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Tf4jj-We-1211th 1st WSMW 120 TF Tis 12tf
Tf4jj-We-1211th 1st WSMW 120 TF Tis 12tf
WORKSHOP MANUAL
ENGINE
(4JJ1 model)
No.TF4JJ-WE-1211TH
67209_Maegaki 2011.7.22 9:17 AM ページ 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0 Introduction
14A Service Information Guide
14B Vehicle Information
1 ENGINE 15B Maintenance Information
15C Functional Inspection
15D Symptom
15E DTC Information
1A Engine Control
1B Mechanical
1C Fuel System
1D Cooling
1E Lubrication
1F Induction
1G Exhaust
1H Aux. Emission Control Devices
1I Speed Control Systems
1J Electrical
2 SUSPENSION 16B Maintenance Information
16C Functional Inspection
16D Symptom
2B Front Suspension
2C Rear Suspension
2D Wheel, Tire System
3 DRIVELINE, AXLE 17B Maintenance Information
17C Functional Inspection
17D Symptom
17E DTC Information
3A Driveline Control
3B Differentials
3C Drive Shaft System
3D Transfer Case
4 BRAKES 18B Maintenance Information
18C Functional Inspection
18D Symptom
18E DTC Information
4A Brake Control
4B Brake System
4C Parking Brake System
4D ABS
5 TRANSMISSION, TRANSAXLE 19B Maintenance Information
19C Functional Inspection
19D Symptom
19E DTC Information
5A Transmission Control
5B Automatic
5C Manual
5E Clutch System
6 STEERING 20B Maintenance Information
20C Functional Inspection
20D Symptom
6B Power Assisted System
67209_Maegaki 2011.7.22 9:17 AM ページ 2
Description Engine
Maintenance Information
(4JJ1)
Table of Contents
Maintenance precautions of engine...............................15B-2
Function, structure, operation of engine........................15B-4
Primary specifications of engine.................................15B-37
Introduction to the trouble diagnosis of engine...........15B-39
15B-2 Maintenance Information (4JJ1)
ECM voltage description The MIL turns on when the engine is turned OFF with
The ECM applies the buffer voltage to various switches ignition switch ON. This is the light test for confirming
and sensors. The ECM can do this because resistance in that the MIL turns on.
the ECM is so high in value that a test light may not When there is no failure diagnosis, the MIL turns OFF
illuminate when connected to the circuit. An ordinary after the engine is started.
shop voltmeter may not give an accurate reading because When the ECM detects a failure, the MIL remains on
the voltmeter input impedance is too low. Use a 10- after the engine is started. When the ECM turns on the
megohm input impedance DMM to ensure accurate MIL due to a failure related to engine performance, a
voltage readings. The input/output devices in the ECM DTC is stored.
include analog-to-digital converters, signal buffers,
counters, and special drivers. The ECM controls most
components with electronic switches which complete a
ground circuit when turned ON.
Operations of MIL
The MIL is installed in the instrument panel cluster. The
MIL shows the engine symbol as ON indication.
The MIL indicates that vehicle maintenance is required
due to a failure related to engine performance. The
following is the list of MIL operation modes.
15B-6 Maintenance Information (4JJ1)
pressure. The barometric pressure sensor provides a
signal to the ECM on the signal circuit, which is relative
to the pressure changes of the barometric pressure. The
ECM should detect a low signal voltage at a low
barometric pressure, such as high altitude place. The
ECM should detect high signal voltage at a high
barometric pressure. The ECM uses this voltage signal to
calibrate the fuel injection quantity and injection timing
for altitude compensation.
1. CKP sensor
2. Sensor rotor
3. Rotational direction
IAT sensor
The IAT sensor is fitted between the air cleaner and
turbocharger. The IAT sensor is inside the MAF sensor.
The IAT sensor is a variable resistor and it measures the Common rail type electronic control injection system
temperature of the air entering the engine. When the IAT For the common rail system, use an accumulator, which
sensor is cold, the sensor resistance is high. When the air is also called common rail, to store pressurized fuel and
temperature increases, the sensor resistance decreases. also use injectors including the electric control solenoid
With high sensor resistance, the ECM detects a high valve to inject the pressurized fuel into the combustion
voltage on the signal circuit. With lower sensor chamber. Injection pressure, injection rate and injection
resistance, the ECM detects a lower voltage on the signal timing are controlled by the ECM, and therefore the
circuit. common rail system can be controlled independently, free
from the influence of engine speed and load. This ensures
stable injection pressure at all time, particularly in the
low engine speed range, and therefore, black smoke
specific to diesel engines generated during vehicle
starting or acceleration can be significantly reduced. As a
result, the cleanliness and volume of exhaust gas are
improved and higher output can be achieved.
Maintenance Information (4JJ1) 15B-9
Injector
Electronic control type injectors controlled by the ECM
are used. Compared with conventional injection nozzles,
a command piston, solenoid valve, etc. are added. An ID
code indicating various injector characteristic is laser
marked on the connector housing. This system uses
injector flow rate information indicated by the ID code to
optimize the injection quantity control. When an injector
is newly installed in the vehicle, it is necessary to input
the ID code in the ECM. QR codes or injector flow rate
information are used to enhance the injection quantity
precision of the injectors. The use of codes enables
injection quantity dispersion control throughout all
pressure ranges, contributing to improvement in
combustion efficiency and reduction in exhaust gas
emissions.
Maintenance Information (4JJ1) 15B-11
4. Fuel inlet port
5. O-ring
Non-injection state
The TWV closes the outlet orifice by means of a spring
force, when no current is supplied from the ECM to the
solenoid. At this point, the fuel pressure applied to the tip
of the nozzle is equivalent to the fuel pressure applied
through the inlet orifice to the control chamber. As for the
force competition in this state, the sum of pressure on the
command piston upper surface and nozzle spring force is
greater than the pressure applied to the nozzle leading
end, and therefore the nozzle is pressed down and the
injection hole is closed.
Injection start
When current is supplied from the ECM to the solenoid,
the TWV is raised to open the outlet orifice and the fuel
flows into the return port. As a result, the nozzle is
pressed up along with the command piston by the fuel
pressure applied to the nozzle leading end and then the
nozzle injection hole opens to inject the fuel.
Injection end
When the ECM finishes supplying power to the solenoid,
the outlet orifice is closed. As a result, the fuel stops
flowing into the return port from the control chamber and
the fuel pressure within the control chamber sharply rises.
Then, the nozzle is pressed down by the command piston
1. Injector ID code
and the nozzle injection hole is closed to stop fuel
2. Fuel leak-off pipe
injection.
3. 2D barcode
15B-12 Maintenance Information (4JJ1)
Fuel supply pump this plunger chamber is regulated by the FRP regulator
The fuel supply pump is the main part of the common rail that is solely controlled with current supplied from the
type electronic fuel injection system. The fuel supply ECM. No current to the solenoid results in maximum fuel
pump is installed in the same location as the conventional flow, whereas full current to the solenoid produces no
injection type pump, which rotates at a 1 to 1 ratio of fuel fuel flow. As the engine runs, these two plungers produce
supply pump to crankshaft speed. The FRP regulator and high pressure in the fuel rail. Since the ECM controls the
fuel temperature sensor are one of the parts of the fuel flow of fuel into the 2 plunger chambers, it therefore
supply pump assembly. controls the quantity and pressure of the fuel supply to
Fuel is drawn from the fuel tank via the fuel supply pump the fuel rail. This optimizes performance, improves fuel
by the use of a trochoid type internal feed pump. This economy and reduces NOx emissions.
feed pump feeds fuel into 2 plunger chambers that are
located inside the fuel supply pump. Fuel that is fed into
Maintenance Information (4JJ1) 15B-13
Fuel rail
Along with the employment of a common rail type
electronic control fuel injection system, the fuel rail is
provided between the fuel supply pump and the injectors
in order to store highly pressurized fuel. The FRP sensor
and pressure limiter are installed on the fuel rail. The FRP
sensor detects the fuel pressure inside the fuel rail and
sends signals to the ECM. Based on this signal, the ECM
controls the fuel pressure inside the fuel rail via the FRP
regulator of the fuel supply pump. The pressure limiter
mechanically opens the valve in order to relieve the
pressure when the fuel pressure inside the fuel rail is
excessive.
FRP sensor
The FRP sensor is installed on the fuel rail and it detects
the fuel pressure in the fuel rail, converts the pressure into
a voltage signal, and sends the signal to the ECM. The
ECM monitors the FRP sensor signal voltage. The higher
pressure inside the fuel rail provides the higher signal
voltage, while the lower pressure provides the lower
signal voltage. The ECM calculates the actual fuel
15B-14 Maintenance Information (4JJ1)
pressure from the voltage signal and uses the result
calculated for fuel injection control and other control
tasks.
Pressure limiter valve
The pressure limiter relieves pressure by opening the
valve if abnormally high pressure is generated. The valve
opens when the pressure in the fuel rail reaches
approximately 220 MPa {32,000 psi}, and closes when
the pressure falls to approximately 50 MPa {7,250 psi}.
Fuel that is relieved from the pressure limiter returns to
the fuel tank.
EGR valve transmitted to the ECM via CAN. The ECM detects a low
The EGR valve is installed on the inlet manifold. The signal voltage when the lift amount is small or at the
ECM controls the opening and closing of the EGR valve closed position. The ECM detects a high signal voltage
based on the driving condition of the engine. The ECM when the lift amount is large.
regulates the EGR valve by controlling the motor. The
motor is controlled based on the pulse width modulated
signals transmitted from the ECM via CAN. EGR valve
control is performed by changing the duty ratio from 0 %
to an appropriate ratio. When the duty ratio increases, the
valve opens. When the duty ratio decreases, the valve
closes.
The position of the EGR valve is detected by the
controller built into the EGR valve body, and the signal is
15B-16 Maintenance Information (4JJ1)
The turbocharger is used to increase the amount of air
that enters the engine cylinders. This allows a
proportional increase of fuel to be injected into the
cylinders, resulting in increased power output, more
complete combustion of fuel, and increased cooling of the
cylinder heads, pistons, valves, and exhaust gas. This
cooling effect helps extend engine life.
Heat energy and pressures in the engine exhaust gas are
utilized to drive the turbine.
Exhaust gas is directed to the turbine housing. The
turbine housing acts as a nozzle to direct the shaft wheel
assembly.
Since the compressor wheel is attached directly to the
shaft, the compressor wheel rotates at the same speed as
the turbine wheel. Clean air from the air cleaner is drawn
into the compressor housing and wheel. The air is
compressed and delivered through a crossover pipe to the
engine air intake manifold, then into the cylinders.
Intake throttle valve
The intake throttle valve is located on the inlet manifold.
The ECM controls the intake throttle valve opening based
on the engine running condition. The ECM controls the
intake throttle valve by controlling the motor. The motor
is controlled based on pulse width modulation signal sent
from the ECM. The intake throttle valve opening angle is
controlled by changing the duty ratio from 0 % to the
appropriate percentage. When the duty ratio increases, the
valve closes. When the duty ratio decreases, the valve
opens.
The intake throttle valve position is detected by the
position sensor, and relayed to the ECM. The position
sensor provides a signal to the ECM on the signal circuit,
which is relative to the position changes of the intake
throttle valve. The ECM should detect a low signal
voltage at a small opening amount or closed position. The
ECM should detect high signal voltage at a large opening
amount.
1. Exhaust gas
2. Turbine wheel
3. Compressor wheel
4. Air cleaner
5. Intercooler
Cooling system
The cooling system is a force-circulation system, and its
main components are a water pump, thermostat, cooling
fan and radiator.
For the engine to run smoothly, the coolant circulates
through the bypass pipe by the water pump and
thermostat to return to the cylinder body, in order to rise
1. Turbocharger nozzle control actuator
the temperature of the engine coolant quickly. At this
2. Nozzle
time, the coolant does not circulate the radiator.
Cylinder block When the coolant temperature reaches the specified
The cylinder block is cast iron, and has a highly rigid value, the thermostat begins to open to increase the
structure with appropriate rib placement. amount of coolant circulating through the radiator.
When the coolant temperature reaches the specified
Piston value, the thermostat is fully opened. Then all of the
The pistons are cast autothermatic pistons cast with coolant circulates through the radiator to cool the engine
aluminum alloy struts, and the combustion chamber is a effectively.
spherical re-entrant system. The figure shows the high-output specifications.
Cylinder head
The cylinder heads are made of aluminum alloy, and
there are 4 valves per cylinder. The head bolts should be
15B-18 Maintenance Information (4JJ1)
Radiator
The radiator is a tube type with a corrugated fin. To raise
the boiling point of the coolant, a pressurized radiator cap
is attached. The open valve pressure of the radiator cap is
93.3 - 122.7 kPa {0.95 - 1.25 kg/cm2 / 13.5 - 17.8 psi}.
Opening/closing mechanism of the radiator cap is double-
action.
The vehicle with a manual transmission is not equipped
with the oil cooler.
Caution:
・ When removing the radiator cap, do not pull it
by force, but loosen the radiator cap until it
cannot rotate further.
・ To install the cap, turn the radiator cap until it
does not turn.
15B-20 Maintenance Information (4JJ1)
Starting system. and starter relay, etc. Each of these main components are
The starting system is composed of the batteries, starter, wired as shown in the starter circuit diagram.
ignition switch, inhibitor switch (for A/T vehicles only)
Note:
・ Starter circuit diagram
Maintenance Information (4JJ1) 15B-21
Starter ring gear, and when the ring gear rotates the engine starts.
The starter is a magnetic shift type starter and is an outer After the engine starts, the plunger returns, the pinion
gearing mesh method reduction starter. separates from the ring gear, and the armature stops
The contact point of the magnetic switch closes and the rotating when the ignition switch is turned off. When the
armature rotates when the ignition switch is turned ON. engine rotation increases faster than the pinion, the pinion
At the same time, the plunger is drawn in and the pinion will be caused to turn in reverse, but because the pinion is
is pushed to the front via the shift lever to mesh with the idling, it does not drive the armature.
Note:
・ Ignition switch
Note:
・ Circuit diagram
15B-24 Maintenance Information (4JJ1)
Exhaust system The main components are a front exhaust pipe and
exhaust silencer.
Maintenance Information (4JJ1) 15B-25
Lubrication system Oil flows through the water cooling oil cooler and around
A full-flow bypass integrated filter element, water- the sliding sections from the oil gallery for lubrication.
cooling oil cooler, and piston coolant oil jet are adopted
for the lubrication system.
15B-26 Maintenance Information (4JJ1)
Note:
・ Engine controls component views
1. EGR valve
2. Intake throttle valve 1. FRP regulator
2. Fuel temperature sensor
Maintenance Information (4JJ1) 15B-29
Note:
・ Vacuum hose piping diagram
Note:
・ General wiring diagram
Maintenance Information (4JJ1) 15B-31
15B-32 Maintenance Information (4JJ1)
Item Specifications
Engine model 4JJ1
Type Diesel, 4-cycle, water-cooled inline DOHC
Combustion chamber type Direct injection
Cylinder liner type No liner
Number of cylinders - inner diameter x stroke 4 - 95.4 × 104.9 mm {3.76 × 4.13 in}
Total piston displacement 2.999 L {152 in3}
Compression ratio : 17.3
Compression pressure : 3 MPa { 435 psi } / 200 r/min
Idling revolution speed : 675 to 725 r/min
Intake : 0.15 mm { 0.0059 in } , while cool
Valve clearance Exhau
: 0.15 mm { 0.0059 in } , while cool
st
Ignition system Compressed ignition
Injection order 1, 3, 4, 2
Lubricatio Lubricating method Force feed method
n device Type of oil pump Gear type
Lubricant capacity : 7.8 L { 1.7 Imp.gal }
Oil filter type Full-flow filter, cartridge type
Oil cooler type Built-in type, water cooled
Cooling Cooling method Coolant forced-circulation system
device Radiator type Corrugated fin, pressure type
Water pump type Centrifugal impeller type, belt drive type
Thermostat type Wax-type units
Coolant capacity
: 4.0 L { 0.88 Imp.gal }
Only engine
: 10.2 L { 2.24 Imp.gal } M/T vehicles
: 10.1 L { 2.22 Imp.gal } A/T vehicles
Coolant total capacity
Including radiator : 9.4 L { 2.07 Imp.gal } MT vehicles, excluding those with
heater
: 9.3 L { 2.05 Imp.gal } AT vehicles, excluding those with heater
Fuel Injection pump type Fuel supply pump, fuel rail type
device Injection nozzle type Electronic control injector, 8-hole
Charging Generator type Alternating current type
device Power output 12 V - 90 A
Regulator type IC type
Starter Starter type Engage magnet type
device Starter type Reduction type
Power output 12 V - 2.3 kW
Preheat Type Glow Plug
device Glow plug standard voltage -
12 V - 3.5 A
current
15B-38 Maintenance Information (4JJ1)
Note:
・ Primary specifications of the cooling system
Item Specifications
Radiator Heat dissipation capacity : 93 kW
Heat dissipation surface area 11.63 m2
Front surface area 0.28 m2 {3 ft2}
Dry mass M/T
: 5.2 kg { 11.5 lb }
vehicle
A/T
: 5.4 kg { 11.9 lb }
vehicle
Radiator cap : 93.3 to 122.7 kPa { 0.95 to 1.25 kgf/cm2 / 13.5 to
Open valve pressure
17.8 psi }
Water pump Pulley ratio : 1.250
Delivery volume
Pump speed 5600rpm : 240 L { 52.8 Imp.gal }
Water temperature at 30 ℃ {86°F}
Pump bearing type Double row shaft
Thermostat Valve initial opening temperature : 85 ℃ { 185 °F }
Full-open temperature : 100 ℃ { 212 °F }
Valve lift at fully open position : 10 mm { 0.39 in }
Note:
・ Primary specifications of lubrication system
Item Specifications
Oil pump relief valve operating pressure : 490 to 686 kPa { 5.0 to 7.0 kgf/cm2 / 71.1 to 99.5 psi }
Oil cooler relief valve operating pressure : 176 to 216 kPa { 1.8 to 2.2 kgf/cm2 / 25.5 to 31.3 psi }
Oil filter relief valve operating pressure : 80 to 120 kPa { 0.8 to 1.2 kgf/cm2 / 11.6 to 17.4 psi }
Oil pressure switch operating pressure : 29.4 to 49.0 kPa { 0.3 to 0.5 kgf/cm2 / 4.3 to 7.1 psi }
Regulating valve : 176.0 to 216.0 kPa { 1.8 to 2.2 kgf/cm2 / 25.5 to 31.3 psi }
Note:
・ Primary specifications of the electrical system
Silencer Double skin and shell structure of circular area on the end plate, baffle
Type
and tail pipe and perforated tube internal structure
Mounting Suspension
4
number of points
Type Rubber
Maintenance Information (4JJ1) 15B-39
Reading flash DTCs The system for communicating with the ECM is the
DLC. The DTCs stored in the ECM memory can be read
Maintenance Information (4JJ1) 15B-41
either by connecting a hand-held diagnostic scanner such three times, it indicates that there is a current DTC or
as a scan tool with the DLC or by counting the number of DTC in the failure history. If 2 or more DTCs have been
flashes of the MIL light when the diagnostic test terminal stored in the ECM's memory, the DTCs will be output
of the DLC is grounded. numerical order with each DTC being displayed three
The DLC terminal 12 is pulled ground by shorting to times. The blinking DTC display will continue as long as
DLC terminal 4 which is a ground wire. Once terminals the DLC is shorted.
12 and 4 have been connected, turn the ignition switch
ON, without starting the engine. If the MIL blinks DTC
DTC type definition A current DTC clears when the diagnostic runs and does
The DTC has three types. Type A, B, and D. Among not fail after one driving cycle.
these DTCs, type A and B DTCs are related to emission After 40 consecutive warm-up cycles with no failure
whereas type D DTC is related to items other than detected, the DTC history will be cleared.
emission. Use a scan tool to clear the MIL and the DTC.
Actions taken when a DTC is set, type A Actions taken when a DTC is set, type D
When the diagnosis is conducted and abnormality is The ECM does not illuminate the MIL.
detected, the ECM illuminates or blinks the MIL. The ECM records the operating conditions at the time
The ECM records the operating conditions at the time when abnormality is detected. The ECM stores this
when abnormality is detected. The ECM stores this information in the failure records.
information in the Freeze Frame/ Failure Records.
Conditions for clearing the DTC, type D
Actions taken when a DTC is set, type B A current DTC clears when the diagnostic runs and does
When the diagnosis is conducted and abnormality is not fail after one driving cycle.
detected in the consecutive driving cycle, the ECM After 40 consecutive warm-up cycles with no failure
illuminates the MIL during the second consecutive detected, the DTC history will be cleared.
driving cycle. Use a scan tool to clear the DTC.
The ECM records the operating conditions at the time
when abnormality is detected. The first time the
abnormality is detected, the ECM stores this information
in the failure records. If the second abnormality is
detected during the next driving cycle, the ECM records
the operating conditions at the time when the abnormality
is detected and stores this information in the freeze frame.
At this time, the failure records are updated.
Clearing condition of the MIL and the DTC
When conducting diagnosis, no failure is detected after
one driving cycle, the ECM turns OFF the MIL.
Functional Inspection (4JJ1) 15C-1
Description Engine
Functional Inspection
(4JJ1)
Table of Contents
Diagnostic system check-engine controls.....................15C-2
Scan tool does not communicate with CAN device......15C-4
Lost communication with the ECM..............................15C-7
Fuel system check.........................................................15C-9
EGR control system check..........................................15C-12
Glow control system check.........................................15C-13
Engine compression pressure inspection.....................15C-14
Glow system check......................................................15C-15
Lubricating system inspection.....................................15C-16
Turbocharger control system check............................15C-17
Charging system check................................................15C-19
15C-2 Functional Inspection (4JJ1)
1. Check if communication with the ECM is available 7. Check for sudden stop failure.
using a scan tool. 8. Check for sudden change failure.
Note: 9. Check for insufficient output or blowup failure.
・ If communication is not possible, check the
10. Check for chuffing or acceleration failure.
communication circuit of the scan tool.
11. Check for abnormal combustion sound failure.
2. Start the engine.
12. Check for poor fuel economy failure.
Functional Inspection (4JJ1) 15C-3
13. Check for black smoke failure.
14. Check for white smoke failure.
15C-4 Functional Inspection (4JJ1)
1. Inspect whether the engine oil is dirty, or contains Check for oil leakage from the cylinder head cover, oil
water. pan, etc. while the vehicle is lifted up.
Note:
・ If oil is excessively dirty or contains water,
change the oil after investigating the causes
and taking appropriate measures.
2. Inspect the engine oil level.
Note:
・ Ensure that the oil level should be halfway
between 2 holes of the oil level gauge.
・ When the oil level is low, replenish it.
3. Remove the oil pressure switch.
4. Install the oil pressure gauge.
Note:
・ The turbine shaft should be free from cause
which allows the shaft to spin with much
friction.
・ The turbocharger nozzle control actuator
should be free from sticking and malfunction.
Refer to "1.Engine 1F.Induction(4JJ1) Turbocharger SST: 5-8840-0279-0 - vacuum pump
assembly inspection".
21. Start the engine.
8. Perform the intake throttle solenoid control with a
scan tool to inspect the intake throttle valve. 22. Conduct turbocharger solenoid control with a scan
tool and execute increase and decrease commands
Note: for desired turbocharger position.
・ The intake throttle valve should be free from
Note:
sticking.
・ The vacuum pump reading should be 50 cmHg
9. Inspect the air cleaner or intake piping. (20 inHg) or more at maximum increase and
10. Inspect the inside of intake pipe, inter cooler or ZERO range at minimum decrease.
turbocharger for oil contamination. 23. If the reading is below specifications, perform the
11. If find out a problem during above procedure, repair following inspection.
or replace the certain parts. 24. Inspect the vacuum hose piping of the turbocharger
nozzle control actuator.
15C-18 Functional Inspection (4JJ1)
25. Inspect the ventilation hose of solenoid valve.
26. Inspect the vacuum hose or pipe.
27. If failure is observed through inspections above,
repair or replace the failed parts.
28. Replace the turbocharger nozzle control valve.
Refer to "1.Engine 1F.Induction(4JJ1) Turbocharger
control solenoid removal".
Refer to "1.Engine 1F.Induction(4JJ1) Turbocharger
control solenoid installation".
Functional Inspection (4JJ1) 15C-19
The charging system warning light will come on when 12. Repair or replace the generator.
ignition switch is turned ON. It should go out once the
engine is running. If it stays on while the engine is
running, the charging system may have a problem.
2. Charging system check inspection
1. Inspect the generator drive belt.
Note:
・ Inspect the generator drive belt for damage
and looseness.
2. Inspect the harness connector.
Note:
・ Inspect the harness connecter for looseness or
disconnection.
3. Turn the ignition switch OFF.
Note:
・ Stop the engine.
4. Turn the ignition switch ON.
Note:
・ The engine is not started.
5. Inspect the charging system warning light.
Note:
・ Check if the charging system warning light
illuminates.
・ If warning light does not illuminate, continue
this procedure.
6. Remove the harness connector from the generator.
7. Earth the IG terminal of harness connector.
8. Inspect the charging system warning light.
Note:
・ Check if the charging system warning light
illuminate.
・ If charging system warning light does not
illuminate, the bulb of charging system warning
light is burned-out.
9. Replace the charging system warning light bulb.
10. Start the engine.
11. Inspect the charging system warning light.
Symptom (4JJ1) 15D-1
Description Engine
Symptom
(4JJ1)
Table of Contents
Preheating time is too short...........................................15D-2
Preheating does not operate..........................................15D-3
Preheating time is too long............................................15D-4
Engine has overcooled..................................................15D-5
White smoke..................................................................15D-6
Surges............................................................................15D-7
Abnormal sound in generator........................................15D-8
Engine has overheated...................................................15D-9
Cuts out.......................................................................15D-10
High idle speed............................................................15D-11
Engine does not turn over...........................................15D-12
Engine does not stop...................................................15D-13
Hard start.....................................................................15D-14
Rough, unstable...........................................................15D-15
Poor fuel economy......................................................15D-17
Black smoke................................................................15D-18
Abnormal combustion noise.......................................15D-19
Hesitation, sag or stumble...........................................15D-20
Defect of turbocharger................................................15D-22
Intermittent conditions of engine................................15D-24
Clogging of the exhaust system..................................15D-27
Exhaust gas leak, noise...............................................15D-28
Starter overrun.............................................................15D-29
Defect of charging system...........................................15D-30
Engine slow to warm up..............................................15D-31
Vibrations and rattling sounds from the exhaust system
.....................................................................................15D-32
Maximum engine speed is too low..............................15D-33
Lack of power, sluggishness or sponginess................15D-34
15D-2 Symptom (4JJ1)
White smoke
1. White smoke description of symptom Note:
White smoke is generated when the engine is under load, ・ Fuel system inspection
idling or hot, or when starting the engine in a cold Inspect for water intrusion in the fuel.
condition. Remove the injector, and visually inspect it.
2. White smoke diagnostics Perform the cylinder balance test with the scan tool.
Perform the injector forced drive with the scan tool.
Note: Confirm the fuel compensation display of each cylinder
・ Preliminary inspection with the scan tool while idling.
Confirm if any problem exists in the vehicle. Note:
Confirm if the ground of the ECM is free of dirt, and is ・ Air intake system inspection
fixed securely in the correct position.
Inspect the fuel quality. Inspect the air cleaner and air intake duct for clogging,
Check the injector ID code of each cylinder. holes and leakage.
Check the scan tool data list. Inspect for any condition that restricts the flow within the
Check the service technical report. turbocharger inlet duct.
Inspect for stuck-close intake throttle valve.
Note: Inspect for clogging or air leakage in the intake manifold.
・ Sensor inspection Inspect the MAF sensor for dirt and damage.
Perform the swirl control solenoid control with the scan
Compare each display of the Engine Coolant
tool. Inspect the diaphragm valve operation when the ON/
Temperature (ECT), Intake Air Temperature (IAT) and
OFF command is executed on the diaphragm valve.
Fuel Temperature to the scan tool data list with the
Inspect the turbocharger turbine wheel, shaft and
engine stopped and being cold. When the difference
compressor wheel for worn and damage.
between the temperature values is 5 ℃ (9 ˚F) or larger,
Inspect the turbocharger oil seal for oil leakage.
inspect for high resistance in each circuit and sensor
Inspect the turbocharger oil return pipe for clogging.
failure while the engine is cold.
{When the ignition switch is turned ON, the MAF sensor Note:
is heated, and as a result, the IAT shows a higher value ・ Engine mechanical inspection
than the normal intake air temperature.}
Confirm the Fuel Rail Pressure (FRP) Sensor display on a Inspect the compression pressure of the engine.
scan tool. It is normal if the Fuel Rail Pressure (FRP) Check for improper idle gear timing.
Sensor display shows 0.9 - 1.0 V when the ignition Inspect the valve clearance.
switch is turned ON without starting the engine after at Inspect the valve stem for sticking.
least 1 minute waited from the stop of engine operation. Inspect for the valve stem oil seal failure.
If not, inspect for high resistance in each circuit and any Inspect the valve seat for worn.
sensor failure. Inspect the valve spring for damage and fatigue.
Fully depress the accelerator pedal while idling in neutral, Inspect the camshaft for worn.
and confirm the Fuel Rail Pressure (FRP) and Desired Inspect for compression leakage due to piston ring
Fuel Rail Pressure (FRP) displays. It is normal if the Fuel damage.
Rail Pressure (FRP) display follows the Desired Fuel Rail Inspect for gasket failure.
Pressure (FRP) display with the tolerance of (-5) - 5 MPa Inspect the piston for seizure.
{(-725) - 725 psi}. Inspect for oil intrusion into the combustion chamber.
Confirm the accelerator pedal position. It is normal if the Note:
Accelerator Pedal Position (APP) display changes
・ Electrical system inspection
linearly from 0 to 100 % in conformity to the accelerator
pedal operation. Inspect the glow plug control system operation.
Confirm the Boost Pressure and Barometric Pressure
(BARO) displays with the ignition switch turned ON and
the engine not started.
It is normal if the difference between both data displays is
within 7.0 kPa (1.0 psi).
The CKP sensor is securely installed, and the sensor rotor
is not damaged.
Symptom (4JJ1) 15D-7
Surges
1. Surges description of symptom Inspect for collapsing, twisting, improper tightening,
cracking, and clogging in the fuel system between the
The vehicle speeds up and slows down with no change in
fuel tank and the supply pump.
the accelerator pedal position.
Check the vent valve and hose of the fuel tank for
2. Surges diagnostics clogging.
{The piping may be clogged due to foreign matters from
Note:
the fuel tank mixed into the fuel system.}
・ Preliminary inspection Inspect the supply pump operation.
Perform the inspection for the engine control system. {The supply pump must be timed with the engine, and the
The driver must be familiar with the A/C compressor adjusted value should be written into the ECM.}
operation. Perform the cylinder balance test with the scan tool.
Use a scan tool in order to confirm that the data display Perform the injector forced drive with the scan tool.
value for the vehicle speed matches with the value of the Note:
speedometer on the vehicle.
Confirm if the ground of the ECM is free of dirt, and is ・ Air intake system inspection
fixed securely in the correct position. Inspect the air cleaner and air intake duct for clogging,
Inspect whether the harness connector is properly holes and leakage.
connected. Inspect for any condition that restricts the flow within the
Inspect the fuel type and quality. turbocharger inlet duct.
Check the injector ID code of each cylinder. Inspect for stuck-close intake throttle valve.
Check the scan tool data list. Inspect for clogging or air leakage in the intake manifold.
Check the service technical report. Inspect the MAF sensor for dirt and damage.
Perform the swirl control solenoid control with the scan
Note:
tool. Inspect the diaphragm valve operation when the ON/
・ Sensor inspection OFF command is executed on the diaphragm valve.
Confirm the Fuel Rail Pressure (FRP) Sensor display on a Inspect the operation of nozzle control actuator of the
scan tool. It is normal if the Fuel Rail Pressure (FRP) turbocharger.
Sensor display shows 0.9 - 1.0 V when the ignition Note:
switch is turned ON without starting the engine after at
least 1 minute waited from the stop of engine operation. ・ Exhaust system inspection
If not, inspect for high resistance in each circuit and any Inspect for any condition that restricts the flow of the
sensor failure. exhaust system.
Fully depress the accelerator pedal while idling in neutral,
Note:
and confirm the Fuel Rail Pressure (FRP) and Desired
Fuel Rail Pressure (FRP) displays. It is normal if the Fuel ・ Other inspections
Rail Pressure (FRP) display follows the Desired Fuel Rail Inspect the output voltage of the generator.
Pressure (FRP) display with the tolerance of (-5) - 5 MPa Inspect whether the EGR system is operating properly.
{(-725) - 725 psi}. Inspect the operation of the A/C.
Confirm the accelerator pedal position. It is normal if the
Accelerator Pedal Position (APP) display changes Note:
linearly from 0 to 100 % in conformity to the accelerator ・ Without automatic transmission model
pedal operation.
Inspect the output voltage of the generator.
Note: Inspect whether the EGR system is operating properly.
・ Fuel system inspection Inspect the operation of the A/C.
Inspect the operation of the torque converter clutch.
Check for air intrusion in the fuel system.
Inspect for water intrusion in the fuel. Note:
Inspect whether the fuel is becoming waxy or freezing. ・ Automatic transmission model
Inspect whether the fuel filter indicator light turns on
continuously or frequently when the engine is driven.
Inspect the fuel filter element for clogging.
Inspect for fuel leakage from the pressure limiter and
injector.
15D-8 Symptom (4JJ1)
Cuts out
1. Cuts out description of symptom Inspect for collapsing, twisting, improper tightening,
cracking, and clogging in the fuel system between the
A constant jerking accompanying the engine rpm increase
fuel tank and fuel supply pump.
{Usually, it is notable when the engine load increases.}.
Check the vent valve and hose of the fuel tank for
Continuous hissing sounds {boiling sounds} are
clogging.
generated from the exhauster when the engine is idling,
{The piping may be clogged due to foreign matters from
the engine rpm is low or accelerating abruptly, and fuel
the fuel tank mixed into the fuel system.}
deficiency occurs, which results in engine stop.
Perform the cylinder balance test with the scan tool.
2. Cuts out diagnostics Perform the injector forced drive with the scan tool.
Confirm the fuel compensation display of each cylinder
Note:
with the scan tool while idling.
・ Preliminary inspection
Note:
Perform the inspection for the engine control system.
Confirm if the ground of the ECM is free of dirt, and is ・ Air intake system inspection
fixed securely in the correct position. Inspect the air cleaner and air intake duct for clogging,
Inspect whether the harness connector is properly holes and leakage.
connected. Inspect for any condition that restricts the flow within the
Check the scan tool data list. turbocharger inlet duct.
Check the service technical report. Inspect for stuck-close intake throttle valve.
Inspect for clogging or air leakage in the intake manifold.
Note:
Inspect the MAF sensor for dirt and damage.
・ Sensor inspection
Note:
Confirm the Fuel Rail Pressure (FRP) Sensor display on a
scan tool. It is normal if the Fuel Rail Pressure (FRP) ・ Exhaust system inspection
Sensor display shows 0.9 - 1.0 V when the ignition Inspect for any condition that restricts the flow of the
switch is turned ON without starting the engine after at exhaust system.
least 1 minute waited from the stop of engine operation.
Note:
If not, inspect for high resistance in each circuit and any
sensor failure. ・ Other inspections
Fully depress the accelerator pedal while idling in neutral, EMI may cause an engine failure.
and confirm the Fuel Rail Pressure (FRP) and Desired The scan tool can usually detect EMI by checking the
Fuel Rail Pressure (FRP) displays. It is normal if the Fuel engine rpm. If the value of rotation speed sharply
Rail Pressure (FRP) display follows the Desired Fuel Rail increases even when the actual engine rpm hardly
Pressure (FRP) display with the tolerance of (-5) - 5 MPa changes, EMI occurs. If any problem is found, inspect
{(-725) - 725 psi}. whether any high-voltage component such as wiring of
Confirm the accelerator pedal position. It is normal if the the injector is connected to the area around the sensor
Accelerator Pedal Position (APP) display changes circuit.
linearly from 0 to 100 % in conformity to the accelerator
pedal operation.
The CKP sensor is securely installed, and the sensor rotor
is not damaged.
The CMP sensor is securely installed, and the camshaft
gear is not damaged.
Note:
・ Fuel system inspection
Check for air intrusion in the fuel system.
Inspect for water intrusion in the fuel.
Inspect whether the fuel is becoming waxy or freezing.
Inspect whether the fuel filter indicator light turns on
continuously or frequently when the engine is driven.
Inspect the fuel filter element for clogging.
Inspect for fuel leakage from the pressure limiter and
injector.
Symptom (4JJ1) 15D-11
Hard start
1. Hard start description of symptom Inspect for fuel leakage from the pressure limiter and
injector.
The engine cranks but does not start for a long time. The
Inspect the fuel system for collapsing, twisting, improper
engine does eventually run, or may start but immediately
tightening, cracking and clogging.
stops.
Inspect the vent valve and hose of the fuel tank for
2. Hard start diagnostics clogging.
{The piping may be clogged due to foreign matters from
Note:
the fuel tank mixed into the fuel system.}
・ Preliminary inspection Inspect the supply pump operation.
Perform the inspection for the engine control system. {The supply pump must be timed with the engine, and the
Confirm if the driver is using the correct starting adjusted value should be written into the ECM.}
procedure. Conduct the cylinder balance test with a scan tool.
Confirm if the ground of the ECM is free of dirt, and is Perform the injector forced drive with a scan tool.
fixed securely in the correct position. Use a scan tool to confirm the Fuel Rail Pressure (FRP)
Inspect whether the harness connector is properly Regulator Valve Feedback Current display.
connected. Note:
Inspect the fuel type, quality and level.
Check the injector ID code of each cylinder. ・ Air intake system inspection
Check the scan tool data list. Inspect the air cleaner and air intake duct for clogging,
Check the service technical report. holes and leakage.
Inspect for any condition that restricts the flow within the
Note:
turbocharger inlet duct.
・ Sensor inspection Inspect for stuck-close intake throttle valve.
Compare each display of the Engine Coolant Inspect for clogging and leakage in the intake manifold.
Temperature (ECT), Intake Air Temperature (IAT) and Note:
Fuel Temperature to the scan tool data list with the
engine in the cold state. ・ Exhaust system inspection
When the difference between the temperature values is 5 Inspect for any condition that restricts the flow of the
℃ (9 ˚F) or larger, inspect for high resistance in each exhaust system.
circuit and sensor failure while the engine is cold.
Note:
{When the ignition switch is turned ON, the MAF sensor
is heated, and as a result, the IAT shows a higher value ・ Engine mechanical inspection
than the normal intake air temperature.} Inspect the compression pressure of the engine.
Confirm the Fuel Rail Pressure (FRP) Sensor display on a Check for improper idle gear timing.
scan tool. It is normal if the Fuel Rail Pressure (FRP) Inspect the valve clearance.
Sensor display shows 0.9 - 1.0 V when the ignition Inspect the valve spring for damage and fatigue.
switch is turned ON without starting the engine after at Inspect the camshaft for worn.
least 1 minute waited from the stop of engine operation. Inspect the ring gear for worn.
If not, inspect for high resistance in each circuit and any Inspect the inside of the engine for seizure.
sensor failure.
The CKP sensor is securely installed, and the sensor rotor Note:
is not damaged. ・ Electrical system inspection
The CMP sensor is securely installed, and the camshaft
Inspect the glow plug control system operation.
gear is not damaged.
Inspect the cranking speed.
Note: Inspect the battery for deterioration.
・ Fuel system inspection
Inspect for air intrusion in the fuel system.
Inspect for water intrusion in the fuel.
Inspect for external fuel leakage, or excessive engine oil.
Inspect whether the fuel is becoming waxy or freezing.
Inspect whether the fuel filter indicator light turns ON
continuously or frequently when the engine is driven.
Inspect the fuel filter element for clogging.
Symptom (4JJ1) 15D-15
Rough, unstable
1. Rough, unstable description of symptom Inspect for external fuel leakage and excessive engine oil.
Inspect whether the fuel is becoming waxy or freezing.
The engine idling speed is not constant. The engine or
Inspect whether the fuel filter indicator light turns ON
vehicle may shake in severe situations. The engine idling
continuously or frequently when the engine is driven.
speed may vary. Any of the above conditions is so severe
Inspect the fuel filter element for clogging.
that engine stalling can occur.
Inspect for fuel leakage from the pressure limiter and
2. Rough, unstable diagnostics injector.
Inspect for collapsing, twisting, improper tightening,
Note:
cracking, and clogging in the fuel system between the
・ Preliminary inspection fuel tank and fuel supply pump.
Perform the inspection for the engine control system. Inspect the vent valve and hose of the fuel tank for
Remove the air cleaner and inspect for dirt, collapsing of clogging.
the air duct or any condition that restricts the flow. {The piping may be clogged due to foreign matters from
Check whether the ground of the ECM is free of dirt, and the fuel tank mixed into the fuel system.}
is fixed securely in the correct position. Inspect the fuel supply pump operation.
Inspect whether the harness connector is properly {The fuel supply pump must be timed with the engine,
connected. and the adjusted value should be written into the ECM.}
Inspect the fuel type and quality. Conduct the cylinder balance test with a scan tool.
Check the injector ID code of each cylinder. Perform the injector forced drive with a scan tool.
Check the scan tool data list. Use a scan tool to confirm the Fuel Rail Pressure (FRP)
Check the service technical report. Regulator Valve Feedback Current display.
Note: Note:
・ Sensor inspection ・ Air intake system inspection
Compare each display of the Engine Coolant Inspect the air cleaner and air intake duct for clogging,
Temperature (ECT), Intake Air Temperature (IAT) and holes and leakage.
Fuel Temperature to the scan tool data list with the Inspect for any condition that restricts the flow within the
engine stopped and being cold. When the difference turbocharger inlet duct.
between the temperature values is 5 ℃ (9 ˚F) or larger, Inspect for stuck-close intake throttle valve.
inspect for high resistance in each circuit and sensor Inspect for clogging and air leakage in the intake
failure while the engine is cold. manifold.
{When the ignition switch is turned ON, the MAF sensor Note:
is heated, and as a result, the IAT shows a higher value
than the normal intake air temperature.} ・ Exhaust system inspection
Confirm the Fuel Rail Pressure (FRP) Sensor display on a Inspect for any condition that restricts the flow of the
scan tool. It is normal if the Fuel Rail Pressure (FRP) exhaust system.
Sensor display shows 0.9 - 1.0 V when the ignition
Note:
switch is turned ON without starting the engine after at
least 1 minute waited from the stop of engine operation. ・ Engine mechanical inspection
If not, inspect for high resistance in each circuit and any Inspect the compression pressure of the engine.
sensor failure. Check for improper idle gear timing.
Fully depress the accelerator pedal during idling in Inspect the valve clearance.
neutral and confirm the Fuel Rail Pressure (FRP) display. Inspect the valve spring for damage and fatigue.
It is normal when the display is always in the range Inspect the camshaft for worn.
between 27 - 33 MPa (3,900 - 4,800 psi). Inspect the basic components of the engine including the
The CKP sensor is securely installed, and the sensor rotor camshaft, cylinder head, piston, etc.
is not damaged.
The CMP sensor is securely installed, and the camshaft Note:
gear is not damaged. ・ Other inspections
Note: EMI may cause an engine failure.
・ Fuel system inspection The scan tool can usually detect EMI by checking the
engine rpm. If the value of rotation speed sharply
Inspect for air intrusion in the fuel system. increases even when the actual engine rpm hardly
Inspect for water intrusion in the fuel.
15D-16 Symptom (4JJ1)
changes, EMI occurs. If any problem is found, inspect
whether any high-voltage component such as wiring of
the injector is wired to the area around the sensor circuit.
Inspect the engine mounting for a malfunction.
Inspect the crank pulley for a mulfunction.
Inspect the generator or A/C compressor.
Inspect the generator output voltage.
Inspect the EGR system operation.
Inspect the operation of the A/C.
Symptom (4JJ1) 15D-17
Note: Inspect the air cleaner and air intake duct for clogging,
holes and leakage.
・ Preliminary inspection
Inspect for any condition that restricts the flow within the
Remove the air cleaner and inspect for dirt, collapsing of turbocharger inlet duct.
the air duct or any condition that restricts the flow. Inspect for stuck-close intake throttle valve.
Check the driver's driving habits. Inspect for clogging or air leakage in the intake manifold.
Check whether the A/C is always ON and the defroster Inspect the MAF sensor for dirt and damage.
mode is ON. Perform the swirl control solenoid control with the scan
Check whether the tire air pressure is appropriate. tool. Inspect the diaphragm valve operation when the ON/
Check whether the tire size has ever been changed. OFF command is executed on the diaphragm valve.
Check whether excessively heavy loads are being carried. Inspect the turbocharger turbine wheel, shaft and
Check whether there has been too much or too frequent compressor wheel for worn and damage.
acceleration. Inspect the operation of nozzle control actuator of the
Inspect for clutch slip. turbocharger.
Inspect for brake drag.
Note:
Inspect the drive belt tension.
Inspect whether the transmission shift pattern and down ・ Exhaust system inspection
shift operation are normal. Inspect for any condition that restricts the flow of the
Inspect the fuel quality. exhaust system.
Inspect the engine oil level and quality.
Instruct the owner to recheck the fuel mileage after Note:
refilling the fuel tank. ・ Engine mechanical inspection
Inspect whether the odometer is operating properly.
Inspect the compression pressure of the engine.
Check the scan tool data list.
Inspect the valve clearance.
Check the service technical report.
Inspect the valve spring for damage and fatigue.
Note: Inspect the camshaft for worn.
・ Sensor inspection
Compare each display of the Engine Coolant
Temperature (ECT), Intake Air Temperature (IAT) and
Fuel Temperature to the scan tool data list with the
engine stopped and being cold. When the difference
between the temperature values is 5 ℃ (9 ˚F) or larger,
inspect for high resistance in each circuit and sensor
failure while the engine is cold.
{When the ignition switch is turned ON, the MAF sensor
is heated, and as a result, the IAT shows a higher value
than the normal intake air temperature.}
Note:
・ Fuel system inspection
Inspect the fuel type and quality.
Check for fuel leakage
Note:
・ Cooling system inspection
15D-18 Symptom (4JJ1)
Black smoke
1. Black smoke description of symptom It is normal if the difference between both data displays is
within 7.0 kPa (1.0 psi).
Black smoke is generated when the engine is under load,
idling or hot, or when starting the engine in a cold Note:
condition. ・ Fuel system inspection
2. Black smoke diagnostics Inspect for water intrusion in the fuel.
Note: Remove the injector, and visually inspect it.
Perform the cylinder balance test with the scan tool.
・ Preliminary inspection
Perform the injector forced drive with the scan tool.
Confirm if any problem exists in the vehicle. Confirm the fuel compensation display of each cylinder
Remove the air cleaner and inspect for dirt, collapsing of with the scan tool while idling.
the air duct or any condition that restricts the flow.
Note:
Confirm if the ground of the ECM is free of dirt, and is
fixed securely in the correct position. ・ Air intake system inspection
Inspect the fuel quality. Inspect the air cleaner and air intake duct for clogging,
Inspect the engine oil level and quality. holes and leakage.
Check the injector ID code of each cylinder. Inspect for any condition that restricts the flow within the
Check the scan tool data list. turbocharger inlet duct and air leakage.
Check the service technical report. Inspect for stuck-close intake throttle valve.
Note: Inspect for clogging or air leakage in the intake manifold.
Inspect the MAF sensor for dirt and damage.
・ Sensor inspection
Inspect the turbocharger turbine wheel, shaft and
Compare each display of the Engine Coolant compressor wheel for worn and damage.
Temperature (ECT), Intake Air Temperature (IAT) and Inspect the turbocharger oil seal for oil leakage.
Fuel Temperature to the scan tool data list with the Inspect the actuator for damage.
engine stopped and being cold. When the difference
Note:
between the temperature values is 5 ℃ (9 ˚F) or larger,
inspect for high resistance in each circuit and sensor ・ Exhaust system inspection
failure while the engine is cold. Inspect for any condition that restricts the flow of the
{When the ignition switch is turned ON, the MAF sensor exhaust system.
is heated, and as a result, the IAT shows a higher value
than the normal intake air temperature.} Note:
Confirm if an abnormality is seen in the Mass Air Flow ・ Engine mechanical inspection
(MAF) display a scan tool.
Inspect the compression pressure of the engine.
Confirm the Fuel Rail Pressure (FRP) Sensor display on a
Check for improper idle gear timing.
scan tool. It is normal if the Fuel Rail Pressure (FRP)
Inspect the valve clearance.
Sensor display shows 0.9 - 1.0 V when the ignition
Inspect the valve stem for sticking.
switch is turned ON without starting the engine after at
Inspect the valve seat for worn.
least 1 minute waited from the stop of engine operation.
