Crankcase installation (4JJ3 with DPD)

1) Referring to the diagram, apply ThreeBond 1207C or equivalent to the crankcase.

Standard value

a: 2.0 to 3.0 mm { 0.079 to 0.118 in } Bead height

b: 4.0 to 5.0 mm { 0.157 to 0.197 in } Bead width

2) Install the O-ring to the crankcase.

3) Install the crankcase to the cylinder block.

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

4) Install the crankcase cover to the crankcase.

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

1) Referring to the diagram, apply ThreeBond 1207B or equivalent to the oil pan.

Standard value

a: 2.0 mm { 0.079 in } Bead height

b: 3.0 mm { 0.118 in } Bead width

2) Install the oil pan to the crankcase.

Tightening torque: 22 N・m { 2.2 kgf・m / 16 lb・ft }

1) Apply ThreeBond 1207C or equivalent to the oil seal retainer.

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

2) Install the oil seal retainer to the cylinder block and crankcase.

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

1) Prepare the special tool.

SST: 5-8840-2991-0 - rear oil seal installer

Special tool number		Part name
5-8840-2991-0	5-8840-2359-0	Center bolt
		Sleeve
		Adapter
	5-8840-2975-0	Fixing bolt

2) Install the crankshaft rear oil seal and slinger to the adapter outer circumference.

3) Install the adapter to the end section of the crankshaft.

4) Insert the sleeve into the adapter section, and tighten with the center bolt until the adapter section makes contact with the sleeve.

5) Remove the adapter and sleeve.

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6) Check that the dimensions from the crankshaft end face to the oil seal end face are within the standard range.

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Standard value

a: 12.2 to 12.8 mm { 0.480 to 0.504 in }

1) Install the rear plate to the cylinder block and crankcase.

Tightening torque: 82 N・m { 8.4 kgf・m / 60 lb・ft }

1. Manual transmission models

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

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

2) Apply engine oil to the threaded portion of the bolts.

3) Temporarily tighten the washer and flywheel to the crankshaft in the order shown in the diagram.

4) Final tighten the flywheel to the crankshaft in the order shown in the diagram.

Tightening torque: 59 N・m { 6.0 kgf・m / 44 lb・ft } 1st time

Tightening Angle : 60 to 90 ° 2nd time

2. Automatic transmission models

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

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

2) Temporarily tighten the following parts to the crankshaft.

3) Final tighten the flywheel to the crankshaft in the order shown in the diagram.

Tightening torque: 59 N・m { 6.0 kgf・m / 44 lb・ft } 1st time

Tightening Angle : 60 to 90 ° 2nd time

1) Apply ThreeBond 1207B or equivalent to the gasket.

2) Referring to the diagram, apply ThreeBond 1207B or equivalent to the cylinder block.

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3) Install the gasket to the cylinder block.

4) Align the positions of the dowel pin and bolt, and install the timing gear case to the cylinder block.

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

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5) Apply engine oil to the threaded portions and seating surfaces of the flange bolts.

6) Install the flange bolt to the timing gear case.

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

7) Temporarily tighten the timing gear case bracket to the timing gear case.

8) Temporarily tighten the timing gear case bracket to the cylinder block.

9) Final tighten the timing gear case bracket to the timing gear case.

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

10) Final tighten the timing gear case bracket to the cylinder block.

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

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1) Apply engine oil to the oil pump gear.

2) Install the oil pump to the timing gear case.

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

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1) Apply soapy water to the O-ring.

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

3) Do not pinch the O-ring.

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

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4) Connect the connector to the fuel supply pump.

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

2) 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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3) Install idle gear A to the idle gear A shaft.

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

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

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

7) Install the crank gear to the crankshaft.

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

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

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) Install the water pump and gasket to the timing gear case.

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

1) Install the crankshaft front oil seal and slinger to the gear case cover using the special tool.

SST: 5-8840-2936-0 - Oil seal installer

2) Measure the dimension from the crankshaft gear rear end face to the oil seal end face.

