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FOR SERVICE TRAINING
4JJ1-TC ENGINE
-Engine Mechanical Features-
-Engine Control System & Diagnosis-
Applicable Model
Model Year
Vehicle Model
Main Market
2005
TFR/TFS
Thailand
2005
UCR/UCS
Thailand & Philippine
ISUZU MOTORS LIMITED
https://www.automotive-manuals.net/
Related Manuals for Isuzu 4JJ1-TC
Summary of Contents for Isuzu 4JJ1-TC
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Page 1
FOR SERVICE TRAINING 4JJ1-TC ENGINE -Engine Mechanical Features- -Engine Control System & Diagnosis- Applicable Model Model Year Vehicle Model Main Market 2005 TFR/TFS Thailand 2005 UCR/UCS Thailand & Philippine ISUZU MOTORS LIMITED https://www.automotive-manuals.net/… -
Page 2: Table Of Contents
DAFTAR ISI Page PENDAHULUAN & FITUR MEKANIKAL —————————————————————————— MESIN —————————————————————————— DATA UTAMA MESIN & SPESIFIKASI ENGINE CONTROL MODULE (ECM) —————————————————————————— KOMPONEN ELEKTRIKAL —————————————————————————— MASS AIR FLOW (MAF) SENSOR & INTAKE —————————————————————————— AIR TEMPERATURE (IAT) SENSOR ENGINE COOLANT TEMPERATURE (ECT) —————————————————————————— SENSOR FUEL TEMPERATURE (FT) SENSOR ——————————————————————————…
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Page 3
—————————————————————————— MESIN BERPUTAR TETAPI TIDAK HIDUP —————————————————————————— ECM DIAGNOSTIC TROUBLE CODE (DTC) LIST —————————————————————————— 111 HASIL DIAGNOSA GEJALA CHECK SHEET ENGINE CONTROL SYSTEM —————————————————————————— WIRING DIAGRAM ELEKTRIKAL —————————————————————————— 134 —————————————————————————— DISTRIBUSI POWER (1 of 2) —————————————————————————— DISTRIBUSI POWER (2 of 2) —————————————————————————— 136 STARTING &… -
Page 4: Pendahuluan & Fitur Mekanikal
INTRODUCTION & ENGINE MECHANICAL FEATURES Truck pick-up TFR/ TFS dan UCR/UCS tahun 2007 memakai mesisn 4JK1-TC pengganti mesin 4JA1-T dan mesin 4JJ1-TC pengganti mesin 4JH1- T. Kedua mesin telah dikembangkan sebagai mesin generasi terbaru dengan tambahan fitur utama yaitu penggunaan common…
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Page 5: Data Utama Mesin & Spesifikasi
4JJ1-TC Engine-2 1. Fuel Rail 2. Leak Off Pipe 3. Fuel Injector 4. Return Pipe 5. Fuel Feed Pipe 6. Fuel Tank 7. Fuel Pump & Sender Assembly 8. Fuel Filler Cap 9. Check Valve 10. Fuel Filter with Water Separator 11.
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Page 6
4JJ1-TC Engine-3 Valve System Valve Layout Double Overhead Camshaft Drive Type Gear & Chain Drive Intake Valve Open At BTDC (°CA) 13.0 Intake Valve Close At ABDC (°CA) 41.0 Exhaust Valve Open At BBDC (°CA) 52.0 Exhaust Valve Close At ATDC (°CA) Intake Valve Clearance At Cold (mm) 0.15 (Between roller and camshaft) -
Page 7: Engine Control Module (Ecm)
1. Isuzu Parts Number 2. Delphi Parts Number 3. Transmission Type 4. 1 & last digit of Isuzu Parts Number 5. Broadcast Code 6. Assembled Factory Code 7. Engineering Revision Level 8. Product Date 9.
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Page 8
4JJ1-TC Engine-5 ECM Connector Pin Assignment Pin No. Fungsi Pin Pin No. Fungsi Pin Pin No. Fungsi Pin Engine Coolant Temperature (ECT) No. 3 Cylinder Fuel Injector Power J1-1 Blank J1-26 J1-51 Sensor Low Reference Supply Engine Coolant Temperature (ECT) No. -
Page 9
4JJ1-TC Engine-6 Pin No. Fungsi Pin Pin No. Fungsi Pin Pin No. Fungsi Pin Accelerator Pedal Position (APP) J2-1 Not Used J2-26 J2-51 Not Used Sensor 2 Shield Ground Diagnostic Request Switch to Data Accelerator Pedal Position (APP) J2-2 J2-27 J2-52 Battery Voltage Feed (Backup) Link Connector (DLC) No. -
Page 10: Fitur Common Rail System
4JJ1-TC Engine-7 DTC yang berhubungan Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Status Menjalankan Kemungkinan Penyebab (Kode Injection Scan Tool Menentukan DTC Intake Control Gejala) Quantity Throttle Lainnya Control Limitation Control P0601 ECM Program Total data ROM Kerusakan ECM.
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Page 11
4JJ1-TC Engine-8 ECM memonitor tegangan battery pada ECM main relay tegangan beban supply pada terminal J2-73 dan ignition voltage pada terminal ignition voltage J2-72 untuk me- mastikan apakah tegangan ada pada range yang sasuai Saat charging system mendeteksi ada malafungsi maka charge indicator akan menyala. -
Page 12
4JJ1-TC Engine-9 DTC yang berhubungan Fail-Safe (Back Up) Sub System Status Fuel Nama DTC di Kondisi untuk Kondisi untuk Status Kemungkinan Penyebab (Kode Injection Scan Tool Menjalankan DTC Menentukan DTC Intake Control Gejala) Quantity Throttle Lainnya Control Limitation Control P0562… -
Page 13
4JJ1-TC Engine-10 DTC yang berhubungan Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Status menjalankan Kemungkinan Penyebab (Kode Injection Scan Tool Menentukan DTC Intake kontrol Gejala) Quantity Throttle lainnya Control Limitation Control P1620 5 Volt… -
Page 14
4JJ1-TC Engine-11 DTC yang berhubungan Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Status menjalankan Kemungkinan Penyebab (Kode Injection Scan Tool menentukan DTC Intake Control Gejala) Quantity Throttle lainnya Control Limitation Control P1622 5 Volt… -
Page 15
4JJ1-TC Engine-12 DTC yang berhubungan Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Status Menjalankan Kemungkinan Penyebab (Kode Injection Scan Tool Menentukan DTC Intake Control Gejala) Quantity Throttle Lainnya Control Limitation Control P1624 5 Volt… -
Page 16: Komponen Elektrikal
4JJ1-TC Engine-13 ELECTRICAL COMPONENTS MASS AIR FLOW (MAF) SENSOR & INTAKE AIR TEMPERATURE (IAT) SENSOR Mass air flow (MAF) sensor adalah alat pengukur aliran udara yang mengukur jumlah udara yang masuk ke mesin. MAF diikatkan antara air cleaner dan turbocharger. MAF sensor menggunakan hot wire element untuk menentukan jumlah udara yang mengalir masuk ke mesin.
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Page 17
4JJ1-TC Engine-14 Intake air t emperature (IAT) sensor diikatkan diantara Ohms IAT Sensor Characteristic -Reference- air cleaner dan turbocharger. IAT berada didalam MAF Volts sensor. IAT sensor adalah sebuah variable resistor. IAT sensor mengukur t emperatur udara yang masuk ke 14000 dalam mesin. -
Page 18
4JJ1-TC Engine-15 MAF & IAT Sensor Connector Face DTC yang berhubungan Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Status Menjalankan Kemungkinan Penyebab (Kode Injection Scan Tool Menentukan DTC Intake Control Gejala) Quantity Throttle… -
Page 19: Engine Coolant Temperature (Ect)
4JJ1-TC Engine-16 ENGINE COOLTANT TEMPERATURE (ECT) SENSOR Engine coolant temperature (ECT) sensor dipasangkan di coolant stream pada thermostat housing. ECT adalah sebuah variable resistor. ECT sensor mengukur tempe- ratur dari cairan pendingin mesin. Engine control modul (ECM) mensupply tegangan 5volts ke ECT sensor signal circuit dan sebuah ground untuk ECT sensor low referen ce circuit.
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Page 20
4JJ1-TC Engine-17 ECT Sensor Connector Face Related DTC Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Menjalankan Kemungkinan Penyebab (Kode Injection Status Control Scan Tool Menentukan DTC Intake Gejala) Quantity Lainnya Throttle Control Limitation… -
Page 21: Fuel Temperature (Ft) Sensor
4JJ1-TC Engine-18 FUEL TEMPERATURE (FT) SENSOR Sensor FT dipasang ke fuel supply pump. Sensor FT adalah sebuah variable resistor. FT sensor mengukur temperature dari bah an bakar yang masuk fuel supply pump. Engine control module (ECM) mensuplai 5volts ke FT signal circuit dan ground untuk FT sensor low re- ference circuit.
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Page 22
4JJ1-TC Engine-19 FT Sensor Connector Face Related DTC Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Menjalankan Kemungkinan Penyebab (Kode Injection Status Control Scan Tool Menentukan DTC Intake Gejala) Quantity Lainnya Throttle Control Limitation… -
Page 23: Crankshaft Position (Ckp) Sensor
4JJ1-TC Engine-20 CRANKSHAFT POSITION (CKP) SENSOR & CAMSHAFT POSITION (CMP) SENSOR Crankshaft position (CKP) sensor ditempatkan disebelah kiri cylinder block dibelakang motor starter. Sensor wheel wheel dipasangkan pada crankshaft. Terdapat 56 notches dengan jarak/notch 6° dan jarak 24° bagian yg dipotong.
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Page 24
4JJ1-TC Engine-21 Camshaft position (CMP) sensor dipasangkan pada chain sprocket cover di bagian paling depan. CMP sensor mendeteksi total 5 (lima) proyeksi, 4(empat) proyeksi di- atur sama tiap jarak 90° dan satu referensi proyeksi pada permukaan camshaft drive sprocket flange, memberikan mengirimkan signals ke engine control module (ECM). -
Page 25
4JJ1-TC Engine-22 No.1TDC No.3TDC 30°CA 90°CA No.1TDC 90°CA 90°CA 30°CA 6°CA Hubungan CKP sensor dan CMP sensor ditunjukan pada gambar diatas. ECM mendeteksi 112 pulse dari CKP sen sor (56 x 2) dan 5 pulse dari CMP sensor per 2 rotasi crankshaft (720°CA). -
Page 26
4JJ1-TC Engine-23 Dalam hal timing chain salah pemasangannya, bentuk gelombang referensi tiap sensor ditunjukan gambar di 19deg.CA samping ini. Di kasus ini timing chain terpasang hanya satu gigi lompat mundur dari arah drive sprocket. CMP sensor signals mundur kira-kira 19°CA dari posisi yang benar (A). -
Page 27
4JJ1-TC Engine-24 Related DTC Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Status Menjalankan Kemungkinan Penyebab (Kode Injection Scan Tool Menentukan DTC Intake Control Gejala) Quantity Throttle Lainnya Control Limitation Control P0219 Engine Engine speed lebih Engine overrun. -
Page 28
4JJ1-TC Engine-25 Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Status Menjalankan Kemungkinan Penyebab (Kode Injection Scan Tool Menentukan DTC Intake Control Gejala) Quantity Throttle Lainnya Control Limitation Control P0340 Camshaft Battery voltage Tidak ada pulse… -
Page 29: Vehicle Speed (Vs) Sensor
4JJ1-TC Engine-26 VEHICLE SPEED (VS) SENSOR Vehicle speed (VS) sensor adalah magnet yang diputar oleh output shaft transmisi. VS sensor menggunakan hall effect element. Berhubungan dengan magnetic field yang dihasilkan dengan memutarkan magnet dan output nya square wave pulse signal. Tegangan 12volts disu- play dari fuse (10A) “Meter”.
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Page 30
4JJ1-TC Engine-27 VS Sensor Connector Face (M/T & A/T 4WD) VS Sensor Connector Face (A/T 2WD) DTC yang berhubungan Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Status Menjalankan Kemungkinan Penyebab (Kode Injection Scan Tool… -
Page 31: Barometric Pressure (Baro) Sensor
4JJ1-TC Engine-28 BAROMETRIC PRESSURE (BARO) SENSOR Barometric pressure (BARO) sensor lokasinya ada di intake manifold. Tetapi, tidak dipasangkan didalam manifold. Hanya ditempatkan di manifold dengan bracket. BARO sensor adalah transducer memiliki tegangan ber- variasi berdasarkan perubahan tekanan barometric. BARO sensor menyediakan signal ke Engine control module (ECM) pada BARO sensor signal circuit, dimana sesuai dengan relatif perubahan tekanan.
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Page 32
4JJ1-TC Engine-29 BARO Sensor Connector Face Related DTC Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Menjalankan Kemungkinan Penyebab (Kode Injection Status Control Scan Tool Menentukan DTC Intake Gejala) Quantity Lainnya Throttle Control Limitation… -
Page 33: Accelerator Pedal Position (App)
4JJ1-TC Engine-30 ACCELERATOR PEDAL POSITION (APP) SENSOR Accelerator pedal position (APP) sensor dipasangkan pada accelerator pedal assembly. Sensor terdiri dari tiga individu sensor dalam satu rumah. Engine Control module (ECM) menggunakan APP sensors untuk me- nentukan jumlah akselerasi atau deselerasi sesuai dengan keinginan pengendara saat mengendarai kendaraan melalui fuel injector control.
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Page 34
4JJ1-TC Engine-31 Jika kendaraan menggunakan automatic transmission, perhitungan accelerator pedal position akan dikirimkan 10.0ms ke transmission control module (TCM). 100Hz-duty signal diberikan dari terminal J2-56 ECM. 1.0ms 10% Off Duty Ratio: Accelerator pedal position 0% 50% Off Duty Ratio: Accelerator pedal position 50% 90% Off Duty Ratio: Accelerator pedal position 100% 5.0ms… -
Page 35
4JJ1-TC Engine-32 Related DTC Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Status Menjalankan Kemungkinan Penyebab (Kode Injection Scan Tool Menentukan DTC Intake Control Gejala) Quantity Throttle Lainnya Control Limitation Control P1120 Accelerator Battery voltage… -
Page 36
4JJ1-TC Engine-33 Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Status Menjalankan Kemungkinan Penyebab (Kode Injection Scan Tool Menentukan DTC Intake Control Gejala) Quantity Throttle Lainnya Control Limitation Control P1123 Accelerator Battery APP sensor 2 dan… -
Page 37
4JJ1-TC Engine-34 Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Status Menjalankan Kemungkinan Penyebab (Kode Injection Scan Tool Menentukan DTC Intake Control Gejala) Quantity Throttle Lainnya Control Limitation Control P1201 Accelerator Battery voltage Kondisi High… -
Page 38: Swirl Control Solenoid Valve
4JJ1-TC Engine-35 SWIRL CONTROL SOLENOID VALVE Swirl control solenoid valve berada di sebelah kiri dari cylinder block dan diikatkan dengan fuel rail bracket. Dengan command signal dari terminal J1-67 ECM sele- noid valve ini memberikan tekanan vacuum ke diapragm actuator untuk mengerjakan swirl control butterfly yang terpasang pada setiap lubang intake.
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Page 39
4JJ1-TC Engine-36 Solenoid Valve Connector Face Related DTC Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Status Menjalankan Kemungkinan Penyebab (Kode Injection Scan Tool Menentukan DTC Intake Control Gejala) Quantity Throttle Lainnya Control Limitation… -
Page 40: System Bahan Bakar
4JJ1-TC Engine-37 FUEL SYSTEM FEATURE OF THE COMMON RAIL SYSTEM 1. Fuel Tank 2. Fuel Filter 3. Fuel Supply Pump 4. One-way Valve 5. Fuel Rail 6. Pressure Limiter Valve 7. Flow Damper 8. Fuel Rail Pressure Sensor 9. Injector 10.
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Page 41: Fuel Supply Pump
4JJ1-TC Engine-38 FUEL SUPPLY PUMP FSP merupakan jantung dari tipe penginjeksian bahan bakar elektronik sistem common rail, injection pump tidak dipakai lagi dan supply pump type plunger dibuat untuk men-supply bahan bakar bertekan tinggi ke fuel rail. Supply pump dipasangkan pada posisi yang sama seperti injection pump konvensional, dan digerakkan 1:1 terhadap mesin.
