SECTION 6A - ENGINE MECHANICAL

Main Data & Speci fications

4JB1T

4JH1-TC

Torque Specifications

Standard Bolts

Flare Nuts

Special Parts Fixing Nuts & Bolts

Cylinder Head Cover, Cylinder Head & Rocker Arm Shaft Bracket

Crankshaft Bearing Cap, Connecting Rod Bearing Cap, Crankshaft Damper Pulley,

Flywheel & Oil Pan

Timing Gear Case, Pulley Housing, Timing Gear & Camshaft

Cooling & Lubricating System

Intake Manifold, Exhaust Ma nifold & Turbocharger – 4JB1T

Intake Manifold, Exhaust Manifold & Turbocharger – 4JH1TC

Inter Cooler – 4JH1TC

Engine Electrical

Fuel Injection System – 4JB1T

Fuel Injection System – 4JH1TC

Engine Mounting Bracket

Recommended Liquid Gasket

LOCTITE Application Procedure

Servicing

Model Identification

Air Cleaner

Lubricating System

Fuel System

Cooling System

Engine Control

Pre-Heating System

General Description

Removal & Installation

Engine Repair Kit

Techline

Engine Overhaul

Removal

External Parts

Internal Parts

Major Components

Minor Components

Rocker Arm Shaft & Rocker Arm

Cylinder Head

Piston & Connecting Rod

Inspection & Repair

Face Warpage

Valve Guide

Valve & Valve Seat Insert

Cylinder Body

Rocker Arm Shaft & Rocker Arm

Valve Spring

Tappet & Push Rod

Camshaft

Crankshaft & Bearing

Crankshaft Bearing Selection

Crankshaft Pilot Bearing

Flywheel & Ring Gear

Piston

Piston Ring

Piston Pin

Cylinder Head Gasket Selection

Connecting Rod

Timing Pulley Housing

Idler Gear Shaft And Idler Gear (Gear Drive Model)

Timing Gear Case Cover

Reassembly

Internal Parts

Minor Components

Rocker Arm Shaft & Rocker Arm

Cylinder Head

Piston & Connecting Rod

Major Components

External Parts

Special Tools

Main Data & Specifications

4JB1T

Item 4JB1T

Engine type

Combustion chamber type

Cylinder liner type

Timing gear train system

Four-cycle, overhead valve, water cooled

Direct injection

Dry type, chrome plated, stainless steel tube

Gear drive

No. of cylinders-bore × stroke mm (in) 4 – 93 × 102 (3.66 × 4.02)

No. of piston rings Compression ring: 2 / Oil ring: 1

Total piston displacement cm3 (in3)

Compression ratio (to 1)

2,771 (169.0)

18.1

Compression pressure kg/cm2 (psi/MPa) 31 (441/3.0) – 200 rpm

Engine weight kg (lb) Approximately 250 (550)

Fuel injection order 1 – 3 – 4 - 2

Fuel injection timing BTDC deg 11

Specified fuel type

Idling speed rpm

Valve clearances (At cold): Intake mm (in)

Exhaust mm (in)

Intake valves Open at (BTDC) deg

Close at (ABDC) deg

Exhaust valves Open at (BBDC) deg

Close at (ATDC) deg

Fuel system

Injection pump type

SAE No. 2 diesel fuel

750

0.4 (0.016)

24.5

55.5

54.0

26.0

BOSCH distributor VE type

Governor type Mechanical (Limit speed)

Injection nozzle type

Injection nozzle opening pressure

(Design value) kg/cm2 (psi/MPa)

Single spring type

Main fuel filter type

Lubricating system

Lubricating method

Hole with 5 orifices

185 (2,631/18.1)

Cartridge paper element and water separator

Pressu re circulation

Specified engine oil (API grade) CD

Oil pump type

Oil filter type

Oil capacity lit(US/UK gal)

Oil cooler type

Gear

Cartridge paper element

6.5 (1.7/1.43)

Water cooled

4JB1T : 4JB1 Engine with turbocharger.

Item 4JB1T

Cooling system

Water pump type

Thermostat type

Air cleaner type

Battery type/voltage × No. of units

Centrifugal

Wax pellet with jiggle valve

Dry paper element

95D31R-12 × 1

Generator capacity V-A (kw) 12 – 50 (600)

Starter motor output V-kw 12 – 2.0 or 12 – 2.8

Turbocharger model

Turbine type

Compressor type

*IHI RHF4H

Radial-inflow

Radial-outflow

*IHI : Ishikawajima-Harima Heavy Industries., Ltd.

4JH1-TC

Item 4JH1TC

Engine type Four-cycle, overhead valve, water cooled

Combustion chamber type Direct injection

Cylinder liner type

Timing gear train system Dry type, chrome plated, stainless steel tube

Gear drive

No. of cylinders-bore × stroke mm (in) 4 – 95.4 × 104.9 (3.76 × 4.13)

No. of piston rings Compression ring: 2 / Oil ring: 1

Total piston displacement cm3 (in3)

Compression ratio (to 1)

2,999 (183.3)

18.3

Compression pressure kg/cm2 (psi/MPa) 28 (398/2.8) – 200 rpm

Engine weight kg (lb) Approximately 274 (604.2)

Fuel injection order 1 – 3 – 4 - 2

Fuel injection timing BTDC deg Not Adjustment

Specified fuel type EC diesel fuel

Idling speed rpm 700±25

Valve clearances (At cold): Intake mm (in)

Exhaust mm (in)

Intake valves Open at (BTDC) deg

Close at (ABDC) deg

Exhaust valves Open at (BBDC) deg

Close at (ATDC) deg

Fuel system

Injection pump type

0.4 (0.016)

24.5

55.5

54.0

26.0

BOSCH VP44

(electronic controlled fuel injection pump)

Injection nozzle type

Injection nozzle opening pressure Double spring type (Hole type)

(Design value) kg/cm2 (psi/MPa) 1st: 198(2,816/19.4)

2nd: 344(4,906/33,800)

Number of injection nozzl e orifices

Main fuel filter type

Lubricating system

Lubricating method

5

Cartridge paper element and water separator

Pressu re circulation

Specified engine oil (API grade) CD

Oil pump type

Oil filter type

Gear

Cartridge paper element

Oil capacity lit (US/UK gal) 6.5 (1.7/1.4) For 4 × 2

7.3 (1.9/1.6) For 4 × 4

Oil cooler type Water cooled

Techline

Item 4JH1TC

Cooling system

Water pump type

Thermostat type

Air cleaner type

Battery type/voltage × No. of units

Generator capacity V-A (kw)

Starter motor output V-kw

Centrifugal

Wax pellet with jiggle valve

Wet paper element

95D31R-12 × 1

12 – 60 (720)

12 – 2.3

Turbocharger model *IHI RHF5H

Turbine type

Compressor type

Radial-inflow

Radial-outflow

*IHI : Ishikawajima-Harima Heavy Industries., Ltd.

Torque Specifi cati ons

Standard Bolts

The torque values given in the following table should be applied whenever a particular torque is not specified.

kg·m (lb·ft/N·m)

8.8

4.8 (4T) (7T) Refined Non-Refined 9.8 (9T)

Strength

Class

Bolt

Identification

Bolt

Diameter ×

Pitch (mm)

M6×

××

×1.0

M8×

××

×1.25

M10 ×

××

×1.25

M12 ×

××

×1.25

M14 ×

××

×1.5

M16 ×

××

×1.5

M18 ×

××

×1.5

M20 ×

××

×1.5

M22 ×

××

×1.5

M24 ×

××

×2.0

*M10×

××

×1.5

*M12×

××

×1.5

*M14×

××

×2.0

*M16×

××

×2.0

0.60 ± 0.20

(4.33 ± 1.44/5.88 ± 1.96)

1.30 ± 0.50

(9.40 ± 3.62/12.74 ± 4.90)

2.80 ± 0.70

(20.25 ± 5.06/27.44 ± 6.86)

6.25 ± 1.25

(45.21 ± 9.04/61.25 ± 12.25)

9.75 ± 1.95

(70.52 ± 14.10/95.55 ± 19.11)

13.30 ± 2.70

(96.20 ± 19.53/130.34 ± 26.46)

19.20 ± 3.80

(138.87 ± 27.49/188.16 ± 37.24)

26.30 ± 5.30

(190.23 ± 38.33/257.74 ± 51.94)

33.90 ± 8.30

(245.20 ± 60.03/332.22 ± 81.34)

45.80 ± 9.20

(331.27 ± 66.54/448.84 ± 90.16)

2.70 ± 0.70

(19.53 ± 5.06/26.46 ± 6.86)

5.80 ± 1.20

(41.95 ± 8.68/56.84 ± 11.76)

9.10 ± 1.80

(65.82 ± 13.02/89.18 ± 17.64)

12.70 ± 2.50

(91.86 ± 18.08/124.46 ± 24.50)

0.75 ± 0.25

(5.43 ± 1.80/7.35 ± 2.45)

1.75 ± 0.55

(12.66 ± 4.00/17.15 ± 5.39)

3.75 ± 0.95

(27.12 ± 6.87/36.75 ± 9.31)

7.75 ± 1.55

(56.06 ± 11.21/75.95 ± 15.19)

11.85 ± 2.35

(85.71 ± 17.00/116.13 ± 23.03)

17.30 ± 3.50

(125.13 ± 25.32/169.54 ± 34.30)

24.90 ± 5.00

(180.10 ± 36.17/244.02 ± 49.00)

34.40 ± 6.90

(248.82 ± 49.41/337.12 ± 67.62)

46.25 ± 9.25

(334.53 ± 66.91/453.25 ± 90.65)

58.20 ± 14.30

(420.96 ± 103.43/570.36 ± 140.14)

3.70 ± 0.90

(26.76 ± 6.50/36.26 ± 8.82)

7.20 ± 1.40

(52.08 ± 10.13/70.56 ± 13.72)

11.20 ± 2.20

(81.01 ± 15.91/109.76 ± 21.56)

16.50 ± 3.30

(119.34 ± 23.87/161.70 ± 32.34)

-

2.40 ± 0.70

(17.36 ± 5.06/23.52 ± 6.86)

5.10 ± 1.30

(36.89 ± 9.40/49.98 ± 12.74)

9.65 ± 1.95

(69.80 ± 14.10/94.57 ± 19.11)

14.50 ± 2.90

(104.88 ± 21.00/142.10 ± 28.42)

20.40 ± 4.10

(147.55 ± 29.66/199.92 ± 40.18)

29.30 ± 5.90

(211.93 ± 42.67/287.14 ± 57.82)

40.40 ± 8.10

(292.21 ± 58.59/395.92 ± 79.38)

54.10 ± 10.80

(391.30 ± 78.12/530.18 ± 105.84)

70.60 ± 14.10

(510.65

±

101.99/691.88

±

138.18)

4.90 ± 1.20

(35.44 ± 8.68/48.02 ± 11.76)

9.10 ± 1.80

(65.82 ± 13.02/89.18 ± 17.64)

13.60 ± 2.70

(98.37 ± 19.53/133.28 ± 26.46)

19.50 ± 3.90

(141.04 ± 28.21/191.10 ± 38.22)

An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials such

as casting. Those shown in parentheses in the strength class indicate the classification by the old standard.

Flare Nuts kg·m (lb·ft/N·m)

Pipe diam eter m m

(in) Torque Pipe diam eter m m

(in) Torque

4.76 (0.187)

6.35 (0.250)

8.00 (0.315)

1.55 ± 0.25 (11.2 ± 1.8/15. 2 ± 2. 45)

2.70 ± 0.30 (19.5 ± 2.1/26. 48 ± 2. 94)

4.50 ± 0.50 (32.5 ± 3.6/44. 14 ± 4. 90)

10.00 (0.394)

12.00 (0.472)

15.00 (0.591)

5.50 ± 0.5 (39.7 ± 3.6/53. 95 ± 4. 90)

9.00 ± 1.0 (65.0 ± 7.2/88. 29 ± 9. 80)

10.75 ± 1.25 (77.7 ± 9.0/105. 45 ± 12. 26)

Special Parts Fixing Nuts & Bolts

Cylinder Head Cover, Cylinder Head & Rocker Arm Shaft Bracket

kg·m (lb·ft/N·m)

Crankshaft Bearing Cap, Connecting Rod Bearing Cap,

Crankshaft Damper Pulley, Flywheel & Oil Pan

kg·m (lb·ft/N·m)

, 4JA1T

4JB1T

,

4JG2T

,

4JA1TC

,

4JH1TC

17±1

(123.0±7.2/166.7±9.8)

Timing Gear Case, Pulley Housing, Timing Gear & Camshaft

kg·m (lb·ft/N·m)



7.7±1

(55.7±7.2/74±9.8)

4JA1TC, 4JH1TC

(scissor gear)

2.4±0.4

(13.7±2.9/18.6±3.9)

3.0±0.5

(21.7±3.6/30±5.0)

7.7±1

(55.7±7.2/74±9.8)

Cooling & Lubricating System

kg·m (lb·ft/N·m)

3.0 ±

±±

± 0.5

(21.7 ±

±±

± 3.6/29.4 ±

±±

± 4.9)

1.9 ±

±±

± 0.5

(13.7 ±

±±

± 3.6/18.6 ±

±±

± 4.9)

Intake Manifold, Exhaust Ma nifold & Turbocharger – 4JB1T

kg·m (lb·ft/N·m)

Intake Manifold, Exhaust Ma nifold & Turbocharger – 4JH1TC

kg·m (lb·ft/N·m)

Inter Cooler – 4JH1TC

kg·m (lb·ft/N·m)

Engine Electrical

kg·m (lb·ft/N·m)

Fuel Injection System – 4JB1T

kg·m (lb·ft/N·m)

3.8 ±

±±

± 0.6

(27.5 ±

±±

± 4.3/37.2 ±

±±

± 5.9)

Fuel Injection System – 4JH1TC

kg·m (lb·ft/N·m)

2.4(17/24)

1.7 ±

±±

± 0.5

(12.0 ±

±±

± 3.6/17.0 ±

±±

± 4.9)

3.8 ±

±±

± 0.6

(27.5 ±

±±

± 4.3/37.2 ±

±±

± 5.9)

3.0 ±

±±

± 0.5

(21.7 ±

±±

± 3.6/29.4 ±

±±

± 4.9)

1.9 ±

±±

± 0.5

(13.7 ±

±±

± 3.6/18.6 ±

±±

± 4.9)

2.4 ±

±±

± 0.4

(13.7 ±

±±

± 2.9/18.6 ±

±±

± 3.9)

1.9 ±

±±

± 0.5

(13.7 ±

±±

± 3.6/18.6 ±

±±

± 4.9)

4.1 ±

±±

± 0.6

(29.6 ±

±±

± 4.3/40.2 ±

±±

± 5.9)

Engine Mounting Bracket

kg·m (lb·ft/N·m)

4.2±0.5

(30.4±3.6/41.2±4.9)

4.2±0.5

(30.4±3.6/41.2±4.9)

12.9 ±

±±

± 2.3

(93.3 ±

±±

± 16.6/126.5 ±

±±

± 22.6)

Recommended Liquid Gasket

Type Brand Name Manufacturer Remarks

RTV*

Silicon Base ThreeBond 1207B

ThreeBond 1207C Three Bond

Three Bond

Water Base ThreeBond 1141E Three Bond

Solvent ThreeBond 1104

BelcoBond 4

BelcoBond 401

BelcoBond 402

Three Bond

Isuzu

Anaerobic LOCTITE 515

LOCTITE 518 Loctite

Loctite Recommended for

transaxle repairs

* RTV : Room Temperature Vulcaniser

Note:

1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.

2. Be careful to use the specified amount of liquid gasket.

Follow the manufacturer’s instructions at all times.

3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying

the liquid gasket.

The connecting surfaces must be perfectly dry.

4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.

Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater

than 0.25 mm (0.01 in). Poor adhesion will result.

Loctite Application Pr ocedure

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242 Blue

LOCTITE 262 Red

LOCTITE 270 Green

LOCTITE 271 Red

1. Completely remove all lubricant and moisture from the bolts and the

female threaded surfaces of the parts to be joined.

The surfaces must be perfectly dry.

2. Apply LOCTITE to the bolts.

3. Tighten the bolts to the specified torque.

4. Wait at least one hour before continuing the installation procedure.

LOCTITE 515 Violet

1. Completely remove lubricant and moisture from the connecting

surfaces.

The surfaces must be perfectly dry.

2. Apply a 2.0 – 2.5 mm bead of LOCTITE to one of the connecting

surfaces.

There must be no gaps in the bead.

3. Tighten the bolts to the specified torque.

4. Let the joined parts set for at least thirty minutes.

Servicing

Servicing refers to general maintenance procedures to be performed by qualified service personnel.

Model Identification

ENGINE SERI AL NUMBER

The engine number is stamped on the front left hand side

of the cylinder body.

