Sealants Lubricants and Locking Compounds
| Description | Purpose | Catalogue number | Part number |
| Sealant | Sealer between metal surfaces cork and hard fibre seals | 15 03 166 | 90 094 714 |
| Sealing compound | Sealant for screw and hose connections in conjunction with fluids | 15 03 295 | 90 485 251 |
| Grease | Multi-purpose grease for (e.g.) wheel bearings alternator starter | 19 48 606 | 90 510 336 |
| Locking compound | Locking agent as adhesive for screw connections | 15 10 177 | 90 167 347 |
| Silicone grease | Grease for all temperature-stressed sliding connections as well as plastic seal rings | 19 70 206 | 90 167 353 |
| Special grease | Installation of oxygen sensor | 19 48 602 | 90 295 397 |
Coolant System
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Coolant capacity | l | 7.0 | 8.4 | 8.6 |
| Fan | | | | |
| Type | | Visco-clutch fan drive | Visco-clutch fan drive | Visco-clutch fan drive |
| Number of Blades | | | 8 | |
| Radiator Cap | | | | |
| Opening pressure | bar/psi | 0.88 to 1.17/13 to 17 | 0.88 to 1.17/13 to 17 | 0.88 to 1.17/13 to 17 |
| Coolant pump | | | | |
| Design | | Centrifugal pump | Centrifugal pump | Centrifugal pump |
| Delivery rate | | | 150 ltr/min @ 2800 rpm | |
| Thermostat | | | | |
| Design | | Wax pellet with jiggle pin | Wax pellet with jiggle pin | Wax pellet with jiggle pin |
| Start of opening | ° C | 82 | 82 | 82 |
| Fully open | ° C | 95 | 95 | 95 |
Drive Belts
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Alternator | | | | |
| Depression | mm | 8 - 12* | 8 - 12* | 8 - 12* |
| Power steering | | | | |
| Depression | mm | 13 - 16* | 13 - 16* | 13 - 16* |
| Air Conditioning | | | | |
| Depression new | mm | 7 - 10* | 7 - 10* | 7 - 10* |
| used | mm | 7 - 8* | 7 - 8* | 7 - 8* |
| | | * with thumb pressure of approx. 98 N. | * with thumb pressure of approx. 98 N. | *with thumb pressure of approx. 98 N. |
| Timing | | | | |
| Tension | kg | 10 - 12 | - | 10 - 12 |
| | | using tension adjustment lever | - | using tension adjustment lever |
Oil Circuit
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Engine oil quality | | | | |
| single and | | CCMC-PD2 also in conjunction | ACEA B2—B3 | CCMC-PD2 also in conjunction |
| multi-grade oils | | with API-../CD if | SAE 10W30 | with API-../CD if |
| | | CMC-PD2 is also specified | - | CCMC-PD2 is also specified |
| Engine oil viscosity | | | | |
| single-grade oils | | | | |
| SAE 10W | °C | minus 25 to 0 | minus 25 to 0 | minus 25 to 0 |
| SAE 20 20W | °C | minus 15 to 15 | minus 15 to 15 | minus 15 to 15 |
| SAE 30 | °C | 0 to 30 | 0 to 30 | 0 to 30 |
| SAE 40 50 | °C | over 25 | over 25 | over 25 |
| multi-grade oils | | | | |
| SAE 5W - 30 | °C | below minus 10 | below minus 10 | below minus 10 |
| SAE 10W - 30 | °C | minus 25 to 30 | minus 25 to 30 | minus 25 to 30 |
| SAE 15W - 40 | ° C | minus 15 to over 30 | minus 15 to over 30 | minus 15 to over 30 |
| SAE 20W - 40 | °C | minus 15 to over 30 | minus 15 to over 30 | minus 15 to over 30 |
| SAE 2-W - 50 | °C | minus 15 to over 30 | minus 15 to over 30 | minus 15 to over 30 |
Oil Circuit (Continued)
Engine Oil Filling Quantity
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| | | Two wheel drive | Four wheel drive | Two wheel drive | Four wheel drive |