Inspect the valve spring for damage and fatigue.
If not, inspect for high resistance in each circuit and any
Inspect the camshaft for worn.
sensor failure.
Inspect for compression leakage due to piston ring
Fully depress the accelerator pedal while idling in neutral,
damage.
and confirm the Fuel Rail Pressure (FRP) and Desired
Inspect for gasket failure.
Fuel Rail Pressure (FRP) displays. It is normal if the Fuel
Inspect the piston for seizure.
Rail Pressure(FRP) display follows the Desired Fuel Rail
Inspect for oil intrusion into the combustion chamber.
Pressure (FRP) display with the tolerance of (-5) - 5 MPa
{(-725) - 725 psi}. Note:
Confirm the accelerator pedal position. It is normal if the ・ Other inspections
Accelerator Pedal Position (APP) display changes
linearly from 0 to 100 % in conformity to the accelerator Inspect for the appropriate EGR system operation.
pedal operation. Inspect for excessive blow-by gas.
Confirm the Boost Pressure and Barometric Pressure
(BARO) displays with the ignition switch turned ON and
the engine not started.
Symptom (4JJ1) 15D-19
Defect of turbocharger
1. Defect of turbocharger diagnostics Note:
Note: ・ When there are abnormal vibrations in the
turbocharger
・ When the output has dropped although the
engine appears to be normal. The cause is bearing damage and contact of the rotating
section with the surrounding sections. Degraded oil, entry
The turbine fins or compressor fins are deformed or
of foreign material in the fuel hose, clogging of the oil
damaged.
filter, or repeated sudden starting and stopping can cause
Replace
bearing failure.
The fins and housing are touching to each other. Replace
Replace
When there is no problem in the lubricating oil system,
There is a large amount of carbon deposits adhering to but there are damages from contacts found in the rotating
the turbine exhaust outlet and are in contact with the section and the surrounding sections, it is suspected that
turbine fins. the rotating section has become unbalanced or the shaft
Clean or replace has been bent. This is caused by bearing worn, or damage
on the turbine wheel or compressor wheel made by flying
When the turbine shaft is manually turned, it catches on
foreign matter.
something or the rotation is heavy.
Replace
Replace
The clearance in the axis direction or rotation direction of Note:
the turbine shaft is large. ・ Oil is leaking into the exhaust or intake pipe,
Measure the clearance and replace it if it exceeds the and the color of exhaust becomes white.
standard value Oil leakage from the turbocharger oil seal.
Note: Repair or replace
・ When output has dropped although the Insufficient oil level due to dirty or clogged oil separator.
turbocharger appears to be basically normal Clean or replace
Air leakage from the rubber hose of the intake air pipe. Clogging in the oil passage of the center housing.
Repair Replace
Air leakage from the intake manifold. Clogging, collapsing or deformation of the oil return
Repair pipe.
Repair or replacement
Clogging of the air cleaner element.
Clean or replace Large turbine shaft clearance.
Measure the clearance and replace it if it exceeds the
Sticking of the intake throttle valve.
standard value
Repair or replace
Degraded engine oil.
Gas leak from each exhaust section.
Replace
Repair or replacement
Excessive exhaust resistance caused by deformed exhaust Note:
muffler or carbon clogging. ・ When noises are generated from the
Repair or replacement turbocharger
Air leakage from the compressor outlet side. Air leakage from the coupling of the rubber hose on the
Repair compressor outlet side or gas leakage from the exhaust
system.
Clogging in the intercooler cooling section. Repair
Clean
Contact of the turbine fins with the housing.
Defective boost sensor. Replace
Replace
Internal damage due to foreign material catching.
Cause due to the vehicle side, such as dragging of the Replace
brake.
Repair Worn or seizure of the turbine shaft bearing.
Replace
Symptom (4JJ1) 15D-23
Note:
・ When excessive worn exists in the rotating
section
Degraded engine oil.
Replace
Clogging in the turbocharger oil feed pipe.
Repair
Low engine oil pressure.
Repair
15D-24 Symptom (4JJ1)
Starter overrun
1. Starter overrun diagnostics
Improper return of ignition switch contact point.
Replace the ignition switch
Improper return of starter relay contact point.
Replace the starter relay
Magnetic switch coil short circuit.
Replace the magnetic switch
15D-30 Symptom (4JJ1)
Description Engine
DTC Information
(4JJ1)
Table of Contents
DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2
Position Correlation.......................................................15E-3 .....................................................................................15E-24
DTC P0045 (Flash Code 33) Turbocharger Boost Control DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3
Solenoid Circuit.............................................................15E-4 .....................................................................................15E-25
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4
Too Low........................................................................15E-5 .....................................................................................15E-26
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure - DTC P0217 (Flash Code 542) Engine Coolant Over
Too High........................................................................15E-6 Temperature Condition................................................15E-27
DTC P0089 (Flash Code 151) Fuel Pressure Regulator DTC P0219 (Flash Code 543) Engine Overspeed Condition
Performance...................................................................15E-7 .....................................................................................15E-28
DTC P0091 (Flash Code 247) Fuel Pressure Regulator DTC P0234 (Flash Code 42) Turbocharger Overboost
Control Circuit Low.......................................................15E-8 Condition.....................................................................15E-29
DTC P0092 (Flash Code 247) Fuel Pressure Regulator DTC P0237 (Flash Code 32) Turbocharger Boost Sensor
Control Circuit High......................................................15E-9 Circuit Low..................................................................15E-30
DTC P0093 (Flash Code 227) Fuel System Leak Detected DTC P0238 (Flash Code 32) Turbocharger Boost Sensor
.....................................................................................15E-10 Circuit High.................................................................15E-31
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low DTC P0299 (Flash Code 65) Turbocharger Underboost
Input.............................................................................15E-11 .....................................................................................15E-32
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High DTC P0335 (Flash Code 15) Crankshaft Position Sensor
Input.............................................................................15E-12 Circuit..........................................................................15E-33
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor DTC P0336 (Flash Code 15) Crankshaft Position Sensor
Circuit Low..................................................................15E-13 Circuit Range/Performance.........................................15E-34
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor DTC P0340 (Flash Code 14) Camshaft Position Sensor
Circuit High.................................................................15E-14 Circuit..........................................................................15E-35
DTC P0117 (Flash Code 23) Engine Coolant Temperature DTC P0380 (Flash Code 66) Glow Plug Circuit.........15E-36
Sensor Circuit Low......................................................15E-15 DTC P0403 (Flash Code 347) Exhaust Gas Recirculation
DTC P0118 (Flash Code 23) Engine Coolant Temperature Control Circuit.............................................................15E-37
Sensor Circuit High.....................................................15E-16 DTC P0404 (Flash Code 45) Exhaust Gas Recirculation
DTC P0122 (Flash Code 43) Throttle Position Sensor Control Circuit Range/Performance............................15E-38
Circuit Low..................................................................15E-17 DTC P0500 (Flash Code 25) Vehicle Speed Sensor...15E-39
DTC P0123 (Flash Code 43) Throttle Position Sensor DTC P0501 (Flash Code 25) Vehicle Speed Sensor Range/
Circuit High.................................................................15E-18 Performance.................................................................15E-40
DTC P0182 (Flash Code 211) Fuel Temperature Sensor DTC P0562 (Flash Code 35) System Voltage Low....15E-41
Circuit Low..................................................................15E-19
DTC P0563 (Flash Code 35) System Voltage High....15E-42
DTC P0183 (Flash Code 211) Fuel Temperature Sensor
Circuit High.................................................................15E-20 DTC P0601 (Flash Code 53) Internal Control Module
Memory Check Sum Error..........................................15E-43
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor
Circuit Low..................................................................15E-21 DTC P0602 (Flash Code 154) Control Module
Programming Error......................................................15E-44
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor
Circuit High.................................................................15E-22 DTC P0604 (Flash Code 153) Internal Control Module
Random Access Memory (RAM) Error......................15E-45
DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1
.....................................................................................15E-23 DTC P0606 (Flash Code 51) ECM/PCM Processor. . .15E-46
15E-2 DTC Information (4JJ1)
DTC P0633 (Flash Code 176) Immobilizer Key Not DTC U0001 (Flash Code 84) High Speed CAN
Programmed - ECM/PCM...........................................15E-47 Communication Bus....................................................15E-72
DTC P0638 (Flash Code 61) Throttle Actuator Control DTC U0101 (Flash Code 85) Lost Communication With
Range/Performance.....................................................15E-48 TCM.............................................................................15E-73
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 DTC U010A (Flash Code 346) Lost Communication With
Circuit..........................................................................15E-49 Exhaust Gas Recirculation Control Module................15E-74
DTC P0650 (Flash Code 77) Malfunction Indicator Lamp DTC U0167 (Flash Code 177) Lost Communication With
(MIL) Control Circuit..................................................15E-50 Vehicle Immobilizer Control Module.........................15E-75
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2
Circuit..........................................................................15E-51
DTC P0661 (Flash Code 58) Intake Manifold Tuning Valve
Control Circuit Low.....................................................15E-52
DTC P0662 (Flash Code 58) Intake Manifold Tuning Valve
Control Circuit High....................................................15E-53
DTC P0697 (Flash Code 57) Sensor Reference Voltage 3
Circuit..........................................................................15E-54
DTC P0700 (Flash Code 185) Transmission Control System
(MIL Request).............................................................15E-55
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too
Low..............................................................................15E-56
DTC P1261 (Flash Code 34) Injector Positive Voltage
Control Circuit Group 1...............................................15E-57
DTC P1262 (Flash Code 34) Injector Positive Voltage
Control Circuit Group 2...............................................15E-58
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation
(EGR) Closed Position Performance...........................15E-59
DTC P161B (Flash Code 179) Immobilizer Wrong
Response......................................................................15E-60
DTC P1621 (Flash Code 54, 254) Control Module Long
Term Memory Performance........................................15E-61
DTC P2122 (Flash Code 121) Pedal Position Sensor 1
Circuit Low Input........................................................15E-62
DTC P2123 (Flash Code 121) Pedal Position Sensor 1
Circuit High Input........................................................15E-63
DTC P2127 (Flash Code 122) Pedal Position Sensor 2
Circuit Low Input........................................................15E-64
DTC P2128 (Flash Code 122) Pedal Position Sensor 2
Circuit High Input........................................................15E-65
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2
Voltage Correlation.....................................................15E-66
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply
Voltage Circuit............................................................15E-67
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply
Voltage Circuit............................................................15E-68
DTC P2227 (Flash Code 71) Barometric Pressure Circuit
Range/Performance.....................................................15E-69
DTC P2228 (Flash Code 71) Barometric Pressure Circuit
Low..............................................................................15E-70
DTC P2229 (Flash Code 71) Barometric Pressure Circuit
High.............................................................................15E-71
DTC Information (4JJ1) 15E-3
Engine Control
Engine Control
(4JJ1)
Table of Contents
DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2
Position Correlation........................................................1A-3 .......................................................................................1A-37
DTC P0045 (Flash Code 33) Turbocharger Boost Control DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3
Solenoid Circuit..............................................................1A-4 .......................................................................................1A-38
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4
Too Low..........................................................................1A-5 .......................................................................................1A-39
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure - DTC P0217 (Flash Code 542) Engine Coolant Over
Too High.........................................................................1A-8 Temperature Condition.................................................1A-40
DTC P0089 (Flash Code 151) Fuel Pressure Regulator DTC P0219 (Flash Code 543) Engine Overspeed Condition
Performance..................................................................1A-11 .......................................................................................1A-41
DTC P0091 (Flash Code 247) Fuel Pressure Regulator DTC P0234 (Flash Code 42) Turbocharger Overboost
Control Circuit Low......................................................1A-13 Condition.......................................................................1A-42
DTC P0092 (Flash Code 247) Fuel Pressure Regulator DTC P0237 (Flash Code 32) Turbocharger Boost Sensor
Control Circuit High.....................................................1A-15 Circuit Low...................................................................1A-44
DTC P0093 (Flash Code 227) Fuel System Leak Detected DTC P0238 (Flash Code 32) Turbocharger Boost Sensor
.......................................................................................1A-17 Circuit High...................................................................1A-45
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low DTC P0299 (Flash Code 65) Turbocharger Underboost
Input..............................................................................1A-20 .......................................................................................1A-46
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High DTC P0335 (Flash Code 15) Crankshaft Position Sensor
Input..............................................................................1A-21 Circuit............................................................................1A-48
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor DTC P0336 (Flash Code 15) Crankshaft Position Sensor
Circuit Low...................................................................1A-22 Circuit Range/Performance...........................................1A-50
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor DTC P0340 (Flash Code 14) Camshaft Position Sensor
Circuit High...................................................................1A-23 Circuit............................................................................1A-51
DTC P0117 (Flash Code 23) Engine Coolant Temperature DTC P0380 (Flash Code 66) Glow Plug Circuit..........1A-53
Sensor Circuit Low.......................................................1A-25 DTC P0403 (Flash Code 347) Exhaust Gas Recirculation
DTC P0118 (Flash Code 23) Engine Coolant Temperature Control Circuit..............................................................1A-54
Sensor Circuit High.......................................................1A-26 DTC P0404 (Flash Code 45) Exhaust Gas Recirculation
DTC P0122 (Flash Code 43) Throttle Position Sensor Control Circuit Range/Performance..............................1A-56
Circuit Low...................................................................1A-28 DTC P0500 (Flash Code 25) Vehicle Speed Sensor.....1A-57
DTC P0123 (Flash Code 43) Throttle Position Sensor DTC P0501 (Flash Code 25) Vehicle Speed Sensor Range/
Circuit High...................................................................1A-29 Performance..................................................................1A-59
DTC P0182 (Flash Code 211) Fuel Temperature Sensor DTC P0562 (Flash Code 35) System Voltage Low......1A-61
Circuit Low...................................................................1A-30
DTC P0563 (Flash Code 35) System Voltage High.....1A-62
DTC P0183 (Flash Code 211) Fuel Temperature Sensor
Circuit High...................................................................1A-31 DTC P0601 (Flash Code 53) Internal Control Module
Memory Check Sum Error............................................1A-63
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor
Circuit Low...................................................................1A-33 DTC P0602 (Flash Code 154) Control Module
Programming Error.......................................................1A-64
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor
Circuit High...................................................................1A-34 DTC P0604 (Flash Code 153) Internal Control Module
Random Access Memory (RAM) Error........................1A-65
DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1
.......................................................................................1A-36 DTC P0606 (Flash Code 51) ECM/PCM Processor.....1A-66
1A-2 Engine Control (4JJ1)
DTC P0633 (Flash Code 176) Immobilizer Key Not DTC U0001 (Flash Code 84) High Speed CAN
Programmed - ECM/PCM.............................................1A-67 Communication Bus......................................................1A-97
DTC P0638 (Flash Code 61) Throttle Actuator Control DTC U0101 (Flash Code 85) Lost Communication With
Range/Performance.......................................................1A-68 TCM..............................................................................1A-99
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 DTC U010A (Flash Code 346) Lost Communication With
Circuit............................................................................1A-69 Exhaust Gas Recirculation Control Module...............1A-100
DTC P0650 (Flash Code 77) Malfunction Indicator Lamp DTC U0167 (Flash Code 177) Lost Communication with
(MIL) Control Circuit...................................................1A-70 Vehicle Immobilizer Control Module.........................1A-101
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2
Circuit............................................................................1A-72
DTC P0661 (Flash Code 58) Intake Manifold Tuning Valve
Control Circuit Low......................................................1A-74
DTC P0662 (Flash Code 58) Intake Manifold Tuning Valve
Control Circuit High.....................................................1A-75
DTC P0697 (Flash Code 57) Sensor Reference Voltage 3
Circuit............................................................................1A-76
DTC P0700 (Flash Code 185) Transmission Control System
(MIL Request)...............................................................1A-78
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too
Low...............................................................................1A-79
DTC P1261 (Flash Code 34) Injector Positive Voltage
Control Circuit Group 1................................................1A-82
DTC P1262 (Flash Code 34) Injector Positive Voltage
Control Circuit Group 2................................................1A-83
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation
(EGR) Closed Position Performance............................1A-84
DTC P161B (Flash Code 179) Immobilizer Wrong
Response.......................................................................1A-85
DTC P1621 (Flash Code 54, 254) Control Module Long
Term Memory Performance..........................................1A-86
DTC P2122 (Flash Code 121) Pedal Position Sensor 1
Circuit Low Input..........................................................1A-87
DTC P2123 (Flash Code 121) Pedal Position Sensor 1
Circuit High Input.........................................................1A-88
DTC P2127 (Flash Code 122) Pedal Position Sensor 2
Circuit Low Input..........................................................1A-89
DTC P2128 (Flash Code 122) Pedal Position Sensor 2
Circuit High Input.........................................................1A-90
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2
Voltage Correlation.......................................................1A-91
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply
Voltage Circuit..............................................................1A-92
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply
Voltage Circuit..............................................................1A-93
DTC P2227 (Flash Code 71) Barometric Pressure Circuit
Range/Performance.......................................................1A-94
DTC P2228 (Flash Code 71) Barometric Pressure Circuit
Low...............................................................................1A-95
DTC P2229 (Flash Code 71) Barometric Pressure Circuit
High...............................................................................1A-96
Engine Control (4JJ1) 1A-3
14. Start the engine while observing the test lamp. 3. Start the engine.
15. Stop the engine while observing the test lamp. 4. Perform a test-run.
16. Ensure that the test lamp illuminates when starting 5. Use the scan tool to confirm that a DTC has not been
the engine and the test lamp does not illuminate detected.
when stopping the engine.
17. When the test light turns on when the engine is
started and turns off when the engine is stopped,
Engine Control (4JJ1) 1A-5
Caution: 41. Install the vacuum pump to the fuel feed hose.
・ The vacuum pump must be cleaned before
connecting to the fuel line.
・ Otherwise, foreign material internal to the tools
line may damage the fuel supply pump.
・ Be careful not to allow the fuel to enter the
vacuum pump.
30. When the fuel does not flow smoothly, repair the
SST: 5-8840-0279-0 - vacuum pump
fuel system.
Caution:
Note:
・ The vacuum pump must be cleaned before
・ When any leakage or restriction exists on the
connecting to the fuel line.
suction side, fuel leakage, clogging in the fuel
filter, twisting or collapsing of the fuel hose or 42. Confirm that the vacuum pump and the fuel line are
pipe, etc. are likely to prevent the fuel from securely connected.
flowing smoothly. Also, foreign materials inside 43. Crank the engine while monitoring the gauge on the
the fuel tank may possibly enter the fuel line vacuum pump.
pickup.
Note:
31. Replace the fuel hose between the fuel supply pump
and the fuel filter with a clear hose. ・ Repeat this procedure 3 times.
・ When the engine RPM or the engine load 35. When the fuel does not flow smoothly, repair the
increases while the air has intruded in the fuel fuel system.
system, fluctuation in the common rail Note:
pressure is caused, and the DTC P0088 may
・ If there is a leakage or a restriction in the
be detected.
suction side, fuel leakage, clogged fuel filter,
25. Confirm that an appropriate clamp is being used and twisting or crushing of the fuel hose and
between the fuel tank and the fuel supply pump. the pipes, will cause insufficient flow of
fuel.Foreign matters in the fuel tank may also
26. If a problem is found, replace the clamp.
enter into the fuel line pickup.
27. Operate the priming pump until the pushing weight
36. Replace the fuel hose between the fuel supply pump
gets heavy.
and the fuel filter with a clear hose.
Note:
37. Bleed the air from the fuel system.
・ When a leak exists in the fuel system between
the primping pump and fuel supply pump, the 38. Start the engine.
pushing weight of the priming pump does not 39. Let the engine idle for the specified period of time or
get heavy. longer.
28. Start the engine. specified time: 1 min
29. Inspect the high pressure side of the fuel system to 40. While keeping the engine speed higher than the
see whether a fuel leak exists between the fuel specified speed for the specified time, observe the
supply pump and the common rail. clear hose.
Note: specified time: 1 min
・ The fuel may leak under the cylinder head
Rotational speed: 3000 r/min Engine
cover from the inlet of the high pressure hose.
・ When the fuel leaks out to the bottom the 41. During the inspection, ensure that many air bubbles
cylinder head cover, the engine oil level is entering in the fuel.
increases. 42. If many air bubbles enter the fuel, repair the fuel
・ Inspect for a fuel leak into the engine oil. system.
30. If a fuel leak is found, repair the appropriate portion. Note:
31. Turn OFF the starter switch. ・ If air bubbles enter the fuel, inspect the fuel
line connections between the fuel supply pump
32. Disconnect the fuel feed hose from the fuel supply and the fuel tank for tightness and fuel hose
pump. for cuts, cracks and for the use of the proper
33. Install the vacuum pump to the fuel feed hose. clamps.
43. Connect the fuel feed hose to the fuel supply pump.
44. Disconnect the fuel injector in-line harness connector
from the fuel injector in order to disable the fuel
injection.
45. Disconnect the fuel feed hose from the fuel tank.
Caution:
SST: 5-8840-0279-0 - vacuum pump ・ Use a pan to collect the fuel from the removed
fuel line.
34. Operate the vacuum pump to confirm that the fuel
flows smoothly. 46. Install the vacuum pump to the fuel feed hose.
Caution:
・ The vacuum pump must be cleaned before
connecting to the fuel line.
・ Otherwise, foreign material internal to the tools
line may damage the fuel supply pump.
・ Be careful not to allow the fuel to enter the
vacuum pump.
1A-10 Engine Control (4JJ1)
SST: 5-8840-0279-0 - vacuum pump 5. Use the scan tool to confirm that a DTC has not been
detected.
Caution:
・ The vacuum pump must be cleaned before
connecting to the fuel line.
47. Confirm that the vacuum pump and the fuel line are
securely connected.
48. Crank the engine while monitoring the gauge on the
vacuum pump.
Note:
・ Repeat this procedure 3 times.
Caution:
・ Cranking should be performed within 5
seconds at a time, and should not exceed 15
seconds in total.
Standard value: -27 kPa {-0.28 kg/cm2 / 8 inHg / -3.98
psi}
Caution:
・ Release the clamp or open the plug when the
gauge on the vacuum pump is likely to indicate
a value at or above the standard value during
the test.
49. When the value is at or below the standard value,
replace the fuel supply pump and the fuel filter
element.
Note:
・ If the fuel supply pump is replaced, the fuel
filter element is also required to be replaced at
the same time.
・ If the fuel supply pump is replaced, perform
learning of unit differences in the fuel supply
pump for the ECM.
Refer to "1.Engine 1C.Fuel System(4JJ1) Fuel supply
pump removal".
Refer to "1.Engine 1C.Fuel System(4JJ1) Fuel supply
pump installation".
Refer to "1.Engine 1C.Fuel System(4JJ1) Fuel filter
element removal".
Refer to "1.Engine 1C.Fuel System(4JJ1) Fuel filter
element installation".
3. DTC P0088 confirm resolution
1. Clear the DTCs with the scan tool.
2. Turn OFF the ignition switch for more than 30
seconds.
3. Start the engine.
4. Perform a test-run.
Engine Control (4JJ1) 1A-11
DTC P0091 3. Remove each glow plug from the cylinder head
assembly.
DTC P0092
Refer to "1.Engine 1J.Electrical(4JJ1) Glow
DTC P0192 plug removal".
DTC P0193 4. Inspect for fuel leakage into the combustion
DTC P0201 chamber.
DTC P0202 5. Inspect whether there is any cylinder that has fuel
leakage into the combustion chamber.
DTC P0203
6. If a fuel leak is found, replace the applicable injector.
DTC P0204
Note:
DTC P2146
・ When the injector has been replace, set the
DTC P2149 injector ID code on the ECM.
2. DTC P0093 diagnostics Refer to "1.Engine 1C.Fuel System(4JJ1)
1. Inspect the high pressure side fuel leakage between Injector removal".
the fuel supply pump and fuel injector. Refer to "1.Engine 1C.Fuel System(4JJ1)
Note: Injector installation".
・ There should not be a fuel leak from the fuel 7. Turn OFF the starter switch.
supply pump. 8. Wait for the specified period of time to reduce the
・ There should not be a fuel leak from the fuel pressure from the common rail.
common rail.
specified time: 1 min
・ There should not be a fuel leak from the
pressure limiter valve. 9. Turn ON the starter switch.
・ There should not be a fuel leak from the fuel 10. Check the Fuel Rail Pressure (FRP) Sensor display
pressure sensor. on the scan tool.
・ There should be no fuel leaks from the fuel standard: 0.9 to 1.0 V
pipe between the fuel supply pump and the
common rail. 11. If the Fuel Rail Pressure (FRP) Sensor display shows
a value that is outside of the specified range, inspect
・ There should be no fuel leaks from the fuel
the fuel pressure sensor harness connector for a poor
pipe between the common rail and the injector.
connection.
・ There should not be a fuel leak from the fuel
pipe sleeve nut. 12. If a problem is found, repair the harness connector.
2. If a fuel leak is found, repair the appropriate portion. 13. Inspect the ECM harness connector for a poor
connection.
Note:
14. If a problem is found, repair the harness connector.
・ The fuel may leak under the cylinder head
cover from the inlet of the high pressure pipe. 15. Inspect each circuit for high resistance.
・ When the fuel leaks out to the bottom the 16. If a problem is found, repair the circuit.
cylinder head cover, the engine oil level
increases. 17. When the harness connector is normal and no high
resistance is found in each circuit, replace the fuel
・ Inspect for a fuel leak into the engine oil.
pressure sensor.
・ Remove and inspect the high pressure pipe
joints connected to the injectors for fuel leaks Refer to "1.Engine 1C.Fuel System(4JJ1) Fuel
from the sleeve nut(s). pressure sensor removal".
1A-18 Engine Control (4JJ1)
Refer to "1.Engine 1C.Fuel System(4JJ1) Fuel Note:
pressure sensor installation". ・ When a leak exists in the fuel system between
18. If the Fuel Rail Pressure (FRP) Sensor display shows the primping pump and fuel supply pump, the
a value that is within the specified range, place the pushing weight of the priming pump does not
shift lever in the neutral position and pull the parking get heavy.
brake lever. 30. Start the engine.
19. Start the engine. 31. Inspect the high pressure side of the fuel system to
20. Conduct a Cylinder Balance Test with the scan tool. see whether a fuel leak exists between the fuel
supply pump and the common rail.
21. Command each injector OFF, and confirm that the
engine rpm changes in each injector. Note:
・ The fuel may leak under the cylinder head
22. If there is an injector whose engine rpm does not
cover from the inlet of the high pressure hose.
change when OFF is commanded, replace the
relevant injector. ・ When the fuel leaks out to the bottom the
cylinder head cover, the engine oil level
Note: increases.
・ When the injector has been replace, set the ・ Inspect for a fuel leak into the engine oil.
injector ID code on the ECM.
32. If a fuel leak is found, repair the appropriate portion.
Refer to "1.Engine 1C.Fuel System(4JJ1)
Injector removal". 33. Turn OFF the starter switch.
Refer to "1.Engine 1C.Fuel System(4JJ1) 34. Disconnect the fuel feed hose from the fuel supply
Injector installation". pump.
23. Inspect the fuel system between the fuel tank and the 35. Install the vacuum pump to the fuel feed hose.
fuel supply pump for clogging.
24. If a problem is found, repair the clogging in the fuel
system.
25. Inspect the fuel hose in the fuel system between the
fuel tank and the fuel supply pump for cuts and
cracks.
26. If a problem is found, replace the fuel hose. SST: 5-8840-0279-0 - vacuum pump
Note: 36. Operate the vacuum pump to confirm that the fuel
・ The fuel hose between the fuel tank and the flows smoothly.
supply pump is slightly vacuumed when the
engine is running. Caution:
・ When the fuel hose is not connected securely, ・ The vacuum pump must be cleaned before
the air can get inside. connecting to the fuel line.
・ When the engine RPM or the engine load ・ Otherwise, foreign material internal to the tools
increases while the air has intruded in the fuel line may damage the fuel supply pump.
system, fluctuation in the common rail ・ Be careful not to allow the fuel to enter the
pressure is caused, and the DTC P0093 may vacuum pump.
be detected. 37. When the fuel does not flow smoothly, repair the
27. Confirm that an appropriate clamp is being used fuel system.
between the fuel tank and the fuel supply pump. Note:
28. If a problem is found, replace the clamp with a ・ If there is a leakage or a restriction in the
proper one. suction side, fuel leakage, clogged fuel filter,
29. Operate the priming pump until the pushing weight and twisting or crushing of the fuel hose and
gets heavy. the pipes, will cause insufficient flow of
fuel.Foreign matters in the fuel tank may also
enter into the fuel line pickup.
Engine Control (4JJ1) 1A-19
38. Replace the fuel hose between the fuel supply pump Note:
and the fuel filter with a clear hose. ・ Repeat this procedure 3 times.
39. Bleed the air from the fuel system. Caution:
40. Start the engine. ・ Cranking should be performed within 5
seconds at a time, and should not exceed 15
41. Let the engine idle for the specified period of time or
seconds in total.
longer.
Standard value: -27 kPa {-0.28 kg/cm2 / 8 inHg / -3.98
specified time: 1 min
psi}
42. While keeping the engine speed higher than the
Caution:
specified speed for the specified time, observe the
clear hose. ・ Release the clamp or open the plug when the
gauge on the vacuum pump is likely to indicate
specified time: 1 min a value at or above the standard value during
Rotational speed: 3000 r/min Engine the test.
43. During the inspection, ensure that many air bubbles 51. When the value is at or below the standard value,
is entering in the fuel. replace the fuel supply pump and the fuel filter
element.
44. If many air bubbles enter the fuel, repair the fuel
system. Note:
・ If the fuel supply pump is replaced, the fuel
Note:
filter element is also required to be replaced at
・ If air bubbles enter the fuel, inspect the fuel the same time.
line connections between the fuel supply pump
・ If the fuel supply pump is replaced, perform
and the fuel tank for tightness and fuel hose
learning of unit differences in the fuel supply
for cuts, cracks and for the use of the proper
pump for the ECM.
clamps.
Refer to "1.Engine 1C.Fuel System(4JJ1) Fuel supply
45. Connect the fuel feed hose to the fuel supply pump.
pump removal".
46. Disconnect the fuel injector in-line harness connector
Refer to "1.Engine 1C.Fuel System(4JJ1) Fuel supply
from the fuel injector in order to disable the fuel
pump installation".
injection.
Refer to "1.Engine 1C.Fuel System(4JJ1) Fuel filter
47. Disconnect the fuel feed hose from the fuel tank.
element removal".
Caution:
Refer to "1.Engine 1C.Fuel System(4JJ1) Fuel filter
・ Use a pan to collect the fuel from the removed element installation".
fuel line.
3. DTC P0093 confirm resolution
48. Install the vacuum pump to the fuel feed hose.
1. Clear the DTCs with the scan tool.
2. Turn OFF the ignition switch for more than 30
seconds.
3. Start the engine.
4. Perform a test-run.
5. Use the scan tool to confirm that a DTC has not been
SST: 5-8840-0279-0 - vacuum pump detected.
Caution:
・ The vacuum pump must be cleaned before
connecting to the fuel line.
49. Confirm that the vacuum pump and the fuel line are
securely connected.
50. Crank the engine while monitoring the gauge on the
vacuum pump.
1A-20 Engine Control (4JJ1)
4. Disconnect the harness connector from the mass air 17. Set the immobilizer function and injector ID code in
flow sensor. the ECM.
5. Inspect the ignition power supply circuit between the Refer to "1.Engine 1J.Electrical(4JJ1) ECM setting".
ECM and the MAF sensor. 18. Conduct learning of unit differences in the fuel
Note: supply pumps for the ECM.
・ There should be no open circuit or high Refer to "1.Engine 1J.Electrical(4JJ1) ECM writing".
resistance.
2. DTC P0102 confirm resolution
6. If a problem is found, repair the ignition power
1. Clear the DTCs with the scan tool.
supply circuit.
2. Turn OFF the ignition switch for more than 30
7. Connect a test cable with fuse between the ignition
seconds.
power supply circuit and the signal circuit of the
MAF sensor harness connector. 3. Start the engine.
8. Check the Mass Air Flow (MAF) Sensor display on 4. Perform a test-run.
the scan tool.
5. Use the scan tool to confirm that a DTC has not been
standard: 4.9 V detected.
9. If the reading is more than the specified value,
inspect the mass air flow sensor harness connector
for a poor connection.
10. If a problem is found, repair the harness connector.
11. When the harness connector is normal, replace the
mass air flow sensor.
Refer to "1.Engine 1F.Induction(4JJ1) MAF and IAT
sensor removal".
Refer to "1.Engine 1F.Induction(4JJ1) MAF and IAT
sensor installation".
12. Inspect the signal circuit between the ECM and the
mass air flow sensor.
Note:
・ There should be no open or high resistance.
・ There should be no short circuit to the low
reference circuit.
・ There should be no short circuit with a metal
component such as a frame.
13. If a problem is found, repair the signal circuit.
Engine Control (4JJ1) 1A-21
8. Check the Intake Throttle Position Sensor display on 5. Use the scan tool to confirm that a DTC has not been
the scan tool. detected.
standard: 4.7 V
9. If the reading is more than the specified value,
inspect the intake throttle valve harness connector
for a poor connection.
10. If a problem is found, repair the harness connector.
11. When the harness connector is normal, replace the
intake throttle valve.
Refer to "1.Engine 1B.Mechanical(4JJ1) Intake
throttle valve removal".
Refer to "1.Engine 1B.Mechanical(4JJ1) Intake
throttle valve installation".
12. Inspect the signal circuit between the ECM and the
intake throttle position sensor.
Note:
・ There should be no open or high resistance.
Engine Control (4JJ1) 1A-29
2. DTC P0237 diagnostics 12. If a problem is found, repair the signal circuit.
1. Turn OFF the ignition switch. 13. Inspect the ECM harness connector for a contact
failure.
2. Disconnect the harness connector from the boost
sensor. 14. If a problem is found, repair the harness connector.
3. Turn ON the ignition switch. 15. When the harness connector is normal, replace the
ECM.
4. Measure the voltage value between the boost sensor
harness connector 5 V power supply circuit and the Refer to "1.Engine 1J.Electrical(4JJ1) ECM removal".
frame ground. Refer to "1.Engine 1J.Electrical(4JJ1)
Standard: 4.7 V ECM installation".
5. When the value is at or below the standard value, 16. Set the immobilizer function and injector ID code on
inspect the 5 V power supply circuit between the the ECM.
ECM and the boost sensor. Refer to "1.Engine 1J.Electrical(4JJ1) ECM setting".
Note: 17. Conduct the unit difference learning of fuel supply
・ There should be no open circuit or high pumps on the ECM.
resistance.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM writing".
・ The DTCs of the sensors that share this circuit
may be detected. 3. DTC P0237 confirm resolution
6. If a problem is found, repair the 5 V power supply 1. Clear the DTC with a scan tool.
circuit. 2. Turn the ignition switch OFF for 30 seconds or
7. Connect a test cable with fuse between the 5 V longer.
power supply circuit and the signal circuit of the 3. Start the engine.
boost sensor harness connector.
4. Perform a test-run.
8. Use a scan tool to confirm the Boost Pressure Sensor
display. 5. Use a scan tool to confirm that a DTC has not been
detected.
Standard: 4.7 V
9. When the value is at or above the standard value,
inspect the boost sensor harness connector for a
contact failure.
10. If a problem is found, repair the harness connector.
Refer to "1.Engine 1F.Induction(4JJ1) Boost
sensor removal".
Refer to "1.Engine 1F.Induction(4JJ1) Boost
sensor installation".
11. Inspect the signal circuit between the ECM and the
boost sensor.
Note:
・ There should be no open circuit or high
resistance.
・ There should be no short circuit to the low
reference circuit.
Engine Control (4JJ1) 1A-45
3962 13000 58-66 5. Use the scan tool to confirm that a DTC has not been
3658 12000 61-69 detected.
3353 11000 64-72
3048 10000 66-74
2743 9000 69-77
2438 8000 71-79
2134 7000 74-82
1829 6000 77-85
1524 5000 80-88
1219 4000 83-91
914 3000 87-95
610 2000 90-98
305 1000 94-102
0 0 sea level 96-104
-305 -1000 101-105
21. If the value shown for the Barometric Pressure
(BARO) display is close to the barometric pressure,
turn OFF the ignition switch.
22. If a problem is found, repair the harness connector.
23. When the harness connector is normal, replace the
boost sensor.
Refer to "1.Engine 1F.Induction(4JJ1) Boost
sensor removal".
Refer to "1.Engine 1F.Induction(4JJ1) Boost
sensor installation".
24. If the Barometric Pressure (BARO) display shows
that a value is outside the specified range, inspect the
barometric pressure sensor harness connector for a
poor connection.
25. If a problem is found, repair the harness connector.
26. When the harness connector is normal, replace the
barometric pressure sensor.
Refer to "1.Engine 1J.Electrical(4JJ1) Barometric
pressure sensor removal".
Refer to "1.Engine 1J.Electrical(4JJ1) Barometric
pressure sensor installation".
27. Inspect the ECM harness connector for a poor
connection.
28. If a problem is found, repair the harness connector.
3. DTC P0299 confirm resolution
1. Clear the DTCs with the scan tool.
2. Turn OFF the ignition switch for more than 30
seconds.
3. Start the engine.
4. Perform a test-run.
1A-48 Engine Control (4JJ1)
standard: 5.5 V 20. When the harness connector is normal, inspect the
crankshaft position sensor.
8. When the value is at or above the standard value,
inspect the signal circuit between the ECM and the Refer to "1.Engine 1B.Mechanical(4JJ1) CKP
CKP sensor. sensor inspection".
Note: 24. Inspect the low reference circuit between the ECM
and the CMP sensor.
・ There should be no open or high resistance.
1A-52 Engine Control (4JJ1)
Note:
・ There should be no open circuit or high
resistance.
・ The CMP sensor shares the low reference
circuit with other sensors.
・ The DTCs of the sensors that share this circuit
may be detected.
25. If a problem is found, repair the low reference
circuit.
26. Inspect the ECM harness connector for a poor
connection.
27. If a problem is found, repair the harness connector.
28. If the harness connector is normal, replace the ECM.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM removal".
Refer to "1.Engine 1J.Electrical(4JJ1)
ECM installation".
29. Set the immobilizer function and injector ID code in
the ECM.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM setting".
30. Conduct learning of unit differences in the fuel
supply pumps for the ECM.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM writing".
3. DTC P0340 confirm resolution
1. Clear the DTCs with the scan tool.
2. Turn OFF the ignition switch for more than 30
seconds.
3. Start the engine.
4. Perform a test-run.
5. Use the scan tool to confirm that a DTC has not been
detected.
Engine Control (4JJ1) 1A-53
2. Disconnect the harness connector from the EGR 13. If a problem is found, repair the CAN Low circuit.
valve. 14. Inspect the CAN high circuit between the EGR valve
3. Turn ON the ignition switch. and the ECM.
5. Check if the test lamp illuminate. 18. Connect a test light between the ignition power
supply circuit and the ground circuit of the vehicle
6. If the test lamp does not illuminate, inspect the speed sensor harness connector.
Meter10 A fuse.
19. Check if the test lamp illuminate.
7. If a problem is found, replace the Meter 10 A fuse.
20. When the test light does not turn on, repair any open
Note: circuit or high resistance in the vehicle speed sensor
・ If the blowout of the fuse is repeated, repair ground circuit.
the cause of Meter10 A fuse blowout. 21. Inspect the installation condition of the speed sensor.
8. If the Meter 10 A fuse is normal, repair the open or Note:
high resistance in the ignition power supply circuit
between the Meter 10 A fuse and the vehicle speed ・ There should be no damage.
sensor. ・ Installation should be performed properly.
9. Intermittently jump the vehicle speed sensor signal 22. If a problem is found, repair the installation
circuit using a test light connected to the frame condition of the speed sensor.
ground while checking the Vehicle Speed display on 23. Inspect the speedometer driven gear.
a scan tool.
Note:
10. Ensure that the scan tool display any vehicle speed.
・ There should be no damage.
・ Installation should be performed properly.
1A-58 Engine Control (4JJ1)
24. If a problem is found, replace the speedometer 39. When the circuit is normal, inspect the ECM harness
driven gear. connector for a poor connection.
25. Inspect the speedometer drive gear. 40. If a problem is found, repair the harness connector.
Note: 41. If the harness connector is normal, replace the ECM.
・ There should be no damage. Refer to "1.Engine 1J.Electrical(4JJ1) ECM removal".
・ Installation should be performed properly.
Refer to "1.Engine 1J.Electrical(4JJ1)
26. If a problem is found, replace the speedometer drive ECM installation".
gear.
42. Set the immobilizer function and injector ID code in
27. Inspect the transmission output shaft. the ECM.
Note: Refer to "1.Engine 1J.Electrical(4JJ1) ECM setting".
・ The teeth should be free from damage. 43. Conduct learning of unit differences in the fuel
・ There should be no excessive play. supply pumps for the ECM.
28. If a problem is found, replace the transmission Refer to "1.Engine 1J.Electrical(4JJ1) ECM writing".
output shaft.
44. Inspect the EHCU harness connector for a poor
29. Inspect the speed sensor harness connector for a poor connection.
connection.
45. If a problem is found, repair the harness connector.
30. If a problem is found, repair the harness connector.
46. When the harness connector is normal, replace the
31. If the harness connector is normal, replace the speed EHCU.
sensor.
Refer to "4.Brakes 4D.ABS(All models)
Refer to "9.Body, Cab, Accessories 9E.Instrumentation, EHCU removal".
Driver Info.(All models) Vehicle speed
Refer to "4.Brakes 4D.ABS(All models)
sensor removal".
EHCU installation".
Refer to "9.Body, Cab, Accessories 9E.Instrumentation,
47. Set the vehicle information on the EHCU.
Driver Info.(All models) Vehicle speed
sensor installation". Refer to "4.Brakes 4D.ABS(All models)
EHCU setting".
Note:
・ With ABS 3. DTC P0500 confirm resolution
32. Turn OFF the starter switch. 1. Clear the DTCs with the scan tool.
33. Disconnect the harness connector from the EHCU. 2. Turn OFF the ignition switch for more than 30
seconds.
34. Turn ON the starter switch.
3. Start the engine.
35. Intermittently jump the EHCU vehicle speed signal
output circuit using a test light connected to the 4. Perform a test-run.
frame ground while checking the Vehicle Speed 5. Use the scan tool to confirm that a DTC has not been
display on a scan tool. detected.
36. Ensure that the scan tool display any vehicle speed.
37. If the scan tool does not display the vehicle speed,
inspect the vehicle speed signal circuit between the
ECM and the EHCU.
Note:
・ There should be no short circuit to the battery
or ignition power supply circuit.
・ There should be no open or high resistance.
・ There should be no short circuit with a metal
component such as a frame.
38. If a problem is found, repair the signal circuit.
Engine Control (4JJ1) 1A-59
10. If a problem is found, repair the harness connector. 24. Inspect the vehicle speed signal circuit between the
ECM and EHCU.
11. Inspect the installation condition of the speed sensor.
Note:
Note:
・ No wiring harness has placed too close to the
・ There should be no damage. fuel injection circuit or components.
・ Installation should be performed properly. ・ No wiring harness is placed too close to the
12. If a problem is found, repair the installation commercial electrical accessories.
condition of the speed sensor. ・ Ensure that the harness is not routed too
13. Inspect the speedometer driven gear. closely to the solenoid, the relay and the
motor.
Note:
25. If a problem is found, repair the harness.
・ There should be no damage.
26. Disconnect the harness connector from the ECM.
・ Installation should be performed properly.
27. Inspect the ECM harness connector for a poor
14. If a problem is found, replace the speedometer
connection.
driven gear.
28. If a problem is found, repair the harness connector.
15. Inspect the speedometer drive gear.
29. Inspect all the wheel speed sensor harness
Note:
connectors for a poor connection.
・ There should be no damage.
1A-60 Engine Control (4JJ1)
30. If a problem is found, repair the harness connector.
31. Disconnect the harness connector from the EHCU.
32. Inspect the EHCU harness connector for a poor
connection.
33. If a problem is found, repair the harness connector.
34. When the harness connector is normal, replace the
EHCU.
Refer to "4.Brakes 4D.ABS(All models)
EHCU removal".
Refer to "4.Brakes 4D.ABS(All models)
EHCU installation".
35. Set the vehicle information on the EHCU.
Refer to "4.Brakes 4D.ABS(All models)
EHCU setting".
2. DTC P0501 confirm resolution
1. Clear the DTCs with the scan tool.
2. Turn OFF the ignition switch for more than 30
seconds.
3. Start the engine.
4. Perform a test-run.
5. Use the scan tool to confirm that a DTC has not been
detected.
Engine Control (4JJ1) 1A-61
10. If a problem is found, repair the harness connector. 2. Turn OFF the ignition switch for more than 30
seconds.
11. Inspect each circuit for high resistance.
3. Start the engine.
12. If a problem is found, repair the intake throttle valve
circuit. 4. Perform a test-run.
13. Inspect the motor circuit between the ECM and the 5. Use the scan tool to confirm that a DTC has not been
intake throttle valve. detected.
Note:
・ There should be no short circuit with a metal
component such as a frame.
Engine Control (4JJ1) 1A-69
7. Measure the voltage value between the 5 V power 5. Use the scan tool to confirm that a DTC has not been
supply circuit for accelerator pedal position sensor 1 detected.
of the accelerator pedal position sensor harness
connector and the frame ground.
standard: 4.7 V
8. If the reading is more than the specified value,
replace the accelerator pedal assembly.
Refer to "1.Engine 1I.Speed Control Systems(4JJ1)
Accelerator pedal assembly removal".
Refer to "1.Engine 1I.Speed Control Systems(4JJ1)
Accelerator pedal assembly installation".
9. When the value is at or below the standard value,
inspect the 5 V power supply circuit of the
accelerator pedal position sensor 1 between the ECM
and the accelerator pedal position sensor.
Note:
・ There should be no short circuit to the low
reference circuit.
・ There should be no short circuit with a metal
component such as a frame.
10. If a problem is found, repair the 5 V power supply
circuit of the accelerator pedal position sensor 1.
11. When the circuit is normal, inspect the ECM harness
connector for a poor connection.
1A-70 Engine Control (4JJ1)
6. If a problem is found, repair the 5 V power supply 18. Measure the voltage value between the 5 V power
circuit of the accelerator pedal position sensor 2. supply circuit for accelerator pedal position sensor 2
of the accelerator pedal position sensor harness
7. Inspect the fuel pressure sensor 5 V power supply connector and the frame ground.
circuit between the ECM and the fuel pressure
sensor. standard: 4.7 V
10. If a problem is found, repair the camshaft position 22. Turn ON the starter switch.
sensor 5 V power supply circuit. 23. Measure the voltage value between the 5 V power
11. Inspect the barometric pressure sensor 5 V power supply circuit for accelerator pedal position sensor 2
supply circuit between the ECM and the barometric of the accelerator pedal position sensor harness
pressure sensor. connector and the frame ground.
4. Turn ON the starter switch. 17. If a problem is found, repair the control circuit.
5. If the test lamp does not illuminate, inspect the 18. Turn OFF the starter switch.
Engine10 A fuse. 19. Disconnect the harness connector from the ECM.
6. If a problem is found, replace the Engine 10 A fuse. 20. Inspect the ECM harness connector for a poor
Note: connection.
・ If the blowout of the fuse is repeated, repair 21. If a problem is found, repair the harness connector.
the cause of Engine 10A fuse blowout.
22. If the harness connector is normal, replace the ECM.
7. Repair the open or the high resistance in the battery
Refer to "1.Engine 1J.Electrical(4JJ1) ECM removal".
power supply circuit between the Engine 10 A fuse
and the swirl control solenoid valve. Refer to "1.Engine 1J.Electrical(4JJ1)
ECM installation".
8. If the test lamp illuminates, connect the test lamp
between the control circuit of the swirl control valve 23. Set the immobilizer function and injector ID code in
harness connector and the battery power supply. the ECM.
9. Perform the Swirl Control Solenoid Control with a Refer to "1.Engine 1J.Electrical(4JJ1) ECM setting".
scan tool.
24. Conduct learning of unit differences in the fuel
10. Command the swirl control solenoid valve ON and supply pumps for the ECM.
OFF.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM writing".
Note: 2. DTC P0661 confirm resolution
・ When commanded ON, the test lamp
illuminates and when commanded OFF, the 1. Clear the DTCs with the scan tool.
test lamp does not illuminate. 2. Turn OFF the ignition switch for more than 30
11. If a test lamp operates properly, inspect the swirl seconds.
control solenoid valve harness connector for a poor 3. Start the engine.
connection.
4. Perform a test-run.
12. If a problem is found, repair the harness connector.
5. Use the scan tool to confirm that a DTC has not been
13. If the harness connector is normal, replace the swirl detected.
control solenoid valve.
