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 to 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.
V) Install the camshaft bearing cap bolts and tighten them evenly in three steps, in the sequence shown in the figure.
- Tightening torque - 18 Nm
G) Check valve clearances and adjust if necessary.
2. Install the cylinder head.
A. Install the cylinder head on 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 "A" And "IN", are proven in the figure.
- "A" - 123 mm
- "IN" - 145 mm
If any of the bolts are out of specification, replace them.
G) Mark the front of the cylinder head bolt head with paint.
d) Tighten the cylinder head bolts 90°in the above sequence.
e) Tighten the cylinder head bolts again by another 90°.
and) Check that the colored label is now facing backwards (180°from original position).
3. Install the wiring harness by connecting the connectors.
4. Install the dipstick guide.
5. Connect fuel hoses.
6. Connect the drain tube.
- Tightening torque - 30 Nm
7. Connect high pressure fuel pipes.
- Tightening torque - 30 Nm
8. Connect a tube of a cooling liquid.
9. Connect the coolant bypass hose and heater hose.
10. Connect the EGR valve pipe (EGR).
Torque:
- bolt - 19 Nm
- nipple nut - 95 Nm
11. Install the coolant outlet.
- 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 a reception pipe of system of release.
A) Tighten the 2 fastening nuts.
- Tightening torque - 63 Nm
b) (2WD) Tighten the 3 nuts securing the exhaust pipe bracket.
- Tightening torque - 63 Nm
V) (4WD) Install 3 exhaust pipe bracket bolts.
- Tightening torque - 40 Nm
16. Install wiring harness.
17. Remove air from the high pressure fuel line.
18. Connect throttle control cable (automatic transmission).
19. Install vacuum tubes.
- Tightening torque - 8 Nm
20. Connect an accelerator cable with an arm.
- Tightening torque - 8 Nm
21. Install the air filter cover with air duct.
22. Fill in coolant.
23. Start the engine and check for oil or coolant leaks.