Inlet manifold installation (4JJ3 with DPD)

Part name

Tightening torque

4: 25 N・m { 2.5 kgf・m / 18 lb・ft }

6: 25 N・m { 2.5 kgf・m / 18 lb・ft }

7: 25 N・m { 2.5 kgf・m / 18 lb・ft }

1) Temporarily tighten the inlet manifold and gasket to the cylinder head.

2) Final tighten the inlet manifold mounting bolts in the order shown in the diagram.

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

3) Connect the vacuum hose to the inlet manifold.

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.

Legend

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 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.

Legend

1) Install the swirl 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 swirl control solenoid valve.

3) Connect the connector to swirl control solenoid valve.

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.

Legend

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) 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 }

Legend

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

Legend

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) Temporarily tighten the EGR cooler bypass pipe and gasket to the inlet manifold and exhaust manifold in the order shown in the diagram.

Legend

2) Final tighten the EGR cooler bypass pipe to the inlet manifold and exhaust manifold in the order shown in the diagram.

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

1) Temporarily tighten the heater pipe to the inlet manifold in the order shown in the diagram.

2) Final tighten the heater pipe to the inlet manifold in the order shown in the diagram.

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

Refer to "1.Engine 1H.Aux. Emission Control Devices(4JJ3 with DPD) EGR valve installation".

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

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

Legend

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

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