Note:
- - Thoroughly clean all parts to be installed.
- - Before installing parts, lubricate all rotating and sliding surfaces with oil.
- - Replace all gaskets and seals with new ones.
1. Install the camshaft.
a) Install the camshaft onto the cylinder head.
b) Install the camshaft bearing caps in accordance with the cylinder numbering and the location of the marks, as shown in the figure.
c) Install the camshaft bearing cap mounting bolts and tighten them evenly in three steps, in the sequence shown in the figure.
- Tightening torque - 18 Nm
d) Check the thermal clearances in the valves and adjust them if necessary.
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: The lengths of bolts "A" and "B" are shown in the figure.
- "A" - 123 mm
- "B" - 145 mm
If any of the bolts do not meet the specified values, replace them.
d) Mark the front of the cylinder head bolt head with paint.
d) Tighten the cylinder head bolts by 90° in the sequence shown above.
e) Tighten the cylinder head bolts again by another 90°.
g) Check that the painted mark is now facing backwards (180° from its original position).
3. Install the wiring harness by connecting the connectors.
4. Install the dipstick guide.
5. Connect the fuel hoses.
6. Connect the drain tube.
- Tightening torque - 30 Nm
7. Connect the high pressure fuel pipes.
- Tightening torque - 30 Nm
8. Connect the coolant pipe.
9. Connect the coolant bypass hose and the heater hose.
10. Connect the exhaust gas recirculation (EGR) valve tube.
Tightening torque:
- bolt - 19 Nm
- nipple nut - 95 Nm
11. Install the coolant outlet pipe.
- Tightening torque - 19 Nm
12. Install the camshaft pulley (see section "Timing belt").
13. Install the timing belt (see section "Timing belt").
14. Install the cylinder head cover (see section "Checking and adjusting thermal clearances in valves").
15. Connect the exhaust pipe.
a) Tighten the 2 mounting nuts.
- Tightening torque - 63 Nm
b) (2WD) Tighten the 3 nuts securing the exhaust pipe bracket.
- Tightening torque - 63 Nm
c) (4WD) Tighten the 3 bolts securing the exhaust pipe bracket.
- Tightening torque - 40 Nm
16. Install the wiring harness.
17. Remove air from the high pressure fuel line.
18. Connect the throttle valve control cable (automatic transmission).
19. Install the vacuum tubes.
- Tightening torque - 8 Nm
20. Connect the accelerator cable to the bracket.
- Tightening torque - 8 Nm
21. Install the air filter cover with the air duct.
22. Fill with coolant.
23. Start the engine and check for oil or coolant leaks.