Note:
- Lubricate all rotating and sliding surfaces with oil before installing parts.
- Replace all gaskets and seals with new ones.
1. Clear adjoining surfaces of a head of the block and the block of cylinders.
2. Install the cylinder head.
A. Install the cylinder head to the cylinder block.
A) Lay a new cylinder head gasket on the cylinder block.
Note: 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 consecutive steps.
- If any bolt is broken or deformed, replace it.
A) Apply a light coat of engine oil to the threads and under the heads of the mounting bolts.
b) Install plate washers under each cylinder head bolt.
V) Install and evenly tighten the 18 cylinder head bolts in several stages in the sequence shown in the figure.
- Tightening torque - 45 Nm
Note: Bolt lengths are shown in the picture.
- external - 123 mm
- internal - 145 mm
If any of the bolts are out of specification, replace them.
G) Mark the front of the cylinder head yolt head with paint.
d) Tighten the cylinder head bolts 90°in the above sequence.
e) Retighten the cylinder head bolts another 90°.
and) Check that the painted one is now facing back, (180°from 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 strut and secure with the bolt.
- Tightening torque - 37.5 Nm
5 Install the exhaust pipe and secure it with three nuts.
- Tightening torque - 63 Nm
6. Connect the #1 turbocharger cooling hose.
7. Connect fuel hoses and heater hoses.
8. Install drain tube with four new gaskets and secure 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 a socket of the gauge indicator of level of a cooling liquid.
12. Install the timing belt guard.
13. Connect the wiring harness to the glow plug connector.
14. Connect the radiator inlet hose.
15. Connect two coolant bypass hoses. Connect the coolant supply hose, install the clamp and tighten the bolt.
16. Install the timing belt (see relevant section).
17. Installing the cylinder head cover assembly with a vacuum pump.
A) Install the camshaft pulley with the mark down.
b) Remove any remaining old sealant.
V) Apply sealant to the cylinder head at the locations shown in the illustration.
G) Install the head cover with ten bolts.
- Tightening torque - 13.5 Nm
I) Tighten the wiring harness bolt.
V) Install and tighten the two #2 timing belt cover bolts.
- Tightening torque - 7.5 Nm
18. Install high pressure fuel lines.
A) Temporarily tighten the four nuts on the side of the injectors.
b) Connect the fuel pipes to the injection pump and tighten the four nuts.
- Tightening torque - 30 Nm
V) Install the injection pump connector mounting bracket and high pressure fuel pipe clamp No. 2, then tighten the 3 nuts,
19. Remove air from nozzles.
A) Loosen the nuts on the high pressure fuel pipes.
b) Turn the engine over with the starter to bleed air until clean fuel comes out of the fuel pipe, then tighten the nuts.
- Tightening torque - 30 Nm
20. Connect the accelerator cable.
21. Connect a vacuum tube and tighten three bolts.
22. Install the vacuum control solenoid valve (EVRV) and electro-pneumatic valve of the exhaust gas recirculation system and fix them with three bolts.
- Tightening torque - 6 Nm
Connect the connectors of the specified valves.
23. Connect vacuum hoses in the places shown in drawing.
24. Connect the crankcase ventilation hose.
25. Install the wiring harness and secure it with four clips.
26. Install the air filter cover with air duct.
27. Fill in coolant.
28. Check for fuel leaks.
A) Press the priming pump button at the top of the filter several times to prime the fuel system.
b) Start the engine and check for leaks.
29. Check for coolant leakage.
30. Check engine operation.