2 to 3 times as shown in the illustration. If the coolant level is down caused by the air was bled, poor the coolant again.

LNW21BSH000301

2 1

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

LNW76BSH002901

2 5 4 3

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

LNW46BSH000101

Legend 1. Flange nut 2. Rubber 3. Stud Bolt 4. Bracket 5. Bracket on the Radiator Side 6. Washer 2. Install the intercooler. 3. Install the fan guide bracket. 4. Mount the reserve tank hose of the coolant on the radiator. 5. Mount the radiator lower hose.

ENGINE COOLING (4JJ1)


After the engine has cooled down sufficiently, check the water level in the filler neck part and replenish if necessary. If the level is extremely low, check for leaks in the cooling water conduit system and reserve tank hose.
1

6B-17

LNW76BSH000101

Legend 1. Reserve Tank 2. MAX Line (Upper Limit) 3. MIN Line (Lower Limit)

Engine coolant change


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

6B-18

ENGINE COOLING (4JJ1)

Fan Clutch with Cooling Fan


Inspection and Repair
Make necessary correction or parts replacement if wear, damage or any other abnormal condition are found through inspection. Visually inspect for damage, leak (silicon grease) or other abnormal conditions. 1. Inspection (on-vehicle) a. Turn the fan clutch by hand when in a low temperature condition before starting the engine, and confirm that it can be turned readily. b. Start the engine to warm it up until the temperature at the fan clutch portion gets to around 85C(185F). Then stop the engine and confirm that the fan clutch can be turned with considerable effort (clutch torque) when turned by hand. If the fan clutch rotates more readily, however, this indicates that the silicone grease is leaking internally. Replace the fan clutch with a new one. 2. Inspection (in unit) Warm up the bimetal of the fan clutch by using the heat gun until the temperature gets to about 85C(185F) when measured with the thermistor. Then confirm that the fan clutch can be turned with considerable effort (clutch torque). If the fan clutch rotates more readily at this time, this indicates that the silicone grease is leaking internally. Replace the fan clutch with a new one.

Heat gun

Thermistor

LNW61BSH003701

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

469#$)50 #"

LNW71CSH000501

ENGINE COOLING (4JJ1) Special Tools


Illustration Tool Number/ Description

6B-19

5-8840-02770-0 Cap tester

5-8840-2603-0 Adapter

#&&" $!

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FUEL SYSTEM (4JJ1)

6C-1

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

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.
3 4 5 7

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 new ones.

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. Explanations on functions and operation Fuel system diagram

11

10

8
LNW71DSF000101

Legend 1. Fuel Rail 2. Pressure Limiter 3. Leak Off Pipe 4. Fuel Injector 5. Fuel Return Pipe 6. Fuel Feed Pipe

7. 8. 9. 10. 11.

Fuel Tank Priming Pump Fuel Filter With Sedimenter Recirculation valve Fuel Supply Pump

FUEL SYSTEM (4JJ1)


Fuel Rail Assembly

6C-3

2 1

RTW76CLF000601

Legend 1. Pressure Limiter

2. Fuel Rail Pressure Sensor

6C-4

FUEL SYSTEM (4JJ1)

Fuel Supply Pump

LNW71DLF000101

Legend 1. Fuel Temperature Sensor 2. Suction Control Valve 3. High Pressure Pipe

4. Camshaft Key 5. Camshaft Nut

FUEL SYSTEM (4JJ1)


Fuel Injector Fuel Filter

6C-5

6 5

2 4

LNW76CSH000101

Legend 1. Element 2. Case 3. Drain Plug 4. Switch Connector Functional Check


RTW76CMH000201

Legend 1. Terminal 2. Fuel Injector ID Code 3. Two Dimensional Barcode 4. Parts Number 5. Part for Mounting the Injection Pipe 6. O-ring

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

6C-6

FUEL SYSTEM (4JJ1)


Discharge the water. Tighten the drain plug after discharging the water. Tighten the air bleeding plug to the specified torque. Tightening torque : 7.5 Nm (0.7 kgm/26 lb in) Ignition switch is turned ON for 15 seconds check for fuel leakage. Check that the warning lamp in the meter is off. Trouble Shooting

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: Set a container at the tip of the plastic hose. Loosen the air bleeding plug and the drain plug. Problems with starting Condition Problems with starting

Possible Cause Fuel tank is empty Air has entered the fuel system. Fuel line is clogged or damaged. Connection to the fuel line is loose. Fuel filter element is clogged. Fault in the feed pump Regulating valve is open. Sticking of the fuel injector Defective engine control system Fill the tank.

Correction Bleed the air. Repair or replace the fuel line. Retighten the connection. Replace the cartridge. Replace the fuel supply pump. Replace Replace the fuel injector. Diagnose system. the engine control

Hunting during idling Condition Hunting during idling Possible Cause Air has entered the fuel system. Leakage or clogging of the fuel system Drops of water have entered the fuel system. Fuel filter element is clogged. Sticking of the fuel injector Defective engine control system Insufficient horsepower Condition Insufficient horsepower Possible Cause Air has entered the fuel system. Leakage or clogging of the fuel system Water mixes in the fuel system Fuel filter element is clogged. Sticking of the fuel injector Defective engine control system Correction Bleed air from the fuel system. Repair or replace the fuel system. Replace the fuel. Replace the element kit. Replace the fuel injector. Diagnose system. the engine control Correction Bleed air from the fuel system. Repair or replace the fuel system. Replace the fuel. Replace the fuel filter element kit. Replace the fuel injector. Diagnose system. the engine control

FUEL SYSTEM (4JJ1)


Maximum engine speed is too low Condition Maximum engine speed is too low Possible Cause Fuel line is clogged or damaged. Defective engine control system Engine does not stop Condition Engine does not stop Exhaust gas is blue or black Condition Exhaust gas is blue or black. Possible Cause Reduction in injection-valve opening pressure or defective atomizing status Engine control system malfunction Correction Replace the fuel injector. Possible Cause Defective engine control system Diagnose system. Correction the engine Diagnose system. Correction Repair or replace the fuel line. the engine

6C-7

control

control

System diagnosis.

Fuel System Check


Description Conforms to a fuel leak. Engine acceleration raises fuel pressure and which increases the leak. Leak could be in the following pipes and locations. Between injectors and fuel rail. Between fuel rail and fuel supply pump. Between fuel supply pump and fuel filter. Between fuel filter and fuel tank. Between pressure limiter and fuel tank. Between injector over flow and leak off pipe. Diagnostic Aids Check the following items. Air in the fuel line Step 1 Action Check the fuel quantity. Was a problem found? Check the fuel quality. 1. 2 2. 3. 4. Discharge the fuel from fuel tank Replenish the tank with specified fuel Bleed the air from the fuel system Start the engine

Clogged fuel filter Fuel pipe malfunction (Crushing, breakage, clogging, disconnection, etc.) Fuel tank malfunction Injector malfunction Fuel supply pump malfunction Pressure limiter malfunction An intermittent may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for poor connections or a damaged harness. Inspect the ECM harness and connector for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. ECU may set a DTC, if there is adequate air in fuel line. Schematic Reference: Engine Controls Schematics Value(s) Yes Go to Step 2 No Add fuel and go to Step 2

Could the engine be started? 3 Bleed the air from fuel system. Refer to Fuel System Air Bleeding in this section. Is the action complete?

Go to Step 7

Go to Step 3

Go to Step 4

6C-8
Step

FUEL SYSTEM (4JJ1)


Action Check the main fuel filter for clogging. Clean, repair, or replace as required. Notice: Replacement of a fuel filter is checking to a dealer. Is the action complete? Check the fuel line for damage and leakage. Clean, repair, or replace as required. Crushed areas Breakage Cracks Loose connections Is the action complete? Check the fuel tank. If a problem is found, clean, repair, or replace as necessary. Foreign material (Clogged suction port) Bent or cracked suction pipe Fuel tank distortion Fuel tank improper installation Clogged fuel cap hole Water Is the action complete? Rebleed the air from the fuel pipe. Refer to Fuel System Air Bleeding in this section. Is the action complete? Value(s) Yes No

Go to Step 5

Go to Step 6

Go to Step 7 Verify repair

FUEL SYSTEM (4JJ1)

6C-9

Fuel Filter Assembly


Components
1 2

LNW76CSF000101

Legend 1. Bolt 2. Fuel Feed Hose

3. Fuel Return Hose 4. Sedimenter Harness Connector

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

Installation
1. 2. 3. 4. 5. Install the fuel filter assembly. Install the bolts for mounting the fuel filter. Install the feed hose and the return hose. Connect the sedimenter harness connector. Bleed out the air. Refer to "Fuel System".