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Page 42
4JJ1-TC Engine-39 1. Fuel Tank 2. Fuel Filter 3. Suction 4. Fuel Inlet 5. Feed Pump 6. Regulating Valve 7. Suction Control Valve (SCV) 8. Return Spring 9. Plunger 10. Suction Valve 11. Delivery Valve 12. Fuel Overflow 13. Return 14. -
Page 43
4JJ1-TC Engine-40 Operation of the Fuel Feed Pump 1. From Fuel Tank 2. Intake Port 3. To Pump Chamber 4. Discharge Port 5. Inner Rotor 6. Outer Rotor 7. Fuel Quantity Decrease 8. Fuel Quantity Increase 9. Fuel Quantity Decrease (Fuel Discharge) 10. -
Page 44
4JJ1-TC Engine-41 Operation of the Fuel Supply Pump 1. Suction Control Valve (SCV) 2. Suction Valve 3. Delivery Valve 4. Eccentric Cam 5. Ring Cam 6. Plunger A Top Dead Center (TDC) at Compression Stroke 7. Plunger B Bottom Dead Center (BDC) at Intake Stroke 8. -
Page 45
4JJ1-TC Engine-42 Operation of Suction Control Valve (SCV) Solenoid valve type linear telah diadopsi. ECM me- Engontrol 250Hz duty ratio (lamanya waktu arus yang bekerja di SCV), yang bertugas mengontrol jumlah bahan bakar yang dikirim ke plunger tekanan tinggi. pressure plunger. Beban berputar supply pump berku- rang hanya saat jumlah bahan bakar yang diterima rail pressure sudah sesuai target. -
Page 46
4JJ1-TC Engine-43 1. Feed Pump 2. Suction Control Valve (SCV) 3. Cylinder 4. Large Valve Opening (Maximum Intake Quantity) 5. Small Valve Opening (Minimum Intake Quantity) https://www.automotive-manuals.net/… -
Page 47
4JJ1-TC Engine-44 Suction Control Valve (SCV) Connector Face Related DTC Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Menjalankan Kemungkinan Penyebab (Kode Injection Status Control Scan Tool Menentukan DTC Intake Gejala) Quantity Lainnya Throttle… -
Page 48: Fuel Rail (Common Rail)
4JJ1-TC Engine-45 FUEL RAIL (COMMON RAIL) Dengan dipergunakannya tipe sistem elektronik peng- injeksian bahan bakar, fuel rail dihubungkan ke saluran tekanan tinggi bahan bakar antara supply pump dan in- jectors. Sensor tekanan dan pressure limiter (pembatas tekanan dipasangkan pada fuel rail. Pressure sensor mendeteksi tekanan bahan bakar didalam fuel rail dan mengirimkan signalnya ke ECM.
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Page 49
4JJ1-TC Engine-46 Operation of the Flow Damper Flow dampers dipasang pada saluran keluar fuel rail untuk meredam gelombang pulsa dari tekanan bahan bakar di dalam fuel rail atau untuk men-stop supplay bahan bakar kar saat terjadi kebocoran didalam flow damper. Bahan bakar dikirimkan ke injector melalui orifice piston. -
Page 50: Fuel Rail Pressure (Frp) Sensor
4JJ1-TC Engine-47 FUEL RAIL PRESSURE (FRP) SENSOR Fuel rail pressure (FRP) sensor dipasangkan di fuel rail dan ia mendeteksi tekanan bahan bakar didalam fuel rail, meng-konversikan tekanan menjadi voltage signal dan dikirim ke engine control module (ECM). ECM mensupai tegangan 5-volts ke FRP sensor pada 5volts reference circuit.
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Page 51
4JJ1-TC Engine-48 Fuel Rail Pressure (FRP) Sensor Connector Face Related DTC Fail-Safe (Back Up) Kondisi untuk Nama DTC Sub System Status Kondisi untuk Pembatas pada Scan Kemungkinan Penyebab (Kode Menjalankan an Fuel Status control Intake Menentukan DTC Tool gejala) Injection… -
Page 52: Fuel Injector
4JJ1-TC Engine-49 FUEL INJECTOR Tipe Injektor Electronic control dikontrol oleh engine control module (ECM). Sama dengan injection nozzle konvensional, ditambah dengan command piston, solenoid valve, dan lain-lain. Barcode dua dimensi menunjukkan karakteristik variasi injector yang ditandai laser pada body fuel injector, dan ID code menunjukkan urutan angka dari (24 figur urutan abjad) tanda laser pada connector housing.
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Page 53
4JJ1-TC Engine-50 ID code setiap fuel injector dapat juga ditemukan pada label yang diberikan dari pabrik yang ditempatkan pada cylinder head cover. Catatan! Apabila memprogram ID code, hanya merecord dari label ini jika fuel injector TIDAK diganti dulu. 1. ID Code Fuel injector silinder no 1 2. -
Page 54
4JJ1-TC Engine-51 Operation of Fuel Injector 1. Return Port 2. Solenoid 3. Two Way Valve (TWV) 4. Outlet Orifice 5. Control Chamber 6. Inlet Orifice 7. Command Piston 8. Nozzle 9. High Pressure Fuel 10. Driving Current 11. Pressure in Control Chamber 12. -
Page 55
4JJ1-TC Engine-52 Fuel Injector Connector Face Related DTC Fail-Safe (Back Up) Kondisi untuk Nama DTC Sub System Status Pembatas Kondisi untuk pada Scan Kemungkinan penyebab an Fuel Status Control (Kode Menjalankan Intake Menentukan DTC Tool Injection Lainnya gejala) Throttle Control… -
Page 56
4JJ1-TC Engine-53 Fail-Safe (Back Up) Kondisi untuk Nama Sub System Status Pembatas Kondisi untuk DTC pada Kemungkinan Penyebab (Kode Menjalankan an Fuel Status Control Menentukan DTC Intake Scan Tool Gejala) Injection Lainnya Throttle Control Quantity Control P0204 Cylinder No.4 Tegangan… -
Page 57
4JJ1-TC Engine-54 Fail-Safe (Back Up) Kondisi untuk Nama Sub System Status Pembatas Kondisi untuk DTC pada Kemungkinan pemyebab (Kode Menjalankan an Fuel Status Control Menentukan DTC Intake Scan Tool Gejala) Injection Lainnya Throttle Control Quantity Control P1261 Injector Tegangan Sirkuit injector… -
Page 58
4JJ1-TC Engine-55 Fail-Safe (Back Up) Kondisi untuk Nama Sub System Status Pembatas Kondisi untuk DTC pada Kemungkinan Penyebab (Kode Menjalankan an Fuel Status Control Menentukan DTC Intake Scan Tool Gejala) Injection Lainnya Throttle Control Quantity Control P1262 Injector Tegangan Sirkuit injector… -
Page 59
4JJ1-TC Engine-56 Fail-Safe (Back Up) Kondisi untuk Nama Sub System Status Pembatsa Kondisi untuk DTC pada Kemungkinan Penyebab (Kode Menjalankan n Fuel Status Control Menentukan DTC Intake Scan Tool Gejala) Injection Lainnya Throttle Control Quantity Control P1263 Injector Circuit Tegangan… -
Page 60: Fitur Saluran Bahan Bakar
4JJ1-TC Engine-57 FITUR ALIRAN BAHAN BAKAR 1. Fuel Rail 2. Leak Off Pipe 3. Fuel Injector 4. Return Pipe 5. Fuel Feed Pipe 6. Fuel Tank 7. Fuel Pump & Sender Assembly 8. Fuel Filler Cap 9. Check Valve 10. Fuel Filter with Water Separator 11.
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Page 61: In-Tank Fuel Pump & Sender Unit
4JJ1-TC Engine-58 FUEL PUMP DI TANGKI & SENDER UNIT Tangki bahan bakar dilengkapi dengan fuel pump dan sender assembly (fuel level sensor). Konstruksi dan fungsi fuel pump adalah sangat mirip dengan fuel pump gasoline engine konvensional. 1. Discharge Port 2. Return Port 3.
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Page 62
4JJ1-TC Engine-59 Fuel Pump Relay Terminal Face Fuel Pump Connector Face DTC yang terkait Fail-Safe (Back Up) Sub System Kondisi untuk Nama Pembatasan Kondisi untuk Status DTC pada Kemingkinan Penyebab (Kode Menjalankan Status control Fuel Menentukan DTC Intake Scan Tool… -
Page 63: Bypass One-Way Valve
4JJ1-TC Engine-60 BYPASS ONE-WAY VALVE Saluran bahan bakar dilengkapi dengan bypass one- way valve yang unik, yang dipasang dekat transmission case. Valve ini bekerja dengan pertimbangan berikut. a. Tujuan dari fungsi bypass valve : Fuel pump dalam tangki mengeluarkan jumlah yang tetap dengan mengabaikan beban atau putaran mesin.
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Page 64: Fuel Injection Quantity Control
4JJ1-TC Engine-61 FUEL INJECTION QUANTITY CONTROL Control ini menentukan quantity penginjeksian bahan bakar dengan menambahkan temperature pendingin, temperature udara yang masuk, dan berat udara yang mengalir koreksi dasar quantity penginjeksian yang dikalkulasi oleh engine control module (ECM), berdasarkan kondisi kerja…
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Page 65
4JJ1-TC Engine-62 Idle Vibration Control Control dibuat agar supaya untuk meredam getaran mesin yang disebabkan oleh torsi yang bervariasi A ngle S peed antara jumlah silinder dengan variasi quantity injeksi bahan bakar pada setiap silinder atau kemampuan injektor. ECM membetulkan quantity injeksi di antara… -
Page 66
4JJ1-TC Engine-63 Fail-Safe (Back Up) Kondisi untuk Nama Sub System Status Pembatas Kondisi untuk DTC pada Kemungkinan Penyebab (Kode Menjalankan an Fuel Status Control Menentukan DTC Intake Scan Tool Gejala) Injection Lainnya Throttle Control Quantity Control P0088 Fuel Rail Teangan… -
Page 67
4JJ1-TC Engine-64 Fail-Safe (Back Up) Kondisi untuk Nama Sub System Status Pembatas Kondisi untuk DTC pada Kemungkinan Penyebab (Kode Menjalankan an Fuel Status Control Menentukan DTC Intake Scan Tool Gejala) Injection Lainnya Throttle Control Quantity Control P0089 Fuel Pressure Tegangan… -
Page 68
4JJ1-TC Engine-65 Fail-Safe (Back Up) Kondisi untuk Nama Sub System Status Pembatas Kondisi untuk DTC pada Kemungkinan Penyebab (Kode Menjalankan an Fuel Status Control Menentukan DTC Intake Scan Tool Gejala) Injection Lainnya Throttle Control Quantity Control P1093 Fuel Rail Teangan… -
Page 69
4JJ1-TC Engine-66 Fail-Safe (Back Up) Kondisi untuk Nama Sub System Status Pembatas Kondisi untuk DTC pada Kemungkinan Penyebab (Kode Menjalankan an Fuel Status Control Menentukan DTC Intake Scan Tool Gejala) Injection Lainnya Throttle Control Quantity Control P1094 Fuel Rail Tegangan… -
Page 70
4JJ1-TC Engine-67 Fail-Safe (Back Up) Kondisi untuk Nama Sub System Status Pembatas Kondisi untuk DTC pada Kemungkinan Penyebab (Kode Menjalankan an Fuel Status Control Menentukan DTC Intake Scan Tool Gejala) Injection Lainnya Throttle Control Quantity Control P1094 Fuel Rail Teganagn… -
Page 71
4JJ1-TC Engine-68 Fail-Safe (Back Up) Kondisi untuk Nama Sub System Status Pembatas Kondisi untuk DTC pada Kemungkinan Penyebab (Kode Menjalankan an Fuel Status Control Menentukan DTC Intake Scan Tool Gejala) Injection Lainnya Throttle Control Quantity Control P1095 Fuel Pressure Teganagn… -
Page 72: Egr (Exhuast Gas Re-Circulation)
4JJ1-TC Engine-69 EGR (EXHAUST GAS RE-CIRCULATION) SYSTEM 1. EGR Cooler 2. Engine Coolant Outlet 3. Engine Coolant Inlet 4. EGR Valve 5. Engine Control Module (ECM) 6. Mass Air Flow (MAF) Sensor 7. Intake Throttle Valve Sistem Exhaust Re-circulation (EGR) dikombinasikan dengan EGR cooler untuk mengurangi temperature dari temperature pembakaran.
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Page 73: Egr Valve
4JJ1-TC Engine-70 EGR VALVE EGR valve dipasang pada intake manifold. Ini untuk mengontrol jumlah EGR gas yang mengalir. Posisi sensor dipasang pada EGR valve body bersamaan dengan EGR valve control motor. EGR valve position sensor merubah tegangan output sesuai dengan posisi EGR valve.
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Page 74
4JJ1-TC Engine-71 Karakteristik dari EGR valve position sensor ditampilkan EGR Valve Characteristic -Reference- dalam grapik dan tabel. Kalkulasi posisi EGR dapat dilihat pada Tech 2 dengan satuan “%”. Tegangan output juga dapat dilihat pada Tech 2. Posisi yang dibutuhkan dan posisi actual dibandingkan dan ECM menyetel gerakan motor EGR valve dengan duty cycle signal. -
Page 75: Intake Throttle (It) Valve
4JJ1-TC Engine-72 INTAKE THROTTLE (IT) VALVE Intake throttle (IT) valve dipasang pada intake manifold. Pengontrolan jumlah EGR gas yang mengalir dengan menurunkan aliran udara yang masuk. Sebuah position sensor dipasang pada intake throttle valve body bersama-sama dengan intake throttle valve control motor.
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Page 76
4JJ1-TC Engine-73 Karakteristik dari intake throttle valve position sensor Intake Throttle Valve Characteristic -Reference- ditampilkan dalam grapik dan tabel. Perhitungan posisi intake throttle dapat dilihat pada the Tech 2 dengan satuan “%”. Tegangan output juga dapat didiliaht pada Tech 2. Posisi yang dibutuhkan dan posisi actual dibandingkan dan ECM menyetel gerakan motor intake throttle valve dengan duty cycle signal. -
Page 77
4JJ1-TC Engine-74 EGR Valve Connector Face Intake Throttle Valve Connector Face Related DTC Fail-Safe (Back Up) Nama DTC Kondisi untuk Sub System Status Pembatas Kondisi untuk Status pada Scan Menjalankan Kemungkinan Penyebab (Kode an Fuel menentukan DTC Intake control yang… -
Page 78
4JJ1-TC Engine-75 Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Status Menjalankan Kemungkinan Penyebab (Kode Injection Scan Tool Menentukan DTC Intake Control Gejala) Quantity Throttle Lainnya Control Limitation Control P0487 Exhaust Gas Tegangan Temperatur pada… -
Page 79
4JJ1-TC Engine-76 Fail-Safe (Back Up) Kondisi untuk Sub System Status Fuel Nama DTC di Kondisi untuk Status Menjalankan Kemungkinan Penyebab (Kode Injection Scan Tool Menentukan DTC Intake Control Gejala) Quantity Throttle Lainnya Control Limitation Control P1485 Intake Throttle Tegangan IT valve control… -
Page 80: Preheating System
4JJ1-TC Engine-77 PREHEATING SYSTEM Preheating system terdiri dari engine control module (ECM), glow relay dan glow plug. ECM menghubungkan glow relay tergantung pada temperature pendingin mesin sebagai energize glow plug. Setelah phase glow, glow plug aktif lagi untuk periode tertentu dengan mesin berputar.
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Page 81
4JJ1-TC Engine-78 Glow Relay Terminal Face Glow Plug Harness Connector Related DTC Fail-Safe (Back Up) Nama DTC Kondisi untuk Sub System Status Fuel Kondisi untuk Name di Scan Menjalankan Kemungkinan Penyebab (Kode Injection Other Control Menentukan DTC Intake Tool Gejala) -
Page 82: Diagnostic
4JJ1-TC Engine-79 DIAGNOSTIK MALFUNCTION INDICATOR LAMP (MIL) Malfunction indicator lamp (MIL) terletak pada instrument panel cluster. MIL akan menampilkan simbol mesin saat diperintah ON: MIL mengindikasikan kerusakan yang berhubungan dengan emisi telah terjadi dan dibutuhkan perbaikan kendaraan. Berikut ini daftar dari mode operasi MIL: MIL menyala kira-kira 4.3 detik saat kunci kontak ON,…
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Page 83: Data Link Connector (Dlc)
4JJ1-TC Engine-80 DATA LINK CONNECTOR (DLC) Data link connector (DLC) terletak pada knee bolster reinforcement panel pengemudi. Komunikasi antara Tech 2 dan ECM menggunakan Keyword 2000 serial data communication. Tidak Digunakan Class 2 Communication Line (ABS Module, SRS Module) Tidak Digunakan…
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Page 84: Flash Diagnostic Trouble Code
3. Pilih tipe kendaraan yang sesuai. F2: Freeze Frame / Failure Records 4. Pilih “F0: Powertrain” kemudian tekan Enter. F1: Data Display 5. Pilih “3.0L 4JJ1-TC” F2: Snapshot Tabel pada sisi kiri memperlihatkan, fungsi yang mana F3: Miscellaneous Test yang digunakan versi kelengkapan tersedia.