Refer to "1.Engine 1B.Mechanical(4JJ1) Swirl control
solenoid valve removal".
Refer to "1.Engine 1B.Mechanical(4JJ1) Swirl control
solenoid valve installation".
14. When the test light remains on, inspect the control
circuit between the ECM and the swirl control
solenoid valve.
Note:
・ There should be no short circuit to the ground.
Engine Control (4JJ1) 1A-75
6. If a problem is found, repair the boost sensor 5 V 18. If it is at or below the standard value, turn the starter
power supply circuit. switch OFF.
7. Inspect the intake throttle position sensor 5 V power 19. Disconnect the harness connector from the
supply circuit between the ECM and the intake crankshaft position sensor.
throttle valve. 20. Turn ON the starter switch.
Note: 21. Measure the voltage value between the boost sensor
・ There should be no short circuit to the battery 5 V power supply circuit of the boost sensor harness
or ignition power supply circuit. connector and the frame ground.
8. If a problem is found, repair the intake throttle standard: 4.7 V
position sensor 5 V power supply circuit.
22. If the reading is more than the specified value,
9. Inspect the CKP sensor 5 V power supply circuit replace the crankshaft position sensor.
between the ECM and the CKP sensor.
Refer to "1.Engine 1B.Mechanical(4JJ1) CKP
Note: sensor removal".
・ There should be no short circuit to the battery Refer to "1.Engine 1B.Mechanical(4JJ1) CKP
or ignition power supply circuit. sensor installation".
10. If a problem is found, repair the crankshaft position 23. If it is at or below the standard value, turn the starter
sensor 5 V power supply circuit. switch OFF.
11. When the value is at or below the standard value, 24. When the value is at or below the standard value,
measure the voltage value between the boost sensor inspect the boost sensor 5 V power supply circuit
5 V power supply circuit of the boost sensor harness between the ECM and the boost sensor.
connector and the frame ground.
Note:
standard: 4.7 V
・ There should be no short circuit to the low
12. If the reading is more than the specified value, reference circuit.
replace the boost sensor. ・ There should be no short circuit with a metal
Refer to "1.Engine 1F.Induction(4JJ1) Boost component such as a frame.
sensor removal". 25. If a problem is found, repair the boost sensor 5 V
Refer to "1.Engine 1F.Induction(4JJ1) Boost power supply circuit.
sensor installation".
Engine Control (4JJ1) 1A-77
26. Inspect the intake throttle position sensor 5 V power
supply circuit between the ECM and the intake
throttle valve.
Note:
・ There should be no short circuit to the low
reference circuit.
・ There should be no short circuit with a metal
component such as a frame.
27. If a problem is found, repair the intake throttle
position sensor 5 V power supply circuit.
28. Inspect the CKP sensor 5 V power supply circuit
between the ECM and the CKP sensor.
Note:
・ There should be no short circuit to the low
reference circuit.
・ There should be no short circuit with a metal
component such as a frame.
29. If a problem is found, repair the crankshaft position
sensor 5 V power supply circuit.
30. Replace the ECM.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM removal".
Refer to "1.Engine 1J.Electrical(4JJ1)
ECM installation".
31. Set the immobilizer function and injector ID code in
the ECM.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM setting".
32. Conduct learning of unit differences in the fuel
supply pumps for the ECM.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM writing".
2. DTC P0697 confirm resolution
1. Clear the DTCs with the scan tool.
2. Turn OFF the ignition switch for more than 30
seconds.
3. Start the engine.
4. Perform a test-run.
5. Use the scan tool to confirm that a DTC has not been
detected.
1A-78 Engine Control (4JJ1)
7. Inspect the ECM harness connector for a poor 19. If a problem is found, repair the clogging in the fuel
connection. system.
8. If a problem is found, repair the harness connector. 20. Inspect the fuel hose between the fuel tank and the
fuel supply pump for cuts and cracks.
9. Inspect each circuit for high resistance.
21. If a problem is found, replace the fuel hose.
10. If a problem is found, repair the circuit.
Note:
11. When the harness connector and each circuit are
・ The fuel hose between the fuel tank and the
normal, replace the fuel pressure sensor.
fuel supply pump is slightly vacuumed when
Refer to "1.Engine 1C.Fuel System(4JJ1) Fuel the engine is running.
pressure sensor removal". ・ When the fuel hose is not connected securely,
Refer to "1.Engine 1C.Fuel System(4JJ1) Fuel the air can get inside.
pressure sensor installation". ・ When the engine speed or the engine load
increases while the air has intruded in the fuel
12. If the Fuel Rail Pressure (FRP) Sensor display shows
system, fluctuation in the common rail
a value that is within the specified range, place the
1A-80 Engine Control (4JJ1)
Note: Note:
・ There should be no short circuit to the ground. ・ There should be no open circuit or high
resistance.
6. If a problem is found, repair the control circuit.
18. Inspect the charge voltage circuit between the ECM
7. Inspect the charge voltage circuit between the ECM and the cylinder No. 4 injector.
and the injector.
Note:
Note:
・ There should be no open circuit or high
・ There should be no short circuit to the battery resistance.
or ignition power supply circuit.
19. If a problem is found, repair the charge voltage
・ There should be no short circuit to the ground.
circuit.
8. If a problem is found, repair the charge voltage
2. DTC P2146 confirm resolution
circuit.
1. Clear the DTCs with the scan tool.
9. If the charge voltage circuit between the ECM and
the injector is normal, replace the ECM. 2. Turn OFF the ignition switch for more than 30
seconds.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM removal".
3. Start the engine.
Refer to "1.Engine 1J.Electrical(4JJ1)
ECM installation". 4. Perform a test-run.
10. Set the immobilizer function and injector ID code in 5. Use the scan tool to confirm that a DTC has not been
the ECM. detected.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM setting".
11. Conduct learning of unit differences in the fuel
supply pumps for the ECM.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM writing".
12. Check whether the insulation resistance between the
injectors of the cylinders No. 1 and No. 4 is at or
above the standard value.
standard: 1 MΩ
Engine Control (4JJ1) 1A-93
Note: Note:
・ There should be no short circuit to the ground. ・ There should be no open circuit or high
resistance.
6. If a problem is found, repair the control circuit.
18. Inspect the charge voltage circuit between the ECM
7. Inspect the charge voltage circuit between the ECM and the cylinder No. 3 injector.
and the injector.
Note:
Note:
・ There should be no open circuit or high
・ There should be no short circuit to the battery resistance.
or ignition power supply circuit.
19. If a problem is found, repair the charge voltage
・ There should be no short circuit to the ground.
circuit.
8. If a problem is found, repair the charge voltage
2. DTC P2149 confirm resolution
circuit.
1. Clear the DTCs with the scan tool.
9. When the charge voltage circuit between the ECM
and the injector is normal, replace the ECM. 2. Turn OFF the ignition switch for more than 30
seconds.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM removal".
3. Start the engine.
Refer to "1.Engine 1J.Electrical(4JJ1)
ECM installation". 4. Perform a test-run.
10. Set the immobilizer function and injector ID code in 5. Use the scan tool to confirm that a DTC has not been
the ECM. detected.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM setting".
11. Conduct learning of unit differences in the fuel
supply pumps for the ECM.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM writing".
12. Check whether the insulation resistance between the
injectors of the cylinders No. 2 and No. 3 is at or
above the standard value.
standard: 1 MΩ
1A-94 Engine Control (4JJ1)
11. If a DTC is not detected, replace the TCM. 27. Turn OFF the starter switch.
Refer to "5.Transmission, Transaxle 28. Connect the harness connector to the instrument
5B.Automatic(TB-50LS) TCM removal". panel cluster.
Refer to "5.Transmission, Transaxle 29. Disconnect the harness connector from the auto air
5B.Automatic(TB-50LS) TCM installation". conditioner control unit.
12. Set the vehicle information on the TCM. 30. Turn ON the starter switch.
Refer to "5.Transmission, Transaxle 31. Check the DTC using the scan tool.
5B.Automatic(TB-50LS) TCM setting". 32. If a DTC is not detected, replace the auto air
13. Turn OFF the starter switch. conditioner control unit.
14. Connect the harness connector to the TCM. Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
15. Disconnect the ICU harness connector from the ICU. assembly removal".
16. Turn ON the starter switch. Refer to "7.HVAC 7B.Heater, Ventilator,
17. Check the DTC using the scan tool. Airconditioner(All models) Control panel
assembly installation".
18. If a DTC is not detected, replace the ICU.
33. Turn OFF the starter switch.
Refer to "9.Body, Cab, Accessories 9J.Security and
Locks(All models) ICU removal". 34. Connect the harness connector to the auto air
conditioner control unit.
Refer to "9.Body, Cab, Accessories 9J.Security and
Locks(All models) ICU installation". 35. Disconnect the harness connector from the TCCM.
19. Set authentication information on the ICU. 36. Turn ON the starter switch.
Refer to "9.Body, Cab, Accessories 9J.Security and 37. Check the DTC using the scan tool.
Locks(All models) ICU setting". 38. When a DTC is not detected, replace the TCCM.
20. Turn OFF the starter switch. Refer to "3.Driveline, Axle 3D.Transfer Case(All
21. Connect the harness connector to the ICU. models) TCCM removal".
1A-98 Engine Control (4JJ1)
Refer to "3.Driveline, Axle 3D.Transfer Case(All 61. Turn ON the starter switch.
models) TCCM installation".
62. Check the DTC using the scan tool.
39. Turn OFF the starter switch.
63. If a DTC is not detected, replace the BCM.
40. Connect the harness connector to the TCCM.
Refer to "9.Body, Cab, Accessories 9E.Instrumentation,
41. Disconnect the harness connector from the EHCU. Driver Info.(All models) BCM removal".
42. Turn ON the starter switch. Refer to "9.Body, Cab, Accessories 9E.Instrumentation,
Driver Info.(All models) BCM installation".
43. Check the DTC using the scan tool.
64. Set the vehicle information on the BCM.
44. If a DTC is not detected, replace the EHCU.
Refer to "9.Body, Cab, Accessories 9E.Instrumentation,
Refer to "4.Brakes 4D.ABS(All models)
Driver Info.(All models) BCM setting".
EHCU removal".
65. When a DTC is detected, inspect the CAN low and
Refer to "4.Brakes 4D.ABS(All models)
CAN high circuits.
EHCU installation".
Note:
45. Set the vehicle information on the EHCU.
・ There should be no short circuit to the battery
Refer to "4.Brakes 4D.ABS(All models) or ignition power supply circuit.
EHCU setting".
・ There should be no open circuit or high
46. Turn OFF the starter switch. resistance.
47. Connect the harness connector to the EHCU. ・ There should be no short circuit between CAN
circuits.
48. Disconnect the harness connector from the EGR
valve. ・ There should be no short circuit to the low
reference circuit.
49. Turn ON the starter switch. ・ There should be no short circuit with a metal
50. Check the DTC using the scan tool. component such as a frame.
51. When a DTC is not detected, replace the EGR valve. 66. If a problem is found, repair the CAN circuit.
Refer to "1.Engine 1H.Aux. Emission Control 67. When the CAN circuit is normal, replace the ECM.
Devices(4JJ1) EGR valve removal". Refer to "1.Engine 1J.Electrical(4JJ1) ECM removal".
Refer to "1.Engine 1H.Aux. Emission Control Refer to "1.Engine 1J.Electrical(4JJ1)
Devices(4JJ1) EGR valve installation". ECM installation".
52. Turn OFF the starter switch. 68. Set the immobilizer function and injector ID code on
53. Connect the harness connector to the EGR valve. the ECM.
54. Disconnect the harness connector from the SRS Refer to "1.Engine 1J.Electrical(4JJ1) ECM setting".
control unit. 69. Conduct the unit difference learning of fuel supply
55. Turn ON the starter switch. pumps on the ECM.
56. Check the DTC using the scan tool. Refer to "1.Engine 1J.Electrical(4JJ1) ECM writing".
57. If a DTC is not detected, replace the SRS control 2. DTC U0001 confirm resolution
unit. 1. Clear the DTCs with the scan tool.
Refer to "8.Restraints 8B.Air Bag Systems(All models) 2. Turn OFF the ignition switch for more than 30
SRS control unit removal". seconds.
Refer to "8.Restraints 8B.Air Bag Systems(All models) 3. Start the engine.
SRS control unit installation".
4. Perform a test-run.
58. Turn OFF the starter switch.
5. Use the scan tool to confirm that a DTC has not been
59. Connect the harness connector to the SRS control detected.
unit.
60. Disconnect the harness connector from the BCM.
Engine Control (4JJ1) 1A-99
Engine
Mechanical
(4JJ1)
Table of Contents
Engine assembly..............................................................1B-3 inspection................................................................1B-251
removal.......................................................................1B-3 installation...............................................................1B-253
installation.................................................................1B-10 Crankshaft...................................................................1B-297
Cylinder head cover.......................................................1B-20 removal...................................................................1B-297
removal.....................................................................1B-20 disassembly.............................................................1B-325
installation.................................................................1B-23 inspection................................................................1B-326
Intake throttle valve.......................................................1B-26 reassembly..............................................................1B-329
removal.....................................................................1B-26 installation...............................................................1B-330
installation.................................................................1B-27 CKP sensor..................................................................1B-371
Exhaust manifold...........................................................1B-29 removal...................................................................1B-371
removal.....................................................................1B-29 inspection................................................................1B-372
inspection..................................................................1B-35 installation...............................................................1B-373
installation.................................................................1B-36 Inlet manifold..............................................................1B-374
Timing chain..................................................................1B-44 removal...................................................................1B-374
removal.....................................................................1B-44 installation...............................................................1B-377
installation.................................................................1B-51 Rocker arm shaft assembly..........................................1B-382
Camshaft........................................................................1B-60 removal...................................................................1B-382
removal.....................................................................1B-60 installation...............................................................1B-388
inspection..................................................................1B-65 Timing gear train.........................................................1B-395
installation.................................................................1B-69 removal...................................................................1B-395
Cylinder head assembly.................................................1B-74 inspection................................................................1B-401
removal.....................................................................1B-74 installation...............................................................1B-403
disassembly...............................................................1B-94 Valve stem oil seal and valve spring...........................1B-412
inspection..................................................................1B-98 removal...................................................................1B-412
reassembly..............................................................1B-104 inspection................................................................1B-433
installation...............................................................1B-109 installation...............................................................1B-434
Flywheel......................................................................1B-137 Piston and connecting rod...........................................1B-463
removal...................................................................1B-137 removal...................................................................1B-463
inspection................................................................1B-139 disassembly.............................................................1B-491
installation...............................................................1B-140 inspection................................................................1B-492
Crankshaft front oil seal..............................................1B-142 reassembly..............................................................1B-497
removal...................................................................1B-142 installation...............................................................1B-498
installation...............................................................1B-147 Crankcase....................................................................1B-536
Crankshaft rear oil seal................................................1B-154 removal...................................................................1B-536
removal...................................................................1B-154 disassembly.............................................................1B-564
installation...............................................................1B-156 reassembly..............................................................1B-565
Timing gear case.........................................................1B-159 installation...............................................................1B-566
removal...................................................................1B-159 CMP sensor.................................................................1B-602
installation...............................................................1B-185 removal...................................................................1B-602
Cylinder block.............................................................1B-220 inspection................................................................1B-603
removal...................................................................1B-220 installation...............................................................1B-604
1B-2 Mechanical (4JJ1)
Engine assembly
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
3. Coolant drain
1. Drain coolant from the radiator.
Note:
・ Open the drain plug at the bottom of the
radiator.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts. 2. Remove the radiator cap from the radiator.
3. Remove the rear under guard from the frame. Warning:
Note: ・ In order to prevent burns, do not open the cap
・ Remove the 4 bolts. when the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Intake air duct removal
1. Remove the intake air duct from the turbocharger
and the intercooler.
1B-4 Mechanical (4JJ1)
Note: 2. MAF sensor
・ Remove the part together with the intake hose. 3. Blow-by hose
4. Intake pipe
5. Barometric pressure sensor
9. 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.
1. Air cleaner assembly
Mechanical (4JJ1) 1B-5
4. Remove the battery from vehicle. 2. Remove the radiator reserve tank from the upper fan
guide.
1. Battery cable
2. Battery bracket 13. A/C compressor drive belt removal
3. Earth 1. Remove the A/C compressor drive belt from the
10. Fuse box disconnect pulley.
1. Glove box
2. Instrument panel assist side lower cover
24. Fuel hose disconnect
21. Instrument panel assist-side lower cover removal 1. Disconnect the fuel hose from the fuel supply pump.
1. Remove the instrument panel assist-side lower cover 2. Disconnect the fuel hose from the fuel leak-off pipe.
from the instrument panel.
Caution:
Note:
・ Cover the exposed portion and do not allow
・ Remove the 4 screws. foreign materials to get into the fuel system.
1. Bracket
1. Bracket
2. Connect the catalyst converter to the catalyst Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
converter bracket. Bolt 1, 3
Note: Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }
・ Temporarily tighten the nuts and bolts in the Bolt 2
order shown in the diagram. 7. Catalyst converter connect
1. Connect the catalyst converter to the front exhaust
pipe.
Tightening torque: 67 N・m { 6.8 kgf・m / 49 lb・ft }
Note:
・ Firmly tighten the nuts and bolts in the order
shown in the diagram.
1. Glove box
10. ECM connect
2. Instrument panel assist side lower cover
1. Connect the harness to the frame.
13. Fan shroud installation
Note:
1. Install the fan guide to the radiator.
・ Pull in the harness toward inside the room.
Note:
2. Connect the harness connector to the ECM.
・ Install the lower fan guide together with the fan
11. Instrument panel assist-side lower cover installation shroud.
1. Install the instrument panel assist-side lower cover to 14. Cooling fan installation
the instrument panel.
1. Install the cooling fan to the fan clutch assembly.
Note:
Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }
・ Install the 4 screws.
Mechanical (4JJ1) 1B-13
Measurement point 3
Frequency of
1. Bolt Amount of flex
vibrations
2. Clip
For a
: 12.4 to 16.4 mm
Note: new : 92 to 112 Hz
{ 0.488 to 0.646 in }
・ The following applies to 4WD. product
When : 16.5 to 19.1 mm
2. Install the front under guard to the frame. : 80 to 92 Hz
reused { 0.650 to 0.752 in }
Note:
Measurement point 4
・ Tighten the 4 bolts.
Frequency of
3. Install the rear under guard to the frame. Amount of flex
vibrations
Mechanical (4JJ1) 1B-17
For a
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in }
product
When : 20.7 to 23.7 mm
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
Note:
・ In the case of adjustment using a frequency
meter
・ Measure the frequency at measurement points
2, 3, and 4 with a frequency meter.
Measurement point 2
Frequency of
Amount of flex
vibrations
For a
: 12.5 to 16.5 mm
new : 92 to 112 Hz
{ 0.492 to 0.650 in }
product
1. Measurement point 1
When : 16.5 to 19.1 mm 2. Measurement point 2
: 79 to 91 Hz
reused { 0.650 to 0.752 in } 3. Measurement point 3
4. Measurement point 4
Measurement point 3
Frequency of Note:
Amount of flex
vibrations ・ After adjusting the tension, tighten the
For a tensioner fixing nut.
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in } Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }
product
When : 16.5 to 19.1 mm 31. Cooling fan belt adjustment
: 80 to 92 Hz
reused { 0.650 to 0.752 in } 1. Adjust tension to a standard value using a tension
meter.
Measurement point 4
Frequency of Note:
Amount of flex
vibrations ・ Move the generator to adjust the tension.
For a 2. Check tension of the cooling fan belt.
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in } Note:
product
When : 20.7 to 23.7 mm ・ When adjusting the amount of flex to the
: 62 to 70 Hz original value
reused { 0.815 to 0.933 in }
・ Apply a load to measurement point 1 of the
cooling fan belt and adjust the amount of flex.
Load: 98 N { 10 kg / 22 lb }
Note:
・ In the case of adjustment using a frequency
meter
・ Measure the frequency at measurement point
1 with a frequency meter.
Position of the belt tension
Fluctuation Frequency
: 5.4 to 6.6 mm
New : 188 to 210 Hz
{ 0.213 to 0.260 in }
: 7.7 to 8.5 mm
Reuse : 160 to 174 Hz
{ 0.303 to 0.335 in }
1B-18 Mechanical (4JJ1)
Note:
・ Press the priming pump until it gets stiff.
1. Measurement point 1
2. Measurement point 2
3. Measurement point 3
4. Measurement point 4 1. Priming pump
2. Fuel filter with the sedimenter
Note:
Caution:
・ After adjusting the tension, tighten the adjust
plate lock bolt and the mounting bolt under the ・ Insufficient air removal work may lead
generator. malfunction of the engine.
34. Battery ground cable connect
Generator tightening torque
: 40 N・m { 4.1 kgf・m / 1. Connect the battery ground cable to the battery.
Mounting bolt
30 lb・ft } 2. Close the engine hood assembly.
: 25 N・m { 2.5 kgf・m /
Adjust plate lock bolt 3. Lower vehicle.
18 lb・ft }
35. ECM setting
Note:
・ If the cooling fan belt is replaced with a new Note:
one, make the new cooling fan belt fit in to ・ When replacing the engine assembly, writing
cope with initial elongation. the injector ID codes into the ECM is required.
・ After making the cooling fan belt fit in, adjust 1. Check the Injector ID Code of the cylinder head
its tension once again. cover.
32. Coolant filling Note:
1. Replenish the radiator with coolant. ・ Record the injector ID codes from the cylinder
head cover labels.
Note:
・ Use the coolant contains 50 % anti-freeze
solution.
・ Pour coolant up to the filler neck.
2. Replenish the radiator reserve tank with coolant.
Note:
・ Pour coolant up to the MAX line.
3. Install the radiator cap to the radiator.
33. Fuel air bleed
1. Press the priming pump.
Mechanical (4JJ1) 1B-19
3. Check the Data List of a scan tool.
Note:
・ Confirm that the coolant temperature display is
at the standard value or higher.
Standard: 65 ℃ { 149 °F }
4. Check the Data List of a scan tool.
Note:
・ Confirm that the Fuel Supply Pump Learning
Status display changes from Not Learned to
Learned.
5. Check the DTC of a scan tool.
Note:
・ Confirm that the scan tool does not detect a
DTC.
1. Cylinder No. 1 injector ID code
2. Cylinder No. 2 injector ID code
3. Cylinder No. 3 injector ID code
4. Cylinder No. 4 injector ID code
5. Injector ID code label
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Engine cover removal
1. Remove the engine cover from the engine.
1. Engine cover
Caution:
・ Do not reuse the clip of the fuel leak-off hose.
7. Vacuum pipe removal
2. Remove the leak-off pipe from the injector.
1. Remove the vacuum pipe from the cylinder head
cover.
1B-22 Mechanical (4JJ1)
installation
1. Oil seal installation
1. Apply the engine oil to the oil seal.
2. Install the oil seal to the cylinder head cover.
Note:
・ Install from the bottom of the cylinder head
cover and insert all the way in.
2. Cam end gasket installation
1. Apply liquid gasket to the cam end gasket.
Note:
・ Apply ThreeBond 1207B to the area indicated
in the diagram.
Bead width: 2.0 to 3.0 mm { 0.079 to 0.118 in }
1. 3.0 - 5.0 mm {0.118 - 0.197 in}
2. 3.0 - 5.0 mm {0.118 - 0.197 in}
1. Leak-off pipe
2. Clip
1. Leak-off pipe
2. Clip
Caution:
・ Do not reuse the leak-off pipe and the clip.
6. Injector connect
1. Connect the harness connector to the injector.
7. Vacuum pipe installation
1. Install the vacuum pipe to the cylinder head cover.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
8. Bracket installation
1. Install the bracket to the cylinder head cover.
10. Boost sensor connect
Mechanical (4JJ1) 1B-25
1. Connect the connector to the boost sensor.
1. Engine cover
11. Intake air duct installation 13. Battery ground cable connect
1. Install the intake air duct to the turbocharger and the 1. Connect the battery ground cable to the battery.
intake hose.
2. Close the engine hood assembly.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Bolt
Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in }
Clip
removal Note:
・ Remove the part together with the intake hose.
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Engine cover removal
1. Remove the engine cover from the engine.
installation
1. Intake throttle valve installation
1. Install the gasket to the intake throttle valve.
2. Install the intake throttle valve to the inlet manifold.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
1. Engine cover
Exhaust manifold
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
3. Coolant drain
1. Drain coolant from the radiator.
Note:
・ Open the drain plug at the bottom of the
radiator.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts. 2. Remove the radiator cap from the radiator.
3. Remove the rear under guard from the frame. Warning:
Note: ・ In order to prevent burns, do not open the cap
・ Remove the 4 bolts. when the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Engine cover removal
1. Remove the engine cover from the engine.
1B-30 Mechanical (4JJ1)
4. Disconnect the intake pipe from the turbocharger
assembly.
5. Remove the air cleaner assembly from vehicle.
1. Engine cover
inspection
1. Exhaust manifold measurement
1. Align a simple straight ruler to the exhaust manifold.
Note:
・ Align the simple straight ruler as shown in the
diagram below.
2. Measure deformation using a feeler gauge.
Note:
・ Use the feeler gauge to measure deformation
of the exhaust manifold.
Standard: 0.3 mm { 0.01 in } The following applies.
Limit: 0.5 mm { 0.02 in }
Note:
・ Replace the exhaust manifold if it exceeds the
limit.
1. Projection
1. Stub bolt
2. Washer
3. Nut
Mechanical (4JJ1) 1B-37
10. Turbocharger feed oil pipe installation 1. Water feed and return pipes
2. Turbocharger water feed hose
1. Install the turbocharger feed oil pipe to the
3. Water pipe
turbocharger and the oil cooler.
4. Turbocharger water feed hose
Tightening torque: 23 N・m { 2.3 kgf・m / 17 lb・ft } 5. Turbocharger water return hose
18. Vacuum hose installation 2. Connect the intake pipe to the turbocharger
assembly.
1. Install the vacuum hose to the turbocharger and the
vacuum pipe. Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in }
3. Connect the vacuum hose to the air cleaner
assembly.
4. Connect the harness connector to the barometric
pressure sensor.
5. Connect the harness connector to the MAF sensor.
20. Blow-by hose connect
1. Connect the blow-by hose to the cylinder head cover.
21. Intake air duct installation
1. Install the intake air duct to the turbocharger and the
intake hose.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Bolt
Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in }
Clip
19. Air cleaner assembly installation
1. Install the air cleaner assembly to vehicle.
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }
1B-42 Mechanical (4JJ1)
1. Engine cover
Timing chain
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Crankshaft adjustment
1. Align the No.1 cylinder to compression top dead
center.
Note:
・ Rotate the crankshaft and align to the
compression top dead center (TDC).
1. Engine cover
9. Injector disconnect
1. Disconnect the connector from the injector.
7. Bracket removal 10. Fuel leak-off hose removal
1. Disconnect the vacuum hose from the turbocharger 1. Remove the fuel leak-off hose from the leak-off
control solenoid valve. pipe.
2. Disconnect the connector from the turbocharger
control solenoid valve.
3. Remove the bracket from the cylinder head cover.
Note:
・ Remove the part together with the
turbocharger control solenoid valve.
1B-46 Mechanical (4JJ1)
15. Timing chain lower cover removal 17. Timing chain upper cover removal
1. Remove the timing chain lower cover from the gear 1. Remove the timing chain upper cover from the
case cover. cylinder head.
2. Remove the baffle plate from the cylinder head. 2. Remove the camshaft bearing cap from the cylinder
head.
Note:
・ Confirm that it is marked.
installation
1. Crankshaft adjustment
1. Align the No.1 cylinder to compression top dead
center.
Note:
・ Rotate the crankshaft and align to the
compression top dead center (TDC).
Note:
・ Align the two timing marks as indicated in the
diagram.
1. Pin
2. Plunger
3. Latch
4. Timing chain tensioner 6. Exhaust camshaft installation
5. Hook
1. Install the exhaust camshaft to the cylinder head.
2. Install the timing chain tensioner to the cylinder Note:
head.
・ Align the timing mark to the idle gear D to
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in } install it.
Mechanical (4JJ1) 1B-53
3. Install the camshaft bearing cap to the cylinder head.
4. Install the bolt to the camshaft bearing cap.
5. Align the camshaft to the alignment mark.
Note:
・ Align the marks of inlet camshaft and the
exhaust camshaft to the mark of the bearing
cap.
1. CMP sensor
1. Liquid gasket
2. Bead height
3. Bead width
1. Cam end gasket
2. Install the timing chain lower cover to the gear case 2. Application area
cover. 3. Bead width
Mechanical (4JJ1) 1B-57
2. Install the cam end gasket to the cylinder head. 1. Install the leak-off pipe to the injector.
16. Cylinder head cover installation
1. Apply liquid gasket to the cylinder head.
Note:
・ Apply ThreeBond 1207B to the area indicated
in the diagram.
1. Leak-off pipe
2. Clip
1. Leak-off pipe
2. Clip
Caution:
・ Do not reuse the leak-off pipe and the clip.
19. Injector connect
1. Connect the harness connector to the injector.
20. Vacuum pipe installation
1. Install the vacuum pipe to the cylinder head cover.
17. Blow-by hose connect
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1. Connect the blow-by hose to the cylinder head cover.
21. Bracket installation
18. Fuel leak-off hose installation
1. Install the bracket to the cylinder head cover.
1B-58 Mechanical (4JJ1)
Note: 1. Connect the connector to the boost sensor.
・ Install the part together with the turbocharger
control solenoid.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1. Engine cover
Camshaft
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Crankshaft adjustment
1. Align the No.1 cylinder to compression top dead
center.
Note:
・ Rotate the crankshaft and align to the
compression top dead center (TDC).
1. Engine cover
9. Injector disconnect
1. Disconnect the connector from the injector.
7. Bracket removal 10. Fuel leak-off hose removal
1. Disconnect the vacuum hose from the turbocharger 1. Remove the fuel leak-off hose from the leak-off
control solenoid valve. pipe.
2. Disconnect the connector from the turbocharger
control solenoid valve.
3. Remove the bracket from the cylinder head cover.
Note:
・ Remove the part together with the
turbocharger control solenoid valve.
1B-62 Mechanical (4JJ1)
2. Remove the baffle plate from the cylinder head. 2. Remove the camshaft bearing cap from the cylinder
head.
Note:
・ Confirm that it is marked.
inspection
1. Inlet camshaft inspection
1. Inspect the inlet camshaft.
Note:
・ Inspect the camshaft journal and the cam for
worn and damage.
・ Replace if there are abnormalities.
2. Inlet camshaft measurement
1. Measure the clearance using a feeler gauge.
Note:
・ Measure the clearance of the camshaft gear
and camshaft bracket in the axis direction.
・ Replace the camshaft gear or camshaft if the
measured value exceeds the limit.
3. Measure the camshaft journal using the micrometer.
Standard: 0.050 to 0.170 mm { 0.002 to 0.007 in }
Note:
Limit: 0.25 mm { 0.010 in }
・ Measure the diameter of the camshaft journal.
Note:
Standard: 29.909 to 29.930 mm { 1.1775 to 1.1783 in }
・ Measure the clearance of the camshaft in the
axis direction prior to disassembly. Limit: 29.809 mm { 1.1736 in }
Note:
・ Measure uneven worn with the camshaft
journal.
Limit: 0.05 mm { 0.0020 in }
Note:
・ Replace the camshaft if the worn exceeds the
limit.
Note:
・ Replace the camshaft bearing if the measured
oil clearance exceeds the limit.
Mechanical (4JJ1) 1B-67
Limit: 0.05 mm { 0.0020 in }
Note:
・ Replace the camshaft if the worn exceeds the
limit.
1. Leak-off pipe
2. Clip
1. Engine cover
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Engine hood assembly removal
1. Open the engine hood.
Note:
・ Support the engine hood.
2. Remove the hinge bolt from the engine hood.
Note:
・ Before removing the hinge from the engine
hood, put a marking of the hinge location for
putting the hinge back in place. 1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts.
3. Remove the rear under guard from the frame.
Note:
・ Remove the 4 bolts.
1. Battery cable
2. Battery bracket
3. Earth
19. Battery removal 1. Disconnect the radiator reserve tank hose from the
radiator.
1. Disconnect the battery ground cable from the frame.
2. Remove the radiator reserve tank from the upper fan
2. Disconnect the battery cable from the battery. guide.
3. Remove the battery bracket from the frame.
4. Remove the battery from vehicle.
1B-78 Mechanical (4JJ1)
1. Turbocharger feed oil pipe 3. Remove the catalyst converter bracket from the rear
cover.
55. Oil return pipe removal
Note:
1. Remove the oil return pipe from the turbocharger
・ Remove the exhaust side from the engine
and the crankcase.
side.
・ Remove the engine side from the crankcase.
59. Water intake pipe removal 2. Remove the water bypass pipe from the cylinder
head assembly.
1. Remove the water intake pipe from the oil filter and
the oil cooler assembly. Note:
Note: ・ Remove the water bypass pipe on the cylinder
head side.
・ Remove it with the hose attached.
2. Remove the baffle plate from the cylinder head. 2. Remove the camshaft bearing cap from the cylinder
head.
Note:
・ Confirm that it is marked.
1. Nut
2. Bolt
disassembly
1. Sprocket removal
1. Remove the sprocket from the idle gear D.
Note:
・ Remove the wire from the engine hanger and
hoist, and remove the engine hanger.
・ Remove both the front engine hanger and rear
engine hanger together.
3. EGR valve removal
1. Remove the EGR valve from the inlet manifold.
Mechanical (4JJ1) 1B-95
1. Valve spring compressor lever 14. Valve stem oil seal removal
2. Valve spring compressor pivot
1. Remove the valve stem oil seal from the cylinder
10. Spring upper seat removal head using a pliers.
inspection Caution:
・ Do not allow to regrind the bottom surface of
1. Cylinder head assembly measurement the cylinder head.
1. Align a simple straight ruler to the cylinder head. Note:
Note: ・ Measure the height of the cylinder head.
・ Align the simple straight ruler as shown in the Standard: 143.4 mm { 5.646 in } Reference
diagram below.
2. Measure deformation using a feeler gauge.
Note:
・ As shown in the diagram, measure the four
sides and two diagonal lines with a feeler
gauge.
・ Replace the cylinder head if the deformation of
the bottom surface of the cylinder head
exceeds the limit.
1. Washer
2. Valve seat insert
3. Press
reassembly
1. Oil seal installation
1. Install the oil seal to the cylinder head using special
tool.
Note:
・ Install it to the injection pipe insertion surface
using the oil seal installer.
・ Tap the seal so that it is not slanted.
Caution:
・ Be careful not to damage the lip section.
1. Cylinder head
2. Oil seal installer
Caution:
・ Move it up and down to confirm that it moves
smoothly.
10. Valve stem end cap installation
1. Install the valve stem end cap to the split collar. 1. Stub bolt
11. Exhaust manifold installation 2. Washer
3. Nut
1. Install the gasket to the engine.
3. Securely tighten the exhaust manifold to the cylinder
Note:
head.
・ Assemble the projection section to the rear
side of the cylinder head. Note:
・ Tighten the 8 nuts according to the order given
in the diagram.
Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft }
Mechanical (4JJ1) 1B-107
Caution: Note:
・ Avoid tightening too much because doing so ・ Temporarily tighten the nuts and bolts in the
may hamper expansion and contraction of the order of 2, 1, 4, 5, 3 as shown in the diagram.
manifold due to heat.
3. Securely tighten the EGR cooler to the cylinder head
and the exhaust manifold.
Note:
・ Completely tighten the nuts and bolts in the
order of 4, 5, 2, 1, 3 as shown in the diagram.
Tightening torque of the EGR cooler
Bolts and nuts : 27 N・m { 2.8 kgf・m /
1, 2, 4, 5 20 lb・ft }
: 25 N・m { 2.5 kgf・m /
Bolt 3
18 lb・ft }
Note:
・ Feed 0.5 cc engine oil from the oil filler.
13. EGR cooler installation
1. Install the gasket to the EGR cooler.
2. Temporarily tighten the EGR cooler to the cylinder
head and the exhaust manifold.
1B-108 Mechanical (4JJ1)
installation
1. Cylinder head gasket preparation
1. Select the cylinder head gasket.
Note:
・ Select the grade for the cylinder head gasket
by measuring the protrusion amount of the
piston head.
・ Three types of gaskets with different thickness
are provided.
・ Select the appropriate grade from three types
of gaskets following the following steps.
・ Before measurement, remove carbon from the
piston head and the cylinder block surface,
and clean the gasket installation portion.
2. Measure the piston using a dial gauge.
Note:
Note:
・ Measure the point 1, 2, 3, and 4 to calculate
・ Measure the protrusion amount of the piston the difference between 1 and, 2, and between
head. 3 and 4 of each cylinder.
3. Calculate average value from measured value.
Note:
・ Calculate the average value for the protrusion
amount of the piston head for each cylinder.
・ Determine the grade of the gasket required for
the maximum value mentioned above
according to the following table.
Note:
・ Refer to the diagram for the measurement
position of the protrusion amount.
・ Make sure that all measuring points are
located as close to the cylinder block as
possible.
1. Measurement point
2. Measurement point
3. Measurement point
4. Measurement point
Note:
・ Cylinder head gasket combination
1B-110 Mechanical (4JJ1)
1. Bead height
2. Bead width
Caution:
・ After applying the liquid gasket, install the
cylinder head within 5 minutes.
3. Cylinder head assembly installation
1. Install the cylinder head assembly to the cylinder
block.
Note:
・ Wipe off the bottom surface of the cylinder
head.
・ Adjust the cylinder block dowel to install the
cylinder head.
2. Install the head bolt to the cylinder head.
Note: Caution:
・ The difference in the protrusion amount of ・ Use new head bolts.
each piston should not exceed 0.05 mm {0.002
in}.
2. Cylinder head gasket installation
1. Apply liquid gasket to the cylinder block.
Note:
・ Apply ThreeBond-1207B or equivalent to the
cylinder block as shown in the diagram.
Bead height: 2 to 3 mm { 0.079 to 0.118 in }
Bead width: 3 to 4 mm { 0.118 to 0.157 in }
Mechanical (4JJ1) 1B-111
3. Tighten the head bolt using a torque wrench.
Note:
・ Tighten the head bolts in the order shown in
the diagram.
Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft }
4. Tighten the head bolt using a torque wrench.
Note:
・ Tighten the head bolts in the order shown in
the diagram.
Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft }
5. Tighten the head bolt using special tool.
Note:
・ Tighten the head bolts in the order shown in
the diagram using an angle gauge.
9. Remove the wire from the engine hanger and the
hoist.
10. Remove the rear engine hanger from the cylinder
head.
5. Rocker arm shaft assembly installation 7. Timing chain tension lever installation
1. Apply the engine oil to the rocker arm shaft 1. Install the timing chain tension lever to the cylinder
assembly. head.
2. Install the rocker arm shaft assembly to the cylinder Note:
head.
・ Place the timing chain tension lever in
Note: between the timing gear case and the cylinder
・ Install the rocker arm shaft assemblies from block.
No. 1 to No. 4 in the numbering order. 8. Timing chain installation
Tightening torque: 21 N・m { 2.1 kgf・m / 15 lb・ft } 1. Install the timing chain to the idle gear D.
9. Idle gear D installation
1. Apply the engine oil to the idle gear shaft.
Note:
・ Apply it to the surface and inside.
2. Apply the engine oil to the bolt.
Note:
・ Apply it to the threaded portion and the seat
surface.
3. Install the idle gear D to the cylinder head.
Note:
・ Install the timing chain onto the sprocket of idle
gear D, and then install idle gear D.
Tightening torque: 59 N・m { 6.0 kgf・m / 44 lb・ft }
1. Surface and inside of the idle gear shaft 11. Timing chain tensioner installation
2. Threaded portion and seat surface of the bolt
1. Connect the hook to the pin.
Note: Note:
・ Align the two timing marks as indicated in the ・ Keep the state that the latch is pushed.
diagram.
・ Insert the plunger.
・ Install the hook to the pin, and fasten the
plunger.
1. Timing chain
2. Timing mark
3. Blue link
4. Yellow link 1. Pin
2. Plunger
10. Timing chain lever pivot installation 3. Latch
4. Timing chain tensioner
1. Install the timing chain lever pivot to the timing
5. Hook
chain tension lever.
Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft } 2. Install the timing chain tensioner to the cylinder
head.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
1B-114 Mechanical (4JJ1)
3. Disconnect the hook from the pin. 13. Inlet camshaft installation
Note: 1. Install the inlet camshaft to the cylinder head.
・ Lightly push the area indicated with an arrow Note:
in the diagram.
・ Align the timing mark to the idle gear D to
・ The hook of the tensioner opens, the plunger install it.
pushes the tension lever, and the chain is
pulled.
1. Liquid gasket
2. Bead height
3. Bead width
Note:
・ Apply LOCTITE 262 or equivalent to the
threaded portion on the cylinder head side.
2. Install the timing chain upper cover to the cylinder
head.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. CMP sensor
1. Liquid gasket
2. Bead height
3. Bead width
1. Noise cover
2. Install the cylinder head cover to the cylinder head. 2. Install the fuel leak-off hose to the leak-off pipe.
Note:
・ Tighten in the order in the diagram.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
1. Leak-off pipe
2. Clip
Caution:
24. Vacuum pipe installation ・ Do not reuse the leak-off pipe and the clip.
1. Install the vacuum pipe to the cylinder head cover. 26. Injector connect
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Connect the harness connector to the injector.
25. Fuel leak-off hose installation 27. Oil filter bracket installation
1. Install the leak-off pipe to the injector. 1. Install the oil filter bracket to the oil filter and the
engine hanger.
1B-120 Mechanical (4JJ1)
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 29. Water intake pipe installation
28. Water bypass pipe installation 1. Temporarily tighten the pipe bracket to the water
intake pipe.
1. Install the water bypass pipe to the cylinder head
assembly. 2. Install the water intake pipe to the oil filter.
Note: Note:
・ Install the water bypass pipe on the cylinder ・ Insert the water intake pipe into the oil filter.
head side. ・ Apply soapy water on the O-ring when
・ Apply soapy water on the O-ring when inserting the pipe.
inserting the pipe.
3. Temporarily tighten the water intake pipe to the oil
cooler and the generator bracket.
Note:
・ Temporarily tighten the nuts and bolts in the
order shown in the diagram.
Note:
・ Firmly tighten the nuts and bolts in the order
shown in the diagram.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 34. Turbocharger feed oil pipe installation
Bolt 1, 3
1. Install the turbocharger feed oil pipe to the
Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft } turbocharger and the oil cooler.
Bolt 2
Tightening torque: 23 N・m { 2.3 kgf・m / 17 lb・ft }
32. Catalyst converter connect
1. Connect the catalyst converter to the front exhaust
pipe.
Tightening torque: 67 N・m { 6.8 kgf・m / 49 lb・ft }
1. Water feed and return pipes Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
2. Turbocharger water feed hose Bolt 1
3. Water pipe
Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }
4. Turbocharger water feed hose
Bolt 2
5. Turbocharger water return hose
37. Exhaust manifold heat protector installation
36. Air duct bracket installation
1. Install the exhaust manifold heat protector to the
1. Temporarily tighten the air duct bracket to the exhaust manifold.
cylinder head assembly.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Note:
・ Temporarily tighten the nuts and bolts in the
order shown in the diagram.
2. Connect the turbocharger water feed hose to the 1. Glow plug terminal
outlet pipe. 2. Glow plug connector
44. Glow plug installation 46. Bracket installation
1. Install the glow plug to the cylinder head. 1. Install the bracket to the cylinder head cover.
Tightening torque: 18 N・m { 1.8 kgf・m / 13 lb・ft } Note:
・ Install the part together with the turbocharger
control solenoid.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1B-126 Mechanical (4JJ1)
2. Connect the connector to the turbocharger control 49. Fuel hose connect
solenoid.
1. Connect the fuel hose to the fuel supply pump.
3. Connect the vacuum hose to the turbocharger control
solenoid.
47. Leak-off pipe installation
1. Install the leak-off pipe to the fuel supply pump and
the common rail assembly.
Tightening torque: 10.3 N・m { 1.1 kgf・m / 91 lb・
in }
1. Fuel hose
For a
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in }
product
When : 20.7 to 23.7 mm
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
Note:
・ In the case of adjustment using a frequency
meter
・ Measure the frequency at measurement points
2, 3, and 4 with a frequency meter.
Measurement point 2
Frequency of
Amount of flex
vibrations
For a
: 12.5 to 16.5 mm
new : 92 to 112 Hz
{ 0.492 to 0.650 in }
product
1. A/C compressor drive belt
When : 16.5 to 19.1 mm
: 79 to 91 Hz
65. A/C compressor drive belt adjustment reused { 0.650 to 0.752 in }
1. Adjust tension to a standard value using a tension Measurement point 3
meter.
Frequency of
Amount of flex
Note: vibrations
・ When adjusting the amount of flex to the For a
: 12.4 to 16.4 mm
original value new : 92 to 112 Hz
{ 0.488 to 0.646 in }
・ Apply a load to measurement points 2, 3, and product
4 of the A/C compressor drive belt and adjust When : 16.5 to 19.1 mm
: 80 to 92 Hz
the amount of flex. reused { 0.650 to 0.752 in }
Load: 98 N { 10 kg / 22 lb } Measurement point 4
Measurement point 2 Frequency of
Amount of flex
Frequency of vibrations
Amount of flex For a
vibrations : 15.9 to 20.7 mm
For a new : 70 to 86 Hz
: 12.5 to 16.5 mm { 0.626 to 0.815 in }
new : 92 to 112 Hz product
{ 0.492 to 0.650 in } When : 20.7 to 23.7 mm
product : 62 to 70 Hz
When : 16.5 to 19.1 mm reused { 0.815 to 0.933 in }
: 79 to 91 Hz
reused { 0.650 to 0.752 in }
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
Mechanical (4JJ1) 1B-131
68. Radiator reserve tank installation
1. Install the radiator reserve tank to the upper fan
guide.
Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }
1. Measurement point 1
2. Measurement point 2
3. Measurement point 3
4. Measurement point 4
Note:
2. Connect the radiator reserve tank hose to the
・ After adjusting the tension, tighten the
radiator.
tensioner fixing nut.
Note:
Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }
・ When the radiator reserve tank is dirty, clean it
66. Generator connect before installation.
1. Connect the harness to the generator. ・ Clean the radiator reserve tank using
detergent.
Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・
in } Terminal nut ・ Scrub inside with a detergent and water.
・ Wash with clean water, and drain the water.
67. Generator cover installation
69. Radiator upper hose installation
1. Install the generator cover to the bracket and the
adjust plate. 1. Install the radiator upper hose to the water outlet
pipe and the radiator.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
Tightening torque: 5 N・m { 0.5 kgf・m / 44 lb・in }
Hose clip
1B-132 Mechanical (4JJ1)
1. Install the intake air duct to the intake throttle valve
and the intake hose.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
Bolt
Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in }
Clip
1. Battery cable
2. Battery bracket
3. Earth
Note:
・ Turn the hood rest to adjust its height, and
adjust the level difference against the engine
hood.
1. 29 mm (1.14 in)
Mechanical (4JJ1) 1B-135
1. Engine cover
1. Hood rest
Flywheel
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Transmission assembly removal SST: 5-8840-0214-0 - crankshaft stopper
inspection Note:
・ Inspect the flywheel installation bolts.
1. Flywheel inspection
・ Replace with a new one if it is significantly
1. Inspect the flywheel. damaged.
Note: ・ Inspection of flywheel for MUX for worn
・ Inspect for cracks, worn, and damage. 2. Inspect the flywheel.
Replace if there are abnormalities.
Note:
2. Ring gear inspection ・ Visually confirm the worn status.
1. Inspect the ring gear. ・ If any significant damage or worn is found,
Note: replace the flywheel.
・ Inspect the tooth surfaces. Replace the ring ・ Inspect the flywheel installation bolts.
gear if it is damaged or significantly worn. ・ Replace with a new one if it is significantly
damaged.
3. Flywheel measurement
Note:
・ Inspection of flywheel for MUA for worn
1. Measure the flywheel using a vernier caliper.
Note:
・ Measure the depth of the flywheel friction
surface.
・ Adjust it if the measured value is out of the
standard value or exceeds the limit.
・ If the measured value exceeds the limit, the
flywheel must be replaced.
Standard: 18 mm { 0.7087 in }
Limit: 19 mm { 0.7480 in }
Note:
・ The depth from the pressure plate installation
surface to the friction surface is indicated.
installation
1. Ring gear installation
1. Heat the ring gear with the gas burner.
Note:
・ Uniformly heat the ring gear using the gas
burner. SST: 5-8522-0024-0 - pilot bearing installer
Heating temperature: 200 ℃ or less { 392 °F or less }
3. Flywheel installation
2. Install the ring gear to the flywheel. 1. Apply the engine oil to the bolt.
Note: Note:
・ Install it with the chamfered side of the ring ・ Apply it to the threaded portion of the bolt.
gear facing the front.