6C-10

FUEL SYSTEM (4JJ1)

Fuel Filter Element


Removal
1. Remove the fuel in the element case. a. Loosen the drain plug at the bottom of the element case. b. When the air breather of the body is loosened, the is run out from the drain plug. 2. Remove the harness of the water warning switch. 3. Remove the element case from the body by rotating the case in a counterclockwise direction, using a socket (width of double socket: 29mm(a)). After removing the case, confirm that the float at the inside bottom can move up and down smoothly. If foreign materials, sludge or other dirty materials are deposited at the bottom of the case, remove it clearly. 4. Remove the O-ring of the body by pulling out the element downward. 5. If foreign material is attached on the surface of the body inner circumference, wipe it with clean cloth.

1 2 3 4

7 8 a
BLW61DMH000101

Legend 1. Cap 2. Air bleeder 3. Filter body 4. O-ring 5. Fuel filter element 6. Element case 7. O-ring 8. Drain plug 9. Wiring connector

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

FUEL SYSTEM (4JJ1)

6C-11

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

4 3

MFW61DLH000101

Legend 1. Salient for socket 2. Float 3. Outside gasket 4. Inside gasket 5. Clean side hole 6. Element kit 7. O-ring grove 3. Apply a thin layer of fresh diesel fuel on the inner circumference of the element case (or the O-ring section at the body side). Turn the element in a clockwise direction until it hits to the body carefully. Biting with the O-ring must be avoided. No hitting of the element to the case means that the element does not have compete insertion. Turn the element and push it in again. 4. Tighten the element case with a torque wrench. Tightening torque: 33 Nm (3.4 kgm / 25 lb ft)

6C-12

FUEL SYSTEM (4JJ1)

Fuel Injector
Components

5 3 4

2 6

LNW76CLF000201

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

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

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

FUEL SYSTEM (4JJ1)


2. Remove the injection pipe sleeve nut (1) from the injector.
1

6C-13

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: If a fuel injector is replaced, cross off the replaced injector ID codes on the label with a marking pen etc. If all fuel injectors are replaced, remove the fuel injector ID code label from the engine cover.

1 2 3 4
LNW71DSH000101

51 51 51 51

16 19 39 19

1A 13 39 19

4JJ1 25 1A OF OF 2C 1C 18 00

24 OF 23 17

17 00 13 00

17 09 14 00

00 09 00 00

14 09 OF 00

00 00 00 00

52 54 57 44

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

LNW76CSH001701


"

Legend 1. 1st Cylinder Injector ID Code 2. 2nd Cylinder Injector ID Code 3. 3rd Cylinder Injector ID Code 4. 4th Cylinder Injector ID Code 5. Engine Cover 6. Injector ID Code Label

#
469$$+50

Legend 1. Fuel Injector 2. Leak Off Pipe 3. Clip 4. Gasket 5. Washer NOTE: Do not tamper with the electromagnetic portion of the fuel injector. Reduced electromagnetic function will result in injector failure.

6C-14

FUEL SYSTEM (4JJ1)


4. Temporarily tighten the clamp bolts. 5. Apply a thin coat of engine oil to the outer surface of the fuel injector side sleeve nuts. 6. Install the fuel injector pipes to the position shown in the illustration. 7. Use a spanner to carefully tighten the sleeve nuts until the fuel injector pipes contact the fuel injector and fuel rail. 8. Tighten the fuel injector pipe clips to the specified torque. Tightening torque: 8 Nm (0.8 kgm / 69 lb in)
" 1

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

#
469$$+50

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

 !
LNW76CMH000101

Legend 1. Fuel Injector 2. Pipe Clip 9. Tighten the injection pipes to the specified torque. Tightening torque Injector Side: 30 Nm (3.1 kgm / 22 lb ft) Fuel rail side: 25 Nm (2.5 kgm / 18 lb ft)
469#$+50$

Legend 1. Fuel Injector 2. Fuel Injector Clamp Bolt 3. Fuel Injector Clamp 3. Install the fuel injector clamps to the cylinder head.

FUEL SYSTEM (4JJ1)


2

6C-15

LNW76CSH000501

Legend 1. Clamp Bolt 2. Sleeve Nut 10. Tighten the fuel injector clamp bolts to the specified torque. Tightening torque: 26 Nm (2.7 kgm / 20 lb ft) 11. Tighten the engine oil level gauge guide tube. Tightening torque: 25 Nm (25 kgm / 18 lb ft) 12. Install the cylinder head cover. Refer to Cylinder Head Cover in ENGINE MECHANICAL section. 13. Program the Fuel Injector ID Codes Refer to Programming in ENGINE CONTROL SYSTEM section.

SAMPLE
5F 05 00 FB 00 F7 1 08 F5 19 FF 04 49

RTW76ESH002601

Legend 1. Fuel Injector ID Code 2. Fuel Injector

6C-16

FUEL SYSTEM (4JJ1)

Torque Specifications

30(3.1/22)

26(2.7/20)

25(2.5/18)

8(0.8kg m/69lb in)

LNW76CLF000101

FUEL SYSTEM (4JJ1)

6C-17

Fuel Pressure Sensor


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

Installation
1. Install the fuel pressure sensor. Tightening torque: 98 Nm (10.0 kgm/72 lb ft) 2. Connect the fuel pressure sensor harness connector.

1
LNW76CSH001601

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

469%$+50

Legend 1. Fuel Rail 2. Fuel Rail Pressure Sensor 3. Fuel Pressure Limiter

6C-18

FUEL SYSTEM (4JJ1)

Fuel Pressure Limiter


Removal
1. 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.

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

LNW76CSH000401

LNW76CSH000301

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

469%$+50

Legend 1. Fuel Rail 2. Fuel Rail Pressure Sensor 3. Fuel Pressure Limiter

FUEL SYSTEM (4JJ1)

6C-19

Fuel Rail Assembly


Components

1 5

2 7

LNW76CLF000301

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

5. Fuel Rail Bracket 6. Space Rubber 7. Fuel Leak Off Pipe

Removal
1. Remove the air intake pipe with the hoses. Disconnect the connector from the boost sensor. Disconnect the hose from the intercooler side. Remove the air intake pipe with the hoses from the intake throttle valve. Do not disconnect the hoses from the air intake pipe.

6C-20

FUEL SYSTEM (4JJ1)

LNW76ASH000501

LNW76CSH000701

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

6. 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.

1
LNW76CSH001601

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

LNW76CSH000401

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

FUEL SYSTEM (4JJ1)

6C-21

LNW76CSH000801

LNW76CSH001201

8. 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.

Legend 1. Fuel Rail 2. Fuel Rail Bracket 3. Space Rubber

Disassembly
1

1. Remove the fuel pressure limiter. 2. Remove the pressure sensor.

LNW76CSH000601

9. 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.
469%$+50

Legend 1. Fuel Rail 2. Fuel Rail Pressure Sensor 3. Fuel Pressure Limiter

Reassembly
1. Install the fuel pressure limiter. Tightening torque: 172 Nm (17.5 kgm/127 lb ft)

6C-22

FUEL SYSTEM (4JJ1)


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

2. Install the fuel pressure sensor. Tightening torque: 98 Nm (10.0 kgm/72 lb ft)

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

1 2 3

LNW76CSH000801

5. Tighten the fuel leak off pipe (1) using the mounting eyebolt using the specified torque. Tightening torque: 10 Nm (1.0 kgm/87 lb in)
LNW76CSH001201

Legend 1. Fuel Rail 2. Fuel Rail Bracket 3. Space Rubber 2. Tighten the fuel pipe using the mounting sleeve nut (1) and the specified torque. Tightening torque: 25Nm (2.5 kgm/18 lb ft)
1

LNW76CSH000401

LNW76CSH000601

3. Connect the fuel rail pressure sensor harness connector.

FUEL SYSTEM (4JJ1)


6. Install the fuel hose (1).

6C-23

Fit the pipe and the hose between the intake throttle valve and the intercooler. Connect the boost sensor connector. Use new clips. Tighten the clip according to the marking. Tightening torque: 6 Nm (0.6 kgm / 52 lb in)

LNW76CSH000701

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

LNW76ASH000501

11. Install the boost sensor connector.

Torque Specifications

25(2.5/18)

44(4.5/33)

25(2.5/18)
LNW76CMF000101

6C-24

FUEL SYSTEM (4JJ1)

Fuel Supply Pump


Components
1 2

4 11 10 9 8 7 6 5

LNW76CMF000201

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

7. 8. 9. 10. 11.