Air Cleaner

Element cleaning procedures will vary according to the

condition of the element.

OIL W ETTED (VISCOUS TYPE) PAPER ELEM ENT

The air cleaner has an oil wetted paper element. No

servicing is required until the replacement interval is

reached. Never attempt to clean the element, no matter

how dirty may appear. The element is designed to provide

normal filtering efficiency until it becomes due for

replacement. Refer to the Item “Service and Maintenance”

in the Owner’s and Driver’s Manual for general service

information.

DUST FOULED ELEMENT

Rotate the element with your hand while applying

compressed air to the inside of the element. This will blow

the dust free.

Compressed air pressure must not exceed 7 kg/cm2 (100

psi/690 kPa).

CARBO N AND DUST FOULED ELEMENT

1. Prepare a cleaning solution of Isuzu Genuine Element

Cleaner (Donaldson D1400) diluted with water.

2. Submerge the element in the solution for twenty

minutes.

3. Remove the element from the solution and rinse it well

with running water.

Water pressure must not exceed 2.8 kg/cm2 (40

psi/270 kPa).

4. Dry the element in a well ventilated area.

An electric fan will hasten drying.

Note:

Do not use compressed air or an open flame to dry the

element quickly. Damage to the element will result.

It will usually take two or three days for the element to

dry completely. Therefore, it is a good idea to have a

spare on hand to use in the interim.

Lubricating System

MAIN OIL FILTER (CARTRIDGE TYPE PAPER

ELEMENT)REPLACEMENT PROCEDURE

1. Loosen the drain plug to drain the engine oil.

2. Wait a few minutes and then retighten the drain plug.

3. Loosen the used oil filter by turning it counterclockwise

with a filter wrench.

4. Clean the oil cooler fitting face. This will allow the new

oil filter to seat properly.

5. Apply a light coat of engine oil to the O-ring.

6. Turn in the new oil filter until the filter O-ring is fitted

against the sealing face.

7. Use the filter wrench to turn in the filter an additional 1

and 1/8 turns.

Filter Wrench: 5-8840-0200-0 (4JB1T, 4JG2T, 4JA1T,

4JA1TC, 4JH1TC)

: 5-8840-0201-0 (4JA1)

8. Check the engine oil level and replenish to the

specified level if required.

Replenished Engine Oil lit (US/UK gal)

4 × 2

4JB1T 4 × 4 6.5 (1.7/1.4)

4 × 2 6.5 (1.7/1.4)

4JH1TC 4 × 4 7.3 (1.9/1.6)

9. Start the engine and check for oil leakage from the

main oil filter.

Fuel System

FUEL FILTER REPLACEMENT PROCEDURE

1. Place the end of the vinyl hose (beneath the drain

plug) in a container.

2. Open the drain plug.

3. Operate the priming pump several times to drain water

from the fuel filter.

4. Close the drain plug.

5. Operate the priming pump and check for fuel leakage.

6. Check that the water level warning light is off.

FUEL FILTER REPLACEMENT PROCEDURE

1. Remove the fuel filter by turning it counterclockwise

with a filter wrench.

Filter Wrench: 5-8840-0253-0 (J-22700)

2. Remove the level sensor from the filter by turning it

counterclockwise with a wrench.

3. Install the level sensor to the water separator body

with wrench.

Level Sensor Torque kg·m (lb.in/N·m)

1.3 (113/13)

4. Clean the water separator cover fitting faces.

This will allow the new fuel filter to seat properly.

5. Apply a light coat of engine oil to the O-ring.

6. Turn in the fuel filter until the sealing face comes in

contact with the O-ring.

7. Turn in the fuel filter an additional 2/3 of a turn with a

filter wrench.

Filter Wrench : 5-8840-0253-0 (J-22700)

8. Loosen the bleeder plug Q on the priming pump body.

9. Operate the priming pump until fuel begins to flow

from the fuel filter.

10. Retighten the bleeder plug Q.

11. Operate the priming pump several times and check for

fuel leakage.

Note:

The use of an HOLDEN genuine fuel filter is strongly

recommended.

DRAI NING PRO CEDURE

The indicator light will come on when the water level in the

water separator exceeds the specified level.

Drain the water and foreign material from the water

separator with the following procedure.

1. Place the end of the vinyl hose (beneath the drain

plug) in a container.

2. Loosen the drain plug Q.

3. Operate the priming pump R several times to drain

the water.

4. After draining the water, tighten the drain plug Q .

5. Operate the priming pump several times and check for

fuel leakage.

6. Check the water separator indicator light. It should be

off.

AI R BLEEDING

1. Loosen the bleeder screw on the injection pump

overflow valve.

2. Operate the priming pump until fuel mixed with foam

flows from the bleeder screw.

3. Tighten the bleeder screw.

4. Operate the priming pump several times and check for

fuel leakage.

INJECTION PUMP AIR BLEEDING (4JH1TC)

Injection pump air bleeding is required to start the engine

when 

• The fuel supply has been exhausted (running out of

gas).

• The fuel filter has been replaced.

• The injection pump has been replaced.

CAUTION:

If the injection pump has been replaced, the air

bleeding procedure will require more time and effort

(this is because there is no fuel in the pump).

1. Loosen the air bleed nut on the priming pump plunger

(at the top of the fuel filter).

2. Move the priming pump plunger up-and-down until

strong resistance is felt (about 15 cycles).

3. Stop pumping and tighten the air bleed nut.

4. Wait for 1 minute.

5. Loosen the air bleed nut on the priming pump plunger

again.

6. Move the priming pump plunger up-and-down until

strong resistance if felt (about 10 cycles).

7. Stop pumping and tighten the air bleed nut.

8. Wait for 1 minute.

9. Loosen the air bleed nut on the priming pump plunger

again.

10. Move the priming pump plunger up-and-down until

strong resistance is felt (about 5 cycles).

11. Stop pumping and tighten the air bleed nut.

12. Press the accelerator and clutch pedals all the way to

the floor and hold them down. Turn the ignition switch

to the ON position. Wait until the glow indicator lamp

turns on and off.

CAUTION:

If the engine is cold, the glow indicator light will stay

on for 47 seconds before turning off.

However, if the engine is hot, the lamp will not turn

on.

13. Turn the ignition switch to the START position and

crank the engine until it starts (do not crank the engine

for more than 10 seconds).

If the engine does not start, repeat Steps 913.

14. Allow the engine to idle for 5 minutes.

Cooling System

COOLANT LEVEL

Check the coolant level and replenish the radiator reserve

tank as necessary.

If the coolant level falls below the “MIN” line, carefully

check the cooling system for leakage. Then add enough

coolant to bring the level up to the “MAX” line.

ENGINE CO OLANT FILLING UP PROCEDURE

1. Make sure that the engine is cool

Warning:

When the coolant is heated to a high temperature, be

sure not to loosen or remove the rediator cap.

Otherwise you might get scalded by hot vapor or

boiling water.

To open the radiator cap, put a piece of thick cloth on

the cap and loosen the cap slowly to reduce the

pressure when the coolant has become cooler.

2. Open rediator cap pour coolant up to filler neck

3. Pour coolant into reservoir tank up to “MAX” line

4. Tighten radiator cap and start the engine. After idling

for 2 to 3 minutes, stop the engine and reopen radiator

cap. If the water level is lower, replenish.

5. After replenish the coolant tighten radiator cap, warm

up the engine at about 2000 rpm. Set heater

adjustment to the highest temperature position, and let

the coolant circulate also intoheater water system.

6. Chech to see the thermometer, continuously idling 5

minutes and stop the engine.

7. When the engine has been cooled, check filler neck

for water level and replenish if required. Should

extreme shortage of coolant is found, check the

coolant system and reservoir tank hosefor leakage.

8. Pour coolant into the reservoir tank up to “MAX” line.

COOLING SYSTEM INSPECTIO N

Install a radiator filler cap tester to the radiator. Apply

testing pressure to the cooling system to check for

leakage. The testing pressure must not exceed the

specified pressure.

Testing Pressure kg/cm2 (psi/kPa)

2 (28/200)

RADIATOR CAP INSPECTION

The radiator filler cap is designed to maintain coolant

pressure in the cooling system at 1.05 kg/cm2 (15 psi/103

kPa).

Check the radiator filler cap with a radiator filler cap tester.

The radiator filler cap must be replaced if it fails to hold the

specified pressure during the test procedure.

Radiator Filler Cap Pressure

Pressu re Valve kg/cm2 (psi/kPa)

0.9 – 1.2 (13 – 17/90 – 120)

Negative Valve (Reference) kg/cm2 (psi/kPa)

0.01 – 0.04 (0.14 – 0.57/0.98 – 3.92)

THERMOSTAT OPERATING TEST

1. Completely submerge the thermostat in water.

2. Heat the water.

Stir the water constantly to avoid direct heat being

applied to the thermostat.

3. Check the thermostat initial opening temperature.

Thermostat Initial Opening Temperature °C (°F)

82 (180)

4. Check the thermostat full opening temperature.

Thermostat Full Opening Temperature °C (°F)

95 (203)

Valve Lift at Fully Open position mm (in)

9.5 (0.37)

QThermometer

RAgitating rod

SWooden piece

DRIVE BELT ADJUSTMENT

Depress the drive belt mid-portion with a 10 kg (22 lb/98N)

force.

Drive Belt Deflection mm (in)

10 (0.39)

Check the drive belt for cracking and other damage.

QCrankshaft damper pulley

RGenerator pulley

SCooling fan pulley

TOil pump pulley or idler pulley

UCompressor pulley or idler pulley

COOLING FAN PULLEY DRIVE BELT

Fan belt tension is adjusted by moving the generator.

Depress the drive belt mid-portion with a 10 kg (22 lb/98N)

force.

Drive Belt Deflection mm (in)

10 (0.39)

QCrankshaft damper pulley

RGenerator pulley

SCooling fan pulley

COMPRESSO R PULLEY DRIVE BELT

Move the idler pulley as required to adjust the compressor

drive belt tension.

If the vehicle is equipped with power steering, move the oil

pump as required

Depress the drive belt mid-portion with a 10 kg (22 lb/98

N) force.

Belt Deflection mm (in)

12 – 15 (0.47 – 0.59)

QCrankshaft damper pulley

ROil pump pulley or idler pulley

POWER STEERING OIL PUM P PULLEY DRIVE BELT

Move the oil pump as required to adjust the oil pump drive

belt tension.

On air conditioner equipped models, both drive belts pulley

must always be replaced as a set.

Depress the drive belt mid-portion with a 10 kg (22 lb/98

N) force.

Belt Deflection mm (in)

14 - 17 (0.55 – 0.67)

QCrankshaft damper pulley

ROil pump pulley

SCompressor pulley or idler pulley

Engine Control

IDLING SPEED ADJUSTMENT

1. Set the vehicle parking brake and chock the drive

wheels.

2. Place the transmission in neutral.

3. Start the engine and allow it to idle until the coolant

temperature reaches 70 - 80°C (158 - 176°F).

4. Disconnect the engine control cable from the control

lever.

5. Set a tachometer to the engine.

6. Check the engine idling speed.

If the engine idling speed is outside the specified

range, it must be adjusted.

Engine Idling Speed rpm

4JA1, 4JB1 750 ± 50

4JA1T 770 ± 50

4JG2T 720 ± 50

4JA1TC 730 ± 25

4JH1TC 700 ± 25

IDLING SPEED ADJUSTMENT (EXCEPT 4JH1TC)

1. Loosen the idling set screw lock nut Q on the injection

pump idling set bolt.

2. Adjust the idling speed to the specified range by

turning the idling set bolt R.

3. Lock the engine set nut Q with the idling set bolt lock

nut.

4. Check that the idling control cable is tight (free of

slack). If required, remove the slack from the cable.

FAST IDLING SPEED INSPECTION

1. Set tachometer to the engine.

2. Disconnect the vacuum hose Q from the fast idle

actuator U on the injection pump.

3. Disconnect the other vacuum hose R from the

vacuum switching valve S and connect it to the fast

idle actuator U.

The vacuum line will now be connected directly from

the vacuum pump T to the fast idle actuator.

4. Check the engine fast idling speed.

If the engine idling speed is outside the specified

range, it must be adjusted.

Fast Idling Speed rpm

850 - 950

FAST IDLING SPEED ADJUSTMENT

1. Loosen the fast idle actuator bracket bolts.

1. Adjust the fast idling speed by moving the actuator

bracket, so that the clearance “S” can be 1 ~ 2 mm

(0.04 ~ 0.08 in.).

2. Tighten the bracket bolts.

ACCELERATOR CONTROL ACCELERATOR

CONTROL CABLE ADJUSTMENT

1. Loosen the accelerator cable clamp bolt Q.

2. Check that the idling control knob is in the engine

idling position.

3. Hold the accelerator lever R in the fully closed

position and stretch the control cable S in the

direction indicated by the arrow to remove any slack.

VALVE CLEARANCE ADJUSTMENT

1. Bring the piston in either the No. 1 cylinder or the No. 4

cylinder to TDC on the compression stroke by turning

the crankshaft until the crankshaft damper pulley TDC

line is aligned with the timing pointer.

2. Check the rocker arm shaft bracket nuts for

looseness.

Tighten any loose rocker arm shaft bracket nuts

before adjusting the valve clearance.

Rocker Arm Shaft Bracket Nut Torque kg·m (lb·ft/N·m)

5.5 ± 0.5 (39.8 ± 3.6/53.9 ± 4.9)

3. Check for play in the No. 1 intake and exhaust valve

push rods.

If the No. 1 cylinder intake and exhaust valve push

rods have play, the No. 1 piston is at TDC on the

compression stroke.

If the No. 1 cylinder intake and exhaust valve push

rods are depressed, the No. 4 piston is at TDC on the

compression stroke.

101RY00014

Adjust the No.1 or the No. 4 cylinder valve clearances

while their respective cylinders are at TDC on the

compression stroke.

Valve Clearance (At Cold) mm (in)

0.4 (0.016)

4. Loosen each valve clearance adjusting screw as

shown in the illustration.

5. Insert a feeler gauge of the appropriate thickness

between the rocker arm and the valve stem end.

6. Turn the valve clearance adjusting screw until a slight

drag can be felt on the feeler gauge.

7. Tighten the lock nut securely.

8. Rotate the crankshaft 360°.

9. Realign the crankshaft damper pulley TDC notched

line with the timing pointer.

10 Adjust the clearances for the remaining valves as

shown in the illustration.

INJECTION TIMING ADJUSTMENT (EXCEPT 4JH1TC)

1. Check that the notched line on the injection pump

flange is aligned with the front plate or the timing gear

case notched line.

2. Bring the piston in the No. 1 cylinder to TDC Q on the

compression stroke by turning the crankshaft until the

crankshaft pulley TDC line is aligned with the timing

mark R.

Note:

Check for play in the No. 1 intake and exhaust valve

push rods.

If the No. 1 cylinder intake and exhaust valve push

rods have play, the No. 1 piston is at TDC on the

compression stroke.

3. Disconnect the injection pipe from the injection pump

4. Remove one bolt from the distributor head.

5. Insert a screwdriver into a hole in the fast idle lever

and turn the lever to release the W-C.S.D. function. (if

so equipped)

6. Install the static timing gauge S.

The probe of the gauge should be depressed inward

approximately 2 mm (0.079 in).

Static Timing Gauge: 5-8840-0145-0 (J-28827)

7. Rotate the crankshaft to bring the piston in the No. 1

cylinder to a point 30 - 40° BTDC.

8. Set the timing gauge needle to zero.

9. Move the crankshaft pulley slightly in both directions to

check that the gauge indication is stable.

10. Turn the crankshaft clockwise and read the gauge

indication when the crankshaft pulley timing mark (11°

°°

°

(4JB1T) on pulley) is aligned with the pointer.

4JB1T = 11 ±

±±

± 2°

°°

° BTDC

Standard Reading mm (in)

0.5 (0.02)

If the injection timing is outside the specified range,

continue with the following steps.

11. Loosen the injection pump fixing nuts and bracket

bolts.

12. Adjust the injection pump setting angle.

When large than

standard value When smaller than

standard value

Gear drive R A

A: Move the injection pump toward the engine.

R: Move the injection pump away from the engine.

COMPRESSI ON PRESSURE MEASUREMENT

1. Start the engine and allow it to idle until the coolant

temperature reaches 70 – 80 °C (158 – 176 °F).

2. Remove the following parts.

•Glow plugs

•Fuel cut solenoid connector

3. Set the adapter and compression gauge to the No. 1

cylinder glow plug hole.

Compression Gauge: 5-8840-2675-0

Adapter; Compression Gauge: 5-8531-7001-0

4. Turn the engine over with the starter motor and take

the compression gauge reading.

