1B Engine Mechanical (4JJ1 Without DPD) PDF

Camshaft removal (4JJ1 without DPD)
1. Component views
Camshaft
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Part name
1. Exhaust camshaft
2. Camshaft upper bracket
3. M8 bolt
4. M6 bolt
5. Inlet camshaft
Tightening torque
3: 18 N・m { 1.8 kgf・m / 13 lb・ft } Wet

4: 7.0 N・m { 0.7 kgf・m / 62 lb・in } Dry
4: 6.0 N・m { 0.6 kgf・m / 53 lb・in } Wet
2. Injector removal
Refer to "1.Engine 1C.Fuel System(4JJ1 without DPD) injector removal".
3. Baffle plate removal
1) Rotate the crankshaft in the forward direction (clockwise) to align the No. 1 cylinder piston to compression top
dead center.
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Legend
1. Top dead center alignment mark on the gear case cover side
2. Top dead center alignment mark on the crank pulley side
2) Remove the baffle plate from the cylinder head.
4. Camshaft removal
1) Measure the axial direction clearance of the camshaft gear and camshaft bracket using a feeler gauge.
Note
If the measured value exceeds the limit, replace the camshaft.
Standard: 0.050 to 0.130 mm { 0.00197 to 0.00512 in }
Limit: 0.250 mm { 0.00984 in }
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Legend
1. Camshaft
2. Camshaft bracket
3. Camshaft gear
2) Use the M5 lock bolt to secure the camshaft gear.
3) Remove the camshaft upper bracket from the camshaft brackets.
Note
Check that there are installation position markings on the camshaft upper brackets.
4) Remove the inlet camshaft and exhaust camshaft from the camshaft brackets.
Caution
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Take measures to prevent the inlet and exhaust sides from becoming mixed up.
Legend

2. Inlet camshaft
3. Exhaust camshaft
Camshaft inspection (4JJ1 without DPD)
1. Camshaft inspection
1. Visual inspection
1) Inspect the camshaft journal and cam for the following.
Damage
Wear
Note
Replace the camshaft if an abnormal condition is found.
2. Camshaft runout measurement
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1) Put the camshaft on the V-block.
2) Slowly turn the camshaft to measure the camshaft runout using a dial gauge.
Limit: 0.05 mm { 0.0020 in }
Note
3. Cam lobe height measurement
1) Measure the height of the cam lobe using a micrometer.
Note
Cam lobe height
Standard 40.8 mm {
value 1.606 in }
Inlet
39.8 mm {
Limit
1.567 in }
Standard 40.8 mm {
value 1.606 in }
Exhaust
39.8 mm {
Limit
1.567 in }
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4. Camshaft journal measurement
1) Measure the diameter of the camshaft journal using a micrometer.
Camshaft journal diameter

29.909 to
Standard 29.930 mm {
value 1.1775 to
Inlet 1.1783 in }
29.809 mm {
Limit
1.1736 in }
29.909 to
Standard 29.930 mm {
value 1.1775 to
Exhaust 1.1783 in }
29.809 mm {
Limit
1.1736 in }
Uneven 0.05 mm {
Limit
wear 0.0020 in }
Note
2) Measure the inner diameter of the camshaft bracket using a cylinder gauge.
3) Calculate the clearance from the camshaft bracket inner diameter and journal diameter measurements.
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Clearance between the camshaft
bracket inner diameter and the
journal diameter
0.070 to 0.112
Standard
mm { 0.0028 to
value
Inlet 0.0044 in }
0.15 mm {
Limit
0.0059 in }
0.070 to 0.112
Standard
mm { 0.0028 to
value
Exhaust 0.0044 in }
0.15 mm {
Limit
0.0059 in }
Note
Replace the camshaft or camshaft bracket if the measured value exceeds the limit.
Camshaft installation (4JJ1 without DPD)
1. Component views
Camshaft
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Part name
1. Exhaust camshaft
3. M8 bolt
4. M6 bolt
5. Inlet camshaft
Tightening torque
3: 18 N・m { 1.8 kgf・m / 13 lb・ft } Wet

4: 7.0 N・m { 0.7 kgf・m / 62 lb・in } Dry
4: 6.0 N・m { 0.6 kgf・m / 53 lb・in } Wet
2. Camshaft installation
dead center.
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Legend
2) Apply the engine oil to the camshaft journal.
3) Install the camshaft to the camshaft brackets with the inlet camshaft and exhaust camshaft markings upward.
Caution
Check the marking on the camshaft upper bracket.
4) Align the camshaft timing marks with idle gear D.
Caution
Loosen the rocker arm adjust nut in advance and loosen the adjust screw by 2 pitch or more.
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Legend
1. Exhaust camshaft gear

2. Inlet camshaft gear
3. Idle gear D
5) Apply engine oil to the following parts.
Camshaft upper bracket sliding surface

Camshaft journal
Threaded portion and seating surface of bolts
6) Align the inlet camshaft and exhaust camshaft alignment marks with the camshaft upper bracket.
Caution
Confirm that the valve cap is correctly installed to the valve stem end.
Check that the valve cap does not come off or ride up.
Legend
1. Alignment mark
7) Temporarily tighten the camshaft upper bracket M8 bolts to the cylinder head in the order shown in the diagram.
Caution
Check the marking on the top surface.
8) Final tighten the camshaft upper bracket M8 bolts to the cylinder head in the order shown in the diagram.
Tightening torque: 18 N・m { 1.8 kgf・m / 13 lb・ft } Wet
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9) Temporarily tighten the camshaft upper bracket M6 bolts to the camshaft brackets in the order shown in the
diagram.
10) Final tighten the camshaft upper bracket M6 bolts to the camshaft brackets in the order shown in the diagram.
Tightening torque: 7.0 N・m { 0.7 kgf・m / 62 lb・in } Dry
Tightening torque: 6.0 N・m { 0.6 kgf・m / 53 lb・in } Wet

11) Remove the lock bolt from the camshaft gear.
3. Rocker arm adjustment
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dead center.
Legend
2) Loosen the adjust screw of the rocker arm using the special tool.
SST: 5-8840-2822-0 - valve clearance adjust nut wrench
Legend
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1. Screwdriver
2. Ring spanner
3. 5-8840-2822-0
3) Insert a feeler gauge between the rocker arm roller and the cam.
Note
Tighten the rocker arm adjust screw, and adjust the valve clearance to the standard value.
Standard: 0.15 mm { 0.0059 in } When cold
4) Lightly tighten the adjust screw with the feeler gauge inserted using the special tool.
Legend
1. Cam (Exhaust side)

2. Cam (Inlet side)
3. Roller (Inlet side)
4. Roller (Exhaust side)
5) Verify that the movement of the feeler gauge becomes stiff.
6) Secure the rocker arm adjust screw with the adjust screw nut.
Tightening torque: 18 N・m { 1.8 kgf・m / 13 lb・ft }
Measurable valve position

Cylinder #1 #2 #3 #4
position IN EX IN EX IN EX IN EX
No. 1
cylinder
compression ○ ○ ○ ○
top dead
center
No. 4
cylinder
top dead
center
7) Rotate the crankshaft for 1 turn, and adjust any remaining valve clearance.
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4. Baffle plate installation
1) Install the baffle plate to the cylinder head.
Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
5. Injector installation
Refer to "1.Engine 1C.Fuel System(4JJ1 without DPD) injector installation".

Crankcase removal (4JJ1 without DPD)
1. Engine removal
Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) Engine removal".
2. Engine oil drain
1) Remove the drain plug from the oil pan, and drain the engine oil to a pan.
2) Install the drain plug to the oil pan.
Caution
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Do not reuse the gasket.
Do not forget to tighten the drain plug.
3. Generator removal
1) Disconnect the B-terminal from the generator.
2) Disconnect the connector from the generator.
3) Remove the upper bracket from the generator and timing gear case.
4) Remove the generator from the lower bracket.

4. A/C compressor bracket removal
1. Models with A/C compressor
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1) Remove the A/C compressor bracket from the cylinder head.
2. Models without A/C compressor
1) Remove the bracket from the A/C compressor bracket.

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5. Intake throttle valve removal
1) Disconnect the connector from the intake throttle valve.
2) Remove the intake throttle valve and gasket from the inlet manifold.
Legend
1. Intake throttle valve
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2. Gasket
6. EGR valve disconnect
1. Euro2 and Euro4 specifications
1) Disconnect the connector from the EGR valve.
7. Vacuum hose disconnect
1) Disconnect the vacuum hose from the inlet manifold.
8. Fuel leak-off pipe removal
1) Remove the fuel leak-off pipe from the fuel supply pump and common rail (fuel rail).
Caution
Cover the exposed section to prevent the intrusion of foreign material.
Legend
1. Fuel leak-off pipe
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9. Fuel feed pipe removal
1) Remove the fuel feed pipe from the fuel supply pump and common rail (fuel rail).
Caution
Legend
1. Fuel feed pipe
10. Injection pipe removal
1) Remove the clip from the injection pipe.
2) Remove the injection pipes from the injector and common rail (fuel rail).
Caution
Do not reuse the injection pipe.
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11. Common rail (fuel rail) removal
1) Remove the common rail (fuel rail) and bracket from the cylinder block.
Caution
Do not hold the FRP sensor.
Take care not to damage the connector section of the FRP sensor.
2) Remove the vacuum pipe from the cylinder block.
Legend
1. Vacuum pipe
2. Common rail (fuel rail) bracket
3. Common rail (fuel rail)
12. Glow plug removal

1) Remove the glow plug terminal and glow plug connector from the glow plug.
Legend
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1. Glow plug terminal
2. Glow plug connector
2) Remove the glow plug from the cylinder head.
Legend
1. Glow plug
13. Turbocharger water hose disconnect
1) Disconnect the turbocharger water feed hose from the water feed and return pipe.
2) Disconnect the turbocharger water return hose from the water feed and return pipe.
Without EGR and Euro2 specifications

Legend
1. Turbocharger water feed hose
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2. Turbocharger water return hose
Euro4 specifications
Legend

14. Exhaust manifold heat protector removal
1. Except Euro4 specifications
1) Remove the exhaust manifold heat protector from the exhaust manifold and bracket.
Without EGR
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2. Euro4 specifications
1) Remove the exhaust manifold heat protector from the exhaust manifold and EGR cooler.
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15. EGR pipe removal
1) Remove the EGR pipe and gasket from the inlet manifold and exhaust manifold.
16. Vacuum hose removal
1) Disconnect the vacuum hose from the turbocharger control solenoid valve.
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2) Remove the vacuum hose from the turbocharger and vacuum pipe.
RHD models
LHD models
17. Fuel leak-off hose removal
1) Disconnect the connector from the injector.
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2) Remove the fuel leak-off hose from the leak-off pipe.
Caution
Do not reuse the clips.
Legend
1. Fuel leak-off hose

2. Injector connector
3) Remove the injector leak-off pipe from the injector.
Caution
Do not reuse the injector leak-off pipe or clip.
Legend
1. Injector leak-off pipe
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2. Clip
18. Cylinder head cover removal
1) Disconnect the blow-by hose from the cylinder head cover.
2) Disconnect the harness clip from the cylinder head cover.

3) Remove the cylinder head cover from the cylinder head.
4) Remove the oil seal from the lower side of the cylinder head cover.
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19. EGR cooler water hose disconnect
1) Disconnect the EGR cooler water feed hose from the EGR cooler.
2) Disconnect the EGR cooler water return hose from the EGR cooler.
Legend
1. EGR cooler water return hose

2. EGR cooler water feed hose
20. Water pipe removal
1. Models with heaters (Except Euro4 specifications)

1) Disconnect the water hose from the water intake pipe.
2) Remove the water pipe from the oil cooler.
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2. Models with heaters (Euro4 specifications)
1) Disconnect the water hose from the water intake pipe and EGR cooler.
3. Models without heaters (Euro4 specifications)

21. Water intake pipe removal
1) Remove the water intake pipe and water hose as a set from the oil filter and oil cooler.
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Except Euro4 specifications
Legend
1. Gasket
2. Water intake pipe (Models without heaters)
3. Water intake pipe (Models with heaters)
22. Oil filter removal
1) Remove the oil filter and gasket from the oil cooler.
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23. Tension pulley removal
1) Remove the tension pulley from the generator bracket.

2) Remove the generator lower bracket from the cylinder block and timing gear case.
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24. Turbocharger oil pipe removal
1) Remove the turbocharger feed oil pipe and gasket from the turbocharger and oil cooler.
Legend
1. Turbocharger feed oil pipe
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2) Remove the oil return pipe and gasket from the turbocharger and crankcase.
25. Injector removal
1) Remove the injector clamp from the injector.
2) Remove the injector from the cylinder head.
Note
If it is difficult to remove the injector, use a remover.
Store the removed injectors with the cylinder numbers attached.
Caution
Cover the exposed portion to prevent foreign material from getting into the fuel system.
Do not damage the injector nozzle.
Absolutely never touch the injector solenoids because that can hinder their performance or cause
damage.
3) Remove the gasket from the injector.
4) Remove the O-ring from the injector.
Caution
Do not reuse the following parts.
Clip
O-ring
Gasket
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Legend
1. Injector
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket

27. Timing chain lower cover removal
1) Remove the noise cover from the timing chain lower cover.
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2) Remove the timing chain lower cover from the gear case cover.
1) Remove the water pipe from the following parts.
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Water outlet pipe
Cylinder head
Turbocharger
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1) Remove the tension pulley from the cylinder head.
30. Timing chain upper cover removal
1) Disconnect the connector from the CMP sensor.

Legend
1. CMP sensor
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2) Remove the timing chain upper cover from the cylinder head.
Legend
1. Timing chain upper cover
31. Timing chain removal
dead center.
Legend
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2) Align the marks of the camshaft upper bracket and camshaft.
Legend
1. Alignment mark
3) Remove the oil feed pipe from the timing chain tensioner.
4) Remove the timing chain tensioner and gasket from the cylinder head.
Legend
1. Oil feed pipe
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2. Timing chain tensioner
3. Gasket
5) Remove the timing chain lever pivot from the timing chain tension lever.
6) Remove the idle gear D shaft bolt and sleeve from idle gear D and sprocket.
7) Remove the sprocket and timing chain as a set from idle gear D.
Legend
1. Idle gear D shaft bolt
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2. Sleeve
3. Sprocket
8) Remove the timing chain from the supply pump sprocket by lowering the timing chain and sprocket.
9) Take the timing chain tension lever out from the cylinder head.
10) Remove the timing chain guide from the cylinder head and cylinder block.
Legend
1. Timing chain guide bolt
32. Fuel supply pump removal
1) Mark the alignment positions of idle gear A and the supply pump gear.
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2) Remove the supply pump gear from the fuel supply pump using a gear puller.
3) Disconnect the connector from the fuel temperature sensor.
4) Disconnect the connector from the FRP regulator.

Legend
1. Fuel temperature sensor connector
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2. FRP regulator connector
5) Remove the fuel supply pump from the timing gear case.
Caution
Do not hold the high pressure pipe.
Legend
1. Fuel supply pump
6) Remove the O-ring from the fuel supply pump.

Legend
1. Fuel supply pump
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2. O-ring
33. Camshaftbracket removal
2) Remove the following parts as a set from the cylinder head.
Camshaft bracket
Rocker arm shaft
Camshaft
Idle gear D
Legend
1. Camshaft bracket
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2. Cylinder head
34. Cylinder head removal
1) Install special tool to the cylinder head.
SST: 5-8840-2999-0 - front engine hanger
Legend
1. 5-8840-2999-0
2. M10 x 1.5 x 25 mm {0.98 in}
3. M10 x 1.5 x 25 mm {0.98 in}
SST: 5-8840-2886-0 - rear engine hanger
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3) Install the wire to the engine hanger and hoist.
4) Remove the cylinder head outside nuts and bolts from the cylinder head.
Legend
1. Nut
2. Bolt
3. Nut
5) Loosen the cylinder head bolts in the order shown in the diagram.
Caution
Do not reuse the cylinder head bolts.
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6) Remove the cylinder head from the cylinder block.
7) Remove the cylinder head gasket and timing gear case gasket from the cylinder head.
Caution
Do not reuse the cylinder head gasket and timing gear case gasket.
35. Crankshaft pulley removal
1) Remove the crankshaft pulley from the crankshaft.
Caution
Do not reuse the crankshaft pulley bolt and washer.
36. Water pump removal
1) Remove the water pump and gasket from the timing gear case.
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37. Vacuum pump removal
1) Remove the vacuum hose from the vacuum pipe and vacuum pump.
2) Remove the vacuum pump oil pipe from the vacuum pump and cylinder block.
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3) Remove the vacuum pump from the gear case cover.
38. Crankshaft front oil seal removal
1) Remove the crankshaft front oil seal from the gear case cover.
Note
To avoid damaging the contact surfaces of the gear case cover, remove the oil seal with a screwdriver
or similar item.
39. Gear case cover removal
1) Remove the cover from the gear case cover.

2) Remove the gear case cover from the timing gear case.
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40. Idle gear removal
1) Apply the dial gauge to the idle gear tooth to be measured, and gently move the gear left and right to measure
the fluctuation of the dial gauge.
Note
Replace the idle gear if the measured value exceeds the standard value.
Limit: 0.30 mm { 0.0118 in }
2) Measure the idle gear axial direction clearance using a feeler gauge.
Note
Replace the idle gear or thrust collar if the measured value exceeds the limit.
Axial direction clearance of the
idle gear.
Idle
Standard value Limit
gear
0.060 to 0.135
A mm { 0.0024 to
0.0053 in }
0.055 to 0.130 0.20 mm
C mm { 0.0022 to { 0.0079
0.0051 in } in }
0.090 to 0.155
D mm { 0.0035 to
0.0061 in }
3) Install the M6 bolt for securing the sub gear to idle gear A.
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Legend
1. M6 bolt
4) Remove the flange from idle gear A.
5) Remove idle gear A from the idle gear A shaft.
6) Remove the idle gear A shaft from the timing gear case.
7) Remove idle gear C from the idle gear C shaft.
8) Remove the idle gear C shaft from the timing gear case.
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9) Remove the crank gear from the crankshaft.
41. Oil pump removal
1) Remove the oil pump from the timing gear case.
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Legend
1. Oil pump
42. Timing gear case removal
1) Remove the timing gear case bracket from the timing gear case and cylinder block.
Legend
1. Timing gear case bracket
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2) Remove the timing gear case and gasket from the cylinder block.
Legend
1. Timing gear case

2. Gasket
Caution
Do not remove bolt 7 shown in the diagram when removing or installing the timing gear case.
Legend
1. Timing gear case
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2. Bolt L = 25 mm {0.98 in}
3. Bolt L = 60 mm {2.36 in}
4. Bolt L = 45 mm {1.77 in}
5. Bolt L = 35 mm {1.38 in}
6. Bolt L = 16 mm {0.63 in}
7. Bolt not to be removed
43. Flywheel removal
1) Install the special tool to the starter installation section of the rear plate.
SST: 5-8840-0214-0 - crankshaft stopper
2) Gradually loosen the flywheel mounting bolts in the order shown in the diagram.
3) Remove the following parts from the crankshaft.
Washer
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Flexible plate
Flywheel
44. Oil seal retainer removal
1) Remove the oil seal retainer and crankshaft rear oil seal as a set from the cylinder block and crankcase.
Caution
Do not reuse the crankshaft rear oil seal.
45. Rear plate removal
1) Remove the rear plate from the cylinder block and crankcase.
46. Crankshaft rear oil seal removal
1) Remove the crankshaft rear oil seal from the oil seal retainer.
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Caution
2) Remove the crankshaft rear slinger from the crankshaft using the special tool.
Note
Referring to the diagram, install the slinger puller and remove the slinger.
SST: 5-8840-2360-0 - rear oil seal remover

47. Oil pan removal
1) Remove the oil pan from the crankcase.
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48. Crankcase removal
1) Remove the crankcase from the cylinder block.
2) Remove the O-ring from the crankcase.
Caution
Do not reuse the O-ring.
Legend
1. O-ring
2. Crankcase
Crankcase disassembly (4JJ1 without DPD)
1. Crankcase disassembly
1) Remove the oil strainer from the crankcase.
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Legend
1. Gasket
2. Oil strainer
3. Bolt
4. Crankcase
2) Remove the crankcase plate from the crankcase.