Noise Cover Timing Chain Cover Lower Nut Sprocket Fuel Supply Pump Gear

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

FUEL SYSTEM (4JJ1)


3. Remove the fan guide.
2 1 3

6C-25

6. Remove the A/C compressor adjust pulley.

2
LNW76ASH000701

1
LNW76CSH001101

Legend 1. Fan Guide Bracket 2. Fan Guide Bracket 3. Bolt 4. Remove the cooling Fan.

Legend 1. Bolt 2. Nut 7. Disconnect the A/C compressor. 8. Remove the A/C compressor bracket. 9. Remove the fuel rail assembly. Refer to removal procedure for Fuel rail assembly in this manual. 10. Remove the cylinder head cover. Refer to removal procedure for Fuel rail assembly in this manual. 11. Disconnect the connector of supply pump. 12. Remove the noise cover.

469#$)50 #"

5. Remove the A/C compressor drive belt.

469#$+50"

Legend 1. Noise Cover

6C-26

FUEL SYSTEM (4JJ1)

13. Remove the timing chain cover assembly. Upper & lower.
 1

469#$)50$' LNW76CSH001001

Legend 1. Timing Chain Cover Upper 2. Timing Chain Cover Lower. 14. Align the timing marks at 3 locations as shown.

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

469#$+50$ LNW76ASH001101

Legend 1. Nut

Legend 1. Crankshaft Damper Pulley 2. Mirror 3. TDC Mark

FUEL SYSTEM (4JJ1)


16. Remove the timing chain tennsioner. 19. Timing chain in moved upwards.

6C-27

2 1
LNW71BSH001401 469#$+50!!

Legend 1. Timing Chain Tennsioner. 2. Gasket 17. Remove the timing chain tension lever pivot. 18. Remove the nut and sprocket.

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

469#$+50"

Legend 1. Tension Lever Pivot 2. Sprocket 3. Nut


RTW56AMH000401

6C-28

FUEL SYSTEM (4JJ1)


23. Remove the supply pump and O-ring.

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

LNW76CSH000901 469#$+50 '

22. Remove the supply pump and supply pump bracket with spacer rubber. NOTE: Do not hold the high pressure pipe, during the supply pump removal procedure. Do not grasp the high pressure pipe, when moving the supply pump from one location to another.

Legend 1. O-ring 2. Supply Pump

Installation
1. Install the O-ring to the fuel supply pump. 2. Install the fuel supply pump. Apply soapy water to the O-rings before attaching. NOTE: Take care not to twist the O-ring.

3 2 1

3. Install the fuel supply pump bracket. Temporarily tighten with the bolts and nuts (Gear case side). Temporarily tighten with the bolts (Cylinder body side). Fully tighten the bolts and nuts (Gear case side). Fully tighten the bolts (Cylinder body side). Tightening torque: 25 Nm (2.5 kgm /18 lb ft)

LNW76CSH001301

Legend 1. Supply pump 2. Space Rubber B 3. Supply Pump Bracket 4. Space Rubber A

FUEL SYSTEM (4JJ1)


3 2 4 !

6C-29

" 

LNW71DSH000401

469#$+50#

Legend 1. Fuel Supply Pump 2. Space Rubber B 3. Fuel Supply Pump Bracket 4. Space Rubber A 4. Confirm that the supply pump camshaft key is turned to the right and is horizontal.

6. 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 bright 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.

469#$+50"!

5. Install the fuel supply pump 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 must be bit with maingear(3)of the idle gear A. Depress the pump gear when it is bitted with scissors gear (4) of the idle gear A.

"

469#$+50#

Legend 1. Timing Mark 2. Dark Plate 2. Timing Mark 2. Yellow Plate

6C-30

FUEL SYSTEM (4JJ1)

7. Install the timing chain tension lever pivot. Handtighten the pivot bolt. Confirm that the tension lever moves smoothly. 8. Attach the hook of the timing chain tensioner. Hold the latch(3) depressed. Insert the plunger(2). Attach the hook (4) to the pin (1) to hold the plunger in place.
1

469#$)50 "

11. Tighten the nut (1) to the specified torque. Tightening torque: 130 Nm (13.3 kgm / 96 lb ft)

LNW71BSH001501

9. Install the gasket (2) and the timing chain tensioner (1). Tighten the nut to the specified torque. Tightening torque: 10 Nm (1.0 kgm/ 87 lb in)

469#$+50$

12. Tighten the timing chain tension lever pivot bolt to the specified torque
2 1
LNW71BSH001401

Tightening torque: 27 Nm (2.8 kgm / 20 lb ft) 13. Turn the crank pulley two rotations (720CA).

10. Unlock the tensioner hook. Press the place of the arrow in the figure. The hook is opened. The plunger pushes the tension lever.

FUEL SYSTEM (4JJ1)


14. Check the mark (1) on the intake camshaft and exhaust camshaft to the mark of camshaft bearing cap.

6C-31

469%$+50 

469#$)50$'

15. Install the cylinder head cover. Refer to Cylinder Head Cover. 16. Apply liquid gasket (ThreeBond TB-1207C or equivalent) to the timing chain cover upper (1). Attach the cover within 5 minutes of applying the liquid gasket.

18. 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.

469#$+50 !

19. Install the timing chain cover lower (1). Tighten the bolts (2) and nuts (3) to the specified torque. Tightening torque: 10 Nm (1.0 kgm / 87 lb in)

469#$+50 

17. 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 head side (2). Tightening torque: 25 Nm (2.5 kgm / 18 lb ft)

6C-32

FUEL SYSTEM (4JJ1)


25. Install the A/C compressor adjust pulley.

1 3

3
LNW76CSH001401

1
LNW76CSH001101

20. Install the noise cover (1). Tighten the bolts to the specified torque. Tightening torque: 10 Nm (1.0 kgm / 87 lb in)

Legend 1. Bolt 2. Nut Tighten the bolt and nut to the specified torque. Bolt Tightening torque: 25 Nm (2.5 kgm/18 lb ft) Nut Tightening torque: 25 Nm (2.5 kgm/18 lb ft) 26. Install the A/C compressor drive belt. Refer to the drive belt tension check procedure for Heating and air conditioning in this manual. 27. Install the cooling fan. 28. Install the fan guide. 29. Install the radiator upper hose. 30. Replenish the engine coolant. 31. Start the engine and let idle. IMPORTANT: In order for the ECM to learn the characteristics of the fuel supply pump, let the engine idle until warn-up. If fuel system DTC's are stored in the meantime, clear the DTC and warn-up the engine again.

469#$+50"

21. Install the connector of supply pump. 22. Install the fuel rail assembly. Refer to the Install procedure for Fuel rail assembly in this manual. 23. Install the A/C compressor bracket. Tighten the bolts to the specified torque. Tightening torque: 25 Nm (2.5 kgm / 18 lb ft) 24. Install the A/C compressor. Tighten the bolts to the specified torque. Tightening torque: 44 Nm (4.5 kgm / 33 lb ft)

FUEL SYSTEM (4JJ1) Torque Specifications

6C-33

25(2.5/18)

25(2.5/18) 27(2.8/20) 10(1.0/87lb in) 25(2.5/18)

130(13.3/96)

10(1.0/87lb in)

10(1.0/87lb in) 25(2.5/18)

10(1.0/87lb in)
LNW76CLF000401

6C-34

FUEL SYSTEM (4JJ1)

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 CASE KIT (with switch) and carry out repairs in case of defective connections between circuits or short circuits.

2 1 3

LNW76CSH000201

Legend 1. Sensor 2. Connector on The Vehicle Side 3. Harness 4. Drain Plug

FUEL SYSTEM (4JJ1)

6C-35

Fuel Tank
Components
1 3 4

LNW21DLF000301

Legend 1. Fuel gauge unit connector 2. Breather hose 3. Fuel feed hose

4. Fuel return hose 5. Band 6. Fuel tank

Removal
1. Loosen the fuel filler cap. 2. Drain the fuel through the drain plug. 3. After draining the fuel tighten the drain plug to its specified torque. Tightening torque: 20 Nm (2.0 kgm / 14 lb ft) 4. Remove the connector from the fuel gauge unit. 5. Remove the breather hose.

6. Remove the fuel feed hose. 7. Remove the fuel return hose. Use a stopcock to prevent fuel from spilling, point it upwards and tie it to the frame. 8. Remove the band for mounting the fuel tank and remove the tip of the band on the frame side. 9. Pull the fuel tank to the outside.

6C-36

FUEL SYSTEM (4JJ1)


Put fuel into the fuel tank and tighten the fuel filler cap. Connect the battery ground cable. After starting the engine, check the hose connections to make sure that there are not any fuel leaks. 6. Connect the connector to the fuel gauge unit.

NOTE: If the fuel tank can not be removed, remove the bracket and lower the fuel tank downwards.