| Initial fill | l | 5.5 | 6.5 | 7.3 | 5.5 | 7.1 |
| With oil filter change | l | 4.5 | | | 4.5 | 6.0 |
| Without oil filter change | l | 3.5 | | | 3.5 | 5.0 |
Oil Pump
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Clearances | | | | |
| Gear teeth and pump body | mm | 0.14 to 0.20 | 0.14 to 0.20 | 0.14 to 0.20 |
| Gears and pump cover | mm | 0.06 to 0.15 | 0.06 to 0.15 | 0.06 to 0.15 |
Adjustment Values/checking Values
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Valve clearance (cold) | mm | 0.4 | 0.4 | 0.4 |
| Adjustment | | Adjusting screw with locknut | Adjusting screw with locknut | Adjusting screw with locknut |
| Compression | bar/psi | Difference in pressure individual cylinders in engine must not exceed 1.0/14.5 | Difference in pressure individual cylinders in engine must not exceed 1.0/14.5 | Difference in pressure individual cylinders in engine must not exceed 1.0/14.5 |
| Compression pressure | bar/psi | 30/435 at 200 rpm | 31/440 at 200 rpm | 30/435 at 200 rpm |
| Pressure loss check | | Pressure loss per cylinder with engine in perfect condition approx. 25% | Pressure loss per cylinder with engine in perfect condition approx. 25% | Pressure loss per cylinder with engine in perfect condition approx. 25% |
| | Pressure deviation between individual cylinders approx. 10% | Pressure deviation between individual cylinders approx. 10% | Pressure deviation between individual cylinders approx. 10% |
| Idle speed: | | | | |
| Lower | rpm | 744 - 795 | 705 - 755 | 696 - 745 |
| Upper | rpm | 4 700 - 4 900 | 4 000 | 4 500 - 4 700 |
| Increase | rpm | 850 - 950 | 835 - 885 | 850 - 950 |
| Charge pressure | bar/psi | 1.15/17 | 1.15/17 | 1.15/17 |
| Injection pump timing | | 12 ° BTDC | 12 ° BTDC | TDC |
Cylinder Head
Cylinder Head Gasket
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Cylinder head gasket new: | | | | |
| Thickness | mm | 1.50 | 1.50 | 1.50 |
| | 1.55 | 1.55 | 1.55 |
| | 1.60 | 1.60 | 1.60 |
| Identification | mm | 1 notch | 1 notch | 1 notch |
| | 2 notches | 2 notches | 2 notches |
| | 3 notches | 3 notches | 3 notches |
| Piston projection | mm | 0.718 - 0.773 | 0.718 - 0.773 | 0.658 - 0.712 |
| | 0.773 - 0.819 | 0.773 - 0.819 | 0.713 - 0.758 |
| | 0.819 - 0.874 | 0.819 - 0.874 | 0.759 - 0.813 |
Cylinder Head (Continued)
Cylinder Head Dimensions
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Deviation of plane surface | mm | 0.05 - 0.20 | 0.05 - 0.20 | 0.05 - 0.20 |
| Height of cylinder head (sealing surface to sealing surface) | mm | 91.95 - 92.05 | | 91.95 - 92.05 |
| Grinding allowance for plane surface maximum | mm | 0.30 | | Not permitted |
| Deviation of sealing surfaces for manifold attachment | mm | 0.05 - 0.20 | 0.05 - 0.20 | 0.55 - 0.20 |
| Grinding allowance for manifold sealing surface maximum | mm | 0.4 | 0.4 | 0.4 |
| Valve indentation of sealing surface: | | | | |
| Intake | mm | 0.73 - 1.28 | | 1.1 - 1.6 |
| Exhaust | mm | 0.7 - 1.2 | | 1.1 - 1.6 |
| Swirl chamber depression | mm | 0 - 0.02 | - | 0 - 0.02 |
Cylinder Head (Continued)
Valve Seat Reworking
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Valve correction angle | | 45 | | 45 |