・ Install the ring gear so that the pattern side 2. Temporarily tighten the flywheel to the crankshaft.
faces toward front. Note:
・ After shrink-fitting, confirm that the ring gear is ・ Temporarily tighten the nuts and bolts in the
airtight against the flywheel. order shown in the diagram.
2. Pilot bearing installation
1. Put the pilot bearing on the flywheel.
Note:
・ Place the pilot bearing so that it crosses
perpendicular to the crankshaft bearing
installation hole.
2. Install the pilot bearing to the flywheel using special
tool.
Note:
・ Hit the pilot bearing outer race with a brass
hammer using a pilot bearing installer, and
then hit the bearing in the crankshaft bearing
installation hole.
Mechanical (4JJ1) 1B-141
Note:
・ For automatic transmission vehicles, install the
sleeve, flywheel, flexible plate, washer in that
order, and temporarily tighten the order in the
diagram.
3. Install special tool to the rear plate.
Note:
・ Install the crankshaft stopper to the starter
installation section of the rear plate.
4. Securely tighten the flywheel to the crankshaft. Refer to "5.Transmission, Transaxle 5E.Clutch
System(MUA) Clutch assembly installation".
Note:
Refer to "5.Transmission, Transaxle 5E.Clutch
・ Tighten in the order in the diagram. System(MUX) Clutch assembly installation".
Tightening torque: 59 N・m { 6.0 kgf・m / 44 lb・ft } 5. Transmission assembly installation
Refer to "5.Transmission, Transaxle
5B.Automatic(TB-50LS) Transmission
assembly installation".
6. Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
3. Lower vehicle.
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
3. Coolant drain
1. Drain coolant from the radiator.
Note:
・ Open the drain plug at the bottom of the
radiator.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts. 2. Remove the radiator cap from the radiator.
3. Remove the rear under guard from the frame. Warning:
Note: ・ In order to prevent burns, do not open the cap
・ Remove the 4 bolts. when the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Engine cover removal
1. Remove the engine cover from the engine.
Mechanical (4JJ1) 1B-143
6. Intake air duct removal
1. Remove the intake air duct from the turbocharger
and the intercooler.
Note:
・ Remove the part together with the intake hose.
1. Engine cover
1. Standard value
For a
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in }
product
When : 20.7 to 23.7 mm
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
Note:
・ In the case of adjustment using a frequency
meter
・ Measure the frequency at measurement points
2, 3, and 4 with a frequency meter.
Measurement point 2
Frequency of
Amount of flex
vibrations
For a
: 12.5 to 16.5 mm
new : 92 to 112 Hz
{ 0.492 to 0.650 in }
product
1. A/C compressor drive belt
When : 16.5 to 19.1 mm
: 79 to 91 Hz
9. A/C compressor drive belt adjustment reused { 0.650 to 0.752 in }
1. Adjust tension to a standard value using a tension Measurement point 3
meter.
Frequency of
Amount of flex
Note: vibrations
・ When adjusting the amount of flex to the For a
: 12.4 to 16.4 mm
original value new : 92 to 112 Hz
{ 0.488 to 0.646 in }
・ Apply a load to measurement points 2, 3, and product
4 of the A/C compressor drive belt and adjust When : 16.5 to 19.1 mm
: 80 to 92 Hz
the amount of flex. reused { 0.650 to 0.752 in }
Load: 98 N { 10 kg / 22 lb } Measurement point 4
Measurement point 2 Frequency of
Amount of flex
Frequency of vibrations
Amount of flex For a
vibrations : 15.9 to 20.7 mm
For a new : 70 to 86 Hz
: 12.5 to 16.5 mm { 0.626 to 0.815 in }
new : 92 to 112 Hz product
{ 0.492 to 0.650 in } When : 20.7 to 23.7 mm
product : 62 to 70 Hz
When : 16.5 to 19.1 mm reused { 0.815 to 0.933 in }
: 79 to 91 Hz
reused { 0.650 to 0.752 in }
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
1B-150 Mechanical (4JJ1)
11. Radiator upper hose installation
1. Install the radiator upper hose to the water outlet
pipe and the radiator.
Tightening torque: 5 N・m { 0.5 kgf・m / 44 lb・in }
Hose clip
1. Measurement point 1
2. Measurement point 2
3. Measurement point 3
4. Measurement point 4
Note:
・ After adjusting the tension, tighten the
1. Radiator upper hose
tensioner fixing nut.
Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft } 12. Radiator reserve tank installation
10. Fan guide installation 1. Install the radiator reserve tank to the upper fan
guide.
1. Install the fan guide to the radiator.
Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }
Note:
・ Install the upper fan guide.
・ Clean the radiator reserve tank using 1. Connect the connector to the boost sensor.
detergent.
・ Scrub inside with a detergent and water.
・ Wash with clean water, and drain the water.
13. Generator cover installation
1. Install the generator cover to the bracket and the
adjust plate.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
1. Engine cover
Mechanical (4JJ1) 1B-153
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Transmission assembly removal SST: 5-8840-0214-0 - crankshaft stopper
installation 1. Install the rear plate to the cylinder block and the
crankcase.
1. Oil seal retainer installation
Tightening torque: 82 N・m { 8.4 kgf・m / 60 lb・ft }
1. Apply liquid gasket to the oil seal retainer.
Note:
・ Apply ThreeBond 1207C or equivalent.
Caution:
・ After applying the liquid gasket, install it within
5 minutes.
2. Rear plate installation
1. 12.2 – 12.8 mm {0.48 – 0.50 in}
Mechanical (4JJ1) 1B-157
4. Flywheel installation
1. Apply the engine oil to the bolt.
Note:
・ Apply it to the threaded portion of the bolt.
2. Temporarily tighten the flywheel to the crankshaft.
Note:
・ Temporarily tighten the nuts and bolts in the
order shown in the diagram.
Note:
・ For automatic transmission vehicles, install the
sleeve, flywheel, flexible plate, washer in that
order, and temporarily tighten the order in the
diagram.
3. Install special tool to the rear plate.
Note:
・ Install the crankshaft stopper to the starter
installation section of the rear plate.
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Engine hood assembly removal
1. Open the engine hood.
Note:
・ Support the engine hood.
2. Remove the hinge bolt from the engine hood.
Note:
・ Before removing the hinge from the engine
hood, put a marking of the hinge location for
putting the hinge back in place. 1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts.
3. Remove the rear under guard from the frame.
Note:
・ Remove the 4 bolts.
1. Battery cable
2. Battery bracket
3. Earth
19. Battery removal 1. Disconnect the radiator reserve tank hose from the
radiator.
1. Disconnect the battery ground cable from the frame.
2. Remove the radiator reserve tank from the upper fan
2. Disconnect the battery cable from the battery. guide.
3. Remove the battery bracket from the frame.
4. Remove the battery from vehicle.
Mechanical (4JJ1) 1B-163
1. Leak-off pipe
1. Feed hose
2. Return hose
53. Air duct bracket removal 1. Water feed and return pipes
2. Turbocharger water feed hose
1. Remove the air duct bracket from the cylinder head.
3. Water pipe
4. Turbocharger water feed hose
5. Turbocharger water return hose
2. Remove the pipe bracket from the oil filter. 62. Oil filter bracket removal
61. Water bypass pipe removal 1. Remove the oil filter bracket from the oil filter and
the engine hanger.
1. Remove the water bypass pipe from the oil filter.
Note:
・ Remove the water bypass pipe on the oil filter
side.
1. Cam end gasket 1. Top dead center alignment mark on the gear case
cover
68. Injector removal 2. Top dead center alignment mark on the crank
1. Remove the injector from the cylinder head. pulley
1. CMP sensor
1. Noise cover
77. Timing chain upper cover removal
75. Timing chain lower cover removal
1. Remove the timing chain upper cover from the
1. Remove the timing chain lower cover from the gear cylinder head.
case cover.
1B-176 Mechanical (4JJ1)
Note:
・ Confirm that the alignment marks of the
camshaft bearing cap and the camshaft are
aligned.
Mechanical (4JJ1) 1B-177
Caution:
・ Do not hold the high pressure pipe when
removing the supply pump.
4. Remove the O-ring from the fuel supply pump.
84. Fuel supply pump removal
1. Disconnect the harness connector from the fuel
temperature sensor.
2. Disconnect the harness connector from the suction
control valve.
Mechanical (4JJ1) 1B-179
Note:
・ Pull out the timing chain tension lever.
88. Timing chain guide removal
1. Install the timing chain guide to the cylinder head
assembly and the cylinder block.
1. Supply pump
2. O-ring
Caution:
・ Do not hold the high pressure pipe when
carrying the supply pump.
85. Idle gear D removal 89. Rocker arm shaft assembly removal
1. Remove the idle gear D from the cylinder head. 1. Remove the rocker arm shaft assembly from the
Note: cylinder head.
・ Drop the timing chain backward. Note:
・ Store the removed rocker arm shaft assembly
so that it can be returned to their original
positions.
Caution:
・ Do not reuse the head bolt.
5. Remove the cylinder head assembly from the
cylinder block.
Note:
・ Install the wire to the engine hanger and the
hoist to lift the cylinder head assembly.
91. Cylinder head gasket removal
1. Remove the cylinder head gasket from the cylinder
head.
Mechanical (4JJ1) 1B-181
Caution:
・ Replace the removed cylinder head gasket
with a new one.
92. Crankshaft pulley removal
1. Remove the crankshaft pulley from the crankshaft.
Caution:
・ Do not reuse the crank pulley bolt.
1. Bracket
2. Remove the vacuum pump oil pipe from the vacuum 97. Gear case cover removal
pump assembly and the cylinder block.
1. Remove the gear case cover from the timing gear
Note: case.
・ Remove the vacuum pump assembly from the
gear case cover.
1. Oil pump
Caution:
・ Do not remove the bolt in the diagram 8 during
maintenance.
Mechanical (4JJ1) 1B-185
installation
1. Timing gear case installation
1. Apply liquid gasket to the gasket.
Note:
・ Apply ThreeBond 1207B or equivalent to the
area indicated in the diagram.
2. Apply liquid gasket to the cylinder block.
Note:
・ Apply ThreeBond 1207B or equivalent to the
area indicated in the diagram.
1. Timing gear case bracket 1. Top dead center alignment mark on the gear case
cover
3. Oil pump assembly installation 2. Top dead center alignment mark on the crank
1. Apply the engine oil to the oil pump gear. pulley
2. Install the oil pump to the timing gear case. 6. Idle gear C installation
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Apply the engine oil to the idle gear C shaft.
Note:
・ Apply it to the gear assembly sections.
2. Install the idle gear C shaft to the timing gear case.
3. Install the idle gear C to the idle gear C shaft.
4. Apply the engine oil to the bolt.
Note:
・ Apply it to the thread and the seat.
5. Temporarily tighten the bolt to the timing gear case.
1. Oil pump
Note:
・ Align the oil holes of the cylinder block and the
idle gear A shaft.
2. Apply the engine oil to the idle gear A shaft.
3. Install the idle gear A shaft to the timing gear case.
4. Install the idle gear A to the idle gear A shaft.
5. Install the idle gear A flange to the idle gear A.
Note:
6. Apply the engine oil to the bolt.
・ Install the idle gear A with the alignment mark
aligned. Note:
・ Apply it to the thread and the seat.
7. Temporarily tighten the bolt to the timing gear case.
1B-188 Mechanical (4JJ1)
1. Bracket
Note:
・ Measure the point 1, 2, 3, and 4 to calculate
the difference between 1 and, 2, and between
3 and 4 of each cylinder.
3. Calculate average value from measured value.
Note:
・ Calculate the average value for the protrusion
amount of the piston head for each cylinder.
・ Determine the grade of the gasket required for
the maximum value mentioned above
according to the following table.
Note:
・ Refer to the diagram for the measurement
position of the protrusion amount.
・ Make sure that all measuring points are
located as close to the cylinder block as
possible.
1. Measurement point
2. Measurement point
3. Measurement point
4. Measurement point
Note:
・ Cylinder head gasket combination
1B-192 Mechanical (4JJ1)
1. Bead height
2. Bead width
Caution:
・ After applying the liquid gasket, install the
cylinder head within 5 minutes.
16. Cylinder head assembly installation
1. Install the cylinder head assembly to the cylinder
block.
Note:
・ Wipe off the bottom surface of the cylinder
head.
・ Adjust the cylinder block dowel to install the
cylinder head.
2. Install the head bolt to the cylinder head.
Note: Caution:
・ The difference in the protrusion amount of ・ Use new head bolts.
each piston should not exceed 0.05 mm {0.002
in}.
15. Cylinder head gasket installation
1. Apply liquid gasket to the cylinder block.
Note:
・ Apply ThreeBond-1207B or equivalent to the
cylinder block as shown in the diagram.
Bead height: 2 to 3 mm { 0.079 to 0.118 in }
Bead width: 3 to 4 mm { 0.118 to 0.157 in }
Mechanical (4JJ1) 1B-193
3. Tighten the head bolt using a torque wrench.
Note:
・ Tighten the head bolts in the order shown in
the diagram.
Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft }
4. Tighten the head bolt using a torque wrench.
Note:
・ Tighten the head bolts in the order shown in
the diagram.
Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft }
5. Tighten the head bolt using special tool.
Note:
・ Tighten the head bolts in the order shown in
the diagram using an angle gauge.
9. Remove the wire from the engine hanger and the
hoist.
10. Remove the rear engine hanger from the cylinder
head.
Note:
・ Align the two timing marks as indicated in the
diagram.
1. Timing mark
2. Dark plate
3. Timing mark
4. Yellow plate
Tightening torque: 130 N・m { 13.3 kgf・m / 96 lb・ 29. Inlet camshaft installation
ft }
1. Install the inlet camshaft to the cylinder head.
1B-198 Mechanical (4JJ1)
Note:
・ Align the timing mark to the idle gear D to
install it.
1. Alignment mark
1. Liquid gasket
2. Bead height
3. Bead width
Note:
・ Apply LOCTITE 262 or equivalent to the
threaded portion on the cylinder head side.
2. Install the timing chain upper cover to the cylinder
head.
1. Exhaust camshaft gear
2. Inlet camshaft gear Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
3. Idle gear D
1. CMP sensor
1. Liquid gasket
2. Bead height
3. Bead width
1. Injector
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket
1. Leak-off pipe
2. Clip
1. Leak-off pipe
2. Clip
4. Securely tighten the water intake pipe to the oil 47. Catalyst converter installation
cooler and the generator bracket. 1. Install the catalyst converter to the turbocharger
Note: assembly.
・ Firmly tighten the nuts and bolts in the order Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft }
shown in the diagram.
1. Turbocharger feed oil pipe 2. Securely tighten the air duct bracket to the cylinder
head assembly.
51. Turbocharger water return hose connect
Note:
1. Connect the turbocharger water return hose to the
・ Firmly tighten the nuts and bolts in the order
water feed and return pipe.
shown in the diagram.
52. Air duct bracket installation 53. Exhaust manifold heat protector installation
1. Temporarily tighten the air duct bracket to the 1. Install the exhaust manifold heat protector to the
cylinder head assembly. exhaust manifold.
54. Water hose connect 56. Turbocharger water feed pipe connect
1. Connect the water hose to the EGR cooler. 1. Connect the turbocharger water feed hose to the
water feed and return pipe.
Note:
・ Connect both the feed hose and return hose to
the EGR cooler.
2. Connect the turbocharger water feed hose to the 1. Glow plug terminal
outlet pipe. 2. Glow plug connector
58. Glow plug installation 60. Bracket installation
1. Install the glow plug to the cylinder head. 1. Install the bracket to the cylinder head cover.
Tightening torque: 18 N・m { 1.8 kgf・m / 13 lb・ft } Note:
・ Install the part together with the turbocharger
control solenoid.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1. Glow plug
1. Fuel hose
1. Measurement point 1
2. Measurement point 2
3. Measurement point 3
4. Measurement point 4
Note:
・ After adjusting the tension, tighten the adjust
plate lock bolt and the mounting bolt under the
79. Cooling fan belt installation
generator.
1. Install the cooling fan belt to the pulley.
Generator tightening torque
80. Cooling fan belt adjustment : 40 N・m { 4.1 kgf・m /
Mounting bolt
1. Adjust tension to a standard value using a tension 30 lb・ft }
meter. : 25 N・m { 2.5 kgf・m /
Adjust plate lock bolt
Note: 18 lb・ft }
・ Move the generator to adjust the tension. Note:
2. Check tension of the cooling fan belt. ・ If the cooling fan belt is replaced with a new
one, make the new cooling fan belt fit in to
Note: cope with initial elongation.
・ When adjusting the amount of flex to the ・ After making the cooling fan belt fit in, adjust
original value its tension once again.
・ Apply a load to measurement point 1 of the
81. A/C compressor drive belt installation
cooling fan belt and adjust the amount of flex.
Mechanical (4JJ1) 1B-213
1. Install the A/C compressor drive belt to the pulley. For a
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in }
product
When : 20.7 to 23.7 mm
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
Note:
・ In the case of adjustment using a frequency
meter
・ Measure the frequency at measurement points
2, 3, and 4 with a frequency meter.
Measurement point 2
Frequency of
Amount of flex
vibrations
For a
: 12.5 to 16.5 mm
new : 92 to 112 Hz
{ 0.492 to 0.650 in }
product
When : 16.5 to 19.1 mm
1. A/C compressor drive belt : 79 to 91 Hz
reused { 0.650 to 0.752 in }
82. A/C compressor drive belt adjustment Measurement point 3
1. Adjust tension to a standard value using a tension Frequency of
Amount of flex
meter. vibrations
Note: For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
・ When adjusting the amount of flex to the { 0.488 to 0.646 in }
product
original value
When : 16.5 to 19.1 mm
・ Apply a load to measurement points 2, 3, and : 80 to 92 Hz
reused { 0.650 to 0.752 in }
4 of the A/C compressor drive belt and adjust
the amount of flex. Measurement point 4
Load: 98 N { 10 kg / 22 lb } Frequency of
Amount of flex
vibrations
Measurement point 2
For a
Frequency of : 15.9 to 20.7 mm
Amount of flex new : 70 to 86 Hz
vibrations { 0.626 to 0.815 in }
product
For a When : 20.7 to 23.7 mm
: 12.5 to 16.5 mm : 62 to 70 Hz
new : 92 to 112 Hz reused { 0.815 to 0.933 in }
{ 0.492 to 0.650 in }
product
When : 16.5 to 19.1 mm
: 79 to 91 Hz
reused { 0.650 to 0.752 in }
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
1B-214 Mechanical (4JJ1)
85. Radiator reserve tank installation
1. Install the radiator reserve tank to the upper fan
guide.
Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }
1. Measurement point 1
2. Measurement point 2
3. Measurement point 3
4. Measurement point 4
Note:
2. Connect the radiator reserve tank hose to the
・ After adjusting the tension, tighten the
radiator.
tensioner fixing nut.
Note:
Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }
・ When the radiator reserve tank is dirty, clean it
83. Generator connect before installation.
1. Connect the harness to the generator. ・ Clean the radiator reserve tank using
detergent.
Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・
in } Terminal nut ・ Scrub inside with a detergent and water.
・ Wash with clean water, and drain the water.
84. Generator cover installation
86. Radiator upper hose installation
1. Install the generator cover to the bracket and the
adjust plate. 1. Install the radiator upper hose to the water outlet
pipe and the radiator.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
Tightening torque: 5 N・m { 0.5 kgf・m / 44 lb・in }
Hose clip
Mechanical (4JJ1) 1B-215
1. Install the intake air duct to the intake throttle valve
and the intake hose.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
Bolt
Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in }
Clip
1. Battery cable
2. Battery bracket
3. Earth
Note:
・ Turn the hood rest to adjust its height, and
adjust the level difference against the engine
hood.
1. 29 mm (1.14 in)
1B-218 Mechanical (4JJ1)
1. Engine cover
1. Hood rest
Cylinder block
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
1. Engine cover
2. Remove the front under guard from the frame.
Note: 4. Coolant drain
・ Remove the 5 bolts. 1. Drain coolant from the radiator.
3. Remove the rear under guard from the frame. Note:
Note: ・ Open the drain plug at the bottom of the
radiator.
・ Remove the 4 bolts.
Mechanical (4JJ1) 1B-221
2. Remove the radiator cap from the radiator. 7. Blow-by hose disconnect
Warning: 1. Disconnect the blow-by hose from the cylinder head
・ In order to prevent burns, do not open the cap cover.
when the engine and radiator are hot. 8. Air cleaner assembly removal
・ Heat liquid and steam may gush out by
1. Disconnect the harness connector from the MAF
pressure.
sensor.
5. Engine oil drain
2. Disconnect the harness connector from the
1. Drain the engine oil from the oil pan. barometric pressure sensor.
Note: 3. Disconnect the vacuum hose from the air cleaner
・ After draining oil, tighten the drain plug to the assembly.
specified torque. 4. Disconnect the intake pipe from the turbocharger
Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft } assembly.
1. Battery cable
2. Battery bracket
3. Earth
4. Remove the battery from vehicle. 1. Disconnect the radiator reserve tank hose from the
radiator.
Mechanical (4JJ1) 1B-223
2. Remove the radiator reserve tank from the upper fan
guide.
2. Disconnect the earth cable from the crankcase. 1. Intake throttle valve
2. Gasket
1. Earth cable
1. Fuel hose
1. Water feed and return pipes 63. Air duct bracket removal
2. Turbocharger water feed hose
1. Remove the air duct bracket from the cylinder head.
3. Water pipe
4. Turbocharger water feed hose
5. Turbocharger water return hose
1. Water feed and return pipes 67. Heater bypass pipe removal
2. Turbocharger water feed hose
1. Disconnect the heater bypass pipe from the water
3. Water pipe
intake pipe.
4. Turbocharger water feed hose
5. Turbocharger water return hose 2. Remove the heater bypass pipe from the oil cooler
assembly and the water bypass hose.
65. Turbocharger feed oil pipe removal
1. Remove the turbocharger feed oil pipe from the
turbocharger and the oil cooler.
2. Remove the pipe bracket from the oil filter. 70. Oil filter bracket removal
69. Water bypass pipe removal 1. Remove the oil filter bracket from the oil filter and
the engine hanger.
1. Remove the water bypass pipe from the oil filter.
Note:
・ Remove the water bypass pipe on the oil filter
side.
1. Cam end gasket 1. Top dead center alignment mark on the gear case
cover
76. Injector removal 2. Top dead center alignment mark on the crank
1. Remove the injector from the cylinder head. pulley
1. CMP sensor
1. Noise cover
85. Timing chain upper cover removal
83. Timing chain lower cover removal
1. Remove the timing chain upper cover from the
1. Remove the timing chain lower cover from the gear cylinder head.
case cover.
Mechanical (4JJ1) 1B-239
Note:
・ Confirm that the alignment marks of the
camshaft bearing cap and the camshaft are
aligned.
1B-240 Mechanical (4JJ1)
Caution:
・ Do not hold the high pressure pipe when
removing the supply pump.
4. Remove the O-ring from the fuel supply pump.
92. Fuel supply pump removal
1. Disconnect the harness connector from the fuel
temperature sensor.
2. Disconnect the harness connector from the suction
control valve.
1B-242 Mechanical (4JJ1)
Note:
・ Pull out the timing chain tension lever.
96. Timing chain guide removal
1. Install the timing chain guide to the cylinder head
assembly and the cylinder block.
1. Supply pump
2. O-ring
Caution:
・ Do not hold the high pressure pipe when
carrying the supply pump.
93. Idle gear D removal 97. Rocker arm shaft assembly removal
1. Remove the idle gear D from the cylinder head. 1. Remove the rocker arm shaft assembly from the
Note: cylinder head.
・ Drop the timing chain backward. Note:
・ Store the removed rocker arm shaft assembly
so that it can be returned to their original
positions.
Caution:
・ Do not reuse the head bolt.
5. Remove the cylinder head assembly from the
cylinder block.
Note:
・ Install the wire to the engine hanger and the
hoist to lift the cylinder head assembly.
99. Cylinder head gasket removal
1. Remove the cylinder head gasket from the cylinder
head.
1B-244 Mechanical (4JJ1)
Caution:
・ Replace the removed cylinder head gasket
with a new one.
100.Crankshaft pulley removal
1. Remove the crankshaft pulley from the crankshaft.
Caution:
・ Do not reuse the crank pulley bolt.
103.Cover removal
1. Remove the cover from the gear case cover.
1. Oil pump
Caution:
・ Do not remove the bolt in the diagram 8 during
maintenance.
Mechanical (4JJ1) 1B-247
111.Flywheel removal
1. Remove the flywheel from the crankshaft.
Note:
・ Gradually loosen the flywheel mounting bolts
in the order shown in the diagram while
confirming that the flywheel does not rotate.
5. Remove the thrust bearing from the cylinder block. 119.Oil cooler assembly removal
6. Remove the upper crankshaft bearing from the 1. Remove the oil cooler assembly from the cylinder
cylinder block. block.
117.Generator bracket removal
1. Remove the generator bracket from the cylinder
block.
Note:
・ Measure the height of the cylinder block.
Standard:259.945 to 260.055 mm { 10.2340 to 10.2384
in }
1. Measurement point
Mechanical (4JJ1) 1B-253
installation
1. Oil jet pipe installation
1. Install the oil jet pipe to the cylinder block.
Note:
・ Align the oil jet pipe dowel pin with the cylinder
block pin hole and tighten with a relief valve.
Tightening torque: 30 N・m { 3.1 kgf・m / 22 lb・ft }
Relief valve
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
M8 bolt
Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }
M6 bolt
Caution:
・ Be careful not to deform or damage the nozzle
of the oil jet pipe. Note:
・ Within 5 minutes after application, install the oil
cooler assembly.
2. Install the O-ring to the oil cooler assembly.
Note:
・ Grease may be applied to the O-ring.
3. Install the oil cooler assembly to the cylinder block.
Note:
・ Tighten in the order in the diagram.
5. Crankshaft installation
1. Install the upper crankshaft bearing to the cylinder
block.
Mechanical (4JJ1) 1B-255
Caution:
・ Be careful not to mistake the bearing shape
when installing.
Note:
・ Gradually tighten the crankshaft bearing cap
bolts to the specified torque in the order
indicated in the diagram.
Tightening torque: 166 N・m { 16.9 kgf・m / 122 lb・
ft } SST: 5-8840-9018-0 - piston setting tool
Caution: Caution:
・ Manually rotate the crankshaft to confirm that ・ When pushing the piston, be careful not to
the crankshaft works smoothly. touch the oil jet against the connecting rod.
・ When pushing the piston, be careful not to
damage the inside of the cylinder block.
1B-258 Mechanical (4JJ1)
6. Install the connecting rod bearing to the connecting Tightening torque: 29.4 N・m { 3.0 kgf・m / 22 lb・
rod bearing cap. ft }
7. Apply the engine oil to the connecting rod bearing. 11. Securely tighten the connecting rod bearing cap to
8. Apply the engine oil to the bolt. the connecting rod.
Note:
・ Apply it to the threaded portion of the
tightening bolts and the seat surface.
9. Temporarily tighten the connecting rod bearing cap
to the connecting rod.
Note:
SST: 5-8840-0266-0 - angle gauge
・ Align the cap and the connecting rod number
markings and install the cap. Note:
・ Tighten the bolts to the specified angle in the
order shown in the diagram.
Specified angle: 45 to 60 °
Note:
・ Confirm that the crankshaft turns smoothly.
7. Crankcase installation
1. Apply liquid gasket to the crankcase.
Note: 1. 1 - 1.5 mm {0.039 - 0.059 in}
2. 1 - 1.5 mm {0.039 - 0.059 in}
・ Apply ThreeBond 1207C or equivalent.
・ When applying it around the O-ring, adjust the 2. Install the oil seal retainer to the cylinder block and
amount so that a liquid gasket does not the crankcase.
protrude.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Note:
・ For automatic transmission vehicles, install the
sleeve, flywheel, flexible plate, washer in that
order, and temporarily tighten the order in the
diagram.
3. Install special tool to the rear plate.
Mechanical (4JJ1) 1B-261
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Caution:
・ Do not remove the bolt in the diagram 8 during
maintenance.
1. Timing gear case bracket 1. Top dead center alignment mark on the gear case
cover
13. Oil pump assembly installation 2. Top dead center alignment mark on the crank
1. Apply the engine oil to the oil pump gear. pulley
2. Install the oil pump to the timing gear case. 16. Idle gear C installation
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Apply the engine oil to the idle gear C shaft.
Note:
・ Apply it to the gear assembly sections.
2. Install the idle gear C shaft to the timing gear case.
3. Install the idle gear C to the idle gear C shaft.
4. Apply the engine oil to the bolt.
Note:
・ Apply it to the thread and the seat.
5. Temporarily tighten the bolt to the timing gear case.
1. Oil pump
Note:
・ Align the oil holes of the cylinder block and the
idle gear A shaft.
2. Apply the engine oil to the idle gear A shaft.
3. Install the idle gear A shaft to the timing gear case.
4. Install the idle gear A to the idle gear A shaft.
5. Install the idle gear A flange to the idle gear A.
Note:
6. Apply the engine oil to the bolt.
・ Install the idle gear A with the alignment mark
aligned. Note:
・ Apply it to the thread and the seat.
7. Temporarily tighten the bolt to the timing gear case.
1B-264 Mechanical (4JJ1)
19. Cover installation 3. Install the vacuum hose to the vacuum pipe and the
vacuum pump assembly.
1. Install the cover to the gear case cover.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
Note:
・ Refer to the diagram for the measurement
position of the protrusion amount.
・ Make sure that all measuring points are
located as close to the cylinder block as
possible.
Note:
・ Measure the point 1, 2, 3, and 4 to calculate
the difference between 1 and, 2, and between
3 and 4 of each cylinder.
3. Calculate average value from measured value.
Note:
・ Calculate the average value for the protrusion
amount of the piston head for each cylinder.
・ Determine the grade of the gasket required for
the maximum value mentioned above
according to the following table.
Note:
・ The difference in the protrusion amount of
each piston should not exceed 0.05 mm {0.002
in}.
24. Cylinder head gasket installation
1. Apply liquid gasket to the cylinder block.
Note:
・ Apply ThreeBond-1207B or equivalent to the
cylinder block as shown in the diagram.
Bead height: 2 to 3 mm { 0.079 to 0.118 in }
Note:
・ Cylinder head gasket combination
1B-268 Mechanical (4JJ1)
3. Tighten the head bolt using a torque wrench.
Note:
・ Tighten the head bolts in the order shown in
the diagram.
Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft }
4. Tighten the head bolt using a torque wrench.
Note:
・ Tighten the head bolts in the order shown in
the diagram.
Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft }
5. Tighten the head bolt using special tool.
Note:
・ Tighten the head bolts in the order shown in
the diagram using an angle gauge.
1. Bead height
2. Bead width
Caution:
・ After applying the liquid gasket, install the
cylinder head within 5 minutes.
25. Cylinder head assembly installation
1. Install the cylinder head assembly to the cylinder SST: 5-8840-0266-0 - angle gauge
block.
Specified angle: 60 to 75 °
Note:
6. Tighten the head bolt using special tool.
・ Wipe off the bottom surface of the cylinder
head. Note:
・ Adjust the cylinder block dowel to install the ・ Tighten the head bolts in the order shown in
cylinder head. the diagram using an angle gauge.
9. Remove the wire from the engine hanger and the 1. Exhaust rocker arm shaft assembly
hoist. 2. Bolt, long
3. Bolt, short
10. Remove the rear engine hanger from the cylinder
4. Intake rocker arm shaft assembly
head.
5. Front
Note:
・ Align the two timing marks as indicated in the
diagram.
Note:
・ Confirm that the supply pump camshaft key is
at a horizontal position on the right side.
Mechanical (4JJ1) 1B-271
Note:
・ Install it to each sprocket.
2. Align the timing chain to the alignment mark.
Note:
・ Align the timing mark of the crankshaft
sprocket and the timing chain link of the dark
plate.
・ Align the timing mark of the fuel supply
sprocket and the timing chain link of the yellow
plate.
3. Temporarily tighten the sprocket to the supply pump
gear.
Note:
・ Align the dowel pin attached to the gear, and
install the fuel supply pump sprocket to the fuel
32. Supply pump gear installation pump shaft.
1. Install the supply pump gear to the fuel supply pump. ・ Tighten the fuel supply pump shaft nut with
your hand.
Note:
・ Align the alignment mark of the supply pump
gear and the mark on the idle gear A.
・ Confirm that the supply pump gear and the
main gear of the idle gear A are engaged.
・ Push in the supply pump gear with the supply
pump gear engaged with the sub gear of the
idle gear A.
1. Timing mark
2. Dark plate
3. Timing mark
4. Yellow plate
1. Pin
2. Plunger
3. Latch
4. Timing chain tensioner 36. Supply pump gear nut installation
5. Hook
1. Securely tighten the sprocket to the supply pump
2. Install the timing chain tensioner to the cylinder gear.
head. Tightening torque: 130 N・m { 13.3 kgf・m / 96 lb・
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in } ft }
Mechanical (4JJ1) 1B-273
Note:
・ Align the timing mark to the idle gear D to
install it.
1. Nut
1. Alignment mark
1. Injector
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket
1. Apply liquid gasket to the cam end gasket. 2. Install the cylinder head cover to the cylinder head.
Note: Note:
・ Apply ThreeBond 1207B to the area indicated ・ Tighten in the order in the diagram.
in the diagram.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
Bead width: 2.0 to 3.0 mm { 0.079 to 0.118 in }
1B-278 Mechanical (4JJ1)
1. Leak-off pipe
2. Clip
・ Apply soapy water on the O-ring when ・ Apply soapy water on the O-ring when
inserting the pipe. inserting the pipe.
3. Temporarily tighten the water intake pipe to the oil
cooler and the generator bracket.
Note:
・ Temporarily tighten the nuts and bolts in the
order shown in the diagram.
2. Securely tighten the air duct bracket to the cylinder 61. Water hose installation
head assembly.
1. Install the water hose to the oil cooler assembly.
Note:
・ Firmly tighten the nuts and bolts in the order
shown in the diagram.
1. Water feed and return pipes 2. Connect the turbocharger water feed hose to the
2. Turbocharger water feed hose outlet pipe.
3. Water pipe
65. Glow plug installation
4. Turbocharger water feed hose
5. Turbocharger water return hose 1. Install the glow plug to the cylinder head.
63. Vacuum hose installation Tightening torque: 18 N・m { 1.8 kgf・m / 13 lb・ft }
1. Glow plug
1. Injection pipe sleeve nut 2. Connect the fuel leak-off hose to the leak-off pipe.
71. Fuel pressure sensor connect 3. Connect the vacuum hose to the vacuum pipe.
1. Connect the connector to the fuel pressure sensor. 73. Fuel feed pipe installation
1. Install the fuel feed pipe to the fuel supply pump and
the common rail assembly.
Tightening torque: 44.1 N・m { 4.5 kgf・m / 33 lb・
ft }
1. Connector
75. Leak-off pipe installation 1. Connect the vacuum hose to the inlet manifold.
1. Install the leak-off pipe to the fuel supply pump and 78. EGR valve connect
the common rail assembly. 1. Connect the connector to the EGR valve.
Tightening torque: 10.3 N・m { 1.1 kgf・m / 91 lb・ 79. Intake throttle valve installation
in }
1. Install the gasket to the intake throttle valve.
2. Install the intake throttle valve to the inlet manifold.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
1. Leak-off pipe
88. Power steering oil pump assembly installation 89. Catalyst converter installation
1. Install the power steering oil pump to the timing gear 1. Install the catalyst converter to the turbocharger
case. assembly.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft }
1. Power steering oil pump 2. Connect the catalyst converter to the catalyst
2. Nut converter bracket.
1. Glove box
2. Instrument panel assist side lower cover
1. Battery cable
2. Battery bracket
3. Earth
2. Install the battery bracket to the frame. 114.Air cleaner assembly installation
Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in } 1. Install the air cleaner assembly to vehicle.
Battery side
Mechanical (4JJ1) 1B-293
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
Mechanical (4JJ1) 1B-295
Note: Note:
・ After adjusting the tension, tighten the ・ After adjusting the tension, tighten the adjust
tensioner fixing nut. plate lock bolt and the mounting bolt under the
generator.
Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }
119.Cooling fan belt adjustment Generator tightening torque
: 40 N・m { 4.1 kgf・m /
1. Adjust tension to a standard value using a tension Mounting bolt
30 lb・ft }
meter.
: 25 N・m { 2.5 kgf・m /
Note: Adjust plate lock bolt
18 lb・ft }
・ Move the generator to adjust the tension.
Note:
2. Check tension of the cooling fan belt. ・ If the cooling fan belt is replaced with a new
Note: one, make the new cooling fan belt fit in to
cope with initial elongation.
・ When adjusting the amount of flex to the
original value ・ After making the cooling fan belt fit in, adjust
its tension once again.
・ Apply a load to measurement point 1 of the
cooling fan belt and adjust the amount of flex. 120.Engine oil filling
Load: 98 N { 10 kg / 22 lb } 1. Replenish the engine with the engine oil.
Note: Note:
・ In the case of adjustment using a frequency ・ Check the tightening of the oil pan drain plug.
meter
Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft }
・ Measure the frequency at measurement point
1 with a frequency meter. 121.Coolant filling
1. Priming pump
2. Fuel filter with the sedimenter
Caution:
・ Insufficient air removal work may lead
malfunction of the engine.
123.Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
3. Lower vehicle.
Mechanical (4JJ1) 1B-297
Crankshaft
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
3. Coolant drain
1. Drain coolant from the radiator.
Note:
・ Open the drain plug at the bottom of the
radiator.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts. 2. Remove the radiator cap from the radiator.
3. Remove the rear under guard from the frame. Warning:
Note: ・ In order to prevent burns, do not open the cap
・ Remove the 4 bolts. when the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Engine oil drain
1. Drain the engine oil from the oil pan.
1B-298 Mechanical (4JJ1)
Note:
・ After draining oil, tighten the drain plug to the
specified torque.
Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft }
Caution:
・ Do not forget to tighten the drain plug.
5. Intake air duct removal
1. Remove the intake air duct from the turbocharger
and the intercooler.
Note:
・ Remove the part together with the intake hose.
1. Battery cable
2. Battery bracket 14. Generator cover removal
3. Earth 1. Remove the generator cover from the bracket and the
adjust plate.
11. 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.
12. Radiator upper hose removal
1. Remove the radiator upper hose from the water
outlet pipe and the radiator.
1B-300 Mechanical (4JJ1)
1. Remove the cooling fan clutch from the water pump 29. Instrument panel assist-side lower cover removal
assembly.
1. Remove the instrument panel assist-side lower cover
Note: from the instrument panel.
・ Remove the part together with the cooling fan. Note:
・ Remove the 4 screws.
2. Disconnect the earth cable from the crankcase. 1. Intake throttle valve
2. Gasket
1. Earth cable
1. Glow plug
1. Feed hose
2. Return hose
57. Air duct bracket removal 1. Water feed and return pipes
2. Turbocharger water feed hose
1. Remove the air duct bracket from the cylinder head.
3. Water pipe
4. Turbocharger water feed hose
5. Turbocharger water return hose
61. Heater bypass pipe removal 2. Remove the pipe bracket from the oil filter.
1. Disconnect the heater bypass pipe from the water 63. Water bypass pipe removal
intake pipe.
1. Remove the water bypass pipe from the oil filter.
2. Remove the heater bypass pipe from the oil cooler
Note:
assembly and the water bypass hose.
・ Remove the water bypass pipe on the oil filter
side.
1. Top dead center alignment mark on the gear case 73. Camshaft bearing cap removal
cover
1. Install the bolt to the camshaft gear.
2. Top dead center alignment mark on the crank
pulley Note:
・ Install the M5 bolt.
72. Baffle plate removal
1. Install the lock bolt to the sub gear.
Note:
・ Use a M5 lock bolt to fix the sub gear.
1. CMP sensor
Note:
・ Confirm that the alignment marks of the
camshaft bearing cap and the camshaft are
aligned.
Mechanical (4JJ1) 1B-315
Note:
・ Lift up the timing chain.
3. Remove the fuel supply pump from the timing gear Caution:
case. ・ Do not hold the high pressure pipe when
carrying the supply pump.
87. Idle gear D removal
1. Remove the idle gear D from the cylinder head.
Note:
・ Drop the timing chain backward.
Caution:
・ Do not hold the high pressure pipe when
removing the supply pump.
4. Remove the O-ring from the fuel supply pump.
88. Timing chain removal
1. Remove the timing chain from the supply pump
sprocket.
89. Timing chain tension lever removal
1. Remove the timing chain tension lever from the
cylinder head assembly.
1B-318 Mechanical (4JJ1)
Note: Note:
・ Pull out the timing chain tension lever. ・ Be very careful not to drop the parts into the
cylinder head front-side gear case or the front
90. Timing chain guide removal
side oil return hole.
1. Install the timing chain guide to the cylinder head ・ Make sure to remember the original position.
assembly and the cylinder block.
92. Cylinder head assembly removal
1. Install the rear engine hanger to the cylinder head.
1. Nut
2. Bolt
Caution:
・ Do not reuse the head bolt.
5. Remove the cylinder head assembly from the
cylinder block.
Note:
・ Install the wire to the engine hanger and the 96. Vacuum pump assembly removal
hoist to lift the cylinder head assembly.
1. Remove the vacuum hose from the vacuum pipe and
93. Cylinder head gasket removal the vacuum pump assembly.
1. Remove the cylinder head gasket from the cylinder
head.
1B-320 Mechanical (4JJ1)
2. Remove the vacuum pump oil pipe from the vacuum 98. Gear case cover removal
pump assembly and the cylinder block.
1. Remove the gear case cover from the timing gear
Note: case.
・ Remove the vacuum pump assembly from the
gear case cover.
1. Oil pump
105.Flywheel removal
1. Remove the flywheel from the crankshaft.
Note:
・ Gradually loosen the flywheel mounting bolts
in the order shown in the diagram while
confirming that the flywheel does not rotate.
Caution:
・ Do not remove the bolt in the diagram 8 during
maintenance.
3. Clean the cylinder liner using a scraper. 2. Remove the bearing cap from the cylinder block.
Note: 3. Remove the lower crankshaft bearing from the
・ Remove carbon from the top of the cylinder bearing cap.
block using a scraper. 4. Remove the crankshaft from the cylinder block.
4. Remove the piston from the cylinder block. 5. Remove the thrust bearing from the cylinder block.
Note: 6. Remove the upper crankshaft bearing from the
・ Pull out the piston and the connecting rod out cylinder block.
to the cylinder head side.
Caution:
・ When pushing out the connecting rod, be
careful not to damage the oil jet and cylinder
block.
5. Remove the connecting rod bearing from the
connecting rod.
Note:
・ When reusing the bearing, organize them
according to the order of the cylinders so that
other cylinder bearings do not get mistaken.
110.Crankshaft removal
1. Remove the bearing cap bolt from the cylinder
block.
Note:
・ Gradually loosen the bolts in the order of the
numbers indicated in the diagram.
Mechanical (4JJ1) 1B-325
disassembly
1. Crank angle sensor rotor removal
1. Remove the crank angle sensor rotor from the
crankshaft.
Note:
・ Confirm that the pin is not removed.
Caution:
・ Measure the thrust clearance prior to
disassembly.
2. Crankshaft bearing measurement
1. Remove the bearing cap from the cylinder block.
2. Remove the lower crankshaft bearing from the
bearing cap.
Note:
10. Install the lower crankshaft bearing to the bearing
・ The removed crankshaft bearing should be cap.
lined in the order of the number.
11. Install the bearing cap to the cylinder block.
3. Remove the crankshaft from the cylinder block.
Note:
4. Remove the upper crankshaft bearing from the
・ Tighten the bolts to the specified torque in the
cylinder block.
order shown in the diagram.
Note:
Tightening torque: 166 N・m { 16.9 kgf・m / 122.4
・ The removed crankshaft bearing should be lb・ft }
lined in the order of the number.
5. Inspect the crankshaft bearing.
Note:
・ Clean the crankshaft journal and top/bottom
bearings.
Mechanical (4JJ1) 1B-327
Note:
・ Replace all of the crankshaft bearings or the
crankshaft if the oil clearance of the journal
exceeds the limit.
・ Remove the plastigage from the bearing and
the crankshaft.
3. Crankshaft inspection
1. Inspect the crankshaft.
Note:
・ Check the crankshaft journal and crank pin
surface for worn and damage.
・ Check the oil seal contact surface for
excessive worn and damage.
・ Check the oil port for clogging.
4. Crankshaft measurement
Caution:
1. Put the crankshaft on the V-block.
・ After tightening the bolts, do not turn the
crankshaft. Note:
・ Carefully set the crankshaft.
12. Remove the bearing cap bolt from the cylinder
block. 2. Measure fluctuation using a dial gauge.
Note: Note:
・ Remove it gently. ・ Slowly rotate the crankshaft to measure the
runout.
13. Measure the oil clearance using the plasti-gauge.
・ Replace the crankshaft if the crankshaft
Note: fluctuation exceeds the limit.
・ Measure the maximum width portion of the
Standard: 0.05 mm or less { 0.0020 in or less }
plastigage crushed by tightening the
crankcase.
・ Determine the oil clearance of the journal.
Standard: 0.030 to 0.054 mm { 0.0012 to 0.0021 in }
Caution:
・ Do not allow the solution to come into contact
with the oil port.
Note: Note:
・ Inspection of the TUFFTRIDE layer of the ・ Wait 30 to 40 seconds.
crankshaft ・ If the color does not change after 30 or 40
seconds, it indicates a residual layer of
Caution:
TUFFTRIDE and the crankshaft can be used.
・ TUFFTRIDE (soft nitriding treatment) is
・ If the test surface turns copper-colored,
implemented to increase the strength of the
replace the crankshaft.
crankshaft.
・ Therefore, the crankshaft surface cannot be Caution:
polished. ・ Copper chloride ammonium solution is highly
corrosive.
4. Clean the crankshaft using organic solvent.
・ Therefore, it is important to immediately clean
Note: the test surface when the test is completed.
・ Thoroughly clean the crankshaft to completely
remove the oil from the test locations.
5. Prepare inspection solution.
Note:
・ Prepare a solution of copper chloride
ammonium of 5 to 10 %.
6. Apply inspection solution to the crankshaft.
Note:
・ Use an oil drop to apply the solution to the test
locations.
・ Maintain the inspection surface at a complete
level so that the solution does not flow.
Mechanical (4JJ1) 1B-329
reassembly
1. Crank angle sensor rotor installation
1. Apply thread locking adhesive to the bolt.
Note:
・ Apply LOCTITE 262 or equivalent to the
threaded portion.
・ LOCTITE is not necessary to be applied for
new bolts.
2. Install the crank angle sensor rotor to the crankshaft.
Note:
・ Install it so that the side without rotor gear
toward front.
・ Align the pin to the hole to install.
Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・
in }
installation
1. Crankshaft installation
1. Install the upper crankshaft bearing to the cylinder
block.
Note:
・ The upper crankshaft bearing have both an oil
hole and an oil groove. The lower crankshaft
bearing do not have oil holes or grooves.
・ It does not exist on the lower crankshaft
bearing.
・ Carefully wipe out foreign materials from the
upper crankshaft bearing.
・ When reusing the removed upper crankshaft
bearing, find the position mark that was
marked at the time of disassembly.
2. Apply the engine oil to the upper crankshaft bearing. 5. Apply the engine oil to the thrust bearing.
Note: Note:
・ Apply enough engine oil before installing the ・ Apply enough engine oil to it.
crankshaft. 6. Install the thrust bearing to the cylinder block.
Caution: Note:
・ Do not apply engine oil to the back surface of ・ Install the thrust bearing onto the cylinder
the bearing and the bearing installation surface block No. 3 journal section front side and rear
of the cylinder block. side.
・ The thrust bearing oil groove must always
faces the sliding surface.
1. No. 1
2. No. 2
3. No. 3
4. No. 4
1. Lot No.
5. No. 5
2. Size code
Note:
・ The crank journal grade mark is marked on the
each crankshaft journal web section.
・ After installing the crankshaft and crankshaft
bearing, each clearance of the crankshaft
journal and bearing must be the same.
1B-332 Mechanical (4JJ1)
Note:
・ Gradually tighten the crankshaft bearing cap
bolts to the specified torque in the order
indicated in the diagram.
Note:
Tightening torque: 166 N・m { 16.9 kgf・m / 122 lb・
・ Install in numerical order, so that the bearing
ft }
cap arrows point toward the front of the
engine. Caution:
・ Always face the number of the bearing cap ・ Manually rotate the crankshaft to confirm that
upward. the crankshaft works smoothly.
Mechanical (4JJ1) 1B-333
6. Flywheel installation
1. Apply the engine oil to the bolt.
1. 1 - 1.5 mm {0.039 - 0.059 in} Note:
2. 1 - 1.5 mm {0.039 - 0.059 in}
・ Apply it to the threaded portion of the bolt.
