Page 1617 of 3573
4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 15
TIMING GEAR
REMOVAL
Preparation:
·Disconnect battery ground cable.
·Drain coolant.
1. P/S Pump Drive Belt
·Loosen P/S pump mounting bolt and adjust bolt,
and remove the drive belt.
2. AC Generator Drive Belt
·Loosen AC Generator mounting bolt (under side)
and adjust plate lock bolt, and remove the drive
belt.
3. Cooling Fan Assembly
·Remove clamp nut, and remove cooling fan asm,
distant pipe, and fan pulley.
4. Crankshaft Damper Pulley
5. Upper Noise Shield Cover
6. Lower Noise Shield Cover
7. Noise Cover Spacer.
8. Timing Gear Case Cover
9. Oil Pipe
10. Idler Gear ÒBÓ and Shaft
1) Measure the camshaft timing gear backlash and the
crenkshaft timing gear backlash before removing the
idler gear.
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6A2 Ð 16 4JG2-NA/4JG2-TURBO ENGINE
2) Measure the idler gear end play before removing the
idler gear.
NOTE:
Refer to the following items for details on the backlash
and end play measurement procedures.
Timing Gear Backlash Measurement
1) Set a dial indicator to the timing gear to measured.
Hold both the gear to be checked and the adjoining
gear stationary.
2) Move the gear to be checked as far as possible to
both the right and the left.
Take the dial indicator reading.
It the measured value exceeds the specified limit, the
timing gear must be replaced.
Idler Gear "A" End Play Measurement
Insert a feeler gauge between the idler gear and the thrust
collar to measure the gap and determine the idler gear
end play.
If the measued value exceeds the specified limit, the the
thrust collar must be replaced.
Standard
mm (in) Timing Gear Backlash
0.10-0.17 (0.0039-0.0067)Limit
0.30 (0.012)
11. Idle Gear
12. Injection Pump
1) Remove the six injection pump bracket bolts 1 from
the timing gear case.
Standard
mm (in) Idler Gear End Play
0.07 (0.0028)Limit
0.2 (0.0079)
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4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 17
2) Remove the injection pump rear bracket bolts 2 from
the injection pump bracket 3.
3) Remove the injection pump rear bracket bolts 4 and
the bracket 5 from the cylinder body.
4) Pull the injection pump along with the injection pump
timing gear free toward the rear of the engine.
NOTE:
Plug the injection pump delivery holder ports with the
shipping caps (or the equivalent) to prevent the entry of
foreign material.
13. Camshaft Timing Gear
1) Use a dial indicator to measure the camshaft end
play.
This must be done before removing the camshaft
gear.
If the camshaft end play exceeds the specified limit,
the thrust plate must be replaced.
2) Remove the camshaft timing gear bolt from the
camshaft.
NOTE:
Hold the camshaft stationaly to prevent the camshaft
from turning.
3) Use the universal puller 1 to pull out the camshaft
timing gear 2.
4) Remove the thrust plate 3.
14. Crank Shaft Gear
INSTALLATION
14. Crank Shaft Gear
1) Install the crankshaft gear.
2) Use the crankshaft gear installer 1 to install the
crankshaft gear 2.
The crankshaft gear timing mark ("X - X") must be
facing outward.
Crankshaft Gear Installer : 9-8522-0020-0
Standard
mm (in) Camshaft End Play
0.050-0.114 (0.0020-0.0044)Limit
0.2 (0.008)
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6A2 Ð 18 4JG2-NA/4JG2-TURBO ENGINE
13. Crankshaft Timing Gear
1) Install the camshaft timing gear to the camshaft.
The timing gear mark ("Y - Y") must be facing out-
ward.
2) Tighten the timing gear to the specified toeque.
64 (6.5/47)N·m(Kg·m/lb·ft)
11. Idle Gear
1) Apply engine oil to the idler gear and the idler gear
shaft.
The idler gear shaft oil hole must be facing up.
2) Position the idler gear setting marks "X" and "Y" so
that they are facing the front of the engine.
3) Align the idler gear "X" setting mark with the crank-
shaft timing gear 1 "X - X" setting mark.
4) Align the idler gear "Y" setting mark with the cam-
shaft timing gear 2 "Y - Y" setting mark.
5) Install the thrust collar and bolts to the cylinder body
through the shaft.
The thrust collar oil hole must be facing up, and the
thrust collar chamfered must be outward.
6) Tighten the idler gear bilt to the specified torque.
19 (1.9/14)N·m(Kg·m/lb·ft)
10. Idler Gear "B" and Shaft
1) Apply engine oil to the idler gear and the idler gear
shaft.
2) Align the idler gear "B" 3 "Z" setting mark with the
idler gear "A" 4 "Z - Z" setting mark.