Compression Pressure kg/cm2 (psi/MPa) at 200 rpm

Standard Limit

4JH1TC 28 (398/2.8) 20 (284/2.0)

Others 31 (441/3.0) 22 (313/2.2)

5. Repeat the procedure (Steps 3 and 4) for the

remaining cylinders.

If the measured value is less than the specified limit,

refer to “Troubleshooting” in Section 6.

Pre-Heating System

SYSTEM INSPECTION PRO CEDURE

1. Disconnect the thermo-switch on the thermostat outlet

pipe.

2. Turn the starter switch to the “ON” position.

If the Pre-heating System is operating properly, the

glow relay will make a clicking sound about seven

seconds after the starter switch is turned on.

3. Measure the glow plug terminal voltage with a circuit

tester immediately after turning the starter switch to

the “ON” position.

Glow Plug Terminal Voltage V

Approx. 11

General Description

4JB1T

F06L200022

The 4J series automotive diesel engine has special designed combustion chambers in the piston. This design provides

superior fuel economy over a wide range of driving conditions.

Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when the

engine is cold, while chrome plated dry type cylinder liners provide the highest durability.

The crankshaft has been tufftrided to provide a longer service life. Because the crankshaft is tufftrided, it cannot be

reground.

The 4JB1T engines are equipped with turbocharger and a Zexel (Bosch) VE-Type distributor injection pump

The 4JH1TC engines are equipped with turbocharger, intercooler and an electronically controlled Bosch VP44 fuel

injection pump.

4JH1TC

Removal & Installation

Read this Section carefully before performing any removal and installation procedure. This Section gives you important

points as well as the order of operation. Be sure that you understand everything in this Section before you begin.

IMPO RTANT OPERATIO NS – REMOVAL

1. Carefully remove the piping, hoses, wiring harness

connectors, engine control cables, and control rods

from the engine.

2. Remove the clutch slave cylinder, the back up light

switch connector, and the speedometer cable from the

transmission.

BATTERY

1. Disconnect the battery cable Q and the grounding

cable R from the battery terminals.

2. Remove the battery clamp S.

Take care not to accidentally short the battery with the

spanner or some other tool.

3. Remove the battery.

4. Disconnect the battery cable at the starter motor and

the ground cable at the cylinder body.

ENGINE HOOD

Apply setting marks to the engine hood Q and the engine

hood hinges R before removing the engine hood.

This will facilitate reinstallation of the engine hood to its

original position.

FUEL FILTER AND WATER SEPARATOR

1. Pull the fuel hose from the fuel filter Q and the water

separator R.

2. Plug the fuel hose to prevent fuel leakage.

3. Remove the fuel filter and the water separator.

AI R CLEANER

Remove the air cleaner duct from the engine.

COOLANT

Remove the coolant drain plug (at the lower left of the

engine) and the radiator drain plug.

Allow the engine coolant to drain completely.

GEAR SHIFT LEVER

1. Place the gear shift lever in the neutral position.

2. Remove the front console from the floor panel.

3. Pull the gear shift lever grommet Q and the dust

cover R to the top of the gear shift lever.

4. Remove the gear shift lever cover bolt S.

5. Remove the gear shift lever T.

6. Remove the gear shift lever hole cover U or the

center console from the floor.

7. Remove the quadrant box V from the transmission

rear cover.

Note:

Cover the quadrant box opening to prevent the entry

of foreign material into the transmission.

TRANSFER CHANGE LEVER (FOR 4 ×

××

× 4)

Perform this procedure after removing the gear shift lever.

1. Place the transfer change lever in the “H” position.

2. Pull the transfer change lever grommet Q and the

dust cover R to the top of the transfer change lever.

3. Remove the retainer bolts S.

4. Remove the transfer change lever T along with the

retainer and the ball seat cover.

5. Remove the change lever hole cover U or the center

console from the floor.

6. Remove the quadrant box V from the transfer case

adapter.

Note:

Cover the quadrant box and change lever openings to

prevent the entry of foreign material into the

transmission.

RADIATOR

1. Remove the cooling fan Q, the pulley R, and the belt

S.

2. Disconnect the radiator upper hose T and the

radiator lower hose U from the engine.

3. Remove the radiator shroud V.

4. Remove the radiator grille from the deflector panel.

5. Remove the radiator W.

Take care not to damage the radiator core.

6. Remove the radiator undercover from the chassis

frome.

SUPPORTING THE VEHICLE

1. Jack up the vehicle.

2. Place chassis stands at the front and the rear of the

vehicle.

3. Remove the wheels from the vehicle.

ENGINE OIL DRAINING

Remove the oil pan drain plug to drain the engine oil.

Do this while the engine is hot.

Do not forget to reinstall the drain plug after draining the

engine oil.

TRANSFER CASE PROTECTOR (4 ×

××

× 4 MODEL)

Remove the transfer case protector Q from the

transmission mounting member R and the side menber

S.

TRANSMISSION OIL DRAINING

1. Remove the transmission oil drain plug.

2. Replace the drain plug after draining the oil.

CONTROL CABLES OR RODS

1. Disconnect the clutch control cable or the hydraulic

cylinder from the transmission.

2. Disconnect the parking brake control cable from the

rear wheel brake back plate.

3. Disconnect the speedometer drive cable from the

transmission.

EXHAUST PIPE

1. Disconnect the exhaust pipe from the exhaust

manifold.

037RY00002

REAR PRO PELLER SHAFT

1. Remove the propeller shaft flange yoke at the drive

pinion Q.

2. Remove the 2nd propeller shaft flange yoke bolts R

at the center bearing.

3. Remove the center bearing retainer bolts S.

4. Remove the 1st propeller shaft T together with the

center bearing from the transmission mainshaft spline.

FRONT PROPELLER SHAFT (FOR 4 ×

××

× 4)

Remove the splined yoke flange bolt at the transfer output

shaft.

Do not allow the splined yoke to fall away from the front

propeller shaft.

If the splined yoke should fall away from the front propeller

shaft, align the setting marks S on the splined yoke Q

and the propeller shaft R to reassemble the two parts.

The setting marks are punched circles approximately 3

mm (0.12 in) in diameter.

TRANSMISSION

1. Check that the lifting wires Q are securely attached.

2. Operate the hoist to slightly raise the engine.

Warning:

Take care not to lift the chassis from the chassis

stands.

If you do accidentally raise the chassis from the

chassis stands, make absolutely certain that the

chassis stands are correctly positioned before

lowering the chassis.

3. Place the jack R beneath the transmission case.

4. Operate the jack to slightly raise the transmission.



5. Remove the transmission member lower mounting

bolts S fixing the transmission member to the chassis

frame rail.

6. Loosen the engine mounting nuts T at the rubber

mountings.

7. Use the jack to slightly lower the transmission.

8. Remove the remaining transmission coupling bolts.

9. Separate the transmission from the engine.

Take care not to damage the transmission, the

engine, and their related parts.

10. Use the jack to lower the transmission together with

the mounting member to the floor.

11. Remove the engine mounting bolts U from the

chassis frame.

12. Use the hoist to lift the engine from the engine

compartment.

IMPORTANT OPERATIONS – INSTALLATION

Follow the removal procedure in the reverse order to

perform the installation procedure. Pay careful attention to

the important points during the installation procedure.

ENGINE

1. Attach a lifting wire to the engine lifting hanger.

2. Operate the hoist to position the engine above the

engine compertment.

Hold the front of the engine slightly higher than the

rear.

3. Slowly lower the engine into the engine compartment.

Be careful not to damage the brake pipes, the fuel

pipes, and other exposed parts.

4. Support the oil pan with a jack.

5. Temporarily tighten the engine front mounting rubber

nuts.

TRANSMISSION

1. Apply a thin coat of molybdenum disulfide grease to

the top gear shaft spline.

2. Place the transmission with the mounting rubbers on a

transmission jack.

3. Carefully move the transmission jack and

transmission into position behind the cab.

4. Slowly raise the transmission jack until the front of the

transmission is aligned with the engine flywheel.

The slope of the engine and the transmission must be

the same.

5. Align the top gear shaft spline with the clutch driven

plate internal spline.

6. Install the transmission to the engine.

Tighten the transmission coupling nuts and bolts to

the specified torque.

Transmission Coupling Nut and Bolt

Torque kg·m (lb.ft/N·m)

3.8 ± 0.8 (27.5 ± 5.8/37.2 ± 7.8)

7. Install the mounting member Q to the mounting

rubber R.

8. Tighten the mounting member nuts S to the specified

torque.

Mounting Rubber Nut Torque kg·m (lb.ft/N·m)

4.2 ± 0.5 (30.4 ± 3.6/41.2 ± 4.9)

9. Install the mounting member T to the sidemembers

U.

10. Tighten the mounting member bolts to the specified

torque.

Mounting Member Bolt Torque kg·m (lb.ft/N·m)

7.8 ± 1.6 (56.1 ± 11.2/76.0 ± 15.2)

11. Tighten the engine mounting rubber nuts to the

specified torque.

Engine Mounting Rubber Nut Torque kg·m (lb.ft/N·m)

4.2 ± 0.5 (30.4 ± 3.6/41.2 ± 4.9)

EXHAUST PIPE

Connect the exhaust pipe to the exhaust manifold.

Torque kg·m (lb.ft/N·m)

6.8 ± 0.5 (49 ± 3.6/67 ± 5)

FRONT PROPELLER SHAFT (FOR 4 ×

××

× 4)

1. Connect the propeller shaft flange yoke to the

matching flange.

2. Tighten the propeller shaft flange yoke bolt to the

specified torque.

Propeller Shaft Flange Yoke Bolt

Torque kg·m (lb.ft/N·m)

3.6 ± 0.3 (26.0 ± 2.2/35.3 ± 2.9)

Note:

If the splined yoke and the front propeller shaft have

accidentally separated, align their setting marks and

recouple them.

Refer to “FRONT PROPELLER SHAFT REMOVAL.”

REAR PRO PELLER SHAFT

1. Place the center bearing and retainer Q together with

the 1st propeller shaft R on the No. 4 crossmember

S.

2. Insert the splined yoke T into the transmission main

shaft spline U.

3. Tighten the center bearing retainer bolts V to the

specified torque.

Center Bearing Retainer Bolt Torque kg·m (lb.ft/N·m)

6.2 ± 0.2 (44.8 ± 1.5/60.8 ± 2.0)

4. Connect the 2nd propeller shaft W center coupling

side X and drive pinion side Y.

Propeller Shaft Flange Yoke Bolt

Torque kg·m (lb.ft/N·m)

3.6 ± 0.3 (26.0 ± 2.2/35.3 ± 2.9)

TRANSFER CASE PROTECTOR (FOR 4 ×

××

× 4)

1. Install the transfer case protector Q to the mounting

member R and the sidemembers S.

2. Tighten the transfer case protector bolts to the

specified torque.

Transfer Case Protector Bolt Torque kg·m (lb.ft/N·m)

3.7 ± 1.0 (26.8 ± 7.2/36.3 ± 9.8)

GEAR SHIFT LEVER

1. Replenish the transmission case and the transfer case

with the specified engine oil.

Transmission and Transfer Case Oil lit (US/UK gal)

4 × 24 × 4

MSG 1.55 (0.41/0.34) 4.40 (1.16/0.97)

MUA 2.95 (0.65/0.54) 2.95 (T/M)

1.45 (Transter)

2. Install the quadrant box to the transmission rear cover.

3. Install the gear shift lever Q to the transmission case.

4. Tighten the gear shift lever cover R bolts to the

specified torque.

Shift Lever Cover Bolt Torque kg·m (lb.ft/N·m)

2.0 ± 0.2 (14.5 ± 1.5/19.6 ± 2.0)

5. Install the dust cover S and the grommet T.

TRANSFER CHANGE LEVER (FOR 4 ×

××

× 4)

1. Insert the transfer change lever Q into the transfer

side case.

2. Install the ball seat cover along with the change lever

retainer R.

3. Tighten the change lever retainer bolts to the specified

torque.

Change Lever Retainer Bolt Torque kg·m (lb.ft/N·m)

2.0 ± 0.2 (14.5 ± 1.5/19.6 ± 2.0)

4. Install the dust cover S and the grommet T.

RADIATOR

1. Install the radiator Q.

Be careful not to damage the radiator core.

2. Install the cooling fan R and the fan shroud S.

3. Connect the radiator upper and lower hoses.

4. Install the radiator undercover to the chassis frame.

5. Install the radiator grill to the deflector panel.

LOWERI NG THE VEHICLE

1. Install the wheels to the vehicle.

2. Place a jack beneath the vehicle.

3. Raise the jack to remove the chassis stands.

4. Lower the vehicle to the ground.

COOLANT REPLENISHMENT

Replenish the cooling system with coolant.

When radiator is emptied (for coolant change, etc.):

After filling with coolant up to the inlet port level, put the

radiator cap on and idle the engine for 5 to 6 consecutive

minute. Then remove the radiator cap and check and see

the coolant level. If the coolant is short, add to the radiator

as well as to the reserve tank.

If the reserve tank coolant level is lower than MIN,

replenish coolant to the reserve tank only.

In case there is no coolant in the reserve tank, make sure

of a drop in coolant temperature and add coolant through

the radiator inlet port. Then remove the cap and check the

coolant level after idling the engine for 5 to 6 consecutive

minutes.

Then add coolant into reserve tank fill up to full level.

Coolant Capacity lit (US/UK gal)

4JB1T 9.5 (2.5/2.1)

4JH1TC 8.4 (2.2/1.8)

ENGINE O IL REPLENISHM ENT

1. Fill the engine through the filler port with new engine

oil of the specified grade.

Engine Oil Capacity and Grade lit (US/UK gal)

4 × 2

4JB1T 4 × 4 6.5 (1.7/1.4)

4 × 2 6.5 (1.7/1.4)

4JH1TC 4 × 4 7.3 (1.9/1.6)

Capacity

For 4JB1T, 4JH1TC CG 10W/30

2. Start the engine and allow it to idle for several

minutes.

3. Stop the engine and wait five minutes for the oil to

settle.

4. Recheck the oil level and replenish if necessary.

ENGINE HOOD

Align the setting marks (applied at removal) on the engine

hood Q and the engine hood hinges R to install the

engine hood.

BATTERY

1. Check the battery fluid level and the specific gravity.

2. Secure the battery with the battery clamp.

Do not overtighten the battery clamp.

3. Connect the battery cable R and the ground cable S

to the battery.

4. Connect the battery cable to the starter motor and the

ground cable to the cylinder body.

5. Apply grease to the battery terminals.

6. Install the battery clamp Q.

Take care not to accidentally short the battery with the

spanner or some other tool.

ENGINE W ARM-UP

After completing the required maintenance procedures,

start the engine and allow it to idle until it is warm.

Check the following:

1. Engine idling speed. Refer to “SERVICING” for the

idle speed adjustment procedure.

2. Engine noise level.

3. Engine lubricating system and cooling system

Carefully check for oil and coolant leakage.

4. Engine control cable operation

5. Clutch engagement

6. Indicator warning light operation

Engine Repair Kit

All of the numbered parts listed below are included in the Engine Repair Kit.

The gaskets marked with an asterisk (*) are also included in the Top Overhaul Kit.

* 1. Cy linder head gasket 12. Water pump O-ring

* 2. Head cover gasket * 13. Water outlet pipe gasket

* 3. Head cover cap nut gasket * 14. Intake pipe gasket

4. Drain cock gasket 15. Thermostat housing gasket

5. Crankshaft rear oil seal * 16. Intake manifold gasket

6. Gear case gasket * 17. Exhaust manifold gasket

7. Oil pan drain plug gasket * 18. Nozzle holder O-ring

8. Oil pan gasket * 19. Nozzle holder gasket

9. Oil filter gasket 20. Crankshaft front oil seal

10. Joint bolt gasket 21. N/A

11. Vacuum pump gasket 22. Inter cooler outlet pipe gasket

4JH1TC only)

Engine Overhaul

Removal

External Parts

These removal steps are based on the 4JB1T engine.

The triangle (

J

) mark indicates the important operations.

REMOVAL STEPS

1. Cooling fan drive belt 16. Turbocharger heat protector

2. Cooling fan pulley 17. Exhaust adaptor

3. Heater pipe (rear side) 18. Turbocharger oil return pipe

4. Oil level gauge and guide tube 19. Turbocharger oil feed pipe

5. Starter motor

J

20. Turbocharger

6. Water drain cock 21. Exhaust manifold heat protector

7. Oil pressure warning switch and 22. Oil cooler with Oil filter

nipple 23. Exhaust manifold

8. Engine mounting bracket 24. Compressor bracket

J

9. Intake manifold 25. Generator bracket

J

10. Fuel injection pipe with clip 26. Power steering oil pump

11. Fuel leak off pipe 27. Vacuum pipe

12. Injection pump

13. Compressor

14. Generator and adjusting plate

15. Water inlet pipe

IMPORTANT OPERATIONS

9. Intake Manifold

1) Disconnect the PCV hose from the cylinder head

cover.