| Lower correction angle | | 15 | | 15 |
| Upper correction angle | | 74 | | 75 |
| Valve seat width: | | | | |
| Intake | mm | 1.7 standard | | 1.7 standard |
| mm | 2.2 (limit) | | 2.2 (limit) |
| Exhaust | mm | 2.0 (standard) | | 2.0 (standard |
| mm | 2.5 (limit) | | 2.5 (limit) |
Cylinder Head (Continued)
Valve Dimensions
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| | Standard | Limit | Standard | Limit | Standard | Limit |
| Stem diameter: | | | | | | | |
| Intake | mm | 7.946 - 7.961 | 7.88 | | | 7.946 - 7.961 | 7.88 |
| Exhaust | mm | 7.921 - 7.936 | 7.85 | | | 7.921 - 7.936 | 7.85 |
| Thickness: | | | | | | | |
| Intake | mm | 1.8 | 1.5 | | | 1.34 | 1.1 |
| Exhaust | mm | 1.8 | 1.5 | | | 1.38 | 1.1 |
| Stem play in bore: | | | | | | | |
| Intake | mm | 0.039 - 0.069 | 0.2 | | | 0.039 - 0.069 | 0.2 |
| Exhaust | mm | 0.064 - 0.093 | 0.25 | | | 0.064 - 0.093 | 0.25 |
| Valve guide height | mm | 13 | | 13 |
Valve Springs
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Free height | mm | 44.4 - 45.3 mm (inner spring) | 44.4 - 45.3 mm (inner spring) | 47.1 - 48.0 |
| mm | 48.2 - 49.7 mm (outer spring) | 48.2 - 49.7 mm (outer spring) | |
| Out of parallel maximum | mm | 3 mm (inner spring) | 3 mm (inner spring) | 1.7 |
| | 3.2 mm (outer spring) | 3.2 mm (outer spring) | |
| Tension at installed height | N | 49 - 57.9 at 37 mm (inner spring) | 49 - 57.9 at 37 mm (inner spring) | 257.7 - 296 at 38 mm |
| N | 117.4 - 205 at 39 mm (outer spring) | 117.4 - 205 at 39 mm (outer spring) | |
Cylinder Head (Continued)
Rockershaft and Arms
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Rockershaft radial runout maximum | mm | 0.3 | 0.3 | 0.3 |
| Rockershaft diameter | mm | 18.90 - 19 | 18.90 - 19 | 18.90 - 19 |
| Rocker arm inside diameter | mm | 19.036 - 19.1 | 19.036 - 19.1 | 19.036 - 19.1 |
| Clearance between rockershaft and rocker arm | mm | 0.01 - 0.2 | 0.01 - 0.2 | 0.01 - 0.2 |
| Push-rod curvature maximum | mm | 0.3 | 0.3 | 0.3 |
Camshaft and Followers
Camshaft
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Radial runout | mm | 0.02 - 0.10 | 0.02 - 0.10 | 0.02 - 0.10 |
| End play | mm | 0.08 - 0.2 | 0.05 - 0.2 | 0.08 - 0.2 |
| Lobe height | mm | 41.65 - 42.08 | 41.65 - 42.08 | 41.65 - 42.08 |
| Journal diameter | mm | 49.6 - 49.975 | 49.6 - 49.975 | 49.6 - 49.975 |
| Bearing inside diameter | mm | 50 - 50.08 | 50 - 50.08 | 50 - 50.08 |
| Clearance between journal and bearing | mm | 0.05 - 0.12 | 0.05 - 0.12 | 0.05 - 0.12 |
Cam Followers
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Stem diameter | mm | 12.95 - 12.99 | 12.95 - 12.99 | 12.95 - 12.99 |
| Clearance between cam follower and cylinder block | mm | 0.03 - 0.1 | 0.03 - 0.1 | 0.03 - 0.1 |
Crank Drive
Cylinder Liner
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Bore diameter | mm | 93.021 (standard) | 93.021 (standard) | 95.404 (standard) |
| mm | 93.1 (limit) | 93.1 (limit) | 95.470 (limit) |
| Projection above sealing surface | mm | 0.01 | 0.01 | 0.01 |
| Difference in projection between individual cylinders maximum | mm | 0.03 | 0.03 | 0.03 |
| Interference fit | mm | 0.01 - 0.019 | 0.01 - 0.019 | 0.01 0 .019 |
Piston
