Isuzu D Max 2011 User Manual

WORKSHOP MANUAL

2011MY UC SERIES

ENGINE

4JJ1 MODEL

SECTION 6

Isuzu Motors Limited

E-Solutions &

Service Marketing Dept.

ENGINE MECHANICAL (4JJ1) 6A-1

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

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 of maintenance

To prevent damage to the engine and ensure reliability 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, for 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, cover the air intake opening to prevent foreign matter 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, for instance, watch out for short circuits and others.

•Apply engine oil to the sliding contact surfaces of the engine before reassembling it. This ensures adequate lubrication when the engine is first started.

•When valve train parts, pistons, piston rings, connecting rods, connecting rod bearings or 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.

•As 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 they 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, they 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/or 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, after finishing the work, wipe off the fuel that has leaked out and make sure there is no fuel leakage after starting the engine.

6A-4 ENGINE MECHANICAL (4JJ1)

How to read the model

RTW56ALF001501

Legend

1.	Engine Model (Stamped)	3. Front
2.	Engine Number (Stamped)

Explanation of functions and operations Electronic engine control

With the control unit, the range from injection to air 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.

Cylinder head

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

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 or closing an electromagnetic valve on the head of the fuel injector.

ECM corrects the dispersion of fuel injection quantity 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 center (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 of 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.

RTW56ASH003701

Legend

1.Screwdriver

2.Ring Spanner

3.Valve Clearance Adjust Nut Wrench

Special tool

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

•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 of the rocker arm. When the movement of the thickness gauge becomes tight, fasten the adjusting screw nut of the rocker arm.

LHW71BSH001201

Legend

1.Cam; Exhaust

2.Cam; Intake

3.Roller; Intake

4.Roller; Exhaust

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	IN	EX	IN	EX	IN		EX	IN		EX
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 mark given on the table 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.

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	294 kPa (43)
	the cylinders

• Measure each cylinder one by one.

Note:

To keep engine speed at 200 rpm or more, use fully 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	Dead or weak battery				Charge battery
						Replace battery
		Incomplete circuit				Connector wiring and/or connectors
						Repair
		Starter motor brushes stuck, worn,				Replace brushes
		or broken
		Starter motor internal damage				Repair motor
	Starter motor not meshed with	Ring gear abrasion				Replace ring gear
	flywheel
		Magnetic switch (starter motor) not				Adjust magnetic switch
		properly adjusted
	Starter motor pinion meshed with	Dead or weak battery				Charge battery
	ring gear but does not rotate					Replace battery
		Insufficient		contact	pressure	Adjust pressure
		between starter motor brushes and
		commutator
		Armature (starter motor) stuck				Repair armature
		Engine internal damage (Seizure)				Repair engine
Engine turns over but does not start
	Condition		Possible Cause			Correction
	Fuel is not delivered to fuel supply	Air in fuel system				Bleed air from fuel system
	pump
		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				Drain existing fuel and replace with
		temperatures				appropriate fuel
		Clogged fuel filter				Replace filter
	Fuel is delivered to fuel supply	Loose injection pipe connections				Tighten connections
	pump
		Loose	or	broken	electrical	Tighten and/or replace connectors
		connectors
		Bad rotational sensor				Replace sensor
		Engine control system malfunction				System diagnosis
	Insufficient or unstable fuel delivery	Air in fuel system				Bleed air from fuel system
	volume
		Feed pump malfunction				Repair pump
		Loose	or	broken	electrical	Tighten and/or replace connectors
		connectors
		Clogged fuel filter				Replace filter
		Engine control system malfunction				System diagnosis

			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	Carbon deposit at nozzle tip	Clean fuel injector assembly
		Sticking nozzle	Replace fuel injector assembly
		Engine control system malfunction	System diagnosis
	Insufficient compression pressure	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	Replace piston ring
		damaged piston ring
		Damaged gasket	Replace gasket
		Piston scoring	Replace piston
	Fuel condition	Water in fuel	Drain existing fuel and replace with
			new fuel
		Poor fuel quality	Drain existing fuel and replace with
			new fuel
	Poor engine aspiration	Clogged intake pipes	Clean or replace pipes
		Clogged air cleaner element	Clean or replace element
	Malfunction detected by engine	Defective sensor	Replace sensor
	control system	Engine control system malfunction	System diagnosis
	EGR valve and/or intake throttle	Intake throttle valve sticking	Repair or replace valve
	valve malfunction	EGR valve sticking	Repair or replace valve
		Engine control system malfunction	System diagnosis
	Turbocharger malfunction	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	Defective sensor		Replace sensor
	control system
					Control unit malfunction		Replace unit
					Engine control system malfunction		System diagnosis
	Insufficient compression pressure				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	Replace piston ring
					damaged piston ring
					Damaged gasket		Replace gasket
					Piston scoring		Replace piston
	Fuel condition				Water in fuel		Drain existing fuel and replace with
							new fuel
	Excessive oil consumption				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	Repair pipe
					pipe
Engine knocking
		Condition			Possible Cause		Correction
	Bad timing				Engine control system malfunction		System diagnosis
	Malfunction	detected	by	engine	Defective sensor		Replace sensor
	control system
					Control unit malfunction		Replace unit
					Engine control system malfunction		System diagnosis
	Fuel condition				Poor quality fuel		Drain existing fuel and replace with
							new fuel
	Poor engine aspiration				Clogged air cleaner element		Clean or replace element
					Clogged intake pipes		Clean or replace pipes
					Engine control system malfunction		System diagnosis
	Engine break-down				Foreign material in cylinders		Engine overhaul
					Scored pistons and/or bearings		Replace pistons and/or bearings