2) Disconnect the intake duct and intake rubber hose

from the turbocharger.

3) Remove the upper intake manifold the lower intake

manifold with intake duct, and the PCV hose.

10. Fuel Injection Pipe with Clip

1) Loosen the injection pipe sleeve nuts at the delivery

valve side Q and injection nozzle side.

Do not apply excessive force to the injection pipes.

2) Loosen the injection pipe clips R.

3) Remove the injection pipes S.

Note:

Plug the delivery holder ports with the shipping caps

to prevent the entry of foreign material.

20. Turbocharger

Plug the turbocharger body oil ports after removing the

turbocharger assembly to prevent the entry of foreign

material.

Internal Parts

Major Components

DISASSEMBLY STEPS-1

1. Water bypass pipe 5. Glow plug and glow plug

2. Thermostat housing with thermo connector

switch

J

6. Rocker arm shaft and rocker

3. Cylinder head cover arm

J

4. Injection nozzle and Injection 7. Push rod

nozzle holder

J

8. Cylinder head

4a. N/A 9. Cylinder head gasket

4b. Injection nozzle and Injection

Nozzle holder (4JA1TC, 4JH1TC)

025L200001

Disassembly Steps-2 (Gear Drive Model)

J

1. Crankshaft damper pulley

2. Gear case upper cover and

lower cover

3. Space rubber

J

4. Timing gear case cover

5. Timing gear oil pipe (Except

4JA1TC, 4JH1TC)

6. Idler gear “B” and shaft

J

6a. Idler gear “B” and shaft (scissor

gear) (4JA1TC, 4JH1TC only)

J

7. Idler gear “A”

8. Idler gear shaft

9. Crankshaft timing gear

J

10. Injection pump

6a

Disassembly Steps-3 (Gear Drive Model)

J

11. Camshaft timing gear

12. Camshaft thrust plate

13. Timing gear case

1. Crankshaft Damper Pulley

Use the remover to remove the damper pulley

NOTE:

Hold the flywheel ring gear stationary to prevent the

crankshaft from turning when removing the

crankshaft pulley.

014RY00046

4. Timing Gear Case Cover

The timing gear case is tightened together with the

injection pump at the 6 points indicated by the arrows in

the illustration.

6a. Idle Gear B (4JA1TC, 4JH1TC only)

Install lock bolts to the holes marked with an arrow in the

illustration to hold the gear in place. Remove the gear.

7. Idler Gear “A”

1. Measure the camshaft timing gear backlash and the

crankshaft timing gear backlash before removing the

idler gear.

2. Measure the idler gear end play before removing the

idler gear.

Note:

Refer to the following items for details on the

backlash and end play measurement procedures.

TIMING GEAR BACKLASH MEASUREMENT

1) Set a dial indicator to the timing gear to measured.

Hold both the gear to be checked and the adjusting

gear stationary.

2) Move the gear to be checked as far as possible to

both the right and the left.

Take the dial indicator reading.

If the measured value exceeds the specified limit, the

timing gear must be replaced.

Timing Gear Backlash mm (in)

Standard Limit

0.10 – 0.17 (0.0039 – 0.0067) 0.30 (0.012)

IDLER GEAR “A” END PLAY MEASUREMENT

Insert a feeler gauge between the idler gear and the thrust

collar to measure the gap and determine the idler gear

end play.

If the measured value exceeds the specified limit, the

thrust collar must be replaced.

Idler Gear End Play mm (in)

Standard Limit

0.07 (0.0028) 0.2 (0.0079)

10. Injection Pump

1 Remove the injection pump rear bracket bolts R from

the injection pump bracket S.

2 Remove the injection pump rear bracket bolts T and

the bracket U from the cylinder body.

3. Pull the injection pump along with the injection pump

timing gear free toward the rear of the engine.

4JH1TC

1 Remove the injection pump upper bracket from the

injection pump.

080L200005

2 Remove the injection pump bottom bracket from the

injection pump.

3 Pull the injection pump along with the injection pump

timing gear free toward the rear of the engine.

Note:

Plug the injection pump delivery holder ports with the

shipping caps (or the equivalent) to prevent the entry

of foreign material.

11. Camshaft Timing Gear

1. Use a dial indicator to measure the camshaft end play.

This must be done before removing the camshaft

gear.

If the camshaft end play exceeds the specified limit,

the thrust plate must be replaced.

Camshaft End Play mm (in)

Standard Limit

0.050 – 0.114

(0.002 – 0.0044) 0.20

(0.008)

2. Remove the camshaft timing gear bolt from the

camshaft.

Note:

Hold the camshaft stationary to prevent the camshaft

from turning.

3. Use the universal puller Q to pull out the camshaft

timing gear R.

Universal Puller: 5-8521-0002-0

4. Remove the thrust plate S.

Minor Components

Rocker Arm Shaft & Rocker Arm

DISASSEMBLY STEPS

J

1. Rocker arm shaft snap ring 5. Rocker arm shaft spring

J

2. Rocker arm 6. Rocker arm shaft snap ring

J

3. Rocker arm shaft bracket 7. Rocker arm shaft

4. Rocker arm

IMPORTANT OPERATIONS

1. Rocker Arm Shaft Snap Ring

2. Rocker Arm

3. Rocker Arm Shaft Bracket

1) Use a pair of pliers to remove the snap rings.

2) Remove the rocker arms.

3) Remove the rocker arm shaft brackets.

If the rocker arms and rocker arm shaft brackets are

to be reinstalled, mark their installation positions by

tagging each rocker arm and rocker arm shaft bracket

with the cylinder number from which it was removed.

Cylinder Head

DISASSEMBLY STEPS

1. Intake manifold

J

6. Intake and exhaust valve

2. Intake manifold gasket 7. Valve stem oil seal

J

3. Split collar 8. Valve spring lower seat

4. Valve spring upper seat 9. Cylinder head

5. Valve spring

IMPORTANT OPERATIONS

3. Split Collar

1) Place the cylinder head on a flat wooden surface.

2) Use the spring compressor to remove the split collars.

Do not allow the valve to fall from the cylinder head.

Spring Compressor: 9-8523-1423-0 (J-29760)

6. Intake and Exhaust Valve

If the intake and exhaust valves are to be reinstalled, mark

their installation positions by tagging each valve with the

cylinder number from which it was removed.

If the intake and exhaust valves are to be replaced, the

valve guides must also be replaced.

Piston & Connecting Rod

DISASSEMBLY STEPS

J

1. Connecting rod bearing

J

4. Piston pin

J

2. Piston ring 5. Connecting rod

J

3. Piston pin snap ring

J

6. Piston

015L200002

4JH1TC

only

IMPORTANT OPERATIONS

1. Connecting Rod Bearing

If the connecting rod bearings are to be reinstalled, mark

their fitting positions by tagging each bearing with the

cylinder number from which it was removed.

2. Piston Ring

1) Clamp the connecting rod in a vise.

Take care not to damage the connecting rod.

2) Use a piston ring replacer to remove the piston rings.

Piston Ring Replacer

Do not attempt to use some other tool to remove the

piston rings. Piston ring stretching will result in

reduced piston ring tension.

3. Piston Pin Snap Ring

Use a pair of pliers to remove the piston pin snap rings.

4. Piston Pin

6. Piston

Tap the piston pin out with a hammer and a brass bar.

If the pistons and piston pins are to be reinstalled, mark

their installation positions by tagging each piston and

piston pin with the cylinder number from which it was

removed.

Inspection & Repair

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during

inspection.

Face Warpage

CYLINDER HEAD LOWER FACE WARPAG E

1. Use a straight edge and a feeler gauge to measure

the four sides and the two diagonals of the cylinder

head lower face.

If the measured values exceed the limit, the cylinder head

must be replaced.

Cylinder Head Lower Face Warpage mm (in)

Standard Limit

0.05

(0.002) or less 0.20

(0.008)

Note:

The cylinder head lower face cannot be reground.

Cylinder Head Height H (Reference) mm (in)

Standard

91.95 – 92.05

(3.620 – 3.624)

MANIFOLD FITTING FACE WARPAGE

Use a straight edge and a feeler gauge to measure the

manifold cylinder head fitting face warpage.

Regrind the manifold cylinder head fitting surfaces if the

measured values are greater than the specified limit but

less than the maximum grinding allowance.

If the measured values exceed the maximum grinding

allowance, the cylinder head must be replaced.

Manifold Fitting Face Warpage mm (in)

Standard Limit Maximum Grinding

Allowance

0.05

(0.002) or less 0.20

(0.008) 0.40

(0.016)

EXHAUST MANIFOLD WARPAGE

Use a straight edge and a feeler gauge to measure the

manifold cylinder head fitting face warpage.

If the measured values exceed the specified limit, the

manifold must be replaced.

Exhaust Manifold Warpage mm (in)

Standard Limit

0.05 (0.002) or less 0.20 (0.008)

Valve Guide

VALVE STEM AND VALVE GUIDE CLEARANCE

Measuring Method-I

1. With the valve stem inserted in the valve guide, set

the dial indicator needle to “0”.

2. Move the valve head from side to side.

Read the dial indicator.

Note the highest dial indication.

If the measured values exceed the specified limit, the

valve and the valve guide must be replaced as a set.

Valve Stem Clearance mm (in)

Standard Limit

Intake Valve0.039 – 0.069

(0.0015 – 0.0027) 0.200

(0.008)

Exhaust Valve 0.064 – 0.093

(0.0025 – 0.0037) 0.250

(0.0098)

Measuring Method-II

1. Measure the valve stem outside diameter.

Refer to the Item “Valve Stem Outside Diameter”.

2. Use a caliper calibrator or a telescoping gauge to

measure the valve guide inside diameter.

VALVE G UI DE REPLACEMENT

Valve Guide Removal

Use a hammer and the valve guide replacer to drive out

the valve guide from the cylinder head lower face.

Valve Guide Replacer: 9-8523-1212-0

Valve Guide Installation

1. Apply engine oil to the valve guide outer

circumference.

2. Attach the valve guide installer to the valve guide.

3. Use a hammer to drive the valve guide into position

from the cylinder head upper face.

Valve Guide Replacer: 9-8523-1212-0

4. Measure the height of the valve guide upper end from

the upper face of the cylinder head.

Valve Guide Upper End Height H (Reference) mm (in)

13 (0.51)

Note:

If the valve guide has been removed, both the valve

and the valve guide must be replaced as a set.

Valve & Valve Seat Insert

VALVE STEM O UTSIDE DI AMETER

Measure the valve stem diameter at three points.

If the measured value is less than the specified limit, the

valve and the valve guide must be replaced as a set.

Valve Stem Outside Diameter mm (in)

Standard Limit

Intake Valve 7.946 – 7.961

(0.3128 – 0.3134) 7.880

(0.3102)

Exhaust Valve 7.921 – 7.936

(0.3119 – 0.3124) 7.850

(0.3090)

VALVE THICKNESS

Measure the valve thickness.

If the measured value is less than the specified limit, the

valve and the valve guide must be replaced as a set.

Intake and Exhaust Valve Thickness mm (in)

Standard Limit

4JB1T 1.8 (0.07) 1.5 (0.06)

Inlet 1.41 (0.0555)

4JH1TC Exhaust 1.38 (0.0543) 1.1 (0.043)

VALVE DEPRESSION

1. Install the valve Q to the cylinder head R.

2. Use a depth gauge or a straight edge with steel rule to

measure the valve depression from the cylinder head

lower surface.

If the measured value exceeds the specified limit, the

valve seat insert must be replaced.

Valve Depression mm (in)

Standard Limit

Intake 0.73 (0.029) 1.28 (0.050)

4JB1T Exhaust 0.70 (0.028) 1.20 (0.047)

4JH1TC Engine 1.1 (0.043) 1.6 (0.063)

3. Check that the rocker arm oil port is free of

obstructions.

If necessary, use compressed air to clean the rocker

arm oil port.

ROCKER ARM CORRECTION

Inspect the rocker arm valve stem contact surfaces for

step wear Q and scoring R.

If the contact surfaces have light step wear or scoring,

they may be honed with an oil stone.

If the step wear or scoring is severe, the rocker arm must

be replaced.

Cylinder Body

CYLINDER BODY UPPER FACE WARPAGE

1. Remove the cylinder body dowel.

2. Remove the cylinder liner.

Refer to “Cylinder Liner Replacement”.

3. Use a straight edge Q and a feeler gauge R to

measure the four sides and the two diagonals of the

cylinder body upper face.

If the measured values exceeds the limit, the cylinder

body must be replaced.

Cylinder Body Upper Face Warpage mm (in)

Standard Limit

0.05 (0.002) or less 0.20 (0.008)

Cylinder Body Height H (Reference) mm (in)

Standard

4JB1T

4JH1TC269.945 – 270.055 (10.6277 – 10.6320)

5. Reinstall the cylinder liner.

Refer to “Cylinder Liner Replacement”.

6. Reinstall the cylinder body dowel.

Rocker Arm Shaft & Rocker Arm

ROCKER ARM SHAFT RUN-OUT

1. Place the rocker arm shaft on a V-block.

2. Use a dial indicator to measure the rocker arm shaft

central portion run-out.

If the run-out is very slight, correct the rocker arm

shaft run-out with a bench press. The rocker arm must

be at cold condition.

If the measured rocker arm shaft run-out exceeds the

specified limit, the rocker arm shaft must be replaced.

Rocker Arm Shaft Run-Out mm (in)

Limit

0.3 (0.012)

ROCKER ARM SHAFT OUTSIDE DIAMETER

Use a micrometer to measure the rocker arm fitting

portion outside diameter.

If the measured value is less than the specified limit, the

rocker arm shaft must be replaced.

Rocker Arm Shaft Outside Diameter mm (in)

Standard Limit

18.98 – 19.00 (0.747 – 0.748) 18.90 (0.744)

ROCKER ARM SHAFT AND ROCKER ARM

CLEARANCE

1. Use either a vernier caliper or a dial indicator to

measure the rocker arm inside diameter.

Rocker Arm Inside Diameter mm (in)

Standard Limit

19.010 – 19.030

(0.748 – 0.749) 19.100 (0.752)

2. Measure the rocker arm shaft outside diameter.

If the measured value exceeds the specified limit,

replace either the rocker arm or the rocker arm shaft.

Rocker Arm Shaft and Rocker Arm

Clearance mm (in)

Standard Limit

0.01 – 0.05

(0.0004 – 0.0020) 0.20 (0.008)

Valve Spring

VALVE SPRING FREE HEIGHT

Use a vernier caliper to measure the valve spring free

height.

If the measured value is less than the specified limit, the

valve spring must be replaced.

Inner and Outer Spring Free Height mm (in)

Standard Limit

4JB1T, 4JH1TC Single spring 48.0 (1.89) 47.1 (1.85)

VALVE SPRI NG SQUARENESS

Use a surface plate and a square to measure the valve

spring squareness.

If the measured value exceeds the specified limit, the

valve spring must be replaced.

Inner and Outer Spring Squareness mm (in)

Limit

4JB1T, 4JH1TC Single Spring 1.7 (0.07)

VALVE SPRI NG TENSION

Use a spring tester to measure the valve spring tension.

If the measured value is less than the specified limit, the

valve spring must be replaced.

Valve Spring Tension kg (lb/N)

Compressed

Height Standard Limit

4JB1T,

4JH1TC Single

Spring 38.9 mm

(1.53 in) 30.2

(66.4/296.0) 26.3

(57.9/257.7)

VALVE SEAT INSERT INSTALLATION

1. Carefully place the attachment Q (having a smaller

outside diameter than the valve seat insert) on the

valve seat insert R.

Note:

The smooth side of the attachment must contact the

valve seat insert.

2. Use a bench press S to gradually apply pressure to

the attachment and press the valve seat insert into

place.

Note:

Do not apply an excessive amount of pressure with

the bench press. Damage to the valve seat insert will

result.

VALVE SEAT INSERT CORRECTION

1. Remove the carbon from the valve seat insert surface.

2. Use a valve cutter (15°, 45°, and 75° blades) to

minimize scratches and other rough areas. This will

bring the contact width back to the standard value.

Remove only the scratches and rough areas. Do not

cut away too much. Take care not to cut away

unblemished areas of the valve seat surface.

Valve Seat Angle degree

45

Note:

Use an adjustable valve cutter pilot.

Do not allow the valve cutter pilot to wobble inside the

valve guide.

3. Apply abrasive compound to the valve seat insert

surface.

4. Insert the valve into the valve guide.

5. Turn the valve while tapping it to fit the valve seat

insert.

6. Check that the valve contact width is correct.

7. Check that the valve seat insert surface is in contact

with the entire circumference of the valve.

VALVE CO NTACT W IDTH

1. Check the valve contact faces for roughness and

unevenness. Make smooth the valve contact surfaces.