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Installation position | | Mark points to timing gear case cover |
| Piston clearance in bore | mm | 0.025 - 0.045 | 0.025 - 0.045 | 0.056 - 0.065 |
| Piston pin hole diameter | mm | 31.002 - 31.010 | | 34.002 - 34.010 |
Crank Drive (Continued)
Piston Rings
| | Standard | Limit |
| 1st compression ring: | | | |
| Gap | mm | 0.2 - 0.4 | 1.5 |
| Clearance between ring and piston groove | mm | 0.09 - 0.125 | 0.15 |
| 2nd compression ring: | | | |
| Gap | mm | 0.2 - 0.4 | 1.5 |
| Clearance between ring and piston groove | mm | 0.05 - 0.075 | 0.15 |
| Oil ring: | | | |
| Gap | mm | 0.1 - 0.3 | 1.5 |
| Clearance between ring and piston groove | mm | 0.03 - 0.07 | 0.15 |
Piston Pins
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Type | | Floating bearing in con-rod and piston 2 circlips in position bushing in con-rod |
| Installation | | Sliding seat |
| Diameter | mm | 30.97 - 31 | | 33.97 - 34 |
| Play: | | | | |
| In piston | mm | 0.002 - 0.015 | | 0.002 - 0.015 |
| In con-rod | mm | 0.008 - 0.02 (standard) | | 0.008 - 0.02 (standard) |
| | | 0.05 (limit) | | 0.05 (limit) |
Crank Drive (Continued)
Con-Rod
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Distortion | mm | 0.08 - 0.2 | 0.08 - 0.2 | 0.08 - 0.2 |
| Parallelism | mm | 0.05 - 0.15 | 0.05 - 0.15 | 0.05 - 0.15 |
Crank Drive (Continued)
Selection Table for Main Bearing Shells
Cylinder block main bearing identification (size mark A in following tables).
- 1. Front bearing
- 2. Second bearing
- 3. Centre and pilot bearings
- 4. Fourth bearing
- 5. Rear bearing
(A) is inset coding bar of bearing bore size in the block at each location.
Crankshaft main bearing identification (size mark B in following tables)
- 1. Front bearing
- 2. Second bearing
- 3. Centre and pilot bearings
- 4. Fourth bearing
- 5. Rear bearing
At location (B) is given coding number of each crankshaft journal size.
Crank Drive (Continued)
Selection Table for Main Bearing Shells - 4JA1T
| Bearing bore in cylinder block | Main bearing journal | Shell colour code | Bearing play mm |
| Size mark 'A' | Diameter (mm) | Diameter (mm) | Size mark 'B' | | |
| 1 | 63.987 - 59.927 | 59.222 - 59.927 | 1 or - | Black | |
| | 59.922 - 59.927 | 2 or - | Blue | 0.031-0.064 (standard) 0.11 (limit) |
| | 59.917 - 59.922 | 3 or - | | |
| 2 | 63.975 - 63.987 | 59.927 - 59.932 | 1 or - | Green | |
| | 59.922 - 59.927 | 2 or - | | 0.031-0.064 (standard) 0.11 (limit) |
| | 59.917 - 59.922 | 3 or - | Black | |
Selection Table for Main Bearing Shells - 4JA1TC
| Bearing bore in cylinder block | Main bearing journal | Shell colour code | Bearing play mm |
| Size mark 'A' | Diameter (mm) | Diameter (mm) | Size mark 'B' | | |
| 1 | | | 1 or - | | |
| | | 2 or - | | |
| | | 3 or - | | |
| 2 | | | 1 or - | | |
| | | 2 or - | | |
| | | 3 or - | | |
Crank Drive (Continued)
Selection Table for Main Bearing Shells - 4JG2T
| Bearing bore in cylinder block | Main bearing journal | Shell colour code | Bearing play mm |
| Size mark 'A' | Diameter (mm) | Diameter (mm) | Size mark 'B' | | |
| 1 | 73.987 - 74.0 | 69.927 - 69.932 | 1 or - | Black | |
| | 69.922 - 69.927 | 2 or - | Blue | 0.031-0.064 (standard) 0.11 (limit) |
| | 69.917 - 69.922 | 3 or - | | |