Crankcase inspection (4JJ1 without DPD)
1. Crankcase inspection
1. Cleaning
1) Gently remove the liquid gasket from the crankcase installation surface.
Caution
Do not damage the crankcase.
1) Inspect the crankcase for the following.
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Cracking
Damage
Note
Replace the crankcase if an abnormal condition is found.
Crankcase reassembly (4JJ1 without DPD)
1. Crankcase reassembly
1) Install the crankcase plate to the crankcase.
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2) Install the oil strainer to the crankcase.
Caution

Legend
1. Gasket
2. Oil strainer
3. Bolt
4. Crankcase
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Crankcase installation (4JJ1 without DPD)
1. Crankcase installation
1) Referring to the diagram, apply ThreeBond 1207C or equivalent to the cylinder block.
Caution
Apply liquid gasket so it does not get on the O-ring groove.
Install the crankcase within 5 minutes of applying the liquid gasket.
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Standard value
a: 2.0 to 3.0 mm { 0.079 to 0.118 in } Bead height
b: 4.0 to 5.0 mm { 0.157 to 0.197 in } Bead width
2) Install the O-ring to the crankcase.
3) Install the crankcase to the cylinder block.
2. Oil pan installation
1) Referring to the diagram, apply ThreeBond 1207B or equivalent to the oil pan.
Caution
After applying the liquid gasket, install the oil pan within 5 minutes.
Standard value
a: 2.0 mm { 0.079 in } Bead height
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b: 3.0 mm { 0.118 in } Bead width
2) Install the oil pan to the crankcase.
3. Rear plate installation
1) Install the rear plate to the cylinder block and crankcase.

4. Oil seal retainer installation
1) Apply ThreeBond 1207C or equivalent to the oil seal retainer.
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Caution
Install the oil seal retainer within 5 minutes of applying liquid gasket.
Standard value
a: 2.0 to 2.5 mm { 0.079 to 0.098 in } Bead width
b: 1.0 to 1.5 mm { 0.039 to 0.059 in } Bead height
2) Install the oil seal retainer to the cylinder block and crankcase.

5. Crankshaft rear oil seal installation
1) Prepare the special tool.
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SST: 5-8840-2991-0 - rear oil seal installer
Note
For oil seal installation, use the combination instructions on the following table.
Part
Special tool number
name
Center
bolt
5-8840-2359-0
Sleeve
5-8840-2991-0
Adapter
Fixing
5-8840-2975-0
bolt
2) Install the crankshaft rear oil seal and slinger to the adapter outer circumference.
Caution
3) Install the adapter to the end section of the crankshaft.
Note
Install with the 2 fixing bolts.
4) Insert the sleeve into the adapter section, and tighten with the center bolt until the adapter section makes
contact with the sleeve.
5) Remove the adapter and sleeve.
Legend
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1. Crankshaft
2. Slinger
3. Oil seal
4. Sleeve
5. Adapter
6. Center bolt
7. Fixing bolt
6) Check that the dimensions from the crankshaft end face to the oil seal end face are within the standard range.
Legend
1. Oil seal end face

2. Crankshaft end face
Standard value
a: 12.2 to 12.8 mm { 0.480 to 0.504 in }

6. Flywheel installation
2) Temporarily tighten the following parts to the crankshaft.
Washer
Flexible plate
Flywheel
3) Final tighten the flywheel to the crankshaft in the order shown in the diagram.
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Tightening torque: 59 N・m { 6.0 kgf・m / 44 lb・ft } 1st time
Tightening Angle : 60 to 90 ° 2nd time
7. Timing gear case installation
1) Apply ThreeBond 1207B or equivalent to the gasket.
2) Referring to the diagram, apply ThreeBond 1207B or equivalent to the cylinder block.
Caution
Install the timing gear case within 5 minutes of applying liquid gasket.
Legend
1. Liquid gasket application area
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3) Install the gasket to the cylinder block.
4) Align the positions of the dowel pin and bolt, and install the timing gear case to the cylinder block.
Caution
Legend
1. Timing gear case

2. Bolt L = 25 mm {0.98 in}
3. Bolt L = 60 mm {2.36 in}
4. Bolt L = 45 mm {1.77 in}
5. Bolt L = 35 mm {1.38 in}
6. Bolt L = 16 mm {0.63 in}
5) Temporarily tighten the timing gear case bracket to the timing gear case.
6) Temporarily tighten the timing gear case bracket to the cylinder block.
7) Final tighten the timing gear case bracket to the timing gear case.
8) Final tighten the timing gear case bracket to the cylinder block.
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Legend
8. Oil pump installation
1) Apply engine oil to the oil pump gear.
2) Install the oil pump to the timing gear case.

Legend
1. Oil pump
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9. Idle gear installation
1. In case of disassembled idle gear A
1) Tighten the sub gear tightening bolt.
2) Secure the sub gear and idle gear to the vise.
3) Turn the sub gear right using the lever until the M6 bolt holes are aligned between idle gear A and the sub gear.
4) Tighten the M6 bolt and check that the sub gear does not move.
1) Apply engine oil to the gear assembly sections of the idle gear C shaft.
2) Install the idle gear C shaft to the timing gear case.
3) Apply engine oil to the threaded portion and seating surface of the idle gear C bolt.
4) Temporarily tighten idle gear C to the idle gear C shaft.
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5) Apply engine oil to the idle gear A shaft.
6) Install the idle gear A shaft to the timing gear case by aligning the cylinder block side oil hole with the idle gear
A shaft oil hole.
Legend
1. Front mark
2. Cylinder block side oil hole
3. Idle gear A shaft oil hole
7) Install idle gear A to the idle gear A shaft by aligning the alignment marks on the idle gear.
Caution
Do not align the alignment marks shown in the following diagram.
8) Apply engine oil to the tooth surface of idle gear A.
9) Install the flange to idle gear A with the front mark facing toward the front.
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10) Apply engine oil to the threaded portions and seating surfaces of the bolts, and then temporarily tighten the
bolts.
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11) Install the crank gear to the crankshaft.
Note
Install after aligning with the idle gear alignment marks.
12) Remove the M6 bolts for securing the sub-gear from idle gear A.
Legend
1. M6 bolt
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13) Final tighten idle gear A to the idle gear A shaft.
14) Final tighten idle gear C to the idle gear C shaft.
Legend
1. Idle gear A bolt

2. Idle gear C bolt
10. Gear case cover installation
1) Referring to the diagram, apply ThreeBond 1207B to the timing gear case.
Caution
Install the gear case cover within 5 minutes of applying liquid gasket.
Legend
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2) Install the gasket to the gear case cover.
Caution
3) Install the gear case cover to the timing gear case.
4) Install the cover to the gear case cover.

11. Crankshaft front oil seal installation
1) Apply engine oil to the lip section of the crankshaft front oil seal.
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Caution
Do not reuse the crankshaft front oil seal.
2) Install the crankshaft front oil seal to the gear case cover using the special tool.
SST: 5-8840-2821-0 - oil seal installer
Legend
1. 5-8840-2821-0
3) While pressing the seal, check the dimension of the crankshaft front oil seal section.
Standard value
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a: 1.5 mm { 0.059 in }
12. Vacuum pump installation
1) Install the vacuum pump to the gear case cover.
2) Install the vacuum pump oil pipe to the vacuum pump and cylinder block.
Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・in }
3) Install the vacuum hose to the vacuum pipe and vacuum pump.

13. Water pump installation
1) Install the water pump and gasket to the timing gear case.
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Caution
14. Crankshaft pulley installation
1) Install the crankshaft pulley by aligning with the crankshaft key.
Note
Secure the ring gear to prevent the crankshaft from turning when tightening the crankshaft pulley
bolt.
Caution
Do not damage the crankshaft damper pulley boss.
15. Cylinder head installation
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1) Clean the upper surface of the cylinder block and lower surface of the cylinder head using a scraper.
Caution
Do this carefully so as to not damage the upper surface of the cylinder block or lower surface of the
cylinder head.
2) Measure the protrusion amount of the piston head using a dial gauge.
Caution
The measurement point should be as close to the cylinder block as possible.
The difference between the protruding amount of each piston must be within the specified range.
Standard: 0.05 mm or less { 0.0020 in or less }

Legend
1. Measurement point
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Legend
3) Select the grade of the cylinder head gasket and timing gear case gasket based on the average of the
measured values.
Caution
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4) Apply ThreeBond 1207B or equivalent to the positions on the cylinder block shown in the diagram.
Caution
After applying the liquid gasket, install the cylinder head within 5 minutes.
Standard value
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5) Place the cylinder head gasket and timing gear case gasket on the cylinder block.
Caution
6) Align the dowel positions, and place the cylinder head on the cylinder block.
Caution
Do not damage the cylinder head gasket and timing gear case gasket.
7) Apply engine oil to the threaded portions and seating surfaces of the cylinder head mounting bolts.
Caution
8) Tighten the cylinder head bolts to the cylinder head using the special tool and a torque wrench in the order
shown in the diagram.
SST: 5-8840-0266-0 - angle gauge
Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft } 2nd time
Note
Retighten to the same torque to prevent variations in the tightening torque.
Tightening Angle : 60 to 75 ° 3rd time
Tightening Angle : 60 to 75 ° 4th time
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9) Install the nuts and bolts to the timing gear case in the order shown in the diagram.
10) Remove the wire from the engine hanger and hoist.
11) Remove special tool from the cylinder head.
16. Camshaftbracket installation
dead center.
Legend
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2) Align the camshaft bracket to the cylinder head.
Legend
1. Camshaft bracket
2. Cylinder head
3) Align the marks of the inlet camshaft and exhaust camshaft with the mark of the bearing cap.
Caution
Be careful of valve cap detachment or looseness.
Legend
1. Alignment mark
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4) Apply engine oil to the threaded portions and seating surfaces of the M8 bolts.
5) Install the camshaft bracket to the cylinder head.
6) Tighten the camshaft bracket bolts in the order shown in the diagram.
17. Fuel supply pump installation
1) Apply soapy water to the O-ring.
2) Install the O-ring to the fuel supply pump.
Caution
Do not pinch the O-ring.
3) Install the fuel supply pump to the timing gear case.
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Legend
1. Fuel supply pump
4) Confirm that the supply pump camshaft key is located in a horizontal position on the right side when seen from
the front.
5) Install the supply pump gear to idle gear A by aligning the alignment marks.
Caution
Check that the supply pump gear and main gear of idle gear A are securely engaged.
Legend
1. Supply pump gear alignment mark

2. Idle gear marking
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3. Main gear
4. Sub-gear
6) Connect the connector to the FRP regulator.
7) Connect the connector to the fuel temperature sensor.
18. Timing chain installation
1) Install the timing chain guide to the cylinder head and cylinder block.
Legend

2) Insert the timing chain tension lever into the gap between the timing gear case and the cylinder block.
3) Align the timing chain with the supply pump sprocket.
4) Install the sprocket and timing chain as a set to idle gear D.
5) Apply engine oil to the threaded portion and seating surface of the idle gear D shaft bolt.
6) Install the idle gear D shaft bolt and sleeve to idle gear D and sprocket.
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Legend

2. Sleeve
3. Sprocket mounting bolt
4. Sprocket
7) Align the 2 timing alignment marks at the location shown in the diagram.
Legend
1. Timing chain
2. Timing mark
3. Blue link
4. Yellow link
8) Install the timing chain lever pivot to the timing chain tension lever.
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9) Push down the timing chain tensioner latch and insert the plunger.
Note
Install the hook to the pin while pressing the plunger.
Legend
1. Pin
2. Plunger
3. Latch
4. Hook
10) Install the timing chain tensioner and gasket to the cylinder head.
Caution
11) Install the oil feed pipe to the timing chain tensioner.
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Legend
1. Oil feed pipe

3. Gasket
12) Lightly press the area indicated by the arrow in the diagram to disconnect the hook from the pin.
Note
The hook of the tensioner opens and the plunger pushes the tension lever to pull the chain.
dead center.
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Legend

Legend
1. Screwdriver
2. Ring spanner
3. 5-8840-2822-0
Note
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Legend

2. Cam (Inlet side)

No. 1
cylinder
top dead
center
No. 4
cylinder
top dead
center
20. Timing chain upper cover installation
1) Referring to the diagram, apply ThreeBond 1207C or equivalent to the timing chain upper cover.
Caution
Install the timing chain cover within 5 minutes of applying the liquid gasket.
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Legend
1. Liquid gasket
Standard value
2) Install the timing chain upper cover to the cylinder head.
Caution
Wipe off any excess liquid gasket.
3) Connect the connector to the CMP sensor.
21. Tension pulley installation
1) Install the tension pulley to the cylinder head.

22. Water pipe installation
1) Install the water pipe to the following parts.
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Water outlet pipe
Cylinder head
Turbocharger
Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in } Bolt, nut
23. Timing chain lower cover installation
1) Referring to the diagram, apply ThreeBond 1207C or equivalent to the timing chain lower cover.
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Caution
Legend
1. Liquid gasket
Standard value
2) Install the timing chain lower cover to the gear case cover.
3) Install the noise cover to the timing chain lower cover.

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1) Apply engine oil to the O-ring.
2) Install the O-ring to the injector.
Caution
Do not damage the O-ring.
3) Clean the cylinder head installation surface and injector.
4) Drop the gasket into the port on the cylinder head side.
Caution
Check that the gasket is seated horizontally.
5) Check that the gasket has been inserted based on the nozzle height using the injector.
Caution
Do not reuse the leak-off pipe or clip.
Press the injector in perpendicularly to ensure that the gasket is not slanted.
Do not hold the injector connector.
Do not forcibly push the gasket into the injector as it will be pushed until it hits the end of the injector
during clamp tightening.
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Legend
1. Injector
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket
6) Install the injector clamp to the injector.

Legend
1. Injector
2. Bolt
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3. Injector clamp
7) Apply engine oil to the threaded portions and seating surfaces of the bolts.
8) Install the injector and injector clamp to the cylinder head.
9) Temporarily tighten the injector clamp tightening bolt to the cylinder head.
26. Turbocharger oil pipe installation
1) Install the oil return pipe and gasket to the turbocharger and crankcase.
Caution
Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in } Turbocharger side
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Crankcase side

2) Install the turbocharger feed oil pipe and gasket to the turbocharger and oil cooler.
Caution
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Legend
1) Install the generator lower bracket to the cylinder block and timing gear case.

2) Temporarily tighten the tension pulley to the generator bracket in the order shown in the diagram.
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3) Final tighten the tension pulley to the generator bracket in the order shown in the diagram.

28. Oil filter installation
1) Temporarily tighten the oil filter and gasket to the oil cooler in the order shown in the diagram.
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Caution
2) Final tighten the oil filter to the oil cooler in the order shown in the diagram.
Caution
Ensure that no dirt or foreign material enters.
29. Water intake pipe installation
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1) Temporarily tighten the water intake pipe and water hose to the oil cooler in the order shown in the diagram.
Caution
Legend

2) Final tighten the water intake pipe and water hose to the oil cooler in the order shown in the diagram.
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Legend

Caution
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1) Install the water pipe to the oil cooler.
2) Connect the water hose to the water intake pipe.

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2) Connect the water hose to the water intake pipe and EGR cooler.
31. EGR cooler water hose connect
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1) Connect the EGR cooler water return hose to the EGR cooler.
2) Connect the EGR cooler water feed hose to the EGR cooler.
Legend

32. Fuel leak-off pipe installation
1) Install the fuel leak-off pipe to the fuel supply pump and common rail (fuel rail).

Legend
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33. Cylinder head cover installation
1) Apply the engine oil to the oil seal.
2) Insert the oil seal from the lower side of the cylinder head cover until it reaches the far end.
3) Referring to the diagram, apply ThreeBond 1217H or 1207C to the cylinder head mating surface.
Caution
Install the cylinder head cover within 5 minutes of applying liquid gasket.
Remove any dirt or dust from the oil seal section on the injector connector side.
Legend
1. Liquid gasket
Standard value
4) Temporarily tighten the cylinder head cover to the cylinder head in the order shown in the diagram.
Caution
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5) Final tighten the cylinder head cover to the cylinder head in the order shown in the diagram.
6) Connect the harness clip to the cylinder head cover.

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7) Connect the blow-by hose to the cylinder head cover.
34. Fuel leak-off hose installation
1) Install the injector leak-off pipe to the injector.
Legend

2. Clip
2) Install the fuel leak-off hose to the leak-off pipe.
3) Connect the connector to the injector.
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Legend

35. Vacuum hose installation
1) Install the vacuum hose to the turbocharger and vacuum pipe.
RHD models
LHD models
2) Connect the vacuum hose to the turbocharger control solenoid valve.
36. EGR pipe installation
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1) Install the EGR pipe and gasket to the inlet manifold and exhaust manifold.
Caution
37. Exhaust manifold heat protector installation
1) Install the exhaust manifold heat protector to the exhaust manifold and bracket.

Without EGR
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1) Install the exhaust manifold heat protector to the exhaust manifold and EGR cooler.

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38. Turbocharger water hose connect
1) Connect the turbocharger water return hose to the water feed and return pipe.
2) Connect the turbocharger water feed hose to the water feed and return pipe.

Legend

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Legend

39. Glow plug installation
1) Install the glow plug to the cylinder head.

Legend
1. Glow plug
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2) Install the glow plug terminal and glow plug connector to the glow plug.
Legend

40. Common rail (fuel rail) installation
1) Install the vacuum pipe to the cylinder block.
2) Temporarily tighten the common rail (fuel rail) and bracket to the cylinder block.
Caution
Do not hold the FRP sensor.
Take care not to damage the connector section of the FRP sensor.
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Legend
1. Vacuum pipe
2. Common rail (fuel rail) bracket
3. Common rail (fuel rail)
3) Final tighten the common rail (fuel rail) and bracket to the cylinder block in the order shown in the diagram.
41. Injection pipe installation
1) Apply engine oil to the threaded portions of the sleeve nuts on the injector side, as well as the injector O-rings.
2) Temporarily tighten the injection pipes to the common rail (fuel rail) and injectors by hand until the sleeve nuts
can no longer turn.
Caution
3) Temporarily tighten the clip to the injection pipe.
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4) Final tighten the injector clamp tightening bolt to the cylinder head.
5) Final tighten the injection pipes to the injectors and common rail (fuel rail).
Tightening torque: 29.5 N・m { 3.0 kgf・m / 22 lb・ft } Injector side
Tightening torque: 29.5 N・m { 3.0 kgf・m / 22 lb・ft } Common rail (fuel rail) side
6) Securely tighten the clip to the injection pipe.
42. Fuel feed pipe installation
1) Install the fuel feed pipe to the fuel supply pump and common rail (fuel rail).
Caution
Do not reuse the fuel feed pipe.
Tightening torque: 29.5 N・m { 3.0 kgf・m / 22 lb・ft }

Legend
1. Fuel feed pipe
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43. Vacuum hose connect
1) Connect the vacuum hose to the inlet manifold.
44. EGR valve connect
1) Connect the connector to the EGR valve.
45. Intake throttle valve installation
1) Install the intake throttle valve and gasket to the inlet manifold.
Caution

Legend

2. Gasket
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2) Connect the connector to the intake throttle valve.
46. A/C compressor bracket installation
1) Temporarily tighten the A/C compressor bracket to the cylinder head.
2) Final tighten the A/C compressor bracket to the cylinder head in the order shown in the diagram.

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3) Install the bracket to the A/C compressor bracket.
47. Generator installation
1) Install the generator to the lower bracket.