2. Install the oil seal retainer to the cylinder block and 2. Temporarily tighten the flywheel to the crankshaft.
the crankcase.
Note:
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
・ Temporarily tighten the nuts and bolts in the
order shown in the diagram.
Caution:
・ After applying the liquid gasket, install it within Note:
5 minutes.
・ For automatic transmission vehicles, install the
5. Rear plate installation sleeve, flywheel, flexible plate, washer in that
order, and temporarily tighten the order in the
1. Install the rear plate to the cylinder block and the
diagram.
crankcase.
3. Install special tool to the rear plate.
Tightening torque: 82 N・m { 8.4 kgf・m / 60 lb・ft }
1B-336 Mechanical (4JJ1)
Note:
・ Install the crankshaft stopper to the starter
installation section of the rear plate.
14. Gear case cover installation 1. Install the cover to the gear case cover.
1. Apply liquid gasket to the timing gear case. Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
Note:
・ Apply ThreeBond 1207B to the area indicated
in the diagram.
Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・ 18. Crankshaft pulley installation
in }
1. Install the crankshaft pulley to the crankshaft.
3. Install the vacuum hose to the vacuum pipe and the
Note:
vacuum pump assembly.
・ Align the crankshaft pulley to the key of the
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } crankshaft and install it.
・ With the fly wheel ring gear as stopped state,
and lock the crankshaft when tightening the
crankshaft pulley bolt.
Tightening torque: 294 N・m { 30.0 kgf・m / 217 lb・
ft }
Caution:
・ Take care not to damage the crankshaft
damper pulley boss portion.
・ Use new crank pulley bolts.
Note:
・ Measure the point 1, 2, 3, and 4 to calculate
the difference between 1 and, 2, and between
3 and 4 of each cylinder.
3. Calculate average value from measured value.
Note:
・ Calculate the average value for the protrusion
amount of the piston head for each cylinder.
・ Determine the grade of the gasket required for
the maximum value mentioned above
according to the following table.
Note:
・ Refer to the diagram for the measurement
position of the protrusion amount.
・ Make sure that all measuring points are
located as close to the cylinder block as
possible.
1. Measurement point
2. Measurement point
3. Measurement point
4. Measurement point
Note:
・ Cylinder head gasket combination
Mechanical (4JJ1) 1B-343
1. Bead height
2. Bead width
Caution:
・ After applying the liquid gasket, install the
cylinder head within 5 minutes.
21. Cylinder head assembly installation
1. Install the cylinder head assembly to the cylinder
block.
Note:
・ Wipe off the bottom surface of the cylinder
head.
・ Adjust the cylinder block dowel to install the
cylinder head.
2. Install the head bolt to the cylinder head.
Note: Caution:
・ The difference in the protrusion amount of ・ Use new head bolts.
each piston should not exceed 0.05 mm {0.002
in}.
20. Cylinder head gasket installation
1. Apply liquid gasket to the cylinder block.
Note:
・ Apply ThreeBond-1207B or equivalent to the
cylinder block as shown in the diagram.
Bead height: 2 to 3 mm { 0.079 to 0.118 in }
Bead width: 3 to 4 mm { 0.118 to 0.157 in }
1B-344 Mechanical (4JJ1)
3. Tighten the head bolt using a torque wrench.
Note:
・ Tighten the head bolts in the order shown in
the diagram.
Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft }
4. Tighten the head bolt using a torque wrench.
Note:
・ Tighten the head bolts in the order shown in
the diagram.
Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft }
5. Tighten the head bolt using special tool.
Note:
・ Tighten the head bolts in the order shown in
the diagram using an angle gauge.
9. Remove the wire from the engine hanger and the
hoist.
10. Remove the rear engine hanger from the cylinder
head.
Note:
・ Align the two timing marks as indicated in the
diagram.
1. Timing mark
2. Dark plate
3. Timing mark
4. Yellow plate
Tightening torque: 130 N・m { 13.3 kgf・m / 96 lb・ 34. Inlet camshaft installation
ft }
1. Install the inlet camshaft to the cylinder head.
Mechanical (4JJ1) 1B-349
Note:
・ Align the timing mark to the idle gear D to
install it.
1. Alignment mark
1. Liquid gasket
2. Bead height
3. Bead width
Note:
・ Apply LOCTITE 262 or equivalent to the
threaded portion on the cylinder head side.
2. Install the timing chain upper cover to the cylinder
head.
1. Exhaust camshaft gear
2. Inlet camshaft gear Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
3. Idle gear D
1. CMP sensor
1. Liquid gasket
2. Bead height
3. Bead width
1. Injector
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket
1. Leak-off pipe
2. Clip
1. Leak-off pipe
2. Clip
4. Securely tighten the water intake pipe to the oil 52. Oil return pipe installation
cooler and the generator bracket. 1. Install the oil return pipe to the turbocharger and the
Note: crankcase.
・ Firmly tighten the nuts and bolts in the order Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
shown in the diagram. Turbocharger side
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Crankcase side
55. Air duct bracket installation 1. Install the exhaust manifold heat protector to the
exhaust manifold.
1. Temporarily tighten the air duct bracket to the
cylinder head assembly. Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Note:
・ Temporarily tighten the nuts and bolts in the
order shown in the diagram.
Mechanical (4JJ1) 1B-357
1. Feed hose
2. Return hose
58. Turbocharger water feed pipe connect 60. Water pipe installation
1. Connect the turbocharger water feed hose to the 1. Install the turbocharger water feed hose to the
water feed and return pipe. cylinder head assembly.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
Bolt, nut
1B-358 Mechanical (4JJ1)
2. Connect the turbocharger water feed hose to the 1. Glow plug terminal
outlet pipe. 2. Glow plug connector
61. Glow plug installation 63. Bracket installation
1. Install the glow plug to the cylinder head. 1. Install the bracket to the cylinder head cover.
Tightening torque: 18 N・m { 1.8 kgf・m / 13 lb・ft } Note:
・ Install the part together with the turbocharger
control solenoid.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1. Glow plug
1. Fuel hose
1. Power steering oil pump 2. Connect the catalyst converter to the catalyst
2. Nut converter bracket.
1. Bracket
Tightening torque: 67 N・m { 6.8 kgf・m / 49 lb・ft } 1. Install the instrument panel assist-side lower cover to
the instrument panel.
Note:
・ Install the 4 screws.
1. Glove box
2. Instrument panel assist side lower cover
1. Glove box
2. Instrument panel assist side lower cover
94. Cooling fan belt installation 98. Radiator reserve tank installation
1. Install the cooling fan belt to the pulley. 1. Install the radiator reserve tank to the upper fan
guide.
95. A/C compressor drive belt installation
Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }
1. Install the A/C compressor drive belt to the pulley.
1. Battery cable
2. Battery bracket
3. Earth
2. Install the battery bracket to the frame. 104.Air cleaner assembly installation
Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in } 1. Install the air cleaner assembly to vehicle.
Battery side
Mechanical (4JJ1) 1B-367
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
Mechanical (4JJ1) 1B-369
Note: Note:
・ After adjusting the tension, tighten the ・ After adjusting the tension, tighten the adjust
tensioner fixing nut. plate lock bolt and the mounting bolt under the
generator.
Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }
109.Cooling fan belt adjustment Generator tightening torque
: 40 N・m { 4.1 kgf・m /
1. Adjust tension to a standard value using a tension Mounting bolt
30 lb・ft }
meter.
: 25 N・m { 2.5 kgf・m /
Note: Adjust plate lock bolt
18 lb・ft }
・ Move the generator to adjust the tension.
Note:
2. Check tension of the cooling fan belt. ・ If the cooling fan belt is replaced with a new
Note: one, make the new cooling fan belt fit in to
cope with initial elongation.
・ When adjusting the amount of flex to the
original value ・ After making the cooling fan belt fit in, adjust
its tension once again.
・ Apply a load to measurement point 1 of the
cooling fan belt and adjust the amount of flex. 110.Engine oil filling
Load: 98 N { 10 kg / 22 lb } 1. Replenish the engine with the engine oil.
Note: Note:
・ In the case of adjustment using a frequency ・ Check the tightening of the oil pan drain plug.
meter
Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft }
・ Measure the frequency at measurement point
1 with a frequency meter. 111.Coolant filling
1. Priming pump
2. Fuel filter with the sedimenter
Caution:
・ Insufficient air removal work may lead
malfunction of the engine.
113.Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
3. Lower vehicle.
Mechanical (4JJ1) 1B-371
CKP sensor
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. CKP sensor removal
1. Disconnect the connector from the CKP sensor.
2. Remove the CKP sensor from the cylinder block.
1. CKP sensor
2. O-ring
1B-372 Mechanical (4JJ1)
inspection
1. CKP sensor inspection
1. Inspect the CKP sensor.
Note:
・ Inspect whether the CKP sensor is securely
installed.
・ Inspect the sensor and connector sections for
damage and dirt.
Mechanical (4JJ1) 1B-373
installation
1. CKP sensor installation
1. Install the CKP sensor to the cylinder block.
Tightening torque: 5 N・m { 0.5 kgf・m / 44 lb・in }
1. CKP sensor
2. O-ring
Inlet manifold
removal Note:
・ Remove the part together with the intake hose.
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Engine cover removal
1. Remove the engine cover from the engine.
1. Install the gasket to the inlet manifold. 1. Connect the connector to the EGR valve.
2. Install the inlet manifold to the cylinder head. 5. Injection pipe installation
14. Oil level gauge guide tube installation 1. Connect the connector to the boost sensor.
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
For a
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in } 1. Measurement point 1
product
2. Measurement point 2
When : 20.7 to 23.7 mm
: 62 to 70 Hz 3. Measurement point 3
reused { 0.815 to 0.933 in }
4. Measurement point 4
Note:
Note:
・ In the case of adjustment using a frequency
meter ・ After adjusting the tension, tighten the
tensioner fixing nut.
・ Measure the frequency at measurement points
2, 3, and 4 with a frequency meter. Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex 1. Engine cover
vibrations
For a 19. Battery ground cable connect
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in } 1. Connect the battery ground cable to the battery.
product
Mechanical (4JJ1) 1B-381
2. Close the engine hood assembly.
1B-382 Mechanical (4JJ1)
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Crankshaft adjustment
1. Align the No.1 cylinder to compression top dead
center.
Note:
・ Rotate the crankshaft and align to the
compression top dead center (TDC).
1. Engine cover
9. Injector disconnect
1. Disconnect the connector from the injector.
7. Bracket removal 10. Fuel leak-off hose removal
1. Disconnect the vacuum hose from the turbocharger 1. Remove the fuel leak-off hose from the leak-off
control solenoid valve. pipe.
2. Disconnect the connector from the turbocharger
control solenoid valve.
3. Remove the bracket from the cylinder head cover.
Note:
・ Remove the part together with the
turbocharger control solenoid valve.
1B-384 Mechanical (4JJ1)
2. Remove the baffle plate from the cylinder head. 2. Remove the camshaft bearing cap from the cylinder
head.
Note:
・ Confirm that it is marked.
Note:
・ Be very careful not to drop the parts into the
cylinder head front-side gear case or the front
side oil return hole.
・ Make sure to remember the original position.
1B-388 Mechanical (4JJ1)
installation
1. Crankshaft adjustment
1. Align the No.1 cylinder to compression top dead
center.
Note:
・ Rotate the crankshaft and align to the
compression top dead center (TDC).
3. Injector installation
1. Install the O-ring to the injector.
2. Install the gasket to the injector.
1. Top dead center alignment mark on the gear case
cover Note:
2. Top dead center alignment mark on the crank ・ Push the part in by hand until it stops.
pulley ・ The gasket is pushed in until it hits the end
when the clamp is tightened, and therefore, do
2. Rocker arm shaft assembly installation not push in the gasket by force.
1. Apply the engine oil to the rocker arm shaft Caution:
assembly.
・ Do not reuse the leak-off pipe and the clip.
2. Install the rocker arm shaft assembly to the cylinder
head.
Note:
・ Install the rocker arm shaft assemblies from
No. 1 to No. 4 in the numbering order.
Tightening torque: 21 N・m { 2.1 kgf・m / 15 lb・ft }
1. Injector
2. Leak-off pipe
Mechanical (4JJ1) 1B-389
3. Clip
4. O-ring
5. Gasket
2. Install the cylinder head cover to the cylinder head. 2. Install the fuel leak-off hose to the leak-off pipe.
Note:
・ Tighten in the order in the diagram.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
1. Leak-off pipe
2. Clip
Caution:
11. Blow-by hose connect ・ Do not reuse the leak-off pipe and the clip.
1. Connect the blow-by hose to the cylinder head cover. 13. Injector connect
12. Fuel leak-off hose installation 1. Connect the harness connector to the injector.
1. Install the leak-off pipe to the injector. 14. Vacuum pipe installation
1. Install the vacuum pipe to the cylinder head cover.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
15. Bracket installation
1. Install the bracket to the cylinder head cover.
Mechanical (4JJ1) 1B-393
Note: 1. Connect the connector to the boost sensor.
・ Install the part together with the turbocharger
control solenoid.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1. Engine cover
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
3. Coolant drain
1. Drain coolant from the radiator.
Note:
・ Open the drain plug at the bottom of the
radiator.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts. 2. Remove the radiator cap from the radiator.
3. Remove the rear under guard from the frame. Warning:
Note: ・ In order to prevent burns, do not open the cap
・ Remove the 4 bolts. when the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Engine cover removal
1. Remove the engine cover from the engine.
1B-396 Mechanical (4JJ1)
5. Intake air duct removal 1. Remove the intake air duct from the intake throttle
valve and the intercooler.
1. Remove the intake air duct from the turbocharger
and the intercooler. Note:
・ Remove the part together with the intake hose.
Note:
・ Remove the part together with the intake hose.
6. Boost sensor disconnect 1. Remove the radiator upper hose from the water
outlet pipe and the radiator.
1. Disconnect the connector from the boost sensor.
Mechanical (4JJ1) 1B-397
Note:
・ Remove the clips and bottom locks on both
sides and remove the upper fan guide.
1. Bracket
2. Remove the vacuum pump oil pipe from the vacuum 20. Gear case cover removal
pump assembly and the cylinder block.
1. Remove the gear case cover from the timing gear
Note: case.
・ Remove the vacuum pump assembly from the
gear case cover.
inspection
1. Idle gear measurement
1. Measure the backlash using a dial gauge.
Note:
・ Touch the dial gauge to the idle gear tooth to
be measured, and gently move the gear left
and right to read the fluctuation on the dial
gauge.
・ Always fasten the gear.
・ Replace the idle gear if the measured value
exceeds the limit.
・ Measure the idle gear backlash before
removing the idle gear A.
Standard: 0.10 to 0.17 mm { 0.004 to 0.007 in }
Limit: 0.30 mm { 0.01 in } 2. Measure the idle gear using a cylinder gauge.
2. Measure the clearance using a feeler gauge. Note:
Note: ・ Measure the inner diameter of the idle gear
・ Insert a feeler gauge into the gap between the bushing.
idle gear and thrust collar to measure the
clearance.
・ Replace either the idle gear or the thrust collar
if the measured value exceeds the limit.
・ Measure the idle gear clearance before
removing the idle gear B.
Standard: 0.060 to 0.135 mm { 0.002 to 0.005 in }
Limit: 0.20 mm { 0.008 in }
2. Idle gear shaft measurement
1. Measure outer diameter using the micrometer.
Standard: 44.950 to 44.975 mm { 1.7697 to 1.7707 in }
Idle gear A shaft
Limit: 44.80 mm { 1.764 in } Idle gear A shaft
Standard: 24.959 to 24.980 mm { 0.9826 to 0.9835 in }
Idle gear C shaft 3. Calculate the clearance from measured value.
Limit: 24.80 mm { 0.976 in } Idle gear C shaft Note:
・ Calculate the clearance between the inner
diameter of the idle gear bushing and the outer
diameter of the idle gear shaft.
・ Replace either the idle gear or the shaft if the
measured value exceeds the limit.
Standard: 0.025 to 0.075 mm { 0.0010 to 0.0030 in }
Clearance between the idle gear A and shaft
Limit: 0.200 mm { 0.0079 in } Clearance between the
idle gear A and shaft
Standard: 0.020 to 0.062 mm { 0.0008 to 0.0024 in }
Clearance between the idle gear C and shaft
1B-402 Mechanical (4JJ1)
Limit: 0.200 mm { 0.0079 in } Clearance between the
idle gear C and shaft
Mechanical (4JJ1) 1B-403
installation
1. Crank gear installation
1. Install the crank gear to the crankshaft.
2. Idle gear C installation
1. Apply the engine oil to the idle gear C shaft.
Note:
・ Apply it to the gear assembly sections.
2. Install the idle gear C shaft to the timing gear case.
3. Install the idle gear C to the idle gear C shaft.
4. Apply the engine oil to the bolt.
Note:
・ Apply it to the thread and the seat.
5. Temporarily tighten the bolt to the timing gear case. Note:
・ Align the oil holes of the cylinder block and the
idle gear A shaft.
2. Apply the engine oil to the idle gear A shaft.
3. Install the idle gear A shaft to the timing gear case.
4. Install the idle gear A to the idle gear A shaft.
Note:
・ Install the idle gear A with the alignment mark
aligned.
4. Gear case cover installation 1. Install the cover to the gear case cover.
1. Apply liquid gasket to the timing gear case. Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
Note:
・ Apply ThreeBond 1207B to the area indicated
in the diagram.
Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・ 1. Power steering oil pump
in } 2. Nut
3. Install the vacuum hose to the vacuum pipe and the 2. Install the power steering oil hose to the bracket.
vacuum pump assembly.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1. Bracket
・ Use new crank pulley bolts. 1. Install the cooling fan clutch to the water pump
assembly.
Note:
・ Install the part together with the cooling fan.
1. Noise cover
1. Install the fan pulley to the water pump assembly. 14. Cooling fan belt installation
12. Cooling fan clutch installation 1. Install the cooling fan belt to the pulley.
15. Cooling fan belt adjustment
1B-408 Mechanical (4JJ1)
1. Adjust tension to a standard value using a tension : 40 N・m { 4.1 kgf・m /
meter. Mounting bolt
30 lb・ft }
Note: : 25 N・m { 2.5 kgf・m /
Adjust plate lock bolt
・ Move the generator to adjust the tension. 18 lb・ft }
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
For a
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in }
product
When : 20.7 to 23.7 mm
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
1. Measurement point 1
Note: 2. Measurement point 2
・ In the case of adjustment using a frequency 3. Measurement point 3
meter 4. Measurement point 4
・ Measure the frequency at measurement points
Note:
2, 3, and 4 with a frequency meter.
・ After adjusting the tension, tighten the
Measurement point 2 tensioner fixing nut.
Frequency of Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }
Amount of flex
vibrations
18. Radiator upper hose installation
For a
: 12.5 to 16.5 mm
new : 92 to 112 Hz 1. Install the radiator upper hose to the water outlet
{ 0.492 to 0.650 in }
product pipe and the radiator.
When : 16.5 to 19.1 mm Tightening torque: 5 N・m { 0.5 kgf・m / 44 lb・in }
: 79 to 91 Hz
reused { 0.650 to 0.752 in } Hose clip
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
For a
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in }
product
When : 20.7 to 23.7 mm
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
1. Radiator upper hose
1. Engine cover
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Install the front under guard to the frame.
Note:
・ Tighten the 4 bolts.
3. Install the rear under guard to the frame.
Note:
・ Tighten the 5 bolts.
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Engine hood assembly removal
1. Open the engine hood.
Note:
・ Support the engine hood.
2. Remove the hinge bolt from the engine hood.
Note:
・ Before removing the hinge from the engine
hood, put a marking of the hinge location for
putting the hinge back in place. 1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts.
3. Remove the rear under guard from the frame.
Note:
・ Remove the 4 bolts.
1. Battery cable
2. Battery bracket
3. Earth
19. Battery removal 1. Disconnect the radiator reserve tank hose from the
radiator.
1. Disconnect the battery ground cable from the frame.
2. Remove the radiator reserve tank from the upper fan
2. Disconnect the battery cable from the battery. guide.
3. Remove the battery bracket from the frame.
4. Remove the battery from vehicle.
1B-416 Mechanical (4JJ1)
1. Turbocharger feed oil pipe 3. Remove the catalyst converter bracket from the rear
cover.
55. Oil return pipe removal
Note:
1. Remove the oil return pipe from the turbocharger
・ Remove the exhaust side from the engine
and the crankcase.
side.
・ Remove the engine side from the crankcase.
59. Water intake pipe removal 2. Remove the water bypass pipe from the cylinder
head assembly.
1. Remove the water intake pipe from the oil filter and
the oil cooler assembly. Note:
Note: ・ Remove the water bypass pipe on the cylinder
head side.
・ Remove it with the hose attached.
2. Remove the baffle plate from the cylinder head. 2. Remove the camshaft bearing cap from the cylinder
head.
Note:
・ Confirm that it is marked.
Note:
・ Loosen it in the order shown in the diagram.
inspection
1. Valve spring inspection
1. Inspect the valve spring.
Note:
・ Visually inspect the valve springs and replace
them when damage or abnormal worn is
found.
2. Valve spring measurement
1. Measure free length using a vernier caliper.
Note:
・ If the measured value is lower than the
specified limit, replace the valve spring.
Standard: 49.04 mm { 1.93 in }
Limit: 48.15 mm { 1.90 in } 3. Measure tension using the spring tester.
Note:
・ Compress the spring to the installation height.
: 37.8 mm { 1.488 in } Installation length
Note:
・ Measure the compressed spring tension.
Standard: 213 N { 21.7 kg / 47.9 lb }
Limit: 188 N { 19.2 kg / 42.3 lb }
Note:
・ If the measured value is lower than the limit,
replace the spring.
1B-434 Mechanical (4JJ1)
Note: Caution:
・ Apply it to the valve stem portion. ・ Move it up and down to confirm that it moves
smoothly.
Mechanical (4JJ1) 1B-435
8. Valve stem end cap installation
1. Install the valve stem end cap to the split collar.
9. Cylinder head gasket preparation
1. Select the cylinder head gasket.
Note:
・ Select the grade for the cylinder head gasket
by measuring the protrusion amount of the
piston head.
・ Three types of gaskets with different thickness
are provided.
・ Select the appropriate grade from three types
of gaskets following the following steps.
・ Before measurement, remove carbon from the
piston head and the cylinder block surface,
and clean the gasket installation portion.
2. Measure the piston using a dial gauge. Note:
・ Measure the point 1, 2, 3, and 4 to calculate
Note:
the difference between 1 and, 2, and between
・ Measure the protrusion amount of the piston 3 and 4 of each cylinder.
head.
3. Calculate average value from measured value.
Note:
・ Calculate the average value for the protrusion
amount of the piston head for each cylinder.
・ Determine the grade of the gasket required for
the maximum value mentioned above
according to the following table.
Note:
・ Refer to the diagram for the measurement
position of the protrusion amount.
・ Make sure that all measuring points are
located as close to the cylinder block as
possible.
1. Measurement point
2. Measurement point
3. Measurement point
4. Measurement point
Note:
・ Cylinder head gasket combination
1B-436 Mechanical (4JJ1)
1. Bead height
2. Bead width
Caution:
・ After applying the liquid gasket, install the
cylinder head within 5 minutes.
11. Cylinder head assembly installation
1. Install the cylinder head assembly to the cylinder
block.
Note:
・ Wipe off the bottom surface of the cylinder
head.
・ Adjust the cylinder block dowel to install the
cylinder head.
2. Install the head bolt to the cylinder head.
Note: Caution:
・ The difference in the protrusion amount of ・ Use new head bolts.
each piston should not exceed 0.05 mm {0.002
in}.
10. Cylinder head gasket installation
1. Apply liquid gasket to the cylinder block.
Note:
・ Apply ThreeBond-1207B or equivalent to the
cylinder block as shown in the diagram.
Bead height: 2 to 3 mm { 0.079 to 0.118 in }
Bead width: 3 to 4 mm { 0.118 to 0.157 in }
Mechanical (4JJ1) 1B-437
3. Tighten the head bolt using a torque wrench.
Note:
・ Tighten the head bolts in the order shown in
the diagram.
Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft }
4. Tighten the head bolt using a torque wrench.
Note:
・ Tighten the head bolts in the order shown in
the diagram.
Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft }
5. Tighten the head bolt using special tool.
Note:
・ Tighten the head bolts in the order shown in
the diagram using an angle gauge.
9. Remove the wire from the engine hanger and the
hoist.
10. Remove the rear engine hanger from the cylinder
head.
13. Rocker arm shaft assembly installation 15. Timing chain tension lever installation
1. Apply the engine oil to the rocker arm shaft 1. Install the timing chain tension lever to the cylinder
assembly. head.
2. Install the rocker arm shaft assembly to the cylinder Note:
head.
・ Place the timing chain tension lever in
Note: between the timing gear case and the cylinder
・ Install the rocker arm shaft assemblies from block.
No. 1 to No. 4 in the numbering order. 16. Timing chain installation
Tightening torque: 21 N・m { 2.1 kgf・m / 15 lb・ft } 1. Install the timing chain to the idle gear D.
17. Idle gear D installation
1. Apply the engine oil to the idle gear shaft.
Note:
・ Apply it to the surface and inside.
2. Apply the engine oil to the bolt.
Note:
・ Apply it to the threaded portion and the seat
surface.
3. Install the idle gear D to the cylinder head.
Note:
・ Install the timing chain onto the sprocket of idle
gear D, and then install idle gear D.
Tightening torque: 59 N・m { 6.0 kgf・m / 44 lb・ft }
1. Surface and inside of the idle gear shaft 19. Timing chain tensioner installation
2. Threaded portion and seat surface of the bolt
1. Connect the hook to the pin.
Note: Note:
・ Align the two timing marks as indicated in the ・ Keep the state that the latch is pushed.
diagram.
・ Insert the plunger.
・ Install the hook to the pin, and fasten the
plunger.
1. Timing chain
2. Timing mark
3. Blue link
4. Yellow link 1. Pin
2. Plunger
18. Timing chain lever pivot installation 3. Latch
4. Timing chain tensioner
1. Install the timing chain lever pivot to the timing
5. Hook
chain tension lever.
Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft } 2. Install the timing chain tensioner to the cylinder
head.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
1B-440 Mechanical (4JJ1)
3. Disconnect the hook from the pin. 21. Inlet camshaft installation
Note: 1. Install the inlet camshaft to the cylinder head.
・ Lightly push the area indicated with an arrow Note:
in the diagram.
・ Align the timing mark to the idle gear D to
・ The hook of the tensioner opens, the plunger install it.
pushes the tension lever, and the chain is
pulled.
1. Liquid gasket
2. Bead height
3. Bead width
Note:
・ Apply LOCTITE 262 or equivalent to the
threaded portion on the cylinder head side.
2. Install the timing chain upper cover to the cylinder
head.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. CMP sensor
1. Liquid gasket
2. Bead height
3. Bead width
1. Noise cover
2. Install the cylinder head cover to the cylinder head. 2. Install the fuel leak-off hose to the leak-off pipe.
Note:
・ Tighten in the order in the diagram.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
1. Leak-off pipe
2. Clip
Caution:
32. Vacuum pipe installation ・ Do not reuse the leak-off pipe and the clip.
1. Install the vacuum pipe to the cylinder head cover. 34. Injector connect
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Connect the harness connector to the injector.
33. Fuel leak-off hose installation 35. Oil filter bracket installation
1. Install the leak-off pipe to the injector. 1. Install the oil filter bracket to the oil filter and the
engine hanger.
1B-446 Mechanical (4JJ1)
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 37. Water intake pipe installation
36. Water bypass pipe installation 1. Temporarily tighten the pipe bracket to the water
intake pipe.
1. Install the water bypass pipe to the cylinder head
assembly. 2. Install the water intake pipe to the oil filter.
Note: Note:
・ Install the water bypass pipe on the cylinder ・ Insert the water intake pipe into the oil filter.
head side. ・ Apply soapy water on the O-ring when
・ Apply soapy water on the O-ring when inserting the pipe.
inserting the pipe.
3. Temporarily tighten the water intake pipe to the oil
cooler and the generator bracket.
Note:
・ Temporarily tighten the nuts and bolts in the
order shown in the diagram.
Note:
・ Firmly tighten the nuts and bolts in the order
shown in the diagram.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 42. Turbocharger feed oil pipe installation
Bolt 1, 3
1. Install the turbocharger feed oil pipe to the
Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft } turbocharger and the oil cooler.
Bolt 2
Tightening torque: 23 N・m { 2.3 kgf・m / 17 lb・ft }
40. Catalyst converter connect
1. Connect the catalyst converter to the front exhaust
pipe.
Tightening torque: 67 N・m { 6.8 kgf・m / 49 lb・ft }
1. Water feed and return pipes Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
2. Turbocharger water feed hose Bolt 1
3. Water pipe
Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }
4. Turbocharger water feed hose
Bolt 2
5. Turbocharger water return hose
45. Exhaust manifold heat protector installation
44. Air duct bracket installation
1. Install the exhaust manifold heat protector to the
1. Temporarily tighten the air duct bracket to the exhaust manifold.
cylinder head assembly.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Note:
・ Temporarily tighten the nuts and bolts in the
order shown in the diagram.
2. Connect the turbocharger water feed hose to the 1. Glow plug terminal
outlet pipe. 2. Glow plug connector
52. Glow plug installation 54. Bracket installation
1. Install the glow plug to the cylinder head. 1. Install the bracket to the cylinder head cover.
Tightening torque: 18 N・m { 1.8 kgf・m / 13 lb・ft } Note:
・ Install the part together with the turbocharger
control solenoid.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1B-452 Mechanical (4JJ1)
2. Connect the connector to the turbocharger control 57. Fuel hose connect
solenoid.
1. Connect the fuel hose to the fuel supply pump.
3. Connect the vacuum hose to the turbocharger control
solenoid.
55. Leak-off pipe installation
1. Install the leak-off pipe to the fuel supply pump and
the common rail assembly.
Tightening torque: 10.3 N・m { 1.1 kgf・m / 91 lb・
in }
1. Fuel hose
For a
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in }
product
When : 20.7 to 23.7 mm
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
Note:
・ In the case of adjustment using a frequency
meter
・ Measure the frequency at measurement points
2, 3, and 4 with a frequency meter.
Measurement point 2
Frequency of
Amount of flex
vibrations
For a
: 12.5 to 16.5 mm
new : 92 to 112 Hz
{ 0.492 to 0.650 in }
product
1. A/C compressor drive belt
When : 16.5 to 19.1 mm
: 79 to 91 Hz
73. A/C compressor drive belt adjustment reused { 0.650 to 0.752 in }
1. Adjust tension to a standard value using a tension Measurement point 3
meter.
Frequency of
Amount of flex
Note: vibrations
・ When adjusting the amount of flex to the For a
: 12.4 to 16.4 mm
original value new : 92 to 112 Hz
{ 0.488 to 0.646 in }
・ Apply a load to measurement points 2, 3, and product
4 of the A/C compressor drive belt and adjust When : 16.5 to 19.1 mm
: 80 to 92 Hz
the amount of flex. reused { 0.650 to 0.752 in }
Load: 98 N { 10 kg / 22 lb } Measurement point 4
Measurement point 2 Frequency of
Amount of flex
Frequency of vibrations
Amount of flex For a
vibrations : 15.9 to 20.7 mm
For a new : 70 to 86 Hz
: 12.5 to 16.5 mm { 0.626 to 0.815 in }
new : 92 to 112 Hz product
{ 0.492 to 0.650 in } When : 20.7 to 23.7 mm
product : 62 to 70 Hz
When : 16.5 to 19.1 mm reused { 0.815 to 0.933 in }
: 79 to 91 Hz
reused { 0.650 to 0.752 in }
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
Mechanical (4JJ1) 1B-457
76. Radiator reserve tank installation
1. Install the radiator reserve tank to the upper fan
guide.
Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }
1. Measurement point 1
2. Measurement point 2
3. Measurement point 3
4. Measurement point 4
Note:
2. Connect the radiator reserve tank hose to the
・ After adjusting the tension, tighten the
radiator.
tensioner fixing nut.
Note:
Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }
・ When the radiator reserve tank is dirty, clean it
74. Generator connect before installation.
1. Connect the harness to the generator. ・ Clean the radiator reserve tank using
detergent.
Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・
in } Terminal nut ・ Scrub inside with a detergent and water.
・ Wash with clean water, and drain the water.
75. Generator cover installation
77. Radiator upper hose installation
1. Install the generator cover to the bracket and the
adjust plate. 1. Install the radiator upper hose to the water outlet
pipe and the radiator.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
Tightening torque: 5 N・m { 0.5 kgf・m / 44 lb・in }
Hose clip
1B-458 Mechanical (4JJ1)
1. Install the intake air duct to the intake throttle valve
and the intake hose.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
Bolt
Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in }
Clip
1. Battery cable
2. Battery bracket
3. Earth
Note:
・ Turn the hood rest to adjust its height, and
adjust the level difference against the engine
hood.
1. 29 mm (1.14 in)
Mechanical (4JJ1) 1B-461
1. Engine cover
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
3. Coolant drain
1. Drain coolant from the radiator.
Note:
・ Open the drain plug at the bottom of the
radiator.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts. 2. Remove the radiator cap from the radiator.
3. Remove the rear under guard from the frame. Warning:
Note: ・ In order to prevent burns, do not open the cap
・ Remove the 4 bolts. when the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Engine oil drain
1. Drain the engine oil from the oil pan.
1B-464 Mechanical (4JJ1)
Note:
・ After draining oil, tighten the drain plug to the
specified torque.
Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft }
Caution:
・ Do not forget to tighten the drain plug.
5. Intake air duct removal
1. Remove the intake air duct from the turbocharger
and the intercooler.
Note:
・ Remove the part together with the intake hose.
1. Battery cable
2. Battery bracket 14. Generator cover removal
3. Earth 1. Remove the generator cover from the bracket and the
adjust plate.
11. 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.
12. Radiator upper hose removal
1. Remove the radiator upper hose from the water
outlet pipe and the radiator.
1B-466 Mechanical (4JJ1)
1. Remove the cooling fan clutch from the water pump 29. Instrument panel assist-side lower cover removal
assembly.
1. Remove the instrument panel assist-side lower cover
Note: from the instrument panel.
・ Remove the part together with the cooling fan. Note:
・ Remove the 4 screws.
2. Disconnect the earth cable from the crankcase. 1. Intake throttle valve
2. Gasket
1. Earth cable
1. Glow plug
1. Feed hose
2. Return hose
57. Air duct bracket removal 1. Water feed and return pipes
2. Turbocharger water feed hose
1. Remove the air duct bracket from the cylinder head.
3. Water pipe
4. Turbocharger water feed hose
5. Turbocharger water return hose
61. Heater bypass pipe removal 2. Remove the pipe bracket from the oil filter.
1. Disconnect the heater bypass pipe from the water 63. Water bypass pipe removal
intake pipe.
1. Remove the water bypass pipe from the oil filter.
2. Remove the heater bypass pipe from the oil cooler
Note:
assembly and the water bypass hose.
・ Remove the water bypass pipe on the oil filter
side.
1. Top dead center alignment mark on the gear case 73. Camshaft bearing cap removal
cover
1. Install the bolt to the camshaft gear.
2. Top dead center alignment mark on the crank
pulley Note:
・ Install the M5 bolt.
72. Baffle plate removal
1. Install the lock bolt to the sub gear.
Note:
・ Use a M5 lock bolt to fix the sub gear.
1. CMP sensor
Note:
・ Confirm that the alignment marks of the
camshaft bearing cap and the camshaft are
aligned.
Mechanical (4JJ1) 1B-481
Note:
・ Lift up the timing chain.
3. Remove the fuel supply pump from the timing gear Caution:
case. ・ Do not hold the high pressure pipe when
carrying the supply pump.
87. Idle gear D removal
1. Remove the idle gear D from the cylinder head.
Note:
・ Drop the timing chain backward.
Caution:
・ Do not hold the high pressure pipe when
removing the supply pump.
4. Remove the O-ring from the fuel supply pump.
88. Timing chain removal
1. Remove the timing chain from the supply pump
sprocket.
89. Timing chain tension lever removal
1. Remove the timing chain tension lever from the
cylinder head assembly.
1B-484 Mechanical (4JJ1)
Note: Note:
・ Pull out the timing chain tension lever. ・ Be very careful not to drop the parts into the
cylinder head front-side gear case or the front
90. Timing chain guide removal
side oil return hole.
1. Install the timing chain guide to the cylinder head ・ Make sure to remember the original position.
assembly and the cylinder block.
92. Cylinder head assembly removal
1. Install the rear engine hanger to the cylinder head.
1. Nut
2. Bolt
Caution:
・ Do not reuse the head bolt.
5. Remove the cylinder head assembly from the
cylinder block.
Note:
・ Install the wire to the engine hanger and the 96. Vacuum pump assembly removal
hoist to lift the cylinder head assembly.
1. Remove the vacuum hose from the vacuum pipe and
93. Cylinder head gasket removal the vacuum pump assembly.
1. Remove the cylinder head gasket from the cylinder
head.
1B-486 Mechanical (4JJ1)
2. Remove the vacuum pump oil pipe from the vacuum 98. Gear case cover removal
pump assembly and the cylinder block.
1. Remove the gear case cover from the timing gear
Note: case.
・ Remove the vacuum pump assembly from the
gear case cover.
1. Oil pump
105.Flywheel removal
1. Remove the flywheel from the crankshaft.
Note:
・ Gradually loosen the flywheel mounting bolts
in the order shown in the diagram while
confirming that the flywheel does not rotate.
Caution:
・ Do not remove the bolt in the diagram 8 during
maintenance.
disassembly
1. Piston disassembly
1. Remove the piston ring from the piston using a ring
pliers.
Note:
・ 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.
1. Grade
2. Front mark notch
1. Measurement position 1
2. Measurement position 2
reassembly
1. Connecting rod assembly reassembly
1. Install the connecting rod to the piston.
Note:
・ Install so that the piston head front mark and
the connecting rod cast mark face the same
direction.
2. Install the snap ring to the piston.
2. Piston reassembly
1. Install the piston ring to the piston using a ring
pliers.
Note:
・ Install the piston ring in the order shown in the
diagram.
・ Install the second and first compression rings
so that the laser markings face upward.
・ Before installing the oil ring, do not create a
1. Front mark gap on the both sides of the expander coil, and
2. Cast mark then install the expander coil in the oil ring
groove.
3. Apply the engine oil to the piston pin.
Note:
・ Apply it enough.
4. Install the piston pin to the connecting rod.
Note:
・ Push it into the piston and the connecting rod
small end portion.
5. Install the snap ring to the piston using a snap ring
pliers.
Caution:
・ Confirm that the snap ring is installed in the
ring groove.
・ Confirm that the connecting rod slides
smoothly.
installation
1. Piston installation
1. Install the connecting rod bearing to the connecting
rod.
2. Apply the engine oil to the connecting rod bearing.
3. Apply the engine oil to the piston ring.
Note:
・ Thoroughly apply it to the piston ring and the
ring groove.
4. Apply the engine oil to the piston.
Note:
・ Thoroughly apply it to the piston side surface.
5. Install the piston to the cylinder block using special
tool. 6. Install the connecting rod bearing to the connecting
Note: rod bearing cap.
・ Face the notch of the piston front mark 7. Apply the engine oil to the connecting rod bearing.
towards the front.
8. Apply the engine oil to the bolt.
・ Use the piston ring compressor to insert the
cylinder block. Note:
・ Apply it to the threaded portion of the
tightening bolts and the seat surface.
9. Temporarily tighten the connecting rod bearing cap
to the connecting rod.
Note:
・ Align the cap and the connecting rod number
markings and install the cap.
SST: 5-8840-9018-0 - piston setting tool
Caution:
・ When pushing the piston, be careful not to
touch the oil jet against the connecting rod.
・ When pushing the piston, be careful not to
damage the inside of the cylinder block.
5. Flywheel installation
1. Apply the engine oil to the bolt.
1. 1 - 1.5 mm {0.039 - 0.059 in} Note:
2. 1 - 1.5 mm {0.039 - 0.059 in}
・ Apply it to the threaded portion of the bolt.
2. Install the oil seal retainer to the cylinder block and 2. Temporarily tighten the flywheel to the crankshaft.
the crankcase.
Note:
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
・ Temporarily tighten the nuts and bolts in the
order shown in the diagram.
Caution:
・ After applying the liquid gasket, install it within Note:
5 minutes.
・ For automatic transmission vehicles, install the
4. Rear plate installation sleeve, flywheel, flexible plate, washer in that
order, and temporarily tighten the order in the
1. Install the rear plate to the cylinder block and the
diagram.
crankcase.
3. Install special tool to the rear plate.
Tightening torque: 82 N・m { 8.4 kgf・m / 60 lb・ft }
Mechanical (4JJ1) 1B-501
Note:
・ Install the crankshaft stopper to the starter
installation section of the rear plate.
13. Cover installation Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・
in }
1. Install the cover to the gear case cover.
3. Install the vacuum hose to the vacuum pipe and the
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
vacuum pump assembly.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Note:
・ Refer to the diagram for the measurement
position of the protrusion amount.
・ Make sure that all measuring points are
located as close to the cylinder block as
possible.
Note:
・ Measure the point 1, 2, 3, and 4 to calculate
the difference between 1 and, 2, and between
3 and 4 of each cylinder.
3. Calculate average value from measured value.
Note:
・ Calculate the average value for the protrusion
amount of the piston head for each cylinder.
・ Determine the grade of the gasket required for
the maximum value mentioned above
according to the following table.
Note:
・ The difference in the protrusion amount of
each piston should not exceed 0.05 mm {0.002
in}.
18. Cylinder head gasket installation
1. Apply liquid gasket to the cylinder block.
Note:
・ Apply ThreeBond-1207B or equivalent to the
cylinder block as shown in the diagram.
Bead height: 2 to 3 mm { 0.079 to 0.118 in }
Note:
・ Cylinder head gasket combination
1B-508 Mechanical (4JJ1)
3. Tighten the head bolt using a torque wrench.
Note:
・ Tighten the head bolts in the order shown in
the diagram.
Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft }
4. Tighten the head bolt using a torque wrench.
Note:
・ Tighten the head bolts in the order shown in
the diagram.
Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft }
5. Tighten the head bolt using special tool.
Note:
・ Tighten the head bolts in the order shown in
the diagram using an angle gauge.
1. Bead height
2. Bead width
Caution:
・ After applying the liquid gasket, install the
cylinder head within 5 minutes.
19. Cylinder head assembly installation
1. Install the cylinder head assembly to the cylinder SST: 5-8840-0266-0 - angle gauge
block.
Specified angle: 60 to 75 °
Note:
6. Tighten the head bolt using special tool.
・ Wipe off the bottom surface of the cylinder
head. Note:
・ Adjust the cylinder block dowel to install the ・ Tighten the head bolts in the order shown in
cylinder head. the diagram using an angle gauge.
9. Remove the wire from the engine hanger and the 1. Top dead center alignment mark on the gear case
hoist. cover
2. Top dead center alignment mark on the crank
10. Remove the rear engine hanger from the cylinder
pulley
head.
21. Rocker arm shaft assembly installation
1. Apply the engine oil to the rocker arm shaft
assembly.
2. Install the rocker arm shaft assembly to the cylinder
head.
Note:
・ Install the rocker arm shaft assemblies from
No. 1 to No. 4 in the numbering order.
Tightening torque: 21 N・m { 2.1 kgf・m / 15 lb・ft }
Note:
・ Align the two timing marks as indicated in the
23. Timing chain tension lever installation diagram.
1. Install the timing chain tension lever to the cylinder
head.
Note:
・ Place the timing chain tension lever in
between the timing gear case and the cylinder
block.
24. Timing chain installation
1. Install the timing chain to the idle gear D.
25. Idle gear D installation
1. Apply the engine oil to the idle gear shaft.
Note:
・ Apply it to the surface and inside.
2. Apply the engine oil to the bolt.
Note:
1. Timing chain
・ Apply it to the threaded portion and the seat
2. Timing mark
surface.
3. Blue link
3. Install the idle gear D to the cylinder head. 4. Yellow link
Note: 26. Fuel supply pump installation
・ Install the timing chain onto the sprocket of idle
gear D, and then install idle gear D. 1. Apply soapy water to the O-ring.
Tightening torque: 59 N・m { 6.0 kgf・m / 44 lb・ft } 2. Install the O-ring to the fuel supply pump.
Caution:
・ Be careful not to twist it.
3. Install the fuel supply pump to the timing gear case.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Mechanical (4JJ1) 1B-511
1. Nut
1. Liquid gasket
2. Bead height
3. Bead width
Note:
・ Apply LOCTITE 262 or equivalent to the
threaded portion on the cylinder head side.
2. Install the timing chain upper cover to the cylinder
head.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. CMP sensor
1. Liquid gasket
2. Bead height
3. Bead width
1. Noise cover
2. Install the cylinder head cover to the cylinder head. 2. Install the fuel leak-off hose to the leak-off pipe.
Note:
・ Tighten in the order in the diagram.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
1. Leak-off pipe
2. Clip
Caution:
44. Vacuum pipe installation ・ Do not reuse the leak-off pipe and the clip.
1. Install the vacuum pipe to the cylinder head cover. 46. Injector connect
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Connect the harness connector to the injector.
45. Fuel leak-off hose installation 47. Oil filter bracket installation
1. Install the leak-off pipe to the injector. 1. Install the oil filter bracket to the oil filter and the
engine hanger.
Mechanical (4JJ1) 1B-519
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 49. Water intake pipe installation
48. Water bypass pipe installation 1. Temporarily tighten the pipe bracket to the water
intake pipe.
1. Install the water bypass pipe to the cylinder head
assembly. 2. Install the water intake pipe to the oil filter.
Note: Note:
・ Install the water bypass pipe on the cylinder ・ Insert the water intake pipe into the oil filter.
head side. ・ Apply soapy water on the O-ring when
・ Apply soapy water on the O-ring when inserting the pipe.
inserting the pipe.
3. Temporarily tighten the water intake pipe to the oil
cooler and the generator bracket.
Note:
・ Temporarily tighten the nuts and bolts in the
order shown in the diagram.
2. Connect the heater bypass pipe to the water inlet 1. Connect the turbocharger water return hose to the
pipe. water feed and return pipe.
1. Water feed and return pipes Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
2. Turbocharger water feed hose Bolt 1
3. Water pipe
Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }
4. Turbocharger water feed hose
Bolt 2
5. Turbocharger water return hose
55. Exhaust manifold heat protector installation
54. Air duct bracket installation
1. Install the exhaust manifold heat protector to the
1. Temporarily tighten the air duct bracket to the exhaust manifold.
cylinder head assembly.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Note:
・ Temporarily tighten the nuts and bolts in the
order shown in the diagram.
1. Connect the turbocharger water feed hose to the Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
water feed and return pipe. Bolt, nut
1. Water feed and return pipes 2. Connect the turbocharger water feed hose to the
2. Turbocharger water feed hose outlet pipe.
3. Water pipe 60. Glow plug installation
4. Turbocharger water feed hose
5. Turbocharger water return hose 1. Install the glow plug to the cylinder head.
Tightening torque: 18 N・m { 1.8 kgf・m / 13 lb・ft }
58. Vacuum hose installation
1. Install the vacuum hose to the turbocharger and the
vacuum pipe.
Mechanical (4JJ1) 1B-523
1. Install the bracket to the cylinder head cover. 64. Fuel hose connect
Note: 1. Connect the fuel hose to the fuel supply pump.
・ Install the part together with the turbocharger
control solenoid.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1B-524 Mechanical (4JJ1)
69. Oil level gauge guide tube installation
1. Apply the engine oil to the O-ring.
2. Install the oil level gauge guide tube to the
crankcase.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1. Fuel hose
1. Bracket Note:
・ Firmly tighten the nuts and bolts in the order
77. Catalyst converter installation
shown in the diagram.
1. Install the catalyst converter to the turbocharger
assembly.
Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft }
1. A/C compressor drive belt 2. Connect the radiator reserve tank hose to the
radiator.
95. Generator connect
Note:
1. Connect the harness to the generator.
・ When the radiator reserve tank is dirty, clean it
Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・ before installation.
in } Terminal nut ・ Clean the radiator reserve tank using
96. Generator cover installation detergent.
・ Scrub inside with a detergent and water.
1. Install the generator cover to the bracket and the
adjust plate. ・ Wash with clean water, and drain the water.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in } 98. Radiator upper hose installation
1. Install the radiator upper hose to the water outlet
pipe and the radiator.
Tightening torque: 5 N・m { 0.5 kgf・m / 44 lb・in }
Hose clip
1. Battery cable
2. Battery bracket
3. Earth
Note:
・ The following applies to 4WD.
2. Install the front under guard to the frame.
Note:
・ Tighten the 4 bolts.
