Generator installation (4JJ3 with DPD)

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 cooling fan belt to the following parts.

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1. M/T models (Euro 5 or above)

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

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2. Except M/T models (Euro 5 or above)

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

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1) Install the intake hose to the intercooler and turbocharger.

Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in }

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1) Install the air cleaner to the vehicle.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

2) Connect the connector to the MAF and IAT sensor.

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1) Align the air duct with the air cleaner and turbocharger.

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2) Referring to the diagram, align the alignment mark positions and connect the air duct to the turbocharger.

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

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3) Install the PCV hose to the cylinder head cover and air duct.

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4) Install the intake air duct to the air cleaner and radiator core support.

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1) Install the engine cover to the engine.

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1. Post procedures

1) Connect the battery cable to the battery negative terminal.

2) Referring to the following, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function.

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

3) Close the engine hood.

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 cooling fan belt, readjust the cooling fan belt tension.

1) Loosen the tension pulley lock nut using a wrench.

2) Adjust the cooling fan belt tension by turning the adjust bolt.

Standard: 98 N { 10.0 kg / 22 lb }

Cooling fan belt tension standard value

Adjustment conditions	Deflection	Vibration frequency
When new	5.0 to 6.0 mm { 0.20 to 0.24 in }	207 to 231 Hz
Reused	7.0 to 7.8 mm { 0.28 to 0.31 in }	176 to 190 Hz

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

Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }

1. M/T models (Euro 5 or above)

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 }

2. Except M/T models (Euro 5 or above)

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

Adjustment conditions	Deflection	Vibration frequency
When new	12.5 to 16.5 mm { 0.49 to 0.65 in }	92 to 112 Hz
Reused	16.5 to 19.1 mm { 0.65 to 0.75 in }	79 to 91 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 }