2) Install the upper bracket to the generator and timing gear case.
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3) Connect the connector to the generator.
4) Connect the B-terminal to the generator.
48. Engine oil filling
1) Replenish the engine with the engine oil.
2) Check the tightening of the oil pan drain plug.
49. Engine installation

Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) Engine installation".
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Crankshaft removal (4JJ1 without DPD)
1. Component views
Crankshaft
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Part name
1. Upper crankshaft bearing

2. Thrust bearing
3. Crank gear
4. Crankshaft
5. Lower crankshaft bearing
6. Bearing cap
7. Bearing cap bolt
Tightening torque
7: 167 N・m { 17.0 kgf・m / 123 lb・ft }
2. Piston removal
Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) Piston removal".
3. CKP sensor removal
1) Remove the CKP sensor from the cylinder block.
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Legend
1. O-ring
2. CKP sensor
4. Crankshaft removal
1) Measure the crankshaft thrust clearance using a feeler gauge.
Note
Replace the thrust bearing if the measured value is outside the standard range.
Caution
When replacing the thrust bearings, replace them as a set.
2) Loosen the bearing cap tightening bolts in the order shown in the diagram.
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3) Remove the bearing cap from the cylinder block.
4) Remove the lower crankshaft bearing from the bearing cap.
Note
If reusing the crankshaft bearings, put number tags on the crankshaft bearings.
5) Remove the crankshaft from the cylinder block.
Caution
When placing the crankshaft, prevent the crank angle sensor rotor from coming in contact with the
ground.
6) Remove the thrust bearing from the cylinder block.
7) Remove the upper crankshaft bearing from the cylinder block.
Note
If reusing the crankshaft bearings, put number tags on the crankshaft bearings.
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Crankshaft disassembly (4JJ1 without DPD)
1. Crankshaft disassembly
1) Remove the crank angle sensor rotor from the crankshaft.
Caution
Check that the pin does not come off.
The crank angle sensor rotor should not be subjected to any impacts by being dropped, etc.
Do not reuse the crank angle sensor rotor that is subjected to impact.
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Legend
1. Crank angle sensor rotor

2. Bolt
3. Pin
Crankshaft inspection (4JJ1 without DPD)
1. Crankshaft inspection
1. Cleaning
1) Clean the following parts.
Crankshaft journal
Crankshaft lower bearing
Crankshaft upper bearing
Crank pin
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1) Inspect the crankshaft journal and crank pin for the following.
Wear
Damage
Clogged oil port
2) Inspect the crankshaft lower bearing for the following.
Wear
Damage
Note
Replace the bearing as a set if an abnormal condition is found.
3) Inspect the crankshaft upper bearing for the following.
Wear
Damage
Note
Replace the bearing as a set if an abnormal condition is found.
4) Clean the crankshaft with organic solvent.
Caution
Thoroughly clean the crankshaft to completely remove any oil from the journal and crank pin.
5) Prepare a 5 to 10% inspection solution of copper (II) ammonium chloride dihydrate dissolved in distilled water.
Warning
Do not allow the solution to come in contact with your eyes, hands, clothes, etc.
If the solution has gotten in your eyes, immediately wash with a large amount of fresh water and seek
medical treatment.
6) Apply inspection solution to the journal and crank pin using an oil can.
Caution
Keep the inspection surface completely level so that the solution stays on the surface.
Do not allow the solution to come near the oil port.
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Legend
1. Drip prohibited area

2. Test liquid drop section
3. Pin or journal moving surface
7) Wait for 30 to 40 seconds before inspecting to see if the color has changed.
Note
If the color doesn't change after 30 to 40 seconds have elapsed, a tufftride layer is still present and
the crankshaft can be reused.
If the inspection solution changed to a copper color, replace the crankshaft.
Caution
Clean it off them with a cloth and wash with water or steam upon completion, because the solution is
highly corrosive.
Do not allow the inspection solution to come in contact with your eyes, hands, clothes, etc. If the
inspection solution has gotten in your eyes, immediately wash with a large amount of fresh water and
seek medical treatment.
3. Crankshaft runout measurement
1) While slowly turning the crankshaft, measure the runout at the crankshaft center using a dial gauge.
Note
If the measured value exceeds the specified value, replace the crankshaft.

4. Crankshaft journal and crank pin measurement
1) Referring to the diagram, measure the 4 crankshaft journal locations using a micrometer.
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Standard: 69.917 to 69.932 mm { 2.7526 to 2.7532 in } Journal section
2) Referring to the diagram, measure the 4 crankshaft crank pin locations using a micrometer.
Standard: 52.915 to 52.930 mm { 2.0833 to 2.0839 in } Pin section
Caution
Do not repair the crankshaft as it has been tufftrided (soft nitriding) to increase its strength.
Because the journal sections and crank pins have undergone soft nitriding (tufftriding) treatment, do
not repair by grinding.
5. Oil clearance measurement
1) Install the crankshaft upper bearing to the cylinder block.
2) Install the crankshaft to the cylinder block.

Caution
Rotate the crankshaft approximately 30° to stabilize the bearing.
Level the crankshaft to install.
3) Referring to the diagram, place PLASTIGAUGE on the crankshaft journal.
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4) Install the crankshaft lower bearing to the bearing cap.
5) Install the bearing caps to the cylinder block in the order shown in the diagram.
Note
Install so that the bearing cap front mark faces the front of the engine.
Legend
1. No. 1
2. No. 2
3. No. 3
4. No. 4
5. No. 5
6) Apply engine oil to the threaded portions and seating surfaces of the bearing cap bolts.
7) Temporarily tighten the crankshaft and bearing cap in the order shown in the diagram.
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8) Carefully tighten the bearing cap bolts to the cylinder block in the order shown in the diagram.
Caution
Carefully place the bearing cap on the cylinder block.
Do not rotate the crankshaft after tightening the bearing caps.
9) Remove the bearing cap from the cylinder block.
Caution
Remove carefully.
10) Measure the widest point of the flattened PLASTIGAUGE, and inspect the oil clearance of the crankshaft
journal section.
11) Measure the maximum width portion of the PLASTIGAUGEs crushed by the tightening of the bearing caps.
Note
Replace all of the crankshaft bearings or the crankshaft if the measured value is outside the standard
range.
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12) Remove any PLASTIGAUGE from the following parts.
Crankshaft lower bearing

Crankshaft journal
Crankshaft reassembly (4JJ1 without DPD)
1. Crankshaft reassembly
1) Apply LOCTITE 262 or equivalent to the threaded portion of the bolt.
Note
Perform this if reusing it.
2) Install the crank angle sensor rotor to the crankshaft.
Note
Install by aligning the rotor hole and pin.
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Caution
The crank angle sensor rotor should not be subjected to any impacts by being dropped, etc.
Do not reuse the crank angle sensor rotor that is subjected to impact.
Legend
1. Crank angle sensor rotor

2. Bolt
3. Rotor hole
4. Pin section
Crankshaft installation (4JJ1 without DPD)
1. Component views
Crankshaft
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Part name

2. Thrust bearing
3. Crank gear
4. Crankshaft
6. Bearing cap
7. Bearing cap bolt
Tightening torque
7: 167 N・m { 17.0 kgf・m / 123 lb・ft }
2. Crankshaft installation
If replacing the crankshaft bearing, select the crankshaft bearing grade.
1) Check the cylinder block journal hole inner diameter grade.
Note
Grade 1, 2, or 3 is marked on the rear right of the cylinder block.
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Legend
1. No. 1
2. No. 2
3. No. 3
4. No. 4
5. No. 5
2) Check the crankshaft journal diameter grade.
Note
The crankshaft journal grade marking is marked on each crankshaft journal.
Legend
1. No. 1
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2. No. 2
3. No. 3
4. No. 4
5. No. 5
3) Check the crankshaft bearing lot number and size code.
Legend
1. Lot No.
2. Grade identification color
4) Select the crankshaft bearing based on the journal hole diameter grades of the crankshaft journal and cylinder
block.
Bearing selection table

Crankshaft bearing housing Crankshaft journal Crankshaft
Grade Grade bearing size
Inner diameter Outer diameter color
mark mark
69.927 to 69.932 mm
1 or - { 2.7530 to 2.7532 in
}
Yellow
73.992 to 74.000 mm 69.922 to 69.927 mm
1 { 2.9131 to 2.9134 in 2 or -- { 2.7528 to 2.7530 in
} }
69.917 to 69.922 mm
3 or --- { 2.7526 to 2.7528 in Red
}
69.927 to 69.932 mm
1 or - { 2.7530 to 2.7532 in Black
}
73.983 to 73.991 mm 69.922 to 69.927 mm
2 { 2.9127 to 2.9130 in 2 or -- { 2.7528 to 2.7530 in Blue
} }
69.917 to 69.922 mm
3 or --- { 2.7526 to 2.7528 in Yellow
}
69.927 to 69.932 mm
1 or - { 2.7530 to 2.7532 in Green
}
73.975 to 73.982 mm 69.922 to 69.927 mm
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3 { 2.9124 to 2.9127 in 2 or -- { 2.7528 to 2.7530 in
} }
Black
69.917 to 69.922 mm
3 or --- { 2.7526 to 2.7528 in
}
5) Install the crankshaft upper bearing to the cylinder block.
Note
Check that the crankshaft upper bearing has oil holes and an oil groove.
Caution
Do not confuse the difference of bearing shapes.
6) Apply engine oil to the sliding surface of the crankshaft upper bearing.
Caution
Do not apply engine oil to the cylinder block installation surface and back surface of the bearing.
7) Thoroughly apply engine oil to the crankshaft journal section.
8) Install the crankshaft to the cylinder block.
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Caution
Prevent the crank angle sensor rotor from coming in contact with the cylinder block, etc., when
installing the crankshaft.
9) Thoroughly apply engine oil to the thrust bearing.
10) Install the thrust bearings to the front and rear sides of the cylinder block No. 3 journal.
Caution
Install so that the oil groove of the thrust bearing touches the crankshaft.
11) Install the lower crankshaft bearing to the bearing cap.
12) Apply engine oil to the sliding surface of the lower crankshaft bearing.
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Caution
Do not apply engine oil to the bearing cap installation surface and back surface of the bearing.
13) Install the bearing caps to the cylinder block in the order shown in the diagram.
Note
Install so that the bearing cap front mark faces the front of the engine.
Legend
1. No. 1
2. No. 2
3. No. 3
4. No. 4
5. No. 5
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15) Final tighten the bearing cap bolts gradually to the cylinder block in the order shown in the diagram.
16) Check that the crankshaft turns smoothly by rotating it manually after tightening each bearing cap location.
3. CKP sensor installation
1) Install the CKP sensor to the cylinder block.

Legend
1. O-ring
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2. CKP sensor
4. Piston installation
Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) Piston installation".

Crankshaft front oil seal removal (4JJ1 without DPD)
1. Component views
Crankshaft front oil seal
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Part name
1. Bolt
2. Washer
3. Crankshaft pulley
4. Crankshaft front oil seal
Tightening torque
1: 294 N・m { 30.0 kgf・m / 217 lb・ft }

Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) Crankshaft pulley removal".
3. Crankshaft front oil seal removal
1) Remove the crankshaft front oil seal from the gear case cover.
Note
To avoid damaging the contact surfaces of the gear case cover, remove the oil seal with a screwdriver
or similar item.
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Crankshaft front oil seal installation (4JJ1 without DPD)
1. Component views
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Part name
1. Bolt
2. Washer
Tightening torque
1: 294 N・m { 30.0 kgf・m / 217 lb・ft }

2. Crankshaft front oil seal installation
1) Apply engine oil to the lip section of the crankshaft front oil seal.
Caution
Do not reuse the crankshaft front oil seal.
2) Install the crankshaft front oil seal to the gear case cover using the special tool.
SST: 5-8840-2821-0 - oil seal installer
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Legend
1. 5-8840-2821-0
3) While pressing the seal, check the dimension of the crankshaft front oil seal section.
Standard value
a: 1.5 mm { 0.059 in }
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Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) Crankshaft pulley installation".

Crankshaft pulley removal (4JJ1 without DPD)
1. Component views
Crankshaft pulley
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Part name
1. Bolt
2. Washer
Tightening torque
1: 294 N・m { 30.0 kgf・m / 217 lb・ft }

2. Preliminary and post procedures
1. Preliminary procedures
1) Open the engine hood.
2) Disconnect the battery cable from the battery negative terminal.
Caution
After turning the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
The ECM may malfunction if the battery cable is disconnected within 1 minute.
If the battery cable is disconnected, perform the following settings after connecting the battery
negative terminal.
Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function
3) Raise the vehicle.
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3. Underguard removal
Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".
4. Coolant drain
Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.
1) Remove the radiator cap from the radiator.
2) Loosen the radiator drain plug, and drain the coolant into a pan.
3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.
Legend
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1. Drain plug
4) Apply LOCTITE 262 or equivalent to the threaded portion of the cylinder block side drain plug.
5) Tighten the drain plug on the cylinder block.
6) Tighten the radiator drain plug.
5. Engine cover removal
1) Remove the engine cover from the engine.
Legend
1. Engine cover
6. Air cleaner removal
1) Disconnect the connector from the MAF and IAT sensor.
2) Disconnect the connector from the barometric pressure sensor.
3) Disconnect the blow-by hose from the air cleaner.
4) Disconnect the vacuum hose from the air cleaner.
5) Disconnect the intake pipe from the turbocharger.
6) Remove the air cleaner from the vehicle.
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Legend
1. Air cleaner
2. MAF and IAT sensor
3. Vacuum hose
4. Blow-by hose
5. Intake pipe
6. Barometric pressure sensor
7. Intake air duct removal
1) Remove the intake hose and intake air duct as a set from the turbocharger and intercooler.
8. Boost pressure sensor disconnect
1) Disconnect the connector from the boost pressure sensor.
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1) Remove the intake hose and intake air duct as a set from the intake throttle valve and intercooler.
10. Radiator reserve tank removal
1) Disconnect the radiator reserve tank hose from the radiator.
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2) Remove the radiator reserve tank from the fan guide.
11. Radiator upper hose removal
1) Remove the radiator upper hose from the water outlet pipe and radiator.
Legend
1. Radiator upper hose
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12. Fan guide removal
1) Remove the fan shroud from the fan guide.
2) Remove the fan guide from the radiator.
Legend
1. Fan guide
2. Clip
3. Fan shroud
13. A/C compressor drive belt removal
1) Loosen the tension pulley lock nut.

2) Loosen the tension pulley adjust bolt.
3) Remove the A/C compressor drive belt from the following parts.
Tension pulley
A/C compressor
Crankshaft pulley
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Legend
1. Lock nut
2. Adjust bolt
3. A/C compressor drive belt
14. Cooling fan belt removal
3) Remove the cooling fan belt from the following parts.
Fan pulley
Generator
Crankshaft pulley
Legend
1. Adjust bolt
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2. Cooling fan belt
3. Lock nut
15. Cooling fan removal
1) Remove the cooling fan from the cooling fan clutch.
Legend
1. Cooling fan clutch

2. Cooling fan
1) Remove the crankshaft pulley from the crankshaft.
Caution
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Crankshaft pulley installation (4JJ1 without DPD)
1. Component views
Crankshaft pulley
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Part name
1. Bolt
2. Washer
Tightening torque
1: 294 N・m { 30.0 kgf・m / 217 lb・ft }

1) Install the crankshaft pulley by aligning with the crankshaft key.
Note
Secure the ring gear to prevent the crankshaft from turning when tightening the crankshaft pulley
bolt.
Caution
Do not damage the crankshaft damper pulley boss.
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3. Cooling fan installation
1) Install the cooling fan to the cooling fan clutch.

Legend

2. Cooling fan
4. Cooling fan belt installation
1) Install the cooling fan belt to the following parts.
Fan pulley
Generator
Crankshaft pulley
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Legend
1. Adjust bolt
2. Cooling fan belt
3. Lock nut
5. A/C compressor drive belt installation
1) Install the A/C compressor drive belt to the following parts.
Tension pulley
A/C compressor
Crankshaft pulley
Legend
1. Lock nut
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2. Adjust bolt
6. Fan guide installation
1) Install the fan guide to the radiator.
2) Install the fan shroud to the fan guide.
Legend
1. Fan guide
2. Clip
3. Fan shroud
7. Radiator upper hose installation

1) Install the radiator upper hose to the water outlet pipe and radiator.
Legend
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8. Radiator reserve tank installation
1) Clean the radiator reserve tank using detergent.
Note
Wash with clean water, and drain the water.
2) Install the radiator reserve tank to the fan guide.
3) Connect the radiator reserve tank hose to the radiator.
9. Intake air duct installation

1) Install the intake hose and intake air duct as a set to the intake throttle valve and intercooler.
Caution
Align the marks on the pipe side and hose side.
Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in } Bolt
Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in } Clamp (Intake throttle side)
Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in } Clamp (Intercooler side)
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10. Boost pressure sensor connect
1) Connect the connector to the boost pressure sensor.
1) Install the intake hose and intake air duct as a set to the turbocharger and intercooler.
Caution
Referring to the diagram, face the threaded portion of the clamp toward the engine front.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Nut, bolt
Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in } Clamp (Turbocharger side)
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12. Air cleaner installation
1) Install the air cleaner to the vehicle.
Legend
1. Air cleaner
3. Vacuum hose
4. Blow-by hose
5. Intake pipe
2) Referring to the diagram, connect the intake pipe to the turbocharger by aligning the alignment marks.
Legend
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1. Alignment mark
3) Connect the blow-by hose to the air cleaner.
4) Connect the vacuum hose to the air cleaner.
5) Connect the connector to the barometric pressure sensor.
6) Connect the connector to the MAF and IAT sensor.
13. Engine cover installation
1) Install the engine cover to the engine.
Legend
1. Engine cover
14. Underguard installation
Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard installation".
1. Post procedures
1) Lower the vehicle.
2) Connect the battery cable to the battery negative terminal.
3) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.
Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".
Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".
4) Close the engine hood.
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16. Coolant filling
1) Fill with engine coolant up to the radiator filler neck.
Note
Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.
Caution
Fill slowly to prevent air from entering the system.
2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator
with engine coolant.
Note
Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant
lowers.
Caution
Repeat the operation until the coolant level no longer drops.
3) Add engine coolant up to the MAX line of the radiator reserve tank.
Legend
1. Radiator reserve tank
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2. MAX line
3. MIN line
4) Install the radiator cap to the radiator.
5) Start and idle the engine.
Caution
Idle the engine for 5 minutes or more.
6) Stop the engine.
Warning
Note
If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.
10) Start the engine.
11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant
temperature gauge reaches the center.
12) With the engine running, check that the thermostat valve is open.
Note
Touch the radiator upper hose, and confirm that it has become warm.
If it has not become warm, go back to Step 11.
Caution
Do not try determining it by using only an engine coolant temperature gauge.
13) Idle the engine for 5 minutes.
14) Stop the engine.
Warning
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Note
19) Repeat steps 10 to 18 until the coolant level no longer lowers.
Caution
If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.
17. Cooling fan belt adjustment
When installing a new belt, initial stretching of the belt occurs.

In addition, when reusing the belt, the belt needs to be fitted to the pulley groove.
After fitting the cooling fan belt, readjust the cooling fan belt tension.
1) Loosen the tension pulley lock nut using a wrench.
2) Adjust the cooling fan belt tension by turning the adjust bolt.
Note
The standard amount of deflection shown is the value obtained when the standard pressure is
applied to the midpoint of the fan pulley and generator.
Standard: 98 N { 10.0 kg / 22 lb }
Caution
Accurately adjust the tension as there is a possibility the service life of the belt may be shortened or
belt squeal may be generated if the tension is not within the appropriate range.
Use a sonic tension meter to verify accurate tension adjustment.
Cooling fan belt tension standard
value
Adjustment Vibration
Deflection
conditions frequency
5.0 to 6.0 mm
207 to 231
When new { 0.20 to 0.24
Hz
in }
7.0 to 7.8 mm
176 to 190
Reused { 0.28 to 0.31
Hz
in }
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Legend
1. Tension pulley adjust bolt

3. Cooling fan belt
4. Tension pulley lock nut
3) Tighten the tension pulley lock nut to the specified torque.
18. A/C compressor drive belt adjustment

After fitting the A/C compressor drive belt, adjust the tension of the A/C compressor drive belt again.
2) Turn the tension pulley adjust bolt to adjust the tension.
Note
The standard deflection shown is the value obtained when the specified load is applied to the
measurement point of the A/C compressor drive belt.
98 N { 10.0 kg / 22 lb } Load
Caution
Measurement point 1
Deflection
12.5 to 16.5
92 to 112
When new mm { 0.49 to
Hz
0.65 in }
16.5 to 19.1
79 to 91
Reused mm { 0.65 to
Hz
0.75 in }
Measurement point 2
Deflection
15.9 to 20.7
70 to 86
Hz
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0.81 in }
20.7 to 23.7
62 to 70
Reused mm { 0.81 to
Hz
0.93 in }
Measurement point 3
Deflection
12.4 to 16.4
92 to 112
Hz
0.65 in }
16.5 to 19.1
80 to 92
Reused mm { 0.65 to
Hz
0.75 in }
Legend

4. Measurement point 1
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Crankshaft rear oil seal removal (4JJ1 without DPD)
1. Component views
Crankshaft rear oil seal
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Part name
1. Bolt
2. Oil seal retainer
3. Crankshaft rear oil seal
Tightening torque
1: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) rear plate removal".
3. Oil seal retainer removal
1) Remove the oil seal retainer and crankshaft rear oil seal as a set from the cylinder block and crankcase.
Caution
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4. Crankshaft rear oil seal removal
1) Remove the crankshaft rear oil seal from the oil seal retainer.
Caution
2) Remove the crankshaft rear slinger from the crankshaft using the special tool.
Note
Referring to the diagram, install the slinger puller and remove the slinger.
SST: 5-8840-2360-0 - rear oil seal remover

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Crankshaft rear oil seal installation (4JJ1 without DPD)
1. Component views
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Part name
1. Bolt
Tightening torque
1: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2. Oil seal retainer installation
1) Apply ThreeBond 1207C or equivalent to the oil seal retainer.
Caution
Install the oil seal retainer within 5 minutes of applying liquid gasket.
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Standard value
2) Install the oil seal retainer to the cylinder block and crankcase.
3. Crankshaft rear oil seal installation
1) Prepare the special tool.