LNW21DMH000501

Mounting
1. Mount the fuel tank. NOTE: If you removed the bracket when removing the fuel tank, attach the bracket to the frame and tighten it to its specified torque. Tightening torque: 55 Nm (5.6 kgm / 41lb ft) Also, when placing the fuel tank on the bracket, make sure the rubber that is attached to fuel tank contacts the bracket. 2. Mount the band onto the fuel tank and tighten the mounting nut to its tightening torque. Tightening torque: 12 Nm (1.2 kgm / 104 lb in) 3. Mount the fuel return hose. 4. Mount the fuel feed hose. Put the hose onto the pipe at least 25 mm (0.9843 in). 5. Mount the breather hose.

FUEL SYSTEM (4JJ1)

6C-37

Fuel Gauge Unit


Components

LNW21DMF000101

Legend 1. Fuel gauge unit connector

2. Fuel gauge unit

Removal
1. Remove the wiring connector from the fuel gauge unit. 2. Remove the mounting screw and remove the fuel gauge unit. NOTE: When removing and attaching the fuel gauge unit, take caution with respect to interference with surrounding objects; do not deform the arm. Also, after removing the fuel gauge unit, place a seal so that foreign materials do not get into the tank.

6C-38

FUEL SYSTEM (4JJ1)


1. While moving the float from E to F, inspect the resistance value between connector terminals 1 J28 - 2 J-28. 2. Confirm that the low fuel light turns on when the float is in the "E" position. If there are any abnormalities found with the inspection, replace with a part that works correctly.

Inspection
The fuel tank unit changes its internal resistance based on the position of the float (height of liquid) and moves the needle of the fuel meter.

LNW21DSH002301

J-28

1/2

Warning lamp lighting point E

LNW76DMF000101

a b

325.2mm / 12.80in (Fuel tank capacity 63L / 13.86Imp.gal) 379.7mm / 14.95in (Fuel tank capacity 75L / 16.5Imp.gal, 100L / 22Imp.gal) 284.8mm / 11.21in (Fuel tank capacity 63L / 13.86Imp.gal) 336.1mm / 13.23in (Fuel tank capacity 75L / 16.5Imp.gal, 100L / 22Imp.gal)

FUEL SYSTEM (4JJ1)


c d 175.1mm / 6.89in (Fuel tank capacity 63L / 13.86Imp.gal) 207.7mm / 8.18in (Fuel tank capacity 75L / 16.5Imp.gal, 100L / 22Imp.gal) 76.7mm / 3.02in (Fuel tank capacity 63L / 13.86Imp.gal) 75.8mm / 2.98in (Fuel tank capacity 75L / 16.5Imp.gal, 100L / 22Imp.gal)

6C-39

Float Position F (FULL stopper) 1/2 Warning lamp lighting point E (EMPTY stopper)

Standard resistance volume () 2.5 33.0 87.0 98.3 1. Mount the fuel gauge unit. 2. Connect the wiring connector to the fuel gauge unit.

Mounting
Perform the removal process backwards for mounting.

Torque Specifications

55(5.6/41)

12(1.2/104lb in)

20(2.0/14)

LNW76DMF000201

MEMO .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. .................................................................................................................. ..................................................................................................................

ENGINE ELECTRICAL (4JJ1)

6D-1

ENGINE
ENGINE ELECTRICAL (4JJ1) TABLE OF CONTENTS
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . .6D-2 Servicing Cautions . . . . . . . . . . . . . . . . . . . . . . .6D-2 Important Generator Components and Function 6D-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .6D-3 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-4 Unit Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-6 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-6 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-6 Inspection and Repair . . . . . . . . . . . . . . . . . . . .6D-8 Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . .6D-8 Stator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-9 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-9 Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . .6D-10 Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . 6D-11 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-12 Final Assembly. . . . . . . . . . . . . . . . . . . . . . . . .6D-12 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-14 Starting Circuit Diagram . . . . . . . . . . . . . . . . . .6D-14 Removal and Installation . . . . . . . . . . . . . . . . .6D-14 Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6D-15 Inspection and Repair . . . . . . . . . . . . . . . . . . .6D-19 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-22 Magnetic Switch . . . . . . . . . . . . . . . . . . . . . . . .6D-24 Pre-Heating System . . . . . . . . . . . . . . . . . . . . . .6D-26 Inspection and Repair . . . . . . . . . . . . . . . . . . .6D-26

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 Function

Generator

Components

and

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. 9 diodes are connected to the stator coil to convert AC to DC. The DC voltage is delivered to the generator output terminal.

AC Generator

RTW76DMF000101

ENGINE ELECTRICAL (4JJ1)


Charging System

6D-3

B S Rotor coil Charge lamp L Charge relay IG-SW Warnning lamp

Stator coil

B F

IC Regulator P E

QOS C/U

SW

RTW56DMF000101

Troubleshooting
Symptoms No charging No charging Possible problem Dead battery Open or shorted wiring Open or shorted ammeter Loose wiring connections One or more generator coils open or shorted Bad diode Bad regulator Loose regulator connections Inadequate charging Possible problem Dead battery

Inadequate charging Excessive charging Unstable charging current Abnormal generator noise

Countermeasure Replace Repair

Replace

Repair

Countermeasure Replace

Battery

6D-4

ENGINE ELECTRICAL (4JJ1)


Possible problem Countermeasure Repair Adjust belt tension Replace Repair Replace Repair

Open or shorted wiring Loose wiring connections Loose generator drive belt Stator coil intermittent short Bad diode Loose battery connections Bad regulator Loose regulator connections Excessive charging Possible problem Bad regulator Unstable charging current Possible problem Open wiring connection or broken wire Loose generator drive belt Open or shorted stator coil Loose terminal connections Bad regulator Loose regulator terminal connections Abnormal operating noise Possible problem Loose generator drive belt Bad bearing Loose rotor core or stator core Bad diode Open or shorted stator coil

Countermeasure Replace

Countermeasure Repair Adjust belt tension Replace Repair Replace Repair

Countermeasure Adjust belt tension Replace Repair Replace Replace 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 L 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.

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).

ENGINE ELECTRICAL (4JJ1)


Specifications Battery power Generator output Rotational direction (Viewed from pulley) Rated speed Maximum speed Volts Amperes rpm 24

6D-5

45 / 50 / 80 Clockwise 5000 12000

6D-6

ENGINE ELECTRICAL (4JJ1)

Unit Servicing
Components
5 4

10

2 1 9

7
LNW76DLF000101

Legend 1. Pulley Nut 2. Pulley 3. Front Cover Assembly 4. Rotor Assembly 5. Stator Assembly

6. 7. 8. 9. 10.

Through Bolts Rear Cover Assembly Rectifier Ball Bearing Ball Bearing

Disassembly
1. Remove the through bolts. 2. Insert a flat-blade screwdriver between the front cover and the stator. Pry the parts apart.

ENGINE ELECTRICAL (4JJ1)


3. Separate the front cover/rotor assembly from the rear cover/stator assembly.

6D-7

8. Remove the bearing retainer and the bearing.

LNW71DSH000201 LNW76DSH000801

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.

9. Remove the B-terminal nut and M5 nut. 10. Remove the rear cover from the stator.

LNW71DSH000301

LNW76DSH000201

7. Remove the screw from the front cover.

6D-8

ENGINE ELECTRICAL (4JJ1)


Limit 30.7 (1.209)

11. Remove the stator assembly.

469"$,50"

12. Remove the rectifier assembly from the stator assembly.

LNW76DSH000501

3. Measure the electrical resistance between the slip rings. If the resistance is greater than the specified limit (open circuit), repair is required. Rotor coil resistance at 20C (68F) (45 A) (50 A) (80 A) 10.5 8.2 10.2

LNW76DSH000601

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 Standard mm (in) 31.7 (1.248)
LNW76DSH000301

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.

6D-9

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: MIN 1 M

LNW76DSH000401 0+9!-50""

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 at 20C (68F) 45 A 50 A 80 A 0.19 0.19 0.07

Brushes
Measure the brush height. If the height is less than the specified limit, the brushes must be replaced. Brush height Standard Limit mm (in) 25 (0.984) 6.5 (0.260)

LNW76DSH000701

6D-10

ENGINE ELECTRICAL (4JJ1) Rectifier Assembly


1

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.