			ENGINE MECHANICAL (4JJ1) 6A-11
Abnormal engine rotation
	Condition	Possible Cause	Correction
	Engine speed cannot be increased	Defective control unit	Replace unit
		Engine control system malfunction	System diagnosis
	Engine speed unstable	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
	Turbocharger malfunction	Damaged turbocharger fan	Replace turbocharger
		Rough turbocharger shaft rotation	Replace turbocharger
		Broken actuator	Replace turbocharger
Abnormal battery charging
	Condition	Possible Cause	Correction
	No charging	Open or shorted wiring and/or	Repair or replace wiring and/or
		connectors	connectors
		Defective generator	Repair or replace generator
		Defective battery	Replace battery
	Insufficient charging	Open or shorted wiring and/or	Repair or replace wiring and/or
		connectors	connectors
		Defective generator	Repair or replace generator
		Loose generator drive belt	Adjust belt tension or replace belt
		Defective battery	Replace battery
	Excessive charging	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	Air leakage from intake pipe rubber						Repair rubber hose
	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		Replace turbine and/or housing
	(Interference)
	Excessive	carbon		deposit		near	Clean or repair exhaust port and/or
	turbine exhaust port that interferes						turbine
	with turbine
	Rough turbine shaft rotation						Repair or replace turbine shaft
	Damaged turbine blade						Repair or replace turbine blade
Blue exhaust smoke	Oil leakage from turbocharger oil						Repair or replace oil seal
	seal
	Clogged	turbocharger			oil	return	Repair pipe
	pipe
	Clogged	center		housing		oil	Repair or replace center housing
	passages
	Engine oil deterioration						Change engine oil
Noisy turbocharger operation	Gas leakage from intake or						Repair intake or exhaust system
	exhaust system
	Turbine	and	housing		contact		Repair or replace turbine and/or
	(Interference)						housing
	Damaged turbine blade						Replace turbine blade
	Turbine shaft bearing abrasion or						Repair or replace bearing
	scoring
Excessive rotating part wear	Engine oil deterioration						Change engine oil
	Clogged turbocharger oil feed pipe						Repair pipe
	Low engine oil pressure						Repair

					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			mm (in)	4-95.4(3.76) × 104.9(4.13)
	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
	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 MECHANICAL (4JJ1) 6A-15

Engine Assembly

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 air cleaner box.

•Remove the air cleaner box.

RTW56ASH003901

Legend

1.ECM Harness Connector

2.ECM

3.Air Cleaner Box

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

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.

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.

RTW76ASH000701

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).

LTW56ASH000101

21.Remove the harness of engine, battery and earth

(1).

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 5-8840- 2823-0).

ENGINE MECHANICAL (4JJ1) 6A-17

RTW56ASH004301

Legend

1. Engine Hanger (Front Side)

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.

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).

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).

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

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).

RTW56ASH004001

22.Install the air cleaner.

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

•Install the air cleaner box.

•Connect the MAF sensor harness connector.

RTW86ASH001601

24.Install the ECM.

25.Connect the ECM harness connector. 26.Install the transmission assembly.

Refer to installation procedure for “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.

ENGINE MECHANICAL (4JJ1) 6A-19

Special Tools

	ILLUSTRATION	PART NO.
		PART NAME

5-8840-2823-0

Engine hanger

6A-20 ENGINE MECHANICAL (4JJ1)

Engine Mount

Components

RTW86ALF000301

Legend
1.	Nut	9.	Bolt (L = 45 mm / 1.77 in)
2.	Bolt (L = 80 mm / 3.15 in)	10.	Bolt (L = 30 mm / 1.18 in)
3.	Bolt (L = 30 mm / 1.18 in)	11.	Bolt (L = 40 mm / 1.57 in)
4.	Bolt (L = 25 mm / 0.98 in)	12.	Bolt (L = 20 mm / 0.79 in)
5.	Bolt (L = 30 mm / 1.18 in)	13.	Bolt (L = 100 mm / 3.94 in)
6.	Engine Foot RH	14.	Engine Foot LH
7.	Engine Mount RH	15.	Engine Mount LH
8.	Bolt (L = 25 mm / 0.98 in)

ENGINE MECHANICAL (4JJ1) 6A-21

Removal

1.Remove the engine hood.

2.Remove the engine cover.

3.Set the hoist and the engine hanger of the special tool (special tool 5-8840-2823-0).