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Page 85
4JJ1-TC Engine-82 Symptom Code Nomor ini berarti identifikasi kerusakan. Setiap DTC terdapat individual symptom, seprti DTC P0100 memiliki dua symptom code (1) dan (2). DTC chart (prosedur pemeriksaan) dipisahkan tergantung pada symptom code ini. 1. DTC 2. Symptom Code F1: Data Display Fungsi dari mode “Data Display”… -
Page 86
4JJ1-TC Engine-83 Rail Pressure Control Fungsi dari tes ini untuk memeriksa apakah fuel rail pressure berubah antara 30 — 60MPa (4350 — 7250psi) saat diperintahkan. Injector Balancing Fungsi dari tes ini untuk memeriksa apakah fuel injector bekerja saat diperintahkan ON/OFF. -
Page 87
4JJ1-TC Engine-84 Intake Throttle Control Fungsi dari tes ini untuk memeriksa apakah posisi aktual dari intake throttle valve bergerak dalam 20 — saat diperintahkan. Gerakan valve yang terganggu oleh benda asing, deposit berlebihan atau valve rusak dapat dipertimbangkan jika Intake Throttle Position Difference besar. -
Page 88: Tech 2 Data & Definisinya
4JJ1-TC Engine-85 DATA TECH 2 & DEFINISI Daftar Data Tech 2 meliputi semua parameter yang berhubungan dengan mesin yang terdapat pada Tech Gunakan Tech Data List hanya setelah ditentukannya berikut ini: Diagnostic Check — Engine Controls selesai. Tidak ada diagnostic trouble code (DTC).
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Page 89
4JJ1-TC Engine-86 Parameter Unit Saat Mesin Saat Mesin Definisi Tech 2 Idle 2000RPM Swirl Control On / Off Parameter ini menampilkan kondisi yang diperintahkan dari swirl control Solenoid solenoid circuit. Tech 2 akan menampilkan On atau Off. On mengindikasikan swirl control solenoid circuit di-massa-kan oleh ECM J1-67 terminal, sehingga tegangan mengalir ke solenoid valve. -
Page 90
4JJ1-TC Engine-87 Parameter Unit Saat Mesin Saat Mesin Definisi Tech 2 Idle 2000RPM °C / °F Fuel 20-60°C / 20-60°C / Parameter ini menampilkan temperatur dari bahan bakar seperti dikalkulasikan Temperature 68-140°F 68-140°F oleh ECM menggunakan signal input dari fuel temperature (FT) sensor. Tech 2 akan menampilkan temperatur rendah saat signal voltage tinggi dan temperatur tinggi saat signal voltage rendah. -
Page 91
4JJ1-TC Engine-88 Parameter Unit Saat Mesin Saat Mesin Definisi Tech 2 Idle 2000RPM Intake Throttle -3 — 3 -3 — 3 Parameter ini menampilkan perbedaan antara actual dan desired value (actual Position intake throttle – desired intake throttle). Ini dapat digunakan untuk menentukan Difference kekakuratan sensor atau intake throttle valve problem. -
Page 92
4JJ1-TC Engine-89 Parameter Unit Saat Mesin Saat Mesin Definisi Tech 2 Idle 2000RPM Desired Injection 6 — 12 9 — 13 Parameter ini menampilkan total injection quantity (main injection quantity + pre Quantity injection quantity) yang diinginkan oleh berdasarkan kondisi pengendaraan terkini. -
Page 93
4JJ1-TC Engine-90 Parameter Unit Saat Mesin Saat Mesin Definisi Tech 2 Idle 2000RPM Engine Mode Halt Mode / Fuel Mode Fuel Mode Parameter ini menampilkan kondisi dari mesin. “Wait Mode” mengindikasikan Wait Mode / ignition switch pada posisi ON. “Crank Mode” mengindikasikan mesin selama Crank Mode / start. -
Page 94: Breaker Box
4JJ1-TC Engine-91 BREAKER BOX Engine control module (ECM) dan konektor lainnya memiliki water proof connector dan special terminal. Water proof terminal tidak memungkinkan penggunaan back probe. Sebagai tambahan, engine control module (ECM) special terminal tidak membiarkan regular digital voltage meter probe untuk masuk, karena bentuk terminal adalah very fin pin type.
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Page 95: Diagnostic System Check
4JJ1-TC Engine-92 PEMERIKSAAN SISTEM DIAGNOSTIK Mulai diagnosa sistem dengan Pemeriksaan Sistem Pemeriksaan Sistem Diagnostik – Kontrol Mesin Diagnostik – Kontrol Mesin. Pemeriksaan Sistem Penting: Diagnostik – Kontrol Mesin akan menyediakan • JANGAN melakukan diagnostik ini jika tidak informasi berikut: terdapat masalah pengendaraan, kecuali prosedur •…
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Page 96
4JJ1-TC Engine-93 Step Tindakan Nilai Tidak Pasang Tech 2. ⎯ Lihat ke Tech 2 Apakah Tech 2 ON? Lihat ke Step 2 Tidak Menyala 1. ON-kan kunci kontak, dengan mesin OFF. 2. Coba untuk mendapatkan komunikasi dengan control module di bawah ini. -
Page 97
4JJ1-TC Engine-94 Step Tindakan Nilai Tidak Apakah Tech 2 menampilkan ECM DTC? • P0090 (Symptom Code 6, 7 & • P0193 (Symptom Code 1 & 2) ⎯ • P0201-P0204 (Symptom Code 6) • P1261 (Symptom Code 1, 3, 5 & 7) •… -
Page 98: Mesin Berputar Tetapi Tidak Hidup
4JJ1-TC Engine-95 MESIN START TETAPI TIDAK HIDUP Bantuan Diagnostik Deskripsi Jika kondisi intermittent dicurigai, lihat ke Kondisi Tabel diagnostik Mesin Start tetapi Tidak Hidup adalah Intermittent pada bagian ini. sebuah pendekatan teratur untuk mengidentifikasi kondisi yang menyebabkan mesin tidak bisa hidup.
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Page 99
4JJ1-TC Engine-96 Step Tindakan Nilai Tidak Lihat parameter Synchronization Mode dengan Tech 2 saat start mesin selama 5 detik. ⎯ Apakah parameter Synchronization Mode mengindikasikan “2” selama start? Lihat ke Step 7 Lihat ke Step 12 1. Lepas engine cover. -
Page 100
4JJ1-TC Engine-97 Step Tindakan Nilai Tidak 1. Kemungkinan penyebab lain untuk kondisi tidak hidup: • Fuel supply pump mechanical timing • Intake tersumbat, exhaust atau ⎯ catalytic converter tersumbat • Kompresi mesin buruk 2. Perbaiki seperlunya. Apakah masalah ditemukan dan diperbaiki? -
Page 101
4JJ1-TC Engine-98 Step Tindakan Nilai Tidak Penting: Penggantian ECM harus di-program. Ganti ECM. Lihat ke Engine Control Module (ECM) Replacement /Restore Fuel Injector ID ⎯ Code Date & Immobilizer Programming (Jika dilengkapi) pada bagian ini. ⎯ Apakah penggantian selesai? Lihat ke Step 17 1. -
Page 102: Ecm Diagnostic Trouble Code (Dtc)
Mesin 4JJ1-TC-99 DAFTAR DIAGNOSTIC TROUBLE CODE (DTC) Fail-Safe (Back-up) Terminal Konektor Terminal Konektor Status Sub Sistem Flash Sensor/ Actuator/ Jumlah (Symptom Status MIL Nama DTC pada Tech 2 Kondisi untuk menampilkan DTC Kondisi untuk pengesetan DTC Kemungkinan Penyebab ECM Yang…
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Page 103
Mesin 4JJ1-TC-100 Fail-Safe (Back-up) Terminal Konektor Terminal Konektor Status Sub Sistem Flash Sensor/ Actuator/ Jumlah (Symptom Status MIL Nama DTC pada Tech 2 Kondisi untuk menampilkan DTC Kondisi untuk pengesetan DTC Kemungkinan Penyebab ECM Yang Code Switch Yang Intake Fuel… -
Page 104
Mesin 4JJ1-TC-101 Fail-Safe (Back-up) Terminal Konektor Terminal Konektor Status Sub Sistem Flash Sensor/ Actuator/ Jumlah (Symptom Status MIL Nama DTC pada Tech 2 Kondisi untuk menampilkan DTC Kondisi untuk pengesetan DTC Kemungkinan Penyebab ECM Yang Code Switch Yang Intake Fuel… -
Page 105
Mesin 4JJ1-TC-102 Fail-Safe (Back-up) Terminal Konektor Terminal Konektor Status Sub Sistem Flash Sensor/ Actuator/ Jumlah (Symptom Status MIL Nama DTC pada Tech 2 Kondisi untuk menampilkan DTC Kondisi untuk pengesetan DTC Kemungkinan Penyebab ECM Yang Code Switch Yang Intake Fuel… -
Page 106
Mesin 4JJ1-TC-103 Fail-Safe (Back-up) Terminal Konektor Terminal Konektor Status Sub Sistem Flash Sensor/ Actuator/ Jumlah (Symptom Status MIL Nama DTC pada Tech 2 Kondisi untuk menampilkan DTC Kondisi untuk pengesetan DTC Kemungkinan Penyebab ECM Yang Code Switch Yang Intake Fuel… -
Page 107
Mesin 4JJ1-TC-104 Fail-Safe (Back-up) Terminal Konektor Terminal Konektor Status Sub Sistem Flash Sensor/ Actuator/ Jumlah (Symptom Status MIL Nama DTC pada Tech 2 Kondisi untuk menampilkan DTC Kondisi untuk pengesetan DTC Kemungkinan Penyebab ECM Yang Code Switch Yang Intake Fuel… -
Page 108
Mesin 4JJ1-TC-105 Fail-Safe (Back-up) Terminal Konektor Terminal Konektor Status Sub Sistem Flash Sensor/ Actuator/ Jumlah (Symptom Status MIL Nama DTC pada Tech 2 Kondisi untuk menampilkan DTC Kondisi untuk pengesetan DTC Kemungkinan Penyebab ECM Yang Code Switch Yang Intake Fuel… -
Page 109
Mesin 4JJ1-TC-106 Fail-Safe (Back-up) Terminal Konektor Terminal Konektor Status Sub Sistem Flash Sensor/ Actuator/ Jumlah (Symptom Status MIL Nama DTC pada Tech 2 Kondisi untuk menampilkan DTC Kondisi untuk pengesetan DTC Kemungkinan Penyebab ECM Yang Code Switch Yang Intake Fuel… -
Page 110
Mesin 4JJ1-TC-107 Fail-Safe (Back-up) Terminal Konektor Terminal Konektor Sub System Status Flash Sensor/ Actuator/ Jumlah (Symptom Status MIL Nama DTC pada Tech 2 Kondisi untuk menampilkan DTC Kondisi untuk pengesetan DTC Kemungkinan Penyebab ECM Yang Code Switch Yang Intake Fuel… -
Page 111
Mesin 4JJ1-TC-108 Fail-Safe (Back-up) Terminal Konektor Terminal Konektor Status Sub Sistem Flash Sensor/ Actuator/ Jumlah (Symptom Status MIL Nama DTC pada Tech 2 Kondisi untuk menampilkan DTC Kondisi untuk pengesetan DTC Kemungkinan Penyebab ECM Yang Code Switch Yang Intake Fuel… -
Page 112
Mesin 4JJ1-TC-109 Fail-Safe (Back-up) Terminal Konektor Terminal Konektor Status Sub Sistem Flash Sensor/ Actuator/ Jumlah (Symptom Status MIL Nama DTC pada Tech 2 Kondisi untuk menampilkan DTC Kondisi untuk pengesetan DTC Kemungkinan Penyebab ECM Yang Code Switch Yang Intake Fuel… -
Page 113
Mesin 4JJ1-TC-110 Fail-Safe (Back-up) Terminal Konektor Terminal Konektor Status Sub Sistem Flash Sensor/ Actuator/ Jumlah (Symptom Status MIL Nama DTC pada Tech 2 Kondisi untuk menampilkan DTC Kondisi untuk pengesetan DTC Kemungkinan Penyebab ECM Yang Code Switch Yang Intake Fuel… -
Page 114: Hasil Diagnosa Gejala
Mesin 4JJ1-TC-111 DIAGNOSA GEJALA Kondisi Intermittent Sebelum Menggunakan Bagian Ini Sebelum menggunakan bagian ini, kamu harus Kondisi Intermittent melakukan Pemeriksaan Sistem Diagnosa – Kontrol Kondisi intermittent dapat atau tidak dapat menyalakan Mesin dan menentukan kriteria berikut: malfunction indicator lamp (MIL) atau menyimpan 1.
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Page 115
Mesin 4JJ1-TC-112 • Pemasangan peralatan elektrikal yang tidak benar; seperti lampu, 2-way audio, motor listrik, telpon selular, dll. • Sirkuit MIL kadang short ke ground. • Massa ECM buruk Hilangnya Memori DTC Periksa dari hilangnya memori DTC dengan melepas engine coolant temperature (ECT) sensor dan idling mesin sampai MIL menjadi ON. -
Page 116: Check Sheet Engine Control System
Mesin 4JJ1-TC-113 Pemeriksaan Tindakan Pemeriksaan Fuel System Periksa fuel system dari kondisi berikut. Lihat ke bagian Fuel System. • Periksa dari adanya udara dalam fuel system. • Periksa dari adanya kontaminasi air dalam bahan bakar. • Periksa dari kebocoran ekternal bahan bakar atau oli mesin kebanyakan.