SST: 5-8840-2991-0 - rear oil seal installer
Note
For oil seal installation, use the combination instructions on the following table.
Part
Special tool number
name
Center
bolt
5-8840-2359-0
Sleeve
5-8840-2991-0
Adapter
Fixing
5-8840-2975-0
bolt
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2) Install the crankshaft rear oil seal and slinger to the adapter outer circumference.
Caution
3) Install the adapter to the end section of the crankshaft.
Note
Install with the 2 fixing bolts.
4) Insert the sleeve into the adapter section, and tighten with the center bolt until the adapter section makes
contact with the sleeve.
5) Remove the adapter and sleeve.
Legend
1. Crankshaft
2. Slinger
3. Oil seal
4. Sleeve
5. Adapter
6. Center bolt
7. Fixing bolt
6) Check that the dimensions from the crankshaft end face to the oil seal end face are within the standard range.
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Legend
1. Oil seal end face

2. Crankshaft end face
Standard value
a: 12.2 to 12.8 mm { 0.480 to 0.504 in }
Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) rear plate installation".

Cylinder block removal (4JJ1 without DPD)
1. Component views
Cylinder block
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Part name
1. Cylinder block
2. Oil jet pipe
3. Relief valve
4. M8 bolt
5. M6 bolt
Tightening torque
3: 30 N・m { 3.1 kgf・m / 22 lb・ft }

4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
5: 8.0 N・m { 0.8 kgf・m / 71 lb・in }
2. Crankshaft removal
Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) crankshaft removal".
3. Oil cooler removal
1) Remove the oil feed upper pipe from the cylinder head and oil cooler.
2) Remove the oil feed lower pipe from the cylinder block and oil cooler.
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Legend
1. Oil feed upper pipe

2. Oil feed lower pipe
3) Remove the oil cooler and O-ring from the cylinder block.
4. Engine foot removal
1) Remove the battery cable bracket from the left side engine foot.
2) Remove the left and right engine feet from the cylinder block.
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Legend
1. Left side engine foot

2. Right side engine foot
5. Oil jet pipe removal
1) Remove the oil jet pipe from the cylinder block.
Caution
Do not damage or deform the oil jet pipe nozzle.
Cylinder block inspection (4JJ1 without DPD)
1. Cylinder block inspection
1. Cleaning
1) Carefully remove the liquid gasket, water stains, or foreign material on the top surface of the cylinder block.
Caution
Do not damage the cylinder block.
1) Inspect the cylinder block for the following.
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Cracking
Damage
Note
Conduct the dye penetrant check and hydraulic (or pneumatic) test as necessary.
If cracks or other damage is found, replace the cylinder block.
3. Cylinder block upper face warpage measurement
1) Remove the dowel pin from the cylinder block.
2) Measure the 4 sides and 2 locations in a diagonal line of the cylinder block top surface using a simple straight
ruler and feeler gauge.
Note
If the measured value exceeds the limit, replace the cylinder block.
Limit: 0.075 mm { 0.0030 in }
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Legend
1. Simple straight ruler

2. Feeler gauge
4. Cylinder block inner diameter measurement
1) Measure the inner diameter of the cylinder bore in the thrust direction and radial direction at the specified
positions using a cylinder gauge.
Legend
a. Thrust direction
b. Radial direction
Measurement position
c: 20 mm { 0.787 in } From the top surface of the cylinder block

2) Calculate the average of the measured values.
Limit: 95.480 mm { 3.7590 in }
Note
If the measured value exceeds the limit, replace the cylinder block.
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Cylinder block installation (4JJ1 without DPD)
1. Component views
Cylinder block
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Part name
1. Cylinder block
2. Oil jet pipe
3. Relief valve
4. M8 bolt
5. M6 bolt
Tightening torque
3: 30 N・m { 3.1 kgf・m / 22 lb・ft }

4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
5: 8.0 N・m { 0.8 kgf・m / 71 lb・in }
2. Oil jet pipe installation
1) Align the oil jet pipe dowel pin with the cylinder block pin hole.
2) Tighten the oil jet pipe to the cylinder block using the following parts.
Relief valve
M8 bolt
M6 bolt
Caution
Do not damage or deform the oil jet pipe nozzle.
After installing the crankshaft, piston, and connecting rod, rotate the crankshaft and make sure that
there is no oil jet pipe interference.
Tightening torque: 30 N・m { 3.1 kgf・m / 22 lb・ft } Relief valve
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Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } M8 bolt
Tightening torque: 8.0 N・m { 0.8 kgf・m / 71 lb・in } M6 bolt
Legend
1. Relief valve
2. M8 bolt
3. M6 bolt
3. Engine foot installation
1) Install the left and right engine feet to the cylinder block.
2) Install the battery cable bracket to the left side engine foot.
Legend
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4. Oil cooler installation
1) Apply ThreeBond 1207B along the oil cooler groove.
Caution
Install the oil cooler within 5 minutes of applying liquid gasket.
Legend
1. Application area
2) Install the O-ring to the oil cooler.
Note
Grease may be applied to the O-ring.
3) Temporarily tighten the oil cooler to the cylinder block.
4) Final tighten the oil cooler to the cylinder block in the order shown in the diagram.
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5) Install the oil feed lower pipe to the cylinder block and oil cooler.
Tightening torque: 54 N・m { 5.5 kgf・m / 40 lb・ft } Cylinder block side
Tightening torque: 14.7 N・m { 1.5 kgf・m / 130 lb・in } Oil cooler side
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Bracket
Legend
1. Oil feed upper pipe

2. Oil feed lower pipe
5. Crankshaft installation
Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) crankshaft installation".

Cylinder head cover removal (4JJ1 without DPD)
1. Component views
Cylinder head cover
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Part name
1. Bolt
2. Oil filler cap gasket
3. Oil filler cap
4. Cylinder head cover
5. Cylinder head cover gasket
6. Oil seal
Tightening torque
1-1: 5.0 N・m { 0.5 kgf・m / 44 lb・in }
1-2: 9.0 N・m { 0.9 kgf・m / 80 lb・in }
Caution
negative terminal.
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4. Coolant drain
Warning
Legend
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1. Drain plug
Legend
1. Engine cover
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Legend
1. Air cleaner
3. Vacuum hose
4. Blow-by hose
5. Intake pipe
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Legend

Legend
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Without EGR
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13. Bracket removal
2) Disconnect the connector from the turbocharger control solenoid valve.
3) Remove the bracket and turbocharger control solenoid valve as a set from the cylinder head cover.
DENSO made turbocharger control solenoid specifications

Pierburg made turbocharger control solenoid specifications
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14. Vacuum pipe removal
1. RHD models
2) Remove the vacuum pipe from the cylinder head cover.
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2. LHD models
2) Remove the vacuum pipe as a set with the harness bracket from the cylinder head cover.
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Legend
1. Harness bracket
Caution
Legend
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Caution
Legend

2. Clip

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Cylinder head cover installation (4JJ1 without DPD)
1. Component views
Cylinder head cover
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Part name
1. Bolt
3. Oil filler cap
6. Oil seal
Tightening torque
1-1: 5.0 N・m { 0.5 kgf・m / 44 lb・in }
1-2: 9.0 N・m { 0.9 kgf・m / 80 lb・in }
Caution
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Legend
1. Liquid gasket
Standard value
Caution

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Legend

2. Clip
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Legend

4. Vacuum pipe installation
1. RHD models
1) Install the vacuum pipe to the cylinder head cover.

2. LHD models
1) Install the vacuum pipe as a set with the harness bracket to the cylinder head cover.
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Legend
1. Harness bracket

5. Bracket installation
1) Install the bracket and turbocharger control solenoid valve as a set to the cylinder head cover.
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DENSO made turbocharger control solenoid specifications
Pierburg made turbocharger control solenoid specifications

2) Connect the connector to the turbocharger control solenoid valve.
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Caution
Without EGR
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Legend
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Legend

Caution
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Caution
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Legend
1. Air cleaner
3. Vacuum hose
4. Blow-by hose
5. Intake pipe

Legend
1. Alignment mark
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Legend
1. Engine cover
1. Post procedures
16. Coolant filling
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Note
Caution
Note
lowers.
Caution
Legend
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2. MAX line
3. MIN line
Caution
6) Stop the engine.
Warning
Note
Note
Caution
Warning
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Note
Caution
Cylinder head removal (4JJ1 without DPD)
1. Component views
Cylinder head
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Part name
1. Cylinder head
2. Gear case nut
3. Gear case bolt
4. Cylinder head bolt
5. Cylinder head gasket
6. Timing gear case gasket
Tightening torque
2: 25 N・m { 2.5 kgf・m / 18 lb・ft }
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4-1: 70 N・m { 7.1 kgf・m / 52 lb・ft }
4-2: 70 N・m { 7.1 kgf・m / 52 lb・ft }
4-3: 60 to 75 °
4-4: 60 to 75 °
Caution
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negative terminal.

3. Engine hood removal
Caution
Two people are required to install or remove the engine hood.
1) Remove the engine hood from the hood hinge.
Note
Mark the hood hinge position before removing the engine hood.
4. Engine oil drain
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Caution
5. Wiper linkage removal
Refer to "9.Body, Cab, Accessories 9B.Wiper, Washer Systems wiper linkage removal".
6. Cowl panel removal
1) Remove the cowl panel from vehicle.

7. Battery removal
1) Disconnect the battery ground cable from the frame.
2) Disconnect the battery cable from the battery.
3) Remove the battery bracket from the frame.
4) Remove the battery from vehicle.
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Legend
1. Battery cable
2. Battery bracket
3. Battery ground cable
Tension pulley
A/C compressor
Crankshaft pulley
Legend
1. Lock nut
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2. Adjust bolt
Fan pulley
Generator
Crankshaft pulley
Legend
1. Adjust bolt
2. Cooling fan belt
3. Lock nut
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11. A/C compressor disconnect
1) Disconnect the A/C compressor from the A/C compressor bracket.

Legend
1. A/C compressor bracket
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2. A/C compressor

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15. Fuel hose disconnect
1) Disconnect the fuel feed hose from the fuel supply pump.
2) Disconnect the fuel return hose from the fuel leak-off pipe.
Legend
1. Fuel feed hose
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2. Fuel return hose
RHD models
LHD models
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Caution
Legend
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Refer to "1.Engine 1C.Fuel System(4JJ1 without DPD) injector removal".
Legend

22. Heater pipe removal
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1. Models with heater
1) Remove the 2 heater hoses from the heater pipe and heater evaporator unit.
Legend
1. Heater hose
2) Remove the heater return hose from the heater pipe and cylinder block.
3) Remove the heater pipe and heater feed hose as a set from the cylinder head and inlet manifold.
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2. Models without heater
1) Remove the water bypass hose from the cylinder head.

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Legend
1. Fan guide
2. Clip
3. Fan shroud

Legend
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2. Cooling fan
25. Oil level gauge guide tube removal
1) Remove the oil level gauge from the oil level gauge guide tube.
2) Remove the oil level gauge guide tube from the crankcase and inlet manifold.
Legend
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2. Gasket
27. Thermostat removal
1) Remove the water outlet pipe from the cylinder head.
2) Remove the thermostat from the thermostat housing.
Caution
Do not damage the thermostat.
Legend
1. Thermostat
2. Jiggle valve

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Legend

Legend

Legend
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Legend
1. Gasket
Legend
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33. Turbocharger bracket removal
1) Remove the turbocharger bracket from the turbocharger and cylinder block.
34. Exhaust pipe adapter removal
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1) Remove the exhaust pipe adapter and gasket from the turbocharger.
35. Catalytic converter removal
1) Disconnect the catalytic converter from the front exhaust pipe and exhaust pipe bracket.
2) Remove the catalytic converter and gasket from the turbocharger.

3) Remove the exhaust pipe bracket from the crankcase.
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Legend
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Legend
1. Glow plug

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Water outlet pipe
Cylinder head
Turbocharger
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1. CMP sensor
Legend
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dead center.
Legend

Legend
1. Alignment mark
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1. Oil feed pipe

3. Gasket
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2. Sleeve
3. Sprocket
Legend
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Camshaft bracket
Rocker arm shaft
Camshaft
Idle gear D
Legend
1. Camshaft bracket
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2. Cylinder head
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1. 5-8840-2999-0
2. M10 x 1.5 x 25 mm {0.98 in}
3. M10 x 1.5 x 25 mm {0.98 in}
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Legend
1. Nut
2. Bolt
3. Nut
Caution
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Caution
Cylinder head disassembly (4JJ1 without DPD)
1. Component views
Cylinder head
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Part name
1. Split collar
2. Spring upper seat
3. Valve spring
4. Valve stem oil seal
5. Spring lower seat
6. Valve guide
7. Cylinder head
8. Inlet valve and exhaust valve
2. Rear engine hanger bracket removal
1) Remove the special tool from the rear engine hanger bracket.
2) Remove the rear engine hanger bracket from the cylinder head.
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3. EGR valve removal
1) Remove the EGR valve and gasket from the inlet manifold.
4. Inlet manifold removal
1. Without EGR
1) Remove the inlet manifold and gasket from the cylinder head.
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3) Remove the EGR pipe adapter and gasket from the inlet manifold.
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5. EGR cooler removal
1) Remove the EGR cooler and gasket from the cylinder head and exhaust manifold.
2) Remove the EGR pipe adapter and gasket from the EGR cooler.
Legend
1. EGR cooler
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2. Exhaust manifold
3. EGR pipe adapter
6. Turbocharger removal
1) Remove the turbocharger and gasket from the exhaust manifold.
7. Bracket removal
1) Remove the bracket from the cylinder head.
Without EGR
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1. Bracket
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1. Bracket
8. Exhaust manifold removal
1) Remove the exhaust manifold and gasket from the cylinder head.
Without EGR
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9. Valve spring removal

1) Remove the valve stem end cap from the valve stem.
2) Remove the split collar from the valve using the special tool.
SST: 5-8840-2865-0 - valve spring compressor adaptor
SST: 5-8840-2546-0 - valve spring compressor
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Legend
1. 5-8840-2865-0
2. 5-8840-2546-0
4) Remove the upper spring seat from the valve spring.
5) Remove the valve spring from the cylinder head.
6) Apply number tags to the valve springs.
10. Valve removal
1) Remove the inlet valve and the exhaust valve from the cylinder head.
Note
Store the removed valves with the number tags.
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11. Valve stem oil seal removal
1) Remove the valve stem oil seal from the cylinder head using pliers.
Caution
Do not reuse the valve stem oil seal.
2) Remove the lower spring seat from the cylinder head.
12. Valve seat insert removal
1) Arc weld the entire inner circumference of the valve seat insert.
2) Cool the valve seat insert for about 3 minutes.
Note
The valve seat insert becomes easier to remove due to the contraction caused by cooling.
3) Remove the valve seat insert from the cylinder head using a screwdriver.
Caution
Do not damage the cylinder head.
13. Valve guide removal
1) Tap out the valve guides from the lower side of the cylinder head using the special tool.
SST: 5-8840-2816-0 - valve guide remover and installer
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14. Oil seal removal
1) Remove the oil seal from the cylinder head.

1) Remove the heater pipe from the cylinder head.
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Models without heater
Models with heater

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Cylinder head inspection (4JJ1 without DPD)
1. Valve guide inspection
1) Inspect the valve stem and valve guide inner diameter section for the following.
Scratches
Abnormal wear
Note
Replace the valve and valve guide as a set if a malfunction is found.
2. Valve inspection
1. Valve stem measurement
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1) Measure the diameter of the valve stem using a micrometer.
Standard: 6.955 to 6.970 mm { 0.2738 to 0.2744 in } Inlet valve
Limit: 6.935 mm { 0.2730 in } Inlet valve
Standard: 6.947 to 6.962 mm { 0.2735 to 0.2741 in } Exhaust valve
Limit: 6.920 mm { 0.2724 in } Exhaust valve
Note
Replace the valve and valve guide as a set if the measured value exceeds the limit.
2. Clearance measurement between valve guide and valve stem
1) Measure the clearance between the valve guide and the valve stem within the range of the measuring points
from the valve guide using a dial gauge.
Standard: 0.030 to 0.060 mm { 0.0012 to 0.0024 in } Inlet valve
Standard: 0.038 to 0.068 mm { 0.0015 to 0.0027 in } Exhaust valve
Limit: 0.250 mm { 0.0098 in }
Note
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3. Valve thickness measurement
1) Measure the thickness of the valve.
Standard: 1.32 mm { 0.0520 in } Inlet valve
Standard: 1.32 mm { 0.0520 in } Exhaust valve
Note
4. Valve depth measurement
1) Remove the carbon and water deposit on the bottom surface of the cylinder head.
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2) Install the valve to the cylinder head.
3) Using a depth gauge or a simple straight ruler, measure the valve depth from the cylinder head lower surface.
Standard: 0.5 mm { 0.020 in }
Limit: 1.2 mm { 0.047 in }
Note
Replace the valve seat or cylinder head if the measured value exceeds the limit.
5. Valve seat contact surface measurement
1) Measure the valve seat contact surface.
Standard: 2.2 mm { 0.087 in } Inlet valve

Standard: 2.2 mm { 0.087 in } Exhaust valve
Note
If the contact surface is damaged or rough, repair the valve seat.
Replace the valve seat if the measured value exceeds the limit.
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3. Valve spring inspection
1) Inspect the valve spring for the following.
Damage
Wear
Note
If an abnormal condition is found, replace the valve spring.
2. Valve spring free length measurement
1) Measure the free length of the valve spring using a vernier caliper.
Note
Replace the valve spring if the measured value exceeds the limit.
Standard: 49.04 mm { 1.9307 in }
Limit: 48.15 mm { 1.8957 in }

3. Valve spring perpendicularity measurement
1) Measure the perpendicularity of the valve spring using a right-angle gauge.
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Note
Limit: 2.1 mm { 0.083 in }
4. Valve spring installation load measurement
1) Install the valve spring to load test equipment.
Standard: 37.8 mm { 1.488 in } Installation height
Note
Standard: 213 N { 21.7 kg / 48 lb }
Limit: 188 N { 19.2 kg / 42 lb }

4. Valve seat insert inspection
1. Cleaning
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1) Remove the carbon from the valve seat insert surface.
Scratches
Uneven sections
Note
If there are scratches or uneven sections, adjust the valve seat insert.
3. Valve seat insert adjustment
1) Adjust the valve seat to the standard value using a seat cutter.
Note
Minimize scratches and other uneven sections to adjust the contact width to the specified value.
Caution
Get rid of only the scratches and uneven portions, but be careful not to over-cut.
Use an adjustable valve cutter pilot.
The valve cutter pilot should not be allowed to scrape inside the valve guide.
Standard value
a: 90 ° Angle 1
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b: 50 ° Angle 2
2) Add compound to the valve seat surface and gently tap the valve while turning it.
Caution
Confirm that there is even contact around the entire circumference.
After fitting, completely remove the compound.
5. Cylinder head inspection
1) Measure the deformation of the cylinder block installation surface using a simple straight ruler and feeler
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gauge.
Note
Referring to the diagram, measure the 4 sides and across opposite corners.
If the measured value exceeds the limit, replace the cylinder head.
Caution
Do not polish the cylinder head lower surface.
Limit: 0.20 mm { 0.0079 in }

2) Measure the deformation of the exhaust manifold installation surface using a simple straight ruler and feeler
gauge.
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Note
Measure the 4 sides and across opposite corners.
Limit: 0.20 mm { 0.0079 in }
0.40 mm { 0.0157 in } Repair limit

Cylinder head reassembly (4JJ1 without DPD)
1. Component views
Cylinder head
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Part name
1. Split collar
3. Valve spring
6. Valve guide
7. Cylinder head
2. Heater pipe installation
1) Apply LOCTITE 262 to the heater pipe press-fit section.
2) Referring to the diagram, install the heater pipe to the cylinder head.
Caution
Press-fit the heater pipe at the angle shown in the diagram until it makes full contact with the cylinder
head.
Models without heater
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Standard value
a: 17.5 °
b: 90 °
Models with heater
Standard value
a: 90 °
3. Oil seal installation
1) Install the oil seal to the cylinder head using the special tool.
Note
Tap the oil seal into the injection pipe insertion surface evenly to prevent it from being tilted.
Caution
Take care not to damage the lip section of the oil seal.
SST: 5-8840-2820-0 - Oil seal installer
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Legend
1. Cylinder head
2. 5-8840-2820-0
4. Valve guide installation
1) Tap in the valve guide from the top of the cylinder head to the standard depth using the special tool.
Caution
When replacing the valve guide, replace as a set with the valve.
SST: 5-8840-2816-0 - valve guide remover and installer
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Standard value
a: 12.5 to 12.7 mm { 0.492 to 0.500 in } Height from the cylinder head top surface to the valve guide end face
5. Valve seat insert installation
1) Put the dolly block on the valve seat insert.
Note
Carefully place a dolly block having an outer diameter smaller than the valve seat insert on top of the
valve seat insert.
2) Install the valve seat insert to the cylinder head using a press.
Note
Gradually apply pressure to the dolly block and push in the valve seat insert.
Caution
Do not apply excessive pressure with the press.
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Legend
1. Dolly block
2. Valve seat insert
3. Press
3) Add compound to the valve seat surface and gently tap the valve while turning it.
Caution
Confirm that there is even contact around the entire circumference.
After fitting, completely remove the compound.
6. Valve stem oil seal installation
1) Install a lower spring seat to the cylinder head.
2) Apply engine oil to the valve guide outer circumference.
3) Install the valve stem oil seal to the cylinder head using the special tool.
4) Inspect for the following.
Is the valve stem oil seal correctly inserted?