3. Install the rear under guard to the frame.
Mechanical (4JJ1) 1B-533
Note: For a
: 15.9 to 20.7 mm
・ Tighten the 5 bolts. new : 70 to 86 Hz
{ 0.626 to 0.815 in }
product
When : 20.7 to 23.7 mm
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
Note:
・ In the case of adjustment using a frequency
meter
・ Measure the frequency at measurement points
2, 3, and 4 with a frequency meter.
Measurement point 2
Frequency of
Amount of flex
vibrations
For a
: 12.5 to 16.5 mm
new : 92 to 112 Hz
{ 0.492 to 0.650 in }
product
When : 16.5 to 19.1 mm
: 79 to 91 Hz
reused { 0.650 to 0.752 in }
107.A/C compressor drive belt adjustment
Measurement point 3
1. Adjust tension to a standard value using a tension
Frequency of
meter. Amount of flex
vibrations
Note: For a
: 12.4 to 16.4 mm
・ When adjusting the amount of flex to the new : 92 to 112 Hz
{ 0.488 to 0.646 in }
original value product
・ Apply a load to measurement points 2, 3, and When : 16.5 to 19.1 mm
: 80 to 92 Hz
4 of the A/C compressor drive belt and adjust reused { 0.650 to 0.752 in }
the amount of flex.
Measurement point 4
Load: 98 N { 10 kg / 22 lb }
Frequency of
Amount of flex
Measurement point 2 vibrations
Frequency of For a
Amount of flex : 15.9 to 20.7 mm
vibrations new : 70 to 86 Hz
{ 0.626 to 0.815 in }
For a product
: 12.5 to 16.5 mm When : 20.7 to 23.7 mm
new : 92 to 112 Hz : 62 to 70 Hz
{ 0.492 to 0.650 in } reused { 0.815 to 0.933 in }
product
When : 16.5 to 19.1 mm
: 79 to 91 Hz
reused { 0.650 to 0.752 in }
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
1B-534 Mechanical (4JJ1)
Note: Note:
・ After adjusting the tension, tighten the ・ After adjusting the tension, tighten the adjust
tensioner fixing nut. plate lock bolt and the mounting bolt under the
generator.
Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }
108.Cooling fan belt adjustment Generator tightening torque
: 40 N・m { 4.1 kgf・m /
1. Adjust tension to a standard value using a tension Mounting bolt
30 lb・ft }
meter.
: 25 N・m { 2.5 kgf・m /
Note: Adjust plate lock bolt
18 lb・ft }
・ Move the generator to adjust the tension.
Note:
2. Check tension of the cooling fan belt. ・ If the cooling fan belt is replaced with a new
Note: one, make the new cooling fan belt fit in to
cope with initial elongation.
・ When adjusting the amount of flex to the
original value ・ After making the cooling fan belt fit in, adjust
its tension once again.
・ Apply a load to measurement point 1 of the
cooling fan belt and adjust the amount of flex. 109.Engine oil filling
Load: 98 N { 10 kg / 22 lb } 1. Replenish the engine with the engine oil.
Note: Note:
・ In the case of adjustment using a frequency ・ Check the tightening of the oil pan drain plug.
meter
Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft }
・ Measure the frequency at measurement point
1 with a frequency meter. 110.Coolant filling
1. Priming pump
2. Fuel filter with the sedimenter
Caution:
・ Insufficient air removal work may lead
malfunction of the engine.
112.Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
3. Lower vehicle.
1B-536 Mechanical (4JJ1)
Crankcase
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
3. Coolant drain
1. Drain coolant from the radiator.
Note:
・ Open the drain plug at the bottom of the
radiator.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts. 2. Remove the radiator cap from the radiator.
3. Remove the rear under guard from the frame. Warning:
Note: ・ In order to prevent burns, do not open the cap
・ Remove the 4 bolts. when the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Engine oil drain
1. Drain the engine oil from the oil pan.
Mechanical (4JJ1) 1B-537
Note:
・ After draining oil, tighten the drain plug to the
specified torque.
Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft }
Caution:
・ Do not forget to tighten the drain plug.
5. Intake air duct removal
1. Remove the intake air duct from the turbocharger
and the intercooler.
Note:
・ Remove the part together with the intake hose.
1. Battery cable
2. Battery bracket 14. Generator cover removal
3. Earth 1. Remove the generator cover from the bracket and the
adjust plate.
11. 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.
12. Radiator upper hose removal
1. Remove the radiator upper hose from the water
outlet pipe and the radiator.
Mechanical (4JJ1) 1B-539
1. Remove the cooling fan clutch from the water pump 29. Instrument panel assist-side lower cover removal
assembly.
1. Remove the instrument panel assist-side lower cover
Note: from the instrument panel.
・ Remove the part together with the cooling fan. Note:
・ Remove the 4 screws.
1. Bracket
2. Disconnect the earth cable from the crankcase. 1. Intake throttle valve
2. Gasket
1. Earth cable
52. Water pipe removal 1. Disconnect the turbocharger water feed hose from
the water feed and return pipe.
1. Disconnect the turbocharger water feed hose from
the outlet pipe.
2. Remove the water pipe from the cylinder head
assembly.
1. Remove the vacuum hose from the turbocharger and 55. Water hose disconnect
the vacuum pipe.
1. Disconnect the water hose from the EGR cooler.
Note:
・ Disconnect both the feed hose and return hose
from the EGR cooler.
Mechanical (4JJ1) 1B-547
60. Oil return pipe removal 1. Remove the water intake pipe from the oil filter and
the oil cooler assembly.
1. Remove the oil return pipe from the turbocharger
and the crankcase. Note:
・ Remove it with the hose attached.
2. Remove the water bypass pipe from the cylinder 65. Injector disconnect
head assembly.
1. Disconnect the connector from the injector.
Note:
66. Fuel leak-off hose removal
・ Remove the water bypass pipe on the cylinder
head side. 1. Remove the fuel leak-off hose from the leak-off
pipe.
2. Remove the camshaft bearing cap from the cylinder 75. Exhaust camshaft removal
head.
1. Remove the exhaust camshaft from the cylinder
Note: head.
・ Confirm that it is marked.
77. Timing chain lower cover removal 79. Timing chain upper cover removal
1. Remove the timing chain lower cover from the gear 1. Remove the timing chain upper cover from the
case cover. cylinder head.
1. Top dead center alignment mark on the gear case 1. Supply pump gear nut
cover
2. Top dead center alignment mark on the crank 82. Timing chain tensioner removal
pulley 1. Remove the timing chain tensioner from the cylinder
head.
Note:
・ Confirm that the alignment marks of the
camshaft bearing cap and the camshaft are
aligned.
81. Supply pump gear nut removal 1. Remove the timing chain lever pivot from the timing
chain tension lever.
1. Turn the nut.
Note:
・ Loosen the nut of the supply pump gear.
Mechanical (4JJ1) 1B-555
Note:
・ Lift up the timing chain.
1. Nut
2. Bolt
95. Water pump assembly removal 2. Remove the vacuum pump oil pipe from the vacuum
pump assembly and the cylinder block.
1. Remove the water pump assembly from the timing
gear case. Note:
・ Remove the vacuum pump assembly from the
gear case cover.
1. Oil pump
Caution:
・ Do not remove the bolt in the diagram 8 during
maintenance.
1B-562 Mechanical (4JJ1)
105.Flywheel removal
1. Remove the flywheel from the crankshaft.
Note:
・ Gradually loosen the flywheel mounting bolts
in the order shown in the diagram while
confirming that the flywheel does not rotate.
108.Crankcase removal
1. Remove the crankcase from the cylinder block.
1. O-ring
2. Crankcase
Caution:
・ Take care not to damage the O-ring.
1B-564 Mechanical (4JJ1)
disassembly
1. Oil strainer removal
1. Remove the oil strainer from the crankcase.
1. Gasket
2. Oil strainer
3. Bolt
4. Crankcase
Mechanical (4JJ1) 1B-565
reassembly
1. Oil strainer installation
1. Install the gasket to the oil strainer.
2. Install the oil strainer to the crankcase.
Tightening torque: 22 N・m { 2.2 kgf・m / 16 lb・ft }
1. Gasket
2. Oil strainer
3. Bolt
4. Crankcase
1B-566 Mechanical (4JJ1)
installation
1. Crankcase installation
1. Apply liquid gasket to the crankcase.
Note:
・ Apply ThreeBond 1207C or equivalent.
・ When applying it around the O-ring, adjust the
amount so that a liquid gasket does not
protrude.
Note:
・ For automatic transmission vehicles, install the
sleeve, flywheel, flexible plate, washer in that
order, and temporarily tighten the order in the
diagram.
3. Install special tool to the rear plate.
1B-568 Mechanical (4JJ1)
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Caution:
・ Do not remove the bolt in the diagram 8 during
maintenance.
1. Timing gear case bracket 1. Top dead center alignment mark on the gear case
cover
7. Oil pump assembly installation 2. Top dead center alignment mark on the crank
1. Apply the engine oil to the oil pump gear. pulley
2. Install the oil pump to the timing gear case. 10. Idle gear C installation
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Apply the engine oil to the idle gear C shaft.
Note:
・ Apply it to the gear assembly sections.
2. Install the idle gear C shaft to the timing gear case.
3. Install the idle gear C to the idle gear C shaft.
4. Apply the engine oil to the bolt.
Note:
・ Apply it to the thread and the seat.
5. Temporarily tighten the bolt to the timing gear case.
1. Oil pump
Note:
・ Align the oil holes of the cylinder block and the
idle gear A shaft.
2. Apply the engine oil to the idle gear A shaft.
3. Install the idle gear A shaft to the timing gear case.
4. Install the idle gear A to the idle gear A shaft.
5. Install the idle gear A flange to the idle gear A.
Note:
6. Apply the engine oil to the bolt.
・ Install the idle gear A with the alignment mark
aligned. Note:
・ Apply it to the thread and the seat.
7. Temporarily tighten the bolt to the timing gear case.
Mechanical (4JJ1) 1B-571
13. Cover installation Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・
in }
1. Install the cover to the gear case cover.
3. Install the vacuum hose to the vacuum pipe and the
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
vacuum pump assembly.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Note:
・ Refer to the diagram for the measurement
position of the protrusion amount.
・ Make sure that all measuring points are
located as close to the cylinder block as
possible.
Note:
・ Measure the point 1, 2, 3, and 4 to calculate
the difference between 1 and, 2, and between
3 and 4 of each cylinder.
3. Calculate average value from measured value.
Note:
・ Calculate the average value for the protrusion
amount of the piston head for each cylinder.
・ Determine the grade of the gasket required for
the maximum value mentioned above
according to the following table.
Note:
・ The difference in the protrusion amount of
each piston should not exceed 0.05 mm {0.002
in}.
18. Cylinder head gasket installation
1. Apply liquid gasket to the cylinder block.
Note:
・ Apply ThreeBond-1207B or equivalent to the
cylinder block as shown in the diagram.
Bead height: 2 to 3 mm { 0.079 to 0.118 in }
Note:
・ Cylinder head gasket combination
Mechanical (4JJ1) 1B-575
3. Tighten the head bolt using a torque wrench.
Note:
・ Tighten the head bolts in the order shown in
the diagram.
Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft }
4. Tighten the head bolt using a torque wrench.
Note:
・ Tighten the head bolts in the order shown in
the diagram.
Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft }
5. Tighten the head bolt using special tool.
Note:
・ Tighten the head bolts in the order shown in
the diagram using an angle gauge.
1. Bead height
2. Bead width
Caution:
・ After applying the liquid gasket, install the
cylinder head within 5 minutes.
19. Cylinder head assembly installation
1. Install the cylinder head assembly to the cylinder SST: 5-8840-0266-0 - angle gauge
block.
Specified angle: 60 to 75 °
Note:
6. Tighten the head bolt using special tool.
・ Wipe off the bottom surface of the cylinder
head. Note:
・ Adjust the cylinder block dowel to install the ・ Tighten the head bolts in the order shown in
cylinder head. the diagram using an angle gauge.
9. Remove the wire from the engine hanger and the 1. Exhaust rocker arm shaft assembly
hoist. 2. Bolt, long
3. Bolt, short
10. Remove the rear engine hanger from the cylinder
4. Intake rocker arm shaft assembly
head.
5. Front
Note:
・ Align the two timing marks as indicated in the
diagram.
Note:
・ Confirm that the supply pump camshaft key is
at a horizontal position on the right side.
1B-578 Mechanical (4JJ1)
Note:
・ Install it to each sprocket.
2. Align the timing chain to the alignment mark.
Note:
・ Align the timing mark of the crankshaft
sprocket and the timing chain link of the dark
plate.
・ Align the timing mark of the fuel supply
sprocket and the timing chain link of the yellow
plate.
3. Temporarily tighten the sprocket to the supply pump
gear.
Note:
・ Align the dowel pin attached to the gear, and
install the fuel supply pump sprocket to the fuel
26. Supply pump gear installation pump shaft.
1. Install the supply pump gear to the fuel supply pump. ・ Tighten the fuel supply pump shaft nut with
your hand.
Note:
・ Align the alignment mark of the supply pump
gear and the mark on the idle gear A.
・ Confirm that the supply pump gear and the
main gear of the idle gear A are engaged.
・ Push in the supply pump gear with the supply
pump gear engaged with the sub gear of the
idle gear A.
1. Timing mark
2. Dark plate
3. Timing mark
4. Yellow plate
1. Pin
2. Plunger
3. Latch
4. Timing chain tensioner 30. Supply pump gear nut installation
5. Hook
1. Securely tighten the sprocket to the supply pump
2. Install the timing chain tensioner to the cylinder gear.
head. Tightening torque: 130 N・m { 13.3 kgf・m / 96 lb・
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in } ft }
1B-580 Mechanical (4JJ1)
Note:
・ Align the timing mark to the idle gear D to
install it.
1. Nut
1. Alignment mark
1. Injector
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket
1. Apply liquid gasket to the cam end gasket. 2. Install the cylinder head cover to the cylinder head.
Note: Note:
・ Apply ThreeBond 1207B to the area indicated ・ Tighten in the order in the diagram.
in the diagram.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
Bead width: 2.0 to 3.0 mm { 0.079 to 0.118 in }
Mechanical (4JJ1) 1B-585
1. Leak-off pipe
2. Clip
・ Apply soapy water on the O-ring when ・ Apply soapy water on the O-ring when
inserting the pipe. inserting the pipe.
3. Temporarily tighten the water intake pipe to the oil
cooler and the generator bracket.
Note:
・ Temporarily tighten the nuts and bolts in the
order shown in the diagram.
2. Securely tighten the air duct bracket to the cylinder 55. Water hose connect
head assembly.
1. Connect the water hose to the EGR cooler.
Note:
Note:
・ Firmly tighten the nuts and bolts in the order
・ Connect both the feed hose and return hose to
shown in the diagram.
the EGR cooler.
54. Exhaust manifold heat protector installation 1. Connect the turbocharger water feed hose to the
water feed and return pipe.
1. Install the exhaust manifold heat protector to the
exhaust manifold.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Mechanical (4JJ1) 1B-589
1. Water feed and return pipes 2. Connect the turbocharger water feed hose to the
2. Turbocharger water feed hose outlet pipe.
3. Water pipe
59. Glow plug installation
4. Turbocharger water feed hose
5. Turbocharger water return hose 1. Install the glow plug to the cylinder head.
57. Vacuum hose installation Tightening torque: 18 N・m { 1.8 kgf・m / 13 lb・ft }
1. Glow plug
1. Install the bracket to the cylinder head cover. 63. Fuel hose connect
Note: 1. Connect the fuel hose to the fuel supply pump.
・ Install the part together with the turbocharger
control solenoid.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1. Fuel hose
1. Bracket
1. Radiator lower hose
76. Catalyst converter installation
75. Power steering oil pump assembly installation 1. Install the catalyst converter to the turbocharger
1. Install the power steering oil pump to the timing gear assembly.
case. Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft }
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Mechanical (4JJ1) 1B-593
2. Connect the catalyst converter to the catalyst Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
converter bracket. Bolt 1, 3
Note: Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }
・ Temporarily tighten the nuts and bolts in the Bolt 2
order shown in the diagram. 77. Catalyst converter connect
1. Connect the catalyst converter to the front exhaust
pipe.
Tightening torque: 67 N・m { 6.8 kgf・m / 49 lb・ft }
Note:
・ Firmly tighten the nuts and bolts in the order
shown in the diagram.
1. Glove box
2. Instrument panel assist side lower cover
Measurement point 3
Frequency of
1. Bolt Amount of flex
vibrations
2. Clip
For a
: 12.4 to 16.4 mm
Note: new : 92 to 112 Hz
{ 0.488 to 0.646 in }
・ The following applies to 4WD. product
When : 16.5 to 19.1 mm
2. Install the front under guard to the frame. : 80 to 92 Hz
reused { 0.650 to 0.752 in }
Note:
Measurement point 4
・ Tighten the 4 bolts.
Frequency of
3. Install the rear under guard to the frame. Amount of flex
vibrations
1B-600 Mechanical (4JJ1)
For a
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in }
product
When : 20.7 to 23.7 mm
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
Note:
・ In the case of adjustment using a frequency
meter
・ Measure the frequency at measurement points
2, 3, and 4 with a frequency meter.
Measurement point 2
Frequency of
Amount of flex
vibrations
For a
: 12.5 to 16.5 mm
new : 92 to 112 Hz
{ 0.492 to 0.650 in }
product
1. Measurement point 1
When : 16.5 to 19.1 mm 2. Measurement point 2
: 79 to 91 Hz
reused { 0.650 to 0.752 in } 3. Measurement point 3
4. Measurement point 4
Measurement point 3
Frequency of Note:
Amount of flex
vibrations ・ After adjusting the tension, tighten the
For a tensioner fixing nut.
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in } Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }
product
When : 16.5 to 19.1 mm 107.Cooling fan belt adjustment
: 80 to 92 Hz
reused { 0.650 to 0.752 in } 1. Adjust tension to a standard value using a tension
meter.
Measurement point 4
Frequency of Note:
Amount of flex
vibrations ・ Move the generator to adjust the tension.
For a 2. Check tension of the cooling fan belt.
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in } Note:
product
When : 20.7 to 23.7 mm ・ When adjusting the amount of flex to the
: 62 to 70 Hz original value
reused { 0.815 to 0.933 in }
・ Apply a load to measurement point 1 of the
cooling fan belt and adjust the amount of flex.
Load: 98 N { 10 kg / 22 lb }
Note:
・ In the case of adjustment using a frequency
meter
・ Measure the frequency at measurement point
1 with a frequency meter.
Position of the belt tension
Fluctuation Frequency
: 5.4 to 6.6 mm
New : 188 to 210 Hz
{ 0.213 to 0.260 in }
: 7.7 to 8.5 mm
Reuse : 160 to 174 Hz
{ 0.303 to 0.335 in }
Mechanical (4JJ1) 1B-601
Note:
・ Pour coolant up to the MAX line.
3. Install the radiator cap to the radiator.
110.Fuel air bleed
1. Press the priming pump.
Note:
・ Press the priming pump until it gets stiff.
1. Measurement point 1
2. Measurement point 2
3. Measurement point 3
4. Measurement point 4
Note:
・ After adjusting the tension, tighten the adjust
plate lock bolt and the mounting bolt under the
generator.
Generator tightening torque 1. Priming pump
: 40 N・m { 4.1 kgf・m / 2. Fuel filter with the sedimenter
Mounting bolt
30 lb・ft }
Caution:
: 25 N・m { 2.5 kgf・m /
Adjust plate lock bolt ・ Insufficient air removal work may lead
18 lb・ft }
malfunction of the engine.
Note:
111.Battery ground cable connect
・ If the cooling fan belt is replaced with a new
one, make the new cooling fan belt fit in to 1. Connect the battery ground cable to the battery.
cope with initial elongation. 2. Close the engine hood assembly.
・ After making the cooling fan belt fit in, adjust
its tension once again. 3. Lower vehicle.
CMP sensor
1. O-ring
2. CMP sensor
1. Engine cover
1. CMP sensor
inspection
1. CMP sensor inspection
1. Inspect the CMP sensor.
Note:
・ Inspect whether the CMP sensor is securely
installed.
・ Inspect the sensor and connector sections for
damage and dirt.
1B-604 Mechanical (4JJ1)
installation
1. CMP sensor installation
1. Install the CMP sensor to the timing chain upper
cover.
Tightening torque: 5 N・m { 0.5 kgf・m / 44 lb・in }
1. Engine cover
1. O-ring
2. CMP sensor
1. CMP sensor
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Swirl control solenoid valve removal
1. Disconnect the harness connector from swirl control
solenoid valve.
2. Remove swirl control solenoid valve from the
bracket.
3. Disconnect the vacuum hose from swirl control
solenoid valve.
1B-606 Mechanical (4JJ1)
installation
1. Swirl control solenoid valve installation
1. Connect the vacuum hose to swirl control solenoid
valve.
2. Install swirl control solenoid valve to the bracket.
Tightening torque: 15 N・m { 1.5 kgf・m / 11 lb・ft }
3. Connect the connector to swirl control solenoid
valve.
2. Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
Mechanical (4JJ1) 1B-607
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts.
3. Remove the rear under guard from the frame.
Note:
・ Remove the 4 bolts.
4. Engine cover removal
1. Remove the engine cover from the engine.
1B-608 Mechanical (4JJ1)
9. Cowl cover removal
1. Remove the cowl cover from the body.
10. Wiper linkage removal
1. Remove the wiper linkage from vehicle.
Note:
・ Remove the bolt and nut from the wiper
linkage.
・ Remove the connector from the wiper motor.
1. Engine cover
3. Remove the catalyst converter bracket from the rear 19. Oil level gauge guide tube removal
cover.
1. Remove the oil level gauge from the oil level gauge
Note: guide tube.
・ Remove the exhaust side from the engine 2. Remove the oil level gauge guide tube from the
side. crankcase.
・ Remove the engine side from the crankcase.
20. Transmission oil level gauge tube removal
1. Remove transmission oil level gauge tube from the
oil pan.
21. Starter motor removal
1. Disconnect the earth cable from the starter motor.
2. Remove the starter motor from the rear plate.
22. Oil pressure switch disconnect
1. Disconnect the connector from the oil pressure
switch.
23. Engine mounting disconnect
1. Install the rear engine hanger to the cylinder head.
installation
1. Engine mounting installation
1. Install the heat protector to the engine mounting.
Tightening torque: 8.2 N・m { 0.8 kgf・m / 73 lb・in }
Note:
・ Install to the right side engine mounting.
2. Install the engine mounting to the frame.
Note:
・ Install both of the left and right engine
mountings.
Tightening torque: 60 N・m { 6.1 kgf・m / 44 lb・ft }
Note:
・ Firmly tighten the nuts and bolts in the order
shown in the diagram.
1. Nut
2. Bolt
1. Hood rest
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Disc wheel removal
1. Remove the disc wheel from vehicle.
3. Engine hood assembly removal
1. Open the engine hood.
Note:
・ Support the engine hood.
2. Remove the hinge bolt from the engine hood.
Note: 1. Bolt
・ Before removing the hinge from the engine 2. Clip
hood, put a marking of the hinge location for
putting the hinge back in place. Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts.
3. Remove the rear under guard from the frame.
Note:
・ Remove the 4 bolts.
Note:
・ Remove the bolt, nut and washer on the front
axle.
・ Remove the bolt, nut and washer on the 1. Wiper arm cover
transfer. 2. Nut
・ Remove the front propeller shaft assembly. 3. Wiper arm, blade
installation
1. Engine mounting installation
1. Install the heat protector to the engine mounting.
Tightening torque: 8.2 N・m { 0.8 kgf・m / 73 lb・in }
Note:
・ Install to the right side engine mounting.
2. Install the engine mounting to the frame.
Note:
・ Install both of the left and right engine
mountings.
Tightening torque: 60 N・m { 6.1 kgf・m / 44 lb・ft }
Note:
・ Firmly tighten the nuts and bolts in the order
shown in the diagram.
1. Nut
2. Bolt
1. 29 mm (1.14 in)
Mechanical (4JJ1) 1B-629
Note:
・ Tighten the 4 bolts.
3. Install the rear under guard to the frame.
Note:
・ Tighten the 5 bolts.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Install the front under guard to the frame.
1B-630 Mechanical (4JJ1)
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
28. Disc wheel installation
1. Install the disc wheel to vehicle.
Note:
・ Install the wheel nuts in the numbered order.
Tightening torque: 118 N・m { 12.0 kgf・m / 87.0 lb・
ft }
Note:
・ Turn the hood rest to adjust its height, and
adjust the level difference against the engine
hood.
1. Hood rest
Supplementary Information
1. Component Views Note:
・ Engine mounting (2WD)
Note:
・ Engine mounting (4WD)
1B-632 Mechanical (4JJ1)
Note:
・ Cylinder head cover
Mechanical (4JJ1) 1B-633
Note:
・ Inlet manifold
1B-634 Mechanical (4JJ1)
Note:
・ Exhaust manifold
Mechanical (4JJ1) 1B-635
Note:
・ Timing gear train
1B-636 Mechanical (4JJ1)
Note:
・ Camshaft assembly
Mechanical (4JJ1) 1B-637
Note:
・ Valve stem oil seal and valve spring
1B-638 Mechanical (4JJ1)
Note:
・ Rocker arm shaft assembly
Mechanical (4JJ1) 1B-639
Note:
・ Cylinder head
1B-640 Mechanical (4JJ1)
Note:
・ Piston and connecting rod
Mechanical (4JJ1) 1B-641
Note:
・ Flywheel
1B-642 Mechanical (4JJ1)
Note:
・ Gear case assembly
Mechanical (4JJ1) 1B-643
Note:
・ Crankshaft front oil seal
1B-644 Mechanical (4JJ1)
Note:
・ Crankshaft rear oil seal
Mechanical (4JJ1) 1B-645
Note:
・ Crankshaft
1B-646 Mechanical (4JJ1)
Note:
・ Cylinder block
Mechanical (4JJ1) 1B-647
1. Cylinder block
Engine
Fuel System
(4JJ1)
Table of Contents
Fuel..................................................................................1C-2 installation...............................................................1C-104
inspection....................................................................1C-2 Fuel sedimenter switch................................................1C-107
Injector.............................................................................1C-3 removal...................................................................1C-107
removal.......................................................................1C-3 inspection................................................................1C-108
installation...................................................................1C-7 installation...............................................................1C-109
Common rail assembly..................................................1C-12 Fuel filter switch..........................................................1C-110
removal.....................................................................1C-12 inspection................................................................1C-110
installation.................................................................1C-15 Fuel filter.....................................................................1C-111
Fuel temperature sensor.................................................1C-18 removal...................................................................1C-111
removal.....................................................................1C-18 installation...............................................................1C-112
inspection..................................................................1C-31 Supplementary Information.........................................1C-113
installation.................................................................1C-32
Pressure limiter..............................................................1C-47
removal.....................................................................1C-47
installation.................................................................1C-48
Fuel pressure sensor......................................................1C-49
removal.....................................................................1C-49
installation.................................................................1C-50
Suction control valve.....................................................1C-51
removal.....................................................................1C-51
installation.................................................................1C-53
Fuel tank........................................................................1C-55
removal.....................................................................1C-55
installation.................................................................1C-57
Fuel tank unit.................................................................1C-59
removal.....................................................................1C-59
inspection..................................................................1C-61
installation.................................................................1C-63
Fuel filter element.........................................................1C-66
removal.....................................................................1C-66
installation.................................................................1C-67
Fuel supply pump..........................................................1C-68
removal.....................................................................1C-68
installation.................................................................1C-81
Fuel filler cap.................................................................1C-96
inspection..................................................................1C-96
Filler neck......................................................................1C-97
removal.....................................................................1C-97
installation.................................................................1C-99
Fuel tube......................................................................1C-101
removal...................................................................1C-101
1C-2 Fuel System (4JJ1)
Fuel
inspection Caution:
・ Confirm that no flammable substances exist
1. Fuel air bleed under the drain hose.
1. Press the priming pump. Note:
Note: ・ Press the priming pump several times to
・ Press the priming pump until it gets stiff. completely drain water.
4. Tighten the drain plug using a wrench.
Tightening torque: 3 N・m { 0.3 kgf・m / 27 lb・in }
5. Turn ON the ignition switch.
Note:
・ Turn the ignition switch ON for 15 seconds and
check for fuel leakage.
・ Confirm that the fuel filter drain warning light is
turned off.
Caution:
・ If the fuel filter drain warning light frequently
turns on, have fuel in the fuel tank drained at
the nearest ISUZU dealer.
・ When draining fuel from the fuel tank, make
sure to stop the engine.
・ When draining fuel from the fuel tank, confirm
1. Priming pump that no flammable substance exists under the
2. Fuel filter with the sedimenter drain hose.
Caution:
・ Insufficient air removal work may lead
malfunction of the engine.
2. Fuel drain water
Note:
・ When the fuel filter drain warning light turns
on, follow the procedure described below to
drain.
1. Install the hose to the drain plug.
Note:
・ Install it on the tip of the drain plug.
2. Prepare a container.
Note:
・ Place the container at the end of the hose
attached to the drain plug.
3. Drain water from the sedimenter.
Note:
・ Loosen the drain plug, and drain water.
Fuel System (4JJ1) 1C-3
Injector
removal
1. Injector safety information
Caution:
・ The holes and gaps constituting the fuel paths
for the fuel system, including the inside of the
injector, have an extremely precise finish.
Therefore, entry of any foreign material may
cause trouble.
・ Be very careful to prevent entry of foreign
materials after removing parts, etc.
2. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Engine cover removal
1. Remove the engine cover from the engine. 5. Boost sensor disconnect
1. Disconnect the connector from the boost sensor.
1. Engine cover
6. Intake air duct removal
4. Intake air duct removal
1. Remove the intake air duct from the intake throttle
1. Remove the intake air duct from the turbocharger
valve and the intercooler.
and the intercooler.
Note:
Note:
・ Remove the part together with the intake hose.
・ Remove the part together with the intake hose.
1C-4 Fuel System (4JJ1)
Caution:
・ Do not reuse the clip of the fuel leak-off hose.
8. Vacuum pipe removal
2. Remove the leak-off pipe from the injector.
1. Remove the vacuum pipe from the cylinder head
cover.
Fuel System (4JJ1) 1C-5
installation
1. Injector installation
1. Install the O-ring to the injector.
2. Install the gasket to the injector.
Note:
・ Push the part in by hand until it stops.
・ The gasket is pushed in until it hits the end
when the clamp is tightened, and therefore, do
not push in the gasket by force.
Caution:
・ Do not reuse the leak-off pipe and the clip.
1. Injector
2. Bolt
3. Injector clamp
3. Temporarily tighten the clip to the injection pipe. 1. Cam end gasket
2. Application area
4. Securely tighten the injector clamp to the cylinder
3. Bead width
head.
Tightening torque: 26 N・m { 2.7 kgf・m / 19 lb・ft } 2. Install the cam end gasket to the cylinder head.
5. Securely tighten the injection pipe to the injector and 4. Cylinder head cover installation
the common rail assembly. 1. Apply liquid gasket to the cylinder head.
Tightening torque: 29.5 N・m { 3.0 kgf・m / 22 lb・ Note:
ft } Injector side
・ Apply ThreeBond 1207B to the area indicated
Tightening torque: 26 N・m { 2.7 kgf・m / 19 lb・ft } in the diagram.
Common rail side
6. Securely tighten the clip to the injection pipe.
Tightening torque: 7.8 N・m { 0.8 kgf・m / 69 lb・in }
3. Cam end gasket installation
1. Apply liquid gasket to the cam end gasket.
Note:
・ Apply ThreeBond 1207B to the area indicated
in the diagram.
Bead width: 2.0 to 3.0 mm { 0.079 to 0.118 in }
1. Leak-off pipe
2. Clip
1. Injector ID code
1C-10 Fuel System (4JJ1)
2. Injector
1. Engine cover
removal Caution:
・ Cover the exposed portion and do not allow
1. Battery ground cable disconnect foreign materials to get into the fuel system.
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Injector safety information
Caution:
・ The holes and gaps constituting the fuel paths
for the fuel system, including the inside of the
injector, have an extremely precise finish.
Therefore, entry of any foreign material may
cause trouble.
・ Be very careful to prevent entry of foreign
materials after removing parts, etc.
3. Starter motor removal
1. Disconnect the earth cable from the starter motor.
2. Remove the starter motor from the rear plate.
4. Fuel feed pipe removal
1. Fuel hose
1. Remove the fuel feed pipe from the fuel supply
pump and the common rail assembly. 6. Vacuum hose disconnect
Caution: 1. Disconnect the vacuum hose from the vacuum pipe.
・ Cover the exposed portion and do not allow
foreign materials to get into the fuel system.
1. Disconnect the fuel hose from the fuel supply pump. 3. Remove the leak-off pipe from the inlet manifold.
1. Leak-off pipe
installation
1. Common rail assembly installation
1. Install the swirl control solenoid valve bracket to the
common rail bracket.
Tightening torque: 15 N・m { 1.5 kgf・m / 11 lb・ft }
1. Connector
6. Leak-off pipe installation 2. Connect the fuel leak-off hose to the leak-off pipe.
1. Install the leak-off pipe to the fuel supply pump and 3. Connect the vacuum hose to the vacuum pipe.
the common rail assembly. 8. Vacuum hose connect
Tightening torque: 10.3 N・m { 1.1 kgf・m / 91 lb・ 1. Disconnect the vacuum hose from the vacuum pipe.
in }
Fuel System (4JJ1) 1C-17
1. Fuel hose
removal Note:
・ Remove the 4 bolts.
1. Injector safety information
Caution:
・ The holes and gaps constituting the fuel paths
for the fuel system, including the inside of the
injector, have an extremely precise finish.
Therefore, entry of any foreign material may
cause trouble.
・ Be very careful to prevent entry of foreign
materials after removing parts, etc.
2. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame. 4. Coolant drain
1. Bolt
2. Clip
2. Remove the radiator cap from the radiator.
Note:
・ The following applies to 4WD. Warning:
・ In order to prevent burns, do not open the cap
2. Remove the front under guard from the frame.
when the engine and radiator are hot.
Note: ・ Heat liquid and steam may gush out by
・ Remove the 5 bolts. pressure.
3. Remove the rear under guard from the frame. 5. Engine cover removal
Fuel System (4JJ1) 1C-19
1. Remove the engine cover from the engine.
10. Battery removal 1. Remove the fan guide from the radiator.
1. Fan clutch assembly 17. Oil level gauge guide tube removal
2. Cooling fan
1. Remove the oil level gauge from the oil level gauge
14. Fan shroud removal guide tube.
1. Remove the fan guide from the radiator. 2. Remove the oil level gauge guide tube from the
crankcase.
Note:
18. A/C compressor assembly disconnect
・ Remove the lower fan guide together with the
fan shroud. 1. Remove the A/C compressor assembly from the A/C
compressor bracket.
15. A/C compressor drive belt removal
1. Remove the A/C compressor drive belt from the
pulley.
1. Leak-off pipe
38. Noise cover removal 1. Remove the timing chain upper cover from the
cylinder head.
1. Remove the noise cover from the timing chain lower
cover.
1. Noise cover 1. Remove the timing chain lower cover from the gear
case cover.
39. Water pipe removal
1. Disconnect the turbocharger water feed hose from
the outlet pipe.
2. Remove the water pipe from the cylinder head
assembly.
Fuel System (4JJ1) 1C-27
Note:
・ Confirm that the alignment marks of the
camshaft bearing cap and the camshaft are
aligned.
1C-28 Fuel System (4JJ1)
Caution:
・ Do not hold the high pressure pipe when
removing the supply pump.
4. Remove the O-ring from the fuel supply pump.
48. Fuel supply pump removal
1. Disconnect the harness connector from the fuel
temperature sensor.
2. Disconnect the harness connector from the suction
control valve.
1C-30 Fuel System (4JJ1)
1. Supply pump
2. O-ring
Caution:
・ Do not hold the high pressure pipe when
carrying the supply pump.
49. Fuel temperature sensor removal
1. Remove the fuel temperature sensor from the fuel
supply pump.
inspection
1. Fuel temperature sensor inspection
1. Measure a resistance using tester.
Note:
・ The fuel temperature sensor is a thermistor
type with electrical resistance reducing
properties in accordance with rises in
temperature.
Temperature Resistance
: 110 ℃ { 230 °F } : 140 Ω
: 100 ℃ { 212 °F } : 180 Ω
: 90 ℃ { 194 °F } : 240 Ω
: 80 ℃ { 176 °F } : 310 Ω
: 70 ℃ { 158 °F } : 420 Ω
: 60 ℃ { 140 °F } : 580 Ω
: 50 ℃ { 122 °F } : 810 Ω
: 40 ℃ { 104 °F } : 1150 Ω
: 30 ℃ { 86 °F } : 1660 Ω
: 20 ℃ { 68 °F } : 2450 Ω
: 10 ℃ { 50 °F } : 3700 Ω
: 0 ℃ { 32 °F } : 5740 Ω
: -10 ℃ { 14 °F } : 9160 Ω
: -20 ℃ { -4 °F } : 15000 Ω
: -30 ℃ { -22 °F } : 25400 Ω
Note:
・ Replace if there are any abnormalities in the
inspection results.
1C-32 Fuel System (4JJ1)
installation Note:
・ Confirm that the supply pump camshaft key is
1. Fuel temperature sensor installation at a horizontal position on the right side.
1. Install the O-ring to the fuel temperature sensor.
2. Install the fuel temperature sensor to the fuel supply
pump.
Tightening torque: 22 N・m { 2.2 kgf・m / 16 lb・ft }
1. Timing mark
2. Dark plate
3. Timing mark
4. Yellow plate 1. Pin
2. Plunger
5. Timing chain lever pivot installation 3. Latch
4. Timing chain tensioner
1. Temporarily tighten the timing chain lever pivot to 5. Hook
the timing chain tension lever.
Note: 2. Install the timing chain tensioner to the cylinder
head.
・ Tighten the pivot bolt with your hand.
・ Confirm that the tension lever moves Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
smoothly.
1C-34 Fuel System (4JJ1)
1. Liquid gasket
2. Bead height
3. Bead width
Note:
・ Apply LOCTITE 262 or equivalent to the
threaded portion on the cylinder head side.
2. Install the timing chain upper cover to the cylinder 2. Connect the turbocharger water feed hose to the
head. outlet pipe.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 11. Noise cover installation
1. Install the noise cover to the timing chain lower
cover.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
1C-36 Fuel System (4JJ1)
1. CMP sensor
1. Leak-off pipe
2. Clip
23. Fuel pressure sensor connect 25. Leak off pipe installation
1. Connect the connector to the fuel pressure sensor. 1. Install the leak-off pipe to the inlet manifold.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1. Connector
24. Leak-off pipe installation 2. Connect the fuel leak-off hose to the leak-off pipe.
1. Install the leak-off pipe to the fuel supply pump and 3. Connect the vacuum hose to the vacuum pipe.
the common rail assembly. 26. Fuel hose connect
Tightening torque: 10.3 N・m { 1.1 kgf・m / 91 lb・ 1. Connect the fuel hose to the fuel supply pump.
in }
1C-40 Fuel System (4JJ1)
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1. Fuel hose
2. Connect the fuel hose to the leak-off pipe. 30. A/C compressor assembly connect
27. Fuel feed pipe installation 1. Install the A/C compressor assembly to the A/C
compressor bracket.
1. Install the fuel feed pipe to the fuel supply pump and
the common rail assembly. Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }
1. Fuel feed pipe 31. Oil level gauge guide tube installation
28. Starter motor installation 1. Apply the engine oil to the O-ring.
1. Install the starter motor to the rear plate. 2. Install the oil level gauge guide tube to the
crankcase.
Tightening torque: 94 N・m { 9.6 kgf・m / 69 lb・ft }
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2. Connect the earth cable to the starter motor.
29. A/C compressor bracket installation
1. Install the A/C compressor bracket to the cylinder
head.
Fuel System (4JJ1) 1C-41
1. Install the A/C compressor drive belt to the pulley. Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
1C-42 Fuel System (4JJ1)
For a
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in }
product
When : 20.7 to 23.7 mm
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
Note:
・ In the case of adjustment using a frequency
meter
・ Measure the frequency at measurement points
2, 3, and 4 with a frequency meter.
Measurement point 2
Frequency of
Amount of flex
vibrations
For a
: 12.5 to 16.5 mm
new : 92 to 112 Hz
{ 0.492 to 0.650 in }
product
1. Measurement point 1
When : 16.5 to 19.1 mm 2. Measurement point 2
: 79 to 91 Hz
reused { 0.650 to 0.752 in } 3. Measurement point 3
4. Measurement point 4
Measurement point 3
Frequency of Note:
Amount of flex
vibrations ・ After adjusting the tension, tighten the
For a tensioner fixing nut.
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in } Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }
product
When : 16.5 to 19.1 mm 35. Fan shroud installation
: 80 to 92 Hz
reused { 0.650 to 0.752 in } 1. Install the fan guide to the radiator.
Measurement point 4 Note:
Frequency of ・ Install the lower fan guide together with the fan
Amount of flex
vibrations shroud.
For a 36. Cooling fan installation
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in } 1. Install the cooling fan to the fan clutch assembly.
product
When : 20.7 to 23.7 mm Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
Fuel System (4JJ1) 1C-43
1. Fan clutch assembly Note:
2. Cooling fan ・ When the radiator reserve tank is dirty, clean it
before installation.
37. Fan guide installation
・ Clean the radiator reserve tank using
1. Install the fan guide to the radiator. detergent.
Note: ・ Scrub inside with a detergent and water.
・ Install the upper fan guide. ・ Wash with clean water, and drain the water.
39. Battery installation
1. Install the battery to vehicle.
41. Intake air duct installation 1. Install the intake air duct to the turbocharger and the
intake hose.
1. Install the intake air duct to the intake throttle valve
and the intake hose. Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Bolt
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
Bolt Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in }
Clip
Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in }
Clip
42. Boost sensor connect 1. Install the engine cover to the engine.
1. Engine cover
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Install the front under guard to the frame.
Note:
・ Tighten the 4 bolts.
1. Priming pump 3. Install the rear under guard to the frame.
2. Fuel filter with the sedimenter
Note:
Caution: ・ Tighten the 5 bolts.
・ Insufficient air removal work may lead
malfunction of the engine.
46. Coolant filling
1. Replenish the radiator with coolant.
Note:
・ Use the coolant contains 50 % anti-freeze
solution.
1C-46 Fuel System (4JJ1)
Pressure limiter
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Leak-off pipe removal
1. Remove the leak-off pipe from the fuel supply pump
and the common rail assembly.
Caution:
・ Cover the exposed portion and do not allow
foreign materials to get into the fuel system.
1. Leak-off pipe
1. Leak-off pipe
Fuel System (4JJ1) 1C-49
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Fuel pressure sensor disconnect
1. Disconnect the connector from the fuel pressure
sensor.
1. Connector
installation
1. Fuel pressure sensor installation
1. Install the fuel pressure sensor to the common rail
assembly.
Tightening torque: 35 N・m { 3.6 kgf・m / 26 lb・ft }
1. Connector
removal Caution:
・ Be careful not to damage the connector by
1. Injector safety information applying excessive force.
Caution:
・ The holes and gaps constituting the fuel paths
for the fuel system, including the inside of the
injector, have an extremely precise finish.
Therefore, entry of any foreign material may
cause trouble.
・ Be very careful to prevent entry of foreign
materials after removing parts, etc.
2. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. 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.
1. Fuel temperature sensor
4. Remove the battery from vehicle. 2. Suction control valve
1. Battery cable
2. Battery bracket
3. Earth
1. O-ring
Fuel System (4JJ1) 1C-53
installation
1. Suction control valve installation
1. Install the O-ring to the fuel supply pump.
1. Fuel hose
Note:
・ Connect the engine harness that fastens the
area around the fuel supply pump.
4. Battery installation
1. Install the battery to vehicle.
1C-54 Fuel System (4JJ1)
Note:
・ Confirm that the Fuel Supply Pump Learning
Status display changes from Not Learned to
Learned.
9. Start the engine.
Note:
・ Start the engine and warm the engine up.
10. Check the data display of a scan tool.
Note:
・ Confirm that the coolant temperature display is
at the standard value or higher.
Standard: 65 ℃ { 149 °F }
11. Check the data display of a scan tool.
Note:
1. Battery cable ・ Confirm that the pump unit difference learning
2. Battery bracket complete status display changes from Not
3. Earth Learned to Learned.
2. Install the battery bracket to the frame. 12. Check the DTC of a scan tool.
Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in } Note:
Battery side ・ Confirm that a scan tool does not detect a
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft } DTC.
Frame side
3. Connect the battery cable to the battery.
4. Connect the battery ground cable to the frame.
5. Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
6. ECM writing
Note:
・ When replacing the fuel supply pump or
suction control valve, this procedure is
required.
1. Connect a scan tool to the DLC.
2. Turn ON the ignition switch.
3. Select the Diagnostics.
4. Select the Engine.
5. Select the engine model.
6. Select the Actuator Test.
7. Select the Fuel Supply Pump Learn Resetting.
Note:
・ Follow the directions on the screen and reset
the ECM Fuel Pump Learning Status.
8. Check the Data List of a scan tool.
Fuel System (4JJ1) 1C-55
Fuel tank
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Fuel filler cap removal
1. Remove the fuel filler cap from the filler neck.
Note:
・ Loosen the fuel filler cap gradually.
Caution:
・ Be careful with fuel spouts due to a pressure
change in the fuel tank.
・ Cover the opening of the filler neck to prevent
foreign materials from getting inside. 1. J-type nut
3. Fuel tube disconnect 2. Inner liner
3. Spats
1. Disconnect the fuel tube from the fuel hose. 4. Screw
2. Disconnect the fuel return tube from the fuel hose. 5. Rear mud guard removal
Note:
・ The following applies to vehicles equipped with
rear mud guards.
1. Remove the rear mud guard from the rear body.
Note:
・ Remove the 3 screws.
1. Fuel tube
2. Fuel return tube
Note:
・ Cover the ends of each hose and pipe to
prevent foreign materials from getting inside.
8. Fuel tank removal
1. Hold the fuel tank using the lifter.
Note:
・ Support the bottom of the fuel tank using the
lifter.
2. Remove the fuel tank band from the frame.
Fuel System (4JJ1) 1C-57
1. J-type nut
2. Inner liner
3. Spats
4. Screw 1. Priming pump
2. Fuel filter with the sedimenter
6. Fuel tube connect
Caution:
1. Connect the fuel return tube to the fuel hose.
・ Insufficient air removal work may lead
2. Connect the fuel tube to the fuel hose. malfunction of the engine.
9. Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
3. Lower vehicle.
10. Fuel inspection
1. Start the engine.
Note:
・ Check for loosening or fuel leakage at the
connections of the fuel system.
Fuel System (4JJ1) 1C-59
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Fuel filler cap removal
1. Remove the fuel filler cap from the filler neck.
Note:
・ Loosen the fuel filler cap gradually.
Caution:
・ Be careful with fuel spouts due to a pressure
change in the fuel tank.
・ Cover the opening of the filler neck to prevent
foreign materials from getting inside. 1. J-type nut
3. Fuel tube disconnect 2. Inner liner
3. Spats
1. Disconnect the fuel tube from the fuel hose. 4. Screw
2. Disconnect the fuel return tube from the fuel hose. 5. Rear mud guard removal
Note:
・ The following applies to vehicles equipped with
rear mud guards.
1. Remove the rear mud guard from the rear body.
Note:
・ Remove the 3 screws.
1. Fuel tube
2. Fuel return tube
inspection
1. Fuel tank unit seal inspection
1. Connect the filler neck to the fuel tank.
Note:
・ Connect both the filler hose and evaporator
hose.
2. Remove the cap from the breather.
3. Install the hose to the fuel tank unit.
Note:
・ Connect the breather to the return-side pipe.
4. Install the fuel filler cap to the filler neck.
Note:
・ Tighten it until it clicks at least once.
5. Apply soapy water to the seal. 1. Positive side power supply terminal
2. Ground terminal
Note:
・ Apply the soapy water to the area around the
fuel gauge unit seal.
・ Inject air from the feed-side pipe of the fuel
tank unit to the fuel tank for at least 15
seconds at the specified pressure.
Standard: 34.3 kPa { 0.35 kgf/cm2 / 5 psi }
Note:
・ Confirm that bubbles are not coming out
around the fuel gauge unit seal.
2. Fuel tank unit inspection
1. Inspect the fuel tank unit.
Note:
・ The fuel tank unit changes the internal
resistance in accordance with the float position
which varies depending on the fluid surface
1. Distance from the point E to the 1/4 point
height and operates the fuel meter indicator.