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Page 117
Mesin 4JJ1-TC-114 Pemeriksaan Tindakan Pemeriksaan Engine Mechanical Periksa mekanikal mesin dari kondisi berikut. Lihat pada bagian Engine Mechanical. • Periksa kompresi silinder yang buruk. Kompresi yang benar adalah lebih dari 1960 kPa (284 psi) dan variasi setiap silinder kurang dari 294 kPa (43 psi). -
Page 118
Mesin 4JJ1-TC-115 Pemeriksaan Tindakan Pemeriksaan Fuel System Periksa fuel system dari kondisi berikut. Lihat ke bagian Fuel System. • Pastikan kerja dari in-tank fuel pump sebelum melakukan prosedur berikut. Jika in-tank fuel pump tidak bekerja, lihat ke DTC P1099 (Symptom Code 5 & 6). -
Page 119
Mesin 4JJ1-TC-116 Pemeriksaan Tindakan Pemeriksaan Engine Periksa mekanikal mesin dari kondisi berikut. Lihat pada bagian Engine Mechanical Mechanical. • Periksa kompresi silinder yang buruk. Kompresi yang benar adalah lebih dari 1960 kPa (284 psi) dan variasi dari setiap silinder kurang dari 294 kPa (43 psi). -
Page 120
Mesin 4JJ1-TC-117 Pemeriksaan Tindakan Pemeriksaan Sensor Periksa sensor-sensor untuk pengontrolan mesin dari kondisi berikut: • Gunakan Tech 2 untuk membandingkan Coolant Temperature dengan Intake Air Temperature (IAT) dan Fuel Temperature (FT) saat kondisi mesin dingin. Jika perbedaan antara pembacaan temperatur lebih dari 5°C (9°F) saat mesin dingin, periksa dari high resistance pada low reference circuit dan signal circuit atau sensor miring. -
Page 121
Mesin 4JJ1-TC-118 Cut Out, Misses Definisi Sentakan yang konstan mengikuti putaran mesin, umumnya lebih nyata sebagai kenaikan beban mesin. Exhaust menimbulkan suara yang teratur saat idle, putaran rendah, atau akselerasi keras sehingga kekurangan bahan bakar dan dapat menyebabkan mesin mati. -
Page 122
Mesin 4JJ1-TC-119 Pemeriksaan Tindakan Air Intake System Checks Periksa air intake system dari kondisi berikut. • Periksa air cleaner dan air intake duct dari hambatan, lubang, atau kebocor- • Periksa dari hambatan pada turbocharger inlet duct. • Periksa intake throttle valve dari kemacetan pada posisi tertutup. -
Page 123
Mesin 4JJ1-TC-120 Pemeriksaan Tindakan Pemeriksaan Sensor Periksa sensor-sensor untuk pengontrolan mesin dari kondisi berikut: • Periksa Fuel Rail Pressure Sensor. Gunakan Tech 2 untuk melihat parameter dengan mesin OFF. Parameter Fuel Rail Pressure Sensor harus kurang dari 1 volt setelah satu ignition cycle. Jika tidak, periksa dari high resistance pada 5 volt reference circuit, low reference circuit, signal circuit or sensor miring. -
Page 124
Mesin 4JJ1-TC-121 Pemeriksaan Tindakan Pemeriksaan Air Intake System Periksa air intake system dari kondisi berikut. • Periksa air cleaner dan air intake duct dari hambatan, lubang, atau bocor. • Periksa dari hambatan pada turbocharger inlet duct. • Periksa intake throttle valve dari kemacetan pada posisi apapun. -
Page 125
Mesin 4JJ1-TC-122 Pemeriksaan Tindakan Pemeriksaan Sensor Periksa sensor-sensor untuk pengontrolan mesin dari kondisi berikut: • Gunakan Tech 2 untuk membandingkan Coolant Temperature dengan Intake Air Temperature (IAT) dan Fuel Temperature (FT) saat kondisi mesin dingin. Jika perbedaan antara pembacaan temperatur lebih dari 5°C (9°F) saat mesin dingin, periksa dari high resistance pada low reference circuit dan signal circuit atau sensor miring. -
Page 126
Mesin 4JJ1-TC-123 Pemeriksaan Tindakan Pemeriksaan Air Intake System Periksa air intake system dari kondisi berikut. • Periksa air cleaner dan air intake duct dari hambatan, lubang, atau bocor. • Periksa dari hambatan atau kebocoran pada intercooler. • Periksa dari hambatan pada turbocharger inlet duct. -
Page 127
Mesin 4JJ1-TC-124 Hesitation, Sag, Stumble Definisi Kendaraan memiliki respon yang kurang saat pedl gas ditekan. Kondisi ini dapat terjadi pada semua kecepat- an kendaraan. Kondisi ini akan semakin parah saat bergerak dari posisi berhenti. Jika cukup parah, kondisi ini dapat menyebabkan mesin mati. -
Page 128
Mesin 4JJ1-TC-125 Pemeriksaan Tindakan Pemeriksaan Fuel System Periksa fuel system dari kondisi berikut. Lihat ke bagian Fuel System. • Pastikan kerja dari in-tank fuel pump sebelum melakukan prosedur berikut. Jika in-tank fuel pump tidak bekerja, lihat ke DTC P1099 (Symptom Code 5 &… -
Page 129
Mesin 4JJ1-TC-126 Pemeriksaan Tindakan Pemeriksaan Engine Mechanical Periksa mekanikal mesin dari kondisi berikut. Lihat pada bagian Engine Mechanical. • Periksa kompresi silinder yang buruk. Kompresi yang benar adalah lebih dari 1960 kPa (284 psi) dan variasi setiap silinder kurang dari 294 kPa (43 psi). -
Page 130
Mesin 4JJ1-TC-127 Pemeriksaan Tindakan Pemeriksaan Fuel System • Jika asap berlebihan, periksa fuel injector dari macet terbuka. Lepas setiap glow plug dari cylinder head dan periksa ujung dari glow plug dari basah karena bahan bakar. Gunakan cylinder compression gauge. Kompresi standar lebih dari 1960 kPa (84 psi) dan variasi dari setiap silinder kurang dari 294 kPa (43 psi). -
Page 131
Mesin 4JJ1-TC-128 Bahan Bakar Boros Definisi Konsumsi bahan bakar, diukur dengan tes jalan sebenarnya dan beberapa tangki bahan bakar, lebih rendah dari seharusnya. Juga, konsumsinya lebih rendah dibanding pada kendaraan pada suatu waktu, seperti terlihat dalam tes jalan sebenarnya. Pemeriksaan… -
Page 132
Mesin 4JJ1-TC-129 Pemeriksaan Tindakan Pemeriksaan Cooling System Periksa sistem pendinginan dari kondisi berikut. Lihat pada bagian Sistem Pendinginan. • Periksa kuantitas air pendingin mesin. • Periksa thermostat mesin dari selalu terbuka atau range panas yang salah. • Periksa engine cooling fan apakah selalu ON. -
Page 133
Mesin 4JJ1-TC-130 Pemeriksaan Tindakan Pemeriksaan Sensor Periksa sensor-sensor untuk pengontrolan mesin dari kondisi berikut: • Gunakan Tech 2 untuk membandingkan Coolant Temperature dengan Intake Air Temperature (IAT) dan Fuel Temperature (FT) saat kondisi mesin dingin. Jika perbedaan antara pembacaan temperatur lebih dari 5°C (9°F) saat mesin dingin, periksa dari high resistance pada low reference circuit dan signal circuit atau sensor miring. -
Page 134
Mesin 4JJ1-TC-131 Pemeriksaan Tindakan Engine Mechanical Check Periksa mekanikal mesin dari kondisi berikut. Lihat pada bagian Engine Mechanical. • Periksa kompresi silinder yang buruk. Kompresi yang benar adalah lebih dari 1960 kPa (284 psi) dan variasi setiap silinder kurang dari 294 kPa (43 psi). -
Page 135
Mesin 4JJ1-TC-132 Pemeriksaan Tindakan Pemeriksaan Fuel System • Periksa fuel injector dari macet terbuka. Lepas setiap glow plug dari cylinder head dan periksa ujung dari glow plug dari basah karena bahan bakar. Gunakan cylinder compression gauge. Kompresi standar lebih dari 1960 kPa (84 psi) dan variasi dari setiap silinder kurang dari 294 kPa (43 psi). -
Page 136
Mesin 4JJ1-TC-133 LEMBAR PEMERIKSAAN ENGINE CONTROL SYSTEM Nama Pemeriksa Nama Customer Model & Tahun Model Nama Pengemudi Chassis No. Tanggal Kendaraan Masuk Engine No. License No. Pembacaan Odometer Km/mil Mesin Tidak □ □ □ □ Mesin tidak bisa start Tidak ada pembakaran… -
Page 137: Wiring Diagram Elektrikal
Mesin 4JJ1-TC-134 ELECTRICAL WIRING DIAGRAM DISTRIBUSI TEGANGAN (1 dari 2) https://www.automotive-manuals.net/…
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Page 138: Distribusi Power (2 Of 2)
Mesin 4JJ1-TC-135 DISTRIBUSI TEGANGAN (2 dari 2) https://www.automotive-manuals.net/…
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Page 139: Starting & Charging System
Mesin 4JJ1-TC-136 SISTEM STARTING & CHARGING https://www.automotive-manuals.net/…
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Page 140: Ecm Power
Mesin 4JJ1-TC-137 TEGANGAN ECM https://www.automotive-manuals.net/…
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Page 141: Ecm Ground
Mesin 4JJ1-TC-138 MASSA ECM https://www.automotive-manuals.net/…
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Page 142: Gauges & Warning Lamps
Mesin 4JJ1-TC-139 GAUGE & LAMPU PERINGATAN https://www.automotive-manuals.net/…
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Page 143: A/C Control, Glow Control
Mesin 4JJ1-TC-140 A/C CONTROL, GLOW CONTROL & NEUTRAL SWITCH https://www.automotive-manuals.net/…
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Page 144: Neutral Switch
Mesin 4JJ1-TC-141 LOKASI RELAY, FUSE & SLOW BLOW FUSE (RUANG MESIN) X1. Front Fog Light X2. Tail Light X3. Horn X4. Dimmer X5. Glow X6. Head Light X8. Starter X9. Condenser Fan X10. Starter Cut X-11. Heater X-12. ECM Main X-13.
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Page 145: Location (Engine Room) Fuse Location (Cabin)
Mesin 4JJ1-TC-142 LOKASI FUSE (CABIN) C-1. Starter (10A) C-2. Rear Wiper (10A) C-3. Elec. IG (10A) C-4. Turn (10A) C-5. Front Wiper (20A) C-6. Engine (10A) C-7. Back Up (15A) C-8. SRS (10A) C-9. TCM (10A) C-10. Meter (10A) C-11. Audio (10A) C-12.
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Page 146: Lokasi Ground
Mesin 4JJ1-TC-143 LOKASI MASSA https://www.automotive-manuals.net/…
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Page 147: Petunjuk Perbaikan
Mesin 4JJ1-TC-144 INSTRUKSI PERBAIKAN PENGGANTIAN ENGINE CONTROL MODULE (ECM)/ PEMROGRAMAN FUEL INJECTOR ID CODE & IMMOBILIZER Jika ECM harus diganti, isi program berikut HARUS di program ke dalam ECM baru. Fuel Injector ID Code Data (24, 0-9 atau A-F karakter untuk setiap fuel injector)
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Page 148
Mesin 4JJ1-TC-145 Mencatat dari setiap injector housing; 1. Lepas setiap fuel injector harness connector. 2. Catat semua nomor (24 angka) dari setiap fuel injector connector housing. 1. Fuel Injector ID Code 2. Fuel Injector Prosedur Pelepasan 1. Lepas kabel negatip battery. -
Page 149
Mesin 4JJ1-TC-146 Tidak ada masalah pada charging system. Semua masalah charging system harus diperbaiki sebelum memprogram ECM. Tegangan battery lebih besar dari 12volt tetapi kurang dari 16 volt. Battery harus di-charge sebe- memprogram ECM jika tegangan battery rendah. Battery charger TIDAK terhubung dengan battery kendaraan. -
Page 150
Mesin 4JJ1-TC-147 3. Pilih F0: Request Info. Jika sudah tersimpan di Tech 2, data akan muncul. Tech 2 meminta pengguna untuk menyimpan data ini “Keep Data” atau meminta informasi kendaraan baru dari control unit “Continue”. Jika tidak ada data dalam Tech 2, ia akan segera memulai identifikasi kendaraan. -
Page 151
Mesin 4JJ1-TC-148 5. Saat kekurangan data ditanya dalam “Validate Vehicle Data”, masukkan informasi yang benar. • Model • Model Year • Engine Type • Model Designator • Destination Code 6. Destination code dapat dibaca dari service ID plate pada engine compartment. destination code terlihat pada sisi kanan dari Body Type. -
Page 152
Mesin 4JJ1-TC-149 3. Pilih F1: Program ECU. OFF-kan semua peralatan kelistrikan, seperti headlight, room light atau peralatan aksesoris. Dan ON-kan kunci kontak. Kemudian, tekan tombol “Okay”. 4. Saat calibration file di-download, “Programming in Process” akan ditampilkan dan status dapat dilihat sebagai grafik. -
Page 153
Mesin 4JJ1-TC-150 9. Pilih F3: Download ID kemudian tekan Enter. 10. Setelah download selesai, OFF-kan kunci kontak selama 30 detik. 11. ON-kan kunci kontak. 12. Pilih F0: Injector ID Code kemudian tekan Enter. Pada saat ini, semua fuel injector ID code data yang di-download dapat verifikasi. -
Page 154: Penggantian Fuel Injector / Fuel
Mesin 4JJ1-TC-151 PENGGANTIAN FUEL INJECTOR/ PEMROGRAMAN FUEL INJECTOR ID CODE Prosedur Pelepasan 1. Lepas cylinder head cover. Lihat ke bagian engine mechanical. 2. Lepas baut engine oil gauge guide tube. 3. Kendorkan baut injection nozzle clamp dan lepas injection nozzle.
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Page 155
Mesin 4JJ1-TC-152 9. Kencangkan mur sleeve injection pipe (2) sesuai torsinya. Torsi pengencangan: 30 N⋅m (3.1 kg⋅m / 22 lb ft) 10. Kencangkan baut clamp sesuai torsinya. Torsi pengencangan: 26 N⋅m (2.7 kg⋅m / 20 lb ft) 11. Kencangkan engine oil level gauge guide tube. -
Page 156: Penggantian Fuel Supply Pump
Mesin 4JJ1-TC-153 PENGGANTIAN FUEL SUPPLY PUMP Prosedur Pelepasan Kuras air pendingin mesin sebagian. Lihat ke bagian engine cooling. Lepas radiator upper hose. Lepas fan guide. Lepas cooling fan. Lepas A/C compressor drive belt. Lepas A/C compressor adjust pulley. Lepas battery.
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Page 157
Mesin 4JJ1-TC-154 21. Lepas timing chain cover upper (1) dan lower (2) 22. Tepatkan silinder No. 1 pada titik mati atas (TMA). Ketiga tanda goresan harus lurus. 23. Sementara lepaskan sprocket nut (1). https://www.automotive-manuals.net/… -
Page 158
Mesin 4JJ1-TC-155 24. Lepas timing chain tensioner (1) (2) (3). 25. Lepas timing chain tension lever pivot (1). 26. Lepas nut (3) and sprocket (2). 27. Timing chain pindahkan ke atas. 28. Beri tanda antara idle gear A dan supply pump gear. -
Page 159
Mesin 4JJ1-TC-156 29. Gunakan gear puller untuk melepas fuel supply pump gear. 30. Lepas fuel supply pump (1) dan supply pump bracket (2). 31. Lepas fuel supply pump (2) dan O-ring (1). Jangan menarik fuel supply pump high pressure pipe (3). Jangan menggunakan pipe sebagai pegangan saat membawa pump. -
Page 160
Mesin 4JJ1-TC-157 4. Pastikan bahwa fuel supply pump camshaft key berputar ke kanan dan horisontal. 5. Pasang fuel supply pump gear dan sprocket dikuti dengan timing gear chain dan nut. Kencangkan nut dengan tangan. 1. Timing Chain 2. Timing Mark 3. -
Page 161
Mesin 4JJ1-TC-158 7. Tahan cam (3) ke bawah. Masukkan plunger (2). Cantelkan pin pada hook untuk menahan plunger pada tempatnya. 1. Pin 2. Plunger 3. Cam 4. Body 5. Hook 8. Pasang timing chain tensioner (1). Kencangkan baut sesuai torsinya. -
Page 162
Mesin 4JJ1-TC-159 11. Putar crank pulley dua putaran (720°CA). Ketiga tanda goresan harus bertemu. 12. Pasang cylinder head cover. Lihat ke bagian engine mechanical. 13. Berikan gasket cair (ThreeBond TB-1207C atau sejenis) pada timing chain cover upper. Pasang cover 5 menit setelah pemberian gasket. -
Page 163
Mesin 4JJ1-TC-160 19. Kencangkan fuel rail bracket dan fuel rail sesuai dengan torsinya. Torsi pengencangan: 25 N⋅m (2.5 kg⋅m / 18 lb ft) (Sisi Atas) Torsi pengencangan: 20 N⋅m (2.0 kg⋅m / 14 lb ft) (Sisi Bawah) 20. Kencangkan vacuum pipe (3) sesuai dengan torsi. -
Page 164: Service Special Tool (Sst)
4JJ1-TC Engine-161 SERVICE SPECIAL TOOL (SST) Nama SST Nomor Part SST Gambar SST Penggunaan SST Valve Clearance Adjust Nut Wrench 5-8840-2822-0 Compression Gage 5-8840-2675-0 & & Gage Adapter 5-8840-2815-0 Engine Hanger 5-8840-2823-0 https://www.automotive-manuals.net/…
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Page 165
4JJ1-TC Engine-162 Gambar SST Penggunaan SST Nama SST Nomor Part SST Camshaft Gear Tool 5-8840-2591-0 Valve Spring Replacer 5-8840-2818-0 & & Pivot Assembly 5-8840-2819-0 Valve Stem Seal Installer 5-8840-2817-0 Injection Pipe Oil Seal Installer 5-8840-2820-0 Valve Guide Remover and Installer… -
Page 166
4JJ1-TC Engine-163 Gambar SST Penggunaan SST Nama SST Gambar SST Piston ring compressor 5-8840-9018-0 Pilot Bearing Remover 5-8840-2000-0 & & Sliding Hammer 5-8840-0019-0 Pilot Bearing Installer 5-8522-0024-0 Crankshaft Stopper 5-8840-0214-0 Oil Seal Installer 5-8840-2821-0 https://www.automotive-manuals.net/… -
Page 167
4JJ1-TC Engine-164 Gambar SST Penggunaan SST Nama SST Nomor Part SST Oil Seal Installer 5-8840-2360-0 Oil Filter Wrench 5-8840-0203-0 Cap Tester 5-8840-0277-0 & & Adapter 5-8840-2603-0 Fuel Pump Retainer Ring Remover 5-8840-2602-0 Connector Test Adapter 5-8840-0385-0 Digital Multimeter 5-8840-0285-0 https://www.automotive-manuals.net/… -
Page 168
4JJ1-TC Engine-165 Gambar SST Penggunaan SST Nama SST Nomor Part SST Tech 2 Kit Breaker Box Adapter Harness https://www.automotive-manuals.net/…
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WORKSHOP MANUAL
2011MY UC SERIES
ENGINE
4JJ1 MODEL
SECTION 6
Isuzu Motors Limited
E-Solutions &
Service Marketing Dept.
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ENGINE MECHANICAL (4JJ1) 6A-1
SECTION 6A
ENGINE MECHANICAL (4JJ1)
TABLE OF CONTENTS
ISUZU DIESEL ENGINE (4JJ1) ……………………. 6A-3
Service Precautions ………………………………….
6A-3Trouble Shooting………………………………………
6A-8Main Data and Specifications…………………….. 6A-13
Special Tools……………………………………………
6A-14Engine Assembly…………………………………………
6A-15Removal
………………………………………………….
6A-15Installation
………………………………………………. 6A-17Special Tools……………………………………………
6A-19Engine Mount
…………………………………………….. 6A-20Components…………………………………………….
6A-20Removal
………………………………………………….
6A-21Installation
………………………………………………. 6A-21Torque Specifications………………………………..
6A-22Special Tools……………………………………………
6A-22Cylinder Head Cover ……………………………………
6A-23Components…………………………………………….
6A-23Removal
………………………………………………….
6A-24Installation
………………………………………………. 6A-25Intake
Manifold……………………………………………
6A-26Components…………………………………………….
6A-26Removal
………………………………………………….
6A-27Installation
………………………………………………. 6A-28Torque Specifications………………………………..
6A-30Turbocharger and Exhaust Manifold ……………… 6A-31
Components…………………………………………….
6A-31Removal
………………………………………………….
6A-32Inspection………………………………………………..
6A-34Installation
………………………………………………. 6A-35Torque Specifications………………………………..
6A-38Timing Gear Train ……………………………………….
6A-39Components…………………………………………….
6A-39Removal
………………………………………………….
