L Series
1. Install the valve cover.
a) Apply sealant to the cylinder head as shown in the figure.
b) (2L-T) Apply sealant to the areas shown in the figure.
c) Place the gasket on the cylinder head cover.
d) Install the cylinder head cover with eight bolts and two nuts.
Tightening torque 4.9 Nm.
2. Install the right engine mount bracket.
Tightening torque 37 Nm
3. Install the exhaust manifold.
a) Install a new gasket and exhaust manifold. Tighten the bolts and nuts to 52 N·m
b) Install the heat shield by tightening the four bolts.
4. Install the intake manifold.
a) Place the new gasket on the cylinder head with the protrusion facing up.
b) (2L-T) Install a new gasket and intake manifold.
c) Tighten the intake manifold nuts and bolts to 24 N·m.
d) (2L-T) Install the heat insulator and secure the glow plug resistor with a nut.
Note: Secure the lower part of the manifold with the oil level indicator tube and wire clamp with three bolts as shown in the figure.
Engine 2L-T)
5. (2L-T) Install the recirculation valve, tubes, valve adapter and check valve assembly.
a) Place a new gasket on the intake manifold.
b) Secure the recirculation valve and tube with two nuts. Tightening torque 13 Nm.
c) Secure the recirculation check valve assembly with three bolts.
d) Connect the connectors of the shut-off and vacuum regulation valves.
d) (2L-T) Install two new gaskets, the EGR valve adapter and the air tube and secure them with four nuts.
Tightening torque 19 Nm
6. (2L-T) Install the throttle assembly.
a) Install the wire holder on two bolts.
b) Install a new gasket and throttle assembly.
c) Connect the connector and vacuum tubes to the vacuum shut-off valve.
7. Install the left engine hanger bracket.
Tightening torque 37 Nm
8. Install the water pipe and water pipe body.
a) Install a new gasket, water pipe and water pipe housing.
Tightening torque 19 Nm.
b) (With heating control device). Connect the bypass hose to the thermostat block.
9. Install the upper timing belt cover with four bolts.
Tightening torque 18 Nm
10. Install the camshaft pulley.
11. Install the injectors.
12. (For 2L-T) Install the fuel injection pump (see the relevant section).
13. Install the timing belt (see the relevant section).
14. Install the turbocharger (for 2L-T engines only).
15. Fill the engine with coolant (see the relevant section).
16. Start the engine and check for leaks.
17. Check the coolant and oil levels.
KZ Series
1. Install the camshaft with the keyway facing up.
a) Install the five camshaft bearing caps.
b) Tighten the cover mounting bolts in the sequence shown in the figure in several stages to a torque of 18 N·m.
2. Installing the rear belt cover
a) Thoroughly clean the mating surfaces of the cover and cylinder head.
b) Apply sealant to the cover as shown in the figure.
c) Apply locking adhesive to the threads of the mounting bolts and tighten the bolts to a torque of 9 Nm.
3. Install the timing gear and camshaft drive belt.
4. Check and adjust valve clearances.
b. Installing the valve cover
a) Apply sealant to the areas shown in the figure.
b) Place the gasket on the cylinder head cover.
c) Replace the cylinder head cover. Tighten the 10 mounting bolts to 9 Nm.
6. Install a new gasket, secure the heater drain pipe with two bolts and nuts.
7. Install the vacuum tubes and hoses. Connect the hoses to the injection pump and the cylinder head.
8. Install a new gasket, secure the fluid supply pipe to the heater with two nuts and a bolt.
9. Place the sealing and heat-insulating gaskets of the injectors into the head, tighten the injectors by hand, tighten to a torque of 64 N·m
Note: Exceeding the injector tightening torque will cause the housing to deform and the injector needle to become stuck.
10. Install new sealing washers and drain pipe on the injectors. Tighten the pipe mounting nuts to 30 N·m, connect the fuel drain hose.
11. Install a new gasket and radiator drain pipe. Tighten the mounting nuts to 13 N·m.
[The original can be read on the website: toyotaman.ru]
12. Install new gaskets and intake manifold. Tighten the mounting nuts to 29 N·m.
a) Connect: wiring fastening clamps; vacuum hose; connectors for boost pressure and coolant temperature sensors.
b) On engines with a height compensator, connect two vacuum hoses to the compensator actuator
13. Install the oil dipstick tube, tighten the tube mounting nut to 29 N·m.
14. Install the high pressure pipes, tighten the pipe mounting nuts to a torque of 15 N·m.
15. Install the bracket and the fuel injection pump lever drive rod.
16. Install the air intake duct.
17. Fill the cooling system.
18. Start the engine and check for fluid leaks.
19. Check oil and coolant levels.