Note:
- Before installing parts, lubricate all rotating and sliding surfaces with oil.
- Replace all gaskets and seals with new ones.
1. Clean the mating surfaces of the cylinder head and cylinder block.
2. Install the cylinder head.
A. Install the cylinder head onto the cylinder block.
a) Place a new cylinder head gasket on the cylinder block.
Note: Please observe the correct position when installing the gasket.
b) Place the cylinder head on the cylinder head gasket.
B. Install the cylinder head bolts.
Note:
- The cylinder head bolts are tightened in three successive steps.
- If any bolt is broken or deformed, replace it.
a) Apply a thin layer of engine oil to the threads and under the heads of the mounting bolts.
b) Install plate washers under each cylinder head bolt.
c) Install and tighten the 18 cylinder head bolts evenly in several steps in the sequence shown in the figure.
- Tightening torque - 45 Nm
Note: Bolt lengths are shown in the figure.
- external - 123 mm
- internal - 145 mm
(The original is published on the website TOYOTAMAN)
If any of the bolts do not meet the specified values, replace them.
d) Mark the front part of the cylinder head with paint.
d) Tighten the cylinder head bolts 90° in the above sequence.
e) Tighten the cylinder head bolts again by another 90°.
g) Check that the painted part is now facing backwards (180° from the original position).
4. Install the exhaust manifold and strut.
a) Connect the oil pipe to the turbocharger and secure it with two nuts.
- Tightening torque - 18.5 Nm
b) Install the exhaust manifold with the stand and secure with a bolt.
- Tightening torque - 37.5 Nm
5 Install the exhaust pipe and secure it with three nuts.
- Tightening torque - 63 Nm
6. Connect turbocharger cooling hose No.1.
7. Connect the fuel and heater hoses.
8. Install the drain tube with four new gaskets and secure it with four nuts.
- Tightening torque - 30 Nm
9. Connect the fuel hose.
10. Install the dipstick guide and secure it with a clamp.
11. Connect the coolant level indicator sensor connector.
12. Install the timing belt protective cover.
13. Connect the wire harness to the glow plug connector.
14. Connect the radiator supply hose.
15. Connect the two coolant bypass hoses. Connect the coolant supply hose, install the clamp and tighten the bolt.
16. Install the timing belt (see the relevant section).
17. Installing the cylinder head cover assembly with the vacuum pump.
a) Install the camshaft pulley with the mark facing down.
b) Remove any remaining old sealant.
c) Apply sealant to the cylinder head in the places shown in the figure.
d) Install the cylinder head cover, securing it with ten bolts.
- Tightening torque - 13.5 Nm
I) Tighten the wiring harness mounting bolt.
c) Install and tighten the two timing belt cover #2 bolts.
- Tightening torque - 7.5 Nm
18. Install the high pressure fuel pipes.
a) Temporarily tighten the four nuts on the injector side.
b) Connect the fuel pipes to the injection pump and tighten the four nuts.
- Tightening torque - 30 Nm
c) Install the fuel injection pump connector mounting bracket and high pressure fuel pipe clamp No.2, then tighten the 3 nuts,
19. Remove air from the injectors.
a) Loosen the nuts of the high pressure fuel line fittings.
b) Crank the engine with the starter to remove air until clean fuel appears from the fuel pipe, then tighten the nuts.
- Tightening torque - 30 Nm
20. Connect the accelerator cable.
21. Connect the vacuum tube and tighten the three bolts.
22. Install the exhaust gas recirculation solenoid valve (EVRV) and the EGR solenoid valve and secure them with three bolts.
- Tightening torque - 6 Nm
Connect the connectors of the specified valves.
23. Connect the vacuum hoses to the locations shown in the figure.
24. Connect the crankcase ventilation hose.
25. Install the wire harness and secure it with four clamps.
26. Install the air filter cover with the air duct.
27. Fill with coolant.
28. Checking for fuel leaks.
a) Press the fuel pump button on the top of the filter several times to prime the fuel system.
b) Start the engine and check for leaks.
29. Check for coolant leaks.
30. Check the engine operation.