3) Tighten the idler gear bolt to the specified torque.
12. Injection Pump
1) Install the O-ring 1 to the injection pump flange 2.
2) Install the injection pump to the timing gear case.
Align the idler gear "B" 3 "V - V" mark with the injec-
tion pump timing gear 4 "V" mark.
76 (7.7/56)N·m(Kg·m/lb·ft)
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4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 19
3) Temporarily tighten the six injection pump nuts 5.
The injection pump nuts will be finally tightened after
the injection pump rear bracket bolts.
4) Install the injection pump rear bracket 6 and the rear
bracket bolts 7 to the cylinder body.
5) Install the rear bracket bolts 8 to the injection pump
bracket 9.
Do not tighten the bolts.
The rear bracket bolts 7 and 8 will be finally tightened
to the specified torque after the injection pump nuts.
6) Tighten the injection pump bracket bolts 7 to the
specified torque.
7) Tighten the injection pump bracket bolts 8 to the
specified torque.
9. Timing Gear Oil Pipe
1) Install the oil pipe to the timing gear case and idler
gear "A".
2) Tighten the oil pipe eye bolt 1 and bolt 2 to the
specified torque.
8. Timing Gear Case Cover
1) Align the gear case with the timing gear case knock
pin and then install the timing gear case cover.
2) Tighten the gear case cover bolts to the specified
torque.
7. Noise Cover Spacer
6. Lower Noise Shield Cover
5. Upper Noise Shield Cover
206(21/152)N·m(Kg·m/lb·ft)
206(21/152)N·m(Kg·m/lb·ft)
13 (1.3/9)N·m(Kg·m/lb·ft)
Page 1622 of 3573
6A2 Ð 20 4JG2-NA/4JG2-TURBO ENGINE
4. Cranshaft Damper Pulley
Tighten the crankshaft damper pulley bolt to the specified
torque.
NOTE:
Hold the flywheel ring gear stationary to prevent the
crankshaft from turning when tightening the damper
pulley.
3. Cooling Fan Assembly
·Mount fan pulley, distance piece, and cooling fan
asm (in this order) on the water pump, and
tighten to the specified torque.
2. AC Generator Drive Belt
·Install AC Generator drive belt and adjust belt
tension.
·Refer to Drive Belt Adjustment in section 6B.
1. P/S Pump Drive Belt
·Install P.S pump drive belt and adjust belt tension.
·Refer to Drive Belt Adjustment in section 6B.
206(21/152)N·m(Kg·m/lb·ft)
206(21/152)N·m(Kg·m/lb·ft)
Page 1623 of 3573
4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 21
VALVE STEM OIL SEAL & VALVE SPRING
REMOVAL
Preparation
·Disconnect battery ground cable.
1. Air cleaner Cover & Air Duct (4JG2-T Only)
·Disconnect air hoses.
·Release clips and bands and remove air cleaner
cover.
2. Intercooler Assembly (4JG2-T Only)
·(Refer to intercooler removal steps in this section)
3. Oil Level Gauge Tube
4. Cylinder Head Cover
5. Rocker Arm Shaft Assembly
·Loosen bolts and nuts of rocker arm shaft
·Bracket by turns and removal rocker
·Shaft asm.
6. Valve Spring
·Apply compressed air to cylinder from the glow
plug hole hold the valve in place.
·Using special tool, compress valve spring and
removal split collar.
Valve spring compressor: 9-8523-1423-0 (J-29760)
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6A2 Ð 22 4JG2-NA/4JG2-TURBO ENGINE
CAUTION
·Put removed valve springs in the order of cylinder
number.
7. Valve Stem Oil Seal
·Removal oil seal by pliers.
CAUTION
·Removed oil controller should not be reused.
CAUTION
·The painted area of the valve spring should be
facing toward.
·Apply compressed air to cylinder from the glow
plug hole to hold the valve in place.
·Install split collar by special tool.
Valve spring compressor: 9-8523-1423-0 (J-29760)
INSTALLATION
7. Valve Stem Oil Seal
·Install new oil seal to valve guide.
·Guide using special tool.
Special tool: 5-8840-2033-0
6. Valve Spring
·Attach the valve spring to the upper spring seat.
5. Rocker Arm Shaft Assembly
·Install rocker arm shaft with a larger oil hole (¿4)
to the front of engine.
·Align fixing bolt with not of rocker arm shaft and
tighten fixing bolt to the specified torque.
54 (5.5/40)
N·m(Kg·m/lb·ft)
4. Cylinder Head Cover
·Install cylinder head cover and tighten bolt to the
specified torque.
13 (1.3/113)
N·m(Kg·m/lb·in)