3 4
469"$,50 

LNW76DMH000101

Tester Wire E U,V, and WN + + NO conductivity Negative side diode check Conductivity BAT U,V, and WN + + Conductivity Positive side diode check NO conductivity

ENGINE ELECTRICAL (4JJ1) Rectifier Assembly


(45A / 50A)
L

6D-11

E P 6 SWITCH 2

B 3 5 LAMP 2 LAMP 1 SWITCH 3 4 2 DIRECT-CURRENT

8 OUTPUT SIGNAL 7 PULSE 5~30V GENERATOR

+ -

1kHz

1 VOLT METER

STABILIZATION POWER SUPPLY

LNW76DSF000101

(80A)
L

E P 7 SWITCH 2

B 4 6 LAMP 2 LAMP 1 SWITCH 3 5 3 DIRECT-CURRENT

9 OUTPUT SIGNAL 8 PULSE 5~30V GENERATOR

+ -

2 SWITCH 1

1kHz

1 VOLT METER

STABILIZATION POWER SUPPLY

RTW46DSF000301

Test circuit Refer to the judgment criteria shown in the Table below.Carefully check Items 1 to 5.If all the items are OK, the IC regulator is normal. Circuit components 1 2 3 4 5 DC regulated power supply Lamps (2) Switches (3) DC voltmeter Pulse generator (Oscillator) 0 - 30 volts variable with output of 1 ampere or more 24 volts, 1.8 watts 0 to 60 volts, 0.5 grade 5 to 30 volt output at a frequency of 1KHz

6D-12

ENGINE ELECTRICAL (4JJ1)

Judgment criteria Lamp condition Lamp 1 On (dim) On or flashing Off or on (dim) On or flashing On Lamp 2 ON

NO. 1 2 3 4 5

Switch 1 ON ON ON OFF ON

Switch 2 OFF ON ON ON ON

Switch Voltmeter 3 reading OFF 24V OFF OFF OFF ON 32V 24V 36V

Remarks Initial excitation check Full excitation check

OFF

Lamp 1 off or dimly lit when the voltmeter shows less than 24 volts or 32 volts Stator and brush separation check Excess voltage check b. Tighten the pulley nut.

ON

Reassembly
Follow the disassembly steps in reverse order to reassemble the generator. Pay close attention to the items below. Be very careful not to reverse battery polarity. Reversed battery polarity will destroy the rectifier diodes. Do not ground the generator B-terminal. Heat and fire damage to the harness will result. If using a fast charge procedure, be sure to disconnect the battery positive cable. If you do not, the rectifier diodes will be exposed to high positive voltage that will destroy them. Be very careful to reassemble the parts to their original positions. Particular care must be taken with insulated parts. Carefully clean all insulated parts so that they are completely free of oil and/or grease. Be sure that B-terminal twist-type stoppers (round terminal) are securely inserted before tightening the nuts.

Tightening torque: 110 Nm (11.2 kgm / 81lb ft)

469"$,50 

Final Assembly
1. Pulley and rotor assembly. Install the pulley and rotor assembly a. Carefully clamp the rotor assembly in a vise.

ENGINE ELECTRICAL (4JJ1)


c. The rear ball bearing is pressed into the wheel eccentric groove.The bearing ring projects from the groove.During installation, rotate the bearing to the point of minimum bearing ring projection.

6D-13

Insert the pin from the outside of the rear cover. Press the brushes into the holder. Complete the assembly procedure.

Pin

Ring

Projection part (0.65mm blow)

eccentric groove

RTW46DSH005301

RTW46DSH004901

3. Use a bench press to install the rear cover assembly to the front cover assembly.

2. Rear cover and stator assembly. Use a pair of long-nose pliers to connect the stator coil leads and the rectifier leads. Finish the work as quickly as possible to prevent the rectifier from heat transferred by the soldering.

469#$,50 

4. Through bolts. place a guide bar through the holes in the front cover and rear cover flange for proper alignment.Install the through bolts.
469"$,50"

Tightening torque:4Nm(0.4 kgm / 35 lb in)

6D-14

ENGINE ELECTRICAL (4JJ1)

Starter Motor
Starting Circuit Diagram
Type : S13-555A

Starter switch

3. Install the E/G oil level gage. 4. Install the A/T oil level gage. 5. Reconnect the battery cable at the starter motor and the ground cable at the cylinder body. 6. Reconnect the battery cable and the ground cable at the battery terminals.

Battery

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 E/G 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. Motor Bolt Torque: 85 (8.7 / 63) Nm (kgm / lb ft)

ENGINE ELECTRICAL (4JJ1) Components


24 V 4.0 kW
6 4 3 2 1 26 8 25 5

6D-15

19

20

21

22

23

24

17

18

10 11 12 13 14

15 16
LNW76DLF000201

Legend 1. Plunger 2. Dust Cover 3. Magnetic Switch 4. Terminal Cover 5. Gear Case 6. T0rsion Spring 7. Dust Cover 8. Shift Lever 9. Through Bolt 10. Rear Cover 11. Brush Holder 12. O Ring 13. Yoke

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

Ball Bearing Armature Ball Bearing Bearing Retainer Pinion Shaft Ball Bearing Clutch Ball Bearing Return Spring Stopper Clip Ball Bearing Bearing Holder

6D-16

ENGINE ELECTRICAL (4JJ1)

24 V 4.5 kW
4 3 2 1 33 34 7 32 6 5

27 26

28

29

30

31

9 24 25

21 19 20

22

23

10 13 14 15 17 18
LNW76DLF000301

12

11

16

Legend 1. Plunger 2. Dust Cover 3. Magnetic Switch 4. Terminal Cover 5. Torsion Spring 6. Shift Lever 7. Dust Cover 8. Gear Case 9. Through Bolt 10. Rear Cover 11. Drain Pipe 12. Brush Holder 13. O Ring 14. Yoke 15. O Ring 16. Ball Bearing 17. Armature

18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

Ball Bearing Bearing Retainer Clip Pinion Stopper Pinion Cushion Spring Sleeve Cover Stopper Washer Pinion Shaft Ball Bearing Clutch Ball Bearing Return Spring Stopper Clip Ball Bearing Bearing Holder

ENGINE ELECTRICAL (4JJ1)


Important Operations 1. Lead Wire Disconnect the lead wire at the magnetic switch.

6D-17

Remove the torsion spring from the magnetic switch.

469"$,50 & 469"$,50 $

2. Magnetic Switch Assembly Remove the magnetic switch bolts, then remove the switch from the shift lever.

3. Through Bolt 4. Screw 5. Rear Cover Remove the through bolts, then remove the rear cover.

469"$,50 % 469"$,50 '

6D-18

ENGINE ELECTRICAL (4JJ1)


9. Armature Remove the brush holder and pull out the armature assembly free from the yoke.

6. Motor Assembly Remove the four brushes from the brush holders.

*HKID

469"$,50! 469"$,50! 

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.

10. 11. 12. 13. 14. 15.

Bearing Retainer Pinion Assembly Dust Cover Shift Lever (4.0kW only) Shift Lever and Lever pin (4.5kW only) Gear Case a. Remove the bearing retainer. b. Remove the pinion from the gear case.

469"$,50!

7. Brush Holder 8. Yoke


LNW76DSH000901

ENGINE ELECTRICAL (4JJ1)


c. Use a screwdriver to remove the stopper clip. Then disassemble the pinion assembly.

6D-19
for

2. Check the commutator mica segments excessive wear. 3. Measure the mica segment depth. Mica Segment Depth Standard Limit mm (in)

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.

469"$,50!"

 !

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 Standard Limit mm (in) 0.05 (0.002) 0.20 (0.079)
# "

469#$,50%

Legend 1. Insulator 2. 0.5 to 0.8 mm (0.020 to 0.030 in) 3. Commutator Segments 4. Correct 5. Incorrect 4. Measure the commutator outside diameter. Commutator Outside Diameter Standard Limit mm (in) 36.5 (1.44) 35.5 (1.40)

469"$,50!#

6D-20

ENGINE ELECTRICAL (4JJ1)


b. 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.

If the measured outside diameter is less than the specified limit, the commutator must be replaced.

0+9#-50'

5. Use a circuit tester to check the armature grounding. a. Hold one probe of the circuit tester against commutator segment. b. Hold the other circuit tester probe against armature core. If the circuit tester indicates continuity, armature is grounded. The armature must be replaced.

for the the the Yoke 1. Use a circuit tester to check the field winding ground. a. Hold one circuit tester probe against the field winding end or brush. b. Hold the other circuit tester probe against the bare surface of the yoke body. There should be no continuity. If there is continuity, the field coil is grounded. The yoke must be replaced.
469"$,50!%

469"$,50!$

6. Use the circuit tester to check the armature for continuity. a. Hold the circuit tester probes against two commutator segments.

469"$,50!&

2. Use the circuit tester to check the field winding continuity. a. Hold one circuit tester probe against the "M" terminal lead wire.

ENGINE ELECTRICAL (4JJ1)


b. 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.

6D-21

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.

469"$,50!' 469"$,50"

Brush and Brush Holder 1. 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 Standard Limit mm (in) 15.5 (0.61) 12 (0.47)

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.