2. Measure the valve contact width.

If the measured value exceeds the specified limit, the

valve seat insert must be replaced.

Valve Contact Width mm (in)

Standard Limit

Intake 1.7 (0.067) 2.2 (0.087)

Exhaust 2.0 (0.079) 2.5 (0.078)

VALVE SEAT INSERT REPLACEMENT

VALVE SEAT INSERT REMOVAL

1. Arc weld the entire inside circumference Q of the

valve seat insert R.

2. Allow the valve seat insert to cool for a few minutes.

This will invite contraction and make removal of the

valve seat insert easier.

3. Use a screwdriver S to pry the valve seat insert free.

Take care not to damage the cylinder head T.

4. Carefully remove carbon and other foreign material

from the cylinder head insert bore.

CYLINDER LINER BO RE MEASUREMENT

Use a cylinder indicator to measure the cylinder bore at

measuring point Q, R in the thrust a-a and axial b-b

directions of the crankshaft.

If the measured value exceeds the specified limit, the

cylinder liner must be replaced.

Measuring Points Q20 mm (0.8 in) for 4JB1T, 4JH1TC

R N/A Australian Vehicles

R160 mm (6.3 in) for 4JB1T, 4JG2T,

4JH1TC

Cylinder Liner Bore (Service Part) mm (in)

Grade 4JB1T 4JH1TC

AX 93.035 – 93.050

(3.6628 – 3.6634) 95.435 – 95.450

(3.7573 – 3.7579)

CX 93.051 – 93.066

(3.6634 – 3.6640) 95.451 – 95.466

(3.7579 – 3.7585)

012L200001

Note:

The inside of the dry type cylinder liner is chrome

plated. It cannot be rebored or honed.

If the inside of the cylinder liner is scored or

scorched, the cylinder liner must be replaced.

CYLINDER LINER PRO J ECTION INSPECTION

1. Hold a straight edge Q along the top edge of the

cylinder liner to be measured.

2. Use a feeler gauge R to measure each cylinder liner

projection.

Cylinder Liner Projection mm (in)

Standard

0 – 0.1 (0 – 0.004)

The difference in the cylinder liner projection height

between any two adjacent cy linders must not exceed

0.03 mm (0.0012 in).

CYLINDER LINER REPLACEMENT

CYLINDER LINER REM OVAL

1. Insert the cylinder liner remover Q into the cylinder

body (from the lower side of the cylinder body) until it

makes firm contact with the cylinder liner.

Cylinder Liner Remover:

5-8840-2039-0 4JB1T Engine

5-8840-2304-0: 4JH1TC Engine

2. Use a bench press R to slowly force the cylinder liner

from the cylinder body.

Note:

Take care not to damage the cylinder body upper face

during the cylinder liner removal procedure.

3. Measure the cylinder body upper face warpage.

Refer to “Cylinder Body Upper Face Warpage”.

CYLINDER LINER G RADE SELECTION

Subtract the average cylinder body bore from the average

cylinder liner outside diameter to obtain the fitting

interference.

Fitting Interference mm (in)

Standard

– 0.0010* – 0.019 (– 0.00004* – 0.0007)

* A minus (–) value indicates that the cylinder body bore

is smaller than the liner outside diameter.

CYLINDER BODY BORE MEASUREMENT

1. Take measurements at measuring point Q across

positions Q-Q, R-R, S-S, and T-T.

Measuring Point Q 98 mm (3.86 in)

2. Calculate the average value of the four measurements

to determine the correct cylinder grade.

3. Consult the following table with the resultant diameter

for the correct liner application.

CYLINDER LINER G RADE SELECTION AND

STANDARD FITTING INTERFERENCE

Accurately measured fitting interference and proper

cylinder liner grade selection are extremely important.

If the cylinder liner fitting interference is too small, engine

cooling efficiency will be adversely affected.

If the cylinder liner fitting interference is too large, it will be

difficult to insert the cylinder liner into the cylinder body.

A mark was stamped on the upper of the cylinder block

during production to indicate the correct liner.

The liner grade (i.e.1.2.3.4) is indicated in metal stamp.

Cylinder Liner Grade

4JB1T mm (in)

Liner

Outside

Grade Cylinder Body

Bore Diameter Liner Outside

Diameter Liner

Bore

Grade Service Liner Bore Measurement

AX 93.035 – 93.050 (3.6628 – 3.6634)

195.001 – 95.010

(3.7402 – 3.7405) 95.011 – 95.020

(3.7406 – 3.7409) CX 93.051 – 93.066 (3.6634 – 3.6640)

AX 93.035 – 93.050 (3.6628 – 3.6634)

295.011 – 95.020

(3.7406 – 3.7409) 95.021 – 95.030

(3.7410 – 3.7413) CX 93.051 – 93.066 (3.6634 – 3.6640)

AX 93.035 – 93.050 (3.6628 – 3.6634)

395.021 – 95.030

(3.7410 – 3.7413) 95.031 – 95.040

(3.7414 – 3.7417) CX 93.051 – 93.066 (3.6634 – 3.6640)

AX 93.035 – 93.050 (3.6628 – 3.6634)

495.031 – 95.040

(3.7414 – 3.7417) 95.041 – 95.050

(3.7418 – 3.7421) CX 93.051 – 93.066 (3.6634 – 3.6640)

4JH1TC mm (in)

Liner

Outside

Grade Cylinder Body

Bore Diameter Liner Outside

Diameter Liner

Bore

Grade Service Liner Bore Measurement

AX 95.435 – 95.450 (3.7573 – 3.7579)

197.001 – 97.010

(3.8189 – 3.8193) 97.011 – 97.020

(3.8193 – 3.8197) CX 95.451 – 95.466 (3.7579 – 3.7585)

AX 95.435 – 95.450 (3.7573 – 3.7579)

297.011 – 97.020

(3.8193 – 3.8197) 97.021 – 97.030

(3.8197 – 3.8200) CX 95.451 – 95.466 (3.7579 – 3.7585)

AX 95.435 – 95.450 (3.7573 – 3.7579)

397.021 – 97.030

(3.8197 – 3.8200) 97.031 – 97.040

(3.8200 – 3.8205) CX 95.451 – 95.466 (3.7579 – 3.7585)

AX 95.435 – 95.450 (3.7573 – 3.7579)

497.031 – 97.040

(3.8200 – 3.8205) 97.041 – 97.050

(3.8205 – 3.8209) CX 95.451 – 95.466 (3.7579 – 3.7585)

CYLINDER LINER INSTALLATION

1. Cylinder Liner Installation Using The Special Tool

1) Use new kerosene or diesel oil to thoroughly clean

the cylinder liners and bores.

2) Use compressed air to blow-dry the cylinder liner

and bore surfaces.

Note:

All foreign material must be carefully removed from

the cylinder liner and the cylinder bore before

installation.

3) Insert the cylinder liner Q into the cylinder body R

from the top of the cylinder body.

4) Set the cylinder liner installer S to the top of the

cylinder liner.

Cylinder Liner Installer: 5-8840-2040-0

5-8840-2313-0 (4JG2T,

4JH1TC)

5) S is directly beneath the bench press shaft center

T.

Note:

Check that the cylinder liner is set perpendicular to

the bench press and that there is no wobble.

6) Use the bench press to apply a seating force of

500 kg (1,100 lb/4,900 N) to the cylinder liner.

7) Apply a force of 2,500 kg (5,500 lb/24,500 N) to

fully seat the cylinder liner.

8) After installing the cylinder liner, measure the

cylinder liner projection.

Refer to “Cylinder Liner Projection Inspection”.

2. Cylinder Liner Installation Using Dry Ice

Cylinder liner is a chrome plated dry type, it is

advisable to use dry ice during the installation

procedure.

Cooling the cylinder liner with dry ice will cause the

cylinder liner to contract, thus making installation

easier.

Note:

It is important that the cylinder liner be inserted to the

cylinder body immediately a fter it has been c ooled.

Warning:

Dry ice must be used with great care. Careless

handling of dry ice can result in severe frostbite.

PISTON GRADE SELECTION

Measure the cylinder liner bore after installing the cylinder

liner. Then select the appropriate piston grade for the

installed cylinder liner.

1. Measure the cylinder liner bore.

Refer to “Cylinder Liner Bore Measurement”

Note:

It is most important that the correct piston grade be

used. Failure to select the correct piston grade will

result in engine failure. Always measure the cylinder

bore and select the correct piston grade.

2. Measure the piston diameter.

Piston Measuring Point mm (in)

4JB1T 74 (2.91)

4JH1TC 71 (2.79)

Grade 4JB1T

AX 92.974 – 92.989

(3.6604 – 3.6610)

CX 92.990 – 93.005

(3.6610 – 3.6616)

Grade 4JH1TC

AX 95.359 – 95.374

(3.7543 – 3.7549)

CX 95.375 – 95.390

(3.7549 – 3.7555)

Cylinder Liner and Piston Clearance mm (in)

4JB1T 0.046 – 0.076 (0.0018 – 0.0030)

4JH1TC 0.061 – 0.091 (0.0024 – 0.0036)

Note:

Cylinder liner kit clearances are preset. However, the

cylinder liner installation procedure may result in

slight decreases in cylinder liner clearances. Always

measure the cylinder liner clearance after installation

to be sure that it is correct.

Tappet & Push Rod

Visually inspect the tappet contact surfaces for pitting,

cracking, and other abnormal conditions. The tappet must

be replaced if any of these conditions are present.

Refer to the illustration at the left.

QNormal contact

RCracking

SPitting

TIrregular contact Uneven contact

UIrregular contact One-sided contact

Note:

The tappet surfaces are spherical. Do not attempt to

grind them with an oil stone or similar tool in an effort

to repair the tappet. If the tappet is damaged, it must

be replaced.

TAPPET OUTSIDE DIAMETER

Measure the tappet outside diameter with a micrometer.

If the measured value is less than the specified limit, the

tappet must be replaced.

Tappet Outside Diameter mm (in)

Standard Limit

12.97 – 12.99

(0.510 – 0.511) 12.95 (0.510)

Tappet and Cylinder Body Clearance mm (in)

Standard Limit

0.01 – 0.046

(0.0004 – 0.0018) 0.10 (0.004)

PUSH ROD CURVATURE

1. Lay the push rod on a surface plate.

2. Roll the push rod along the surface plate and measure

the push rod curvature with a thickness gauge.

If the measured value exceeds the specified limit, the

push rod must be replaced.

Pushrod Curvature mm (in)

Limit

0.3 (0.012)

3. Visually inspect both ends of the push rod for

excessive wear and damage. The push rod must be

replaced if these conditions are discovered during

inspection.

Camshaft

Visually inspect the journals, the cams, the oil pump drive

gear, and the camshaft bearings for excessive wear and

damage. The camshaft and the camshaft bearings must

be replaced if these conditions are discovered during

inspection.

CAM SHAFT JOURNAL DIAMETER

Use a micrometer to measure each camshaft journal

diameter in two directions (Q and R). If the measured

value is less than the specified limit, the camshaft must be

replaced.

Camshaft Journal Diameter mm (in)

Standard Limit

49.945 – 49.975

(1.9663 – 1.9675) 49.60 (1.953)

CAM HEIGHT

Measure the cam height H with a micrometer. If the

measured value is less than the specified limit, the

camshaft must be replaced.

Cam Height Hmm (in)

Standard Limit

42.08 (1.657) 41.65 (1.640)

CAM SHAFT RUN-OUT

1. Mount the camshaft on V-blocks.

2. Measure the run-out with a dial indicator.

If the measured value exceeds the specified limit, the

camshaft must be replaced.

Camshaft Run-Out mm (in)

Standard Limit

0.02 (0.0008) 0.10 (0.004)

CAM SHAFT AND CAMSHAFT BEARI NG CLEARANCE

Use an inside dial indicator to measure the camshaft

bearing inside diameter.

Crankshaft Bearing Inside Diameter mm (in)

Standard Limit

50.00 – 50.03

(1.968 – 1.970) 50.08 (1.972)

If the clearance between the camshaft bearing inside

diameter and the journal exceeds the specified limit, the

camshaft bearing must be replaced.

Camshaft Bearing Clearance mm (in)

Standard Limit

0.05 (0.002) 0.12 (0.005)

CAM SHAFT BEARI NG REPLACEM ENT

CAM SHAFT BEARI NG REMOVAL

1. Remove the cylinder body plug plate.

2. Use the bearing replacer to remove the camshaft

bearing.

Bearing Replacer: 5-8840-2038-0

CAMSHAFT BEARING INSTALLATION

1. Align the bearing oil holes with the cylinder body oil

holes.

2. Use the replacer to install the camshaft bearing.

Bearing Replacer: 5-8840-2038-0

Crankshaft & Bearing

Inspect the surface of the crankshaft journals and

crankpins for excessive wear and damage.

Inspect the oil seal fitting surfaces for excessive wear and

damage.

Inspect the oil ports for obstructions.

Note:

To increase crankshaft strength, tufftriding (Nitrizing

Treatment) has been applied. Because of this, it is not

possible to regrind the crankshaft surfaces.

Therefore, under size bearing are not available.

CRANKSHAFT TUFFTRIDING INSPECTIO N

1. Use an organic cleaner to thoroughly clean the

crankshaft. There must be no traces of oil on the

surfaces to be inspected.

2. Prepare a 5 – 10% solution of ammonium cuprous

chloride (dissolved in distilled water).

3. Use a syringe to apply the solution to the surface to be

inspected.

Hold the surface to be inspected perfectly horizontal to

prevent the solution from running.

Note:

Do not allow the solution to come in contact with the

oil ports and their surrounding area.

JUDGMENT

1. Wait for thirty to forty seconds.

If there is no discoloration after thirty or forty seconds,

the crankshaft is usable.

If discoloration appears (the surface being tested will

become the color of copper), the crankshaft must be

replaced.

2. Steam clean the crankshaft surface immediately after

completing the test.

Note:

The ammonium cuprous chloride solution is highly

corrosive. Because of this, it is imperative that the

surfaces being tested be cleaned immediately after

completing the test.

CRANKSHAFT RUN-OUT

1. Set a dial indicator to the center of the crankshaft

journal.

2. Gently turn the crankshaft in the normal direction of

rotation.

Read the dial indicator as you turn the crankshaft.

If the measured value exceeds the specified limit, the

crankshaft must be replaced.

Crankshaft Run-Out mm (in)

Standard Limit

0.05 (0.002) or less 0.08 (0.003)

BEARI NG SPREAD

Use a vernier caliper to measure the bearing spread.

If the measured value is less than the specified limit, the

bearing must be replaced.

Bearing Spread mm (in)

Limit

Crankshaft Bearing 4JB1T &

4JH1TC 74.5 (2.93)

Connecting Rod Bearing 56.5 (2.22)

CRANKSHAFT JOURNAL AND CRANKPIN

DIAMETER

1. Use a micrometer to measure the crankshaft journal

diameter across points Q - Q and R - R.

2. Use the micrometer to measure the crankshaft journal

diameter at the two points (S and T).

3. Repeat Steps

Q and R to measure the crankpin

diameter.

If the measured values are less than the specified

limit, the crankshaft must be replaced.

Crankshaft Journal Diameter mm (in)

Standard Limit

4JB1T,

4JH1TC 69.92 – 69.93

(2.7527 – 2.7531) 69.91 (2.7524)

Crankpin Diameter mm (in)

Standard Limit

52.92 – 52.93

(2.0833 – 2.0839) 52.90 (2.083)

Crankshaft Journal and Crankpin

Uneven Wear mm (in)

Standard Limit

0.05 (0.002) or less 0.08 (0.003)

CRANKSHAFT JOURNAL AND BEARING

CLEARANCE

If the clearance between the measured bearing inside

diameter and the crankshaft journal diameter exceeds the

specified limit, the bearing and/or the crankshaft must be

replaced.

Crankshaft Journal and Bearing Clearance mm (in)

Standard Limit

0.031 – 0.064

(0.0012 – 0.0025) 0.110 (0.0043)

CONNECTING ROD BEARING INSIDE DIAMETER

1. Install the bearing to the connecting rod big end.

2. Tighten the bearing cap to the specified torque.

Connecting Rod Bearing Cap Bolt

Torque kg·m (lb.ft/N·m)

1st step ; 3.0 ± 0.5(21.7 ± 3.6 /

29 ± 5)

4JB1T & 4JH1TC

engine 2nd step ; 45° ~ 75°

3. Use an inside dial indicator to measure the connecting

rod bearing inside diameter.

CRANKPI N AND BEARING CLEARANCE

If the clearance between the measured bearing inside

diameter and the crankpin exceeds the specified limit, the

bearing and/or the crankshaft must be replaced.

Crankpin and Bearing Clearance mm (in)

Standard Limit

0.029 – 0.066

(0.0011 – 0.0026) 0.100 (0.0039)

CLEARANCE MEASUREMENTS (WITH PLASTIGAGE)

Crankshaft Journal and Bearing Clearance

1. Clean the cylinder body, the journal bearing fitting

surface, the bearing caps, and the bearings.

