Idle gear installation (4JJ3 without DPD)

Part name

Tightening torque

2: 8.0 N・m { 0.8 kgf・m / 71 lb・in }

3: 130 N・m { 13.3 kgf・m / 96 lb・ft }

6: 59 N・m { 6.0 kgf・m / 44 lb・ft }

14: 32 N・m { 3.3 kgf・m / 24 lb・ft }

16: 59 N・m { 6.0 kgf・m / 44 lb・ft }

21: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

24-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }

24-2: 180 °

24-3: 60 °

1) Apply engine oil to the sliding surface of the idle gear D shaft and idle gear inner surface.

2) Install the idle gear D shaft to the camshaft brackets.

3) Install idle gear D to the idle gear shaft.

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4) Apply engine oil to the gear assembly sections of the idle gear C shaft.

5) Install the idle gear C shaft to the timing gear case.

6) Apply engine oil to the threaded portion and seating surface of the idle gear C bolt.

7) Temporarily tighten idle gear C to the idle gear C shaft.

8) Apply engine oil to the idle gear A shaft.

9) Install the idle gear A shaft to the timing gear case by aligning the cylinder block side oil hole with the idle gear A shaft oil hole.

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10) Install idle gear A to the idle gear A shaft.

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11) Apply engine oil to the tooth surface of idle gear A.

12) Install the flange to idle gear A with the front mark facing toward the front.

13) Apply engine oil to the threaded portions and seating surfaces of the bolts, and then temporarily tighten the bolts.

14) Install the crank gear to the crankshaft.

15) Final tighten idle gear A to the idle gear A shaft.

Tightening torque: 32 N・m { 3.3 kgf・m / 24 lb・ft }

16) Final tighten idle gear C to the idle gear C shaft.

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

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1) 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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1) Referring to the diagram, apply ThreeBond 1207B to the timing gear case.

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2) Install the gasket to the gear case cover.

3) Install the gear case cover to the timing gear case.

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

4) Install the cover to the gear case cover.

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

1) Install the vacuum pump to the gear case cover.

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

2) Install the vacuum pump oil pipe to the vacuum pump and cylinder block.

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

3) Install the vacuum pipe as a set with the vacuum hose to the timing gear case and vacuum pump.

Tightening torque: 32 N・m { 3.3 kgf・m / 24 lb・ft } Vacuum pump side

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

1) Install the power steering oil pump to the timing gear case.

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

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2) Install the power steering oil hose to the bracket.

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1) Rotate the crankshaft in the forward direction (clockwise) to align the No. 1 cylinder piston to compression top dead center.

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2) Apply the engine oil to the camshaft journal.

3) Install the camshaft to the camshaft brackets with the inlet camshaft and exhaust camshaft markings upward.

4) Align the camshaft timing marks with idle gear D.

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5) Apply engine oil to the following parts.

6) Align the inlet camshaft and exhaust camshaft alignment marks with the camshaft upper bracket.

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7) Temporarily tighten the camshaft upper bracket M8 bolts to the cylinder head in the order shown in the diagram.

8) Final tighten the camshaft upper bracket M8 bolts to the cylinder head in the order shown in the diagram.

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

9) Temporarily tighten the camshaft upper bracket M6 bolts to the camshaft brackets in the order shown in the diagram.

10) Final tighten the camshaft upper bracket M6 bolts to the camshaft brackets in the order shown in the diagram.

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

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

11) Remove the lock bolt from the camshaft gear.

1) Install the timing chain guide to the cylinder head and cylinder block.

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

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2) Insert the timing chain tension lever into the gap between the timing gear case and the cylinder block.

3) Align the timing chain with the supply pump sprocket.

4) Install the sprocket and timing chain as a set to idle gear D.

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

5) Apply engine oil to the threaded portion and seating surface of the idle gear D shaft bolt.

6) Install the idle gear D shaft bolt and sleeve to idle gear D and sprocket.

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

7) Align the 2 timing alignment marks at the location shown in the diagram.

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

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

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

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

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

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

Tightening torque: 14.7 N・m { 1.5 kgf・m / 130 lb・in }

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12) 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 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.

1) Install the tension pulley to the cylinder head.

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

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 }

1) Rotate the crankshaft in the forward direction (clockwise) to align the No. 1 cylinder piston to compression top dead center.

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2) Loosen the adjust screw of the rocker arm using the special tool.

SST: 5-8840-2822-0 - valve clearance adjust nut wrench

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3) Insert a feeler gauge between the rocker arm roller and the cam.

Standard: 0.15 mm { 0.0059 in } When cold

4) Lightly tighten the adjust screw with the feeler gauge inserted using the special tool.

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5) Verify that the movement of the feeler gauge becomes stiff.

6) Secure the rocker arm adjust screw with the adjust screw nut.

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

Measurable valve position

Cylinder position	#1		#2		#3		#4
	IN	EX	IN	EX	IN	EX	IN	EX
No. 1 cylinder compression top dead center	○	○	○			○
No. 4 cylinder compression top dead center				○	○		○	○

7) Rotate the crankshaft for 1 turn, and adjust any remaining valve clearance.

1) Install the baffle plate to the cylinder head.

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

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 }

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

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

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 water pipe to the following parts.

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

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 }

Refer to "1.Engine 1B.Mechanical(4JJ3 without DPD) crankshaft front oil seal installation".