469"$,50"

LNW61DSH002701

6D-22
Bearing

ENGINE ELECTRICAL (4JJ1)


b. Install the dust cover. and Dust Cover Bolt Torque: 10.6 (1.08 / 78) Nm (kgm/lb in)

Inspect the bearings for excessive wear damage.Replace the bearings if necessary.

469"$,50""

Reassembly
Important Operations 1. Magnetic Switch Assembly a. Attach the torsion spring to the hole in the magnetic switch as illustrated. b. Insert the shift lever into the plunger hole of the magnetic switch.

469"$,50#%

4. Pinion Assembly Apply a coat of grease to the reduction gear and install the pinion assembly to the armature shaft.

LNW61DSH002801

469"$,50#$

2. Gear Case 3. Dust Cover a. Install the magnetic switch assembly in the gear case.

5. Brush Holders a. Install the brushes into the brush holder with raising the spring end of the brush spring. Take care not to damage the commutator face.

ENGINE ELECTRICAL (4JJ1)


b. Install the brush holder with aligning the peripheries of the yoke and the brush holder.

6D-23

469"$,50 $ 469"$,50"#

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: 0.3 - 1.0 (0.012 - 0.039) mm (in)

6. Through Bolt Install the through bolts in the rear cover and tighten them to the specified torque. Through Bolt Torque: 8.1 (0.83 / 69.7) Nm (kgm/lb in)

0.3-1.0mm

LNW61DSH002901

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: 8.6 (0.88 / 74.9) Nm (kgm/lb in)

LNW76DSH001001

6D-24

ENGINE ELECTRICAL (4JJ1)


3. Return Test Disconnect the battery positive lead at the S terminal. The pinion should return to its home position.
5

Magnetic Switch
The following tests must be performed with the starter motor fully assembled. The yoke lead wire must be disconnected from the "M" terminal. To prevent coil burning, complete each test as quickly as possible (within three to five seconds). Temporarily connect the solenoid switch between the clutch and the housing and run the following test. Complete each test within three to five seconds. 1. Pull-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 battery positive terminal, the pinion should flutter.
5

469"$,50"%

469"$,50"$

2. Hold-in Maintenance Test Disconnect the lead at the M terminal. The pinion should continue to flutter.

469"$,50#'

ENGINE ELECTRICAL (4JJ1)

6D-25

8.6 (0.88 / 6.4)

8.1 (0.83 / 6.0)

LNW76DLF000401

6D-26

ENGINE ELECTRICAL (4JJ1)

Pre-Heating System
Inspection and Repair
Make the necessary adjustments, repairs, and part replacement if excessive wear of damage is discovered during inspection. Visual Check Check the main fuses and glow indicator for damage. Replace the part(s) if required. Glow Relay The glow relay is located in the relay box the engine compartment. Use an ohmmeter to measure the resistance between terminals No.2 and No.3. If the measured value is outside the specified range, the glow relay must be replaced.
LNW21KSH001401

Glow Relay Resistance: 94 - 114

1 3 4 4 2 1 3 2

LNW61DSH003001

Glow Plug Use a circuit tester to test the glow plugs for continuity. Glow Plug Resistance (Reference): Approximately 0.9

EXHAUST SYSTEM (4JJ1)

6F-1

ENGINE
EXHAUST SYSTEM (4JJ1) TABLE OF CONTENTS
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-2 Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6F-2 Explanations on functions and operation . . . . . . 6F-2 Functional check . . . . . . . . . . . . . . . . . . . . . . . . 6F-3 List of abnormal phenomena . . . . . . . . . . . . . . . 6F-3 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . 6F-3 Exhaust Silencer and Exhaust Pipe . . . . . . . . . . . 6F-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-4 DPD Disassembly . . . . . . . . . . . . . . . . . . . . . . . 6F-5 DPD Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 6F-6 DPD Reassembly. . . . . . . . . . . . . . . . . . . . . . . . 6F-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-8 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-10 Exhaust Brake System . . . . . . . . . . . . . . . . . . . . 6F-11 Service Precautions . . . . . . . . . . . . . . . . . . . . . 6F-11 Explanations on functions and operation . . . . . 6F-11 Functional check . . . . . . . . . . . . . . . . . . . . . . . 6F-11 Exhaust Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-13 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-14 Exhaust Throttle . . . . . . . . . . . . . . . . . . . . . . . . . 6F-15 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-15 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-17 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-18 EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-19 Service Precautions . . . . . . . . . . . . . . . . . . . . . 6F-19 Explanations on functions and operation . . . . . 6F-19 EGR Valve and EGR Cooler . . . . . . . . . . . . . . . . 6F-20 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-21 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-22

6F-2

EXHAUST SYSTEM (4JJ1)

Exhaust System
Service Precautions
Offset in position of the exhaust system during assembly may sometimes cause vibrations or rattling noise. Therefore, temporarily tighten the bolt until all the parts have been positioned, and sequentially tighten from the engine side to the rear pipe side.

Explanations on functions and operation


The exhaust brake assembly operates the auxiliary brakes by adjusting the exhaust pressure. The silencer has a built-in catalytic converter and the catalyst is a ceramic monolith (honeycomb). This reduces the CO and HC in the exhaust gas. The rear exhaust pipe has a built-in post silencer. This improves the silencing effect. The main parts consist of the front exhaust pipe, center exhaust pipe, exhaust brake unit, silencer with built-in catalyst, and rear exhaust pipe.

3 2

7 1 6

9 5

LNW76FLF000201

Legend 1. Front Exhaust Pipe A 2. Exhaust Brake Assembly 3. Front Exhaust Pipe B 4. DPD(Diesel Particulate Specification)

Defuser,

EURO

5. 6. 7. 8. 9.

Exhaust Silencer(EURO 3 Specification) Exhaust Throttle Assembly Exhaust Silencer Center Exhaust Pipe Rear Exhaust Pipe

EXHAUST SYSTEM (4JJ1) Functional check


During check or repairs of the exhaust system, confirm that the clearance between the body and the floor is adequate. Adequate care should be taken to prevent damage due to heating or vibrations in the body panel as it may lead to exhaust gas entering the cabin. Check for loose or damaged connectors and leakage of exhaust gas. Check for degradation, cracks or damage to the clamp or rubber. If the pipe or silencer is damaged or has a dent then repair or replace it. Vibration or rattling noise from the exhaust system Condition Possible Cause Correction

6F-3

Check for dents, damage holes or cracks due to corrosion, and abnormal noise during operation. If CO or HC value in the exhaust gas increases when measuring the exhaust gas (vehicle inspection, etc.), replace the silencer (built-in catalyst).

List of abnormal phenomena


Vibration or rattling noise from the exhaust system. Clogging of the exhaust system. Exhaust leakage or noise.

Trouble Shooting

Vibration or rattling noise from the Loose or misaligned components Match the joints and then re-tighten. exhaust system Or,check for damage in the hanger, mounting brackets and clamps. Clogging of the exhaust system Condition Clogging of the exhaust system Possible Cause Correction

The exhaust brake is in the ON Refer to the Engine Control Systems status. in 6E section, check the electric system and repair if there are abnormalities. Check if the shaft movement in the exhaust brake throttle valve moves is jerky and replace if there is an abnormality. Clogging or deformation of the Repair or replace the exhaust piping. exhaust piping.

Exhaust leakage or noise Condition Exhaust leakage or noise Possible Cause Defect or misalignment in mounting Correction Match the joints and then re-tighten.

Damage or burn-out of exhaust Replace the damaged parts. piping or silencer Defective components in the Replace the defective parts. exhaust system (clamps, pipes, silencer) Internal damage to silencer Replace the silencer

6F-4

EXHAUST SYSTEM (4JJ1)

Exhaust Silencer and Exhaust Pipe


Removal
1. Remove the rear exhaust pipe. Remove the clamp and rear exhaust pipe.
3

2 1

4 5

LNW76FSH000101

LNW76FSH000501

2. 3. 4. 5. 6.

Remove the center exhaust pipe. Remove the exhaust silencer. Remove the exhaust throttle air pipe. Remove the exhaust throttle assembly. Remove the exhaust silencer(EURO 3 Specification). 7. Remove the DPD assembly (EURO 4 Specification). Remove the 2 connectors on the DPD exhaust temperature sensor. Remove the clip that secures the connectors on the DPD exhaust temperature sensor. Remove the 2 DPD differential pressure hoses. Remove the DPD assembly from the front pipe.