2. Install the bearings to the cylinder body.

3. Carefully place the crankshaft on the bearings.

4. Rotate the crankshaft approximately 30° to seat the

bearing.

5. Place the Plastigage (arrow) over the crankshaft

journal across the full width of the bearing.

6. Install the bearing caps with the bearing.

7. Tighten the bearing caps to the specified torque.

Crankshaft Bearing Cap Bolt Torque kg·m (lb.ft/N·m)

17 ± 1 (123.0 ± 7.2/166.7 ± 9.8)

Do not allow the crankshaft to turn during bearing cap

installation and tightening.

8. Remove the bearing cap.

9. Compare the width of the Plastigage attached to either

the crankshaft or the bearing against the scale printed

on the Plastigage container.

If the measured value exceeds the limit, perform the

following additional steps.

1) Use a micrometer to measure the crankshaft

outside diameter.

2) Use an inside dial indicator to measure the

bearing inside diameter.

If the crankshaft journal and bearing clearance

exceeds the limit, the crankshaft and/or the

bearing must be replaced.

Crankshaft Journal and Bearing Clearance mm (in)

Standard Limit

0.031 – 0.064

(0.0012 – 0.0025) 0.110 (0.0043)

CRANKPI N AND BEARING CLEARANCE

1. Clean the crankshaft, the connecting rod, the bearing

cap, and the bearings.

2. Install the bearing to the connecting rod and the

bearing cap.

Do not allow the crankshaft to move when installing

the bearing cap.

3. Prevent the connecting rod from moving.

4. Attach the Plastigage to the crankpin.

Apply engine oil to the Plastigage to keep it from

falling.

5. Install the bearing cap and tighten it to the specified

torque.

Do not allow the connecting rod to move when

installing and tightening the bearing cap.

Connecting Rod Bearing Cap Bolt

Torque kg·m (lb.ft/N·m)

1st step ; 3.0 ± 0.5(21.7 ± 3.6 /

29 ± 5)

4JB1T & 4JH1TC

engine 2nd step ; 45° ~ 75°

6. Remove the bearing cap.

7. Compare the width of the Plastigage attached to either

the crankshaft or the bearing against the scale printed

on the Plastigage container.

If the measured value exceeds the specified limit,

perform the following additional steps.

1) Use a micrometer to measure the crankpin

outside diameter.

2) Use an inside dial indicator to measure the

bearing inside diameter.

If the crank pin and bearing clearance exceeds the

specified limit, the crankshaft and/or the bearing

must be replaced.

Crankpin and Bearing Clearance mm (in)

Standard Limit

0.029 – 0.066

(0.0011 – 0.0026) 0.100 (0.0039)

Crankshaft Bearing Selection

Crankshaft bearing selection is based on the measured

diameters of the crankshaft journals and the bearing

inserts.

Match the crankshaft bearing housing grade marks and

the crankshaft journal grade marks in the table below to

determine the correct crankshaft bearing size.

CRANKSHAFT BEARI NG HOUSING GRADE MARK

POSITION

Crankshaft bearing housing grade marks 1 or 2 are

stamped on the rear right hand side of the cylinder body.

Example:

12112

No. 1 Bearing

Housing No. 2 Bearing

Housing No. 3 Bearing

Housing No. 4 Bearing

Housing No. 5 Bearing

Housing

CRANKSHAFT JOURNAL GRADE M ARK POSITION

The crankshaft journal grade marks (1 or -) are stamped

on each crankshaft journal web.

The crankshaft journal and bearing clearance must be the

same for each position after installation of the crankshaft

and the crankshaft bearings.

Note:

The crankshaft journal mark No. 4 is stamped on

crankshaft No. 4 journal web front side or rear side.

REFERENCE

4JB1T & 4JH1TC ENGINE mm (in)

Crankshaft BearingQCrankshaft Journal R

Grade

Mark Diameter Grade

Mark Diameter

Crankshaft

Bearing

Size Color

Code S

1 or

-69.927 – 69.932

(2.7530 – 2.7532) Black

2 or

- - 69.922 – 69.927

(2.7528 – 2.7530)

1

73.987 –

74.000

(2.9129 –

2.9134) 3 or

- - - 69.917 – 69.922

(2.7556 – 2.7528)

Blue

1 or

-69.927 – 69.932

(2.7530 – 2.7532)

2 or

- - 69.922 – 69.927

(2.7528 – 2.7530)

Green

2

73.975 –

73.987

(2.9124 –

2.9129) 3 or

- - - 69.917 – 69.922

(2.7556 – 2.7528) Black

Crankshaft Pilot Bearing

Check the crankshaft pilot bearing for excessive wear and

damage and replace it if necessary.

CRANKSHAFT PILOT BEARING REPLACEMENT

CRANKSHAFT PILOT BEARING REMOVAL

Use the pilot bearing remover to remove the crankshaft

pilot bearing.

Pilot Bearing Remover: 5-8840-2000-0

Sliding Hammer: 5-8840-0019-0 (J-23907)

CRANKSHAFT PILOT BEARI NG INSTALLATION

1. Place the crankshaft pilot bearing right angle across

the crankshaft bearing installation hole.

2. Tap around the edges of the crankshaft pilot bearing

outer races with a brass hammer to drive the bearing

into the crankshaft bearing installation hole.

Pilot Bearing Installer: 5-8522-0024-0

Note:

Strike only the crankshaft pilot bearing outer race with

the hammer. Do not strike the bearing inner race.

Bearing damage and reduced bearing service life will

result.

Flywheel & Ring Gear

FLYWHEEL

1. Inspect the flywheel friction surface for excessive wear

and heat cracks.

2. Measure the flywheel friction surface depth.

If the measured value is within the specified limit, the

flywheel may be reground.

If the measured value exceeds the specified limit, the

flywheel must be replaced.

Flywheel Friction Surface Depth Q mm (in)

Standard Limit

4JB1T 14 (0.551) 15 (0.591)

4JH1TC 18 (0.708) 19 (0.748)

Flywheel Friction Surface Roughness mm (in)

Less than 0.006 (0.00024)

RING GEAR

Inspect the ring gear.

If the ring gear teeth are broken or excessively worn, the

ring gear must be replaced.

RING GEAR REPLACEMENT

RING GEAR REMOVAL

Strike around the edges of the ring gear with a hammer

and chisel to remove it.

RING GEAR INSTALLATION

1. Heat the ring gear evenly with a gas burner to invite

thermal expansion.

Do not allow the temperature of the gas burner to

exceed 200°C (390°F).

2. Install the ring gear when it is sufficiently heated.

The ring gear must be installed with the chamfer

facing the clutch.

Piston

PISTON GRADE SELECTION AND CYLINDER BORE

MEASUREMENT

Refer to the Section “CYLINDER BODY”, Item “Cylinder

Liner Bore Measurement” for details on piston grade

selection and cylinder liner bore measurement.

Piston Ring

PISTON RING GAP

1. Insert the piston ring horizontally (in the position it

would assume if it were installed to the piston) into the

cylinder liner.

2. Push the piston ring into the cy linder bore until it

reaches the measuring point Q or R where the

cylinder liner bore is the smallest.

Do not allow the piston ring to slant to one side or the

other. It must be perfectly horizontal.

Measuring Point Q10 mm (0.4 in)

or

Measuring Point R120 mm (4.7 in)

3. Use a feeler gauge to measure the piston ring gap.

If the measured value exceeds the specified limit, the

piston ring must be replaced.

Piston Ring Gap

4JB1T mm (in)

Standard Limit

1st Compression Ring

2nd Compression Ring 0.2 – 0.4

(0.008 – 0.016)

Oil Ring 0.1 – 0.3

(0.004 – 0.012)

1.5

(0.059)

4JH1TC mm (in)

Standard Limit

1st 0.30 – 0.50

(0.0118 – 0.0197)

Compression

ring 2nd 0.30 – 0.50

(0.0118 – 0.0197)

Oil ring 0.25 – 0.45

(0.0098 – 0.0117)

0.15

(0.0059)

PISTON RING AND PISTON RING GROOVE

CLEARANCE

Use a feeler gauge to measure the clearance between the

piston ring and the piston ring groove at several points

around the piston.

If the clearance between the piston ring and the piston ring

groove exceeds the specified limit, the piston ring must be

replaced.

Piston Ring and Piston Ring Groove

Clearance

4JB1T mm (in)

Standard Limit

1st Compression Ring 0.09 – 0.125

(0.0035 – 0.0049)

2nd Compression Ring 0.05 – 0.085

(0.002 – 0.0033)

Oil Ring 0.03 – 0.070

(0.0012 – 0.0028)

0.15

(0.0059)

4JH1TC mm (in)

Standard Limit

1st 0.09 – 0.13

(0.0035 – 0.0051)

Compression

ring 2nd 0.05 – 0.09

(0.0020 – 0.0035)

Oil ring 0.03 – 0.07

(0.0012 – 0.0028)

0.15

(0.0059)

4. Visually inspect the piston rings.

If a piston ring groove is damaged or distorted, the

piston must be replaced.

015RY00029

Piston Pin

PISTON PIN DI AMETER

Use a micrometer to measure the piston pin diameter at

several points.

If the measured value is less than the specified limit, the

piston pin must be replaced.

Piston Pin Diameter mm (in)

Standard Limit

4JH1TC 30.995 – 31.000

(1.2202 – 1.2204) 30.97 (1.219)

4JB1T 33.994 – 34.000

(1.3383 – 1.3386) 33.97 (1.337)

PISTON PIN AND PISTON CLEARANCE

Use and inside dial indicator to measure the piston pin

hole (in the piston).

Piston Pin Hold mm (in)

Standard

4JB1T 34.002 – 34.010 (1.3387 – 1.3390)

4JH1TC 31.005 – 31.013 (1.2207 – 1.2210)

Piston Pin and Piston Pin Hole Clearance mm (in)

4JB1T 0.002 – 0.015 (0.00008 – 0.0006)

4JH1TC 0.005 – 0.018 (0.00019 – 0.0007)

Cylinder Head Gasket Selection

Cylinder head gasket is determined by the piston head

projection from the cylinder body upper surface, in order to

improve engine performance.

Three types of gasket are provided by the difference of

thickness. Select the adequet one out of three grades of

gasket, according to the following procedure.

Before measurement, clear off carbon from the piston

head and cylinder body surface and also clean the place

where a gasket was installed.

015RY00030

PISTON HEAD PROJECTION MEASURING POINT

1. Use a dial indicator to measure the piston projection

amount.

2. Refer to the illustration for the piston head projection

measuring positions.

All measuring positions should be as close as possible

to the cylinder liner.

3. Measure the points Q R S T and obtain two

differences Q–R and S–T on each cylinder.

Calculate the average value of the piston head

projection on each cylinder.

4. Obtain the maximum value in the four cylinders.

5. Determine the gasket grade required to the maximum

value described above in accordance with the following

table.

4JB1T Cylinder Head Gasket Thickness mm (in)

Gasket Grade

Mark Piston Projection Gasket Thickness

(Reference)

A0.758 – 0.813

(0.0298 – 0.0320) 1.6

(0.0630)

B0.813 – 0.859

(0.0320 – 0.0338) 1.65

(0.0650)

C0.859 – 0.914

(0.0338 – 0.0360) 1.70

(0.0669)

4JH1TC Cylinder Head Gasket Thickness mm (in)

Gasket Grade

Mark Piston Projection Gasket Thickness

(Reference)

A0.215 – 0.265

(0.0085 – 0.0104) 1.3

(0.5118)

B0.265 – 0.315

(0.0104 – 0.0124) 1.35

(0.5315)

C0.315 – 0.365

(0.0124 – 0.0144) 1.4

(0.5512)

For 4JB1T & 4JH1TC

Connecting Rod

CONNECTING ROD AL IGNMENT

Use a connecting rod aligner to measure the distortion and

the parallelism between the connecting rod big end hole

and the connecting rod small end hole.

If either the measured distortion or parallelism exceed the

specified limit, the connecting rod must be replaced.

Connecting Rod Alignment

Per Length of 100 mm (3.94 in) mm (in)

Standard Limit

Distortion 0.08 or Less (0.003) 0.20 (0.008)

Parallelism 0.05 or Less (0.002) 0.15 (0.006)

CONNECTING RO D SIDE FACE CLEARANCE

1. Install the connecting rod to the crankpin.

2. Use a feeler gauge to measure the clearance between

the connecting rod big end side face and the crankpin

side face.

If the measured value exceeds the specified limit, the

connecting rod must be replaced.

Connecting Rod Big End and Crankpin Side

Face Clearance mm (in)

Standard Limit

0.23 (0.009) 0.35 (0.014)

PISTON PIN AND CONNECTING ROD SMALL END

BUSHING CLEARANCE

Use a caliper calibrator and a dial indicator to measure the

piston pin and connecting rod small end bushing

clearance.

If the clearance between the piston pin and the connecting

rod small end bushing exceeds the specified limit, replace

the piston pin and/or the connecting rod bushing.

Piston Pin and Connecting Rod Small End

Bushing Clearance mm (in)

Standard Limit

0.008 – 0.020

(0.0003 – 0.0008) 0.050 (0.002)

CONNECTING ROD BUSHING REPLACEMENT

CONNECTING ROD BUSHING REMOVAL

1. Set the connecting rod small end to the bench press

V-block Q.

2. Use the bench press R and the bar S to slowly force

the bushing from the connecting rod T.

Note:

Take care not to damage the connecting rod with the

bar when removing the bushing.

CONNECTING RO D BUSHING I NSTALLATION

1. Set the connecting rod small end Q to the bench

press V-block.

The connecting rod must be perfectly horizontal.

2. Use the bench press R and the bar S to slowly force

the bushing with oil hole into position.

3. Use a pin hole grinder T fitted with a reamer U to

ream the piston pin hole.

Timing Pulley Housing

Replace the crankshaft front oil seal if it is worn or

damaged.

Take care not to damage the oil seal fitting surfaces.

CRANKSHAFT FRONT OIL SEAL REPLACEMENT

OIL SEAL REMOVAL

With the oil seal pushed in deep, install the special tool as

shown in the illustration and remove the oil seal.

Oil Seal Remover: 5-8840-2362-0

Note:

Take care not to damage sealing surface of front plate

and crankshaft when removing oil seal.

OIL SEAL INSTALLATION

Use the special tool to install the oil seal.

1. With the oil seal attached to the sleeve, insert it into

the front end section of the crankshaft.

2. With the oil seal end section attached securely to the

crankshaft, tighten up the center bolt until the sleeve

hits the front end reference plane of the crankshaft

securely.

3. Remove the sleeve.

4. With the seal pressed in, check the dimension of the

oil seal section.

Standard Dimension = 0.9 ± 0.3 mm

Note:

Install the oil seal after assembling the timing pulley

housing. The oil seal lip section is applied with oil.

Take notice of the press-in direction of the oil seal.

Front Oil Seal Installer: 5-8840-2361-0

Idler Gear Shaft And Idler Gear

(Gear Drive Model)

IDLER GEAR “A” SHAFT OUTSIDE DIAMETER

Use a micrometer to measure the idler gear shaft outside

diameter.

If the measured value is less than the specified limit, the

idler gear shaft must be replaced.

Idler Gear “A” Shaft Outside Diameter mm (in)

Standard Limit

44.945 – 44.975

(1.769 – 1.770) 44.845 (1.766)

IDLER GEAR “A” SHAFT INSIDE DIAMETER

1. Use an inside dial indicator or an inside micrometer to

measure the idler gear inside diameter.

Idler Gear Inside Diameter mm (in)

Standard Limit

45.0 – 45.03

(1.7717 – 1.7718) 45.10 (1.7756)

If the clearance between the idler gear shaft outside

diameter and the idler gear inside diameter exceeds the

limit, the idler gear must be replaced.

Idler Gear Shaft and Idler Gear Clearance mm (in)

Standard Limit

0.025 – 0.085

(0.0010 – 0.0033) 0.200 (0.008)

IDLER GEAR “B”

BEARI NG REPLACEMENT

BEARING REMOVAL

Use a bench press or a hammer and a bar to remove the

bearing from the idler gear.

BEARING INSTALLATION

Use a bench press and bar to install the bearing into the

idler gear.

Bearing Projection and Height mm (in)

Projection Q0.4 – 0.6 (0.016 – 0.024)

Height R23.7 – 24.0 (0.933 – 0.945)

Note:

The bench press and bar should make contact only

with the bearing outer races. Do not allow them to

make contact with the bearing inner races.

Bearing damage and reduced bearing service life will

result.

Timing Gear Case Cover

Replace the crankshaft front oil seal if it is excessively

worn or damaged.