Is it slanted?
Whether the garter spring is removed
SST: 5-8840-2882-0 - valve stem seal installer
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7. Valve installation
1) Apply engine oil to the valve stems of the inlet valve and exhaust valve.
2) Install the inlet valve and the exhaust valve to the cylinder head.
8. Valve spring installation
1) Install the valve spring to the cylinder head.
2) Install the spring upper seat to the valve spring.
3) Install the split collar to the valve using the special tool.
SST: 5-8840-2865-0 - valve spring compressor adaptor

SST: 5-8840-2546-0 - valve spring compressor
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Legend
1. 5-8840-2865-0
2. 5-8840-2546-0
4) Move the valve spring up and down to check that it moves smoothly.
5) Apply engine oil to the valve stem end cap and valve stem end.
6) Install the valve stem end cap to the valve stem.
9. Exhaust manifold installation
1) Install the gasket to the cylinder head.
Note
Face the gasket protruding portion to the cylinder head rear side.
Caution
Legend
1. Protrusion
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2) Referring to the diagram, temporarily tighten the exhaust manifold to the cylinder head.
Legend
1. Stud bolt
2. Washer
3. Nut
3) Final tighten the exhaust manifold to the cylinder head in the order shown in the diagram.
Caution
Do not over-tighten since it will expand or contract due to the heat of the manifold.
Without EGR
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10. Bracket installation

1) Install the bracket to the cylinder head.
Without EGR
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1. Bracket
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1. Bracket
11. Turbocharger installation
1) Install the turbocharger and gasket to the exhaust manifold.
Caution
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2) Pour approx. 1.0 cc of engine oil into the oil feed port.
12. EGR cooler installation
1) Temporarily tighten the EGR pipe adapter and gasket to the EGR cooler in the order shown in the diagram.
Caution
2) Final tighten the EGR pipe adapter to the EGR cooler in the order shown in the diagram.

3) Temporarily tighten the EGR cooler and gasket to the cylinder head and exhaust manifold in the order shown in
the diagram.
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Caution
4) Final tighten the EGR cooler to the cylinder head and exhaust manifold in the order shown in the diagram.

13. Inlet manifold installation
1. Without EGR
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1) Temporarily tighten the inlet manifold and gasket to the cylinder head.
Caution
2) Final tighten the inlet manifold mounting bolts in the order shown in the diagram.
1) Install the EGR pipe adapter to the inlet manifold.
Caution
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Caution
Caution
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14. EGR valve installation
1) Install the EGR valve and gasket to the inlet manifold.
Caution
Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft } Nut
Tightening torque: 24 N・m { 2.4 kgf・m / 18 lb・ft } Bolt
15. Rear engine hanger bracket installation

1) Install the rear engine hanger bracket to the cylinder head.
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2) Install the special tool to the rear engine hanger bracket.

Cylinder head installation (4JJ1 without DPD)
1. Component views
Cylinder head
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Part name
1. Cylinder head
2. Gear case nut
3. Gear case bolt
Tightening torque
2: 25 N・m { 2.5 kgf・m / 18 lb・ft }
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4-1: 70 N・m { 7.1 kgf・m / 52 lb・ft }
4-2: 70 N・m { 7.1 kgf・m / 52 lb・ft }
4-3: 60 to 75 °
4-4: 60 to 75 °
Caution
cylinder head.
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Caution

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measured values.
Caution
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Caution
Standard value
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Caution
Caution
Caution
Note
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dead center.
Legend
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1. Camshaft bracket
2. Cylinder head
Caution
Legend
1. Alignment mark
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Legend

2. Sleeve
4. Sprocket
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1. Timing chain
2. Timing mark
3. Blue link
4. Yellow link
Note
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1. Pin
2. Plunger
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3. Latch
4. Hook
Caution
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1. Oil feed pipe

3. Gasket
Note
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dead center.
Legend
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1. Screwdriver
2. Ring spanner
3. 5-8840-2822-0
Note
Legend

2. Cam (Inlet side)
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No. 1
cylinder
top dead
center
No. 4
cylinder
top dead
center
Caution
Legend
1. Liquid gasket
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Standard value
Caution
Water outlet pipe

Cylinder head
Turbocharger

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Caution
Legend
1. Liquid gasket
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Standard value

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1. Glow plug

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11. Exhaust pipe adapter installation
1) Install the exhaust pipe adapter and gasket to the turbocharger.
Caution
12. Catalytic converter installation
1) Install the catalytic converter and gasket to the turbocharger.

Caution
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2) Temporarily tighten the exhaust pipe bracket to the crankcase and catalytic converter in the order shown in the
diagram.
3) Final tighten the exhaust pipe bracket to the crankcase and catalytic converter in the order shown in the
diagram.

13. Turbocharger bracket installation
1) Install the turbocharger bracket to the turbocharger and cylinder block.
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Caution

Caution
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Caution
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Caution
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19. Thermostat installation
1) Install the thermostat to the thermostat housing with the jiggle valve facing the front of the vehicle.
Legend
1. Thermostat
2. Jiggle valve
2) Install the water outlet pipe to the cylinder head.
Caution
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Legend

2. Gasket
21. Oil level gauge guide tube installation
2) Install the oil level gauge guide tube to the crankcase and inlet manifold.
3) Install the oil level gauge to the oil level gauge guide tube.
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Legend

2. Cooling fan
Legend
1. Fan guide
2. Clip
3. Fan shroud
1) Temporarily tighten the heater pipe to the inlet manifold in the order shown in the diagram.
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2) Connect the heater feed hose to the cylinder head.
3) Final tighten the heater pipe to the inlet manifold in the order shown in the diagram.
4) Install the heater return hose to the heater pipe and cylinder block.

5) Install the 2 heater hoses to the heater pipe and heater evaporator unit.
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1. Heater hose
2. Models without heater
1) Install the water bypass hose to the cylinder head.

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Note
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Refer to "1.Engine 1C.Fuel System(4JJ1 without DPD) injector installation".
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RHD models
LHD models
31. Fuel hose connect
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1) Connect the fuel return hose to the fuel leak-off pipe.
2) Connect the fuel feed hose to the fuel supply pump.
Legend
1. Fuel return hose

2. Fuel feed hose

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35. A/C compressor connect
1) Connect the A/C compressor to the A/C compressor bracket.

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2. A/C compressor
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Fan pulley
Generator
Crankshaft pulley
Legend
1. Adjust bolt
2. Cooling fan belt
3. Lock nut

Tension pulley
A/C compressor
Crankshaft pulley
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Legend
1. Lock nut
2. Adjust bolt
39. Battery installation
1) Install the battery to vehicle.
2) Install the battery bracket to the frame.
Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in } Battery side
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft } Frame side
3) Connect the battery cable to the battery.
4) Connect the battery ground cable to the frame.

Legend
1. Battery cable
2. Battery bracket
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40. Cowl panel installation
1) Install the cowl panel to vehicle.
41. Wiper linkage installation
Refer to "9.Body, Cab, Accessories 9B.Wiper, Washer Systems wiper linkage installation".

43. Engine hood installation
1) Align the engine hood with the marking position placed during removal, and temporarily secure.
2) Adjust the clearance between the engine hood and the fender to the standard value.
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Dimensions
a. Clearance: 4.0 mm {0.16 in}
b. Height, level difference: -1.5 mm ｛-0.06 in｝
3) Final tighten the hinge bolt to the engine hood.
44. Engine hood adjustment
1) Turn the hood rest to adjust its height, and adjust the level difference against the engine hood.
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1. Hood rest
1. Post procedures
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Note
Standard: 98 N { 10.0 kg / 22 lb }
Caution

value
Deflection
5.0 to 6.0 mm
207 to 231
When new { 0.20 to 0.24
Hz
in }
7.0 to 7.8 mm
176 to 190
Reused { 0.28 to 0.31
Hz
in }
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3. Cooling fan belt

Note
98 N { 10.0 kg / 22 lb } Load
Caution
Measurement point 1
Deflection
12.5 to 16.5
92 to 112
Hz
0.65 in }
16.5 to 19.1
79 to 91
Reused mm { 0.65 to
Hz
0.75 in }
Measurement point 2
Deflection
15.9 to 20.7
70 to 86
Hz
0.81 in }
20.7 to 23.7
62 to 70
Reused mm { 0.81 to
Hz
0.93 in }
Measurement point 3
Deflection
12.4 to 16.4
92 to 112
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Hz
0.65 in }
16.5 to 19.1
80 to 92
Reused mm { 0.65 to
Hz
0.75 in }
Legend


Engine removal (4JJ1 without DPD)
Caution
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negative terminal.

3. Coolant drain
Warning
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1. Drain plug
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1. Air cleaner
3. Vacuum hose
4. Blow-by hose
5. Intake pipe
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8. Transmission removal
Refer to "5.Transmission, Transaxle 5B.Automatic(TB-50LS) transmission removal".
Refer to "5.Transmission, Transaxle 5B.Automatic(AWR6B45) transmission removal".
9. Battery removal

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1. Battery cable
2. Battery bracket
10. Fuse box disconnect
1) Remove the fuse box cover from the fuse box.
2) Disconnect the engine harness from the fuse box.
3) Disconnect the battery harness from the fuse box.
Legend
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13. Heater hose removal
Legend
1. Heater hose
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Tension pulley
A/C compressor
Crankshaft pulley
Legend
1. Lock nut
2. Adjust bolt
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Legend

2. A/C compressor
Legend
1. Fan guide
2. Clip
3. Fan shroud
Fan pulley
Generator
Crankshaft pulley
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1. Adjust bolt
2. Cooling fan belt
3. Lock nut

Legend
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2. Cooling fan
19. Glove box removal
1) Remove the glove box from the instrument panel.
RHD
Legend
1. Glove box
LHD
Legend
1. Glove box
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20. Instrument panel passenger-side lower cover removal
1) Remove the instrument panel passenger-side lower cover from the instrument panel.
RHD
Legend
1. Instrument panel passenger-side lower cover
LHD
Legend
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21. ECM disconnect
1) Disconnect the connector from the ECM.
2) Pull out the harness to the engine room side.
3) Disconnect the harness from the frame.
1) Disconnect the vacuum hose from the vacuum pipe.
2) Remove the harness bracket from the inlet manifold and common rail (fuel rail) bracket.
Legend
1. Fuel feed hose
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2. Fuel return hose

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26. Power steering oil pump disconnect
1) Disconnect the power steering oil pump and power steering oil hose as a set from the timing gear case.
Legend
1. Power steering oil pump
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2. Nut
2) Remove the power steering oil hose from the bracket.
Legend
1. Bracket
27. Radiator lower hose disconnect
1) Disconnect the radiator lower hose from the water intake pipe.
Legend
1. Radiator lower hose
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28. Engine removal
Legend
1. 5-8840-2999-0
2. M10 x 1.5 x 25 mm {0.98 in}
3. M10 x 1.5 x 25 mm {0.98 in}
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4) Hold up the engine as high as not to be lifted up.
5) Disconnect the engine mounting from the frame.
6) Remove the engine from vehicle.

Engine installation (4JJ1 without DPD)
1. Engine installation
1) Install the engine to the vehicle using a hoist.
Note
Slowly operate to move the engine to the installation position.
Slowly operate the hoist so that the transmission side is low, while pulling to the rear of the engine.
2) Connect the engine mounting to the frame.
Caution
Always tighten bolts while the engine is securely seated on the frame to prevent bolts from
loosening.
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2. Radiator lower hose connect
1) Connect the radiator lower hose to the water intake pipe.
Legend
3. Power steering oil pump connect

1) Install the power steering oil pump to the timing gear case.
Legend
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2. Nut
2) Install the power steering oil hose to the bracket.
Legend
1. Bracket
Caution
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Caution
diagram.
diagram.
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1. Fuel return hose
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2. Fuel feed hose
1) Install the harness bracket to the inlet manifold and common rail (fuel rail) bracket.
2) Connect the vacuum hose to the vacuum pipe.
8. ECM connect
1) Connect the harness to the frame.
2) Pull in the harness toward inside the room.
3) Connect the connector to the ECM.
9. Instrument panel passenger-side lower cover installation
1) Install the instrument panel passenger-side lower cover to the instrument panel.
RHD
Legend
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LHD
Legend
10. Glove box installation
1) Install the glove box to the instrument panel.
RHD
Legend
1. Glove box
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LHD
Legend
1. Glove box

Legend
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2. Cooling fan
Fan pulley
Generator
Crankshaft pulley
Legend
1. Adjust bolt
2. Cooling fan belt
3. Lock nut

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Legend
1. Fan guide
2. Clip
3. Fan shroud
Legend
2. A/C compressor
Tension pulley
A/C compressor
Crankshaft pulley
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Legend
1. Lock nut
2. Adjust bolt
16. Heater hose installation
Legend
1. Heater hose
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Note
Legend
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19. Fuse box connect
1) Connect the battery harness to the fuse box.
2) Connect the engine harness to the fuse box.
3) Install the fuse box cover to the fuse box.
20. Transmission installation
Refer to "5.Transmission, Transaxle 5B.Automatic(TB-50LS) transmission installation".
Refer to "5.Transmission, Transaxle 5B.Automatic(AWR6B45) transmission installation".

Legend
1. Battery cable
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2. Battery bracket
Caution

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Legend
1. Air cleaner
3. Vacuum hose
4. Blow-by hose
5. Intake pipe

Legend
1. Alignment mark
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Caution
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1. Post procedures
28. Fuel air bleed
2) Press the priming pump until it becomes hard.
Caution
Completely bleed air, as insufficient air bleeding may lead to engine malfunctions.
Legend
1. Priming pump
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2. Fuel filter with sedimenter
29. Coolant filling
Note
Caution
Note
lowers.
Caution
Legend
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2. MAX line
3. MIN line
Caution
6) Stop the engine.
Warning
Note
Note
Caution
Warning
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Note
Caution

Note
Standard: 98 N { 10.0 kg / 22 lb }
Caution
value
Deflection
5.0 to 6.0 mm
207 to 231
When new { 0.20 to 0.24
Hz
in }
7.0 to 7.8 mm
176 to 190
Reused { 0.28 to 0.31
Hz
in }
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Legend

3. Cooling fan belt

Note
98 N { 10.0 kg / 22 lb } Load
Caution
Measurement point 1
Deflection
12.5 to 16.5
92 to 112
Hz
0.65 in }
16.5 to 19.1
79 to 91
Reused mm { 0.65 to
Hz
0.75 in }
Measurement point 2
Deflection
15.9 to 20.7
70 to 86
Hz
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0.81 in }
20.7 to 23.7
62 to 70
Reused mm { 0.81 to
Hz
0.93 in }
Measurement point 3
Deflection
12.4 to 16.4
92 to 112
Hz
0.65 in }
16.5 to 19.1
80 to 92
Reused mm { 0.65 to
Hz
0.75 in }
Legend

32. ECM setting
If the engine has been replaced, perform Injector ID Code programming and fuel supply pump relearning.
1. Injector ID Code programming
Check the label attached to the engine cover at the time of factory shipment or the housing of each injector for the
Injector ID Code.
Label on the cylinder head cover (Sample)
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Legend
1. No. 1 cylinder Injector ID Code

5. Injector ID Code label
The correct order of the ID codes shown in the following injector illustration is as follows.
72 04 F9 F8 F0 00 F0 E7 09 F6 F9 96
Injector (Sample)
Legend
1. Injector ID Code
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2. Injector
1) Connect the scan tool to the DLC.
2) Turn ON the ignition switch.
3) Select the scan tool item.
Diagnostics
Engine
4JJ1
Programming
Injector ID Code
Program Injector ID Code
4) Program the Injector ID Code into the ECM by following the on-screen instructions.
5) After the programming is completed, turn the ignition switch OFF for 30 seconds.
2. Fuel Supply Pump Relearning
1) Turn ON the ignition switch.
2) Select the scan tool item.
Diagnostics
Engine
4JJ1
Actuator Test
Fuel Supply Pump Learn Resetting
3) Reset the Fuel Supply Pump Learning by following the on-screen instructions.
4) Turn OFF the ignition switch for 30 seconds.
5) Start and idle the engine until the engine coolant temperature reaches 65°C {149°F} or more.
6) Observe the Fuel Supply Pump Learning Status parameter on the scan tool.
7) The procedure is complete when the parameter changes from Not Learned to Learned.
33. Engine vehicle inspection
1. Inspection before starting the engine
Engine oil level

Engine coolant level
Items around the engine that may get caught
2. Inspection after starting the engine
Abnormal noise
Abnormal vibration
Fuel leakage
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Oil leakage
Water leakage
Air leakage
Exhaust gas leakage
Exhaust gas color
3. Inspection after stopping the engine
Engine oil level

Engine coolant level
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Engine mounting installation (4JJ1 without DPD)
1. Component views
Engine mounting
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Part name
1. Nut
3. Bolt
4. Bolt
5. Bolt
6. Bolt
7. Left side mounting cover
8. Bolt
9. Left side engine mounting
10. Bolt
11. Nut
13. Bolt
14. Bolt
15. Bolt
16. Right side mounting cover
17. Right side engine mounting
18. Bolt
19. Bolt
20. Heat protector
21. Bolt
22. Bolt
Tightening torque
1: 52 N・m { 5.3 kgf・m / 38 lb・ft }
3: 51 N・m { 5.2 kgf・m / 38 lb・ft }
4: 157 N・m { 16.0 kgf・m / 116 lb・ft }
5: 51 N・m { 5.2 kgf・m / 38 lb・ft }
6: 51 N・m { 5.2 kgf・m / 38 lb・ft }
8: 60 N・m { 6.1 kgf・m / 44 lb・ft }
10: 60 N・m { 6.1 kgf・m / 44 lb・ft }
11: 52 N・m { 5.3 kgf・m / 38 lb・ft }
13: 51 N・m { 5.2 kgf・m / 38 lb・ft }
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14: 51 N・m { 5.2 kgf・m / 38 lb・ft }
15: 60 N・m { 6.1 kgf・m / 44 lb・ft }
18: 60 N・m { 6.1 kgf・m / 44 lb・ft }
19: 8.2 N・m { 0.8 kgf・m / 73 lb・in }
21: 51 N・m { 5.2 kgf・m / 38 lb・ft }
22: 51 N・m { 5.2 kgf・m / 38 lb・ft }
2. Engine mounting installation
1) Install the engine mounting to the engine foot.
2) Hold up the engine as high as not to be lifted up.

3) Install the left and right engine feet to the engine.
Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft } M10
Tightening torque: 157 N・m { 16.0 kgf・m / 116 lb・ft } M14
4) Lower the engine.
5) Connect the engine mounting to the frame.
Caution
Always tighten bolts while the engine is securely seated on the frame.
Tightening bolts while the engine mounting has risen up off the frame may cause bolts to be
loosened.
6) Install the heat protector to the right side engine mounting.
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7) Referring to the diagram, check that the stopper of the heat protector is making contact with the engine
mounting end.
Legend
1. Heat protector stopper
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2. Engine mounting
3. Oil pressure switch connect
1) Connect the connector to the oil pressure switch.
4. Starter motor installation
Refer to "1.Engine 1J.Electrical(4JJ1 without DPD) starter motor installation".

Caution
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Caution
diagram.
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diagram.