| 2 | 73.975 - 73.987 | 69.92 - 73.987 | 1 or - | Green | |
| | 69.922 - 69.927 | 2 or - | | 0.031-0.064 (standard) 0.11 (limit) |
| | 69.917 - 69.922 | 3 or - | Black | |
Crankshaft Drive (Continued)
Crankshaft
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Crankshaft and con-rod journals: | | | | |
| Main journal diameter | mm | 59.91 - 59.3 | | 69.91 - 69.93 |
| Con-rod journal diameter | mm | 52.90 - 52.93 | | 52/90 - 52.93 |
| Uneven wear limit | mm | 0.08 | | 0.08 |
| Radial run-out | mm | 0.05 - 0.08 | | 0.05 - 0.08 |
| Axial play | mm | 0.1 - 0.3 | | 0.1 - 0.3 |
| Main bearing play | mm | 0.031 - 0.110 | | 0.031 - 0.110 |
| Con-rod bearing play | mm | 0.029 - 0.1 | | 0.029 - 0.1 |
| Con-rod lateral play | mm | 0.023 - 0.35 | | 0.023 - 0.35 |
Crank Drive (Continued)
Flywheel
| Engine | mm | 4JA1T | 4JA1TC | 4JG2T |
| Starter ring gear | mm | Heat ring gear to 200° maximum before fitting |
| Friction surface depth 'A; | mm | 20 - 21 | 20 - 21 | 18 - 19 |
| Surface roughness | mm | Less than 0.006 | Less than 0.006 | Less than 0.006 |
Cylinder Block
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Deviation of plane surface | mm | 0.05 - 0.20 | 0.05 - 0.20 | 0.05 - 0.20 |
| Height of cylinder block (sealing surface to sealing surface) | mm | 244.945 - 245.055 | | 269.945 - 270.055 |
Mechanical Injection System
Injection Pump
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Type | | Bosch VE distributor | Bosch VP44 distributor | Bosch VE distributor |
Injectors
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Type | | hole with 5 jets | hole with 5 jets — double spring type | Pintaux |
| Opening pressure | bar/psi | 181.43/2.631 | 195/2830 1ste stage 338/4906 2nd stage | 147.1/2134 |
Quick on Start Pre Heating System
| Engine | | 4JA1T | 4JG2T | 4JA1TC |
| Control | | Electronic | - |
| Glow plug resistance | ohm | Approx. 0.9 at 25 °C | - |
| Coolant temperature sensor resistor | k ohm | 12 at - 15 °C | 12 at - 15 °C | - |
| | 6 at 0 °C | 6 at 0 °C | - |
| | 3.6 at 10 °C | 3.6 at 10 °C | - |
| | 2.45 at 20 °C | 2.45 at 20 °C | - |
| | 1.1 at 40 °C | 1.1 at 40 °C | - |
| | 0.6 at 60 °C | 0.6 at 60 °C | - |
| | 0.3 at 80 °C | 0.3 at 80 °C | - |
| Dropping resistor | ohm | - | 225 - 225 at | - |
| | - | approx. 25 °C | - |
Quick Warming Up System
| Engine | | 4JA1T | 4JG2T | 4JA1TC |
| Idling speed under quick | | Engine coolant temperature less than 80 °C | - |
| warming up system | | Ambient air temperature less than 15 °C | - |
| conditions | | Quick warming up system on 900 rpm | - |
| | | Quick warming up system switch off 720 rpm - 4JG2T | - |
| | | Quick warming up system switch off 770 rpm - 4JA1T | - |
| Quick warming up system | | No load engine speed more than 1750 rpm | - |
| cancellation conditions | | Acceleration opening more than 55% - 4JA1T | - |
| | | Engine coolant temperature more than 80 °C | - |
| | | Ambient air temperature more than 15 °C | - |
| Ambient temperature switch: | | | | |
| Off to on | °C | 8 | 8 | - |
| On to off | °C | Approx. 15 | Approx. 15 | - |
| Vacuum switch valve resistance | ohm | 40 at 20 °C | 40 at 20 °C | - |
| Intake throttle valve clearance | mm | 1.0 | 1.0 | - |
| Exhaust throttle valve clearance: | | | | |
