Common rail (fuel rail) installation (4JJ3 with DPD)

Part name

Tightening torque

3: 51 N・m { 5.2 kgf・m / 38 lb・ft }

1) Install the common rail (fuel rail) to the cylinder block.

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

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2) Connect the connector to the FRP sensor.

3) Connect the connector to the pressure-reducing valve.

1) Apply engine oil to the threaded portions of the sleeve nuts on the injector side, as well as the injector O-rings.

2) Temporarily tighten the injection pipes to the common rail (fuel rail) and injectors by hand until the sleeve nuts can no longer turn.

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3) Temporarily tighten the clip to the injection pipe.

4) Final tighten the injector clamp bolt to the cylinder head.

Tightening torque: 26 N・m { 2.7 kgf・m / 19 lb・ft }

5) Final tighten the injection pipes to the injectors and common rail (fuel rail).

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

Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft } Common rail (fuel rail) side

6) Securely tighten the clip to the injection pipe.

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

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) 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 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) Install the leak-off pipe to the inlet manifold.

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

2) Connect the 2 leak-off hoses to the leak-off pipe.

3) Connect the 3 vacuum hoses to the vacuum pipe.

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4) Temporarily tighten the harness brackets to the inlet manifold in the order shown in the diagram.

5) Final tighten the harness brackets to the inlet manifold in the order shown in the diagram.

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

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 A/C compressor drive belt to the following parts.

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1) Apply 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 }

3) Install the oil level gauge to the oil level gauge guide tube.

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 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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Refer to "1.Engine 1B.Mechanical(4JJ3 with DPD) Intake throttle valve installation".

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 }