Page 985 of 6020
FUEL SYSTEM 6C – 21
RTW 46CSH000201
Installation
1. Injection Pump
1) Install the injection pump gear (W hen gear is removed).
Injection Pump Gear Nut N⋅m (kg ⋅m/lb ft)
64 (6.5 / 47)
2) Bring the piston in the No.1 cylinder to TDC on the
compression stroke by turning the crankshaft until the
crankshaft pulley TDC line aligned with the timing
mark.
020L200017
3) Install the injection pump to the timing gear case with
align the timing mark on the pump gear to the arrow
mark on the timing gear case cover.
4) Check that the setting marks of the injection pump gear and the idler gear B are aligned.
5) Remove the lock bolt (M6 × 30) from the idle gear “B”.
6C-7
6) Tighten the injection pump fixing bolts to the specified
torque.
Injection Pump Bolts Torque N·m (kg·m/lb ft)
19 (1.9 / 14)
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Page 986 of 6020

6C – 22 FUEL SYSTEM
4JA1T (L)
RTW 46CSH000101
4JA1TC/4JH1TC
RTW 36AMH000101
2. Injection Pump Bracket
1) Install the injection pump bracket (6) and the bracket bolts (7) and (8) to the cylinder body. Temporarily
tighten the bracket bolts.
2) Tighten the bracket bolts (7) to the specified torque.
3) Tighten the bracket bolts (8) to the specified torque.
Note:
Tighten the bracket bolt (8) first.
Injection Pump Bracket Torque N·m(kg·m / lb ft)
(8) 19 (1.9 / 14)
(7) 40 (4.1 / 30)
3. Timing Check Hole Cover
Install the timing check hole cover and tighten bolts to the
specified torque.
Timing Check Hole Cover Bolts
Torque N·m(kg·m / lb ft)
8 (0.8 / 69)
4. Injection Pump Cover (4JA1TC/4JH1TC only)
5. Intake Manifold
1) Install the intake manifold with gasket.
Intake Manifold Bolts
Torque N·m(kg·m / lb ft)
19 (1.9 / 14)
Intake Manifold Nuts Torque N·m(kg·m / lb ft)
24 (2.4 / 17)
2) Install the EGR valve to the intake manifold and EGR pipe temporarily.
3) Tighten the nuts and bolts to the specified torque
Torque N ⋅m (kg ⋅m/lb ft)
Nuts 24 (2.4/17)
Bolts 27 (2.8/20)
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Page 987 of 6020