4.Remove the engine mount.

•Before removing the engine mount, hang the engine with a hoist.

•Remove the bolts of the engine mount.

•Hoist the engine assembly slightly to remove the engine mount.

Installation

1.Install the engine mount and tighten up with the specified torque.

Tightening torque: 52 N m (5.3 kg m / 38 lb ft)

2.Remove the engine hanger.

3.Install the engine cover.

4.Install the engine hood.

•Check if nothing is wrong with the engine mount by starting the engine.

RTW56ASH022401

6A-22 ENGINE MECHANICAL (4JJ1)

Torque Specifications

RTW86ALF000401

Special Tools

	ILLUSTRATION	PART NO.
		PART NAME

5-8840-2823-0

Engine hanger

ENGINE MECHANICAL (4JJ1) 6A-23

Cylinder Head Cover

Components

RTWB6ALF000101

Legend
1.	Oil Filler Cap	5.	Nozzle Seal Cover
2.	Oil Filler Cap Gasket	6.	Head Cover Gasket
3.	Cylinder Head Cover	7.	Nut
4.	Bolt

6A-24 ENGINE MECHANICAL (4JJ1)

Removal

1.Remove the engine cover.

2.Remove the intake air duct (3).

3.Remove the harness bracket (6).

RTW56ASH025001

Legend

1.Blow-by Hose

2.Leak-off Hose

3.Intake Air Duct

4.Fuel Injector Connector

5.Leak-off Hose

6.Harness Bracket

4.Disconnect the fuel injector connectors (2).

5.Remove the fuel leak off hoses (1).

RTW76ASH000101

Note: Do not reuse the leak off pipe ASM. (1) and clips

(2).

LNW86ASH000701

Legend

1.Leak off pipe ASM.

2.Clip

6.Disconnect the blow-by hose.

7.Remove the cylinder head cover.

RTWB6ASH000101

8.Remove the nozzle seal cover from the cylinder head cover.

•Remove from the lower side of cylinder head cover.

ENGINE MECHANICAL (4JJ1) 6A-25

9.Remove the cam end gaskets (1).

•Remove the liquid gasket that has adhered to cylinder head completely.

•Apply attaching cam end gasket.

Apply the liquid gasket (ThreeBond TB-1207B or equivalent).

RTW56ASH020501

Installation

1.Install the nozzle seal cover.

•Insert from the lower side of cylinder head cover.

•Apply soapy water or engine oil to the surface of cylinder head cover side.

•Insert the nozzle seal cover as far as it will go.

2.Install the cam end gaskets.

•Apply the liquid gasket (ThreeBond TB-1207B or equivalent) and mount.

RTW56ASH020601

Legend

1.Cam End Gasket

2.Apply The Liquid Gasket

3.2.0 - 3.0 mm (0.079 - 0.118 in)

RTW56ASH022701

Legend

1.3.0 - 5.0 mm (0.118 - 0.197 in)

2.3.0 - 5.0 mm (0.118 - 0.197 in)

3.Install the cylinder head cover.

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

•Tighten the nut and bolts in order shown in the illustration.

RTW56ASH004801

4.Install the blow-by hose.

5.Install the leak-off hose and the fuel injector connector.

6.Install the harness bracket to the cylinder head cover.

7.Install the intake air duct.

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

8. Install the engine cover.

6A-26 ENGINE MECHANICAL (4JJ1)

Intake Manifold

Components

RTW76ALF000201

Legend
1.	Intake Duct	4.	Intake Manifold
2.	Throttle Assembly	5.	EGR Valve Assembly Gasket
3.	Intake Manifold Gasket	6.	EGR Valve Assembly

ENGINE MECHANICAL (4JJ1) 6A-27

Removal

1.Remove the engine cover.

2.Disconnect the connectors.

•Fuel Injector

•Throttle Assembly

•EGR Valve

•Glow Plug

•Barometric Sensor

•A/C Compressor Connector

3.Remove the A/C belt.

4.Remove the A/C compressor.

5.Remove the A/C compressor bracket.

6.Remove the intake air duct (Standard output).

RTW56ASH024801

Legend

1.A/C Compressor Bracket

2.Intake Air Duct

3.A/C Compressor

7. Remove the injector leak-off hoses (1).

RTW56ASH024301

8.Remove the engine oil level gauge guide tube.

9.Remove the EGR valve.

RTW66ASH003001

10.Remove the injection pipes.

• Remove sequentially from No.1 cylinder.

6A-28 ENGINE MECHANICAL (4JJ1)

11.Disconnect the vacuum hose of swirl control valve

(1).

RTW66ASH003101

12.Remove the throttle assembly and gasket.

RTW56ASH005201

Legend

1.Throttle Assembly

2.Intake Manifold

13.Remove the intake manifold.

RTW56ASH018001

14.Remove the intake manifold gasket.

Installation

1.Install the intake manifold gasket.

2.Install the intake manifold.

•Tighten the nuts and bolts in the order described in the drawing.

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

RTW56ASH018001