Legend 1. Differential Pressure Pipe (F) 2. Exhaust Temperature Sensor (R) 3. Differential Pressure Sensor 4. Differential Pressure Hose (F) 5. Differential Pressure Hose (R) 6. Differential Pressure Pipe (R) 7. Exhaust Temperature Sensor (F) NOTE: In the event that the differential pressure sensor assembly must be removed, pay attention to the following points. Do not loosen the 4 screws used to tighten the differential pressure sensor. If these screws have been loosened, replace the differential pressure sensor assembly. If the differential sensor assembly is dropped, it cannot be reused.

EXHAUST SYSTEM (4JJ1)

6F-5

1 2 3

LNW76FSH000201

LNW76FSH000301

Legend 1. Sensor Assembly 2. Tightening Screw 8. Remove the front exhaust pipe (B). 9. Remove the exhaust brake. Remove the air hose and the exhaust brake assembly. 10. Remove the front pipe (A). Remove the clamp and front pipe.

Legend 1. Hose Clip 2. Sleeve Nut (Rr) 3. Clip 4. Sleeve Nut (Ft) 5. Disassemble the DPD assembly. Loosen the nuts used for mounting the oxidation catalyst section, and detach the oxidation catalyst section. Loosen the nuts used for mounting the filter and detach the filter and rear case. NOTE: Do not submit the DPD assembly to high impact or drop the assembly.

DPD Disassembly
1. Loosen the clip (1) from the hose connecting to the differential pressure pipe and remove the hose. 2. Loosen the sleeve nuts (2) and (4) that secure the differential pressure pipe. 3. Remove the clip (3) that secure the differential pressure pipe. 4. Remove the differential pressure pipe.

6F-6

EXHAUST SYSTEM (4JJ1)

4 3

1 2

LNW41GSH000201

LNW41GSH000601

Legend 1. Oxidation Catalyst Section 2. Gasket 3. Filter Section 4. Gasket 5. Rear Case

Legend 1. Filter 2. Filter Case 3. If the differential pressure sensor assembly has been replaced, carry out the following steps (on the vehicle). Without turning the engine on, turn the key from "OFF" to "ON". The DPD lamp is turned on, and then after 30 seconds turned off. After confirming that the DPD lamp has gone off, turn the key to the "OFF" position and leave for 15 seconds. 4. Check the oxidation catalyst. Visually inspect the catalyst for erosion, damage, or plugging.

DPD Inspection
1. Perform an external appearance inspection on exhaust pipe related components. Damage to a body panel caused by heating or vibration can lead to exhaust gas intruding into the cabin. Inspect the connections for looseness, damage, and exhaust gas leaks. Inspect the clamps and rubber for deterioration, cracks, and damage. Inspect the pipe and silencer for dents and corrosion induced cracks, and if damaged, repair or replace the damaged part(s). 2. Perform an DPD related inspection. Visually inspect the filter for erosion, damage, or blocking. Light shines through the filter from the opposite side. If light is transmitted and is visible, replace the filter section. NOTE: Before DPD disassemble, be sure to use a scan tool to check the DPD differential pressure, status, and inspection and servicing details. Refer to the "Engine control" section for details.

DPD Reassembly
1. Insert gaskets in the filter section and the rear case and tighten temporarily with bolts and nuts. 2. Insert gaskets in the filter section and oxidation catalyst and tighten temporarily with bolts and nuts. NOTE: Check the mounting location of the filter section and rear case, and the filter section and oxidation catalyst, and tighten each pipe bracket in 2 places by tightening the bolts alternatively. 3. Tighten the bolts and nuts to the specified torque. Tighten all of the bolts and nuts twice. Torque : 25 Nm (2.5 kgm / 18 lbft)

EXHAUST SYSTEM (4JJ1)


NOTE: After tightening all of the bolts and all of the nuts, tighten them all to the same torque (tightening twice)

6F-7

7. Insert the hose for the differential pressure pipe until it reaches the spool and secure with a clip.

4 3 2

1
5

2
1

LNW76FSH000301
LNW41GSH000201

Legend 1. Oxidation Catalyst Section 2. Gasket 3. Filter Section 4. Gasket 5. Rear Case 4. Insert the protruded section of the differential pressure pipe (only Ft side) into DPF and tighten the sleeve nut (4) by hand. Then, tighten the sleeve nut (Rr) (2) by hand. NOTE: Clean the old anti-seize compound from the sleeve nut and apply new anti-seize compound. 5. Fix the pipe in place using a clip (3). Torque: 10 Nm (1.0 kgm / 87 lbin) 6. Fully tighten the sleeve nuts. Torque (Ft): 45 Nm (4.6 kgm / 33 lbft) Torque (Rr): 35 Nm (3.6 kgm / 26 lbft)

Legend 1. Hose Clip 2. Sleeve Nut (Rr) 3. Clip 4. Sleeve Nut (Ft) NOTE: If the procedures described above are not followed, the sleeve nut may become loose. Air-tightness check Once the engine is warmed up, run at maximum non-load RPM. To ensure there are no gas leakages, with the engine revved up, spray soapy water on the pressure hose (1) and sleeve nuts (2) (4) connecting parts.

6F-8

EXHAUST SYSTEM (4JJ1)


Attach the hose clips (4 locations) securely to prevent gas leakage.
1

2 3

NOTE: Do not confuse the front/rear directions. Do not use hoses that are cracked. Do not overtighten or remove the differential sensor assembly's tightening screws. If there is a gas leak in the coupling section, a sensor malfunction may occur. Ensure to check for gas leakage after starting the engine.

LNW76FSH000301

Legend 1. Hose clip 2. Sleeve Nut (Rr) 3. Clip 4. Sleeve Nut (Ft)

Installation
NOTE: A possible cause of vibration or looseness is the misspositioning of the exhaust system during assembly. Therefore, do not fully tighten the bolts until all the components are positioned, and when positioned, tighten the bolts starting at the engine and working outwards. Do not re-use gaskets or nuts that were removed. 1. Install the front exhaust pipe A. Torque : 67 Nm (6.8 kgm / 49 lbft) NOTE: Tighten the front exhaust pipe so that it is balanced, and make sure there are not any gas leaks. 2. Install the exhaust brake and front exhaust pipe B. Install the air hose. Torque : 27 Nm (2.8 kgm / 20 lbft) 3. Install the DPD assembly to the front pipe (EURO 4 Specification). Torque : 22 Nm (2.2 kgm / 16 lbft) 4. Install the DPD differential pressure hose to the differential pressure pipe (EURO 4 Specification). Insert the front side of the differential pressure hose into the port of the differential pressure sensor that is marked "F" (white).

6 5

3 4

LNW41GSH000901

Legend 1. Differential Pressure Sensor 2. Clip 3. Differential Pressure Hose 4. Properly Fitted Hoses 5. Reversely Fitted Hoses 6. Differential Pressure Hose 7. Clip 8. Differential Pressure Sensor

EXHAUST SYSTEM (4JJ1)

6F-9

6. Fix the DPD temperature sensor harness with clips (EURO 4 Specification). 7. Install the exhaust silencer to the front pipe (EURO 3 Specification).
1
F

Torque : 50 Nm (5.1 kgm / 37 lbft) 8. Install the exhaust throttle assembly and extension pipe. Torque : 27 Nm (2.8 kgm / 20 lbft) 9. Install the exhaust throttle air hose. 10. Install the center exhaust pipe. 11. Install the rear exhaust pipe. Tighten the clamp. Torque : 50 Nm (5.1 kgm / 37 lbft)
LNW41GSH000801

5 4 3

Legend 1. Nut 2. F; Front Mark 3. Rear Side Differential Pressure Hose Spigot 4. Front Side Differential Pressure Hose Spigot 5. Bracket 5. Connect the DPD temperature sensor connectors (EURO 4 Specification). NOTE: Do not confuse the front/rear directions.

3
LNW76FSH000501

2 1

4 5

LNW76FSH000101

Legend 1. Differential pressure pipe (F) 2. Exhaust temperature sensor 1 (filter inlet) 3. Differential pressure sensor 4. Differential pressure hose (F) 5. Differential pressure hose (R) 6. Differential pressure pipe (R) 7. Exhaust temperature sensor 2 (catalyst inlet)

6F-10

EXHAUST SYSTEM (4JJ1)

Torque Specifications

22(2.2/16)

27(2.8/20)

27(2.8/20) 67(6.8/49)

50(5.1/37)

50(5.1/37)

LNW76FLF000401

EXHAUST SYSTEM (4JJ1)

6F-11

Exhaust Brake System


Service Precautions
During assembly and mounting, mount the parts appropriately at the specified tightening torque value.

Explanations on functions and operation

LNW21GMF001401

Functional check
Operational check Confirm the sound of the valve touching the stopper when the exhaust brake is operated in the idling condition.

