Fuel supply pump installation (4JJ3 with DPD)

Part name

Tightening torque

1: 10 N・m { 1.0 kgf・m / 89 lb・in }

3: 130 N・m { 13.3 kgf・m / 96 lb・ft }

6: 50 N・m { 5.1 kgf・m / 37 lb・ft }

10: 25 N・m { 2.5 kgf・m / 18 lb・ft }

1) Apply soapy water to the O-ring.

2) Install the O-ring to the fuel supply pump.

3) Install the fuel supply pump to the timing gear case.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

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4) Align 3 marks on the supply pump gear and idle gear A, and install the supply pump gear to the supply pump shaft.

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5) Install the special tool to the starter installation section of the rear plate.

SST: 5-8840-0214-0 - crankshaft stopper

6) Align the supply pump gear dowel pin with the notched section of the supply pump sprocket, and then install the supply pump sprocket to the supply pump gear.

Tightening torque: 130 N・m { 13.3 kgf・m / 96 lb・ft }

7) Connect the connector to the fuel supply pump.

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8) Remove the special tool from the starter installation section of the rear plate.

1) Install the idle gear D sprocket and timing chain as a set to idle gear D and the supply pump gear sprocket.

Tightening torque: 8.0 N・m { 0.8 kgf・m / 71 lb・in }

2) Install the idle gear D center bolt and sleeve to the idle gear D shaft.

Tightening torque: 59 N・m { 6.0 kgf・m / 44 lb・ft }

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3) Align the idle gear D alignment mark with the blue link of the timing chain.

4) Install the timing chain to the supply pump sprocket.

5) Align the supply pump sprocket alignment mark with the yellow plate position of the timing chain.

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6) Install the timing chain lever pivot to the timing chain tension lever.

Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft }

7) Push down the timing chain tensioner latch and insert the plunger.

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8) Install the oil feed pipe to the cylinder block.

Tightening torque: 54 N・m { 5.5 kgf・m / 40 lb・ft } Eyebolt

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Bracket

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9) Install the timing chain tensioner and gasket to the cylinder head.

Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }

10) Install the oil feed pipe to the timing chain tensioner.

Tightening torque: 14.7 N・m { 1.5 kgf・m / 11 lb・ft }

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11) Remove the M6 lock bolt from idle gear A.

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12) Install the plug to the gear case cover.

Tightening torque: 50 N・m { 5.1 kgf・m / 37 lb・ft }

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13) Lightly press the area indicated by the arrow in the diagram to disconnect the hook from the pin.

1) Referring to the diagram, apply ThreeBond 1207C or equivalent to the timing chain lower cover.

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Standard value

a: 2.0 to 2.5 mm { 0.079 to 0.098 in } Bead height

b: 2.0 to 2.5 mm { 0.079 to 0.098 in } Bead width

2) Install the timing chain lower cover to the gear case cover.

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

3) Install the noise cover to the timing chain lower cover.

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

4) Install the idle pulley to the timing chain lower cover.

Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }

1) Referring to the diagram, apply ThreeBond 1207C or equivalent to the timing chain upper cover.

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Standard value

a: 1.0 to 1.5 mm { 0.039 to 0.059 in } Bead height

b: 2.0 to 2.5 mm { 0.079 to 0.098 in } Bead width

2) Install the timing chain upper cover to the cylinder head.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

3) Connect the connector to the CMP sensor.

4) Install the idle pulley to the timing chain upper cover.

Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }

1) Apply the engine oil to the oil seal.

2) Insert the oil seal from the lower side of the cylinder head cover until it reaches the far end.

3) Referring to the diagram, apply ThreeBond 1217H or 1207C to the cylinder head mating surface.

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Standard value

a: 2.0 to 2.5 mm { 0.079 to 0.098 in } Bead width

b: 1.0 to 1.5 mm { 0.039 to 0.059 in } Bead height

4) Temporarily tighten the cylinder head cover to the cylinder head in the order shown in the diagram.

Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in }

5) Final tighten the cylinder head cover to the cylinder head in the order shown in the diagram.

Tightening torque: 9.0 N・m { 0.9 kgf・m / 80 lb・in }

6) Install the harness bracket to the cylinder head cover.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Harness bracket

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7) Connect the harness clip to the cylinder head cover.