| At 0.53 bar/8 psi | mm | 0.15 | 0.15 | - |
| At 0.35 bar/5 psi | mm | 1.15 | 1.15 | - |
Starter
Identification Data
| Engine | 4JA1T | 4JA1TC | 4JG2T |
| Type | Hitachi | | Hitachi S14-03 |
| Opel Part No. | 94 433 912 | | 94 387 653 |
Test Data
| Engine | | | 4JA1T | 4JA1TC | 4JG2T |
| Idle speed check | Current | amps | | | 160 or less |
| Speed | rmp | | | 3900 or more |
| Voltage | volts | | | 11 |
| On load speed check | Current | amps | | | 300 |
| Speed | rmp | | | 200 or more |
| Voltage | volts | | | 10.85 |
| Torque | Nm | | | 7.4 or more |
| Short circuit check | Current | amps | | | 1300 or less |
| Voltage | volts | | | 3 |
| Torque | Nm | | | 36 or more |
| Commutator | Diameter minimum | mm | 34 | | 36.5 |
| Runout | mm | 0.02-0.05 | | 30.05-0.1 |
| Insulator depth | mm | 0.2 | | 0.2-0.8 |
| Brushes | Length | mm | 9.5-14.5 | | 11-18 |
| Spring tension | N | | | 28-35 |
| Pinion travel | | mm | 0.3-1.3 | | 0.3-1.3 |
Alternator
Test Data
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Nominal voltage | volts | 12 | 12 | 12 |
| Current output maximum | amps | 50 at 5000 rpm | 60 at 5000 rpm | 60 at 6000 rpm |
| Slip rings diameter | mm | 30.6-31.6 | | 30.6-31.6 |
| Brush length | mm | 6-20 | | 6-20 |
| Excitation winding resistance | ohm | 4.2 at 20 °C | | 4.2 at 20 °C |
| Stator winding resistance | ohm | 0.1 | | 0.1 |
Alternator (Continued)
Vacuum Pump
| Engine | | 4JA1T | 4JA1TC | 4JG2T |
| Housing inside diameter | mm | 57-57.1 | 57-57.1 | 60-60.1 |
| Vane length | mm | 12.5-13.5 | 12.5-13.5 | 14.2-15.2 |
Recommended Torque Values
| Diesel Engine | 4JA1T | 4JA1TC | 4JG2T |
| Nm | Nm | Nm |
| Air conditioning compressor | 59 | 59 | 59 |
| Alternator: | | | |
| Adjuster plate bolt | 19 | 19 | 19 |
| Pivot bolt | 40 | 40 | 40 |
| Pulley nut | 50 | 50 | 50 |
| Through bolts | 6 | 6 | 6 |
| Axle mounting bolts | 152 | 152 | 152 |
| Camshaft: | | | |
| Gear to camshaft bolt | - | 108 | - |
| Oil seal retainer bolts | 18 | - | 18 |
| Pulley centre boss bolt | 64 | - | 64 |
| Pulley to centre boss bolts | 8 | - | 8 |
| Pulley flange bolts | 8 | - | 8 |
| Thrust washer plate bolts | - | 19 | - |
| Con-rod bearing cap to con-rod | 83 | 83 | 29 + 45° |
Recommended Torque Values (Continued)
| Diesel Engine | 4JA1T | 4JA1TC | 4JG2T |
| Nm | Nm | Nm |
| Coolant temperature sensor | 34 | 34 | 34 |
| Coolant pipes to intake manifold | 19 | 19 | 19 |
| Clutch slave cylinder bolts | 28 | 40 | 45 |
| Crankshaft: | | | |
| Main bearing caps | 167 | 167 | 167 |
| Damper pulley bolts | 19 | - | 19 |
| Pulley boss bolt | 206 | 206 | 206 |
| Cylinder head cover bolts | 13 | 13 | 13 |
| Cylinder head to cylinder block bolts | 49 +60 to 75° +60 to 75° | 49 +60 to 75° +60 to 75° | 49 +60 to 75° +60 to 75° |
| Dipstick tube bolts | 19 | 19 | 19 |
| Engine damping block to engine: | | | |
| Small bolts | 40 | 40 | 40 |
| Large bolts | 117 | 117 | 117 |
Recommended Torque Values (Continued)
| Diesel Engine | 4JA1T | 4JA1TC | 4JG2T |
| Nm | Nm | Nm |
| Exhaust gas recirculation: | | | |
| Exhaust manifold side nut and bolt | 26 | 24 | 26 |
| Exhaust gas recirculation valve nut | 24 | 24 | 24 |
| EGR cooler bracket to cylinder head | - | 19 | - |