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Legend
1. Air cleaner
3. Vacuum hose
4. Blow-by hose
5. Intake pipe

Legend
1. Alignment mark
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Caution
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Dimensions
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1. Hood rest

Legend
1. Engine cover
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1. Post procedures

Exhaust manifold removal (4JJ1 without DPD)
1. Component views
Exhaust manifold (Without EGR)
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Part name
1. Bolt
2. Nut
3. Exhaust manifold
4. Gasket
5. Bolt
6. Heat protector
7. Bolt
Tightening torque
1: 52 N・m { 5.3 kgf・m / 38 lb・ft }
2: 52 N・m { 5.3 kgf・m / 38 lb・ft }
5: 25 N・m { 2.5 kgf・m / 18 lb・ft }
7: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Exhaust manifold (Euro2 specifications)
Part name cardiagn.com

1. Bolt
2. Nut
3. Exhaust manifold
4. Gasket
5. Bolt
6. Heat protector
7. Bolt
Tightening torque
1: 52 N・m { 5.3 kgf・m / 38 lb・ft }

2: 52 N・m { 5.3 kgf・m / 38 lb・ft }
5: 25 N・m { 2.5 kgf・m / 18 lb・ft }
7: 25 N・m { 2.5 kgf・m / 18 lb・ft }
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Part name
1. Nut and bolt

2. EGR cooler
3. Bolt
4. Exhaust manifold
5. Gasket
6. Nut
7. Bolt
8. Heat protector
9. Bolt
10. Bolt
11. Heat protector
12. Bolt
Tightening torque
1: 27 N・m { 2.8 kgf・m / 20 lb・ft }
3: 52 N・m { 5.3 kgf・m / 38 lb・ft }
6: 52 N・m { 5.3 kgf・m / 38 lb・ft }
7: 25 N・m { 2.5 kgf・m / 18 lb・ft }
9: 25 N・m { 2.5 kgf・m / 18 lb・ft }
10: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 27 N・m { 2.8 kgf・m / 20 lb・ft }
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Caution
negative terminal.

4. Coolant drain
Warning
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1. Drain plug

Legend
1. Engine cover
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1. Air cleaner
3. Vacuum hose
4. Blow-by hose
5. Intake pipe
1. RHD models
2) Remove the vacuum pipe from the cylinder head cover.

2. LHD models
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2) Remove the vacuum pipe as a set with the harness bracket from the cylinder head cover.
Legend
1. Harness bracket
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13. Turbocharger bracket removal
1) Remove the turbocharger bracket from the turbocharger and cylinder block.
14. Turbocharger removal
1) Remove the water feed and return pipe, as well as the gasket from the turbocharger.
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2) Remove the turbocharger and gasket from the exhaust manifold.
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Legend

Without EGR
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18. EGR cooler removal
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1) Remove the EGR cooler and gasket from the cylinder head and exhaust manifold.
2) Remove the EGR pipe adapter and gasket from the EGR cooler.
Legend
1. EGR cooler
2. Exhaust manifold
3. EGR pipe adapter
19. Exhaust manifold removal
1) Remove the exhaust manifold and gasket from the cylinder head.
Without EGR
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Exhaust manifold inspection (4JJ1 without DPD)
1. Exhaust manifold inspection
1) Inspect the exhaust manifold for cracks.
2. Deformation measurement
1) Referring to the diagram, put a simple straight ruler on the exhaust manifold.
2) Measure exhaust manifold deformation using a feeler gauge.
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Limit: 0.5 mm { 0.020 in }
Note
If the measured value exceeds the limit, replace the exhaust manifold.
Exhaust manifold installation (4JJ1 without DPD)
1. Component views
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Part name
1. Bolt
2. Nut
3. Exhaust manifold
4. Gasket
5. Bolt
6. Heat protector
7. Bolt
Tightening torque
1: 52 N・m { 5.3 kgf・m / 38 lb・ft }
2: 52 N・m { 5.3 kgf・m / 38 lb・ft }
5: 25 N・m { 2.5 kgf・m / 18 lb・ft }
7: 25 N・m { 2.5 kgf・m / 18 lb・ft }

1. Bolt
2. Nut
3. Exhaust manifold
4. Gasket
5. Bolt
6. Heat protector
7. Bolt
Tightening torque
1: 52 N・m { 5.3 kgf・m / 38 lb・ft }

2: 52 N・m { 5.3 kgf・m / 38 lb・ft }
5: 25 N・m { 2.5 kgf・m / 18 lb・ft }
7: 25 N・m { 2.5 kgf・m / 18 lb・ft }
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Part name
1. Nut and bolt

2. EGR cooler
3. Bolt
4. Exhaust manifold
5. Gasket
6. Nut
7. Bolt
8. Heat protector
9. Bolt
10. Bolt
11. Heat protector
12. Bolt
Tightening torque
1: 27 N・m { 2.8 kgf・m / 20 lb・ft }
3: 52 N・m { 5.3 kgf・m / 38 lb・ft }
6: 52 N・m { 5.3 kgf・m / 38 lb・ft }
7: 25 N・m { 2.5 kgf・m / 18 lb・ft }
9: 25 N・m { 2.5 kgf・m / 18 lb・ft }
10: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 27 N・m { 2.8 kgf・m / 20 lb・ft }
2. Exhaust manifold installation
1) Install the gasket to the cylinder head.
Note
Face the gasket protruding portion to the cylinder head rear side.
Caution
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Legend
1. Protrusion
2) Referring to the diagram, temporarily tighten the exhaust manifold to the cylinder head.
Legend
1. Stud bolt
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2. Washer
3. Nut
3) Final tighten the exhaust manifold to the cylinder head in the order shown in the diagram.
Caution
Do not over-tighten since it will expand or contract due to the heat of the manifold.
Without EGR
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3. EGR cooler installation
1) Temporarily tighten the EGR pipe adapter and gasket to the EGR cooler in the order shown in the diagram.
Caution
2) Final tighten the EGR pipe adapter to the EGR cooler in the order shown in the diagram.
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3) Temporarily tighten the EGR cooler and gasket to the cylinder head and exhaust manifold in the order shown in
the diagram.
Caution
4) Final tighten the EGR cooler to the cylinder head and exhaust manifold in the order shown in the diagram.
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Caution
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Without EGR
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Legend

7. Turbocharger installation
1) Install the turbocharger and gasket to the exhaust manifold.
Caution

2) Pour approx. 1.0 cc of engine oil into the oil feed port.
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Caution

Caution
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Legend
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Caution
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Caution
diagram.
diagram.
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1. RHD models
1) Install the vacuum pipe to the cylinder head cover.

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2. LHD models
1) Install the vacuum pipe as a set with the harness bracket to the cylinder head cover.

Legend
1. Harness bracket
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1. Air cleaner
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3. Vacuum hose
4. Blow-by hose
5. Intake pipe
Legend
1. Alignment mark

Caution
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Legend
1. Engine cover
1. Post procedures
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19. Coolant filling
Note
Caution
Note
lowers.
Caution
Legend
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2. MAX line
3. MIN line
Caution
6) Stop the engine.
Warning
Note
Note
Caution
Warning
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Note
Caution
Flywheel removal (4JJ1 without DPD)
1. Component views
Flywheel
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Part name
1. Flywheel
2. Flexible plate
3. Flexible plate washer
4. Flywheel bolt
Tightening torque
4-1: 59 N・m { 6.0 kgf・m / 44 lb・ft }
4-2: 60 to 90 °
2. Transmission removal
Refer to "5.Transmission, Transaxle 5B.Automatic(TB-50LS) transmission removal".
Refer to "5.Transmission, Transaxle 5B.Automatic(AWR6B45) transmission removal".
3. Flywheel removal
2) Gradually loosen the flywheel mounting bolts in the order shown in the diagram.
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3) Remove the following parts from the crankshaft.
Washer
Flexible plate
Flywheel
Flywheel disassembly (4JJ1 without DPD)
1. Flywheel disassembly
1) Remove the ring gear from the flywheel using a chisel and hammer.
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Flywheel inspection (4JJ1 without DPD)
1. Flywheel inspection
1) Inspect the flywheel and mounting bolts for the following.
Cracking
Damage
Note
Replace the flywheel or mounting bolt if an abnormal condition is found.
2) Inspect the ring gear for the following.
Damage
Significant wear
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Note
Replace the ring gear if an abnormal condition is found.
Flywheel reassembly (4JJ1 without DPD)
1. Flywheel reassembly
1) Uniformly heat up the inside of the ring gear with a gas burner.
Caution
Perform this with the heating temperature at less than the standard value.
Standard: less than 200 ℃ { less than 392 °F }
2) Referring to the diagram, install the ring gear to the flywheel.
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Legend
1. Chamfered side
2. Ring gear
3. Flywheel
Flywheel installation (4JJ1 without DPD)
1. Component views
Flywheel
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Part name
1. Flywheel
2. Flexible plate
4. Flywheel bolt
Tightening torque
4-1: 59 N・m { 6.0 kgf・m / 44 lb・ft }
4-2: 60 to 90 °
2) Temporarily tighten the following parts to the crankshaft.
Washer
Flexible plate
Flywheel
3) Final tighten the flywheel to the crankshaft in the order shown in the diagram.
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3. Transmission installation
Refer to "5.Transmission, Transaxle 5B.Automatic(TB-50LS) transmission installation".
Refer to "5.Transmission, Transaxle 5B.Automatic(AWR6B45) transmission installation".

Idle gear removal (4JJ1 without DPD)
1. Component views
Idle gear
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Part name
1. Gear case cover

2. Bolt
3. Supply pump gear nut
5. Idle gear D
8. Idle gear D sprocket
9. Timing chain
10. Supply pump sprocket
11. Supply pump gear
12. Idle gear A
13. Vacuum pump gear
14. Idle gear A bolt
15. Power steering oil pump gear
16. Idle gear C bolt
17. Idle gear C
18. Crankshaft gear
19. Oil pump gear
20. Cover
21. Bolt
23. Washer
24. Bolt
Tightening torque
2: 8.0 N・m { 0.8 kgf・m / 71 lb・in }
3: 130 N・m { 13.3 kgf・m / 96 lb・ft }
6: 59 N・m { 6.0 kgf・m / 44 lb・ft }
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14: 32 N・m { 3.3 kgf・m / 24 lb・ft }
16: 59 N・m { 6.0 kgf・m / 44 lb・ft }
21: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
24: 294 N・m { 30.0 kgf・m / 217 lb・ft }
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Water outlet pipe

Cylinder head
Turbocharger

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RHD models
LHD models
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Caution
Legend
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Caution
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2. Clip

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1. CMP sensor
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dead center.
Legend
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1. Alignment mark
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1. Oil feed pipe
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3. Gasket
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2. Sleeve
3. Sprocket
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13. Camshaft removal
1) Measure the axial direction clearance of the camshaft gear and camshaft bracket using a feeler gauge.
Note
Limit: 0.250 mm { 0.00984 in }
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Legend
1. Camshaft
2. Camshaft bracket
3. Camshaft gear
Note
Caution
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2. Inlet camshaft
3. Exhaust camshaft
Legend
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2. Nut
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1. Bracket
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Note
Limit: 0.30 mm { 0.0118 in }
Note
idle gear.
Idle
gear
0.060 to 0.135
A mm { 0.0024 to
0.0053 in }
0.055 to 0.130 0.20 mm
C mm { 0.0022 to { 0.0079
0.0051 in } in }
0.090 to 0.155
D mm { 0.0035 to
0.0061 in }
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1. M6 bolt
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10) Remove idle gear D from the idle gear shaft.
11) Remove the idle gear D shaft from the camshaft brackets.
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Legend
1. Idle gear D
2. Idle gear D shaft
3. Camshaft bracket
Idle gear inspection (4JJ1 without DPD)
1. Idle gear inspection
1) Measure the idle gear shaft outer diameter using a micrometer.
Note
If the measured value exceeds the limit, replace the idle gear shaft.
Idle gear shaft outer diameter

Idle
Standard
gear Limit
value
shaft
44.950 to
44.975 mm { 44.80 mm {
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A
1.7697 to 1.7638 in }
1.7707 in }
24.959 to
24.980 mm { 24.80 mm {
C, D
0.9826 to 0.9764 in }
0.9835 in }
2) Measure the inner diameter of the idle gear bushing using a dial gauge.
3) Calculate the clearance between the idle gear shaft outer diameter and the idle gear bushing inner diameter.
Note
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If the measured value exceeds the limit, replace the idle gear or idle gear shaft.
Clearance between idle gear A

and the shaft
Idle
Standard
gear Limit
value
shaft
0.025 to
0.075 mm { 0.20 mm {
A
0.0010 to 0.0079 in }
0.0030 in }
0.020 to
0.062 mm { 0.20 mm {
C, D
0.0008 to 0.0079 in }
0.0024 in }
Idle gear installation (4JJ1 without DPD)
1. Component views
Idle gear
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Part name
1. Gear case cover

2. Bolt
5. Idle gear D
9. Timing chain
12. Idle gear A
17. Idle gear C
18. Crankshaft gear
19. Oil pump gear
20. Cover
21. Bolt
23. Washer
24. Bolt
Tightening torque
2: 8.0 N・m { 0.8 kgf・m / 71 lb・in }
3: 130 N・m { 13.3 kgf・m / 96 lb・ft }
6: 59 N・m { 6.0 kgf・m / 44 lb・ft }
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14: 32 N・m { 3.3 kgf・m / 24 lb・ft }
16: 59 N・m { 6.0 kgf・m / 44 lb・ft }
21: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
24: 294 N・m { 30.0 kgf・m / 217 lb・ft }
1) Apply engine oil to the sliding surface of the idle gear D shaft and idle gear inner surface.
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2) Install the idle gear D shaft to the camshaft brackets.
3) Install idle gear D to the idle gear shaft.
A shaft oil hole.
Legend
1. Front mark
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Caution
bolts.
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Note
Legend
1. M6 bolt
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Legend
1. Idle gear A bolt

2. Idle gear C bolt
Caution
Legend
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Caution

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Legend

2. Nut

Legend
1. Bracket
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6. Camshaft installation
dead center.
Legend
Caution
Caution
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Loosen the rocker arm adjust nut in advance and loosen the adjust screw by 2 pitch or more.
Legend

3. Idle gear D

Camshaft journal
Threaded portion and seating surface of bolts
Caution
Legend
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1. Alignment mark
7) Temporarily tighten the camshaft upper bracket M8 bolts to the cylinder head in the order shown in the diagram.
Caution
8) Final tighten the camshaft upper bracket M8 bolts to the cylinder head in the order shown in the diagram.
9) Temporarily tighten the camshaft upper bracket M6 bolts to the camshaft brackets in the order shown in the
diagram.
10) Final tighten the camshaft upper bracket M6 bolts to the camshaft brackets in the order shown in the diagram.

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Legend
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Legend

2. Sleeve
4. Sprocket
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Legend
1. Timing chain
2. Timing mark
3. Blue link
4. Yellow link
Note
Legend
1. Pin
2. Plunger
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3. Latch
4. Hook
Caution
Legend
1. Oil feed pipe

3. Gasket
Note
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Caution
Legend
1. Liquid gasket
Standard value

Caution
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Caution
Legend
1. Liquid gasket
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Standard value
dead center.
Legend
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Legend
1. Screwdriver
2. Ring spanner
3. 5-8840-2822-0
Note
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Legend

2. Cam (Inlet side)

No. 1
cylinder
top dead
center
No. 4
cylinder
top dead
center

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Caution
Legend
1. Liquid gasket
Standard value
Caution
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Legend

2. Clip
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Legend

RHD models
LHD models
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Water outlet pipe

Cylinder head
Turbocharger
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Inlet manifold removal (4JJ1 without DPD)
1. Component views
Inlet manifold (Without EGR)
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Part name
1. Intake air duct

2. Bolt
3. Bolt
4. Bracket
5. Clamp
6. Bolt
8. Intake throttle valve gasket
9. Inlet manifold
10. Bolt
11. Bolt
12. Nut
13. Inlet manifold gasket
Tightening torque
2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
3: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
5: 4.0 N・m { 0.4 kgf・m / 35 lb・in }
6: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
10: 25 N・m { 2.5 kgf・m / 18 lb・ft }
11: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Inlet manifold (Euro2 specifications)
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Part name
1. Intake air duct
2. Bolt
3. Bolt
4. Bracket
5. Clamp
6. Bolt
9. Bolt
10. EGR pipe adapter
11. EGR valve
12. Nut
13. Bolt
14. EGR valve gasket
15. Bolt
16. Nut
17. Inlet manifold
Tightening torque
2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
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3: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
5: 4.0 N・m { 0.4 kgf・m / 35 lb・in }
6: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
9: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 27 N・m { 2.8 kgf・m / 20 lb・ft }
13: 24 N・m { 2.4 kgf・m / 18 lb・ft }
15: 25 N・m { 2.5 kgf・m / 18 lb・ft }
16: 25 N・m { 2.5 kgf・m / 18 lb・ft }

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Part name
1. Intake air duct

2. Bolt
3. Bolt
4. Bracket
5. Clamp
6. Bolt
9. Inlet manifold
10. EGR valve
11. Nut
12. Bolt
14. Bolt
15. Nut
Tightening torque
2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

3: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
5: 4.0 N・m { 0.4 kgf・m / 35 lb・in }
6: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
11: 27 N・m { 2.8 kgf・m / 20 lb・ft }
12: 24 N・m { 2.4 kgf・m / 18 lb・ft }
14: 25 N・m { 2.5 kgf・m / 18 lb・ft }
15: 25 N・m { 2.5 kgf・m / 18 lb・ft }
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Caution
negative terminal.

4. Coolant drain
Warning
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Legend
1. Drain plug

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Legend
1. Air cleaner
3. Vacuum hose
4. Blow-by hose
5. Intake pipe
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Legend

Legend

Without EGR
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Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) Intake throttle valve removal".
Legend
1. Heater hose
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2) Remove the heater return hose from the heater pipe and cylinder block.
3) Remove the heater pipe and heater feed hose as a set from the cylinder head and inlet manifold.
11. EGR valve removal
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Refer to "1.Engine 1H.Aux. Emission Control Devices(4JJ1 without DPD) EGR valve removal".
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Tension pulley
A/C compressor
Crankshaft pulley
Legend
1. Lock nut
2. Adjust bolt

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Legend

2. A/C compressor

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1) Disconnect the leak-off hose from the leak-off pipe.
4) Remove the vacuum pipe from the inlet manifold.

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Caution
19. Inlet manifold removal
1. Without EGR
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3) Remove the EGR pipe adapter and gasket from the inlet manifold.
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Inlet manifold installation (4JJ1 without DPD)
1. Component views
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Part name
1. Intake air duct

2. Bolt
3. Bolt
4. Bracket
5. Clamp
6. Bolt
9. Inlet manifold
10. Bolt
11. Bolt
12. Nut
Tightening torque
2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
3: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
5: 4.0 N・m { 0.4 kgf・m / 35 lb・in }
6: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
10: 25 N・m { 2.5 kgf・m / 18 lb・ft }
11: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 25 N・m { 2.5 kgf・m / 18 lb・ft }
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Part name
1. Intake air duct
2. Bolt
3. Bolt
4. Bracket
5. Clamp
6. Bolt
9. Bolt
11. EGR valve
12. Nut
13. Bolt
15. Bolt
16. Nut
17. Inlet manifold
Tightening torque
2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
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3: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
5: 4.0 N・m { 0.4 kgf・m / 35 lb・in }
6: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
9: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 27 N・m { 2.8 kgf・m / 20 lb・ft }
13: 24 N・m { 2.4 kgf・m / 18 lb・ft }
15: 25 N・m { 2.5 kgf・m / 18 lb・ft }
16: 25 N・m { 2.5 kgf・m / 18 lb・ft }

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Part name
1. Intake air duct

2. Bolt
3. Bolt
4. Bracket
5. Clamp
6. Bolt
9. Inlet manifold
10. EGR valve
11. Nut
12. Bolt
14. Bolt
15. Nut
Tightening torque
2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

3: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
5: 4.0 N・m { 0.4 kgf・m / 35 lb・in }
6: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
11: 27 N・m { 2.8 kgf・m / 20 lb・ft }
12: 24 N・m { 2.4 kgf・m / 18 lb・ft }
14: 25 N・m { 2.5 kgf・m / 18 lb・ft }
15: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2. Inlet manifold installation
1. Without EGR
Caution
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1) Install the EGR pipe adapter to the inlet manifold.
Caution

Caution
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Caution
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can no longer turn.
Caution

1) Install the vacuum pipe to the inlet manifold.
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4) Connect the leak-off hose to the leak-off pipe.

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Legend

2. A/C compressor
Tension pulley
A/C compressor
Crankshaft pulley
Legend
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1. Lock nut
2. Adjust bolt
Caution
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10. EGR valve installation
Refer to "1.Engine 1H.Aux. Emission Control Devices(4JJ1 without DPD) EGR valve installation".
1) Temporarily tighten the heater pipe to the inlet manifold in the order shown in the diagram.
2) Connect the heater feed hose to the cylinder head.