6A-40Disassembly…………………………………………….
6A-42Reassembly……………………………………………..
6A-42Inspection………………………………………………..
6A-43Installation
………………………………………………. 6A-44Torque Specifications………………………………..
6A-47Camshaft Assembly …………………………………….
6A-48Components…………………………………………….
6A-48Removal
………………………………………………….
6A-49Disassembly…………………………………………….
6A-50Reassembly …………………………………………….
6A-52Installation
………………………………………………. 6A-53Torque Specifications………………………………..
6A-55Special Tools……………………………………………
6A-55Valve Stem Seal and Valve Spring ……………….. 6A-56
Components…………………………………………….
6A-56Removal
………………………………………………….
6A-57Inspection………………………………………………..
6A-58Installation
………………………………………………. 6A-59Special Tools……………………………………………
6A-60Cylinder
Head…………………………………………….. 6A-61Components…………………………………………….
6A-61Removal
………………………………………………….
6A-61Disassembly…………………………………………….
6A-69Inspection………………………………………………..
6A-71Reassembly …………………………………………….
6A-76Installation
………………………………………………. 6A-77Torque Specifications………………………………..
6A-88Special Tools……………………………………………
6A-88Piston and Connecting Rod…………………………..
6A-89Components…………………………………………….
6A-89Removal
………………………………………………….
6A-89Disassembly…………………………………………….
6A-90Reassembly …………………………………………….
6A-94Installation
………………………………………………. 6A-95Torque Specifications………………………………..
6A-97Special Tools……………………………………………
6A-97Flywheel
…………………………………………………….
6A-98Components…………………………………………….
6A-98Removal
………………………………………………….
6A-98Inspection………………………………………………..6A-100
Installation
………………………………………………. 6A-100Torque
Specifications………………………………..6A-102Special
Tools……………………………………………6A-102Gear Case Assembly
…………………………………..6A-103Components…………………………………………….6A-103
Removal
………………………………………………….6A-104Installation
………………………………………………. 6A-105Torque
Specifications………………………………..6A-107 -
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6A-2 ENGINE MECHANICAL (4JJ1)
Crankshaft Front Oil
Seal……………………………..6A-108Components…………………………………………….6A-108
Removal
………………………………………………….6A-108Installation
……………………………………………….6A-109Torque
Specifications………………………………..6A-110Special
Tools……………………………………………6A-110Crankshaft Rear Oil Seal
……………………………..6A-111Components…………………………………………….6A-111
Removal
………………………………………………….6A-112Installation
……………………………………………….6A-112Special
Tools……………………………………………6A-113Crankshaft………………………………………………….6A-114
Components…………………………………………….6A-114
Removal
………………………………………………….6A-115Disassembly…………………………………………….6A-116
Reassembly……………………………………………..6A-116
Inspection………………………………………………..6A-116
Installation
……………………………………………….6A-120Torque
Specifications………………………………..6A-123Cylinder Block
…………………………………………….6A-124Components…………………………………………….6A-124
Removal
………………………………………………….6A-124Inspection………………………………………………..6A-125
Installation
……………………………………………….6A-126Lubrication
System………………………………………6A-128Service Precautions
………………………………….6A-128Functional Check
……………………………………..6A-129Oil Filter Cartridge
……………………………………….6A-131Components…………………………………………….6A-131
Removal
………………………………………………….6A-131Installation
……………………………………………….6A-131Special
Tools……………………………………………6A-132Oil Filter Assembly and Oil Cooler
…………………6A-133Components…………………………………………….6A-133
Removal
………………………………………………….6A-133Installation
……………………………………………….6A-135Crank Case and Oil
Pan……………………………….6A-137Components…………………………………………….6A-137
Removal
………………………………………………….6A-138Disassembly…………………………………………….6A-139
Reassembly……………………………………………..6A-139
Installation
……………………………………………….6A-140Torque
Specifications………………………………..6A-142Oil Pump
……………………………………………………6A-143Components…………………………………………….6A-143
Removal
………………………………………………….6A-143Disassembly…………………………………………….6A-145
Reassembly
…………………………………………….6A-145Inspection………………………………………………..6A-145
Installation
………………………………………………. 6A-146Oil Pressure SW
…………………………………………6A-149Components…………………………………………….6A-149
Removal
………………………………………………….6A-150Inspection………………………………………………..6A-150
Installation
………………………………………………. 6A-150Circuit
check…………………………………………….6A-150Air Cleaner Element
…………………………………….6A-151Removal
………………………………………………….6A-151Cleaning
………………………………………………….6A-151Installation
………………………………………………. 6A-151 -
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ENGINE MECHANICAL (4JJ1) 6A-3
ISUZU DIESEL ENGINE (4JJ1)
Service Precautions
Matters that require attention in terms of
maintenance
To prevent damage to the engine and ensure reliabilityof its
performance, pay attention to the following inmaintaining the engine:
• When lifting up or supporting the engine, do not
apply a jack on the oil pan.
When taking down the engine on the ground, do
not make the bearing surface of the oil pan touch
the ground directly. Use a wooden frame, for
example, to support the engine with the engine
foot and the flywheel housing.
Because there is only a small clearance between
the oil pan and the oil pump strainer, it can
damage the oil pan and the oil strainer.
• When the air duct or air cleaner is removed,
coverthe air intake opening to prevent foreign matter
from getting into the cylinder. If it gets
contaminated, it can considerably damage the
cylinder and others while the engine is operating.
• When maintaining the engine, never fail to remove
the battery earth cable. If not, it may damage the
wire harness or electrical parts. If you need
electricity on for the purpose of inspection, for
instance, watch out for short circuits and others.
• Apply engine oil to the sliding contact surfaces
ofthe engine before reassembling it. This ensures
adequate lubrication when the engine is first
started.
• When valve train parts, pistons, piston rings,
connecting rods, connecting rod bearings or
crankshaft journal bearings are removed, put them
in order and keep them.
• When installing them, put them back in the same
location they were removed from.
• Gaskets, oil seals, O-rings, etc. must be replaced
with new ones when the engine is reassembled.
• As for parts where a liquid gasket is used, remove
an old liquid gasket completely and clean it up
thoroughly so that no oil, water or dust is clinging
to them. Then, apply the designated liquid gasket
to each place anew before assembly.
• Surfaces covered with liquid gasket must be
assembled within 5 minutes of gasket application.
If more than 5 minutes has elapsed, remove the
existing liquid gasket and apply a new liquid
gasket.
• When assembling or installing parts, fasten them
with the prescribed tightening torque so that they
are installed properly.
Matters that require attention in specifically dealing
with this engine.
Holes or clearances in the fuel system, which serve as
a passage of fuel, including the inside of the injector,
are made with extreme precision. For this reason, they
are highly sensitive to foreign matter and, if it gets in,
itcan lead to an accident on the road, for instance; thus,
make sure that foreign matter is prevented from getting
in.
When servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the
system.
• Before beginning the service procedure, wash the
fuel line and the surrounding area.
• Perform the service procedures with clean hands.
Do not wear work gloves.
• Immediately after removing the fuel hose and/or
fuel pipe, carefully tape vinyl bags over theexposed ends of the
hose or pipe.•
If parts are to be replaced (fuel hose, fuel pipe,
etc.) do not open the new part packaging until
installation.
Work procedure
• The fuel opening must be quickly sealed when
removing the fuel pipe, injection pipe, fuel injector,
fuel supply pump, and fuel rail.
•
The eyebolts and gasket must be stored in a cleanparts box with
a lid to prevent adhesion of foreignmatter.
• Fuel leakage could cause fires. Therefore, after
finishing the work, wipe off the fuel that has leaked
out and make sure there is no fuel leakage after
starting the engine.
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6A-4 ENGINE MECHANICAL (4JJ1)
How to read the model
RTW56ALF001501
Legend
1. Engine Model (Stamped)
2. Engine Number (Stamped)
3. Front
Explanation of functions and operations
Electronic engine controlWith the control unit, the range from
injection to airintake/exhaust, including fuel injection quantity, injection
timing, intake air restriction, EGR, and idling rpm, is
controlled.
Piston
The piston is aluminum-alloy and a thermal flow piston
with a strut cast, while the combustion chamber is a
round reentrant type.
Cylinder head
The cylinder head is aluminum-alloy and there are 4valves per
cylinder. The angular tightening method ofthe cylinder head bolt further increases reliability and
durability.
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ENGINE MECHANICAL (4JJ1) 6A-5
EGR system
Based upon data, including water temperature, engine
speeds or engine loads, it is controlled via Engine
Control Module (ECM) to purify exhaust by recycling
part of it.
Its main components include an EGR valve, an EGR
cooler and various sensors.
Connecting rod cap bolt
The angular tightening method of the connecting rod
cap bolt further increases reliability and durability.
Fuel rail-type electronic control injection system
The fuel rail-type electronic control injection system is
composed of a fuel supply pump that sets the target
pressure of high-pressure fuel and supply it, a fuel rail
that measures such high-pressure fuel and a fuel
injector that turns it into a fine spray and injects it.
Eachis controlled via ECM based upon various signals, whileinjection
timing or fuel injection quantity is controlledunder every possible driving condition.
Fuel injector
The fuel injector is a 6-hole nozzle that adjusts fuel
injection quantity or injection timing by opening or
closing an electromagnetic valve on the head of the fuel
injector.
ECM corrects the dispersion of fuel injection quantity
between fuel injector according to ID code data in
memory. At the replacement of fuel injector, ID code
data should be stored in ECM.
Fuel filter with sedimenter
It is a fuel filter with sedimenter that gets rid of water
bymaking use of the difference in specific gravity between
light oil and water, which comes with an indicator that
notifies you that it is filled with water.
Preheating system
The preheating system consists of the ECM, the glow
relay, glow plugs and the glow indicator lamp. The
preheating system is operated when the engine coolant
temperature is low, and makes the engine easy to start.
Lubrication system
It is an oil filter with full-flow bypass, which uses a
water-cool oil cooler and oil jet to cool the piston.
Functional inspection
Inspection/adjustment of valve clearance
1. Inspection of valve clearance
• Remove the fuel injector harness assembly.
• Remove the leak off hose.
• Remove the cylinder head cover.
• Rotate the crankshaft to make the No.1
cylinder meet the compression top dead center
(TDC).
RTW76ASH001301
Legend
1. TDC
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6A-6 ENGINE MECHANICAL (4JJ1)
• Insert a 0.15 mm (0.006 in) thickness gauge
between the roller of the rocker arm and the
camshaft to tighten up the adjusting screw of
the rocker arm. When the movement of the
thickness gauge becomes tight, fasten the
adjusting screw nut of the rocker arm.
Valve clearance mm (in)
Intake valve 0.15 (0.006)
Exhaust valve 0.15 (0.006)
Note:
Adjust while cold.
2. Adjustment of valve clearance
• Loosen each adjusting screw of the rocker arm
completely.
RTW56ASH003701
Legend
1. Screwdriver
2. Ring Spanner
3. Valve Clearance Adjust Nut Wrench
Special tool
Valve clearance adjust nut wrench: 5-8840-2822-0
• Insert a 0.15 mm (0.006 in) thickness gauge
between the roller of the rocker arm and the
camshaft to tighten up the adjusting screw of
the rocker arm. When the movement of the
thickness gauge becomes tight, fasten the
adjusting screw nut of the rocker arm.
LHW71BSH001201
Legend
1. Cam; Exhaust
2. Cam; Intake
3. Roller; Intake
4. Roller; Exhaust
Tightening torque:
Rocker arm adjustment screw nut
18 N⋅⋅⋅⋅m (1.8 kg⋅⋅⋅⋅m / 13 lb ft)
Adjustment table
Cylinder No. 1 2 3 4
Valve
arrangementIN EX IN EX IN EX IN EX
No. 1 cylinder
Compression
TDC
No. 4 cylinder
Compression
TDC
× × × ×
• If the No.1 cylinder is the compression TDC, adjusta
valve clearance with mark given on the tableand if the No. 4 cylinder is the compression TDC,
adjust that with × mark.
• Install the cylinder head cover.
Refer to «Cylinder Head Cover.»
• Install the leak off hose.
• Install the fuel injector harness assembly.
Compression pressure inspection
• Warm up the engine.
• Disconnect the negative battery cable.
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ENGINE MECHANICAL (4JJ1) 6A-7
• Remove the all glow plugs.
Note:
When the harness connector is removed, ECM judges
that it broke down and DTC is recorded. Upon
completion of measurement, never fail to clear the
memory of the ECM.(For how to clear the memory of the ECM, refer
to“ENGINE CONTROL SYSTEM” Section)
• Connect the negative battery cable.
• Turn on the starter to emit foreign matter within
thecylinders.
• Install an adapter and a gauge of a compression
gauge of the special tool.
RTW56ASH003801
Compression gauge: 5-8840-2675-0
Gauge adapter: 5-8840-2815-0
• Turn on the starter to inspect compression
pressure.
Compression pressure MPa(psi)/200rpm
Standard 2.84 − 3.24 (412 − 469)
Limit 1.96 (284)
Differences among
the cylinders 294 kPa (43)
• Measure each cylinder one by one.
Note:
To keep engine speed at 200 rpm or more, use fully
charged batteries.
• Remove a compression gauge of the special tool.
• Disconnect the negative battery cable.
• Install the glow plugs.
• Connect the negative battery cable.
A list of defective phenomena
• Engine does not turn over.
• Engine turns over but does not start.
• Excessive black exhaust smoke.
• Excessive white exhaust smoke.
• Engine knocking.
• Abnormal engine rotation.
• Abnormal battery charging.
• Turbocharger trouble shooting.
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6A-8 ENGINE MECHANICAL (4JJ1)
Trouble Shooting
Engine does not turn over
Condition Possible Cause Correction
Dead or weak battery Charge battery
Replace battery
Incomplete circuit Connector wiring and/or connectorsRepair
Starter motor brushes stuck, worn,
or broken
Replace brushes
Starter motor does not rotate
Starter motor internal damage Repair motor
Ring gear abrasion Replace ring gearStarter motor not meshed
withflywheelMagnetic switch (starter motor) not
properly adjusted
Adjust magnetic switch
Dead or weak battery Charge battery
Replace battery
Insufficient contact pressurebetween starter motor brushes
andcommutator
Adjust pressure
Armature (starter motor) stuck Repair armature
Starter motor pinion meshed with
ring gear but does not rotate
Engine internal damage (Seizure) Repair engine
Engine turns over but does not start
Condition Possible Cause Correction
Air in fuel system Bleed air from fuel system
Air entering fuel pipe Replace pipe and bleed air from
fuel system
Empty fuel tank Replenish fuel
Clogged strainer (fuel suction) Clean or replace strainer
Clogged fuel pipe Clean or replace pipe
Feed pump malfunction Replace pump
Use of wrong fuel for prevailing
temperatures
Drain existing fuel and replace with
appropriate fuel
Fuel is not delivered to fuel supply
pump
Clogged fuel filter Replace filter
Loose injection pipe connections Tighten connections
Loose or broken electricalconnectors
Tighten and/or replace connectors
Bad rotational sensor Replace sensor
Fuel is delivered to fuel supply
pump
Engine control system malfunction System diagnosis
Air in fuel system Bleed air from fuel system
Feed pump malfunction Repair pump
Loose or broken electrical
connectors
Tighten and/or replace connectors
Clogged fuel filter Replace filter
Insufficient or unstable fuel delivery
volume
Engine control system malfunction System diagnosis
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ENGINE MECHANICAL (4JJ1) 6A-11
Abnormal engine rotation
Condition Possible Cause Correction
Defective control unit Replace unitEngine speed cannot be
increasedEngine control system malfunction System diagnosis
Defective control unit Replace unit
Engine control system malfunction System diagnosis
Clogged fuel filter element Replace element
Defective fuel injector(s) Replace fuel injector assembly
Water in fuel Drain existing fuel and replace with
new fuel
Engine speed unstable
Air in fuel system Bleed air from fuel system
Damaged turbocharger fan Replace turbocharger
Rough turbocharger shaft rotation Replace turbocharger
Turbocharger malfunction
Broken actuator Replace turbocharger
Abnormal battery charging
Condition Possible Cause Correction
Open or shorted wiring and/or
connectors
Repair or replace wiring and/or
connectors
Defective generator Repair or replace generator
No charging
Defective battery Replace battery
Open or shorted wiring and/or
connectors
Repair or replace wiring and/or
connectors
Defective generator Repair or replace generator
Loose generator drive belt Adjust belt tension or replace
beltInsufficient charging
Defective battery Replace battery
Shorted wiring Repair or replace wiring
Defective generator Repair or replace generator
Excessive charging
Defective battery Replace battery
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6A-12 ENGINE MECHANICAL (4JJ1)
Turbocharger Troubleshooting
Condition Possible Cause Correction
Air leakage from intake pipe rubber
hose
Repair rubber hose
Air leakage from intake cover Repair intake cover
Clogged intercooler cooling section Clean cooling section
Clogged air cleaner element Clean or replace element
Intake throttle valve stuck Repair or replace throttle valve
Turbine and housing contact
(Interference)
Replace turbine and/or housing
Excessive carbon deposit near
turbine exhaust port that interferes
with turbine
Clean or repair exhaust port and/or
turbine
Rough turbine shaft rotation Repair or replace turbine shaft
Engine has less than normal power
Damaged turbine blade Repair or replace turbine blade
Oil leakage from turbocharger oilseal
Repair or replace oil seal
Clogged turbocharger oil return
pipe
Repair pipe
Clogged center housing oil
passages
Repair or replace center housing
Blue exhaust smoke
Engine oil deterioration Change engine oil
Gas leakage from intake or
exhaust system
Repair intake or exhaust system
Turbine and housing contact
(Interference)
Repair or replace turbine and/or
housingDamaged turbine blade Replace turbine blade
Noisy turbocharger operation
Turbine shaft bearing abrasion or
scoring
Repair or replace bearing
Engine oil deterioration Change engine oil
Clogged turbocharger oil feed pipe Repair pipe
Excessive rotating part wear
Low engine oil pressure Repair
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ENGINE MECHANICAL (4JJ1) 6A-13
Main Data and Specifications
Item Engine model 4JJ1
Type Diesel/4-cycle/water cooling-type in-line DOHC
Combustion chamber type Direct injection type
Cylinder liner type
Liner less
Number of cylinders -cylinder
bore × strokes
mm (in) 4-95.4(3.76) × 104.9(4.13)
Displacement cc (cu.in) 2999 (183)
Compression ratio 17.5
Compression pressure MPa (psi)/rpm 3 (435)/200
Idling speed rpm 700 ± 25
Valve clearance Intake 0.15 (0.006) (cold)
mm (in) Exhaust 0.15 (0.006) (cold)
Ignition type Compressed ignition
Injection order 1 — 3 — 4 — 2
Lubricating system
Lubricating type Pressure delivery type
Oil pump type Gear type
Volume of lubricating oil L (qts) 8.0 (8.5)
Oil filter type Full flow filter (cartridge type)
Oil cooling type Built-in-type, water cooling
Cooling system
Cooling type Water cooling type
Radiator type Corrugated fin (pressure type)
Water pump type Centrifugal, belt drive type
Thermostat type Wax-type units
Thermostat valve-opening temperature °C (°F) 85 (185)
Volume of coolant L (qts) M/T8.7 (9.2) A/T 8.6 (9.1) (incl.