| EGR cooler to brackets | - | 19 | - |
| Exhaust manifold:: | | | |
| Exhaust manifold to cylinder head nuts and bolts: | 26 | 26 | 26 |
| Heat shield bolts | - | 19 | - |
| Flywheel to crankshaft | 118 | 118 | 118 |
| Front exhaust pipe to turbocharger adapter | 67 | 67 | 67 |
| Glow plugs | 23 | 23 | 23 |
| Idler gear bolts | - | 19 | - |
| Injection pump: | | | |
| Adjusting bolt | 19 | - | 19 |
| Head plug | 17 | - | 17 |
Recommended Torque Values (Continued)
| Diesel Engine | 4JA1T | 4JA1TC | 4JG2T |
| Nm | Nm | Nm |
| Heat shield bolts | - | 19 | - |
| Lower s upport bracket bolts | 19 | 40 | 19 |
| Pulley nut | 64 | not allowed | 64 |
| Timing gear case mounting bolts | - | 19 | - |
| Upper support bracket bolts | - | 25 | - |
| Injector: | | | |
| Retaining bolt | 37 | 37 | - |
| Setting screw | - | - | 64 |
| Body nut | 30 | 69 | 30 |
| Leak off pipe | - | 17 | 69 |
| Injector pipe nuts | 29 | 29 | 29 |
| Intake manifold to cylinder head | 19 | 19 | 19 |
| Intercooler: | | | |
| Brackets to intake manifold and cylinder head | - | 20 | - |
| Cover plate bolts | - | 20 | - |
Recommended Torque Values (Continued)
| Diesel Engine | 4JA1T | 4JA1TC | 4JG2T |
| Nm | Nm | Nm |
| Intercooler to mounting brackets | - | 20 | - |
| Intercooler pipe | - | 22 | - |
| Oil cooler centre bolt | 22 | 22 | 22 |
| Oil filter housing: | | | |
| Pressure relief valve | 20 | 20 | 20 |
| Retaining bolts | 19 | 19 | 19 |
| Oil pan: | | | |
| Bolts | 19 | 19 | 19 |
| Nuts | 24 | 24 | 24 |
| Drain plug | 44 | 44 | 44 |
| Oil pump: | | | |
| Bolts | 19 | 19 | 19 |
| Sleeve nut | 25 | 25 | 25 |
| Strainer/cover bolts | 16 | 16 | 16 |
| Power steering pump: | | | |
Recommended Torque Values (Continued)
| Diesel Engine | 4JA1T | 4JA1TC | 4JG2T |
| Nm | Nm | Nm |
| Lock bolt | 37 | 37 | 37 |
| Suction pipe bolts | 21 | 21 | 21 |
| Pressure hose nut | 20 | 20 | 20 |
| Rear plate cylinder block | 82 | 82 | 82 |
| Rockershaft bolts | 54 | 54 | 54 |
| Scissor gear: | | | |
| Gear to hub bolt | - | 108 | - |
| Lock bolt | - | 74 | - |
| Starter: | | | |
| Mounting bolts | 69 | 69 | 69 |
| Terminal B | 9 | 9 | 9 |
| Terminal M | 9 | 9 | 9 |
| Solenoid switch bolts | 7 | 7 | 7 |
| Through bolts | 6 | 6 | 6 |
| Thermostat housing bolts | 19 | 19 | 19 |
Recommended Torque Values (Continued)
| Diesel Engine | 4JA1T | 4JA1TC | 4JG2T |
| Nm | Nm | Nm |
| Timing belt tensioner centre bolt | 76 | - | 76 |
| Timing cover bolts | 8 | 19 | 8 |
| Timing gear case bolts | - | 19 | - |
| Timing pulley housing bolts | 19 | | 19 |
| Track rod: | | | |
| Nuts to relay arm | 59 | 59 | 59 |
| Nuts to pitman arm and outer rods | 98 | 98 | 98 |
| Turbocharger: | | | |
| Nuts | 26 | 26 | 26 |
| Exhaust adapter bolts | 26 | 26 | 26 |
| Coolant connection block | - | 8 | - |
| Oil feed pipe bolts : | | | |
| Cylinder block end | 29 | 54 | 29 |
| Turbocharger end | 22 | 22 | 22 |
| Retaining clip | 18 | 18 | 18 |
| Oil return pipe bolts | 8 | 8 | 8 |
Recommended Torque Values (Continued)
| Diesel Engine | 4JA1T | 4JA1TC | 4JG2T |
| Nm | Nm | Nm |
| Vacuum pump screws | 7 | 7 | 7 |
| Valve clearance lock nut | 15 | 15 | 15 |
| Visco-clutch and fan assembly | 8 | 8 | 8 |
| Water pump to cylinder block | 20 | 20 | 20 |