2. Distance from the point E to the 1/2 point
・ While moving the float from E to F, measure 3. Distance from the point E to the 3/4 point
the resistance value between the positive 4. Distance from the point E to the point F
power supply terminal and the ground terminal 5. Point F
of the connector. 6. 3/4 point
7. 1/2 point
8. 1/4 point
9. Point E
Float
Actual Resistance
posit Distance
capacity value
ion
: 73.5 L
Poin : 171.6 mm
{ 16.17 : 14 to 20 Ω
t F { 6.756 in }
Imp.gal }
1C-62 Fuel System (4JJ1)
: 55.2 L
: 116.2 mm : 31.25 to
3/4 { 12.14
{ 4.575 in } 37.25 Ω
Imp.gal }
: 39.9 L
: 76.8 mm
1/2 { 8.78 : 42 to 48 Ω
{ 3.024 in }
Imp.gal }
: 24.7 L
: 43.1 mm : 69.75 to
1/4 { 5.43
{ 1.697 in } 77.75 Ω
Imp.gal }
Poin : 0 mm { 0 : 9.5 L { 2.09 : 100.5 to
t E in } Imp.gal } 104.5 Ω
Note:
・ Connect the fuel tank unit to the connector on
the vehicle and move the float.
・ Confirm that the low fuel warning light turns on
when the float is at the E position.
・ If any abnormality is found in the inspection
result, replace the relevant part with a normal
one.
Fuel System (4JJ1) 1C-63
installation Caution:
・ Do not damage the hose and tube by
1. Fuel tank unit installation contacting with other parts.
Note: Note:
・ Clean the seal surfaces of the fuel tank and ・ Put the fuel tank on the lifter and install the fuel
the fuel gauge unit. tank by elevating the lifter.
Caution: 2. Connect the connector to the fuel gauge unit.
・ Foreign materials on the seal surface cause
Caution:
fuel leakage.
・ Securely connect the connector to the stopper.
1. Install the seal to the fuel tank.
3. Install the fuel tank band to the frame.
Note:
Tightening torque: 68 N・m { 6.9 kgf・m / 50 lb・ft }
・ Install a new fuel gauge unit seal along the
groove of the fuel tank opening. Caution:
2. Install the fuel gauge unit to the fuel tank. ・ Securely install the anchor of the tank band to
the guide hole of the frame.
Note:
・ Install it gradually not to distort the float arm.
・ Install the flange of the fuel gauge unit on the
fuel gauge unit seal, in such a way that the
convex portion of the fuel gauge unit fits with
the concave portion of the fuel tank.
3. Install the retainer ring to the fuel tank.
Note:
・ Align the positions of the alignment mark on
the retainer side and the alignment mark on
the fuel tank side as shown in the diagram.
1. Screw
2. J-type nut
3. Inner liner
4. Rear mud guard
1. Priming pump
2. Fuel filter with the sedimenter
Caution:
・ Insufficient air removal work may lead
malfunction of the engine.
10. Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
3. Lower vehicle.
11. Fuel inspection
1. Start the engine.
Note:
・ Check for loosening or fuel leakage at the
connections of the fuel system.
1C-66 Fuel System (4JJ1)
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Fuel filter removal
1. Disconnect the connector from the fuel sedimenter
switch.
2. Disconnect the connector from the pressure switch.
3. Disconnect the fuel hose from the fuel filter
assembly.
Note:
・ Disconnect the feed hose and the return hose,
and plug the hoses to prevent the fuel from
spilling.
1. Fuel filter body
4. Remove the fuel filter from the fuel filter bracket. 2. Fuel filter element
3. O-ring
4. Element case
Caution:
・ Use the ISUZU genuine fuel filters for
replacement.
installation
1. Fuel filter element installation
1. Install the fuel filter element to the fuel filter body.
2. Install the element case to the fuel filter body.
Caution:
・ Insufficient air removal work may lead
malfunction of the engine.
4. Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
1C-68 Fuel System (4JJ1)
removal Note:
・ Remove the 4 bolts.
1. Injector safety information
Caution:
・ The holes and gaps constituting the fuel paths
for the fuel system, including the inside of the
injector, have an extremely precise finish.
Therefore, entry of any foreign material may
cause trouble.
・ Be very careful to prevent entry of foreign
materials after removing parts, etc.
2. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame. 4. Coolant drain
1. Bolt
2. Clip
2. Remove the radiator cap from the radiator.
Note:
・ The following applies to 4WD. Warning:
・ In order to prevent burns, do not open the cap
2. Remove the front under guard from the frame.
when the engine and radiator are hot.
Note: ・ Heat liquid and steam may gush out by
・ Remove the 5 bolts. pressure.
3. Remove the rear under guard from the frame. 5. Engine cover removal
Fuel System (4JJ1) 1C-69
1. Remove the engine cover from the engine.
10. Battery removal 1. Remove the fan guide from the radiator.
1. Fan clutch assembly 17. Oil level gauge guide tube removal
2. Cooling fan
1. Remove the oil level gauge from the oil level gauge
14. Fan shroud removal guide tube.
1. Remove the fan guide from the radiator. 2. Remove the oil level gauge guide tube from the
crankcase.
Note:
18. A/C compressor assembly disconnect
・ Remove the lower fan guide together with the
fan shroud. 1. Remove the A/C compressor assembly from the A/C
compressor bracket.
15. A/C compressor drive belt removal
1. Remove the A/C compressor drive belt from the
pulley.
1. Leak-off pipe
38. Noise cover removal 1. Remove the timing chain upper cover from the
cylinder head.
1. Remove the noise cover from the timing chain lower
cover.
1. Noise cover 1. Remove the timing chain lower cover from the gear
case cover.
39. Water pipe removal
1. Disconnect the turbocharger water feed hose from
the outlet pipe.
2. Remove the water pipe from the cylinder head
assembly.
Fuel System (4JJ1) 1C-77
Note:
・ Confirm that the alignment marks of the
camshaft bearing cap and the camshaft are
aligned.
1C-78 Fuel System (4JJ1)
Caution:
・ Do not hold the high pressure pipe when
removing the supply pump.
4. Remove the O-ring from the fuel supply pump.
48. Fuel supply pump removal
1. Disconnect the harness connector from the fuel
temperature sensor.
2. Disconnect the harness connector from the suction
control valve.
1C-80 Fuel System (4JJ1)
1. Supply pump
2. O-ring
Caution:
・ Do not hold the high pressure pipe when
carrying the supply pump.
Fuel System (4JJ1) 1C-81
installation Note:
・ Align the alignment mark of the supply pump
1. Fuel supply pump installation gear and the mark on the idle gear A.
1. Apply soapy water to the O-ring. ・ Confirm that the supply pump gear and the
2. Install the O-ring to the fuel supply pump. main gear of the idle gear A are engaged.
・ Push in the supply pump gear with the supply
Caution: pump gear engaged with the sub gear of the
・ Be careful not to twist it. idle gear A.
3. Install the fuel supply pump to the timing gear case.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1. Timing mark
2. Dark plate
3. Timing mark
4. Yellow plate 1. Pin
2. Plunger
4. Timing chain lever pivot installation 3. Latch
4. Timing chain tensioner
1. Temporarily tighten the timing chain lever pivot to
5. Hook
the timing chain tension lever.
Note: 2. Install the timing chain tensioner to the cylinder
head.
・ Tighten the pivot bolt with your hand.
・ Confirm that the tension lever moves Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }
smoothly.
・ The hook of the tensioner opens, the plunger Bead height: 2.0 to 2.5 mm { 0.079 to 0.098 in }
pushes the tension lever, and the chain is Bead width: 2.0 to 2.5 mm { 0.079 to 0.098 in }
pulled.
Caution:
・ After applying the liquid gasket, install the
cover within 5 minutes.
1. Nut
1. Noise cover
1. CMP sensor
1. Leak-off pipe
2. Clip
2. Connect the connector to the turbocharger control
2. Install the fuel leak-off hose to the leak-off pipe. solenoid.
3. Connect the vacuum hose to the turbocharger control
solenoid.
18. Common rail assembly installation
1. Install the swirl control solenoid valve bracket to the
common rail bracket.
Tightening torque: 15 N・m { 1.5 kgf・m / 11 lb・ft }
1. Leak-off pipe
2. Clip
Caution:
・ Do not reuse the leak-off pipe and the clip.
16. Vacuum pipe installation
1. Install the vacuum pipe to the cylinder head cover.
1. Common rail assembly
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 2. Vacuum pipe
17. Bracket installation 3. Common rail bracket
4. Swirl control solenoid valve bracket
1. Install the bracket to the cylinder head cover.
2. Install the common rail assembly to the cylinder
Note:
block.
・ Install the part together with the turbocharger
control solenoid.
Fuel System (4JJ1) 1C-87
Note:
・ Install the part together with the common rail
bracket.
・ Tighten in the order in the diagram.
Caution:
・ Do not grasp the pressure sensor during a
work.
・ Be careful not to damage the connector unit of
the pressure sensor.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
21. Injection pipe connect 1. Install the leak-off pipe to the fuel supply pump and
the common rail assembly.
1. Connect the injection pipe to the common rail
assembly. Tightening torque: 10.3 N・m { 1.1 kgf・m / 91 lb・
in }
Note:
・ Tighten the injection pipe sleeve nut.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1C-88 Fuel System (4JJ1)
24. Leak off pipe installation 2. Connect the fuel hose to the leak-off pipe.
1. Install the leak-off pipe to the inlet manifold. 26. Fuel feed pipe installation
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Install the fuel feed pipe to the fuel supply pump and
the common rail assembly.
Tightening torque: 44.1 N・m { 4.5 kgf・m / 33 lb・
ft }
For a
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in }
product
When : 20.7 to 23.7 mm
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
Note:
・ In the case of adjustment using a frequency
meter
・ Measure the frequency at measurement points
2, 3, and 4 with a frequency meter.
Measurement point 2
Frequency of
Amount of flex
vibrations
For a
: 12.5 to 16.5 mm
new : 92 to 112 Hz
{ 0.492 to 0.650 in }
product
1. A/C compressor drive belt
When : 16.5 to 19.1 mm
: 79 to 91 Hz
33. A/C compressor drive belt adjustment reused { 0.650 to 0.752 in }
1. Adjust tension to a standard value using a tension Measurement point 3
meter.
Frequency of
Amount of flex
Note: vibrations
・ When adjusting the amount of flex to the For a
: 12.4 to 16.4 mm
original value new : 92 to 112 Hz
{ 0.488 to 0.646 in }
・ Apply a load to measurement points 2, 3, and product
4 of the A/C compressor drive belt and adjust When : 16.5 to 19.1 mm
: 80 to 92 Hz
the amount of flex. reused { 0.650 to 0.752 in }
Load: 98 N { 10 kg / 22 lb } Measurement point 4
Measurement point 2 Frequency of
Amount of flex
Frequency of vibrations
Amount of flex For a
vibrations : 15.9 to 20.7 mm
For a new : 70 to 86 Hz
: 12.5 to 16.5 mm { 0.626 to 0.815 in }
new : 92 to 112 Hz product
{ 0.492 to 0.650 in } When : 20.7 to 23.7 mm
product : 62 to 70 Hz
When : 16.5 to 19.1 mm reused { 0.815 to 0.933 in }
: 79 to 91 Hz
reused { 0.650 to 0.752 in }
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
Fuel System (4JJ1) 1C-91
1. Fan clutch assembly
2. Cooling fan
1. Measurement point 1
2. Measurement point 2
3. Measurement point 3
4. Measurement point 4
Note:
・ After adjusting the tension, tighten the
tensioner fixing nut.
Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft } 1. Upper fan guide
2. Clip
34. Fan shroud installation
3. Lower fan guide
1. Install the fan guide to the radiator. 4. Fan shroud
Note: 37. Radiator reserve tank installation
・ Install the lower fan guide together with the fan
1. Install the radiator reserve tank to the upper fan
shroud.
guide.
35. Cooling fan installation
Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }
1. Install the cooling fan to the fan clutch assembly.
Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }
1. Battery cable
2. Battery bracket
3. Earth
1. Priming pump
2. Fuel filter with the sedimenter
43. Engine cover installation
1. Install the engine cover to the engine. Caution:
・ Insufficient air removal work may lead
malfunction of the engine.
45. Coolant filling
1. Replenish the radiator with coolant.
Note:
・ Use the coolant contains 50 % anti-freeze
solution.
1C-94 Fuel System (4JJ1)
inspection
1. Fuel filler cap inspection
1. Inspect the fuel filler cap.
Note:
・ Inspect the seal state of the fuel cap.
1. Seal ring
Caution:
・ The same fuel cap must be used for
replacement.
・ It must be replaced with the same type
because the fuel filler cap is designed mainly
for this application.
・ Otherwise, it may cause the fall of the engine
performance.
Fuel System (4JJ1) 1C-97
Filler neck
removal Note:
・ The following applies to vehicles equipped with
1. Battery ground cable disconnect rear mud guards.
1. Open the engine hood assembly. 1. Remove the rear mud guard from the rear body.
2. Disconnect the battery ground cable from the battery. Note:
3. Raise vehicle using the jack. ・ Remove the 3 screws.
2. Fuel filler cap removal
1. Remove the fuel filler cap from the filler neck.
Note:
・ Loosen the fuel filler cap gradually.
Caution:
・ Be careful with fuel spouts due to a pressure
change in the fuel tank.
・ Cover the opening of the filler neck to prevent
foreign materials from getting inside.
3. Front flap removal
Note:
・ The following applies to standard cabs.
1. Remove the front flap from the rear body.
Note:
・ Remove the 3 screws. 1. Screw
2. J-type nut
3. Inner liner
4. Rear mud guard
installation
1. Filler neck installation
1. Connect the evaporator hose to the filler neck.
Note:
・ Install the part to the original position by
aligning each mark.
2. Install the filler neck to the rear body and the fuel
filler hose.
Note:
・ Install the part to the original position by
aligning each mark.
Tightening torque: 6 N・m { 0.6 kgf・m / 53 lb・in }
Filler neck
Tightening torque: 2 N・m { 0.20 kgf・m / 17.7 lb・
in } Fuel tank side clamp 1. Screw
2. J-type nut
Tightening torque: 3 N・m { 0.31 kgf・m / 26.6 lb・ 3. Inner liner
in } Clamp on the filler pipe side 4. Rear mud guard
2. Inner liner installation
4. Front flap installation
1. Install the inner liner to the rear body.
Note:
Note: ・ The following applies to standard cabs.
・ The following applies to standard cabs with
1. Install the front flap to the rear body.
front flaps.
・ Left side: Install the 7 clips. Note:
・ The following applies to standard cabs without ・ Install the 3 screws.
front flaps. ・ Securely insert the J-type nut until it hits the
・ Left side: Install the 10 clips. inner end of the panel.
・ The following applies to wide cabs.
・ Left side: Install the 9 clips and the screw.
3. Rear mud guard installation
Note:
・ The following applies to vehicles equipped with
rear mud guards.
1. Install the rear mud guard to the rear body.
Note:
・ Tighten the 3 screws to the specified torque.
Tightening torque: 3 N・m { 0.3 kgf・m / 27 lb・in }
Note:
・ Securely insert the J-type nut until it hits the
inner end of the panel.
1. J-type nut
2. Inner liner
3. Spats
4. Screw
Fuel tube
removal
1. Fuel tube safety information
Caution:
・ Do not light a match, or do not generate a
flame.
・ Avoid fire at the workshop, and prevent
inflammables from catching fire.
・ Disconnect the battery ground cable and
prevent electric short circuit.
・ When performing welding or similar heat
generating works, preprocess the pipelines or
associated parts to protect them from thermal
damage or spattering.
・ Do not contact the assembly with the
electrolyte of the battery.
・ Do not wipe the assembly with the cloth that 1. Fuel tube
has been used to wipe the spilled electrolyte. 2. Fuel return tube
・ Do not use the piping to which the electrolyte
of the battery was scattered or the cloth which 5. Front flap removal
was soaked with the electrolyte of the battery Note:
after wiping the piping. ・ The following applies to standard cabs.
2. Battery ground cable disconnect 1. Remove the front flap from the rear body.
1. Open the engine hood assembly.
Note:
2. Disconnect the battery ground cable from the battery. ・ Remove the 3 screws.
3. Raise vehicle using the jack.
3. Fuel filler cap removal
1. Remove the fuel filler cap from the filler neck.
Note:
・ Loosen the fuel filler cap gradually.
Caution:
・ Be careful with fuel spouts due to a pressure
change in the fuel tank.
・ Cover the opening of the filler neck to prevent
foreign materials from getting inside.
4. Fuel tube disconnect
1. Disconnect the fuel tube from the fuel hose.
2. Disconnect the fuel return tube from the fuel hose.
1. J-type nut
2. Inner liner
3. Spats
4. Screw
1. Screw
2. J-type nut
3. Inner liner
4. Rear mud guard
2. Remove the fuel tube from the fuel gauge unit. Caution:
Note: ・ Cover the removed connector with a plastic
bag to prevent dust or rain water from
・ To remove the quick connector, hold the quick
entering.
connector with one hand while pushing the
square release button of the connector as
shown in the diagram, and pull out the
connector with the other hand.
1. O-ring
2. Port
3. Connector
4. Plastic tube
Caution:
・ Do not use any tool.
・ When disconnecting the connector, remove it
barehanded.
・ Use lubricating oil, or push and pull the
connector until the pipe is disconnected.
1C-104 Fuel System (4JJ1)
installation Caution:
・ Securely connect the connector to the stopper.
1. Fuel tube installation
3. Install the fuel tank band to the frame.
1. Inspect the fuel tube.
Tightening torque: 68 N・m { 6.9 kgf・m / 50 lb・ft }
Note:
Caution:
・ If there are flaws, dents, or cracks, replace the
port and connector. ・ Securely install the anchor of the tank band to
the guide hole of the frame.
・ When installing a connector, remove dusts
collected on a port.
・ If there are rusts, dents or damages, replace
the connector.
2. Install the fuel tube to the fuel gauge unit.
Note:
・ Insert the connector straight until it clicks.
・ After the connector clicks, pull it out with the
force of 49 N {5 kg /11 lb}, and securely lock it
so as not to be drawn in.
1. Screw
2. J-type nut
3. Inner liner
4. Rear mud guard
1. Install the front flap to the rear body. 8. Fuel filler cap installation
Note: 1. Install the fuel filler cap to the filler neck.
・ Install the 3 screws. Note:
・ Securely insert the J-type nut until it hits the ・ Tighten the filler cap until it clicks at least 3
inner end of the panel. times.
9. Fuel air bleed
1. Press the priming pump.
1C-106 Fuel System (4JJ1)
Note:
・ Press the priming pump until it gets stiff.
1. Priming pump
2. Fuel filter with the sedimenter
Caution:
・ Insufficient air removal work may lead
malfunction of the engine.
10. Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
3. Lower vehicle.
11. Fuel inspection
1. Start the engine.
Note:
・ Check for loosening or fuel leakage at the
connections of the fuel system.
12. Fuel tube inspection
1. Start the engine.
Note:
・ Start the engine and observe the engine idle
speed.
・ Dusts in the fuel system may affect the fuel
injection system.
2. Inspect the fuel tube.
Note:
・ Check for fuel leakage.
Fuel System (4JJ1) 1C-107
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Fuel filter removal
1. Disconnect the connector from the fuel sedimenter
switch.
2. Disconnect the connector from the pressure switch.
3. Disconnect the fuel hose from the fuel filter
assembly.
Note:
・ Disconnect the feed hose and the return hose,
and plug the hoses to prevent the fuel from
spilling.
1. Fuel filter body
4. Remove the fuel filter from the fuel filter bracket. 2. Fuel filter element
3. O-ring
4. Element case
inspection
1. Fuel sedimenter switch inspection
1. Check continuity of the fuel sedimenter switch.
Note:
・ Confirm that there is continuity between the
switch connector terminals when the float of
the fuel sedimenter is above the drain line.
2. Turn ON the ignition switch.
3. Disconnect the connector from the fuel sedimenter
switch.
4. Check lighting of the warning light.
Note:
・ Connect the connector terminal to the harness
side, and confirm that the sedimenter warning
light turns on.
・ If any abnormality is found in the inspection,
replace the switch section and repair any
connection failure or open circuit between the
circuits.
1. Sensor
2. Vehicle-side connector
3. Harness
4. Drain valve
Fuel System (4JJ1) 1C-109
installation
1. Fuel sedimenter switch installation
1. Install the element case to the fuel filter body.
1. Priming pump
2. Fuel filter with the sedimenter
Caution:
・ Insufficient air removal work may lead
malfunction of the engine.
4. Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
1C-110 Fuel System (4JJ1)
inspection
1. Fuel filter switch inspection
1. Inspect the fuel filter switch using the circuit tester.
Note:
・ Attach the circuit tester on the terminals of the
fuel filter switch and confirm that no continuity
exists.
・ If there is continuity, replace the part.
2. Install the vacuum pump to the fuel filter.
Note:
・ Install a vacuum pump to the engine-side pipe
of the fuel filter.
・ Seal the pipe on the fuel tank side.
Caution:
・ Be careful to prevent fuel from entering the
vacuum pump.
3. Inspect the fuel filter switch using the circuit tester.
Note:
・ Generate a negative pressure with the vacuum
pump and inspect that continuity exists at the
specified pressure value.
Specified pressure: -38 to -42 kPa { -0.39 to -0.43 kgf/
cm2 / 285 to 315 mmHg }
Note:
・ If there is no continuity, replace the part.
Fuel System (4JJ1) 1C-111
Fuel filter
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Fuel filter removal
1. Disconnect the connector from the fuel sedimenter
switch.
2. Disconnect the connector from the pressure switch.
3. Disconnect the fuel hose from the fuel filter
assembly.
Note:
・ Disconnect the feed hose and the return hose,
and plug the hoses to prevent the fuel from
spilling.
4. Remove the fuel filter from the fuel filter bracket.
1C-112 Fuel System (4JJ1)
1. Priming pump
Fuel System (4JJ1) 1C-113
Supplementary Information
1. Component Views Note:
・ Fuel filter assembly
Note:
・ Fuel injector
1C-114 Fuel System (4JJ1)
Note:
・ Common rail assembly
Fuel System (4JJ1) 1C-115
Note:
・ Fuel supply pump
1C-116 Fuel System (4JJ1)
Note:
・ Suction control valve
Fuel System (4JJ1) 1C-117
Note:
・ Fuel tank
1C-118 Fuel System (4JJ1)
Note:
・ Fuel gauge unit
Fuel System (4JJ1) 1C-119
Engine
Cooling
(4JJ1)
Table of Contents
Coolant............................................................................1D-2
inspection....................................................................1D-2
Cooling fan belt...............................................................1D-4
removal.......................................................................1D-4
inspection....................................................................1D-6
installation..................................................................1D-7
Water pump assembly...................................................1D-10
removal.....................................................................1D-10
inspection..................................................................1D-14
installation................................................................1D-15
Thermostat.....................................................................1D-20
removal.....................................................................1D-20
inspection..................................................................1D-22
installation................................................................1D-23
Engine coolant temperature sensor...............................1D-25
removal.....................................................................1D-25
inspection..................................................................1D-27
installation................................................................1D-28
Cooling fan clutch.........................................................1D-29
removal.....................................................................1D-29
inspection..................................................................1D-33
installation................................................................1D-34
Radiator.........................................................................1D-39
removal.....................................................................1D-39
inspection..................................................................1D-42
installation................................................................1D-44
Radiator cap..................................................................1D-48
removal.....................................................................1D-48
inspection..................................................................1D-49
installation................................................................1D-50
A/C compressor drive belt............................................1D-51
removal.....................................................................1D-51
inspection..................................................................1D-52
installation................................................................1D-53
Supplementary Information..........................................1D-55
1D-2 Cooling (4JJ1)
Coolant
inspection Note:
・ Inspection of coolant leakage
1. Coolant inspection
2. Inspect water leak using the radiator cap tester.
Note:
Note:
・ Inspection of coolant level
・ Apply the pressure specified below, and
1. Inspect coolant. inspect the locations described below for a
Note: leak.
・ Inspect the coolant level in the reserve tank, Pressure: 196 kPa { 2.0 kgf/cm2 }
and when the level is between MAX and MIN,
then the level is appropriate. Inspection points for coolant leakage
・ Open the radiator cap and confirm that the Radiator
radiator is filled with the coolant up to the filler Water pump
portion inside the radiator. Parts
Radiator hose
Caution: Heater hose
・ Make sure to inspect the coolant level only
when the engine is cool.
Note:
・ If the coolant is insufficient, remove the cap of
the reserve tank and refill the coolant to the
level around the MAX line.
Reference amount of coolant
Manual transmission : 8.7 L { 1.91 Imp.gal }
Automatic transmission : 8.6 L { 1.89 Imp.gal }
Note:
・ Reference replacement period: Every 2 years
Note:
・ Engine coolant concentration
3. Set concentration to a standard value.
Note:
・ The concentration of the engine coolant affects
its freezing temperature. Therefore, the
concentration should be adjusted to the lowest
atmospheric temperature.
・ Use the Isuzu genuine engine coolant.
・ When the mixing ratio of the engine coolant is
60 % or higher, it overheats easily, and when it
is 30 % or lower, it cannot sufficiently prevent
1. Radiator reserve tank corrosion. Therefore, make sure to use the
2. MAX engine coolant with a specified concentration.
3. MIN ・ If the engine coolant with concentrations other
than a specified one is used, the anti-freezing
Cooling (4JJ1) 1D-3
Note:
・ Coolant scope method
・ Measure the concentration using a coolant
scope.
1. Radiator
2. Hydrometer
Note:
・ The temperature of the coolant should be
within the specified range.
Specified temperature: 0 to 50 ℃ { 32 to 122 °F }
1D-4 Cooling (4JJ1)
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Intake air duct removal
1. Remove the intake air duct from the turbocharger
and the intercooler.
Note:
・ Remove the part together with the intake hose.
inspection Note:
・ After adjusting the tension, tighten the adjust
1. Cooling fan belt inspection plate lock bolt and the mounting bolt under the
1. Inspect the cooling fan belt. generator.
Note: Generator tightening torque
・ Inspect the belt for worn and damage, and : 40 N・m { 4.1 kgf・m /
Mounting bolt
replace it with a new one as necessary. 30 lb・ft }
・ Adjust the tension of the cooling fan belt as : 25 N・m { 2.5 kgf・m /
Adjust plate lock bolt
necessary. 18 lb・ft }
2. Inspect tension. Note:
Note: ・ If the cooling fan belt is replaced with a new
・ The following is the belt tension adjusting one, make the new cooling fan belt fit in to
method based on belt deflection. cope with initial elongation.
・ Apply a load to measurement point 1 of the ・ After making the cooling fan belt fit in, adjust
cooling fan belt and adjust the amount of flex. its tension once again.
Load: 98 N { 10 kg / 22 lb }
Note:
・ The following is the belt tension adjusting
method with a sonic tension meter.
・ Measure the frequency at measurement point
1 with a sonic tension meter.
Position of the belt tension
Deflection Frequency
: 5.4 to 6.6 mm
New : 188 to 210 Hz
{ 0.213 to 0.260 in }
: 7.7 to 8.5 mm
Reuse : 160 to 174 Hz
{ 0.303 to 0.335 in }
1. Measurement point 1
2. Measurement point 2
3. Measurement point 3
4. Measurement point 4
Cooling (4JJ1) 1D-7
installation Note:
・ After adjusting the tension, tighten the adjust
1. Cooling fan belt installation plate lock bolt and the mounting bolt under the
1. Install the cooling fan belt to the pulley. generator.
2. Cooling fan belt adjustment Generator tightening torque
1. Adjust tension to a standard value using a tension : 40 N・m { 4.1 kgf・m /
Mounting bolt
meter. 30 lb・ft }
: 25 N・m { 2.5 kgf・m /
Note: Adjust plate lock bolt
18 lb・ft }
・ Move the generator to adjust the tension.
Note:
2. Check tension of the cooling fan belt.
・ If the cooling fan belt is replaced with a new
Note: one, make the new cooling fan belt fit in to
・ When adjusting the amount of flex to the cope with initial elongation.
original value ・ After making the cooling fan belt fit in, adjust
・ Apply a load to measurement point 1 of the its tension once again.
cooling fan belt and adjust the amount of flex. 3. A/C compressor drive belt installation
Load: 98 N { 10 kg / 22 lb } 1. Install the A/C compressor drive belt to the pulley.
Note:
・ In the case of adjustment using a frequency
meter
・ Measure the frequency at measurement point
1 with a frequency meter.
Position of the belt tension
Fluctuation Frequency
: 5.4 to 6.6 mm
New : 188 to 210 Hz
{ 0.213 to 0.260 in }
: 7.7 to 8.5 mm
Reuse : 160 to 174 Hz
{ 0.303 to 0.335 in }
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
For a
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in } 1. Measurement point 1
product
2. Measurement point 2
When : 20.7 to 23.7 mm
: 62 to 70 Hz 3. Measurement point 3
reused { 0.815 to 0.933 in }
4. Measurement point 4
Note:
Note:
・ In the case of adjustment using a frequency
meter ・ After adjusting the tension, tighten the
tensioner fixing nut.
・ Measure the frequency at measurement points
2, 3, and 4 with a frequency meter. Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
For a 1. Air cleaner assembly
: 15.9 to 20.7 mm 2. MAF sensor
new : 70 to 86 Hz
{ 0.626 to 0.815 in } 3. Blow-by hose
product
4. Intake pipe
Cooling (4JJ1) 1D-9
5. Barometric pressure sensor
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
3. Coolant drain
1. Drain coolant from the radiator.
Note:
・ Open the drain plug at the bottom of the
radiator.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts. 2. Remove the radiator cap from the radiator.
3. Remove the rear under guard from the frame. Warning:
Note: ・ In order to prevent burns, do not open the cap
・ Remove the 4 bolts. when the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Engine cover removal
1. Remove the engine cover from the engine.
Cooling (4JJ1) 1D-11
5. Intake air duct removal 1. Remove the radiator upper hose from the water
outlet pipe and the radiator.
1. Remove the intake air duct from the turbocharger
and the intercooler.
Note:
・ Remove the part together with the intake hose.
1. Disconnect the radiator reserve tank hose from the 2. Disconnect the harness connector from the
radiator. barometric pressure sensor.
2. Remove the radiator reserve tank from the upper fan 3. Disconnect the vacuum hose from the air cleaner
guide. assembly.
4. Disconnect the intake pipe from the turbocharger
assembly.
5. Remove the air cleaner assembly from vehicle.
1D-12 Cooling (4JJ1)
inspection
1. Water pump assembly inspection
1. Inspect the water pump assembly.
Note:
・ The water pump assembly cannot be
disassembled.
・ If excessive wear or damage is found, replace
the water pump assembly.
・ If cracks are found on the water pump body,
replace the water pump assembly.
・ If coolant leakage from the seal unit is found,
replace the water pump assembly.
・ Coolant leakage from the seal unit
・ If excessive radial play during manual rotation
of the fan center or abnormal sounds are
found, replace the water pump assembly.
・ If cracks or corrosion is found on the impeller,
replace the water pump assembly.
・ If excessive thrust play of the fan center is
found, replace the water pump assembly.
Standard: 0.2 mm { 0.0079 in } or less
Cooling (4JJ1) 1D-15
For a
: 12.5 to 16.5 mm
new : 92 to 112 Hz
{ 0.492 to 0.650 in }
product
When : 16.5 to 19.1 mm
: 79 to 91 Hz
reused { 0.650 to 0.752 in }
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
1. Measurement point 1 vibrations
2. Measurement point 2 For a
: 15.9 to 20.7 mm
3. Measurement point 3 new : 70 to 86 Hz
{ 0.626 to 0.815 in }
4. Measurement point 4 product
When : 20.7 to 23.7 mm
Note: : 62 to 70 Hz
reused { 0.815 to 0.933 in }
・ After adjusting the tension, tighten the adjust
plate lock bolt and the mounting bolt under the Note:
generator. ・ In the case of adjustment using a frequency
meter
Generator tightening torque
・ Measure the frequency at measurement points
: 40 N・m { 4.1 kgf・m / 2, 3, and 4 with a frequency meter.
Mounting bolt
30 lb・ft }
: 25 N・m { 2.5 kgf・m / Measurement point 2
Adjust plate lock bolt
18 lb・ft } Frequency of
Amount of flex
vibrations
Note:
For a
・ If the cooling fan belt is replaced with a new : 12.5 to 16.5 mm
new : 92 to 112 Hz
one, make the new cooling fan belt fit in to { 0.492 to 0.650 in }
product
cope with initial elongation.
When : 16.5 to 19.1 mm
・ After making the cooling fan belt fit in, adjust : 79 to 91 Hz
reused { 0.650 to 0.752 in }
its tension once again.
7. A/C compressor drive belt adjustment Measurement point 3
Frequency of
1. Adjust tension to a standard value using a tension Amount of flex
vibrations
meter.
For a
Note: : 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
・ When adjusting the amount of flex to the product
original value When : 16.5 to 19.1 mm
: 80 to 92 Hz
・ Apply a load to measurement points 2, 3, and reused { 0.650 to 0.752 in }
4 of the A/C compressor drive belt and adjust
the amount of flex. Measurement point 4
Frequency of
Load: 98 N { 10 kg / 22 lb } Amount of flex
vibrations
Measurement point 2 For a
: 15.9 to 20.7 mm
Frequency of new : 70 to 86 Hz
Amount of flex { 0.626 to 0.815 in }
vibrations product
Cooling (4JJ1) 1D-17
1. Measurement point 1
2. Measurement point 2
3. Measurement point 3
4. Measurement point 4
1. Engine cover
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Install the front under guard to the frame.
Note:
・ Tighten the 4 bolts.
3. Install the rear under guard to the frame.
1D-20 Cooling (4JJ1)
Thermostat
removal Note:
・ The following applies to 4WD.
1. Engine cover removal
2. Remove the front under guard from the frame.
1. Remove the engine cover from the engine.
Note:
・ Remove the 5 bolts.
3. Remove the rear under guard from the frame.
Note:
・ Remove the 4 bolts.
1. Engine cover
1. Bolt
2. Clip
Cooling (4JJ1) 1D-21
2. Remove the radiator cap from the radiator. Caution:
Warning: ・ Take care not to damage the thermostat.
・ In order to prevent burns, do not open the cap
when the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Radiator upper hose removal
1. Remove the radiator upper hose from the water
outlet pipe and the radiator.
1. Front
2. Thermostat
3. Jiggle valve
6. Thermostat removal
1. Remove the thermostat from the thermostat housing.
1D-22 Cooling (4JJ1)
inspection
1. Thermostat inspection
1. Inspect the thermostat.
Note:
・ Make the necessary adjustments, repairs, and
part replacements if excessive worn or
damage is found.
2. Measure the thermostat using the engine coolant
temperature gauge.
Note:
・ Place the thermostat in water completely.
・ Heat the water.
・ Stir water continually to avoid directly heating
the thermostat.
・ Check the valve temperature of the
thermostat.
Initial valve-opening
: 85 ℃ { 185 °F }
temperature
Full-open temperature : 100 ℃ { 212 °F }
Valve lift amount at full-
open : 10 mm { 0.39 in }
1. Piece of wood
2. Stirring stick
Cooling (4JJ1) 1D-23
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 2. Replenish the radiator reserve tank with coolant.
Note:
・ Pour coolant up to the MAX line.
3. Install the radiator cap to the radiator.
5. Front under guard installation
Note:
・ The following applies to 2WD.
1. Install the front under guard to the frame.
Note:
・ Tighten the clip and the 5 bolts.
Note:
・ The following applies to 4WD.
2. Install the front under guard to the frame.
Note:
・ Tighten the 4 bolts.
3. Install the rear under guard to the frame.
Note:
・ Tighten the 5 bolts.
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
3. Coolant drain
1. Drain coolant from the radiator.
Note:
・ Open the drain plug at the bottom of the
radiator.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts.
3. Remove the rear under guard from the frame. 2. Remove the radiator cap from the radiator.
Note: Warning:
・ Remove the 4 bolts. ・ In order to prevent burns, do not open the cap
when the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Engine coolant temperature sensor removal
1. Disconnect the connector from the engine coolant
temperature sensor.
1D-26 Cooling (4JJ1)
Note:
・ If any abnormality is found in the resistance
value, replace the engine coolant temperature
sensor.
Caution:
・ Be careful not to allow water to get into the
terminal section.
・ Wipe off the water droplets on the sensor after
the inspection.
Note:
・ Temperature vs resistance value, approximate
value
Temperature Resistance value
: 120 ℃ { 248 °F } : 115 Ω
: 110 ℃ { 230 °F } : 150 Ω
: 100 ℃ { 212 °F } : 190 Ω
: 90 ℃ { 194 °F } : 250 Ω
: 80 ℃ { 176 °F } : 330 Ω
: 70 ℃ { 158 °F } : 450 Ω
: 60 ℃ { 140 °F } : 610 Ω
1D-28 Cooling (4JJ1)
installation Note:
・ Tighten the clip and the 5 bolts.
1. Engine coolant temperature sensor installation
1. Apply thread locking adhesive to the engine coolant
temperature sensor.
Note:
・ Apply Loctite 262 or equivalent to the threaded
portion.
2. Install the engine coolant temperature sensor to the
cylinder head assembly.
Tightening torque: 20 N・m { 2.0 kgf・m }
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Install the front under guard to the frame.
Note:
・ Tighten the 4 bolts.
3. Install the rear under guard to the frame.
1. Water outlet pipe Note:
2. Engine coolant temperature sensor ・ Tighten the 5 bolts.
3. Connect the connector to the engine coolant
temperature sensor.
2. Coolant filling
1. Replenish the radiator with coolant.
Note:
・ Use the coolant contains 50 % anti-freeze
solution.
・ Pour coolant up to the filler neck.
2. Replenish the radiator reserve tank with coolant.
Note:
・ Pour coolant up to the MAX line.
3. Install the radiator cap to the radiator.
3. Front under guard installation
Note:
4. Battery ground cable connect
・ The following applies to 2WD.
1. Connect the battery ground cable to the battery.
1. Install the front under guard to the frame.
2. Close the engine hood assembly.
Cooling (4JJ1) 1D-29
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
3. Coolant drain
1. Drain coolant from the radiator.
Note:
・ Open the drain plug at the bottom of the
radiator.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts. 2. Remove the radiator cap from the radiator.
3. Remove the rear under guard from the frame. Warning:
Note: ・ In order to prevent burns, do not open the cap
・ Remove the 4 bolts. when the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Engine cover removal
1. Remove the engine cover from the engine.
1D-30 Cooling (4JJ1)
5. Intake air duct removal 1. Remove the radiator upper hose from the water
outlet pipe and the radiator.
1. Remove the intake air duct from the turbocharger
and the intercooler.
Note:
・ Remove the part together with the intake hose.
1. Disconnect the radiator reserve tank hose from the 2. Disconnect the harness connector from the
radiator. barometric pressure sensor.
2. Remove the radiator reserve tank from the upper fan 3. Disconnect the vacuum hose from the air cleaner
guide. assembly.
4. Disconnect the intake pipe from the turbocharger
assembly.
5. Remove the air cleaner assembly from vehicle.
Cooling (4JJ1) 1D-31
inspection
1. Cooling fan clutch inspection
1. Inspect the cooling fan clutch.
Note:
・ If any worn, damage, or other abnormalities
are found, repair or replace the defective parts.
・ Visually inspect for abnormalities such as
silicone grease leakage.
・ Vehicle inspection
・ Rotate the fan clutch by hand while the engine
is still cool before starting, and confirm that it
rotates easily.
・ Start the engine and warm it up until the
temperature of the fan clutch section reaches
about 85 ℃ {185 ℉}.
・ Then, stop the engine, and confirm that 1. Hot air gun
considerable labor and clutch torque are 2. Thermistor
necessary to rotate the fan clutch by hand.
・ If the fan clutch is easy to rotate, that indicates
that silicone grease leaks inside. Replace it
with a new one.
Note:
・ Unit inspection
・ When measuring with a thermistor, warm the
bimetal of the fan clutch with a hot air gun until
the temperature reaches about 85 ˚C {185 ˚F}.
・ Then, confirm that considerable labor and
clutch torque are necessary to rotate the fan
clutch.
・ If the fan clutch is easy to rotate, that indicates
that silicone grease leaks inside. Replace it
with a new one.
1D-34 Cooling (4JJ1)
For a
: 12.5 to 16.5 mm
new : 92 to 112 Hz
{ 0.492 to 0.650 in }
product
When : 16.5 to 19.1 mm
: 79 to 91 Hz
reused { 0.650 to 0.752 in }
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
1. Measurement point 1 vibrations
2. Measurement point 2 For a
: 15.9 to 20.7 mm
3. Measurement point 3 new : 70 to 86 Hz
{ 0.626 to 0.815 in }
4. Measurement point 4 product
When : 20.7 to 23.7 mm
Note: : 62 to 70 Hz
reused { 0.815 to 0.933 in }
・ After adjusting the tension, tighten the adjust
plate lock bolt and the mounting bolt under the Note:
generator. ・ In the case of adjustment using a frequency
meter
Generator tightening torque
・ Measure the frequency at measurement points
: 40 N・m { 4.1 kgf・m / 2, 3, and 4 with a frequency meter.
Mounting bolt
30 lb・ft }
: 25 N・m { 2.5 kgf・m / Measurement point 2
Adjust plate lock bolt
18 lb・ft } Frequency of
Amount of flex
vibrations
Note:
For a
・ If the cooling fan belt is replaced with a new : 12.5 to 16.5 mm
new : 92 to 112 Hz
one, make the new cooling fan belt fit in to { 0.492 to 0.650 in }
product
cope with initial elongation.
When : 16.5 to 19.1 mm
・ After making the cooling fan belt fit in, adjust : 79 to 91 Hz
reused { 0.650 to 0.752 in }
its tension once again.
7. A/C compressor drive belt adjustment Measurement point 3
Frequency of
1. Adjust tension to a standard value using a tension Amount of flex
vibrations
meter.
For a
Note: : 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
・ When adjusting the amount of flex to the product
original value When : 16.5 to 19.1 mm
: 80 to 92 Hz
・ Apply a load to measurement points 2, 3, and reused { 0.650 to 0.752 in }
4 of the A/C compressor drive belt and adjust
the amount of flex. Measurement point 4
Frequency of
Load: 98 N { 10 kg / 22 lb } Amount of flex
vibrations
Measurement point 2 For a
: 15.9 to 20.7 mm
Frequency of new : 70 to 86 Hz
Amount of flex { 0.626 to 0.815 in }
vibrations product
1D-36 Cooling (4JJ1)
1. Measurement point 1
2. Measurement point 2
3. Measurement point 3
4. Measurement point 4
1. Engine cover
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Install the front under guard to the frame.
Note:
・ Tighten the 4 bolts.
3. Install the rear under guard to the frame.
Cooling (4JJ1) 1D-39
Radiator
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
3. Coolant drain
1. Drain coolant from the radiator.
Note:
・ Open the drain plug at the bottom of the
radiator.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts. 2. Remove the radiator cap from the radiator.
3. Remove the rear under guard from the frame. Warning:
Note: ・ In order to prevent burns, do not open the cap
・ Remove the 4 bolts. when the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Engine cover removal
1. Remove the engine cover from the engine.
1D-40 Cooling (4JJ1)
5. Intake air duct removal 1. Remove the radiator upper hose from the water
outlet pipe and the radiator.
1. Remove the intake air duct from the turbocharger
and the intercooler.
Note:
・ Remove the part together with the intake hose.
inspection Note:
・ Cleaning of inside of radiator and water
1. Radiator inspection passage
1. Inspect the radiator. ・ Wash the inside of the radiator and coolant
Note: path with water.
・ A bent fin causes ventilation to fall, and may ・ Remove all scales and rust.
cause overheat. ・ Washing the radiator core
・ Any bent fin must be straightened. Caution:
・ When straightening, pay attention especially to ・ Do not apply high-pressure washing to the
the bottom of the fin. radiator, intercooler, and peripheral parts while
・ Remove filth, insects, or any other foreign they are installed in the vehicle.
matter. Note:
2. Clean the radiator using detergent. ・ Seal the hose connection with a cap or fabric
Note: tape.
・ Wash the inside of the radiator and the engine ・ Wet the front and rear surfaces of the radiator
coolant path with water and a mild detergent. sufficiently.
・ Remove every sign of scales and rust. ・ For fouling that can be removed by splashing
tap water, thoroughly wash them off.
3. Inspect the radiator using the radiator cap tester. ・ Do not use a high-pressure washing machine
Note: or brush.
・ Send the air of the specified pressure from the 2. Apply detergent to the radiator.
filler neck to the radiator using a radiator cap
tester. Note:
・ Leakage from the radiator. ・ Apply a type of mild detergent which contains
approximately 8 % of surface acting agent,
・ Leakage from the coolant pump and leave it for 10 minutes.
・ Leakage from the water hose. ・ Use of material other than mild detergent may
・ Check the rubber hose for bulging. cause corrosion.
・ Spray mild detergent on the front and rear
surfaces of the fin, and leave it for 10 minutes.
3. Clean the radiator using the high-pressure washing
machine.
Note:
・ Wash off mild detergent with a high-pressure
washing machine.
・ Wash the radiator from the engine side.
・ Apply high-pressure water perpendicular to the
fins.
・ Do not bring the high-pressure water too close
to the fins.
Caution:
・ Watch for deformation of the fins.
Note:
・ Clean the radiator core if it is found dirty.
2. Radiator cleaning
1. Clean the radiator using tap water.
Cooling (4JJ1) 1D-43
1. Radiator
Note:
・ After washing, inspect the fins to confirm that
dirt has been completely washed off.
・ If washing is insufficient, wash them again.
・ If dirt remains, fine black particles are seen
attached on the fins.
4. Clean the radiator using tap water.
Note:
・ Wash off detergent ingredients on the fins and
resin parts thoroughly with the tap water.
・ Remove the seal on the hose connection.
・ Thoroughly clean and dry the hose connection.
1D-44 Cooling (4JJ1)
installation
1. Radiator installation
1. Install the radiator to vehicle.
Note:
・ Be careful not to damage the radiator core with
the fan blades. Install the radiator together with
the hose as a unit.
2. Install the bracket to the radiator.
Note:
・ Support the radiator upper tank with the
bracket to fix the radiator.
1. Upper fan guide 2. Connect the radiator reserve tank hose to the
2. Clip radiator.
3. Lower fan guide
Note:
4. Fan shroud
・ When the radiator reserve tank is dirty, clean it
7. Radiator upper hose installation before installation.
1. Install the radiator upper hose to the water outlet ・ Clean the radiator reserve tank using
pipe and the radiator. detergent.
・ Scrub inside with a detergent and water.
Tightening torque: 5 N・m { 0.5 kgf・m / 44 lb・in }
Hose clip ・ Wash with clean water, and drain the water.
9. Intake air duct installation
1. Install the intake air duct to the turbocharger and the
intake hose.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Bolt
Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in }
Clip
1. Engine cover
Radiator cap
removal
1. Radiator cap removal
1. Open the engine hood assembly.
2. Remove the radiator cap from the radiator.
Caution:
・ Do not loosen or remove the radiator cap
when the coolant is hot.
・ Steam and boiling water may burst out causing
burns or heat related injuries.
・ When opening the radiator cap, place a thick
cloth over the cap when the coolant is cooled,
and turn it gradually to release the pressure
before opening it.
Cooling (4JJ1) 1D-49
inspection
1. Radiator cap inspection
1. Inspect the radiator cap.
Note:
・ Make the necessary adjustments, repairs, and
part replacements if excessive worn or
damage is found.
2. Measure the radiator cap using the radiator cap
tester.
Note:
・ Measure the open valve pressure of the
pressure valve.
・ Replace the cap if the open valve pressure is
not at the standard value.
Standard: 93.3 to 122.7 kPa { 0.95 to 1.25 kgf/cm2 /
13.5 to 17.8 psi }
installation
1. Radiator cap installation
1. Install the radiator cap to the radiator.
2. Close the engine hood assembly.
Cooling (4JJ1) 1D-51
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Engine cover removal
1. Remove the engine cover from the engine.
1. Engine cover
Measurement point 3
Amount of belt
Frequency
deflection
: 12.4 to 16.4 mm
New : 92 to 112 Hz
{ 0.488 to 0.646 in }
: 16.5 to 19.1 mm
Reuse : 80 to 92 Hz
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency 1. Measurement point 1
deflection
: 15.9 to 20.7 mm 2. Measurement point 2
New : 70 to 86 Hz 3. Measurement point 3
{ 0.626 to 0.815 in }
4. Measurement point 4
: 20.7 to 23.7 mm
Reuse : 62 to 70 Hz
{ 0.815 to 0.933 in } Note:
Note: ・ After adjusting the tension, tighten the
tensioner fixing nut.
・ The following is the belt tension adjusting
method with a sonic tension meter. Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }
・ Measure the frequency at measurement point
2, 3, and 4 with a frequency meter.
Measurement point 2
Amount of belt
Frequency
deflection
Cooling (4JJ1) 1D-53
installation Frequency of
Amount of flex
vibrations
1. A/C compressor drive belt installation
For a
: 15.9 to 20.7 mm
1. Install the A/C compressor drive belt to the pulley. new : 70 to 86 Hz
{ 0.626 to 0.815 in }
product
When : 20.7 to 23.7 mm
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
Note:
・ In the case of adjustment using a frequency
meter
・ Measure the frequency at measurement points
2, 3, and 4 with a frequency meter.
