Page 1625 of 3573
4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 23
2. Intercooler Assembly (4JG2-T Only)
·Refer to intercooler installation steps in this
section.
1. Air Cleaner Cover & Air Duct (4JG2-T Only) 3. Oil Level Gauge Guide Tube
·Tighten guide tube to the specified torque.
19 (1.9/14)
N·m(Kg·m/lb·ft)
Page 1626 of 3573
6A2 Ð 24 4JG2-NA/4JG2-TURBO ENGINE
ROCKER ARM SHAFT ASSEMBLY
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 remove rocker shaft asm.
Page 1627 of 3573
4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 25
INSTALLATION
5. Rocker Arm Shaft Assembly
·Install rocker arm shaft with larger oil hole (¿4) to
the front of engine.
·Align fixing bolt with not of rocker arm shaft and
tighten fixing bolts to the specified torque.
54 (5.5/40)N·m (kg·m/lb·ft)
·Adjust valve clearance refreshing to section valve
clearance adjustment.
4. Cylinder Head Cover
·Install cylinder head cover and tighten bolts to the
specified torque.
3. Oil Level Gauge Guide Tube
·Tighten guide tube to the specified torque.
2. Intercooler Assembly (4JG2-T Only)
·Refer to intercooler installation steps in this
section.
1. Air Cleaner Cover & Air Duct (4JG2-T Only)
13 (1.3/113)N·m (kg·m/lb·in)
19 (1.9/14)N·m (kg·m/lb·ft)
Page 1628 of 3573
6A2 Ð 26 4JG2-NA/4JG2-TURBO ENGINE
CYLINDER HEAD
Page 1629 of 3573

4JG2-NA/4JG2-TURBO ENGINE 6A 2Ð 27
REMOVAL
Preparation
·Remove battery. (two batteries for cold area)
·Disconnect window washer hose, and remove
engine hood.
·Drain coolant.
·Space stand and front right tire.
1. Radiator Hose : Upper
·Disconnect upper radiator hose from engine side.
2. Air Cleaner Cover & Air Duct
3. Intercooler Assembly (4JG2-T Only)
·(Refer to intercooler removal steps in this section)
4. Oil Level Gauge Guide Tube
5. P/S Pump
·Loosen P/S pump fixing bolts and adjusting bolt
and remove two drive belts.
·Remove two fixing bolts (front side). A fixing nut
(rear side) and support P/S pump asm with oil
hoses by tying to body side.
6. A/C Compressor Assembly
·Remove A/C compressor fixing bolt (rear under
side of compressor) by using a long extension bar
at under side of wheel arch.
·Disconnect magnetic clutch harness connector.
·Remove fixing bolts (upper and front lower side of
compressor) and set A/C compressor asm with
pipe line on battery carrier.
7. Water Hose; CSD
·Disconnect CSD water hoses from heater hose
side.
8. Engine Harness
·Disconnect five harness connectors from units on
thermostat housing.
9. Heater Hose: Rear Side
·Disconnect heater hose from heater pipe.
10. Water Bypass Hose
·Disconnect water bypass hose from water pump.
11. Water Inlet Hose: Turbo (4JG2-T Only)
·Disconnect from water outlet pipe of engine.
12 Water Outlet Hose: Turbo (4JG2-T Only)
·Disconnect from water inlet pipe of engine.
13 Oil Feed Pipe: Turbo (4JG2-T Only)
·Remove two joint bolts (from turbocharger and
cylinder block) and oil feed pipe.
14. Oil Return Pipe Fixing Nut (4JG2-T Only)
·Remove oil return pipe fixing nut from cylinder
block.
15. Oil Cooler Hose
Page 1630 of 3573

6A2 Ð 28 4JG2-NA/4JG2-TURBO ENGINE
16. Exh. Manifold; W/turbo (4JG2-T Only)
·Remove exh. manifold bracket fixing bolt from
exh. manifold.
·Remove exh. manifold fixing bolts and nuts from
cylinder head.
·After pulling out exh. manifold a little, remove oil
return pipe flange from stud bolt and remove exh.
manifold w/turbo.
17. Front Exhaust Pipe
18. Fuel Leak Off Hose
19. Cylinder Head Cover
20. Glow Plug Harness
21. Injection Pipe
·Loosen sleeve nuts on injection pump side.
·Disconnect sleeve nuts on injection pipe.
22. Fuel Leak Off Pipe
23. Rocker Arm Shaft Assembly
24. Push Rod
25. Cylinder Head W/inlet Manifold
·Disconnect cylinder head bolts in sequence shown
in Figure.
26. Cylinder Head Gasket
INSTALLATION
26. Cylinder Head Gasket
·Determine cylinder head gasket grade by
measuring projection of piston head.
·Install dowel in cylinder block.
·Install cylinder head gasket with top mark up.
25. Cylinder Head W/intake Manifold
·Clean up cylinder head lower surface and cylinder
body upper surface.
·Install cylinder head as softly.
·Apply engine oil to screw and seat of cylinder
head bolts.
·Tighten cylinder head bolts in following sequence.
24. Push Rod
·Inspect curvature, excessive wear and damage.
(Refer to push rod inspection)
1st Step
N·m (kg·m/lb·ft)
49 (5.0/36)
2nd Step
60°3rd Step
60°
Page 1631 of 3573