radiator)Fuel system
Injection pump type Fuel supply pump fuel rail type
Fuel injector type Electronic control injector
6-hole
Fuel pump type Into the fuel tank type
Charging system
Generator type AC type
Power output V-A 12 — 110
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ENGINE MECHANICAL (4JJ1) 6A-15
Engine Assembly
Removal
1. Disconnect the negative battery cable.
2. Remove the engine hood.
3. Drain the coolant.
4. Remove the starter motor.
5. Remove the transmission assembly.
Refer to removal procedure for “TRANSMISSION”
in this manual.
6. Disconnect the ECM harness connector.
7. Remove the ECM.
8. Remove the air cleaner.
• Disconnect the MAF sensor harness connector.
• Remove the intake pipe with the lid of air
cleaner box.
• Remove the air cleaner box.
RTW56ASH003901
Legend
1. ECM Harness Connector
2. ECM
3. Air Cleaner Box
9. Remove the clip (1) and clip (2)
RTW86ASH001601
Legend
1. Clip
2. Clip
10. Remove the intake hose (intercooler — intake
throttle).
11. Remove the intake hose (turbocharger —
intercooler).
Remove the harness connector.
RTW56ASH004001
Legend
1. Intake Hose (intercooler — intake throttle)
2. Intake Hose (turbocharger — intercooler)
12. Remove the radiator upper hose.
13. Remove the engine harness clip (1).
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6A-16 ENGINE MECHANICAL (4JJ1)
RTW76ASH001401
14. Remove the breather hose and lower hose of the
radiator.
15. Remove the fan guide.
16. Remove the drive belt.
17. Remove the fan assembly.
18. Remove the radiator.
19. Remove the A/C compressor.
RTW76ASH000701
Legend
1. A/C Compressor Bracket
2. A/C Compressor
• Disconnect the connector.
• Disconnect the A/C generator harness.
• Disconnect the terminal B cable and harness
connector from the generator.
20. Remove the power steering pump.
• Remove the bracket of power steering oil hose
(1).
LTW56ASH000101
21. Remove the harness of engine, battery and earth
(1).
RTW86ASH002001
Legend
1. Earth
22. Remove the connector of the shift on the fly (4×4).
23. Remove the vacuum hose of brake master-vac.
24. Remove the front exhaust pipe.
25. Disconnect the fuel hose on the feed and return
sides.
26. Install the engine hanger (special tool 5-8840-
2823-0).
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ENGINE MECHANICAL (4JJ1) 6A-17
RTW56ASH004301
Legend
1. Engine Hanger (Front Side)
RTW56ASH004401
Legend
1. Engine Hanger (Rear Side)
27. Hang wire on the engine hanger and hoist to lift
up the engine slightly.28. Remove the engine mount.
• Remove the fastening bolts for the engine mount
on the engine side.
29. Remove the engine assembly.
• Hoist the engine slightly to provide space to
remove the catalytic converter.
Installation
Notice:
Be absolutely sure that each harness is reconnected to
its original position.
1. Install the engine assembly.
• Hang wire on the engine hanger and hoist to lift up
the engine.
• Operate a hoist slowly to move the engine to the
place where it is to be installed.
• Make the transmission side lower and operate a
hoist slowly, pulling it backward to the engine.
2. Install the engine mount.
Tightening torque: 48 N⋅⋅⋅⋅m (4.9kg⋅⋅⋅⋅m / 35 lb ft)
3. Remove the engine hanger.
4. Install the catalytic converter.
Tightening torque: 27 N⋅⋅⋅⋅m (2.8kg⋅⋅⋅⋅m / 20 lb ft)
5. Install the front exhaust pipe.
Tightening torque: 67 N⋅⋅⋅⋅m (6.8kg⋅⋅⋅⋅m / 49 lb ft)
6. Install the fuel hose on the feed and return sides.
7. Install the vacuum hose of brake master-vac.
8. Install the connector of the shift on the fly (4×4).
9. Install the harness of engine, battery and earth (1).
RTW86ASH002001
10.Install the power steering pump.
Tightening torque: 25 N⋅⋅⋅⋅m (2.5kg⋅⋅⋅⋅m / 18 lb ft)
• Install the bracket of power steering oil hose.
11.Install the A/C compressor.
Tightening torque: 25 N⋅⋅⋅⋅m (2.5kg⋅⋅⋅⋅m / 18 lb ft)
• Install the connector.
12.Install the A/C generator harness.
• Install the terminal B cable and the harness
connector to the generator.
13.Install the radiator.
Tightening torque: 25 N⋅⋅⋅⋅m (2.5kg⋅⋅⋅⋅m / 18 lb ft)
14.Install the fan assembly.
Tightening torque: 8 N⋅⋅⋅⋅m (0.8kg⋅⋅⋅⋅m / 69 lb in)
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6A-18 ENGINE MECHANICAL (4JJ1)
15.Install the drive belt.
Refer to removal procedure for “DRIVE BELT” in
this manual.
16.Install the fan guide.
17.Install the breather hose and lower hose of the
radiator.
18.Install the engine harness clip (1).
RTW76ASH001401
19.Install the radiator upper hose.
20.Install the intake hose (turbocharger -intercooler).
• Install the harness connector.
21.Install the intake hose (intercooler — intake throttle).
RTW56ASH004001
22.Install the air cleaner.
• Install the intake pipe with the lid of air
cleanerbox.
• Install the air cleaner box.
• Connect the MAF sensor harness connector.
23. Install the clip (1) and clip (2)
RTW86ASH001601
24.Install the ECM.
25.Connect the ECM harness connector.
26.Install the transmission assembly.
Refer to installation procedure for
“TRANSMISSION”.
27.Install the starter motor.
Tightening torque: 94 N⋅⋅⋅⋅m (9.6kg⋅⋅⋅⋅m / 69 lb ft)
28.Replenish the coolant.
29.Install the engine hood.
Tightening torque: 10 N⋅⋅⋅⋅m (1.0kg⋅⋅⋅⋅m / 87 lb in)
30.Connect the negative battery cable.
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ENGINE MECHANICAL (4JJ1) 6A-19
Special Tools
ILLUSTRATIONPART NO.
PART NAME
5-8840-2823-0
Engine hanger
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6A-20 ENGINE MECHANICAL (4JJ1)
Engine Mount
Components
RTW86ALF000301
Legend
1. Nut2. Bolt (L = 80 mm / 3.15 in)
3. Bolt (L = 30 mm / 1.18 in)
4. Bolt (L = 25 mm / 0.98 in)
5. Bolt (L = 30 mm / 1.18 in)
6. Engine Foot RH
7. Engine Mount RH
8. Bolt (L = 25 mm / 0.98 in)
9. Bolt (L = 45 mm / 1.77 in)10. Bolt (L = 30 mm / 1.18 in)
11. Bolt (L = 40 mm / 1.57 in)
12. Bolt (L = 20 mm / 0.79 in)
13. Bolt (L = 100 mm / 3.94 in)
14. Engine Foot LH
15. Engine Mount LH
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ENGINE MECHANICAL (4JJ1) 6A-21
Removal
1. Remove the engine hood.
2. Remove the engine cover.
3. Set the hoist and the engine hanger of the special
tool (special tool 5-8840-2823-0).
4. Remove the engine mount.
• Before removing the engine mount, hang the
engine with a hoist.
• Remove the bolts of the engine mount.
• Hoist the engine assembly slightly to remove the
engine mount.
RTW56ASH022401
Installation
1. Install the engine mount and tighten up with the
specified torque.
Tightening torque: 52 N⋅⋅⋅⋅m (5.3 kg⋅⋅⋅⋅m / 38 lb ft)
2. Remove the engine hanger.
3. Install the engine cover.
4. Install the engine hood.
• Check if nothing is wrong with the engine
mount by starting the engine.
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ENGINE MECHANICAL (4JJ1) 6A-23
Cylinder Head Cover
Components
RTWB6ALF000101
Legend
1. Oil Filler Cap2. Oil Filler Cap Gasket
3. Cylinder Head Cover
4. Bolt
5. Nozzle Seal Cover6. Head Cover Gasket
7. Nut
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ENGINE MECHANICAL (4JJ1) 6A-25
9. Remove the cam end gaskets (1).
• Remove the liquid gasket that has adhered to
cylinder head completely.
RTW56ASH020501
Installation
1. Install the nozzle seal cover.
• Insert from the lower side of cylinder head
cover.
• Apply soapy water or engine oil to the surface
of cylinder head cover side.
• Insert the nozzle seal cover as far as it will go.
2. Install the cam end gaskets.
• Apply the liquid gasket (ThreeBond TB-1207B
or equivalent) and mount.
RTW56ASH020601
Legend
1. Cam End Gasket
2. Apply The Liquid Gasket
3. 2.0 — 3.0 mm (0.079 — 0.118 in)
• Apply attaching cam end gasket.
Apply the liquid gasket (ThreeBond TB-1207B
or equivalent).
RTW56ASH022701
Legend
1. 3.0 — 5.0 mm (0.118 — 0.197 in)
2. 3.0 — 5.0 mm (0.118 — 0.197 in)
3. Install the cylinder head cover.
Tightening torque: 10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)
• Tighten the nut and bolts in order shown in the
illustration.
RTW56ASH004801
4. Install the blow-by hose.
5. Install the leak-off hose and the fuel injector
connector.
6. Install the harness bracket to the cylinder head
cover.
7. Install the intake air duct.
Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)
8. Install the engine cover.
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6A-26 ENGINE MECHANICAL (4JJ1)
Intake Manifold
Components
RTW76ALF000201
Legend
1. Intake Duct2. Throttle Assembly
3. Intake Manifold Gasket
4. Intake Manifold5. EGR Valve Assembly Gasket
6. EGR Valve Assembly
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ENGINE MECHANICAL (4JJ1) 6A-27
Removal
1. Remove the engine cover.
2. Disconnect the connectors.
• Fuel Injector
• Throttle Assembly
• EGR Valve
• Glow Plug
• Barometric Sensor
• A/C Compressor Connector
3. Remove the A/C belt.
4. Remove the A/C compressor.
5. Remove the A/C compressor bracket.
6. Remove the intake air duct (Standard output).
RTW56ASH024801
Legend
1. A/C Compressor Bracket
2. Intake Air Duct
3. A/C Compressor
7. Remove the injector leak-off hoses (1).
RTW56ASH024301
8. Remove the engine oil level gauge guide tube.
9. Remove the EGR valve.
RTW66ASH003001
10. Remove the injection pipes.
• Remove sequentially from No.1 cylinder.
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6A-28 ENGINE MECHANICAL (4JJ1)
11. Disconnect the vacuum hose of swirl control valve
(1).
RTW66ASH003101
12. Remove the throttle assembly and gasket.
RTW56ASH005201
Legend
1. Throttle Assembly
2. Intake Manifold
13. Remove the intake manifold.
RTW56ASH018001
14. Remove the intake manifold gasket.
Installation
1. Install the intake manifold gasket.
2. Install the intake manifold.
• Tighten the nuts and bolts in the order
described in the drawing.
Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)
RTW56ASH018001
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ENGINE MECHANICAL (4JJ1) 6A-29
3. Install the throttle assembly and gasket.
• Tighten the bolts to the specified torque.
Tightening torque: 10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)
4. Install the vacuum hose of swirl control valve.
5. Install the injection pipe (fuel rail — fuel injector).
• It installs sequentially from No. 4 cylinder.
Tightening torque: 29 N⋅⋅⋅⋅m (3.0 kg⋅⋅⋅⋅m / 22 lb ft)
6. Install the EGR valve.
• Tighten the nuts to the specified torque.
Tightening torque: 27 N⋅⋅⋅⋅m (2.8 kg⋅⋅⋅⋅m / 20 lb ft)
7. Install the engine oil level guide tube.
Tighten the nuts to the specified torque.
Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)
8. Connect the connector of other parts.
• Fuel Injector
• Throttle Assembly• EGR Valve
• Glow Plug
• Barometric Sensor
• A/C Compressor Connector
9. Install the leak-off hoses.
RTW56ASH024301
Legend
1. Injector Leek-off Hose
10. Install the intake air duct.
Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)
11.Install the A/C compressor bracket.
Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)
12.Install the A/C compressor and A/C compressor
connector.
Tightening torque: 44 N⋅⋅⋅⋅m (4.5 kg⋅⋅⋅⋅m / 33 lb ft)
13. Install the A/C belt.
Check the A/C belt tension.
• Depress (2) or (4) the A/C belt mid-portion with
98 N (10 kg / 22 lb) force.
• Measure frequency of the specified section (1)
or (3) using a frequency meter.
A/C Belt tension position (1)
Deflection mm(in) Frequency (Hz)
New 9-12 (0.35-0.47) 159-189
Reuse 12-14 (0.47-0.55) 137-155
A/C Belt tension position (3)
Deflection mm(in) Frequency (Hz)
New 5-7 (0.2-0.28) 256-310
Reuse 7-9 (0.28-0.35) 220-252
RTW86ASH001801
Legend
1. Position
2. Deflection
3. Position
4. Deflection
5. Compressor
6. Compressor belt
7. Crank pulley
14. Install the engine cover.
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6A-30 ENGINE MECHANICAL (4JJ1)
Torque Specifications
RTW76AMF000101
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ENGINE MECHANICAL (4JJ1) 6A-31
Turbocharger and Exhaust Manifold
Components
RTW56ALF002101
Legend
1. Turbocharger Assembly2. Exhaust Manifold
3. Heat Protector
4. Catalyst Converter
5. Oil Feed Pipe
6. Oil Return Pipe7. Intake Hose for Intercooler and Intake
Throttle8. Intake Duct for Turbocharger and Air Cleaner
9. Intake Hose for Turbocharger and Intercooler
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6A-32 ENGINE MECHANICAL (4JJ1)
Removal
1. Loosen the radiator drain plug to drain coolant.
2. Remove the engine cover.
3. Remove the intake hose from the intercooler and
intake throttle.
4. Remove the intake hose from the turbocharger
and the intercooler.
5. Remove the air intake duct from the turbocharger
and the air cleaner.
6. Remove the EGR cooler.
Refer to “EGR Cooler” in EXHAUST SYSTEM
Section.
7. Remove the oil feed pipe.
8. Remove the oil return pipe.
• Loosen clamps (1) of A/T oil cooler pipe.
RTW56ASH025101
9. Remove the water feed and return pipe.
RTW56ASH005401
Legend
1. Oil Feed Pipe
2. EGR Cooler
3. Water Feed Pipe
4. Water Return Pipe
5. Oil Return Pipe
10. Remove the front exhaust pipe.
RTW56ASH018301
Legend
1. Gasket
2. Front Exhaust Pipe (4×2 High Ride Suspention,
4×4)
3. Gasket4. Front Exhaust Pipe (4×2 Except High Ride
Suspention)
11. Disconnect the front propeller shaft flange (1)
(Front Diff Side, 4×4 only).