CRANKSHAFT FRONT OIL SEAL REPLACEMENT

OIL SEAL REMOVAL

Use a plastic hammer and a screwdriver to tap around the

oil seal to free it from the gear case cover.

Take care not to damage the oil seal lip surfaces.

OIL SEAL INSTALLATION

Use the installer to install the front oil seal Q to the gear

case cover R.

Oil Seal Installer: 5-8840-2061-0

Note the oil seal installation depth S shown in the

illustration.

Depth S = 1 mm (0.039 in.)

Reassembly

Internal Parts

Minor Components

Rocker Arm Shaft & Rocker Arm

REASSEM BLY STEPS

J

1. Rocker arm shaft 5. Rocker arm

2. Rocker arm shaft snap ring 6. Rocker arm shaft spring

3. Rocker arm 7. Rocker arm shaft snap ring

4. Rocker arm shaft bracket

IMPORTANT OPERATIONS

1. Rocker Arm Shaft

1) Position the rocker arm shaft with the large oil hole

(4φ) facing the front of the engine.

2) Install the rocker arm shaft together with the rocker

arm, the rocker arm shaft bracket, and the spring.

Cylinder Head

REASSEM BLY STEPS

1. Cylinder head 6. Valve spring upper seat

2. Valve spring lower seat

J

7. Split collar

J

3. Valve stem oil seal

J

8. Intake manifold gasket

J

4. Intake and exhaust valve

J

9. Intake manifold

J

5. Valve spring

IMPORTANT OPERATIONS

3. Valve Stem Oil Seal

1) Apply a coat of engine oil to the oil seal inner face.

2) Use an oil seal installer to install the oil seal to the

valve guide.

Oil Seal Installer: 5-8840-2033-0

4. Intake and Exhaust Valve

1) Apply a coat of engine oil to each valve stem before

installation.

2) Install the intake and exhaust valves.

3) Turn the cylinder head up to install the valve springs.

Take care not to allow the installed valves to fall free.

5. Valve Spring

Install the valve spring with their fine pitched end (painted)

facing down.

7. Split Collar

1) Use the spring compressor to compress the valve

spring into position.

Spring Compressor: 9-8523-1423-0 (J-29760)

2) Install the split collars to the valve stem.

3) Set the split collars by tapping around the head of the

collar with a rubber hammer.

8. Intake Manifold Gasket

9. Intake Manifold

1) Install the manifold gasket with the end having the

sharp corners facing the front of the engine.

2) Install the intake manifold to the cylinder head.

3) Tighten the manifold bolts to the specified torque.

Manifold Bolt Torque kg·m (lb.ft/N·m)

1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

Piston & Connecting Rod

REASSEM BLY STEPS

J

1. Piston

J

5. Piston pin snap ring

J

2. Piston pin snap ring

J

6. Piston ring

J

3. Connecting rod

J

7. Connecting rod bearing

J

4. Piston pin

015L200003

For 4JH1TC only

For 4JB1T only

IMPORTANT OPERATIONS

1. Piston

2. Piston Pin Snap Ring

3. Connecting Rod

1) Clamp the connecting rod in a vise.

Take care not to damage the connecting rod.

2) Use a pair of pliers to install the piston pin snap ring to

the piston.

Install the piston to the connecting rod so that the piston

head front mark  and the connecting rod “ISUZU”

casting mark  are facing in the same direction.

1. Piston Pin

1) Apply a coat of engine oil to the piston pin and the

piston pin hole.

2) Use your fingers to force the piston pin into the piston

until it makes contact with the snap ring.

2. Piston Pin Snap Ring

3) Use your fingers to force the piston pin snap ring into

the piston snap ring groove.

4) Check that the connecting rod moves smoothly on the

piston pin.

015R100018

3. Piston Ring

1) Use a piston ring replacer to install the three piston

rings.

Piston Ring Replacer

Install the piston rings in the order shown in the

illustration.

Oil ring

 2nd compression ring

 1st compression ring

Note:

Install the compression rings with the stamped side

facing up.

Insert the expander coil into the oil ring groove so that

there is no gap on either side of the expander coil

before installing the oil ring.

2) Apply engine oil to the piston ring surfaces.

3) Check that the piston rings rotate smoothly in the

piston ring grooves.

4. Connecting Rod Bearing

Carefully wipe any oil or other foreign material from the

connecting rod bearing back face and the connecting rod

bearing fitting surface.

Major Components

REASSEM BLY STEPS-1

J

1. Timing gear case

J

2. Camshaft thrust plate

J

3. Camshaft timing gear

014RY00048

REASSEM BLY STEPS-2

J

4. Crankshaft timing gear

J

9. Injection pump

J

5. Idler gear shaft

J

10. Timing gear case cover

J

6. Idler gear “A” 11. Space rubber

J

7. Idler gear “B” and shaft 12. Gear case cover upper cover

J

7a. Idler gear “B” and shaft (Scissor

gear and lower cover

J

8. Timing gear oil pipe (Except

4JA1TC, 4JH1TC)

J

13. Crankshaft damper pulley

7a

REASSEM BLY STEPS-3

J

32. Cylinder head gasket 37. Water by-pass hose

J

33. Cylinder head

J

38.

34. Push rod Glow plug and glow plug

connector

J

35. Rocker arm shaft and rocker

arm

J

39. Injection nozzle and Injection

nozzle holder

J

36.

J

39a. Injection nozzle (4JG2T engine)Thermostat housing with thermo

switch 39b. Injection nozzle and injection

nozzle holder (4JA1TC, 4JH1TC)

J

40. Cylinder head cover

IMPORTANT OPERATIONS

1. Cylinder Body

Use compressed air to thoroughly clean the inside and

outside surfaces of the cylinder body, the oil holes, and the

water jackets.

2. Tappet

1) Apply a coat of engine oil to the tappet  and the

cylinder body tappet insert holes .

2) Locate the position mark applied at disassembly (if the

tappet is to be reused).

Note:

The tappet must be installed before the camshaft

installation.

3. Crankshaft Upper Bearing

The crankshaft upper bearings have an oil hole and an oil

groove. The lower bearings do not.

1) Carefully wipe any foreign material from the upper

bearing.

Note:

Do not apply engine oil to the bearing back faces and

the cylinder body bearing fitting surfaces.

2) Locate the position mark applied at disassembly if the

removed upper bearings are to be reused.

4. Crankshaft

Apply an ample coat of engine oil to the crankshaft

journals and the crankshaft bearing surfaces before

installing the crankshaft.

5. Crankshaft Thrust Bearing

Apply an ample coat of engine oil to the thrust bearings

before installation.

Install the thrust bearings to the crankshaft center journal.

The thrust bearing oil grooves must be facing the sliding

faces.

6. Crankshaft Bearing Cap With Lower Bearing

Before the crankshaft bearing installation, select the

appropriate bearings in accordance with the description in

CRANK BEARING SELECTION of INSPECTION AND

REPAIR.

1) Apply the recommended liquid gasket or its equivalent

to the No. 5 crankshaft bearing cap  as shown in the

illustration.

2) Install the arch gasket  to the No. 5 bearing cap.

Use your fingers to push the arch gasket into the

bearing cap groove.

Take care not to scratch the arch gasket outer

surface.

3) Apply the recommended liquid gasket or its equivalent

to the No. 5 crankshaft bearing cap cylinder body

fitting surfaces at the points () shown in the

illustration.

Note:

Be sure that the bearing cap fitting surface is

completely free of oil before applying the liquid

gasket.

Do not allow the liquid gasket to obstruct the cylinder

thread holes and bearings.

4) Install the bearing caps with the bearing cap head

arrow mark facing the front of the engine.

The bearing cap numbers must be facing up.

5) Apply engine oil to the crankshaft bearing cap bolts.

6) Temporarily tighten the bearing cap bolts.

The bolts will be tightened to the specified torque after

the crankshaft rear oil seal is installed.

7. Crankshaft Rear Oil Seal

1) Tighten the adapter to the crankshaft rear end section

with 2 bolts.

2) Insert the oil seal into the peripheral section of the

adapter.

3) Insert the sleeve into the adapter section, and 1)

tighten it with a bolt (M12 × 1.75L = 70) until the

adapter section hits the sleeve.

4) Remove the adapter and the sleeve.

5) With the seal pressed in, check the dimension of the

oil seal section.

Standard Dimension = 12.5 ± 0.3 mm

Oil Seal Installer: 5-8840-2359-0

8. Camshaft

1) Apply a coat of engine oil to the camshaft and the

camshaft bearings.

Install the camshaft to the cylinder body.

Take care not to damage the camshaft bearings.

9. Timing Gear Case

1) Tighten the timing gear case with timing gear case

gasket to the specified torque.

Timing Gear Case Bolt Torque kg·m (lb.ft/N·m)

1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

10. Camshaft Thrust Plate

Install the thrust plate to the cylinder body and tighten the

thrust plate bolts to the specified torque.

Thrust Plate Bolt Torque kg·m (lb.ft/N·m)

1.8 ± 0.5 (13.0 ± 3.6/17.6 ± 4.9)

11. Camshaft Timing Gear

1) Install the camshaft timing gear to the camshaft.

The timing gear mark (“Y – Y” or “”) must be facing

outward.

2) Tighten the timing gear to the specified torque.

Timing Gear Bolt Torque kg·m (lb.ft/N·m)

11.0 ± 1 (79.6 ± 7.2/107.8 ± 9.8)

12. Crankshaft Timing Gear

Use the crankshaft timing gear installer  to install the

crankshaft timing gear .

The crankshaft timing gear setting mark (“X – X” or “”)

must be facing outward.

Crankshaft Timing Gear Installer: 9-8522-0020-0

13. Idler Gear Shaft

14. Idler Gear “A”

1) Apply engine oil to the idler gear and the idler gear

shaft.

The idler gear shaft oil hole A must be facing up.

2) Position the idler gear setting marks “X” or “”, “Y” or

“” and “Z” or “” so that they are facing the front of

the engine.

3) Align the idler gear “X” or “” setting mark with the

crankshaft timing gear  “X – X” or “” setting mark.

4) Align the idler gear “Y” or “” setting mark with the

camshaft timing gear  “Y – Y” or “ ” setting mark.

5) Install the thrust collar and bolts to the cylinder body

through the shaft.

The thrust collar oil hole must be facing up, and the

thrust collar chamfered must be outward.

6) Tighten the idler gear bolt to the specified torque.

Idler Gear “A” Bolt Torque kg·m (lb.ft/N·m)

3.0 ± 0.5 (21.7 ± 3.6/30 ± 5.0)

15. Idler Gear “B” and Shaft

1) Apply engine oil to the idler gear and the idler gear

shaft.

2) Align the idler gear “B”  “Z” or “” setting mark with

the idler gear “A”  “Z – Z” or “” setting mark.

3) Tighten the idler gear bolt to the specified torque.

Idler Gear “B” Bolt Torque kg·m (lb.ft/N·m)

7.7 ± 1.0 (55.7 ± 7.2/74 ± 9.8)

15a. If the idle gear “B” is disassemble, reassemble in the

following procedure.

Idle Gear B (scissor gear) Reassembly Steps (4JH1TC

only)

1) Drive pins into the main gear, the front gear, and the

rear gear.

2) Apply pressure to the main gear bearing from the front

side of the main gear (the side with the groove).

3) Place the special tool in a vise so that the main gear is

pushed up toward the rear side.

Scissor gear setting tool

Base 5-8673-9149-0

4) Set the spring as shown in the illumination.

5) Position the rear gear so that it pin is aligned with the

receiving end of the spring.

6) Install the snap ring to the main gear groove.

7) Set the rear gear setting hole to the pin of the special

tool.

8) Place the special tool in a vise so that the main gear is

pushed up toward the front side.

9) Repeat Steps 3, 4, and 5.

10) Use the special tool to mesh the teeth of the front

gear, the main gear, and the rear gear.

Scissor gear setting tool

Lever 5-8673-9150-0

11) Insert a lock bolt (M6×1 L=30) into the scissor gear

fixing hole to prevent the scissor gear from turning.

16. Timing Gear Oil Pipe (Except 4JH1TC)

1) Install the oil pipe to the timing gear case and idler

gear “A”.

2) Tighten the oil pipe eye bolt  and bolt  to the

specified torque.

Eye Joint and Bolt Torque kg·m (lb.ft/N·m)

1.25 ± 0.25 (9.0 ± 1.8/12.3 ± 2.5)

17. Injection Pump

1) Install the O-ring  to the injection pump flange .

2) Install the injection pump to the timing gear case.

Align the idler gear “B”  “V – V” or “” mark with the

injection pump timing gear  “V” or “” mark.

3) Install the injection pump rear bracket  and the rear

bracket bolts  to the cylinder body.

4) Install the rear bracket bolts  to the injection pump

bracket .

5) Tighten the injection pump bracket bolts to the

specified torque.

Injection Pump Bracket Bolt Torque kg·m (lb.ft/N·m)

, 1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

4.1 ± 0.6 (29.6 ± 4.3/40.2 ± 5.9)

4JH1TC

1) Install the O-ring  to the injection pump flange .

2) Install the injection pump to the timing gear case.

Align the idler gear “B”  “” mark with the injection

pump timing gear  “” mark.

3) Install the injection pump bracket.

4) Tighten the injection pump bracket bolts to the

specified torque.

Injection Pump Bracket Bolt Torque kg·m (lb.ft/N·m)

4.1 ± 0.6 (29.6 ± 4.3/40.2 ± 5.9)

5) Remove the scissor gear set bolt.



18. Timing Gear Case Cover

6) Align the gear case with the timing gear case knock

pin and then install the timing gear case cover.

7) Tighten the gear case cover bolts to the specified

torque.

Gear Case cover Bolt Torque kg·m (lb.ft/N·m)

1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

19. Crankshaft Damper Pulley

Tighten the crankshaft damper pulley bolt to the specified

torque.

Note:

Hold the flywheel ring gear stationary to prevent the

crankshaft from turning when tightening the damper

pulley.

Crankshaft Damper Pulley Bolt Torque kg·m (lb.ft/N·m)

21.0 ± 2.0 (151.9 ± 14.5/206.0 ± 19.6)

Take care not to damage the crankshaft damper pulley

boss.

20. Piston and Connecting Rod with Upper Bearing

21. Connecting Rod Bearing Cap with Lower Bearing

1) Apply a coat of engine oil to the circumference of each

piston ring and piston.

2) Position the piston ring gaps as shown in the

illustration.

Oil ring

 2nd compression ring

 1st compression ring

3) Apply a coat of molybdenum disulfide grease to the

two piston skirts.

This will facilitate smooth break-in when the engine is

first started after reassembly.

4) Apply a coat of engine oil to the upper bearing

surfaces.

5) Apply a coat of engine oil to the cylinder w all.

6) Position the piston head front mark so that it is facing

the front of the engine.

7) Use the piston ring compressor to compress the

piston rings.

Piston Ring Compressor: 5-8840-9018-0 (J-8037)

8) Use a hammer grip to push the piston in until the

connecting rod makes contact with the crankpin.

At the same time, rotate the crankshaft until the

crankpin is at BDC.

9) Align the bearing cap cylinder number marks and the

connecting rod cylinder number marks.

The cylinder number marks must be turned toward the

exhaust manifold.

10) Apply a coat of engine oil to the threads and setting

faces of each connecting rod cap bolt.

11) Tighten the connecting rod caps to the specified

torque.

Connecting Rod Bearing Cap Bolt

Torque kg·m (lb.ft/N·m)

1st step ; 3.0 ± 0.5(21.7 ± 3.6 / 29

± 5)

4JB1T / 4JH1TC

engine 2nd step ; 45° ~ 75°

22. Pis ton Cooling Oil Pipe

1) Install the piston cooling oil pipe to the cylinder body.

2) Tighten the oil pipe bolts and relief valve to the

specified torque.

Oil Pipe Bolt Torque kg·m (lb.ft/N·m)

 M8 × 1.25 1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

 M6 × 1.00 0.8 ± 0.2 (5.8 ± 1.5/7.8 ± 2.0)

Relief valve Torque kg·m (lb.ft/N·m)

 M16 × 1.5 3.0 ± 0.5 (21.7 ± 3.6/29.4 ± 4.9)

Note:

Check that there is no interference between the piston

and the oiling jet pipe T

TT

T by slowly rotating the

crankshaft.

23. Oil Pump with Oil Pipe

Install the oil pump with the oil pipe and tighten the bolts to

the specified torque.

Oil Pump Bolt Torque kg·m (lb.ft/N·m)

1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

Note:

Take care not to damage the O-rings when tightening

the oil pipe bolts.

24. Oil Pan

1) Apply the recommended liquid gasket (three bond

TB1207 & TB1207C) or its equivalent to arch gasket

fitting surface as shown in the illustration.

2) Install the crank case front gasket 1 to the timing gear

case ar ches.

The gasket projection 2 must be facing forward.