4JG2-NA/4JG2-TURBO ENGINE 6A 2Ð 29
23. Rocker Arm Shaft Assembly
·Loosen all adjusting screws.
·Align fixing bolts to not of rocker arm shaft and
tighten them to the specified torque.
·Valve clearance adjustment.
·Refer to valve clearance adjustment steps in
section 00.
22. Fuel Leak Off Pipe
·Install fuel leak off pipe with new copper gasket
and tighten joint bolts to the specified torque.
54 (5.5/40)N·m (kg·m/lb·ft)
21. Injection Pipe
·Install injection pipes and sleeve nuts securely and
tighten them to the specified torque.
29 (3.0/22)N·m (kg·m/lb·ft)
29 (3.0/22)N·m (kg·m/lb·ft)
20. Glow Plug Harness
19. Cylinder Head Cover
·Apply engine oil to the rocker arms and the valve
spring.
·Install the cylinder head cover gasket to the
cylinder head cover.
·Tighten the cylinder head cover nuts to the
specified torque in the numerical order shown in
the illustration.
18. Fuel Leak Off Hose
17. Front Exh. Pipe
·Install front exhaust pipe and tighten fixing bolts to
the specified torque.
13 (1.3/113)N·m (kg·m/lb·in)
19 (1.9/14)N·m (kg·m/lb·ft)
16. Exh. Manifold W/turbo (4JG2-T Only)
·Install manifold gasket in cylinder head.
·Insert exh. manifold into studs on cylinder head a
little.
·Under this condition, insert oil return pipe frange
into studs on crankcase.
·Tighten exh. manifold fixing bolts and nut to
specified torque.
26 (2.7/20)N·m (kg·m/lb·ft)
15. Oil Cooler Hose
14. Oil Return Pipe: Turbo (4JG2-T Only)
·Tighten joint bolt to the specified torque.
8 (0.8/69)N·m (kg·m/lb·in)
Page 1632 of 3573

6A2 Ð 30 4JG2-NA/4JG2-TURBO ENGINE
13. Oil Feed Pipe: Turbo (4JG2-T Only)
·Tighten joint bolts (cylinder block and turbo
charger side) to the specified torque.
12. Water Outlet Hose: Turbo (4JG2-T Only)
·Connect to water inlet pipe of engine.
11. Water Inlet Hose: Turbo (4JG2-T Only)
·Connect to water outlet pipe.
10. Water Bypass Hose
·Water bypass hose connect to water inlet pipe.
9. Heater Hose
·Connect to heater pipe.
8. Engine Harness
·Connect five harness connecters to units on
thermostat housing.
7. Water Hose: CSD
6. A/C Compressor
·Tighten temporarily fixing bolts (upper and front
lower sides of compressor.)
·Tighten fixing bolt (rear under side of compressor)
to the specified torque by using a long extension
bar and torque wrench at under side of wheel arch.
·Tighten fixing bolts (front upper and lower sides of
compressor) to the specified torque.
5. P/S Pump Drive Belt
·Install drive belts adjust belt tension by adjusting
bolt and tighten locking bolt to the specified
torque.
·Refer to ÒDrive Belt AdjustmentÓ in section 6B.
4. Oil Level Gauge Guide Tube
·Tighten guide tube to the specified torque.
23 (23/17)N·m (kg·m/lb·ft)
37 (3.8/27)N·m (kg·m/lb·ft)
40 (4.1/30)N·m (kg·m/lb·ft)
19 (1.9/14)N·m (kg·m/lb·ft)
3. Intercooler Assembly (4JG2-T Only)
·Refer to ÒDrive Belt AdjustmentÓ in section 6B.
2. Intake Air Duct (4JG2-T Only)
1. Radiator Hose Upper
·Connect to water outlet pipe.