RTW76ASH002301
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ENGINE MECHANICAL (4JJ1) 6A-33
12. Remove the catalyst converter.
RTW56ALH000201
13. Remove the turbocharger from the exhaust
manifold.
RTW56ASH005501
Legend
1. Exhaust Manifold
2. Gasket
3. Turbocharger
14. Remove the exhaust manifold.
• Remove the 8 nuts from the exhaust manifold.
RTW56ASH005601
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6A-34 ENGINE MECHANICAL (4JJ1)
Inspection
• Inspection of the exhaust manifold. Inspect the
plane surface of the plane on which the
manifold and the cylinder head are to be
installed.
Manifold installation plane surface mm (in)
Standard 0.3 (0.01) or lower
Limit 0.5 (0.02)
Note:
If the plane surface exceeds the limit, replace it.
LNW21BSH022301
• Check a crack in the exhaust manifold visually.
Carefully inspect the turbocharger for abrasion and/or
excessive wear. Make any necessary adjustments,
repairs, and/or part replacements.
Wheel shaft axial play
Use a dial gauge to measure the wheel axle shaft play
when a force of 12 N (1.2 kg / 2.6 lb) is alternately
applied to both sides of the compressor wheel.
Axial play mm (in)
Standard 0.03 − 0.06 (0.0012 − 0.0024)
Limit 0.09 (0.0035)
LNW21BSH022201
Wheel shaft and bearing clearance
Use a dial gauge to measure the clearance between the
wheel shaft and the bearing.
Clearance mm (in)
Standard 0.056 − 0.127 (0.0022 − 0.0050)
Limit 0.14 (0.0055)
LNW21BSH022301
Legend
1. Oil Outlet
2. Oil Intake
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6A-36 ENGINE MECHANICAL (4JJ1)
2. Install the gasket and turbocharger to the exhaust
manifold. Tighten the nuts to the specified torque.
Tightening torque: 27 N⋅⋅⋅⋅m (2.8 kg⋅⋅⋅⋅m / 20 lb ft)
RTW56ASH005501
Legend
1. Exhaust Manifold
2. Gasket
3. Turbocharger
3. Install the catalyst converter.
Tighten the nuts to the specified torque.
Tightening torque: 27 N⋅⋅⋅⋅m (2.8 kg⋅⋅⋅⋅m / 20 lb ft)
4. Connect the front propeller shaft flange (Front
Diff Side, 4×4 only).5. Install the front exhaust pipe.
Tighten the nuts to the specified torque.
Tightening torque
Exhaust Manifold Side: 67 N⋅⋅⋅⋅m (6.8 kg⋅⋅⋅⋅m / 49 lb ft)
Exhaust Pipe Side: 43 N⋅⋅⋅⋅m (4.4 kg⋅⋅⋅⋅m / 32lb ft)
6. Install the water feed pipe to the turbocharger (1).
• Tighten the joint bolts to the specified torque.
Tightening torque: 54 N⋅⋅⋅⋅m (5.5 kg⋅⋅⋅⋅m / 40 lb ft)
• Install the pipe bracket and tighten the bolts to
the specified torque.
Tightening torque: 10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)
• Install the rubber hoses between the water
return pipes and the thermostat housing.
RTW56ASH019101
7. Install the water return pipe. Tighten the joint bolt
to the specified torque.
Tightening torque: 54 N⋅⋅⋅⋅m (5.5 kg⋅⋅⋅⋅m / 40 lb ft)
RTW56ASH019001
8. Install the turbocharger oil feed pipe to the top of
the turbocharger. Tighten the joint bolts to the
specified torque.
Tightening torque (Turbo charger side):
22.5 N⋅⋅⋅⋅m (2.3 kg⋅⋅⋅⋅m / 17 lb ft)
Tightening torque (Oil cooler side):
22.5 N⋅⋅⋅⋅m (2.3 kg⋅⋅⋅⋅m / 17 lb ft)
• Install the pipe bracket and tighten the bolts to
the specified torque.
Tightening torque: (Clip)
10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)
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ENGINE MECHANICAL (4JJ1) 6A-37
RTW96ASH000101
Legend
1. Oil Feed Pipe
2. Clip
3. For Dia 8.00 mm (0.31 in)
4. For Dia 10.00 mm (0.39 in)
5. Oil Return Pipe
9. Tighten the oil return pipe bolts and nuts to the
specified torque.
Tightening torque (Turbocharger side):
10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)
Tightening torque (Crank case side):25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18
lb ft)10.Install the EGR cooler.
• Refer to “EGR Cooler” in EXHAUST SYSTEM
section.
11. Install the heat protector.
• Refer to “EGR Cooler” in EXHAUST SYSTEM
section.
12. Install the intake hose between the intercooler and
the intake throttle .
13. Install the intake hose between the turbocharger
and the intercooler .14. Install the intake duct between the
turbochargerand the air cleaner .
Tightening torque: 4 N⋅⋅⋅⋅m (0.4 kg⋅⋅⋅⋅m / 35 lb in)
15.Replenish the coolant.
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6A-38 ENGINE MECHANICAL (4JJ1)
Torque Specifications
RTW86ALF000701
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ENGINE MECHANICAL (4JJ1) 6A-39
Timing Gear Train
Components
RTW56ALF001101
Legend
1. Oil Pump Gear2. Crankshaft Gear
3. Idle Gear D
4. Exhaust Camshaft Gear
5. Intake Camshaft Gear
6. Idle Gear D Sprocket
7. Timing Chain
8. Injection Pump Sprocket9. Injection Pump Gear
10. Idle Gear A
11. Vacuum Pump Gear
12. Power Steering Oil Pump Gear
13. Idle Gear C
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6A-40 ENGINE MECHANICAL (4JJ1)
Removal
1. Partially drain the engine coolant.
2. Remove the radiator upper hose.
RTW56FSH000101
3. Remove the fan guide.
RTW46BSH000101
Legend
1. Fan Guide2. Clips
3. Lower Fan Guide
4. Fan Shroud
4. Remove the cooling fan and fan pulley.
RTW56ASH025401
5. Remove the A/C compressor drive belt and fan
belt.
6. Remove the crank pulley.
Note:
Do not reuse the crank pulley bolt.
7. Remove the power steering pump with hose.
RTW56ASH021101
Legend
1. Power Steering Pump
2. Nut
• Disconnect the bracket (1) of power steering oil
hose.
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ENGINE MECHANICAL (4JJ1) 6A-41
LTW56ASH000101
8. Remove the vacuum pump.
• Remove the vacuum pipe bracket and vacuum
pipe.
• Remove the oil pipe (feed side and return side)
of vacuum pump.
RTWB6ASH000801
9. Remove the front cover.
RTWB6ASH001001
10. Install the M6 bolt to the idle gear A.
11. Remove the idle gear A and idle gear A flange, idle
gear A shaft.
RTW56ASH011301
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ENGINE MECHANICAL (4JJ1) 6A-43
• Align the sub gear pin with the hole in the right
side of the idle gear A spring. Press the sub-
gear into place.
RTW56ASH022001
Legend
1. Snap Ring
2. Sub-gear
3. Spring
4. Idle Gear A
• Use a pair of snap ring pliers to snuggly install
the snap ring.
Inspection1. Measurement of idle gear backlash
• Apply a dial gauge on the teeth of the idle
gearto be measured and move the gear to right and
left lightly to read how much the dial gauge
shook (never fail to fix the gear).
• If the measurement exceeds the limit, replace
the idle gear.
Backlash of the idle gear mm (in)
Standard 0.10 − 0.17 (0.004 − 0.007)
Limit 0.30 (0.01)
• Measure backlash of the idle gear before
removing the idle gear A.
2. Measurement of end clearance of the idle gear.
• Insert a thickness gauge between the idle gear
and the thrust collar to measure a clearance.
• If the measurement exceeds the limit, replace
either the idle gear or the thrust collar.
End clearance of the idle gear mm (in)
Standard 0.060 − 0.135 (0.002 − 0.005)
Limit 0.20 (0.008)
• Measure an end clearance of the idle gear
before removing the idle gear B.
3. External diameter of the idle gear shaft.
• Use a micrometer to measure an external
diameter of each idle gear shaft.
• If the measurement exceeds the limit, replace
the shaft.
External diameter of the idle gear A shaft mm (in)
Standard 44.950 − 44.975 (1.7697 − 1.7707)
Limit 44.80 (1.764)
External diameter of the idle gear C shaft mm (in)
Standard 24.959 − 24.980 (0.9826 − 0.9835)
Limit 24.80 (0.976)
RTW56ASH021601
4. Clearance between the idle gear and the idle gear
shaft
• Measure an inside diameter of the idle gear
bush to calculate a clearance between the idle
gear and the idle gear shaft.
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6A-44 ENGINE MECHANICAL (4JJ1)
• If the measurement exceeds the limit, replace
either the idle gear or the shaft.
Clearance between the idle gear A and the shaft
mm (in)
Standard 0.025 − 0.075 (0.0010 − 0.0030)
Limit 0.200 (0.0079)
Clearance between the idle gear C and the shaft
mm (in)
Standard 0.020 − 0.062 (0.0008 − 0.0024)
Limit 0.200 (0.0079)
LNW21BSH003601
Installation
1. Install the crankshaft gear.
2. Install the idle gear C.
• Apply engine oil over the part where the gear
ofthe idle gear shaft is to be put together.
• Apply engine oil to the bolt screw thread and
seat, and temporarily tighten together with the
flange (tighten fully in later process).
RTW56ASH011401
3. Install the idle gear A.
4. Tighten sub gear setting bolt.
• Use the M6 bolts and lever to turn sub gear to
right direction until it aligns with the M6 bolt
hole between idle gear A and sub gear.
• Tighten the M6 bolt to a suitable torque to
prevent the sub gear from moving.
RTW56ASH011501
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ENGINE MECHANICAL (4JJ1) 6A-45
• Align the oil hole of the cylinder body (2) with
the oil hole of the idle gear A shaft (3).
• Install the flange so that the front mark (1) face
toward the front.
• Install the idle gear A and idle gear A flange,
idle gear A shaft at the position shown in the
figure.
• Apply engine oil over the part where the gear
ofthe idle gear shaft is to be put together.
• Apply engine oil to the bolt screw thread and
seat, and temporarily tighten together with the
flange (tighten fully in later process).
LNW81BSH000401
• Attach, aligning with the gear crank: idle A
andtiming mark.
RTW56ALH000301
5. Tighten the bolts of idle gear A and idle gear C to
the specified torque.
Tightening torque:
idle gear A 32 N⋅⋅⋅⋅m (3.3 kg⋅⋅⋅⋅m / 24 lb ft)
idle gear C 59 N⋅⋅⋅⋅m (6.0 kg⋅⋅⋅⋅m / 43 lb ft)
RTW56ASH011701
Legend
1. Idle Gear A Bolt
2. Idle Gear C Bolt
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6A-46 ENGINE MECHANICAL (4JJ1)
6. Remove the M6 bolt from the idle gear A.
7. Install the gear case cover.
• Apply the liquid gasket (ThreeBond TB-1207B
or equivalent).
RTW56ASH020101
Legend
1. Apply the liquid gasket
• Install the gasket in slot of the gear case cover.
• Tighten the bolts to the specified torque.
Tightening torque: 8 N⋅⋅⋅⋅m (0.8 kg⋅⋅⋅⋅m / 69 lb in)
RTW56ASH012101
8. Install the vacuum pump.
Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)
• Install the oil pipe (feed side and return side) of
vacuum pump.
• Install the vacuum pipe bracket and vacuum
pipe.
9. Install the power steering pump.
• Tighten the nuts to the specified torque.
Tightening torque: 25 N⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft)
• Connect the bracket (1) of power steering oil
hose.
LTW56ASH000101
10. Install the crank pulley.
• Please use new crank pulley bolt.
• Tighten the bolt to the specified torque.
Tightening torque: 294 N⋅⋅⋅⋅m (30.0 kg⋅⋅⋅⋅m / 217 lb ft)
11. Install the A/C compressor drive belt and fan belt.
Refer to drive belt tension check procedure for
Heating and air conditioning and Engine cooling in
this manual.
12. Install the cooling fan.
13. Install the fan guide.
14. Install the radiator upper hose.
15. Replenish the engine coolant.
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ENGINE MECHANICAL (4JJ1) 6A-47
Torque Specifications
LNW76ALF000601
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ENGINE MECHANICAL (4JJ1) 6A-49
Removal
1. Rotate the crankshaft to make the No. 1 cylinder
meet the compression TDC.
RTW76ASH001301
Legend
1. TDC
2. Remove the engine cover.
3. Remove the cylinder head cover.
Refer to «Cylinder Head Cover».
4. Install the M5 lock bolt of fixing sub gear.
RTW56ASH007101
5. Remove the baffle plate (1).
RTW56ASH006301
6. Remove the camshaft bearing cap and camshaft.
• Check the engraved making on the camshaft
bearing caps.
RTW56ASH018401
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6A-50 ENGINE MECHANICAL (4JJ1)
RTW56ASH013801
Disassembly1. Remove the sub gear assembly.
• Clamp the camshaft in a vise. Insert soft metal
protectors (aluminum) between the vise
surfaces and the camshaft.
• Use 5-8840-2591-0 to turn sub gear to right
direction to remove the M5 bolt.
RTW56ASH006801
• Use a pair of snap ring pliers to remove the
scissor gear assembly.
Note:
Take care not to damage the camshaft cams and
journals.
RTW56ASH006401
2. Remove the camshaft gear.
• Use a press (1) and socket (2) to remove the
camshaft gear (3).
RTW56ASH006501
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ENGINE MECHANICAL (4JJ1) 6A-51
3. Remove the dowel pin.
4. Inspect the camshaft visually.
• Check if the journal and cam parts of the
camshaft are worn or damaged, if so, replace
it.
LNW21BSH020201
5. Inspect an end clearance of the camshaft.
• Use a thickness gauge to measure an end
clearance of the camshaft gear and the
camshaft bracket.
• If the measurement exceeds the limit, replace
the camshaft gear or the camshaft.
End clearance of the camshaft mm (in)Standard 0.050 − 0.170
(0.003 − 0.007)Limit 0.25 (0.010)
Note:
Measure an end clearance of the camshaft before
disassembling.
RTW56ASH013901
6. Check if the cam lobe is worn.
• Use a micrometer to measure the height of the
cam lobe.
• If the height of the cam lobe is at the limit or
less, replace the camshaft.
Height of the cam lobe mm (in)
Inlet Exhaust
Standard 40.6 (1.60) 40.6 (1.60)
Limit 39.6 (1.56) 39.6 (1.56)
LNW21BSH020401
7. Check if the camshaft journal is worn.
• Use a micrometer to measure wear which is
not even with a diameter of the camshaft
journal.
• If the measured uneven wear exceeds the limit,
replace the camshaft.
External diameter of the camshaft journal part
mm (in)
Standard 29.909 − 29.930
(1.1775 − 1.1783)
Limit 29.809 (1.1736)
Partial wear of the camshaft journal part mm (in)
Limit 0.05 (0.0020)
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6A-52 ENGINE MECHANICAL (4JJ1)
LNW21BSH020501
8. Check if the camshaft is runout.
• Place the camshaft on a V block to measure a
runout with a dial gauge.
• Rotate the camshaft slowly to measure how
much the dial indicator shook. If it exceeds the
limit, replace the camshaft.
Runout of the camshaft mm (in)
Limit 0.05 (0.0020)
LNW21BSH020601
9. Measure a camshaft journal oil clearance.
a. Measure an inside diameter of the camshaft
bearing with a dial gauge.
b. Read the difference between the inside
diameter of the camshaft bearing and the
diameter of the camshaft journal.
If the measured oil clearance exceeds the limit,
replace the camshaft bearing.
Clearance of the journal part mm (in)
Standard0.070 − 0.112
(0.0028 − 0.0044)
Limit 0.15 (0.0059)
RTW86ASH000101
Reassembly
1. Install the dowel pin.
2. Install the camshaft gear.
• Align the knock pin with the slot in the camshaft
gear. Use a press to install the camshaft gear
to the camshaft.
RTW56ASH006601
Legend
1. Camshaft
2. Dowel Pin
3. Camshaft Gear
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ENGINE MECHANICAL (4JJ1) 6A-53
3. Install the sub gear assembly.
• Clamp the camshaft in a vise. Insert soft metal
protectors (aluminum) between the vise
surfaces and the camshaft. Press against the
pin on the left side of the camshaft gear spring
(3) to make a gap on the right side of the
spring. Push the spring into place.
• Align the sub gear pin (2) with the hole in the
right side of the camshaft gear damper spring
(3). Press the sub-gear into place.
RTW56ASH006701
Legend
1. Snap Ring
2. Sub-gear
3. Damper Spring
4. Camshaft Gear
• Use a pair of snap ring pliers to snuggly install
the snap ring.
4. Tighten sub gear setting bolt.
• Use 5-8840-2591-0 to turn sub gear to right
direction until it aligns with the M5 bolt hole
between camshaft driven gear and sub gear.