Measurement point 2
Frequency of
Amount of flex
vibrations
For a
: 12.5 to 16.5 mm
new : 92 to 112 Hz
{ 0.492 to 0.650 in }
product
When : 16.5 to 19.1 mm
: 79 to 91 Hz
reused { 0.650 to 0.752 in }
1. A/C compressor drive belt
Measurement point 3
2. A/C compressor drive belt adjustment Frequency of
Amount of flex
1. Adjust tension to a standard value using a tension vibrations
meter. For a
: 12.4 to 16.4 mm
Note: new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
・ When adjusting the amount of flex to the
original value When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
・ Apply a load to measurement points 2, 3, and
4 of the A/C compressor drive belt and adjust Measurement point 4
the amount of flex. Frequency of
Amount of flex
Load: 98 N { 10 kg / 22 lb } vibrations
For a
Measurement point 2 : 15.9 to 20.7 mm
new : 70 to 86 Hz
Frequency of { 0.626 to 0.815 in }
Amount of flex product
vibrations
When : 20.7 to 23.7 mm
For a : 62 to 70 Hz
: 12.5 to 16.5 mm reused { 0.815 to 0.933 in }
new : 92 to 112 Hz
{ 0.492 to 0.650 in }
product
When : 16.5 to 19.1 mm
: 79 to 91 Hz
reused { 0.650 to 0.752 in }
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
1D-54 Cooling (4JJ1)
1. Measurement point 1
2. Measurement point 2
3. Measurement point 3
4. Measurement point 4
Note:
・ After adjusting the tension, tighten the
tensioner fixing nut.
Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }
3. Engine cover installation
1. Install the engine cover to the engine.
1. Engine cover
Supplementary Information
1. Component Views Note:
・ Radiator
Engine
Lubrication
(4JJ1)
Table of Contents
Engine oil.........................................................................1E-2
inspection....................................................................1E-2
Oil filter element..............................................................1E-3
removal........................................................................1E-3
installation...................................................................1E-4
Oil filter...........................................................................1E-5
removal........................................................................1E-5
installation.................................................................1E-11
Oil cooler assembly.......................................................1E-19
removal......................................................................1E-19
installation.................................................................1E-29
Oil pressure switch........................................................1E-42
removal......................................................................1E-42
inspection..................................................................1E-43
installation.................................................................1E-44
Oil pan...........................................................................1E-45
removal......................................................................1E-45
installation.................................................................1E-47
Oil pump assembly........................................................1E-49
removal......................................................................1E-49
disassembly...............................................................1E-54
inspection..................................................................1E-55
reassembly.................................................................1E-57
installation.................................................................1E-58
Supplementary Information...........................................1E-65
1E-2 Lubrication (4JJ1)
Engine oil
1. Lower limit
2. Upper limit
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Oil filter element removal
1. Install the hose to the oil drain pipe.
Note:
・ Prepare the oil pan tray to catch the drain oil.
2. Remove the oil filter element from the oil filter
bracket using special tool.
Note:
・ Use the oil filter wrench to remove the oil filter
element.
installation Note:
・ Check the tightening of the oil pan drain plug.
1. Oil filter element installation
Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft }
Note:
3. Battery ground cable connect
・ Remove oil, foreign materials, and dust on the
pan of the oil filter bracket. 1. Connect the battery ground cable to the battery.
・ Clean the oil filter installation surface. 2. Close the engine hood assembly.
1. Apply the engine oil to the oil filter element.
Note:
・ Apply grease or engine oil to the seal section.
2. Install the oil filter element to the oil filter bracket
using special tool.
Note:
・ Use the oil filter wrench to install it.
Oil filter
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
1. Oil filter element
2. Remove the front under guard from the frame. 2. Oil pan section of the oil filter bracket
Note: 3. Hose
・ Remove the 5 bolts. 4. Oil pan tray
1. Engine cover
1. Feed hose
1. Water feed and return pipes 2. Return hose
2. Turbocharger water feed hose
3. Water pipe 12. Exhaust manifold heat protector removal
4. Turbocharger water feed hose 1. Remove the exhaust manifold heat protector from
5. Turbocharger water return hose the exhaust manifold.
10. Water pipe removal
1E-8 Lubrication (4JJ1)
19. Heater bypass pipe removal 2. Remove the pipe bracket from the oil filter.
1. Disconnect the heater bypass pipe from the water 21. Water bypass pipe removal
intake pipe.
1. Remove the water bypass pipe from the oil filter.
2. Remove the heater bypass pipe from the oil cooler
Note:
assembly and the water bypass hose.
・ Remove the water bypass pipe on the oil filter
side.
1. Oil filter installation 1. Apply the engine oil to the oil filter element.
17. Vacuum hose installation 2. Connect the intake pipe to the turbocharger
assembly.
1. Install the vacuum hose to the turbocharger and the
vacuum pipe. Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in }
3. Connect the vacuum hose to the air cleaner
assembly.
4. Connect the harness connector to the barometric
pressure sensor.
5. Connect the harness connector to the MAF sensor.
19. Blow-by hose connect
1. Connect the blow-by hose to the cylinder head cover.
20. Intake air duct installation
1. Install the intake air duct to the turbocharger and the
intake hose.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Bolt
Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in }
Clip
18. Air cleaner assembly installation
1. Install the air cleaner assembly to vehicle.
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }
1E-16 Lubrication (4JJ1)
1. Engine cover
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
For a
: 15.9 to 20.7 mm 1. Measurement point 1
new : 70 to 86 Hz
{ 0.626 to 0.815 in } 2. Measurement point 2
product
3. Measurement point 3
When : 20.7 to 23.7 mm 4. Measurement point 4
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
Note:
Note:
・ After adjusting the tension, tighten the
・ In the case of adjustment using a frequency
tensioner fixing nut.
meter
1E-18 Lubrication (4JJ1)
Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft } Note:
26. Cooling fan belt adjustment ・ After adjusting the tension, tighten the adjust
plate lock bolt and the mounting bolt under the
1. Adjust tension to a standard value using a tension generator.
meter.
Generator tightening torque
Note:
: 40 N・m { 4.1 kgf・m /
・ Move the generator to adjust the tension. Mounting bolt
30 lb・ft }
2. Check tension of the cooling fan belt. : 25 N・m { 2.5 kgf・m /
Adjust plate lock bolt
Note: 18 lb・ft }
・ When adjusting the amount of flex to the Note:
original value ・ If the cooling fan belt is replaced with a new
・ Apply a load to measurement point 1 of the one, make the new cooling fan belt fit in to
cooling fan belt and adjust the amount of flex. cope with initial elongation.
Load: 98 N { 10 kg / 22 lb } ・ After making the cooling fan belt fit in, adjust
its tension once again.
Note:
27. Battery ground cable connect
・ In the case of adjustment using a frequency
meter 1. Connect the battery ground cable to the battery.
・ Measure the frequency at measurement point 2. Close the engine hood assembly.
1 with a frequency meter.
3. Lower vehicle.
Position of the belt tension
Fluctuation Frequency
: 5.4 to 6.6 mm
New : 188 to 210 Hz
{ 0.213 to 0.260 in }
: 7.7 to 8.5 mm
Reuse : 160 to 174 Hz
{ 0.303 to 0.335 in }
1. Measurement point 1
2. Measurement point 2
3. Measurement point 3
4. Measurement point 4
Lubrication (4JJ1) 1E-19
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
3. Coolant drain
1. Drain coolant from the radiator.
Note:
・ Open the drain plug at the bottom of the
radiator.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts. 2. Remove the radiator cap from the radiator.
3. Remove the rear under guard from the frame. Warning:
Note: ・ In order to prevent burns, do not open the cap
・ Remove the 4 bolts. when the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Engine cover removal
1. Remove the engine cover from the engine.
1E-20 Lubrication (4JJ1)
1. Engine cover
Note:
・ Prepare the oil pan tray to catch the drain oil.
2. Remove the oil filter element from the oil filter
bracket using special tool.
Note:
・ Use the oil filter wrench to remove the oil filter
element. 7. Blow-by hose disconnect
1. Disconnect the blow-by hose from the cylinder head
cover.
Lubrication (4JJ1) 1E-21
8. Air cleaner assembly removal
1. Disconnect the harness connector from the MAF
sensor.
2. Disconnect the harness connector from the
barometric pressure sensor.
3. Disconnect the vacuum hose from the air cleaner
assembly.
4. Disconnect the intake pipe from the turbocharger
assembly.
5. Remove the air cleaner assembly from vehicle.
1. Water feed and return pipes 19. Water feed and return pipe removal
2. Turbocharger water feed hose
1. Remove the water feed and return pipe from the
3. Water pipe
turbocharger.
4. Turbocharger water feed hose
5. Turbocharger water return hose
1. Turbocharger feed oil pipe 1. Disconnect the catalyst converter from the catalyst
converter bracket.
18. Oil return pipe removal 2. Remove the catalyst converter from the turbocharger
1. Remove the oil return pipe from the turbocharger assembly.
and the crankcase.
1E-24 Lubrication (4JJ1)
3. Remove the catalyst converter bracket from the rear 23. Turbocharger assembly removal
cover.
1. Remove the turbocharger from the exhaust manifold.
Note:
・ Remove the exhaust side from the engine
side.
・ Remove the engine side from the crankcase.
31. Heater bypass pipe removal 2. Remove the pipe bracket from the oil filter.
1. Disconnect the heater bypass pipe from the water 33. Water bypass pipe removal
intake pipe.
1. Remove the water bypass pipe from the oil filter.
2. Remove the heater bypass pipe from the oil cooler
Note:
assembly and the water bypass hose.
・ Remove the water bypass pipe on the oil filter
side.
2. Install the water intake pipe to the oil filter. 1. Install the heater bypass pipe to the oil cooler and the
water bypass hose.
Note:
Note:
・ Insert the water intake pipe into the oil filter.
・ Temporarily tighten nuts starting from the rear
・ Apply soapy water on the O-ring when
side, and then firmly tighten them in the same
inserting the pipe.
order.
3. Temporarily tighten the water intake pipe to the oil
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
cooler and the generator bracket.
Note:
・ Temporarily tighten the nuts and bolts in the
order shown in the diagram.
4. Securely tighten the water intake pipe to the oil 1. Install the generator to the bracket.
cooler and the generator bracket.
1E-32 Lubrication (4JJ1)
1. Stub bolt
2. Washer
3. Nut
Note:
・ Feed 0.5 cc engine oil from the oil filler.
17. Turbocharger bracket installation
1. Install the turbocharger bracket to the turbocharger
14. Generator connect and the cylinder block.
1. Connect the harness to the generator. Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・
in } Terminal nut
1E-34 Lubrication (4JJ1)
20. Water feed and return pipe installation 22. Turbocharger feed oil pipe installation
1. Install the water feed and return pipe to the 1. Install the turbocharger feed oil pipe to the
turbocharger. turbocharger and the oil cooler.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in } Tightening torque: 23 N・m { 2.3 kgf・m / 17 lb・ft }
1. Water feed and return pipes 26. Exhaust manifold heat protector installation
2. Turbocharger water feed hose
1. Install the exhaust manifold heat protector to the
3. Water pipe
exhaust manifold.
4. Turbocharger water feed hose
5. Turbocharger water return hose Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Tightening torque of the EGR cooler 1. Connect the water hose to the EGR cooler.
Bolts and nuts : 27 N・m { 2.8 kgf・m / Note:
1, 2, 4, 5 20 lb・ft } ・ Connect both the feed hose and return hose to
: 25 N・m { 2.5 kgf・m / the EGR cooler.
Bolt 3
18 lb・ft }
Lubrication (4JJ1) 1E-37
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
For a
: 15.9 to 20.7 mm
36. Engine oil filling new : 70 to 86 Hz
{ 0.626 to 0.815 in }
product
1. Replenish the engine with the engine oil. When : 20.7 to 23.7 mm
: 62 to 70 Hz
Note: reused { 0.815 to 0.933 in }
・ Check the tightening of the oil pan drain plug. Note:
Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft } ・ In the case of adjustment using a frequency
meter
1E-40 Lubrication (4JJ1)
・ Measure the frequency at measurement points Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }
2, 3, and 4 with a frequency meter. 39. Cooling fan belt adjustment
Measurement point 2 1. Adjust tension to a standard value using a tension
Frequency of meter.
Amount of flex
vibrations Note:
For a ・ Move the generator to adjust the tension.
: 12.5 to 16.5 mm
new : 92 to 112 Hz
{ 0.492 to 0.650 in } 2. Check tension of the cooling fan belt.
product
When : 16.5 to 19.1 mm Note:
: 79 to 91 Hz
reused { 0.650 to 0.752 in } ・ When adjusting the amount of flex to the
original value
Measurement point 3
・ Apply a load to measurement point 1 of the
Frequency of
Amount of flex cooling fan belt and adjust the amount of flex.
vibrations
For a Load: 98 N { 10 kg / 22 lb }
: 12.4 to 16.4 mm
new : 92 to 112 Hz Note:
{ 0.488 to 0.646 in }
product
・ In the case of adjustment using a frequency
When : 16.5 to 19.1 mm meter
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
・ Measure the frequency at measurement point
Measurement point 4 1 with a frequency meter.
Frequency of Position of the belt tension
Amount of flex
vibrations
Fluctuation Frequency
For a
: 15.9 to 20.7 mm : 5.4 to 6.6 mm
new : 70 to 86 Hz New : 188 to 210 Hz
{ 0.626 to 0.815 in } { 0.213 to 0.260 in }
product
: 7.7 to 8.5 mm
When : 20.7 to 23.7 mm Reuse : 160 to 174 Hz
: 62 to 70 Hz { 0.303 to 0.335 in }
reused { 0.815 to 0.933 in }
1. Measurement point 1
1. Measurement point 1
2. Measurement point 2
2. Measurement point 2
3. Measurement point 3
3. Measurement point 3
4. Measurement point 4
4. Measurement point 4
Note:
・ After adjusting the tension, tighten the
tensioner fixing nut.
Lubrication (4JJ1) 1E-41
Note:
・ After adjusting the tension, tighten the adjust
plate lock bolt and the mounting bolt under the
generator.
Generator tightening torque
: 40 N・m { 4.1 kgf・m /
Mounting bolt
30 lb・ft }
: 25 N・m { 2.5 kgf・m /
Adjust plate lock bolt
18 lb・ft }
Note:
・ If the cooling fan belt is replaced with a new
one, make the new cooling fan belt fit in to
cope with initial elongation.
・ After making the cooling fan belt fit in, adjust
its tension once again.
40. Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
3. Lower vehicle.
1E-42 Lubrication (4JJ1)
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Oil pressure switch disconnect
1. Disconnect the connector from the oil pressure
switch.
3. Oil pressure switch removal
1. Remove the oil pressure switch from the cylinder
block.
Lubrication (4JJ1) 1E-43
inspection
1. Oil pressure switch inspection
1. Inspect continuity using tester.
Note:
・ Confirm the continuity between the switch
terminal and body ground without a load
applied.
・ If there is no continuity, replace it with a
normal one.
installation
1. Oil pressure switch installation
1. Install the oil pressure switch to the cylinder block.
Tightening torque: 15 N・m { 1.5 kgf・m / 11 lb・ft }
Oil pan
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts.
3. Remove the rear under guard from the frame.
Note:
・ Remove the 4 bolts.
1. Earth cable
Lubrication (4JJ1) 1E-47
installation Note:
・ Check the tightening of the oil pan drain plug.
1. Oil pan installation
Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft }
1. Apply liquid gasket to the oil pan.
3. Front under guard installation
Note:
Note:
・ Apply ThreeBond 1207B or equivalent.
・ The following applies to 2WD.
1. Install the front under guard to the frame.
Note:
・ Tighten the clip and the 5 bolts.
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
3. Coolant drain
1. Drain coolant from the radiator.
Note:
・ Open the drain plug at the bottom of the
radiator.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts. 2. Remove the radiator cap from the radiator.
3. Remove the rear under guard from the frame. Warning:
Note: ・ In order to prevent burns, do not open the cap
・ Remove the 4 bolts. when the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Engine cover removal
1. Remove the engine cover from the engine.
1E-50 Lubrication (4JJ1)
5. Intake air duct removal 1. Remove the radiator upper hose from the water
outlet pipe and the radiator.
1. Remove the intake air duct from the turbocharger
and the intercooler.
Note:
・ Remove the part together with the intake hose.
2. Remove the cooling fan belt from the pulley. 1. Remove the fan pulley from the water pump
assembly.
10. Fan guide removal
13. Fan shroud removal
1. Remove the fan guide from the radiator.
1. Remove the fan guide from the radiator.
Note:
Note:
・ Remove the clips and bottom locks on both
sides and remove the upper fan guide. ・ Remove the lower fan guide together with the
fan shroud.
14. Noise cover removal
1. Remove the noise cover from the timing chain lower
cover.
1. Bracket
disassembly
1. Oil pump assembly disassembly
1. Remove the spring pin from the oil pump.
2. Remove the spring seat from the oil pump.
3. Remove the spring from the oil pump.
4. Remove the from the oil pump.
1. Spring pin
2. Spring seat
3. Spring
4. Valve
Lubrication (4JJ1) 1E-55
inspection
1. Oil pump assembly inspection
1. Measure outer diameter using the micrometer.
Note:
・ Measure the outer diameter of the driven gear
shaft and the drive gear shaft.
Standard: 15.989 to 16.000 mm { 0.62949 to 0.62992
in }
Limit: 15.900 mm { 0.62598 in }
reassembly
1. Oil pump assembly reassembly
1. Install the to the oil pump.
2. Install the spring to the oil pump.
3. Install the spring seat to the oil pump.
4. Install the spring pin to the oil pump.
1. Spring pin
2. Spring seat
3. Spring
4. Valve
1E-58 Lubrication (4JJ1)
installation Caution:
・ After applying the liquid gasket, install the
1. Oil pump assembly installation cover within 5 minutes.
1. Apply the engine oil to the oil pump gear. 2. Install the gasket to the gear case cover.
2. Install the oil pump to the timing gear case. 3. Install the gear case cover to the timing gear case.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }
Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・ 1. Power steering oil pump
in } 2. Nut
3. Install the vacuum hose to the vacuum pipe and the 2. Install the power steering oil hose to the bracket.
vacuum pump assembly.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1. Bracket
・ Use new crank pulley bolts. 1. Install the cooling fan clutch to the water pump
assembly.
Note:
・ Install the part together with the cooling fan.
1. Noise cover
1. Install the fan pulley to the water pump assembly. 12. Cooling fan belt installation
10. Cooling fan clutch installation 1. Install the cooling fan belt to the pulley.
13. Cooling fan belt adjustment
Lubrication (4JJ1) 1E-61
1. Adjust tension to a standard value using a tension : 40 N・m { 4.1 kgf・m /
meter. Mounting bolt
30 lb・ft }
Note: : 25 N・m { 2.5 kgf・m /
Adjust plate lock bolt
・ Move the generator to adjust the tension. 18 lb・ft }
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
For a
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in }
product
When : 20.7 to 23.7 mm
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
1. Measurement point 1
Note: 2. Measurement point 2
・ In the case of adjustment using a frequency 3. Measurement point 3
meter 4. Measurement point 4
・ Measure the frequency at measurement points
Note:
2, 3, and 4 with a frequency meter.
・ After adjusting the tension, tighten the
Measurement point 2 tensioner fixing nut.
Frequency of Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }
Amount of flex
vibrations
16. Radiator upper hose installation
For a
: 12.5 to 16.5 mm
new : 92 to 112 Hz 1. Install the radiator upper hose to the water outlet
{ 0.492 to 0.650 in }
product pipe and the radiator.
When : 16.5 to 19.1 mm Tightening torque: 5 N・m { 0.5 kgf・m / 44 lb・in }
: 79 to 91 Hz
reused { 0.650 to 0.752 in } Hose clip
Measurement point 3
Frequency of
Amount of flex
vibrations
For a
: 12.4 to 16.4 mm
new : 92 to 112 Hz
{ 0.488 to 0.646 in }
product
When : 16.5 to 19.1 mm
: 80 to 92 Hz
reused { 0.650 to 0.752 in }
Measurement point 4
Frequency of
Amount of flex
vibrations
For a
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in }
product
When : 20.7 to 23.7 mm
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
1. Radiator upper hose
1. Engine cover
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Install the front under guard to the frame.
19. Engine cover installation
Note:
1. Install the engine cover to the engine.
・ Tighten the 4 bolts.
3. Install the rear under guard to the frame.
1E-64 Lubrication (4JJ1)
Note:
・ Tighten the 5 bolts.
Supplementary Information
1. Component Views Note:
・ Oil filter cartridge
Note:
・ Oil cooler
1E-66 Lubrication (4JJ1)
1. Oil cooler
Note:
・ Oil pan
Lubrication (4JJ1) 1E-67
1. Oil pan
Note:
・ Oil pump
1E-68 Lubrication (4JJ1)
Note:
・ Oil pressure switch
Lubrication (4JJ1) 1E-69
Engine
Induction
(4JJ1)
Table of Contents
Air cleaner element..........................................................1F-2
removal........................................................................1F-2
inspection....................................................................1F-3
installation...................................................................1F-4
Turbocharger assembly....................................................1F-5
removal........................................................................1F-5
inspection..................................................................1F-11
installation.................................................................1F-13
Turbocharger control solenoid.......................................1F-20
removal......................................................................1F-20
inspection..................................................................1F-21
installation.................................................................1F-22
Boost sensor...................................................................1F-23
removal......................................................................1F-23
inspection..................................................................1F-24
installation.................................................................1F-25
Intercooler......................................................................1F-26
removal......................................................................1F-26
inspection..................................................................1F-29
installation.................................................................1F-30
MAF and IAT sensor.....................................................1F-33
removal......................................................................1F-33
inspection..................................................................1F-34
installation.................................................................1F-35
Supplementary Information...........................................1F-36
1F-2 Induction (4JJ1)
removal
1. Air cleaner element removal
1. Open the engine hood assembly.
2. Remove the air cleaner cover from the air cleaner
box.
3. Remove the air cleaner element from the air cleaner
box.
Induction (4JJ1) 1F-3
inspection
1. Air cleaner element inspection
1. Inspect the air cleaner element.
Note:
・ Inspect for excessive dirt or damage.
2. Air cleaner element cleaning
Note:
・ Dry element
1. Clean the air cleaner element using air.
Note:
・ Clean the element by applying the
compressed air from the element clean side.
Air pressure: 392 to 490 kPa { 4 to 5 kgf/cm2 / 57 to 71
psi }
1F-4 Induction (4JJ1)
installation
1. Air cleaner element installation
1. Install the air cleaner element to the air cleaner box.
2. Install the air cleaner cover to the air cleaner box.
3. Close the engine hood assembly.
Induction (4JJ1) 1F-5
Turbocharger assembly
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
3. Coolant drain
1. Drain coolant from the radiator.
Note:
・ Open the drain plug at the bottom of the
radiator.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts. 2. Remove the radiator cap from the radiator.
3. Remove the rear under guard from the frame. Warning:
Note: ・ In order to prevent burns, do not open the cap
・ Remove the 4 bolts. when the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Engine cover removal
1. Remove the engine cover from the engine.
1F-6 Induction (4JJ1)
4. Disconnect the intake pipe from the turbocharger
assembly.
5. Remove the air cleaner assembly from vehicle.
1. Engine cover
inspection
1. Turbocharger assembly inspection
1. Measure play using a dial gauge.
Note:
・ Measure the play of the wheel in the direction
of the wheel axis when a load is applied on the
both sides of the compressor wheel.
Load: 12 N { 1.2 kg / 2.7 lb }
Standard: 0.03 to 0.06 mm { 0.0012 to 0.0024 in }
Limit: 0.09 mm { 0.0035 in }
1. Oil outlet
2. Oil inlet
Note:
・ Actuator operation inspection
3. Install the vacuum pump to the actuator.
1. Actuator
2. Vacuum pump
installation
1. Turbocharger heat protector installation
1. Install the turbocharger heat protector to the
turbocharger.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Note:
・ Feed 0.5 cc engine oil from the oil filler.
3. Turbocharger bracket installation
1. Install the turbocharger bracket to the turbocharger
and the cylinder block.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1F-14 Induction (4JJ1)
8. Turbocharger feed oil pipe installation 1. Water feed and return pipes
2. Turbocharger water feed hose
1. Install the turbocharger feed oil pipe to the
3. Water pipe
turbocharger and the oil cooler.
4. Turbocharger water feed hose
Tightening torque: 23 N・m { 2.3 kgf・m / 17 lb・ft } 5. Turbocharger water return hose
16. Vacuum hose installation 2. Connect the intake pipe to the turbocharger
assembly.
1. Install the vacuum hose to the turbocharger and the
vacuum pipe. Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in }
3. Connect the vacuum hose to the air cleaner
assembly.
4. Connect the harness connector to the barometric
pressure sensor.
5. Connect the harness connector to the MAF sensor.
18. Blow-by hose connect
1. Connect the blow-by hose to the cylinder head cover.
19. Intake air duct installation
1. Install the intake air duct to the turbocharger and the
intake hose.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Bolt
Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in }
Clip
17. Air cleaner assembly installation
1. Install the air cleaner assembly to vehicle.
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }
1F-18 Induction (4JJ1)
1. Engine cover
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Engine cover removal
1. Remove the engine cover from the engine.
1. Engine cover
inspection
1. Turbocharger control solenoid inspection
1. Inspect the turbocharger control solenoid using the
circuit tester.
Note:
・ Measure the resistance value between
terminals 1 and 2.
Temperature of the condition: 20 ℃ { 68 °F }
resistance characteristics
Resistance: 11 to 13 Ω
1F-22 Induction (4JJ1)
1. Engine cover
Boost sensor
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Engine cover removal
1. Remove the engine cover from the engine.
1. Engine cover
inspection
1. Boost sensor inspection
1. Inspect the boost sensor.
Note:
・ Inspect the boost sensor for filth or damage.
・ Inspect the connector terminal section for
abnormality.
Induction (4JJ1) 1F-25
installation
1. Boost sensor installation
1. Install the boost sensor to the air duct.
Tightening torque: 2 N・m { 0.2 kgf・m }
1. Engine cover
Intercooler
removal 1. Screw
2. Clip
1. Intercooler safety information
4. Front bumper assembly removal
Caution:
・ If oil builds up inside the intercooler, remove 1. Remove the front bumper assembly from vehicle.
the drain plug to drain the oil. Note:
1. Remove the drain plug from the intercooler. ・ Remove the 10 clips.
Note:
・ Put the hand into the bumper opening and
remove the drain plug with a tool.
2. Drain the engine oil from the intercooler.
Note:
・ Prepare a shop cloth under the drain plug to
catch the drained oil with it.
3. Install the drain plug to the intercooler.
Note:
・ Confirm that the engine oil has been drained
before installing the drain plug.
Tightening torque: 1.2 N・m { 0.12 kgf・m / 10.6 lb・
in }
2. Battery ground cable disconnect
1. Open the engine hood assembly. 5. Front bumper impact bar assembly removal
2. Disconnect the battery ground cable from the battery. 1. Remove the bumper seal from vehicle.
3. Radiator grille removal Note:
1. Remove the radiator grille from vehicle. ・ Remove the 6 clips on one side.
Note:
・ Remove the screws.
・ Remove the 4 clips.
3. Remove the front bumper impact bar assembly from 7. Intercooler removal
vehicle.
1. Disconnect the intake air hose from the intercooler.
Note:
・ Disconnect it at both the turbocharger and
intake throttle sides.
inspection Note:
・ If dirt is not thoroughly washed off, repeat the
1. Intercooler inspection cleaning work.
1. Inspect the intercooler. ・ If dirt remains, fine black particles are seen
Note: attached on the fins.
・ Repair the intercooler fins if they are deformed 4. Clean the intercooler using tap water.
as it can lead to a drop in heat dissipation and Caution:
reduce engine performance.
・ Thoroughly rinse off the detergent ingredients
・ When repairing, take sufficient care not to to prevent it from remaining on the fins and the
damage the base of the fins. resin portions.
2. Intercooler cleaning 5. Clean the connection using tap water.
Caution: Note:
・ Do not apply high-pressure washing to the ・ Remove the seal, and clean the hose
radiator, intercooler, and peripheral parts while connection.
they are installed in the vehicle.
・ Thoroughly clean and dry the hose connection.
Note:
・ Before cleaning, seal the hose connections
with caps, fabric tape, etc.
1. Clean the intercooler using tap water.
Note:
・ Wet the front and rear surfaces of the
intercooler sufficiently.
・ For fouling that can be removed by splashing
tap water, thoroughly wash them off.
Caution:
・ Do not use a high-pressure washing machine
or brush.
2. Apply detergent to the intercooler.
Note:
・ Apply a type of mild detergent which contains
approximately 8 % of surface acting agent,
and leave it for 10 minutes.
Caution:
・ Do not use materials other than mild detergent
because doing so may cause corrosion.
3. Clean the intercooler using the high-pressure
washing machine.
Note:
・ Wash off mild detergent with a high-pressure
washing machine.
Caution:
・ Apply the high pressure water perpendicular to
the fins from the engine side of the intercooler.
・ Do not bring the high-pressure water too close
to the fins.
・ Watch for deformation of the fins.
1F-30 Induction (4JJ1)
installation 1. Install the front end engine hood stay to the frame.
1. Intercooler installation
1. Install the intercooler to the frame.
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }
1. Screw
2. Clip
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. MAF and IAT sensor disconnect
1. Remove the harness connector from the MAF sensor.
3. MAF and IAT sensor removal
1. Remove the MAF sensor from the air cleaner
assembly.
Note:
・ Remove the MAF sensor and the IAT sensor
from the air cleaner assembly.
1F-34 Induction (4JJ1)
inspection
1. MAF sensor inspection
1. Inspect the MAF sensor.
Note:
・ Inspect the MAF sensor for filth and damage.
Caution:
・ There should be no solvents or lubricants
adhering to the detecting section of the sensor.
2. IAT sensor inspection
1. Inspect the IAT sensor using the circuit tester.
1. Gasket
2. MAF sensor power source
3. MAF sensor GND
4. MAF sensor signal
5. IAT sensor signal
6. IAT sensor GND
Note:
・ Measure the resistance value between the
signal terminal and the GND terminal of the
IAT sensor in the temperature of the condition
with a circuit tester.
Temperature of the condition: 25 ℃ { 77 °F }
Resistance: 1.8 to 2.2 kΩ
Caution:
・ There should be no solvents or lubricants
adhering to the detecting section of the sensor.
Induction (4JJ1) 1F-35
installation
1. MAF and IAT sensor installation
1. Install the MAF sensor to the air cleaner assembly.
Note:
・ Install the MAF sensor and the IAT sensor to
the air cleaner assembly.
Tightening torque: 1.5 N・m { 0.15 kgf・m / 13 lb・
in }
2. MAF and IAT sensor connect
1. Install the harness connector to the MAF sensor and
the IAT sensor.
3. Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
1F-36 Induction (4JJ1)
Supplementary Information
1. Component Views Note:
・ Turbocharger
Engine
Exhaust
(4JJ1)
Table of Contents
Exhaust pipe....................................................................1G-2
removal.......................................................................1G-2
inspection....................................................................1G-3
installation..................................................................1G-4
Catalyst converter............................................................1G-5
removal.......................................................................1G-5
installation..................................................................1G-6
Supplementary Information............................................1G-7
1G-2 Exhaust (4JJ1)
Exhaust pipe
removal
1. Exhaust silencer assembly removal
1. Remove the rear hanger rubber from the exhaust
silencer.
2. Remove the exhaust silencer from the front exhaust
pipe.
inspection
1. Exhaust pipe inspection
1. Inspect the exhaust pipe.
Note:
・ Make the necessary adjustments, repairs, and
part replacements if excessive worn or
damage is found.
・ Check the pipe for corrosion, cracking,
damage, and improper installation, and make
repairs if necessary.
・ Check the rubber ring for degradation and
damage, and make repairs if necessary.
2. Exhaust silencer assembly inspection
1. Inspect the exhaust silencer.
Note:
・ Make the necessary adjustments, repairs, and
part replacements if excessive worn or
damage is found.
・ Check the pipe for corrosion, cracking,
damage, and improper installation, and make
repairs if necessary.
・ Check the rubber ring for degradation and
damage, and make repairs if necessary.
1G-4 Exhaust (4JJ1)
installation
1. Front exhaust pipe installation
1. Install the front exhaust pipe to the catalyst
converter.
Tightening torque: 67 N・m { 6.8 kgf・m / 49 lb・ft }
Catalyst converter
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Catalyst converter disconnect
1. Disconnect the catalyst converter from the front
exhaust pipe.
3. Catalyst converter removal
1. Disconnect the catalyst converter from the catalyst
converter bracket.
2. Remove the catalyst converter from the turbocharger
assembly.
installation
1. Catalyst converter installation
1. Install the catalyst converter to the turbocharger
assembly.
Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft }
Supplementary Information
1. Component Views Note:
・ Exhaust pipe
Engine
Aux. Emission Control Devices
(4JJ1)
Table of Contents
EGR cooler......................................................................1H-2
removal.......................................................................1H-2
installation..................................................................1H-6
EGR valve.....................................................................1H-10
removal.....................................................................1H-10
inspection..................................................................1H-11
installation................................................................1H-12
Supplementary Information..........................................1H-13
1H-2 Aux. Emission Control Devices (4JJ1)
EGR cooler
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Front under guard removal
Note:
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts and the clip.
3. Coolant drain
1. Drain coolant from the radiator.
Note:
・ Open the drain plug at the bottom of the
radiator.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Remove the front under guard from the frame.
Note:
・ Remove the 5 bolts. 2. Remove the radiator cap from the radiator.
3. Remove the rear under guard from the frame. Warning:
Note: ・ In order to prevent burns, do not open the cap
・ Remove the 4 bolts. when the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Engine cover removal
1. Remove the engine cover from the engine.
Aux. Emission Control Devices (4JJ1) 1H-3
4. Disconnect the intake pipe from the turbocharger
assembly.
5. Remove the air cleaner assembly from vehicle.
1. Engine cover
installation
1. EGR cooler installation
1. Install the gasket to the EGR cooler.
2. Temporarily tighten the EGR cooler to the cylinder
head and the exhaust manifold.
Note:
・ Temporarily tighten the nuts and bolts in the
order of 2, 1, 4, 5, 3 as shown in the diagram.
3. Securely tighten the EGR cooler to the cylinder head
and the exhaust manifold.
Note:
・ Completely tighten the nuts and bolts in the
order of 4, 5, 2, 1, 3 as shown in the diagram.
Tightening torque of the EGR cooler
3. Water hose connect
Bolts and nuts : 27 N・m { 2.8 kgf・m /
1, 2, 4, 5 20 lb・ft } 1. Connect the water hose to the EGR cooler.
: 25 N・m { 2.5 kgf・m / Note:
Bolt 3
18 lb・ft } ・ Connect both the feed hose and return hose to
the EGR cooler.
2. Connect the turbocharger water feed hose to the 7. Air cleaner assembly installation
outlet pipe.
1. Install the air cleaner assembly to vehicle.
5. Turbocharger water feed pipe connect
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }
1. Connect the turbocharger water feed hose to the
water feed and return pipe.
Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in } 3. Install the radiator cap to the radiator.
Clip 12. Front under guard installation
Note:
・ The following applies to 2WD.
1. Install the front under guard to the frame.
Note:
・ Tighten the clip and the 5 bolts.
1. Bolt
2. Clip
Note:
・ The following applies to 4WD.
2. Install the front under guard to the frame.
Note:
・ Tighten the 4 bolts.
3. Install the rear under guard to the frame.
Note:
・ Tighten the 5 bolts.
1. Engine cover
EGR valve
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. EGR valve disconnect
1. Disconnect the connector from the EGR valve.
3. EGR valve removal
1. Remove the EGR valve from the inlet manifold.
Aux. Emission Control Devices (4JJ1) 1H-11
inspection
1. EGR valve inspection
1. Inspect the EGR valve.
Note:
・ Clean the EGR valve if carbon is piled up.
1H-12 Aux. Emission Control Devices (4JJ1)
installation
1. EGR valve installation
1. Install the EGR valve to the inlet manifold.
Tightening torque of the EGR valve
Nut : 27 N・m { 2.8 kgf・m / 20 lb・ft }
Bolt : 24 N・m { 2.4 kgf・m / 18 lb・ft }
2. EGR valve connect
1. Connect the connector to the EGR valve.
3. Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
Aux. Emission Control Devices (4JJ1) 1H-13
Supplementary Information
1. Component Views Note:
・ EGR cooler
1. EGR cooler
Engine
Speed Control Systems
(4JJ1)
Table of Contents
Accelerator pedal assembly..............................................1I-2
removal.........................................................................1I-2
inspection.....................................................................1I-3
installation....................................................................1I-4
1I-2 Speed Control Systems (4JJ1)
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Accelerator pedal assembly removal
1. Disconnect the harness connector from the
accelerator pedal position sensor.
2. Remove the accelerator pedal assembly from the
dash panel.
Speed Control Systems (4JJ1) 1I-3
inspection
1. Accelerator pedal assembly inspection
1. Connect a scan tool to vehicle.
2. Turn ON the ignition switch.
3. Adjust the accelerator pedal position sensor.
Note:
・ Check the voltage of the accelerator pedal
position sensor as shown in the table below.
Pedal
Position
Voltage as
Pedal as
APP Sensor observed on
Position observe
the Tech2
d on the
Tech2
: 0.75 to
1 Pedal at reset 0
0.85 V
Pedal at full : 3.12 to
1 1
travel 3.22 V
: 1.55 to
2 Pedal at reset 0
1.65 V
Pedal at full : 3.95 to
2 1
travel 4.05 V
1I-4 Speed Control Systems (4JJ1)
installation
1. Accelerator pedal assembly installation
1. Install the accelerator pedal assembly to the dash
panel.
Tightening torque: 6.5 N・m { 0.7 kgf・m / 58 lb・in }
Engine
Electrical
(4JJ1)
Table of Contents
Generator..........................................................................1J-2
removal........................................................................1J-2
installation....................................................................1J-4
Glow plug.........................................................................1J-8
removal........................................................................1J-8
inspection...................................................................1J-10
installation..................................................................1J-11
Glow relay......................................................................1J-13
inspection...................................................................1J-13
ECM...............................................................................1J-14
removal......................................................................1J-14
installation..................................................................1J-17
writing........................................................................1J-18
setting.........................................................................1J-19
Barometric pressure sensor.............................................1J-21
removal......................................................................1J-21
inspection...................................................................1J-22
installation..................................................................1J-23
Starter motor...................................................................1J-24
removal......................................................................1J-24
disassembly................................................................1J-25
inspection...................................................................1J-28
reassembly..................................................................1J-31
installation..................................................................1J-34
Ignition switch................................................................1J-35
inspection...................................................................1J-35
Supplementary Information............................................1J-36
1J-2 Electrical (4JJ1)
Generator
1. Engine cover
installation Note:
・ When adjusting the amount of flex to the
1. Generator installation original value
1. Install the generator to the bracket. ・ Apply a load to measurement point 1 of the
cooling fan belt and adjust the amount of flex.
Load: 98 N { 10 kg / 22 lb }
Note:
・ In the case of adjustment using a frequency
meter
・ Measure the frequency at measurement point
1 with a frequency meter.
Position of the belt tension
Fluctuation Frequency
: 5.4 to 6.6 mm
New : 188 to 210 Hz
{ 0.213 to 0.260 in }
: 7.7 to 8.5 mm
Reuse : 160 to 174 Hz
{ 0.303 to 0.335 in }
1. Measurement point 1
2. Measurement point 2
3. Measurement point 3
4. Measurement point 4
Note:
・ After adjusting the tension, tighten the adjust
3. Cooling fan belt installation
plate lock bolt and the mounting bolt under the
1. Install the cooling fan belt to the pulley. generator.
4. Cooling fan belt adjustment Generator tightening torque
1. Adjust tension to a standard value using a tension : 40 N・m { 4.1 kgf・m /
Mounting bolt
meter. 30 lb・ft }
Note: : 25 N・m { 2.5 kgf・m /
Adjust plate lock bolt
18 lb・ft }
・ Move the generator to adjust the tension.
2. Check tension of the cooling fan belt.
Electrical (4JJ1) 1J-5
Note: For a
: 12.4 to 16.4 mm
・ If the cooling fan belt is replaced with a new new : 92 to 112 Hz
{ 0.488 to 0.646 in }
one, make the new cooling fan belt fit in to product
cope with initial elongation. When : 16.5 to 19.1 mm
: 80 to 92 Hz
・ After making the cooling fan belt fit in, adjust reused { 0.650 to 0.752 in }
its tension once again.
Measurement point 4
5. A/C compressor drive belt installation Frequency of
Amount of flex
1. Install the A/C compressor drive belt to the pulley. vibrations
For a
: 15.9 to 20.7 mm
new : 70 to 86 Hz
{ 0.626 to 0.815 in }
product
When : 20.7 to 23.7 mm
: 62 to 70 Hz
reused { 0.815 to 0.933 in }
Note:
・ In the case of adjustment using a frequency
meter
・ Measure the frequency at measurement points
2, 3, and 4 with a frequency meter.
Measurement point 2
Frequency of
Amount of flex
vibrations
For a
: 12.5 to 16.5 mm
new : 92 to 112 Hz
{ 0.492 to 0.650 in }
product
1. A/C compressor drive belt When : 16.5 to 19.1 mm
: 79 to 91 Hz
reused { 0.650 to 0.752 in }
6. A/C compressor drive belt adjustment
1. Adjust tension to a standard value using a tension Measurement point 3
meter. Frequency of
Amount of flex
vibrations
Note:
For a
・ When adjusting the amount of flex to the : 12.4 to 16.4 mm
new : 92 to 112 Hz
original value { 0.488 to 0.646 in }
product
・ Apply a load to measurement points 2, 3, and
When : 16.5 to 19.1 mm
4 of the A/C compressor drive belt and adjust : 80 to 92 Hz
reused { 0.650 to 0.752 in }
the amount of flex.
Load: 98 N { 10 kg / 22 lb } Measurement point 4
Frequency of
Measurement point 2 Amount of flex
vibrations
Frequency of For a
Amount of flex : 15.9 to 20.7 mm
vibrations new : 70 to 86 Hz
For a { 0.626 to 0.815 in }
: 12.5 to 16.5 mm product
new : 92 to 112 Hz When : 20.7 to 23.7 mm
{ 0.492 to 0.650 in } : 62 to 70 Hz
product reused { 0.815 to 0.933 in }
When : 16.5 to 19.1 mm
: 79 to 91 Hz
reused { 0.650 to 0.752 in }
Measurement point 3
Frequency of
Amount of flex
vibrations
1J-6 Electrical (4JJ1)
9. Air cleaner assembly installation
1. Install the air cleaner assembly to vehicle.
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }
1. Measurement point 1
2. Measurement point 2
3. Measurement point 3
4. Measurement point 4
Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・ Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in }
in } Terminal nut 3. Connect the vacuum hose to the air cleaner
8. Generator cover installation assembly.
1. Install the generator cover to the bracket and the 4. Connect the harness connector to the barometric
adjust plate. pressure sensor.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in } 5. Connect the harness connector to the MAF sensor.
10. Blow-by hose connect
1. Connect the blow-by hose to the cylinder head cover.
11. Intake air duct installation
1. Install the intake air duct to the turbocharger and the
intake hose.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Bolt
Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in }
Clip
Electrical (4JJ1) 1J-7
1. Engine cover
Glow plug
removal Note:
・ Remove the part together with the intake hose.
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Engine cover removal
1. Remove the engine cover from the engine.
1. Glow plug
1J-10 Electrical (4JJ1)
inspection
1. Glow plug inspection
1. Inspect the glow plug.
Note:
・ Make the necessary adjustments, repairs, and
part replacements if excessive worn or
damage is found.
・ Check the main fuse for damage.
・ Replace the parts if necessary.
2. Glow plug measurement
1. Measure a resistance using the circuit tester.
Standard: 0.9 Ω Reference
Electrical (4JJ1) 1J-11
1. Engine cover
Glow relay
inspection
1. Glow relay inspection
1. Inspect the glow relay.
Note:
・ Make the necessary adjustments, repairs, and
part replacements if excessive worn or
damage is found.
・ Check the main fuse for damage.
・ Replace the parts if necessary.
2. Glow relay measurement
Note:
・ The glow relay is installed in the relay box in
the engine compartment.
1. Measure a resistance using the circuit tester.
Note:
・ Measure the resistance value between
measurement terminals No. 1 and No. 2, and
replace the glow relay if the measured value is
not within the specified range.
Standard: 94 to 114 Ω
ECM
1. Injector ID code
2. Injector
7. ECM removal
1. Remove the ECM from the reinforcement.
Note:
・ Remove it together with the ECM bracket.
2. Remove the ECM from the ECM bracket.
1. Bolt
2. Nut
3. Bolt
4. ECM bracket
5. ECM
Electrical (4JJ1) 1J-17
1. Glove box
2. Instrument panel assist side lower cover
writing
1. ECM writing
Note:
・ Re-learning of the supply pump
1. Connect a scan tool to the DLC.
2. Start the engine.
Note:
・ Start the engine and warm the engine up.
3. Check the Data List of a scan tool.
Note:
・ Confirm that the Engine Coolant Temperature
(ECT) display is at the standard value or
higher.
Standard: 65 ℃ { 149 °F }
4. Check the Data List of a scan tool.
Note:
・ Confirm that the Fuel Supply Pump Learning
Status display changes from Not Learned to
Learned.
5. Check the DTC of a scan tool.
Note:
・ Confirm that the scan tool does not detect a
DTC.
・ If required, perform an engine control system
inspection.
Electrical (4JJ1) 1J-19
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Barometric pressure sensor removal
1. Disconnect the connector from the barometric
pressure sensor.
2. Remove the barometric pressure sensor from the air
cleaner assembly.
1J-22 Electrical (4JJ1)
inspection
1. Barometric pressure sensor inspection
1. Inspect the barometric pressure sensor.
Note:
・ Confirm that the barometric pressure sensor is
securely installed.
・ Inspect the sensor and connector sections for
damage and dirt.
Electrical (4JJ1) 1J-23
installation
1. Barometric pressure sensor installation
1. Install the barometric pressure sensor to the air
cleaner assembly.
Tightening torque: 5 N・m { 0.5 kgf・m / 44 lb・in }
Starter motor
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Transmission oil level gauge tube removal
1. Remove transmission oil level gauge tube from the
oil pan.
3. 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.
4. Starter motor removal
1. Disconnect the earth cable from the starter motor.
2. Remove the starter motor from the rear plate.
Electrical (4JJ1) 1J-25
disassembly
1. Magnetic switch removal
1. Disconnect the lead wire from the magnetic switch.
4. Yoke removal
1. Remove the brush from the brush holder.
Note:
2. Magnetic switch disassembly
・ Remove the 4 brushes.
1. Remove the torsion spring from the magnetic switch.
2. Remove the plunger from the magnetic switch.
3. Remove the dust cover from the magnetic switch.
1J-26 Electrical (4JJ1)
2. Remove the yoke from the gear case. 5. Pinion assembly removal
Note: 1. Remove the bearing retainer from the gear case.
・ Remove it together with the armature and the 2. Remove the pinion assembly from the gear case.
brush holder.
3. Remove the dust cover from the gear case.
4. Remove the shift lever from the gear case.
inspection
1. Armature measurement
1. Measure the commutator using a dial gauge.
Note:
・ Measure the fluctuation, and replace the
commutator if the measured value exceeds the
limit.
Standard: 0.05 mm { 0.0020 in }
Limit: 0.25 mm { 0.0098 in }
1. Insulator
2. Measurement point
3. Commutator segment
4. Normal
5. Defect
4. Install the shift lever to the magnetic switch. 1. Install the armature to the yoke.
installation
1. Starter motor installation
1. Install the starter motor to the rear plate.
Tightening torque: 94 N・m { 9.6 kgf・m / 69 lb・ft }
2. Connect the earth cable to the starter motor.
2. Oil level gauge guide tube installation
1. Apply the engine oil to the O-ring.
2. Install the oil level gauge guide tube to the
crankcase.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Ignition switch
Supplementary Information
1. Component Views Note:
・ Starter motor
Electrical (4JJ1) 1J-37
1: 8.6 N・m { 0.88 kgf・m / 76 lb・in } 2: 8.1 N・m { 0.83 kgf・m / 72 lb・in }
TF4JJ-WE-1211TH_67209_奥付 2011.7.22 9:20 AM ページ 1
WORKSHOP MANUAL
ENGINE
(4JJ1 model)
Issued by ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
TF4JJ-WE-1211TH_67209_奥付 2011.7.22 9:20 AM ページ 2
2012MY
WORKSHOP MANUAL
ENGINE
(4JJ1 model)
No.TF4JJ-WE-1211TH