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Dimensions

a: 10.2 to 10.8 mm { 0.402 to 0.425 in }

3) Install the cover to the gear case cover.

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

1) Apply engine oil to the threaded portions and seating surfaces of the bolts.

2) Install the crankshaft pulley to the crankshaft in the order shown in the diagram.

Tightening torque: 30 N・m { 3.1 kgf・m / 22 lb・ft } 1st time

3) Retighten the bolts in the order shown in the diagram using the special tool.

SST: 5-8840-0266-0 - angle gauge

Tightening Angle : 180 ° 2nd time

4) Retighten the bolts in the order shown in the diagram using the special tool.

SST: 5-8840-0266-0 - angle gauge

Tightening Angle : 60 ° 3rd time

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

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 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) 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) Clean the upper surface of the cylinder block and lower surface of the cylinder head using a scraper.

2) Measure the protrusion amount of the piston head using a dial gauge.

Standard: 0.05 mm or less { 0.0020 in or less }

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3) Select the grade of the cylinder head gasket and timing gear case gasket based on the average of the measured values.

4) Apply ThreeBond 1207B or equivalent to the positions on the cylinder block shown in the diagram.

Standard value

a: 2.0 to 3.0 mm { 0.079 to 0.118 in } Bead height

b: 3.0 to 4.0 mm { 0.118 to 0.157 in } Bead width

5) Place the cylinder head gasket and timing gear case gasket on the cylinder block.

6) Align the dowel positions, and place the cylinder head on the cylinder block.

7) Apply engine oil to the threaded portions and seating surfaces of the cylinder head mounting bolts.

8) Tighten the cylinder head bolts to the cylinder head using the special tool and a torque wrench in the order shown in the diagram.

SST: 5-8840-0266-0 - angle gauge

Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft } 1st time

Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft } 2nd time

Tightening Angle : 60 to 75 ° 3rd time

Tightening Angle : 60 to 75 ° 4th time

9) Install the nuts and bolts to the timing gear case in the order shown in the diagram.

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

10) Remove the wire from the engine hanger and hoist.

11) Remove special tool from the cylinder head.

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) Align the camshaft bracket to the cylinder head.

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3) Align the marks of the inlet camshaft and exhaust camshaft with the mark of the bearing cap.

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4) Apply engine oil to the threaded portions and seating surfaces of the M8 bolts.

5) Tighten the camshaft bracket bolts in the order shown in the diagram.

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

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 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 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) Install the baffle plate to the cylinder head.

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

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 generator lower bracket to the cylinder block and timing gear case.

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

2) Temporarily tighten the tension pulley to the generator bracket in the order shown in the diagram.

3) Final tighten the tension pulley to the generator bracket in the order shown in the diagram.

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

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 EGR gas pressure sensor bracket to the cylinder head.

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

2) Install the EGR gas pressure pipe to the exhaust manifold and bracket in the order shown in the diagram.

Tightening torque: 55 N・m { 5.6 kgf・m / 41 lb・ft } Nipple

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

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

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

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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) 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 water pipe to the following parts.

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

1) Install the tension pulley to the cylinder head.

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

1) Apply engine oil to the O-ring.

2) Install the O-ring to the injector.

3) Clean the cylinder head installation surface and injector.

4) Drop the gasket into the port on the cylinder head side.

5) Check that the gasket has been inserted based on the nozzle height using the injector.

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6) Install the injector clamp to the injector.

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7) Apply engine oil to the threaded portions and seating surfaces of the bolts.

8) Install the injector and injector clamp to the cylinder head.

9) Temporarily tighten the injector clamp bolt to the cylinder head.

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 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 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) 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) 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.

Legend

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 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 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.

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

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 }

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

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

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

2) Connect the connector to charge air cooler temperature sensor 2.

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) Replenish the engine with the engine oil.

2) Check the tightening of the oil pan drain plug.

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

Refer to "1.Engine 1B.Mechanical(4JJ3 with DPD) engine installation".