3) Install the rear arch gasket 2 to the No. 5 bearing cap.

Use your fingers to push the arch gasket into the

bearing cap groove.

Take care not to scratch the arch gasket outer

surface.

Also apply the recommended liquid gasket (TB1207B

& TB1207C) or its equivalent to arch gasket fitting

area as indicated in the illustration.

4) Apply the recommended liquid gasket or its equivalent

to groove of the crank case fitting surface as shown in

the illustration.

Note:

Be sure that the crank case fitting surface is

completely free of oil and dust before applying the

liquid gasket.

5) Install the crank case to the cylinder body.

6) Tighten the crank case bolts to the specified torque a

little at a time in the sequence shown in the illustration.

Crank Case Bolt Torque kg·m (lb.ft/N·m)

1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

25. Cylinder Body Rear Plate

1) Align the rear plate with the cylinder body knock pins.

2) Tighten the rear plate to the specified torque.

Rear Plate Torque kg·m (lb.ft/N·m)

8.4 ± 0.8 (60.8 ± 5.8/83.3 ± 7.8)

26. Flywheel

1) Block the crankshaft with a piece of hard wood to

prevent the flywheel from turning.

2) Apply a coat of engine oil to the threads of the flywheel

bolts.

3) Align the flywheel with the crankshaft dowel pin.

4) Tighten the flywheel bolts to the specified torque in the

numerical order shown in the illustration.

Flywheel Bolt Torque kg·m (lb.ft/N·m)

12.0 ± 0.5 (86.8 ± 3.6/117.6 ± 4.9)

26. Injection Pump

1) Install the injection pump  to the timing pulley

housing .

2) Temporarily tighten the three injection pump nuts .

The injection pump nuts will be finally tightened after

the injection pump rear bracket bolts.

3) Install the injection pump rear bracket  and the rear

bracket bolts  to the cylinder body.

4) Install the rear bracket bolts  to the injection pump

bracket.

Do not tighten the bolts.

The rear bracket bolts  and  will be finally tighten

tened to the specified torque after the injection pump

nuts.

5) Tighten the injection pump nuts to the specified

torque.

Injection Pump Nut and Bracket Bolt

Torque kg·m (lb.ft/N·m)

, 1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

32. Cylinder Head Gasket

The cylinder head gasket “TOP” mark must be facing up.

Note:

Before the gasket installation, measure the piston

head projection and select the appropriate head

gasket.

Refer to “INSPECTION AND REPAIR”, “Cylinder Head

Gasket Selection”.

33. Cylinder Head

1) Align the cylinder body dowels and the cylinder head

dowel holes.

Carefully place the cylinder head on the cylinder head

gasket.

2) Apply a coat of engine oil to the cy linder head bolt

threads and setting faces.

3) Tighten the cylinder head bolts in two steps.

Follow the numerical sequence shown in the

illustration.

Cylinder Head Bolt Torque kg·m (lb.ft/N·m)

1st Step 2nd Step 3rd Step

5.0 ± 0.5

(36.2 ± 3.6/49.00 ± 4.90) 60° ~ 75°60° ~ 75°

Cylinder Head Bolt Torque kg·m (lb.ft/N·m)

1st Step 2nd Step

New

bolt

5.0 ± 0.5

(36.2 ± 3.6/

83.3 ± 4.9)

8.7 ± 0.5

(62.9 ± 3.6/

85.26 ± 4.90)

4JB1

For

CHINA

only Reuse

bolt

8.5 ± 0.5

(61.4 ± 3.6/

83.3 ± 4.9)

10.5 ± 0.5

(75.9 ± 3.6/

102.90 ± 4.90)

35. Rocker Arm Shaft and Rocker Arm

Tighten the rocker arm shaft bracket bolts in the numerical

order shown in the illustration.

Rocker Arm Shaft Bracket Bolt Torque kg·m (lb.ft/N·m)

5.5 ± 0.5 (39.8 ± 3.6/53.9 ± 4.9)

36. Thermostat Housing

1) Install the thermostat housing.

2) Tighten the thermostat housing bolts to the specified

torque.

Thermostat Housing Bolt Torque kg·m (lb.ft/N·m)

1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

38. Glow Plug and Glow Plug Connector

1) Install the glow plugs to the cylinder head.

2) Tighten the glow plugs to the specified torque.

Glow Plug Torque kg·m (lb.ft/N·m)

2.25 ± 0.25 (16.3 ± 1.8/22.1 ± 2.5)

3) Install the glow plug connector.

39. Injection Nozzle Holder

1) Install the injection nozzle gasket  and the O-ring 

to the injection nozzle holder .

Be sure that the O-ring fits snugly in the injection

nozzle groove.

2) Install the nozzle holder toghther with the nozzle holder

bracket  to the cylinder head.

Nozzle Holder Bracket Bolt Torque kg·m (lb.ft/N·m)

3.8 ± 0.6 (27.5 ± 4.3/37.2 ± 5.9)

3) Tighten the holder nut with washer  to the specified

torque.

Injection Nozzle Holder Nut Torque kg·m (lb.ft/N·m)

3.8 ± 0.6 (26.0 ± 4.3/37.2 ± 5.9)

IMPORTANT OPERATIONS

39a.Nozzle Holder Assembly (4JG2T Engine)

Install the parts in sequence of corrugated washer, nozzle

gasket and nozzle holder.

Do not reuse the corrugated washer and nozz le gasket.

Use the new one.

The corrugated washer should be installed with blue color

painted side turned to the nozzl e.

Tighten the nozzle holder.

Nozzle Holder Torque kg·m (lb.ft/N·m)

6.5 ± 0.5 (47.0 ± 3.6/63.7 ± 4.9)

Install the leak-off pipe via the copper gasket.

Leak Off Pipe Torque kg·m (lb.ft/N·m)

3.5 – 4.7 (25.3 – 34.0/34.3 – 46.1)

NOTE ON VALVE CLEARANCE ADJUSTMENT

Valve clearances must be adjusted before the cylinder

head cover is reinstalled.

Refer to “Valve Clearance Adjustment” in the “Servicing”

Section of this Manual.

40. Cylinder Head Cover

1) Apply engine oil to the rocker arm and the valve

spring.

2) Install the cylinder head cover gasket to the head

cover.

Check to see that the head cover gasket has no loose

areas.

3) Tighten the cylinder head cover nuts in the numerical

order shown in the illustration.

Cylinder Head Cover Bolt Torque kg·m (lb.ft/N·m)

1.3 ± 0.5 (9.4 ± 3.6/12.7 ± 4.9)

4) Connect the PCV hose to the cylinder head cover.

External Parts

These installation steps are based on the 4JB1T engine.

INSTALLATION STEPS

J

1. Generator bracket

J

16. Intake manifold

J

2. Water inlet pipe

J

17. Compressor bracket

J

3. Heater pipe (Rear side)

J

18. Compressor

J

4. Generator and adjusting plate

J

19. Starter motor

J

5. Engine mounting bracket

J

20. Power steering oil pump bracket

J

6. Exhaust manifold

J

21. Power steering oil pump

7. Exhaust manifold heat protector 22. Water drain cock

J

8. Turbocharger 23. Oil pressure warning switch and

J

9. Turbocharger oil return pipe nipple

J

10. Turbocharger oil feed pipe 24. Oil level gauge guide tube

J

11. Oil cooler with Oil filter

J

25. Cooling fan pulley

12. Turbocharger heat protector

J

26. Cooling fan drive belt

13. Injection pump 27. Vacuum pipe

J

14. Fuel injection pipe with clip

15. Fuel leak off pipe

IMPORTANT OPERATIONS

1. Generator Bracket

Install the generator bracket to the cylinder body and

tighten the bracket bolts to the specified torque.

Bracket Bolt Torque kg·m (lb.ft/N·m)

4.1 ± 0.6 (29.7 ± 4.3/40.2 ± 5.9)

2. Water Inlet Pipe

1) Tighten the water inlet pipe bolts to the specified

torque.

Suction Pipe Bolt Torque kg·m (lb.ft/N·m)

1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

3. Heater Pipe (Rear Side)

1) Install the heater pipe to the cylinder head.

2) Connect the oil cooler return hose and feed hose to

the oil cooler.

3) Connect the water rubber hose to the heater pipe.

4. Generator and Adjusting Plate

1) Install the generator to the bracket Q.

2) Temporarily tighten the generator bolt R and

adjusting plate bolts S.

The bolts will be finally tightened after installation of

the cooling fan drive belt.

3) Connect the vacuum pump rubber hose T to the

vacuum pump U, and the oil pan V.

4) Connect the vacuum oil pipe W to the vacuum pump,

and the cylinder body.

5. Engine Mounting Bracket

Install the engine mounting bracket to the cylinder body

and tighten the bracket bolts to the specified torque.

Mounting Bracket Bolt Torque kg·m (lb.ft/N·m)

Right Side M10 × 1.25 (9T) 5.6 (40.5/54.9)

RM10 × 1.25 (7T) 4.1 (30/40)

Left Side RM14 × 1.50 (7T) 12 (86.7/118)

6. Exhaust Manifold

1) Install the exhaust manifold Q to the cylinder head R

with the manifold gasket S.

2) Tighten the exhaust manifold bolts to the specified

torque a little at a time.

Exhaust Manifold Bolt Torque kg·m (lb.ft/N·m)

2.7 ± 0.5 (19.5 ± 3.6/26.5 ± 4.9)

3) Install the exhaust manifold bracket to the manifold

and the cylinder body.

Manifold Bracket Bolt Torque kg·m (lb.ft/N·m)

1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

8. Turbocharger

1) Install the turbocharger and the gasket.

2) Temporarily tighten the turbocharger nuts at this time.

They will be fully tightened after the installation of the

turbocharger oil pipe.

Always install new nuts and new gasket.

3) Install the exhaust adapter with gasket and tighten the

adapter nut to the specified torque.

Adapter Nut Torque kg·m (lb.ft/N·m)

2.7 ± 0.5 (19.5 ± 3.6/26.5 ± 4.9)

9. Turbocharger Oil Return Pipe

1) Install the oil return pipe with gasket to the

turbocharger.

2) Tighten the turbocharger oil return pipe to the

specified torque.

Turbocharger Oil Reutrn Pipe Torque kg·m (lb.ft/N·m)

0.8 ± 0.2 (5.8 ± 1.4/7.8 ± 2.0)

10. Turbocharger Oil Feed Pipe

1) Before installing the oil feed pipe, supply 10 – 20 cc of

clean engine oil to the turbocharger center housing

through the oil feed opening.

2) Turn the rotating assembly with your hand to

thoroughly lubricate the internal parts.

3) Tighten the oil feed pipe to the specified torque.

Turbocharger Oil Feed Pipe Joint

Bolt Torque kg·m (lb.ft/N·m)

QM10 × 1.5 2.25 ± 0.25 (16.3 ± 1.8/22.1 ± 2.5)

RM14 × 1.5 5.5 ± 0.25 (39.8 ± 1.8/53.9 ± 2.5)

4) Tighten the turbocharger nut to the specified torque.

Turbocharger Nut Torque kg·m (lb.ft/N·m)

2.7 ± 0.5 (19.5 ± 3.6/26.5 ± 4.9)

11. Oil Cooler with Oil Filter

1) Install the O-ring to the oil filter flange groove.

2) Tighten the oil filter and oil cooler to the specified

torque.

Oil Filter Flange Bolt Torque kg·m (lb.ft/N·m)

1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

3) Lightly oil the O-ring of oil filter cartridge.

4) Turn in the new oil filter cartridge by hand until the

sealing face is fitted again the O-ring.

5) Use the filter wrench to turn in the oil filter and

additional one and 1·1/8 turns.

6) Start the engine and check for oil leakage from oil

filter.

13. Fuel Injection Pipe with Clip

1) Temporarily tighten the injection pipe sleeve nut.

2) Set the clip in the illustrated position.

Note:

Make absolutely sure that the clip is correctly

positioned.

An improperly positioned clip will result in injection

pipe breakage and fuel pulsing noise.

3) Tighten the injection pipe sleeve nut to the specified

torque.

Injection Pipe Sleeve Nut Torque kg·m (lb.ft/N·m)

3 ± 1 (21.7 ± 7.2/29.4 ± 9.8)

16. Intake Manifold

1) Install the manifold gasket to the intake manifold.

2) Connect the intake rubber hose to the intake duct.

3) Tighten the intake manifold bolts and the flange nuts

to the specified torque.

Intake Manifold Bolt Torque kg·m (lb.ft/N·m)

1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

Intake Manifold Flange Nut Torque kg·m (lb.ft/N·m)

1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

4) Connect the PCV hose to the cylinder head cover.

17. Compressor Bracket

1) Install the compressor bracket to the cylinder head.

2) Tighten the bracket bolts to the specified torque.

Bracket Bolt Torque kg·m (lb.ft/N·m)

QM 8 × 1.25 1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

RM10 × 1.25 4.1 ± 0.6 (30 ± 7.2/40 ± 6)

18. Compressor

1) Install the compressor to the compressor bracket.

2) Tighten the compressor bolts to the specified torque.

Compressor Bolt Torque kg·m (lb.ft/N·m)

3.8 ± 1.0 (27.5 ± 7.2/37.2 ± 9.8)

19. Starter Motor

Tighten the starter motor bolts to the specified torque.

Starter Motor Bolt Torque kg·m (lb.ft/N·m)

7.0 ± 1.0 (50.6 ± 7.2/68.6 ± 9.8)

20. Power Steering Oil Pump Bracket

21. Power Steering Oil Pump

1) Install the oil pump bracket to the cylinder head.

2) Tighten the pump bracket nut and bolts to the

specified torque.

Oil Pump Bracket Nut and Bolt

Torque kg·m (lb.ft/N·m)

QM10 × 1.25 (7T) 3.75 ± 0.95

(27.1 ± 6.9/36.75 ± 9.31)

RM 8 × 1.25 (7T) 1.75 ± 0.55

(12.7 ± 4.0/17.75 ± 5.39)

SM 8 × 1.25 (4T) 1.30 ± 0.50

(9.4 ± 3.6/12.74 ± 4.90)

3) Install the oil pump to the bracket.

4) Temporarily tighten the oil pump nut Q and bolts R.

The nut and bolts will be finally tightened after

installation of the drive belt.

25. Cooling Fan Pulley

1) Install the cooling fan pulley to the water pump with

spacer.

2) Tighten the cooling fan pulley bolts to the specified

torque.

Cooling Fan Pulley Bolt Torque kg·m (lb.ft/N·m)

0.8 ± 0.2 (5.8 ± 1.4/7.8 ± 2.0)

26. Cooling Fan Drive Belt

Install the fan drive belt and adjust the belt tension

referring SERVICING of this section.

EGR PIPE ( IF EQUIPPED)

Install EGR pipe and tighten fixing bolt and nuts to the

specified torque.

Bolt kg·m (lb.ft/N·m)

2.7 ± 0.5 (19.5 ± 3.6/26.5 ± 4.9)

Nuts kg·m (lb.ft/N·m)

2.4 ± 0.5 (17.4 ± 3.6/23.5 ± 4.9)

Special Tool s

Illustration Tool Number Tool Name

5-8840-0200-0 (4JG2T,

4JB1T, 4JA1T, 4JA1TC,

4JH1TC)

5-8840-0201-0 (4JA1)

Filter Wrench

5-8840-0253-0

(J-22700) Filter Wrench

5-8840-0145-0

(J-28827) Static Timing Gauge

5-8840-2675-0 Compression Gauge

5-8531-7001-0 Adapter; Compression Gauge

5-8840-2034-0 Nozzle Holder Remover

5-8840-0019-0

(J-23907) Sliding Hammer

5-8840-0161-0 Fixing Wrench

5-8840-0086-0 Timing Pulley Puller

5-8521-0002-0 Universal Puller

5-8840-2362-0 Oil Seal Remover

Illustration Tool Number Tool Name

9-8523-1423-0

(J-29760) Spring Compressor

9-8523-1212-0 Valve Guide Replacer

5-8840-2039-0

5-8840-2304-0

(4JG2T, 4JH1TC)

Cylinder Liner Remover

5-8840-2040-0

5-8840-2313-0

(4JG2T, 4JH1TC) Cylinder Liner Installer

5-8840-2038-0 Bearing Replacer; Camshaft

5-8840-2000-0 Pilot Bearing Remover

5-8522-0024-0 Pilot Bearing Installer

5-8840-2361-0 Front Oil Seal Installer

Illustration Tool Number Tool Name

5-8840-2033-0 Oil Seal Installer

5-8840-9018-0

(J-8037) Piston Ring Compressor

5-8840-2359-0 Oil Seal Installer

9-8522-0020-0 Crankshaft Timing Gear Installer

5-8840-0266-0 Angle Gauge

Base

5-8673-9149-0

Lever

5-8673-9150-0

Scissor gear setting tool