Page 1609 of 3573
4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 7
INSTALLATION
5. Cylinder Head Cover
·Apply engine oil to the rocker arms and the valve
springs.
·Install the cylinder head cover gasket to the
cylinder head cover.
·The gasket must be perfectly smooth with no
loose areas.
·Tighten the cylinder head cover nuts to the
specified torque in the numerical order.
13 (1.3/113 lb·in)N·m(Kg·m/lb·in)
4. Oil Level Gauge Tube
19 (1.9/14)N·m(Kg·m/lb·ft)
Bolt
3. Heater and Oil Cooler Pipe Fixing Bolts
2. Intercooler Assembly (4JG2-T Only)
·(Refer to intercooler installation steps in this
section.)
1. Air Cleaner Cover & Air Duct
Page 1610 of 3573
6A2 Ð 8 4JG2-NA/4JG2-TURBO ENGINE
INLET MANIFOLD
REMOVAL
1. Intercooler (4JG2-T only)
2. Oil Level Gauge Tube (4JG2-T only)
3. Heater and Oil Cooler Pipe Fixing Bolts.
·Remove fixing bolts from inlet manifold.
4. Injection Pipes
5. Inlet Manifold
INSTALLATION
5. Inlet Manifold
·Tighten the fixing bolts and nuts to the specified
19 (1.9/14)
N·m(Kg·m/lb·ft) Bolt
24(2.4/18)N·m(Kg·m/lb·ft)
Nut
Page 1611 of 3573
4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 9
4. Injection Pipes
·Tighten the sleeve nut to the specified torque
3. Heater and Oil Cooler Pipe Fixing Bolts
·Tighten fixing bolts to the specified torque
2. Oil Level Gauge Tube (4JG2-T only)
1. Inter Cooler (4JG2-T only)
·Refer to ÒInter cooler installationÓsteps in this
section.19 (1.9/14)N·m(Kg·m/lb·ft)
29 (3.0/22)N·m(Kg·m/lb·ft)
Page 1612 of 3573
6A2 Ð 10 4JG2-NA/4JG2-TURBO ENGINE
EXHAUST MANIFOLD
REMOVAL
1. Turbocharger (4JG2-T only)
·Refer to the ÒTurbochargerÓ removal in this
section.
2. Exhaust Manifold
INSTALLATION
2. Exhaust Manifold
·Tighten the fixing nuts and bolts to the specified
torque.
1. Turbocharger (4JG2-T only)
·Refer to the ÒTurbochargerÓ installation in this
section.
26 (2.7/20)
N·m(Kg·m/lb·ft)
Bolt
19 (1.9/14)
N·m(Kg·m/lb·ft)
Nut
Page 1613 of 3573
4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 11
TURBOCHARGER (4JG2-T only)
REMOVAL
Preparation
·Space stand and remove right front tire
·Remove battery
·Drain coolant
1. Air Cleaner Cover & Air Duct
·Disconnect connecting rubbers and stay fixing
bolts.
2. Intercooler Assembly (4JG2-T Only)
·Refer to intercooler removal steps in this section.
3. Power Steering (P/S) Pump Drive Belts
·Loosen P/S pump fixing bolts and adjusting bolt
and remove two drive belt.
4. Engine Ground Cable
Page 1614 of 3573
6A2Ð 12 4JG2-NA/4JG2-TURBO ENGINE
5. Air Conditioner (A/C) Compressor Assembly
·Remove A/C compressor fixng bolt (rear under
side of compressor) by using a long extension bar
at under side of wheel arch.
·Disconnect magnetic clutch harness connector.
·Removal fixing bolts (upper and front lower sides
of compressor) and set A/C compressor asm with
pipelines on battery cable.
6. Water Inlet Pipe: Turbo (4JG2-T Only)
7. Oil Feed Pipe: Turbo (4JG2-T Only)
·Remove joint bolt from turbo charger.
·Plug up oil port of turbocharger to prevent
entrance of foreign material.
8. Oil Return Pipe: Turbo (4JG2-T Only)
·Disconnect oil return pipe flange from
turbocharger.
9. Water Outlet Pipe: Turbo (4JG2-T Only)
10. Exh. Pipe: Ft (4JG2-T Only)
11. Heat Protector (4JG2-T Only)
12. Exh. Adapter (4JG2-T Only)
13. Turbocharger Assembly (4JG2-T Only)
·Remove turbocharger asm from exhaust
manifold.
Page 1615 of 3573
4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 13
26 (2.7/20)N·m(Kg·m/lb·ft)
INSTALLATION
13. Turbocharger Assembly (4JG2-T Only)
·Install the turbocharger asm with gasket in exh.
manifold and tighten fixing nuts to the specified
torque.
12. Exh. Adapter (4JG2-T Only)
·Install exh. adapter and tighten bolts to the
specified torque.
11. Heat Protector (4JG2-T Only)
10. Exh. Pipe: Ft
·Install exh. pipe and tighten bolts to the specified
torque.
9. Water Outlet Pipe: Turbo (4JG2-T Only)
·Install water outlet pipe with new gasket to the
specified torque.
26 (2.7/20)N·m(Kg·m/lb·ft)
67 (6.8/49)N·m(Kg·m/lb·ft)
8(0.8/6)N·m(Kg·m/lb·ft)
Page 1616 of 3573

6A2Ð 14 4JG2-NA/4JG2-TURBO ENGINE
8. Oil Return Pipe: Turbo (4JG2-T Only)
·Install oil return pipe with new gasket in
turbocharger and tighten joint bolt to the
specified torque.
7. Oil Feed Pipe: Turbo (4JG2-T Only)
·Apply about 100 cc engine oil to oil feed hose of
turbocharger housing before installing oil feed
pipe.
·Lubricate turbocharger securely by rotating
turbine shaft by hand.
·Install oil feed pipe with new gasket and tighten
joint bolt to the specified torque.
6. Water Inlet Pipe: Turbo (4JG2-T Only)
·Install water inlet pipe with new gasket and
tighten joint bolt to the specified torque.
4. Engine Ground Cable
3. P/S Pump Drive Belts
·Install drive belts, adjust belt tension by adjusting
bolt and tighten locking bolt to the specified
torque.
·Refer to drive belt adjustment steps in section 6B.
2. Intercooler Assembly (4JG2-T Only)
·Refer to intercooler installation steps in this
section.
1. Air Cleaner Cover & Air Duct (4JG2-T Only)
·Connect inlet and outlet connecting hoses and
tighten stay fixing bolts.
·Install right front tire.
·Fill coolant
·Install battery and connect battery cables.
5. A/C Compressor Assembly
·Tighten temporarily fixing bolts (front upper and
lower sides of compressor)
·Tighten fixing bolt (rear under side of
compressor) to the specified torque by using
along extension bar and torque wrench at under
side of wheel arch.
·Tighten fixing bolts (front upper and lower side of
compressor) to the specified torque.
8(0.8/6)N·m(Kg·m/lb·ft)
123 (2.3/17)229 (3.0/22)N·m(Kg·m/lb·ft)
8(0.8/6)N·m(Kg·m/lb·ft)
37 (3.8/27)N·m(Kg·m/lb·ft)