3) Final tighten the heater pipe to the inlet manifold in the order shown in the diagram.
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4) Install the heater return hose to the heater pipe and cylinder block.
Legend
1. Heater hose
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Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) Intake throttle valve installation".
Without EGR
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Caution

Legend
1. Air cleaner
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3. Vacuum hose
4. Blow-by hose
5. Intake pipe
Legend
1. Alignment mark

1. Post procedures
17. Coolant filling
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Note
Caution
Note
lowers.
Caution
Legend
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2. MAX line
3. MIN line
Caution
6) Stop the engine.
Warning
Note
Note
Caution
Warning
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Note
Caution

Note
98 N { 10.0 kg / 22 lb } Load
Caution
Measurement point 1
Deflection
12.5 to 16.5
92 to 112
Hz
0.65 in }
16.5 to 19.1
79 to 91
Reused mm { 0.65 to
Hz
0.75 in }
Measurement point 2
Deflection
15.9 to 20.7
70 to 86
Hz
0.81 in }
20.7 to 23.7
62 to 70
Reused mm { 0.81 to
Hz
0.93 in }
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Measurement point 3
Deflection
12.4 to 16.4
92 to 112
Hz
0.65 in }
16.5 to 19.1
80 to 92
Reused mm { 0.65 to
Hz
0.75 in }
Legend

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Intake throttle valve removal (4JJ1 without DPD)
Caution
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negative terminal.

Legend
1. Engine cover

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Legend
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2. Gasket
Intake throttle valve installation (4JJ1 without DPD)
Caution
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Legend

2. Gasket
Caution
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Legend
1. Engine cover
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1. Post procedures

Piston removal (4JJ1 without DPD)
1. Component views
Piston
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Part name
1. Snap ring
2. Piston pin
3. Piston ring
4. Piston
5. Connecting rod
6. Connecting rod bearing
7. Connecting rod cap
8. Connecting rod bolt
Tightening torque
8-1: 29.4 N・m { 3.0 kgf・m / 22 lb・ft }
8-2: 45 to 60 °
2. Crankcase removal
Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) Crankcase removal".
3. Piston removal
1) Remove all carbon from the top of the cylinder bore using a scraper.
2) Turn the crankshaft to align it to bottom dead center.
3) Remove the connecting rod bearing cap from the connecting rod.
4) Remove the connecting rod bearing from the connecting rod bearing cap.
Note
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Organize the removed bearings according to the cylinders using tags, etc.
5) Turn the crankshaft to align it to top dead center.
6) Remove the piston and connecting rod from the cylinder block.
Note
Pull out the piston and connecting rod from the cylinder head side.
Push out from the lower end of the connecting rod by using the handle of a hammer, etc., so as not to
damage the bearing.
Caution
When pushing out the connecting rod, do not damage the oil jet and cylinder inner surface.
7) Remove the connecting rod bearing from the connecting rod.
Note
Organize the removed bearings according to the cylinders using tags, etc.
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Piston disassembly (4JJ1 without DPD)
1. Component views
Piston
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Part name
1. Snap ring
2. Piston pin
3. Piston ring
4. Piston
5. Connecting rod
Tightening torque
8-1: 29.4 N・m { 3.0 kgf・m / 22 lb・ft }
8-2: 45 to 60 °
2. Piston disassembly
1) Remove the piston ring from the piston using ring pliers.
Caution
When reusing the piston rings, organize them according to the order of the cylinders so that other
cylinder pistons and piston rings do not get mistaken.
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2) Remove the snap ring from the piston.
Caution
Do not reuse the snap ring.
3) Remove the piston pin from the piston and connecting rod.
Caution
Organize the disassembled piston pins, pistons, and connecting rods in the same order as the
cylinders.
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Piston inspection (4JJ1 without DPD)
1. Piston inspection
1. Cleaning
1) Remove any carbon from the following parts.
Piston head
Piston ring groove
Piston ring end gap
Caution
Do not use a wire brush.
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1) Inspect the piston for the following.
Cracking
Wear
Seizing
2) Inspect the connecting rod bearing for the following.
Wear
Damage
Spalling
Note
Replace the bearings as an assembly if there are abnormal conditions.
3) Inspect the piston pin for the following.
Crack
Wear
Damage
3. Measurement of clearance between cylinder bore and piston
1) Measure the inner diameter of the cylinder bore in the thrust direction and radial direction at the specified
positions using a cylinder gauge.
Legend
a. Thrust direction
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b. Radial direction
c: 20 mm { 0.787 in } Measurement position from the upper surface of the cylinder block
d: 80 mm { 3.15 in } Measurement position from the upper surface of the cylinder block
e: 140 mm { 5.51 in } Measurement position from the upper surface of the cylinder block
2) Calculate the average measured value excluding the maximum and minimum values.
3) Measure the piston outer diameter at the measurement position in the diagram, perpendicular to the piston pin.
a: 11 mm { 0.433 in } From the bottom surface of the piston

4) Calculate the clearance between the piston and the cylinder bore inner diameter.
Note
If the measured value is outside the standard range, replace the piston.
5) Select a piston so that the clearance is the specified value.
Note
Grades A, B, and C are marked on the top of the piston when shipped from the factory.
Grade Outer diameter

95.340 to 95.369 mm {
A
3.7535 to 3.7547 in }
95.350 to 95.379 mm {
B
3.7539 to 3.7551 in }
95.360 to 95.389 mm {
C
3.7543 to 3.7555 in }
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Legend
1. Grade marking
2. Front mark
4. Measurement of piston ring joint
1) Insert the piston ring into the cylinder bore.
Note
Push the piston ring into the cylinder using the piston until the cylinder bore is at the position where
it is smallest.
Push in a right angle to the cylinder wall.
Caution
Do not decline the piston ring in either direction.
2) Measure the clearance of the ring joint using a feeler gauge.
Note
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If the measured value is outside the standard range, replace the piston ring.
Piston ring joint clearance

Piston ring Standard value
0.32 to 0.46 mm {
Top ring
0.0126 to 0.0181 in }
0.42 to 0.66 mm {
2nd ring
0.0165 to 0.0260 in }
0.27 to 0.56 mm {
Oil ring
0.0106 to 0.0220 in }
5. Measurement of clearance between piston ring and piston ring groove
1) Remove all carbon from the piston ring grooves.
2) Install the piston ring to the piston.
3) Measure the clearance between the piston ring groove and the piston ring using a feeler gauge.
Note
Top ring cannot be measured, because of its shape.
Replace the piston or piston ring if the measured value exceeds the limit.
Clearance between piston ring

and piston ring groove
Standard
Piston ring Limit
value
Top ring - -
0.06 to 0.12
mm { 0.15 mm {
2nd ring
0.0024 to 0.0059 in }
0.0047 in }
0.03 to 0.07
mm { 0.15 mm {
Oil ring
0.0012 to 0.0059 in }
0.0028 in }
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6. Measurement of clearance between piston and piston pin
1) Apply the engine oil to the piston pin.
2) Insert the piston pin to the piston.
3) Inspect whether a certain amount of resistance exists in the piston when the piston pin is lightly pushed.
Note
Inspect with the piston at room temperature.
If there is looseness, measure the clearance of the piston and piston pin.
4) Measure the outer diameter of the piston pin using a micrometer.
Note
If the measured value is outside the standard range, replace the piston pin.
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5) Calculate the clearance between the inner diameter of the piston pin hole and the outer diameter of the piston
pin.
Note
Replace the piston or piston pin if the measured value exceeds the standard value.
6) Measure the connecting rod small end bushing inner diameter using a dial gauge.
7) Calculate the clearance between the inner diameter of the connecting rod small end bushing and the outer
diameter of the piston pin.
Note
Replace the connecting rod or piston pin if the measured value exceeds the limit.
Limit: 0.050 mm { 0.0020 in }

7. Connecting rod measurement
1) Measure the twisting and degree of parallelization of the connecting rod using a connecting rod aligner.
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Note
For a connecting rod alignment of 100 mm {3.94 in}, measure the twist and the degree of
parallelization of the large end hole and the small end hole.
Replace the connecting rod if the measured value exceeds the standard value.
Standard: 0.05 mm { 0.0020 in } Twisting
Standard: 0.05 mm { 0.0020 in } Degree of parallelization
8. Connecting rod oil clearance measurement
Note
The removed caps should be lined up in the order of the cylinder number.
2) Clean the bearing and crankshaft pin.
3) Place the PLASTIGAUGE on the crankshaft pin.
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4) Apply engine oil to the threaded portions and seating surfaces of the tightening bolts.
5) Temporarily tighten the connecting rod bearing caps and connecting rods to the crankshaft.
6) Final tighten the tightening bolts in the order shown in the diagram using the special tool.
Caution
Do not rotate the crankshaft.
Tightening torque: 29.4 N・m { 3.0 kgf・m / 22 lb・ft } 1st time

8) Measure the widest point of the flattened PLASTIGAUGE, and measure the oil clearance of the crank pin
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section.
Note
Replace the bearings as a set if the measured value is outside the standard range.
9) Remove any PLASTIGAUGE from the following parts.
Connecting rod bearing

Crank pin
Piston reassembly (4JJ1 without DPD)
1. Component views
Piston
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Part name
1. Snap ring
2. Piston pin
3. Piston ring
4. Piston
5. Connecting rod
Tightening torque
8-1: 29.4 N・m { 3.0 kgf・m / 22 lb・ft }
8-2: 45 to 60 °
2. Piston reassembly
1) Sufficiently apply engine oil to the piston pin.
2) Install the snap ring for one side to the piston.
Caution
3) Align the piston to the connecting rod.
Caution
Install so that the piston head front mark and the connecting rod convex mark face the same
direction.
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Legend
1. Front mark
2. Convex mark
4) Install the piston pin to the piston and connecting rod.
5) Install the snap ring to the piston.
Caution
Make sure that the snap ring opening is facing upward.
Confirm that the snap ring securely fits into the piston groove and that both the piston and
connecting rod move smoothly.
6) Install the oil ring to the piston.
Note
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There is no top or bottom direction for the oil ring.
Caution
The oil ring joint and coil expander joint should be 180° opposite from each other.
Install so that there is no opening at the coil expander joint section.
7) Install the 2nd ring to the piston using ring pliers.
Note
Install the 2nd ring with the N2TA laser mark facing up.
Caution
Check that it is installed with the laser mark facing up.
Do not damage the piston skirt.
8) Install the top ring to the piston using ring pliers.
Note
Install the top ring with the NT laser mark facing up.
Caution
Check that it is installed with the laser mark facing up.
Do not damage the piston skirt.
9) Check that there is the marking on the upper surface of the piston ring.
Upper face
Piston ring
marking
Top ring NT
2nd ring N2TA
Legend
1. Top ring joint
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2. 2nd ring joint
3. Oil ring joint
4. Coil expander joint
Piston installation (4JJ1 without DPD)
1. Component views
Piston
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Part name
1. Snap ring
2. Piston pin
3. Piston ring
4. Piston
5. Connecting rod
Tightening torque
8-1: 29.4 N・m { 3.0 kgf・m / 22 lb・ft }
8-2: 45 to 60 °
2. Piston installation
1) Install the connecting rod bearing to the connecting rod.
2) Apply engine oil to the sliding surface of the connecting rod bearing.
Caution
Do not apply engine oil to the connecting rod bearing installation surface and the back surface of the
bearing.
3) Sufficiently apply the engine oil to the following locations.
Piston ring
Piston ring groove
Piston side surface
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Cylinder bore surface
4) Turn the crankshaft in the forward direction and align to top dead center.
5) Install the piston to the cylinder block using the special tool.
Note
Face the piston front mark towards the front.
Use the piston ring compressor to insert the piston into the cylinder block.
SST: 5-8840-9018-0 - piston setting tool
Caution
When pushing the piston, do not allow the connecting rod to interfere with the oil jet.
If the crank pin is at bottom dead center, the connecting rod may hit and damage the oil jet.
Do not damage the cylinder block inner surface.
6) Install the connecting rod bearing to the bearing cap.
7) Apply engine oil to the sliding surface of the connecting rod bearing.
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Caution
Do not apply engine oil to the connecting rod bearing installation surface and the back surface of the
bearing.
9) Temporarily tighten the bearing caps to the connecting rods after matching their cylinder numbers.
10) Final tighten the bearing cap bolts to the connecting rod using a torque wrench and the special tool.
Tightening torque: 29.4 N・m { 3.0 kgf・m / 22 lb・ft } 1st time
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11) Turn the crankshaft and check that it turns smoothly without interference.
Caution
Check that there is no oil jet deformation and that there is no interference with other parts.
3. Crankcase installation
Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) Crankcase installation".

Rear plate removal (4JJ1 without DPD)
1. Component views
Rear plate
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Part name
1. Bolt
2. Rear plate
3. Bolt
Tightening torque
1: 82 N・m { 8.4 kgf・m / 60 lb・ft }

3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2. Flywheel removal
Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) Flywheel removal".
1) Remove the rear plate from the cylinder block and crankcase.
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Rear plate installation (4JJ1 without DPD)
1. Component views
Rear plate
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Part name
1. Bolt
2. Rear plate
3. Bolt
Tightening torque
1: 82 N・m { 8.4 kgf・m / 60 lb・ft }

3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1) Install the rear plate to the cylinder block and crankcase.
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Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) Flywheel installation".

Rocker arm shaft removal (4JJ1 without DPD)
1. Component views
Rocker arm shaft
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Part name
1. Rocker arm
2. Spacer
3. Bolt
4. Rocker arm shaft
5. Camshaft bracket
6. Plate
Tightening torque
3: 9.5 N・m { 1.0 kgf・m / 84 lb・in } Wet
Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) Timing chain removal".
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Caution
5. Injector removal
Note
Caution
damage.
Caution
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Clip
O-ring
Gasket
Legend
1. Injector
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket

Camshaft bracket
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Rocker arm shaft
Camshaft
Idle gear D
Legend
1. Camshaft bracket
2. Cylinder head
7. Rocker arm shaft removal
Note
Caution
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Legend

2. Inlet camshaft
3. Exhaust camshaft
3) Remove the rocker arm shaft from the rocker arms and camshaft brackets.
Caution
If reusing the rocker arm, perform the procedures necessary to install it to its original position.
4) Remove the spacer from the rocker arm shaft.
5) Remove the plate from the camshaft bracket.

Legend
1. Rocker arm
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2. Spacer
3. Bolt
4. Rocker arm shaft
5. Camshaft bracket
6. Plate
Rocker arm shaft installation (4JJ1 without DPD)
1. Component views
Rocker arm shaft
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Part name
1. Rocker arm
2. Spacer
3. Bolt
4. Rocker arm shaft
5. Camshaft bracket
6. Plate
Tightening torque
3: 9.5 N・m { 1.0 kgf・m / 84 lb・in } Wet
2. Rocker arm shaft installation
1) Put the plate on the camshaft bracket.
2) Loosen the adjust screw of the rocker arm.
Note
Loosen all the adjust screws.
3) Set the camshaft lower brackets in the order of journal number.
Caution
Check the stamping from No. 2 to No. 4.
4) Install the rocker arm shaft to the camshaft brackets while assembling the rocker arm.
5) Install the spacer to the rocker arm shaft.
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7) Temporarily tighten the rocker arm shaft to the camshaft bracket.
Caution
Check that the plate is securely installed.
8) Final tighten the No. 5 journal section rocker arm shaft to the camshaft bracket.
Note
Final tighten the bolts other than for the No. 5 journal section after assembling them to the cylinder
head.
Legend
1. Rocker arm
2. Spacer
3. Bolt
4. Rocker arm shaft
5. Camshaft bracket
6. Plate
Caution
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Caution
Loosen the rocker arm adjust nut and then loosen the adjust screw by 2 pitches or more.
Legend

3. Idle gear D

Camshaft journal
Threaded portions and seating surfaces of the M6 bolts
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Legend
1. Alignment mark
14) Temporarily tighten the camshaft upper bracket M6 bolts to the camshaft brackets.
Caution
15) Final tighten the camshaft upper bracket M6 bolts to the camshaft brackets.
dead center.
Legend
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Legend
1. Camshaft bracket
2. Cylinder head
Caution
Legend
1. Alignment mark
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5) Temporarily tighten the camshaft brackets to the cylinder head in the order shown in the diagram.
6) Final tighten the camshaft brackets to the cylinder head in the order shown in the diagram.
7) Securely tighten the rocker arm shaft to the camshaft bracket.

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dead center.
Legend

Legend
1. Screwdriver
2. Ring spanner
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3. 5-8840-2822-0
Note
Legend

2. Cam (Inlet side)

No. 1
cylinder
top dead
center
No. 4
cylinder
top dead
center
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Caution
Caution
Caution
Legend
1. Injector
2. Leak-off pipe
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3. Clip
4. O-ring
5. Gasket
Legend
1. Injector
2. Bolt
3. Injector clamp
can no longer turn.
Caution
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Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) Timing chain installation".
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Swirl control solenoid valve removal (4JJ1 without DPD)
Caution
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negative terminal.

2. Swirl control solenoid valve removal
1) Disconnect the connector from the swirl control solenoid valve.
2) Disconnect the vacuum hose from swirl control solenoid valve.
3) Remove the swirl control solenoid valve from the common rail (fuel rail) bracket.
Legend
1. Swirl control solenoid valve
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Swirl control solenoid valve installation (4JJ1 without DPD)
1. Swirl control solenoid valve installation
1) Install the swirl control solenoid valve to the common rail (fuel rail) bracket.
2) Connect the vacuum hose to swirl control solenoid valve.
3) Connect the connector to swirl control solenoid valve.
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Legend
1. Swirl control solenoid valve
1. Post procedures

Timing chain removal (4JJ1 without DPD)
Caution
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negative terminal.

Legend
1. Engine cover
4. Coolant drain
Warning
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Legend
1. Drain plug
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Legend
1. Air cleaner
3. Vacuum hose
4. Blow-by hose
5. Intake pipe
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Legend

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Tension pulley
A/C compressor
Crankshaft pulley
Legend
1. Lock nut
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2. Adjust bolt
Caution
Legend


Caution
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Legend

2. Clip

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Water outlet pipe

Cylinder head
Turbocharger

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Legend
1. CMP sensor
Legend
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dead center.
Legend

Legend
1. Alignment mark
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Legend
1. Oil feed pipe

3. Gasket
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Legend

2. Sleeve
3. Sprocket
Legend
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Timing chain installation (4JJ1 without DPD)
dead center.
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Legend

Legend
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Legend

2. Sleeve
4. Sprocket
Legend
1. Timing chain
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2. Timing mark
3. Blue link
4. Yellow link
Note
Legend
1. Pin
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2. Plunger
3. Latch
4. Hook
Caution
Legend
1. Oil feed pipe

3. Gasket
Note
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Caution
Legend
1. Liquid gasket
Standard value

Caution
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Water outlet pipe

Cylinder head
Turbocharger

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Caution
Legend
1. Liquid gasket
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Standard value

Caution
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Legend
1. Liquid gasket
Standard value
Caution

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Legend

2. Clip
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Legend

Tension pulley
A/C compressor
Crankshaft pulley
Legend
1. Lock nut
2. Adjust bolt
Caution
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Legend

Caution
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Caution
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Legend
1. Air cleaner
3. Vacuum hose
4. Blow-by hose
5. Intake pipe

Legend
1. Alignment mark
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Legend
1. Engine cover
1. Post procedures
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19. Coolant filling
Note
Caution
Note
lowers.
Caution
Legend
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2. MAX line
3. MIN line
Caution
6) Stop the engine.
Warning
Note
Note
Caution
Warning
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Note
Caution

Note
98 N { 10.0 kg / 22 lb } Load
Caution
Measurement point 1
Deflection
12.5 to 16.5
92 to 112
Hz
0.65 in }
16.5 to 19.1
79 to 91
Reused mm { 0.65 to
Hz
0.75 in }
Measurement point 2
Deflection
15.9 to 20.7
70 to 86
Hz
0.81 in }
20.7 to 23.7
62 to 70
Reused mm { 0.81 to
Hz
0.93 in }
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Measurement point 3
Deflection
12.4 to 16.4
92 to 112
Hz
0.65 in }
16.5 to 19.1
80 to 92
Reused mm { 0.65 to
Hz
0.75 in }
Legend

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Timing gear case removal (4JJ1 without DPD)
1. Component views
Timing gear case
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Part name
1. Bolt
2. Upper generator bracket
3. Bolt
4. Bolt
5. Generator
6. Lower generator bracket
7. Bolt
8. Nut
10. Gasket
11. Timing gear case
12. Bolt
Tightening torque
1: 25 N・m { 2.5 kgf・m / 18 lb・ft }
3: 40 N・m { 4.1 kgf・m / 30 lb・ft }
4: 51 N・m { 5.2 kgf・m / 38 lb・ft }
7: 25 N・m { 2.5 kgf・m / 18 lb・ft }
8: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 25 N・m { 2.5 kgf・m / 18 lb・ft }
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Caution
negative terminal.

3. Engine oil drain
Caution
4. Engine hood removal
Caution
Two people are required to install or remove the engine hood.
1) Remove the engine hood from the hood hinge.

