Cylinder head installation (4JJ3 without DPD)

Part name

Tightening torque

2: 25 N・m { 2.5 kgf・m / 18 lb・ft }

3: 25 N・m { 2.5 kgf・m / 18 lb・ft }

4-1: 70 N・m { 7.1 kgf・m / 52 lb・ft }

4-2: 70 N・m { 7.1 kgf・m / 52 lb・ft }

4-3: 60 to 75 °

4-4: 60 to 75 °

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 }

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 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) Install the glow plug terminal and glow plug connector to the glow plug.

Tightening torque: 1.0 N・m { 0.10 kgf・m / 8.9 lb・in }

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1) Install the thermostat to the thermostat housing with the jiggle valve facing the front of the vehicle.

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2) Install the water outlet pipe to the cylinder head.

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

3) Connect the water hose to the water outlet pipe.

1) Install the EGR valve and gasket to the inlet manifold.

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

Tightening torque: 24 N・m { 2.4 kgf・m / 18 lb・ft } Bolt

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.

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) Connect the radiator lower hose and clamp to the water intake pipe.

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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 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) 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.

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1) Connect the fuel return hose to the fuel leak-off pipe.

2) Connect the fuel feed hose to the fuel supply pump.

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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) 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 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 }

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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 (Intake throttle valve side)

2) Connect the air intake hose to the intercooler.

Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in } Clamp (Intercooler side)

3) Connect the connector to the boost pressure sensor.

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

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1) Install the fan pulley to the water pump.

2) Install the cooling fan and cooling fan clutch as a set to the water pump.

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

1) Install the fan guide to the radiator.

Tightening torque: 6.5 N・m { 0.7 kgf・m / 58 lb・in }

2) Install the fan shroud to the fan guide.

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1) Clean the radiator reserve tank using detergent.

2) Assemble the reserve tank hose to the radiator reserve tank.

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3) Install the radiator reserve tank to the fan guide.

Tightening torque: 8.4 N・m { 0.9 kgf・m / 74 lb・in }

4) Connect the radiator reserve tank hose to the radiator.

1) Install the radiator upper hose and clamp to the thermostat and radiator.

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1) Install the battery to vehicle.

2) Install the battery bracket to the frame.

Tightening torque: 4.0 N・m { 0.41 kgf・m / 35.4 lb・in } Battery side

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

3) Connect the battery cable to the battery.

4) Connect the battery ground cable to the frame.

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Refer to "1.Engine 1F.Induction(4JJ3 without DPD) Turbocharger installation".

1) Install the cowl panel to vehicle.

Refer to "9.Body, Cab, Accessories 9B.Wiper, Washer Systems wiper linkage installation".

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 "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors engine hood installation".

1. Post procedures

1) Lower the vehicle.

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

3) 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".

4) 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 }

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 }