FUEL SYSTEM 6C – 23
6. Injection Pipe
Install the injection pipe.
Injection Pipe Torque N·m(kg·m / lb ft)
29 (3.0 / 22)
Nozzle Side (4JA1TC/4JH1TC) N·m(kg·m / lb ft)
29 (3.0 / 22)
Pump Side (4JA1TC/4JH1TC) N·m(kg·m / lb ft)
40 (4.1 / 30)
7. Injection Pipe Clip Install the injection pipe clip.
Note:
Make absolutely sure that the clip is correctly
positioned.
Injection Pipe Clip Torque N·m(kg·m / lb in)
8 (0.8 / 69)
8. Leak Off Pipe and Leak Off Hose
Install the leak off pipe to injection nozzle and connect the
leak off hose to the injection pump.
9. Fuel Filter Bracket (Except EURO III model)
Install the fuel filter bracket and tighten bolts to the
specified torque.
Fuel Filter Bracket Bolts Torque N·m(kg·m / lb ft)
21 (2.1 / 15)
10. Fuel Filter Assembly (Except EURO III model) Install the fuel filter assembly to bracket and tighten bolts
to the specified torque.
Fuel Filter Assembly Bolts
Torque N·m(kg·m / lb ft)
21 (2.1 / 15)
11. Fuel Pipe
1) Connect the fuel hoses to the fuel filter or priming pump.
2) Connect the fuel hoses to the injection pump.
12. Oil Level Gauge Install the oil level gauge and tighten bolts to the specified
torque.
Oil Level Gauge Bolts
Torque N·m(kg·m / lb ft)
M8: 19 (1.9 / 14)
M6: 8 (0.8/6 lb in)
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Page 988 of 6020
6C – 24 FUEL SYSTEM
13. Throttle Position Sensor Harness Connector
(4JA1TC/4JH1TC only)
Reconnect the harness connector to the throttle position
sensor.
14. Power Steering Pump Bracket
15. Fan
16. Vacuum Hose
Connect the vacuum hose to the EGR valve and the
intake throttle.
Euro under Euro I Euro II Euro III
4JA1L without with with Not used
4JA1TC Not used Not used Not used With cooler
(EGR cooler)
4JH1TC without with with With
(EGR cooler)
17. Accelerator Control Cable
1) Connect the accelerator cable to the injection pump (4JA1T) the intake throttle. (4JA1TC/4JH1TC only)
18. Power Steering Pump Assembly
19. Drive Belt
Install the drive belt and adjust the belt tension.
20. Battery
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Page 989 of 6020
FUEL SYSTEM 6C – 25
INJECTION NOZZLE (4JA1L)
DISASSEMBLY
RTW 76CMF000401
Disassembly Steps
1. Retaining nut 2. Nozzle & pin
3. Spacer & pin
4. Lift Piece
5. Spring seat
6. Push rod
7. Shim (Second nozzle opening pressure adjustment)
8. Second spring 9. Collar
10. Spring seat
11. First spring
12. Shim (First nozzle opening pressure adjustment)
13. Nozzle holder body
14. Eye bolt
Important Operations
Injection nozzle adjustment is possible only on the 4JA1L
engine.
The two-spring nozzle holder has been developed to
reduce NOx (Nitrogen Oxides) and particulates from direct
injection diesel engine exhaust.
Before disassembly remove carbon deposit from nozzle
and nozzle holder using a wire brush and wash the outside
nozzle holder assembly.
Caution:
Do not touch nozzle holes with the wire brush during
cleaning it.
Disassemble the nozzle holder assembly to numerical
order.
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Page 990 of 6020
6C – 26 FUEL SYSTEM
REASSEMBLY
RTW 76CMF000501
Reassembly Steps
1. Nozzle holder body 2. Shim (First opening pressure adjustment)
3. First spring
4. Spring seat
5. Collar
6. Second spring
7. Push rod
8. Shim (Second opening pressure adjustment) 9. Spring seat
10. Lift Piece
11. Spacer & pin
12. Nozzle & pin
13. Retaining nut
14. Eye bolt
Important Operations
The nozzle holder is adjusted as the components are
reassembled in the sequence above.
As adjustment of the two-spring nozzle holder is made in
hundredths of a millimeter, clean the parts thoroughly in
light oil to completely remove any dirt or foreign matter.
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Page 991 of 6020

FUEL SYSTEM 6C – 27
REASSEMBLY AND ADJUSTMENT PROCEDURE
1 First nozzle opening pressure adjustment Adjust the first nozzle opening pressure using the shim.
2
Full needle valve lift confirmation Confirm the full needle valve lift in accordance with the
closed method.
3 Pre-lift confirmation
Confirm pre-lift in accordance with the closed method.
CAUTION:
If not as specified, replace the nozzle assembly, lift
piece, pins and spacer using the nozzle service kit.
4
Second nozzle opening pressure
confirmation Confirm the second nozzle opening pressure in accordance
with the closed method.
5 Second nozzle opening pressure
adjustment Adjust the second nozzle opening pressure using the shim.
6
Final inspection Confirm the condition of the fuel spray with the nozzle and
nozzle holder assembled.
First nozzle opening pressure adjustment
Nozzle needle valve full-lift 0.25 mm (0.0098 in)
Nozzle needle valve pre-lift 0.04 mm(0.0016 in) at 20,000 kPa (2901 psi, 204 kg/cm2)
Nozzle pressure
4JA1T(L) 1st Stage 19.1 MPa (2759 psi, 194 kg/cm2)
2nd Stage 25.5-27.0 MPa (3768-3911 psi, 260-275 kg/cm2)
NOTE: Only 4JA1L can perform adjustment of a nozzle.
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Page 992 of 6020
6C – 28 FUEL SYSTEM
Injection Nozzle Adjustment
First nozzle opening pressure adjustment
1.Clamp the nozzle holder in a vise.
2. Install the shim, first spring and spring seat in the nozzle holder.
3. Install the collar, second spring, shim, spring seat and pushrod in the nozzle holder.
4. Install the pins, lift piece and spacer in the nozzle holder.
040MV015.tif
040MV016.tif
040MV017.tif
040MV018.tif
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