Note
Mark the hood hinge position before removing the engine hood.
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5. Wiper linkage removal
Refer to "9.Body, Cab, Accessories 9B.Wiper, Washer Systems wiper linkage removal".
6. Cowl panel removal
1) Remove the cowl panel from vehicle.
7. Battery removal

Legend
1. Battery cable
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2. Battery bracket
8. Radiator lower hose disconnect
1) Disconnect the radiator lower hose from the water intake pipe.
Legend

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Legend
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2. A/C compressor

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Legend

2. Gasket

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Legend
1. Fuel feed hose

2. Fuel return hose
18. Fuel feed pipe removal
1) Remove the fuel feed pipe from the fuel supply pump and common rail (fuel rail).
Caution
Legend
1. Fuel feed pipe

1) Disconnect the leak-off hose from the leak-off pipe.
4) Remove the vacuum pipe from the inlet manifold.
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Legend


Legend
1. Glow plug
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RHD models
LHD models
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Legend

Legend
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Legend


Without EGR
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Legend
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Legend
1. Gasket
31. Oil filter removal
1) Remove the oil filter and gasket from the oil cooler.
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1) Remove the tension pulley from the generator bracket.

2) Remove the generator lower bracket from the cylinder block and timing gear case.
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Caution
Legend
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Caution
Legend

2. Clip

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Caution
Legend
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Caution
Note
Caution
damage.
Caution
Clip
O-ring
Gasket
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Legend
1. Injector
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket

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Water outlet pipe

Cylinder head
Turbocharger

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Legend
1. CMP sensor
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Legend
dead center.
Legend
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Legend
1. Alignment mark
Legend
1. Oil feed pipe
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3. Gasket
Legend
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2. Sleeve
3. Sprocket
Legend
44. Fuel supply pump removal
1) Mark the alignment positions of idle gear A and the supply pump gear.
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2) Remove the supply pump gear from the fuel supply pump using a gear puller.
3) Disconnect the connector from the fuel temperature sensor.
4) Disconnect the connector from the FRP regulator.

Legend
1. Fuel temperature sensor connector
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2. FRP regulator connector
5) Remove the fuel supply pump from the timing gear case.
Caution
Do not hold the high pressure pipe.
Legend
1. Fuel supply pump
6) Remove the O-ring from the fuel supply pump.

Legend
1. Fuel supply pump
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2. O-ring
Camshaft bracket
Rocker arm shaft
Camshaft
Idle gear D
Legend
1. Camshaft bracket
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2. Cylinder head
Legend
1. 5-8840-2999-0
2. M10 x 1.5 x 25 mm {0.98 in}
3. M10 x 1.5 x 25 mm {0.98 in}
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Legend
1. Nut
2. Bolt
3. Nut
Caution
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Caution
47. Water pump removal
1) Remove the water pump and gasket from the timing gear case.
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Legend

2. Nut

Legend
1. Bracket
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Note
Limit: 0.30 mm { 0.0118 in }
Note

idle gear.
Idle
gear
0.060 to 0.135
A mm { 0.0024 to
0.0053 in }
0.055 to 0.130 0.20 mm
C mm { 0.0022 to { 0.0079
0.0051 in } in }
0.090 to 0.155
D mm { 0.0035 to
0.0061 in }
Legend
1. M6 bolt
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52. Oil pump removal
1) Remove the oil pump from the timing gear case.

Legend
1. Oil pump
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53. Timing gear case removal
1) Remove the timing gear case bracket from the timing gear case and cylinder block.
Legend
2) Remove the timing gear case and gasket from the cylinder block.
Legend
1. Timing gear case
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2. Gasket
Caution
Legend
1. Timing gear case

2. Bolt L = 25 mm {0.98 in}
3. Bolt L = 60 mm {2.36 in}
4. Bolt L = 45 mm {1.77 in}
5. Bolt L = 35 mm {1.38 in}
6. Bolt L = 16 mm {0.63 in}
Timing gear case installation (4JJ1 without DPD)
1. Component views
Timing gear case
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Part name
1. Bolt
3. Bolt
4. Bolt
5. Generator
7. Bolt
8. Nut
10. Gasket
12. Bolt
Tightening torque
1: 25 N・m { 2.5 kgf・m / 18 lb・ft }
3: 40 N・m { 4.1 kgf・m / 30 lb・ft }
4: 51 N・m { 5.2 kgf・m / 38 lb・ft }
7: 25 N・m { 2.5 kgf・m / 18 lb・ft }
8: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2. Timing gear case installation
1) Apply ThreeBond 1207B or equivalent to the gasket.
2) Referring to the diagram, apply ThreeBond 1207B or equivalent to the cylinder block.
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Caution
Install the timing gear case within 5 minutes of applying liquid gasket.
Legend
3) Install the gasket to the cylinder block.
4) Align the positions of the dowel pin and bolt, and install the timing gear case to the cylinder block.
Caution

Legend
1. Timing gear case

2. Bolt L = 25 mm {0.98 in}
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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}
5) Temporarily tighten the timing gear case bracket to the timing gear case.
6) Temporarily tighten the timing gear case bracket to the cylinder block.
7) Final tighten the timing gear case bracket to the timing gear case.
8) Final tighten the timing gear case bracket to the cylinder block.

Legend
3. Oil pump installation
1) Apply engine oil to the oil pump gear.
2) Install the oil pump to the timing gear case.
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Legend
1. Oil pump
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A shaft oil hole.
Legend
1. Front mark
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Caution
bolts.
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Note
Legend
1. M6 bolt
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Legend
1. Idle gear A bolt

2. Idle gear C bolt
Caution
Legend
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Caution

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Legend

2. Nut

Legend
1. Bracket
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8. Water pump installation
1) Install the water pump and gasket to the timing gear case.
Caution
Caution
cylinder head.
Caution
Legend
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Legend
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measured values.
Caution
Caution
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Standard value
Caution
Caution
Caution
Note
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dead center.
Legend

Legend
1. Camshaft bracket
2. Cylinder head
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Caution
Legend
1. Alignment mark
11. Fuel supply pump installation
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1) Apply soapy water to the O-ring.
2) Install the O-ring to the fuel supply pump.
Caution
Do not pinch the O-ring.
3) Install the fuel supply pump to the timing gear case.
Legend
1. Fuel supply pump
4) Confirm that the supply pump camshaft key is located in a horizontal position on the right side when seen from
the front.
5) Install the supply pump gear to idle gear A by aligning the alignment marks.
Caution
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Check that the supply pump gear and main gear of idle gear A are securely engaged.
Legend
1. Supply pump gear alignment mark

2. Idle gear marking
3. Main gear
4. Sub-gear
6) Connect the connector to the FRP regulator.
7) Connect the connector to the fuel temperature sensor.

Legend
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Legend

2. Sleeve
4. Sprocket
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Legend
1. Timing chain
2. Timing mark
3. Blue link
4. Yellow link
Note
Legend
1. Pin
2. Plunger
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3. Latch
4. Hook
Caution
Legend
1. Oil feed pipe

3. Gasket
Note
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dead center.
Legend
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Legend
1. Screwdriver
2. Ring spanner
3. 5-8840-2822-0
Note
Legend

2. Cam (Inlet side)
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No. 1
cylinder
top dead
center
No. 4
cylinder
top dead
center
Caution
Legend
1. Liquid gasket
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Standard value
Caution

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Water outlet pipe
Cylinder head
Turbocharger
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Caution
Legend
1. Liquid gasket
Standard value

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Caution
Caution
Caution
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Legend
1. Injector
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket

Legend
1. Injector
2. Bolt
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3. Injector clamp
can no longer turn.
Caution
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Legend
Caution
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Legend
1. Liquid gasket
Standard value
Caution

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Legend

2. Clip
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Legend

1) Install the generator lower bracket to the cylinder block and timing gear case.
2) Temporarily tighten the tension pulley to the generator bracket in the order shown in the diagram.
3) Final tighten the tension pulley to the generator bracket in the order shown in the diagram.
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25. Oil filter installation
1) Temporarily tighten the oil filter and gasket to the oil cooler in the order shown in the diagram.
Caution
2) Final tighten the oil filter to the oil cooler in the order shown in the diagram.
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Caution
Ensure that no dirt or foreign material enters.
Caution
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Legend


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Legend

Caution
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Caution
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Caution
diagram.
diagram.
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Caution

Caution
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Legend
Caution
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Without EGR
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Legend


Legend

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Legend

RHD models
LHD models
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Legend
1. Glow plug
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Legend

1) Install the vacuum pipe to the inlet manifold.

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4) Connect the leak-off hose to the leak-off pipe.
Legend
1. Fuel return hose

2. Fuel feed hose
39. Fuel feed pipe installation

1) Install the fuel feed pipe to the fuel supply pump and common rail (fuel rail).
Caution
Do not reuse the fuel feed pipe.
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Legend
1. Fuel feed pipe
Caution

Legend

2. Gasket
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Legend

2. A/C compressor

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48. Radiator lower hose connect
1) Connect the radiator lower hose to the water intake pipe.

Legend
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Legend
1. Battery cable
2. Battery bracket
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Dimensions

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Legend
1. Hood rest
1. Post procedures

Supplementary Information (4JJ1 without DPD)
1. Component views
Engine mounting
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Part name
1. Nut
3. Bolt
4. Bolt
5. Bolt
6. Bolt
7. Left side mounting cover
8. Bolt
9. Left side engine mounting
10. Bolt
11. Nut
13. Bolt
14. Bolt
15. Bolt
16. Right side mounting cover
17. Right side engine mounting
18. Bolt
19. Bolt
20. Heat protector
21. Bolt
22. Bolt
Tightening torque
1: 52 N・m { 5.3 kgf・m / 38 lb・ft }
3: 51 N・m { 5.2 kgf・m / 38 lb・ft }
4: 157 N・m { 16.0 kgf・m / 116 lb・ft }
5: 51 N・m { 5.2 kgf・m / 38 lb・ft }
6: 51 N・m { 5.2 kgf・m / 38 lb・ft }
8: 60 N・m { 6.1 kgf・m / 44 lb・ft }
10: 60 N・m { 6.1 kgf・m / 44 lb・ft }
11: 52 N・m { 5.3 kgf・m / 38 lb・ft }
13: 51 N・m { 5.2 kgf・m / 38 lb・ft }
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14: 51 N・m { 5.2 kgf・m / 38 lb・ft }
15: 60 N・m { 6.1 kgf・m / 44 lb・ft }
18: 60 N・m { 6.1 kgf・m / 44 lb・ft }
19: 8.2 N・m { 0.8 kgf・m / 73 lb・in }
21: 51 N・m { 5.2 kgf・m / 38 lb・ft }
22: 51 N・m { 5.2 kgf・m / 38 lb・ft }
Cylinder head cover

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Part name
1. Bolt
3. Oil filler cap
6. Oil seal
Tightening torque
1-1: 5.0 N・m { 0.5 kgf・m / 44 lb・in }
1-2: 9.0 N・m { 0.9 kgf・m / 80 lb・in }
Cylinder head
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Part name
1. Cylinder head
2. Gear case nut
3. Gear case bolt
Tightening torque
2: 25 N・m { 2.5 kgf・m / 18 lb・ft }
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4-1: 70 N・m { 7.1 kgf・m / 52 lb・ft }
4-2: 70 N・m { 7.1 kgf・m / 52 lb・ft }
4-3: 60 to 75 °
4-4: 60 to 75 °
Camshaft
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Part name
1. Exhaust camshaft
3. M8 bolt
4. M6 bolt
5. Inlet camshaft
Tightening torque
3: 18 N・m { 1.8 kgf・m / 13 lb・ft } Wet
4: 7.0 N・m { 0.7 kgf・m / 62 lb・in } Dry
4: 6.0 N・m { 0.6 kgf・m / 53 lb・in } Wet
Rocker arm shaft

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Part name
1. Rocker arm
2. Spacer
3. Bolt
4. Rocker arm shaft
5. Camshaft bracket
6. Plate
Tightening torque
3: 9.5 N・m { 1.0 kgf・m / 84 lb・in } Wet
Idle gear
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Part name
1. Gear case cover

2. Bolt
5. Idle gear D
9. Timing chain
12. Idle gear A
17. Idle gear C
18. Crankshaft gear
19. Oil pump gear
20. Cover
21. Bolt
23. Washer
24. Bolt
Tightening torque
2: 8.0 N・m { 0.8 kgf・m / 71 lb・in }
3: 130 N・m { 13.3 kgf・m / 96 lb・ft }
6: 59 N・m { 6.0 kgf・m / 44 lb・ft }
14: 32 N・m { 3.3 kgf・m / 24 lb・ft }
16: 59 N・m { 6.0 kgf・m / 44 lb・ft }
21: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
24: 294 N・m { 30.0 kgf・m / 217 lb・ft }
Crankshaft pulley
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Part name
1. Bolt
2. Washer
Tightening torque
1: 294 N・m { 30.0 kgf・m / 217 lb・ft }
Piston
Part name
1. Snap ring
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2. Piston pin
3. Piston ring
4. Piston
5. Connecting rod
Tightening torque
8-1: 29.4 N・m { 3.0 kgf・m / 22 lb・ft }

8-2: 45 to 60 °
Flywheel
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Part name
1. Flywheel
2. Flexible plate
4. Flywheel bolt
Tightening torque
4-1: 59 N・m { 6.0 kgf・m / 44 lb・ft }
4-2: 60 to 90 °
Timing gear case

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Part name
1. Bolt
3. Bolt
4. Bolt
5. Generator
7. Bolt
8. Nut
10. Gasket
12. Bolt
Tightening torque
1: 25 N・m { 2.5 kgf・m / 18 lb・ft }
3: 40 N・m { 4.1 kgf・m / 30 lb・ft }
4: 51 N・m { 5.2 kgf・m / 38 lb・ft }

7: 25 N・m { 2.5 kgf・m / 18 lb・ft }
8: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 25 N・m { 2.5 kgf・m / 18 lb・ft }
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Part name
1. Bolt
2. Washer
Tightening torque
1: 294 N・m { 30.0 kgf・m / 217 lb・ft }

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Part name
1. Bolt
Tightening torque
1: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Rear plate
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Part name
1. Bolt
2. Rear plate
3. Bolt
Tightening torque
1: 82 N・m { 8.4 kgf・m / 60 lb・ft }
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Crankshaft
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Part name

2. Thrust bearing
3. Crank gear
4. Crankshaft
6. Bearing cap
7. Bearing cap bolt
Tightening torque
7: 167 N・m { 17.0 kgf・m / 123 lb・ft }

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Part name
1. Intake air duct

2. Bolt
3. Bolt
4. Bracket
5. Clamp
6. Bolt
9. Inlet manifold
10. Bolt
11. Bolt
12. Nut
Tightening torque
2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
3: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
5: 4.0 N・m { 0.4 kgf・m / 35 lb・in }

6: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
10: 25 N・m { 2.5 kgf・m / 18 lb・ft }
11: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 25 N・m { 2.5 kgf・m / 18 lb・ft }

1. Intake air duct
2. Bolt
3. Bolt
4. Bracket
5. Clamp
6. Bolt
9. Bolt
11. EGR valve
12. Nut
13. Bolt
15. Bolt
16. Nut
17. Inlet manifold
Tightening torque
2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
3: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
5: 4.0 N・m { 0.4 kgf・m / 35 lb・in }
6: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
9: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 27 N・m { 2.8 kgf・m / 20 lb・ft }
13: 24 N・m { 2.4 kgf・m / 18 lb・ft }
15: 25 N・m { 2.5 kgf・m / 18 lb・ft }
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16: 25 N・m { 2.5 kgf・m / 18 lb・ft }

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Part name
1. Intake air duct

2. Bolt
3. Bolt
4. Bracket
5. Clamp
6. Bolt
9. Inlet manifold
10. EGR valve
11. Nut
12. Bolt
14. Bolt
15. Nut
Tightening torque
2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

3: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
5: 4.0 N・m { 0.4 kgf・m / 35 lb・in }
6: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
11: 27 N・m { 2.8 kgf・m / 20 lb・ft }
12: 24 N・m { 2.4 kgf・m / 18 lb・ft }
14: 25 N・m { 2.5 kgf・m / 18 lb・ft }
15: 25 N・m { 2.5 kgf・m / 18 lb・ft }
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Part name
1. Bolt
2. Nut
3. Exhaust manifold
4. Gasket
5. Bolt
6. Heat protector
7. Bolt
Tightening torque
1: 52 N・m { 5.3 kgf・m / 38 lb・ft }
2: 52 N・m { 5.3 kgf・m / 38 lb・ft }
5: 25 N・m { 2.5 kgf・m / 18 lb・ft }
7: 25 N・m { 2.5 kgf・m / 18 lb・ft }
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Part name
1. Bolt
2. Nut
3. Exhaust manifold
4. Gasket
5. Bolt
6. Heat protector
7. Bolt
Tightening torque
1: 52 N・m { 5.3 kgf・m / 38 lb・ft }
2: 52 N・m { 5.3 kgf・m / 38 lb・ft }
5: 25 N・m { 2.5 kgf・m / 18 lb・ft }
7: 25 N・m { 2.5 kgf・m / 18 lb・ft }
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Part name
1. Nut and bolt

2. EGR cooler
3. Bolt
4. Exhaust manifold
5. Gasket
6. Nut
7. Bolt
8. Heat protector
9. Bolt
10. Bolt
11. Heat protector
12. Bolt
Tightening torque
1: 27 N・m { 2.8 kgf・m / 20 lb・ft }
3: 52 N・m { 5.3 kgf・m / 38 lb・ft }
6: 52 N・m { 5.3 kgf・m / 38 lb・ft }
7: 25 N・m { 2.5 kgf・m / 18 lb・ft }
9: 25 N・m { 2.5 kgf・m / 18 lb・ft }
10: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 27 N・m { 2.8 kgf・m / 20 lb・ft }
Cylinder head
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Part name
1. Split collar
3. Valve spring
6. Valve guide
7. Cylinder head
Cylinder block
Part name
1. Cylinder block
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2. Oil jet pipe
3. Relief valve
4. M8 bolt
5. M6 bolt
Tightening torque
3: 30 N・m { 3.1 kgf・m / 22 lb・ft }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
5: 8.0 N・m { 0.8 kgf・m / 71 lb・in }

1B Engine Mechanical (4JJ1 Without DPD) PDF

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Camshaft removal (4JJ1 without DPD)

3: 18 N・m { 1.8 kgf・m / 13 lb・ft } Wet

4: 6.0 N・m { 0.6 kgf・m / 53 lb・in } Wet

Refer to "1.Engine 1C.Fuel System(4JJ1 without DPD) injector removal".

3. Baffle plate removal

2) Remove the baffle plate from the cylinder head.

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

Limit: 0.250 mm { 0.00984 in }

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

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

1. Camshaft upper bracket

1) Inspect the camshaft journal and cam for the following.

2. Camshaft runout measurement

Limit: 0.05 mm { 0.0020 in }

3. Cam lobe height measurement

1) Measure the height of the cam lobe using a micrometer.

1) Measure the diameter of the camshaft journal using a micrometer.

Camshaft journal diameter

3: 18 N・m { 1.8 kgf・m / 13 lb・ft } Wet

4: 6.0 N・m { 0.6 kgf・m / 53 lb・in } Wet

2) Apply the engine oil to the camshaft journal.

1. Exhaust camshaft gear

5) Apply engine oil to the following parts.

Camshaft upper bracket sliding surface

Tightening torque: 18 N・m { 1.8 kgf・m / 13 lb・ft } Wet

Tightening torque: 7.0 N・m { 0.7 kgf・m / 62 lb・in } Dry

Tightening torque: 6.0 N・m { 0.6 kgf・m / 53 lb・in } Wet

3. Rocker arm adjustment

Standard: 0.15 mm { 0.0059 in } When cold

1. Cam (Exhaust side)

Tightening torque: 18 N・m { 1.8 kgf・m / 13 lb・ft }

Measurable valve position

1) Install the baffle plate to the cylinder head.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

Refer to "1.Engine 1C.Fuel System(4JJ1 without DPD) injector installation".

Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) Engine removal".

2. Engine oil drain

2) Install the drain plug to the oil pan.

Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft }

1) Disconnect the B-terminal from the generator.

2) Disconnect the connector from the generator.

4) Remove the generator from the lower bracket.

1. Models with A/C compressor

2. Models without A/C compressor

1) Remove the bracket from the A/C compressor bracket.

1) Disconnect the connector from the intake throttle valve.

1. Intake throttle valve

6. EGR valve disconnect

1. Euro2 and Euro4 specifications

1) Disconnect the connector from the EGR valve.

7. Vacuum hose disconnect

1) Disconnect the vacuum hose from the inlet manifold.

8. Fuel leak-off pipe removal

1. Fuel leak-off pipe

1. Fuel feed pipe

10. Injection pipe removal

1) Remove the clip from the injection pipe.

2) Remove the vacuum pipe from the cylinder block.

12. Glow plug removal

2) Remove the glow plug from the cylinder head.

13. Turbocharger water hose disconnect

Without EGR and Euro2 specifications