8) Connect the PCV hose to the cylinder head cover.

1) Install the glow plug to the cylinder head.

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

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2) Connect the connector to the glow plug.

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1) Install the following parts to the inlet manifold.

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

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2) Connect the connector to the intake throttle valve.

1) Install the injector leak-off pipe to the injector.

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2) Install the fuel leak-off hose to the leak-off pipe.

3) Connect the connector to the injector.

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1) Install the air duct bracket to the cylinder head cover.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

1) Install the intake duct to the intake throttle valve.

2) Connect the connector to the boost pressure sensor.

1) Install the differential pressure sensor bracket to the cylinder head cover.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2) Install the harness bracket to the cylinder head cover.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

3) Connect the following sensor harnesses to the harness bracket.

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Refer to "1.Engine 1Z.Engine Electrical Control(4JJ3 with DPD) exhaust differential pressure sensor installation".

Refer to "1.Engine 1J.Electrical(4JJ3 with DPD) starter motor installation".

1) Install the tension pulley to the cylinder head.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

1) Install the water pipe to the following parts.

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

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

Tightening torque: 10.3 N・m { 1.1 kgf・m / 91 lb・in } Fuel supply pump side

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Cylinder block side

Tightening torque: 10.3 N・m { 1.1 kgf・m / 91 lb・in } Common rail (fuel rail) side

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1) Install the fuel feed pipe to the fuel supply pump and common rail (fuel rail).

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

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1) Connect the fuel return hose to the fuel leak-off pipe.

2) Connect the fuel feed hose to the fuel supply pump.

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1) Install the EGR cooler bypass control solenoid valve and bracket as a set to the inlet manifold.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2) Connect the vacuum hose to the EGR cooler bypass control solenoid valve.

3) Connect the connector to the EGR cooler bypass control solenoid valve.

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1) Temporarily tighten the A/C compressor bracket to the cylinder head.

2) Final tighten the A/C compressor bracket to the cylinder head in the order shown in the diagram.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

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

Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }

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1) Install the EGR water pipe to the oil cooler and turbocharger lower bracket.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2) Connect the water hose to the water intake pipe and return hose.

1) Temporarily tighten the oil filter and gasket to the oil cooler in the order shown in the diagram.

2) Final tighten the oil filter to the oil cooler in the order shown in the diagram.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

1) Clean the oil filter mounting surface.

2) Apply grease or engine oil to the oil filter element seal section.

3) Install the oil filter element to the oil filter bracket using the special tool.

SST: 5-8840-0203-0 - oil filter wrench

Tightening torque: 19.6 N・m { 2.0 kgf・m / 14 lb・ft }

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1) Temporarily tighten the water intake pipe and water hose to the oil cooler in the order shown in the diagram.

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

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

1) Install the fan pulley to the water pump.

2) Install the cooling fan and cooling fan clutch as a set to the water pump.

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

1) Install the generator to the lower bracket.

Tightening torque: 40 N・m { 4.1 kgf・m / 30 lb・ft }

2) Install the upper bracket to the generator and timing gear case.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

3) Connect the connector to the generator.

4) Connect the B-terminal to the generator.

Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・in }

1) Install the cooling fan belt to the following parts.

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1. M/T models (Euro 5 or above)

1) Install the A/C compressor drive belt to the following parts.

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2. Except M/T models (Euro 5 or above)

1) Install the A/C compressor drive belt to the following parts.

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1) Feed 1 cc (approximately 20 drops) of engine oil into the oil feed port.

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2) Install the turbocharger oil pipe and gasket to the turbocharger.

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

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3) Install the water feed and return pipe, as well as the gasket to the turbocharger.

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

4) Install the following parts as a set to the exhaust manifold.

Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft }

5) Connect the connector to the turbocharger.

1) Install the turbocharger bracket to the cylinder block.

Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft } M10

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } M8

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1) Connect the turbocharger oil pipe to the oil cooler and crankcase.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Crankcase side

Tightening torque: 23 N・m { 2.3 kgf・m / 17 lb・ft } Oil cooler side

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1) Connect the turbocharger water return hose to the water feed and return pipe.