6F-12

EXHAUST SYSTEM (4JJ1)

Exhaust Brake
Components

2 10 4 5 6 3

LNW76FMF000101

Legend 1. Power Chamber, Insulator, Gasket and Bearing 2. Lock Nuts and Clevis Joint 3. Split Pin and washer 4. Exhaust Brake Valve

5. Front Exhaust Pipe B 6. Exhaust Brake Assembly 7. Front Exhaust Pipe A

Removal
1. 2. 3. 4. Remove the vacuum and clips. Remove the nut. Remove the exhaust pipe. Remove the exhaust brake assembly.

Disassembly
1. 2. 3. 4. Remove the split pin. Remove the lock nuts. Remove the clevis joint. Remove the power chamber.

Reassembly
1. Mount the power chamber.

EXHAUST SYSTEM (4JJ1)


Tightening torque : 14 Nm (1.4kgm / 122lbin) Unit check

6F-13

Negative pressure in the power chamber caused by the vacuum pump. When a pressure of 53.3 to 93.3 kPa (400 to 700 mmHg) is applied, the exhaust brake valve should open or close smoothly.

LNW21GSH001601

2. Mount the lock nuts. 3. After mounting the clevis joint, tighten the lock nuts to the specified torque. Tightening torque : 13Nm (1.3kgm / 113lbin)

LNW21GSH001401

Installation
1. Mount the exhaust brake assembly. Tightening torque : 17Nm (1.7 kgm / 12 lbft)

LNW21GSH002201

4. Mount the split pin.

Inspection
Check for damage or degradation in the parts mentioned below. Exhaust brake valve Exhaust brake shaft Butterfly valve Bush Power chamber
LNW46FSH000101

6F-14

EXHAUST SYSTEM (4JJ1)


3. Mount the nuts. Tightening torque : 67 Nm (6.8kgm / 49lbft) 4. Mount the vacuum hose and the clips.

2. Mount the exhaust pipe.

LNW76FSH000401

Torque Specifications

M6

41 (4.2/30)

27 (2.8/20)

67 (6.8/49)
LNW76FMF000201

EXHAUST SYSTEM (4JJ1)

6F-15

Exhaust Throttle
Components

2 12 4 5 6 11 7 9 8 3

10

LNW76GMF000101

Legend 1. Power Chamber 2. Gasket 3. Insulator 4. Bearing 5. Lock Nuts and Clevis Joint 6. Pin and Split Pin

7. 8. 9. 10. 11. 12.

Cover Extension Silencer Exhaust Center Pipe DPD (Diesel Particulate Defuser) Exhaust Throttle Body Exhaust Throttle Asembly

Removal
1. 2. 3. 4. 5. Remove the vacuum hose and clip. Remove the nut. Remove the rear exhaust pipe. Remove the center exhaust pipe. Remove the exhaust silencer.

6F-16

EXHAUST SYSTEM (4JJ1)


Unit inspection Apply vacuum pressure to the power chamber using a vacuum pump. The exhaust throttle valve should open and close smoothly when pressure of 75 - 93.3kPa {560 700mmHg} is applied.

LNW76FSH000601

6. Remove the exhaust throttle assembly.

Disassembly
1. 2. 3. 4. Remove the split pin. Remove the lock nut. Remove the clevis joint. Remove the power chamber.
LNW21GSH001401

NOTE: Do not change the exhaust throttle's adjustment as it may have an affect on DPD performance.

Inspection
Inspect the following parts deterioration, etc. Exhaust throttle valve Exhaust throttle shaft Butterfly valve Power chamber for damage and

Reassembly
1. Install the power chamber. Tightening torque 14 Nm (1.4 kgm / 122 lbin)

LNW41GSH001101

2. Install the lock nut. 3. After mounting the clevis joint, tighten the lock nut to specified tightening torque. Tightening torque 13 Nm (1.3 kgm / 113 lbin)

EXHAUST SYSTEM (4JJ1)


NOTE: Do not adjust or remove the adjusting bolt. Do not remove the lever. 4. Install the rear exhaust pipe.

6F-17

LNW76FSH000601

Tightening torque 50 Nm (5.1 kgm / 37 lbin)


LNW41GSH001201

Legend 1. Lever 2. Adjusting bolt 4. Install the split pin.

5. Install the vacuum hose and clip.

Installation
1. Install the exhaust throttle assembly. Tightening torque 20Nm (2.0kgm / 14 lbin)

LNW21GSH002301

2. Install the exhaust silencer. 3. Install the exhaust center pipe.

6F-18

EXHAUST SYSTEM (4JJ1)

Torque Specifications

13 (1.3/113lb in)

14 (1.4/122lb in)

27 (2.8/20)

50 (5.1/37)

LNW76GLF000101

EXHAUST SYSTEM (4JJ1)

6F-19

EGR System
Service Precautions
Perform EGR related assembly according to the usual procedure of temporarily fitting and then permanently tightening the parts so that unnecessary stresses are not applied on the parts.

Explanations on functions and operation


Re-circulate a part of the exhaust gas of the EGR system in the intake manifold.Reduce the combustion temperature and inhibit NOx generation since inert gases may be mixed up in the intake sir. An electronic control system is used in this EGR to balance the requirements of operability and low emissions.A DC motor is operated using the control current of the Engine Control Module (ECM) to control the EGR. Refer to the chapter on Engine Control System for details on fault diagnosis of the EGR system.
2

LNW46FMF000501

Legend 1. EGR cooler 2. Engine Control Module (ECM)

3. EGR Valve DC Motor

6F-20

EXHAUST SYSTEM (4JJ1)

EGR Valve and EGR Cooler


Components

1 2 3 4

5 6

LNW71FLF000101

Legend 1. EGR Valve 2. EGR Valve Gasket 3. EGR Cooler

4. Heat Protector 5. EGR Cooler Gasket 6. EGR Cooler Gasket

Removal
1. Drain the coolant. 2. Remove the turbocharger. Refer to Turbocharger in ENGINE MECHANICAL section.

EXHAUST SYSTEM (4JJ1)


3. Remove the heat protector.

6F-21

b. Tighten the bolt and nuts by final tightening order. Final tightening order : 345126 Tightening torque : Bolt, Nut 1 to 5 27 Nm (2.8 kgm / 20 lbft) Bolt 6 52 Nm (5.3 kgm / 38 lbft)

6 1 2
LNW71FSH000101

4 3 5

4. Remove the EGR cooler. Disconnect the Water pipe rubber hose (IN , OUT) and remove the EGR cooler and gasket. 5. Remove the EGR valve.
LNW71FSH000201

3. Connect the water pipe rubber hose (IN,OUT). 4. Install the heat protector Tightening torque : 25 Nm (2.5 kgm / 18 lbft) 5. Install the turbocharger. Refer to Turbocharger in ENGINE MECHANICAL section. 6. Replenish the coolant.

LNW71FSH000301

Installation
1. Install the EGR valve. Tightening torque : 27 Nm (2.8kgm / 20lbft) 2. Install the EGR Cooler. a. Install the gaskets and the EGR cooler. Temporarily tighten the bolts and the nuts. Temporary tightening order : 123456

6F-22

EXHAUST SYSTEM (4JJ1)

Torque Specifications

52 (5.3/38)

27 (2.8/20)

27 (2.8/20)

25 (2.5/18)

27 (2.8/20)

LNW76FLF000101

ACCELERATOR CONTROL SYSYEM (4JJ1)

6H-1

ENGINE
ACCELERATOR CONTROL SYSYEM (4JJ1) TABLE OF CONTENTS
Accelerator Pedal Assembly . . . . . . . . . . . . . . . . .6H-2 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .6H-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6H-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6H-2

6H-2

ACCELERATOR CONTROL SYSYEM (4JJ1)

Accelerator Pedal Assembly


Components

1 2

LNW41ILF000101

Legend 1. Nut 2. Connector 3. Control Link and Bracket Assembly

4. Accelerator Pedal 5. Bolt

Removal
1. Nut to Contorol Link and Bracket Assembly 2. Bolt to Accelerator Pedal 3. Harness Connector to Accelerator Switch Connector and Accelerator Position Sensor NOTE: Disconnect the battery ground cable when the harness connector is disconnected.

Installation
1. Install the Harness Connector 2. Instal the Accelerator Pedal Bolt 3. Install the Control Link and Bracket Assembly

LG4JJ-WE-0761

You are requested to order this manual using the manual number that is shown above.

This manual is applicable for vehicles in all countries except the USA, Canada and Mexico.

All rights reserved. This manual may not be reproduced in whole or in part, without the permission in writing of ISUZU MOTORS LIMITED. Issued by

ISUZU MOTORS LIMITED


SERVICE MARKETING DEPARTMENT Tokyo, Japan First edition August. 2006

No. LG4JJ-WE-0761