Timing gear case installation (4JJ3 with DPD)

Part name

Tightening torque

1: 25 N・m { 2.5 kgf・m / 18 lb・ft }

3: 40 N・m { 4.1 kgf・m / 30 lb・ft }

5: 51 N・m { 5.2 kgf・m / 38 lb・ft }

7: 25 N・m { 2.5 kgf・m / 18 lb・ft }

8: 25 N・m { 2.5 kgf・m / 18 lb・ft }

12: 25 N・m { 2.5 kgf・m / 18 lb・ft }

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

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

Legend

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 }

Legend

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 }

Legend

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 }

Legend

4) Connect the connector to the fuel supply pump.

Legend

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.

Legend

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

Legend

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 }

Legend

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

Legend

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 }

Legend

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

Legend

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 water pump and gasket to the timing gear case.

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

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 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) 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 power steering oil pump to the timing gear case.

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

Legend

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

Legend

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

Legend

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 }

Legend

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

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