2) Connect the turbocharger water feed hose to the water feed and return pipe.

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1) Temporarily tighten the EGR duct and gasket to the EGR cooler in the order shown in the diagram.

2) Final tighten the EGR duct to the EGR cooler in the order shown in the diagram.

Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft }

3) Install the EGR duct gasket to the cylinder head.

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

5) Final tighten the EGR cooler to the cylinder head and exhaust manifold in the order shown in the diagram.

Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft }

6) Install the harness bracket to the EGR duct.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

7) In the order shown in the diagram, temporarily tighten the heat protector to the EGR duct.

8) In the order shown in the diagram, final tighten the heat protector to the EGR duct.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

1) Connect the EGR cooler water return hose to the EGR cooler.

2) Connect the EGR cooler water feed hose to the EGR cooler.

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1) Install the air cleaner to the vehicle.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

2) Connect the connector to the MAF and IAT sensor.

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1) Install the battery to vehicle.

2) Install the battery bracket to the frame.

Tightening torque: 4.0 N・m { 0.41 kgf・m / 35.4 lb・in } Battery side

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft } Frame side

3) Connect the battery cable to the battery.

4) Connect the battery ground cable to the frame.

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1) Align the air duct with the air cleaner and turbocharger.

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2) Referring to the diagram, align the alignment mark positions and connect the air duct to the turbocharger.

Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in }

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3) Install the PCV hose to the cylinder head cover and air duct.

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1) Temporarily tighten the DPD and exhaust pipe bracket to the crankcase in the order shown in the diagram.

2) Temporarily tighten the DPD bracket to the following parts in the order shown in the diagram.

3) Temporarily tighten the DPD to the turbocharger using a V-band.

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4) Final tighten the DPD and exhaust pipe bracket to the crankcase in the order shown in the diagram.

Tightening torque: 94 N・m { 9.6 kgf・m / 69 lb・ft }

5) Final tighten the DPD bracket to the following parts in the order shown in the diagram.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

6) Align the markings, and then connect the differential pressure hoses to the DPD.

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7) Final tighten the V-band to the DPD and turbocharger.

Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・in }

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8) Install the heat protector to the turbocharger.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

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Refer to "1.Engine 1G.Exhaust(4JJ3 with DPD) exhaust pipe installation".

Refer to "1.Engine 1D.Cooling(4JJ3 with DPD) radiator installation".

1) Open the engine hood.

2) Press the priming pump until it becomes hard.

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When installing a new belt, initial stretching of the belt occurs.
In addition, when reusing the belt, the belt needs to be fitted to the pulley groove.
After fitting the cooling fan belt, readjust the cooling fan belt tension.

1) Loosen the tension pulley lock nut using a wrench.

2) Adjust the cooling fan belt tension by turning the adjust bolt.

Standard: 98 N { 10.0 kg / 22 lb }

Cooling fan belt tension standard value

Adjustment conditions	Deflection	Vibration frequency
When new	5.0 to 6.0 mm { 0.20 to 0.24 in }	207 to 231 Hz
Reused	7.0 to 7.8 mm { 0.28 to 0.31 in }	176 to 190 Hz

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3) Tighten the tension pulley lock nut to the specified torque.

Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }

When installing a new belt, initial stretching of the belt occurs.
In addition, when reusing the belt, the belt needs to be fitted to the pulley groove.
After fitting the A/C compressor drive belt, adjust the tension of the A/C compressor drive belt again.

1) Loosen the tension pulley lock nut.

2) Turn the tension pulley adjust bolt to adjust the tension.

98 N { 10.0 kg / 22 lb } Load

Measurement point 1

Adjustment conditions	Deflection	Vibration frequency
When new	10.2 to 11.2 mm { 0.40 to 0.44 in }	163 to 179 Hz
Reused	12.1 to 13.3 mm { 0.48 to 0.52 in }	131 to 147 Hz

Measurement point 4

Adjustment conditions	Deflection	Vibration frequency
When new	6.8 to 7.4 mm { 0.27 to 0.29 in }	249 to 273 Hz
Reused	7.9 to 8.7 mm { 0.31 to 0.34 in }	201 to 225 Hz

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3) Tighten the tension pulley lock nut to the specified torque.

Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }