Isuzu D Max 2011 User Manual

WORKSHOP MANUAL

2011MY UC SERIES

ENGINE

4JJ1 MODEL

SECTION 6

Isuzu Motors Limited

E-Solutions &

Service Marketing Dept.

SECTION 6A

ENGINE MECHANICAL (4JJ1)

TABLE OF CONTENTS

ISUZU DIESEL ENGINE (4JJ1) ......................... 6A-3

Service Precautions ........................................ 6A-3

Trouble Shooting ............................................. 6A-8

Main Data and Specifications.......................... 6A-13

Special Tools................................................... 6A-14

Engine Assembly................................................ 6A-15

Removal .......................................................... 6A-15

Installation ....................................................... 6A-17

Special Tools................................................... 6A-19

Engine Mount ..................................................... 6A-20

Components.................................................... 6A-20

Removal .......................................................... 6A-21

Installation ....................................................... 6A-21

Torque Specifications...................................... 6A-22

Special Tools................................................... 6A-22

Cylinder Head Cover .......................................... 6A-23

Components.................................................... 6A-23

Removal .......................................................... 6A-24

Installation ....................................................... 6A-25

Intake Manifold ................................................... 6A-26

Components.................................................... 6A-26

Removal .......................................................... 6A-27

Installation ....................................................... 6A-28

Torque Specifications...................................... 6A-30

Turbocharger and Exhaust Manifold .................. 6A-31

Components.................................................... 6A-31

Removal .......................................................... 6A-32

Inspection ........................................................ 6A-34

Installation ....................................................... 6A-35

Torque Specifications...................................... 6A-38

Timing Gear Train .............................................. 6A-39

Components.................................................... 6A-39

Removal .......................................................... 6A-40

Disassembly .................................................... 6A-42

Reassembly..................................................... 6A-42

Inspection ........................................................ 6A-43

Installation ....................................................... 6A-44

Torque Specifications...................................... 6A-47

Camshaft Assembly ........................................... 6A-48

Components.................................................... 6A-48

Removal .......................................................... 6A-49

ENGINE MECHANICAL (4JJ1) 6A-1

Disassembly.................................................... 6A-50

Reassembly .................................................... 6A-52

Installation ....................................................... 6A-53

Torque Specifications...................................... 6A-55

Special Tools................................................... 6A-55

Valve Stem Seal and Valve Spring .................... 6A-56

Components.................................................... 6A-56

Removal .......................................................... 6A-57

Inspection........................................................ 6A-58

Installation ....................................................... 6A-59

Special Tools................................................... 6A-60

Cylinder Head..................................................... 6A-61

Components.................................................... 6A-61

Removal .......................................................... 6A-61

Disassembly.................................................... 6A-69

Inspection........................................................ 6A-71

Reassembly .................................................... 6A-76

Installation ....................................................... 6A-77

Torque Specifications...................................... 6A-88

Special Tools................................................... 6A-88

Piston and Connecting Rod................................ 6A-89

Components.................................................... 6A-89

Removal .......................................................... 6A-89

Disassembly.................................................... 6A-90

Reassembly .................................................... 6A-94

Installation ....................................................... 6A-95

Torque Specifications...................................... 6A-97

Special Tools................................................... 6A-97

Flywheel ............................................................. 6A-98

Components.................................................... 6A-98

Removal .......................................................... 6A-98

Inspection........................................................6A-100

Installation .......................................................6A-100

Torque Specifications...................................... 6A-102

Special Tools................................................... 6A-102

Gear Case Assembly .........................................6A-103

Components....................................................6A-103

Removal ..........................................................6A-104

Installation .......................................................6A-105

Torque Specifications...................................... 6A-107

6A-2 ENGINE MECHANICAL (4JJ1)

Crankshaft Front Oil Seal ...................................6A-108

Components....................................................6A-108

Removal ..........................................................6A-108

Installation .......................................................6A-109

Torque Specifications......................................6A-110

Special Tools...................................................6A-110

Crankshaft Rear Oil Seal ...................................6A-111

Components....................................................6A-111

Removal ..........................................................6A-112

Installation .......................................................6A-112

Special Tools...................................................6A-113

Crankshaft ..........................................................6A-114

Components....................................................6A-114

Removal ..........................................................6A-115

Disassembly ....................................................6A-116

Reassembly.....................................................6A-116

Inspection ........................................................6A-116

Installation .......................................................6A-120

Torque Specifications......................................6A-123

Cylinder Block ....................................................6A-124

Components....................................................6A-124

Removal ..........................................................6A-124

Inspection ........................................................6A-125

Installation .......................................................6A-126

Lubrication System.............................................6A-128

Service Precautions ........................................6A-128

Functional Check ............................................6A-129

Oil Filter Cartridge ..............................................6A-131

Components....................................................6A-131

Removal ..........................................................6A-131

Installation .......................................................6A-131

Special Tools...................................................6A-132

Oil Filter Assembly and Oil Cooler .....................6A-133

Components....................................................6A-133

Removal ..........................................................6A-133

Installation .......................................................6A-135

Crank Case and Oil Pan.....................................6A-137

Components....................................................6A-137

Removal ..........................................................6A-138

Disassembly ....................................................6A-139

Reassembly.....................................................6A-139

Installation .......................................................6A-140

Torque Specifications......................................6A-142

Oil Pump ............................................................6A-143

Components....................................................6A-143

Removal ..........................................................6A-143

Disassembly....................................................6A-145

Reassembly ....................................................6A-145

Inspection........................................................6A-145

Installation .......................................................6A-146

Oil Pressure SW ................................................6A-149

Components....................................................6A-149

Removal ..........................................................6A-150

Inspection........................................................6A-150

Installation .......................................................6A-150

Circuit check.................................................... 6A-150

Air Cleaner Element ........................................... 6A-151

Removal ..........................................................6A-151

Cleaning ..........................................................6A-151

Installation .......................................................6A-151

ENGINE MECHANICAL (4JJ1) 6A-3

ISUZU DIESEL ENGINE (4JJ1)

Service Precautions

Matters that require attention in terms o maintenance

To prevent damage to the engine and ensure reliabilit of its performance, pay attention to the following in maintaining the engine:

• When lifting up or supporting the engine, do not apply a jack on the oil pan.

When taking down the engine on the ground, do

not make the bearing surface of the oil pan touch the ground directly. Use a wooden frame, fo example, to support the engine with the engine foot and the flywheel housing.

Because there is only a small clearance between

the oil pan and the oil pump strainer, it can damage the oil pan and the oil strainer.

• When the air duct or air cleaner is removed, cove the air intake opening to prevent foreign matte from getting into the cylinder. If it gets contaminated, it can considerably damage the cylinder and others while the engine is operating.

• When maintaining the engine, never fail to remove the battery earth cable. If not, it may damage the wire harness or electrical parts. If you need electricity on for the purpose of inspection, fo instance, watch out for short circuits and others.

•

pply engine oil to the sliding contact surfaces o the engine before reassembling it. This ensures adequate lubrication when the engine is first started.

• W hen valve train parts, pistons, piston rings, connecting rods, connecting rod bearings o crankshaft journal bearings are removed, put them in order and keep them.

• When installing them, put them back in the same location they were removed from.

• Gaskets, oil seals, O-rings, etc. must be replaced with new ones when the engine is reassembled.

•

s for parts where a liquid gasket is used, remove an old liquid gasket completely and clean it up thoroughly so that no oil, water or dust is clinging to them. Then, apply the designated liquid gasket to each place anew before assembly.

• Surfaces covered with liquid gasket must be assembled within 5 minutes of gasket application. If more than 5 minutes has elapsed, remove the existing liquid gasket and apply a new liquid gasket.

• When assembling or installing parts, fasten them with the prescribed tightening torque so that the are installed properly.

Matters that require attention in specifically dealing with this engine.

Holes or clearances in the fuel system, which serve as a passage of fuel, including the inside of the injector, are made with extreme precision. For this reason, the are highly sensitive to foreign matter and, if it gets in, it can lead to an accident on the road, for instance; thus, make sure that foreign matter is prevented from getting in.

When servicing the fuel system, every precaution must be taken to prevent the entry of foreign material into the system.

• Before beginning the service procedure, wash the fuel line and the surrounding area.

• Perform the service procedures with clean hands. Do not wear work gloves.

• Immediately after removing the fuel hose and/o fuel pipe, carefully tape vinyl bags over the exposed ends of the hose or pipe.

• If parts are to be replaced (fuel hose, fuel pipe, etc.) do not open the new part packaging until installation.

Work procedure

• The fuel opening must be quickly sealed when removing the fuel pipe, injection pipe, fuel injector, fuel supply pump, and fuel rail.

• The eyebolts and gasket must be stored in a clean parts box with a lid to prevent adhesion of foreign matter.

• Fuel leakage could cause fires. Therefore, afte finishing the work, wipe off the fuel that has leaked out and make sure there is no fuel leakage afte starting the engine.

6A-4 ENGINE MECHANICAL (4JJ1)

How to read the model

Legend

1. Engine Model (Stamped)

2. Engine Number (Stamped)

Explanation of functions and operations Electronic engine control

With the control unit, the range from injection to ai intake/exhaust, including fuel injection quantity, injection timing, intake air restriction, EGR, and idling rpm, is controlled.

Piston

The piston is aluminum-alloy and a thermal flow piston with a strut cast, while the combustion chamber is a round reentrant type.

3. Front

Cylinder head

The cylinder head is aluminum-alloy and there are 4 valves per cylinder. The angular tightening method o the cylinder head bolt further increases reliability and durability.

RTW56ALF001501

ENGINE MECHANICAL (4JJ1) 6A-5

EGR system

Based upon data, including water temperature, engine speeds or engine loads, it is controlled via Engine Control Module (ECM) to purify exhaust by recycling part of it.

Its main components include an EGR valve, an EGR cooler and various sensors.

Connecting rod cap bolt

The angular tightening method of the connecting rod cap bolt further increases reliability and durability.

Fuel rail-type electronic control injection system

The fuel rail-type electronic control injection system is composed of a fuel supply pump that sets the target pressure of high-pressure fuel and supply it, a fuel rail that measures such high-pressure fuel and a fuel injector that turns it into a fine spray and injects it. Each is controlled via ECM based upon various signals, while injection timing or fuel injection quantity is controlled under every possible driving condition.

Fuel injector

The fuel injector is a 6-hole nozzle that adjusts fuel injection quantity or injection timing by opening o closing an electromagnetic valve on the head of the fuel injector.

ECM corrects the dispersion of fuel injection quantit between fuel injector according to ID code data in memory. At the replacement of fuel injector, ID code data should be stored in ECM.

Fuel filter with sedimenter

It is a fuel filter with sedimenter that gets rid of water by making use of the difference in specific gravity between light oil and water, which comes with an indicator that notifies you that it is filled with water.

Preheating system

The preheating system consists of the ECM, the glow relay, glow plugs and the glow indicator lamp. The preheating system is operated when the engine coolant temperature is low, and makes the engine easy to start.

Lubrication system

It is an oil filter with full-flow bypass, which uses a water-cool oil cooler and oil jet to cool the piston.

Functional inspection

Inspection/adjustment of valve clearance

1. Inspection of valve clearance

• Remove the fuel injector harness assembly.

• Remove the leak off hose.

• Remove the cylinder head cover.

• Rotate the crankshaft to make the No.1

cylinder meet the compression top dead cente (TDC).

RTW76ASH001301

Legend

1. TDC

6A-6 ENGINE MECHANICAL (4JJ1)

• Insert a 0.15 mm (0.006 in) thickness gauge between the roller of the rocker arm and the camshaft to tighten up the adjusting screw o the rocker arm. When the movement of the thickness gauge becomes tight, fasten the adjusting screw nut of the rocker arm.

Valve clearance mm (in)

Intake valve 0.15 (0.006)

Exhaust valve 0.15 (0.006)

Note: Adjust while cold.

2. Adjustment of valve clearance

• Loosen each adjusting screw of the rocker arm completely.

Legend

1. Cam; Exhaust

2. Cam; Intake

3. Roller; Intake

4. Roller; Exhaust

LHW71BSH001201

Legend

1. Screwdriver

2. Ring Spanner

3. Valve Clearance Adjust Nut Wrench

Special tool Valve clearance adjust nut wrench: 5-8840-2822-0

RTW56ASH003701

Tightening torque:

Rocker arm adjustment screw nut

18 N⋅⋅⋅⋅m (1.8 kg⋅⋅⋅⋅m / 13 lb ft)

Adjustment table

Cylinder No. 1 2 3 4

Valve arrangement

No. 1 cylinder Compression TDC

No. 4 cylinder Compression TDC

• If the No.1 cylinder is the compression TDC, adjust a valve clearance with and if the No. 4 cylinder is the compression TDC, adjust that with × mark.

• Install the cylinder head cover.

Refer to "Cylinder Head Cover."

• Install the leak off hose.

• Install the fuel injector harness assembly.

Compression pressure inspection

• Warm up the engine.

• Disconnect the negative battery cable.

IN EX IN EX IN EX IN EX

× × × ×

mark given on the table

ENGINE MECHANICAL (4JJ1) 6A-7

• Remove the all glow plugs.

Note: When the harness connector is removed, ECM judges that it broke down and DTC is recorded. Upon completion of measurement, never fail to clear the memory of the ECM. (For how to clear the memory of the ECM, refer to “ENGINE CONTROL SYSTEM” Section)

• Connect the negative battery cable.

• Turn on the starter to emit foreign matter within the

cylinders.

• Install an adapter and a gauge of a compression gauge of the special tool.

A list of defective phenomena

• Engine does not turn over.

• Engine turns over but does not start.

• Excessive black exhaust smoke.

• Excessive white exhaust smoke.

• Engine knocking.

• Abnormal engine rotation.

• Abnormal battery charging.

• Turbocharger trouble shooting.

RTW56ASH003801

Compression gauge: 5-8840-2675-0 Gauge adapter: 5-8840-2815-0

• Turn on the starter to inspect compression pressure.

Compression pressure MPa(psi)/200rpm

Standard 2.84 − 3.24 (412 − 469)

Limit 1.96 (284)

Differences among

the cylinders

294 kPa (43)

• Measure each cylinder one by one.

Note: To keep engine speed at 200 rpm or more, use full charged batteries.

• Remove a compression gauge of the special tool.

• Disconnect the negative battery cable.

• Install the glow plugs.

• Connect the negative battery cable.

6A-8 ENGINE MECHANICAL (4JJ1)

Trouble Shooting

Engine does not turn over

Condition Possible Cause Correction

Starter motor does not rotate

flywheel

Starter motor pinion meshed with ring gear but does not rotate

Engine turns over but does not start

Dead or weak battery Charge battery

Replace battery

Incomplete circuit Connector wiring and/or connectors

Repair

Starter motor brushes stuck, worn, or broken

Starter motor internal damage Repair motor

Ring gear abrasion Replace ring gear Starter motor not meshed with

Magnetic switch (starter motor) not properly adjusted

Dead or weak battery Charge battery

Insufficient contact pressure between starter motor brushes and commutator

Armature (starter motor) stuck Repair armature

Engine internal damage (Seizure) Repair engine

Replace brushes

Adjust magnetic switch

Replace battery

Adjust pressure

Condition Possible Cause Correction

Fuel is not delivered to fuel supply pump

Fuel is delivered to fuel supply pump

Insufficient or unstable fuel delivery volume

Air in fuel system Bleed air from fuel system

Air entering fuel pipe Replace pipe and bleed air from

fuel system

Empty fuel tank Replenish fuel

Clogged strainer (fuel suction) Clean or replace strainer

Clogged fuel pipe Clean or replace pipe

Feed pump malfunction Replace pump

Use of wrong fuel for prevailing temperatures

Clogged fuel filter Replace filter

Loose injection pipe connections Tighten connections

Loose or broken electrical connectors

Bad rotational sensor Replace sensor

Engine control system malfunction System diagnosis

Air in fuel system Bleed air from fuel system

Feed pump malfunction Repair pump

Drain existing fuel and replace with appropriate fuel

Tighten and/or replace connectors

Loose or broken electrical connectors

Clogged fuel filter Replace filter

Engine control system malfunction System diagnosis

Tighten and/or replace connectors

ENGINE MECHANICAL (4JJ1) 6A-9

Excessive black exhaust smoke

Condition Possible Cause Correction

Bad injection timing Engine control system malfunction System diagnosis

Bad fuel injector condition

Insufficient compression pressure

Fuel condition

control system

Carbon deposit at nozzle tip Clean fuel injector assembly

Sticking nozzle Replace fuel injector assembly

Engine control system malfunction System diagnosis

Excessive valve clearance Adjust clearance

Sticking valve stem (valve open) Repair or replace valve

Damaged valve spring Replace spring

Valve seat abrasion Repair valve seat

Compression leakage due to damaged piston ring

Damaged gasket Replace gasket

Piston scoring Replace piston

Water in fuel Drain existing fuel and replace with

Poor fuel quality Drain existing fuel and replace with

Clogged intake pipes Clean or replace pipes Poor engine aspiration

Clogged air cleaner element Clean or replace element

Defective sensor Replace sensor Malfunction detected by engine

Engine control system malfunction System diagnosis

Replace piston ring

new fuel

EGR valve and/or intake throttle valve malfunction

Turbocharger malfunction

Intake throttle valve sticking Repair or replace valve

EGR valve sticking Repair or replace valve

Engine control system malfunction System diagnosis

Damaged turbocharger blade Replace turbocharger

Rough turbocharger shaft rotation Replace turbocharger

Oil leakage from oil seal Replace turbocharger

Broken actuator Replace turbocharger

6A-10 ENGINE MECHANICAL (4JJ1)

Excessive white exhaust smoke

Condition Possible Cause Correction

Bad injection timing Engine control system malfunction System diagnosis

Malfunction detected by engine control system

Insufficient compression pressure

Fuel condition Water in fuel Drain existing fuel and replace with

Excessive oil consumption

Engine knocking

Defective sensor Replace sensor

Control unit malfunction Replace unit

Engine control system malfunction System diagnosis

Excessive valve clearance Adjust clearance

Sticking valve stem (valve open) Repair or replace valve

Damaged valve spring Replace spring

Valve seat abrasion Repair valve seat

Compression leakage due to damaged piston ring

Damaged gasket Replace gasket

Piston scoring Replace piston

Worn or damaged piston ring(s) Replace ring(s)

Defective valve stem oil seal Replace oil seal

Defective turbocharger oil seal Replace turbocharger

Clogged turbocharger oil return pipe

Replace piston ring

new fuel

Repair pipe

Condition Possible Cause Correction

Bad timing Engine control system malfunction System diagnosis

Malfunction detected by engine control system

Fuel condition Poor quality fuel Drain existing fuel and replace with

Poor engine aspiration

Defective sensor Replace sensor

Control unit malfunction Replace unit

Engine control system malfunction System diagnosis

new fuel

Clogged air cleaner element Clean or replace element

Clogged intake pipes Clean or replace pipes

Engine control system malfunction System diagnosis

Foreign material in cylinders Engine overhaul Engine break-down

Scored pistons and/or bearings Replace pistons and/or bearings

Abnormal engine rotation

Condition Possible Cause Correction

ENGINE MECHANICAL (4JJ1) 6A-11

Defective control unit Replace unit Engine speed cannot be increased

Engine control system malfunction System diagnosis

Engine speed unstable

Turbocharger malfunction

Abnormal battery charging

Condition Possible Cause Correction

No charging

Insufficient charging

Defective control unit Replace unit

Engine control system malfunction System diagnosis

Clogged fuel filter element Replace element

Defective fuel injector(s) Replace fuel injector assembly

Water in fuel Drain existing fuel and replace with

new fuel

Air in fuel system Bleed air from fuel system

Damaged turbocharger fan Replace turbocharger

Rough turbocharger shaft rotation Replace turbocharger

Broken actuator Replace turbocharger

Open or shorted wiring and/or connectors

Defective generator Repair or replace generator

Defective battery Replace battery

Open or shorted wiring and/or connectors

Repair or replace wiring and/or connectors

Excessive charging

Defective generator Repair or replace generator

Loose generator drive belt Adjust belt tension or replace belt

Defective battery Replace battery

Shorted wiring Repair or replace wiring

Defective generator Repair or replace generator

Defective battery Replace battery

6A-12 ENGINE MECHANICAL (4JJ1)

Turbocharger Troubleshooting

Condition Possible Cause Correction

Engine has less than normal power

Blue exhaust smoke

Air leakage from intake pipe rubber hose

Air leakage from intake cover Repair intake cover

Clogged intercooler cooling section Clean cooling section

Clogged air cleaner element Clean or replace element

Intake throttle valve stuck Repair or replace throttle valve

Turbine and housing contact (Interference)

Excessive carbon deposit near turbine exhaust port that interferes with turbine

Rough turbine shaft rotation Repair or replace turbine shaft

Damaged turbine blade Repair or replace turbine blade

Oil leakage from turbocharger oil seal

Clogged turbocharger oil return pipe

Clogged center housing oil passages

Repair rubber hose

Replace turbine and/or housing

Clean or repair exhaust port and/or turbine

Repair or replace oil seal

Repair pipe

Repair or replace center housing

Noisy turbocharger operation

Excessive rotating part wear

Engine oil deterioration Change engine oil

Gas leakage from intake or exhaust system

Turbine and housing contact (Interference)

Damaged turbine blade Replace turbine blade

Turbine shaft bearing abrasion or scoring

Engine oil deterioration Change engine oil

Clogged turbocharger oil feed pipe Repair pipe

Low engine oil pressure Repair

Repair intake or exhaust system

Repair or replace turbine and/or housing

Repair or replace bearing

ENGINE MECHANICAL (4JJ1) 6A-13

Main Data and Specifications

Item Engine model 4JJ1

Type Diesel/4-cycle/water cooling-type in-line DOHC

Combustion chamber type Direct injection type

Cylinder liner type Liner less

Number of cylinders -cylinder bore × strokes

Displacement cc (cu.in) 2999 (183)

Compression ratio 17.5

Compression pressure MPa (psi)/rpm 3 (435)/200

Idling speed rpm 700 ± 25

Valve clearance Intake 0.15 (0.006) (cold)

mm (in) Exhaust 0.15 (0.006) (cold)

Ignition type Compressed ignition

Injection order 1 - 3 - 4 - 2

Lubricating system

Lubricating type Pressure delivery type

Oil pump type Gear type

Volume of lubricating oil L (qts) 8.0 (8.5)

Oil filter type Full flow filter (cartridge type)

Oil cooling type Built-in-type, water cooling

mm (in) 4-95.4(3.76) × 104.9(4.13)

Cooling system

Cooling type Water cooling type

Radiator type Corrugated fin (pressure type)

Water pump type Centrifugal, belt drive type

Thermostat type Wax-type units

Thermostat valve-opening temperature °C (°F) 85 (185)

Volume of coolant L (qts) M/T8.7 (9.2) A/T 8.6 (9.1) (incl. radiator)

Fuel system

Injection pump type Fuel supply pump fuel rail type

Fuel injector type Electronic control injector

6-hole

Fuel pump type Into the fuel tank type

Charging system

Generator type AC type

Power output V-A 12 - 110

6A-14 ENGINE MECHANICAL (4JJ1)

Item Engine model 4JJ1

Regulator type IC

Starting system Engage magnet type

Starter type Reduction type

Power output V-kW 12 – 2.3

Preheat system type Glow plug

Glow plug standard voltage/electric current V-A 12 - 3.5

Special Tools

ILLUSTRATION

PART NO.

PART NAME

5-8840-2822-0

Valve clearance

adjust nut wrench

5-8840-2675-0

Compression gauge

5-8840-2815-0

Compression gauge

adapter

Engine Assembly

ENGINE MECHANICAL (4JJ1) 6A-15

Removal

1. Disconnect the negative battery cable.

2. Remove the engine hood.

3. Drain the coolant.

4. Remove the starter motor.

5. Remove the transmission assembly.

Refer to removal procedure for “TRANSMISSION”

in this manual.

6. Disconnect the ECM harness connector.

7. Remove the ECM.

8. Remove the air cleaner.

• Disconnect the MAF sensor harness connector.

• Remove the intake pipe with the lid of ai

cleaner box.

• Remove the air cleaner box.

RTW86ASH001601

Legend

1. Clip

2. Clip

10. Remove the intake hose (intercooler - intake throttle).

11. Remove the intake hose (turbocharger intercooler). Remove the harness connector.

Legend

1. ECM Harness Connector

2. ECM

3. Air Cleaner Box

9. Remove the clip (1) and clip (2)

RTW56ASH003901

RTW56ASH004001

Legend

1. Intake Hose (intercooler - intake throttle)

2. Intake Hose (turbocharger - intercooler)

12. Remove the radiator upper hose.

13. Remove the engine harness clip (1).

6A-16 ENGINE MECHANICAL (4JJ1)

RTW76ASH001401

14. Remove the breather hose and lower hose of the radiator.

15. Remove the fan guide.

16. Remove the drive belt.

17. Remove the fan assembly.

18. Remove the radiator.

19. Remove the A/C compressor.

LTW56ASH000101

21. Remove the harness of engine, battery and earth (1).

Legend

1. A/C Compressor Bracket

2. A/C Compressor

• Disconnect the connector.

• Disconnect the A/C generator harness.

• Disconnect the terminal B cable and harness

connector from the generator.

20. Remove the power steering pump.

• Remove the bracket of power steering oil hose (1).

RTW76ASH000701

RTW86ASH002001

Legend

1. Earth

22. Remove the connector of the shift on the fly (4×4).

23. Remove the vacuum hose of brake master-vac.

24. Remove the front exhaust pipe.

25. Disconnect the fuel hose on the feed and return sides.

26. Install the engine hanger (special tool 5-88402823-0).

ENGINE MECHANICAL (4JJ1) 6A-17

Legend

1. Engine Hanger (Front Side)

RTW56ASH004301

1. Install the engine assembly.

• Hang wire on the engine hanger and hoist to lift up

the engine.

• Operate a hoist slowly to move the engine to the

place where it is to be installed.

• Make the transmission side lower and operate a

hoist slowly, pulling it backward to the engine.

2. Install the engine mount.

Tightening torque: 48 N⋅⋅⋅⋅m (4.9kg⋅⋅⋅⋅m / 35 lb ft)

3. Remove the engine hanger.

4. Install the catalytic converter.

Tightening torque: 27 N⋅⋅⋅⋅m (2.8kg⋅⋅⋅⋅m / 20 lb ft)

5. Install the front exhaust pipe.

Tightening torque: 67 N⋅⋅⋅⋅m (6.8kg⋅⋅⋅⋅m / 49 lb ft)

6. Install the fuel hose on the feed and return sides.

7. Install the vacuum hose of brake master-vac.

8. Install the connector of the shift on the fly (4×4).

9. Install the harness of engine, battery and earth (1).

RTW56ASH004401

Legend

1. Engine Hanger (Rear Side)

27. Hang wire on the engine hanger and hoist to lift up the engine slightly.

28. Remove the engine mount.

• Remove the fastening bolts for the engine mount

on the engine side.

29. Remove the engine assembly.

• Hoist the engine slightly to provide space to

remove the catalytic converter.

Installation

Notice: Be absolutely sure that each harness is reconnected to its original position.

RTW86ASH002001

10.Install the power steering pump.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5kg⋅⋅⋅⋅m / 18 lb ft)

• Install the bracket of power steering oil hose.

11.Install the A/C compressor.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5kg⋅⋅⋅⋅m / 18 lb ft)

• Install the connector.

12.Install the A/C generator harness.

• Install the terminal B cable and the harness connector to the generator.

13.Install the radiator.

Tightening torque: 25 N⋅⋅⋅⋅m (2.5kg⋅⋅⋅⋅m / 18 lb ft)

14.Install the fan assembly.

Tightening torque: 8 N⋅⋅⋅⋅m (0.8kg⋅⋅⋅⋅m / 69 lb in)

6A-18 ENGINE MECHANICAL (4JJ1)

15.Install the drive belt. Refer to removal procedure for “DRIVE BELT” in

this manual.

16.Install the fan guide.

17.Install the breather hose and lower hose of the radiator.

18.Install the engine harness clip (1).

RTW76ASH001401

19.Install the radiator upper hose.

20.Install the intake hose (turbocharger -intercooler).

• Install the harness connector.

21.Install the intake hose (intercooler - intake throttle).

23. Install the clip (1) and clip (2)

RTW86ASH001601

24.Install the ECM.

25.Connect the ECM harness connector.

26.Install the transmission assembly. Refer to installation procedure fo

“TRANSMISSION”.

27.Install the starter motor.

Tightening torque: 94 N⋅⋅⋅⋅m (9.6kg⋅⋅⋅⋅m / 69 lb ft)

28.Replenish the coolant.

29.Install the engine hood.

Tightening torque: 10 N⋅⋅⋅⋅m (1.0kg⋅⋅⋅⋅m / 87 lb in)

30.Connect the negative battery cable.

RTW56ASH004001

22.Install the air cleaner.

• Install the intake pipe with the lid of air cleane box.

• Install the air cleaner box.

• Connect the MAF sensor harness connector.