• Tighten the M5 bolt to a suitable torque to
prevent the sub-gear from moving.
RTW56ASH006801
Installation
1. Check the crankshaft to make the No. 1 cylinder
meet the compression TDC.
RTW76ASH001301
Legend
1. TDC
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6A-54 ENGINE MECHANICAL (4JJ1)
2. Install the camshaft assembly.
• Align timing mark on intake camshaft and
exhaust camshaft to idle gear D.
RTW56ASH007001
Legend
1. Exhaust Camshaft Gear
2. Intake Camshaft Gear
3. Idle Gear D
3. Camshaft bearing caps, tighten ten bolts on one
side bank to the specified torque.
• Apply engine oil to camshaft journal and
bearing surface of camshaft bearing caps.
RTW56ASH018401
4. Check that the alignment marks (camshaft bearing
cap and camshaft) are aligned.
RTW56ASH006901
Legend
1. Align mark on intake camshaft and exhaust
camshaft to mark of bearing cap
• Apply engine oil over the screw part and tighten
up the bearing cap with the prescribed torque.
Tightening torque: 18 N⋅⋅⋅⋅m (1.8kg⋅⋅⋅⋅m / 13 lb ft)
5. Remove the M5 lock bolt of fixing sub gear.
6. Adjustment of valve clearance.
• Refer to installation procedure for inspection /
adjustment of valve clearance in this manual.
7. Install the baffle plate. Tighten the bolts to the
specified torque.
Tightening torque: 10 N⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in)
8. Install the cylinder head cover.
Refer to «Cylinder Head Cover».
9. Install the engine cover.
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6A-56 ENGINE MECHANICAL (4JJ1)
Valve Stem Seal and Valve Spring
Components
RTW56ALF001301
Legend
1. Exhaust Rocker Arm Shaft Assembly2. Bolt (Long)
3. Bolt (Short)
4. Intake Rocker Arm Shaft Assembly
5. Fuel Injector Assembly
6. Bolt
7. Fuel Injector Clamp
8. Pin9. Spring Lower Seat
10. Valve Stem Oil Seal
11. Valve Spring
12. Spring Upper Seat
13. Split Collar
14. Valve Stem End Cap
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ENGINE MECHANICAL (4JJ1) 6A-57
Removal
1. Remove the cylinder head.
Refer to “Cylinder Head”.
2. Remove the valve stem end cap.
3. Remove the split collar.
• Use a replacer to compress the valve spring to
remove the split collar.
Special tool
Valve spring replacer: 5-8840-2818-0 (1)
Pivot assembly: 5-8840-2819-0 (2)
RTW56ASH012301
4. Remove the spring upper seat.
• Remove the special tool to remove the upper
seat.
5. Remove the valve spring.
• Put the removed valve springs in order by
cylinder number.
6. Remove the valve stem oil seal.
• Use pliers to remove the oil seal.
RTW56ASH012401
Note:
Do not use the removed oil seal again.
7. Remove the spring lower seat.
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6A-58 ENGINE MECHANICAL (4JJ1)
Inspection
Inspect the valve spring
Note:
Check the valve spring visually and if there is clear
damage or wear, replace it.1. Free length
• Measure free length of the spring and if it is
shorter than the prescribed limit, replace the
spring.
Free length of the valve spring mm (in)
Inlet / Exhaust
Standard 49.04 (1.93)
Limit 48.15 (1.90)
LNW21BSH017001
2. Valve spring 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.
Valve spring squareness mm (in)
Limit 2.1 (0.083)
LNW21BSH017101
3. Tension
• Use a spring tester to compress the spring to
the installation height. Measure tension of the
compressed spring. If the measurement is
lower than the limit, replace the spring.
Tension of the valve spring N (kg / lb)
Inlet / Exhaust
Installation length mm (in) 37.80 (1.488)
Standard 213 (21.7 / 47.8)
Limit 188 (19.2 / 42.3)
LNW21BSH056701
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ENGINE MECHANICAL (4JJ1) 6A-59
Installation
1. Install the spring lower seat.
2. Install the valve stem oil seal.
• Apply engine oil over the peripheral part of the
valve guide and install the oil seal by using a
valve stem seal installer.
Note:
After installing the valve stem oil seal, check if it
isinserted nice and deep and the oil seal is not tilted
orthe garter spring has not come off.
Special tool
Valve stem seal installer: 5-8840-2882-0
RTW56ASH013701
3. Install the valve spring.
4. Install the spring upper seat.
5. Install the split collar.
• Use a replacer to compress the valve spring
and install the split collar.
Special tool
Valve spring replacer: 5-8840-2818-0 (1)
Pivot assembly: 5-8840-2819-0 (2)
RTW56ASH012301
Note:
Move it up and down to check if it moves smoothly.
6. Install the valve stem end cap.
7. Install the cylinder head.
Refer to “Cylinder Head”.
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6A-60 ENGINE MECHANICAL (4JJ1)
Special Tools
ILLUSTRATIONPART NO.
PART NAME
5-8840-2818-0
Valve spring replacer
5-8840-2819-0
Pivot assembly
5-8840-2882-0
Valve stem seal installer
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ENGINE MECHANICAL (4JJ1) 6A-61
Cylinder Head
Components
RTW56ALF001001
Legend
1. Fuel Injector Clamp2. Fuel Injector Assembly
3. Glow Plug
4. Intake and Exhaust Valves
5. Cylinder Head6. Timing Chain Tension Lever
7. Timing Chain Guide
8. Timing Chain Tensioner
Note:
To avoid electric shock;
Set the switch to the ‘OFF’ position and disconnect the
negative battery cable before checking or repairing the
fuel injector, wiring or/and connectors.
Removal
1. Remove the engine head cover.
2. Drain the engine coolant.
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6A-62 ENGINE MECHANICAL (4JJ1)
3. Remove the radiator upper hose.
RTW56FSH000101
4. Remove the fan guide.
RTW46BSH000101
Legend
1. Upper Fan Guide
2. Clips
3. Lower Fan guide
4. Fan Shroud
5. Remove the cooling Fan.
RTW56ASH025401
6. Rotate the crankshaft to make the No.1 cylinder
meet the compression top dead center (TDC).
RTW76ASH001301
Legend
1. TDC
7. Remove the A/C compressor drive belt.
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ENGINE MECHANICAL (4JJ1) 6A-63
8. Remove the A/C compressor adjust pulley.
RTW56ASH010601
Legend
1. Bolt
2. Nut
9. Remove the battery.
10. Disconnect the A/C compressor connector and
A/C compressor with hose.
11. Remove the A/C compressor bracket.
RTW56ASH024201
Legend
1. A/C Compressor Bracket
2. Intake Duct
3. A/C Compressor
12. Remove the intake hose and duct.
RTW56ASH022501
Legend
1. Intake Hose for Intercooler and Intake Throttle
2. Intake Duct for Turbocharger and Air Cleaner
3. Intake Hose for Turbocharger and Intercooler
13. Disconnect the fuel injector connectors (2).
14. Remove the fuel leak off hoses (1).
RTW76ASH000101
Note:
Do not reuse the fuel leak off hose clips.
15. Disconnect each connectors.
• Glow Plug
• EGR Valve
• Throttle Assembly
• Barometric Sensor
• Water temperature sensor
• Camshaft Position sensor
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6A-64 ENGINE MECHANICAL (4JJ1)
16. Remove the harness bracket.
17. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
18. Remove the EGR cooler heat protector.
19. Remove the EGR cooler water pipe.
20. Remove the EGR cooler.
21. Loosen the nuts of catalyst converter and
turbocharger.
RTW56ASH006201
Legend
1. Catalyst Converter
2. Turbocharger
22. Remove the exhaust front pipe.
RTW56ASH007701
Legend
1. Exhaust Front Pipe (4×2 High Ride Suspension,
4×4)
2. Exhaust Front Pipe (4×2 Except High Ride
Suspension)
23. Disconnect the Front drive shaft (1). (4×4)
RTW76ASH002301
24. Remove the catalyst converter.
RTW56ALH000201
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ENGINE MECHANICAL (4JJ1) 6A-65
25. Remove the A/T oil cooler pipe brackets (A/T).
RTW56ASH025101
Legend
1. A/T Oil Cooler Pipe Bracket
26. Remove the turbocharger water return pipe and
hose.
RTW56ASH019001
27. Remove the turbocharger water feed pipe (1) and
hose.
RTW56ASH019101
28. Remove the turbocharger engine oil feed pipe.
29. Remove the engine oil level gauge guide tube.
30. Remove the fuel return pipe and hose (1).
RTW56ASH019201
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6A-66 ENGINE MECHANICAL (4JJ1)
31. Remove the fuel injection pipe clip.
32. Remove the fuel injection pipe.
33. Remove the vacuum hose (1).
RTW66ASH003101
34. Remove the timing chain cover lower.
35. Remove the timing chain cover upper.
RTWB6ASH000301
Legend
1. Timing Chain Cover Upper2. Timing Chain Cover Lower
36.Remove the water by pass pipe (1).
RTW56ASH008401
37. Remove the glow plugs (1).
RTW56ASH019301
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ENGINE MECHANICAL (4JJ1) 6A-67
38.Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
39. Install the lock bolt for camshaft scissor gear.
RTW56ASH007101
40. Remove the fuel injector assembly.
41. Remove the baffle plate.
42. Remove the camshaft bearing caps.
RTW56ASH018401
43.Remove the camshaft.
44. Remove the rocker arm shaft assembly.
Note:
Keep the removed rocker arm shaft assembly properly
so that they may be put back to the original place.
RTW56ASH012201
Legend
1. Exhaust Rocker Arm Shaft Assembly
2. Bolt (Long)
3. Bolt (Short)
4. Intake Rocker Arm Shaft Assembly
5. Front
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6A-68 ENGINE MECHANICAL (4JJ1)
Note:
Pay full attention so as not to drop the parts in the
gearcase of the front part of the cylinder head or a hole into
which oil pours back in the front.
Note:
Remember the original position.
45. Remove the timing chain tensioner.
RTW56CSH003701
Legend
1. Timing Chain Tensioner
2. Gasket
3. Nut
46. Remove the idle gear D.
• Timing chain is dropped behind.
RTW56ASH022101
47. Remove the timing chain tension lever pivot.
RTW56ASH019401
48. Remove the timing chain from supply pump
sprocket.
49. Remove the chain guide bolts from cylinder head.
RTW56ASH019501
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ENGINE MECHANICAL (4JJ1) 6A-69
50. Remove the cylinder head gear case nuts (1) and
bolts (2).
RTW56ASH020801
51. Remove the cylinder head bolt (1).
RTW56ASH008501
Note:
Do not reuse the cylinder head bolt.
52. Remove the cylinder head assembly.
• Loosen the cylinder head bolts in the order
described in the drawing.
• Remove the cylinder head gasket.
Note:
Replace the head gasket with a new one once it is
removed.
RTW56ASH008601
Disassembly
1. Remove the throttle assembly.
• Refer to procedure for Intake Manifold in this
manual.
2. Remove the intake manifold assembly.
• Refer to procedure for Intake Manifold in this
manual.
3. Remove the turbocharger.
• Refer to “Turbocharger and Exhaust Manifold”.
4. Remove the exhaust manifold assembly.
• Refer to procedure for Turbocharger and
Exhaust Manifold in this manual.
5. Remove the water outlet pipe.
6. Remove the valve stem end cap.
Refer to procedure for valve stem and valve in thismanual.
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6A-70 ENGINE MECHANICAL (4JJ1)
7. Remove the split collar.
• Use a replacer to compress the valve spring to
remove the split collar.
Special tool
Valve spring replacer: 5-8840-2818-0 (1)
Pivot assembly: 5-8840-2819-0 (2)
RTW56ASH012301
8. Remove the spring upper seat.
• Remove the special tool to remove the upper
seat.
9. Remove the valve spring.
• Put the removed valve springs in order by
cylinder number.
10. Remove the intake and exhaust valve.
• Sort the removed valves according to cylinders
by using tags others.
LNW21BSH016801
11. Remove the valve stem oil seal.
• Refer to procedure for valve stem and valve in
this manual.
12. Remove the spring lower seat.
13. Remove the valve guide.
• Use the valve guide replacer to press out the
valve guides from the bottom side of the
cylinder head.
Special tool
Valve guide remover and installer:
5-8840-2816-0
RTW56ASH008701
14. Remove the cam end gaskets (1).
RTW56ASH020501
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ENGINE MECHANICAL (4JJ1) 6A-71
15. Remove the oil seals.
RTW56ASH008801
Inspection
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
Cylinder Head Lower Face Warpage
1. Use a straight edge and a thickness gauge to
measure the four sides and the two diagonals of
the cylinder head lower face.
2. The cylinder head lower surface warpage is more
than the limit, it should be replaced.
RTW56ASH008901
Cylinder Head Lower Face Warpage mm (in)
Standard 0.05 (0.002) or less
Limit 0.20 (0.0079)
Note:
The cylinder head lower face cannot be regrind.
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6A-72 ENGINE MECHANICAL (4JJ1)
011RY00013
Cylinder Head Height (H) (Reference) mm (in)
Standard 143.4 (5.646)
RTW56ASH017401
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 0.05 (0.002) or less
Limit 0.20 (0.008)
Maximum Grinding Allowance 0.40 (0.016)
RTW56ASH017501
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.
Exhasut Manifold Warpage mm (in)
Standard 0.05 (0.002) or less
Limit 0.20 (0.008)
027RY00002
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ENGINE MECHANICAL (4JJ1) 6A-73
Valve Stem Cap
Make the necessary part replacements.
If excessive wear or damage is discovered during
inspection.
Valve Stem Outside Diameter
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)
Intake Valve Exhaust Valve
Standard6.955 – 6.970
(0.2738 – 0.2744)
6.947 – 6.962
(0.2735 – 0.2741)
Limit6.935
(0.2730)
6.920
(0.2724)
011LX027
Valve Stem and Valve Guide Clearance
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.
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)
Intake Valve Exhaust Valve
Standard0.030 – 0.060
(0.0012 – 0.0024)
0.038 – 0.068
(0.0015 – 0.0027)
Limit0.200
(0.008)
0.250
(0.0098)
011RY00023
Valve ThicknessMeasure 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 Exhasut Valve Thickness mm (in)
Standard 1.32 (0.052)
Limit 1.1 (0.043)
014RY00020
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6A-74 ENGINE MECHANICAL (4JJ1)
Valve Depression
1. Install the valve (1) to the cylinder head (2).
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 1.8 (0.07)
Limit 2.5 (0.098)
014RY00021
Valve Contact Width
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)
Intake Exhaust
Standard 1.4 (0.055) 1.4 (0.055)
Limit 2.2 (0.087) 2.5 (0.098)
014RY00027
Repair of the seat surface• Remove carbon from the surface
of the valveinsert seat.
• Use a seat cutter to minimize the scratch and
other roughness, thereby returning the contact
width to the standard value.
LNW71BSH013501
Legend
1. 90°
2. 50°
Note:
Remove only scratches and roughness, and do not cut
the surface too much.
Use the free adjustment valve cutter pilot.
Do not let the valve cutter pilot waver inside the valve
guide.
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ENGINE MECHANICAL (4JJ1) 6A-75
LNW21BSH056101
• Attach compound in the valve insert seat.
• Insert the valve into the valve guide.
• Attach compound on the valve seat surface, rotate
the valve and hit it lightly to grind it, and confirm
that it has even contact all round.
Note:
Remove compound completely after grinding.
LNW21BSH031801
Remove the valve seat insert
• Arc-weld the entire inner diameter of the valve seat
insert.
• Cool the valve seat insert for two to three minutes.
Contraction due to cooling makes it easier to
remove the valve seat insert.• Remove the valve seat
insert, using a screwdriver . Be sure not to harm the cylinder head.
LNW21BSH056001
Legend
1. Arc-Weld
2. Valve Seat Insert
3. Screw Driver
Install the valve seat insert
• Carefully place a washer (the outer diameter is
smaller than the valve seat insert) on the valve
seat insert.
• Use the press to apply pressure gradually on the
washer, thereby pushing the valve seat insert.
Note:
Do not apply too much pressure with the press. Attach
compound on the valve seat surface, rotate the valveand hit it
lightly to grind it, and confirm that it has evencontact all round.
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6A-76 ENGINE MECHANICAL (4JJ1)
LNW21BSH018601
Legend
1. Attach Compound
2. Valve Seat
3. Press
Reassembly
1. Install the oil seal.
• Install on the surface of the injection pipe insert.
• Hammer it in so that the seal does not incline.
Note:
Be sure not to harm the lip.
Special tool
Injection pipe oil seal installer: 5-8840-2820-0
RTW56ASH008801
RTW56ASH009101
Legend
1. Cylinder Head
2. Oil Seal Installer
2. Install the valve guide.
• Hammer in the valve guide from the upper
surface of the cylinder head, using the valve
guide installer.
Special tool
Valve guide remover and installer:
5-8840-2816-0
Note:
When replacing the valve guide, it must be replacedtogether with
the valve.RTW56ASH009001
• H
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