Series L
1. Install the valve cover.
A) Apply sealant to the cylinder head as shown.
b) (2L-T) Apply sealant in the places shown in the picture.
V) Place the gasket on the cylinder head cover.
G) Reinstall the head cover with eight bolts and two nuts.
Tightening torque 4.9 N.m.
2. Install the right engine hanger.
Tightening torque 37 N.m
3. Install the exhaust manifold.
A) Install a new gasket and exhaust manifold. Tighten bolts and nuts to 52 Nm
b) Install the heat shield by tightening the four bolts.
4. Install the intake manifold.
A) Place a new gasket on the cylinder head with the tab facing up.
b) (2L-T) Install a new gasket and intake manifold.
V) Tighten the intake manifold nuts and bolts to 24 Nm.
G) (2L-T) Install the heat insulator and secure the glow plug resistor with the nut.
Note: Fix the lower part of the manifold together with the oil gauge tube and wire clamp with three bolts, as shown in the figure.
Engine 2L-T)
5. (2L-T) Install the recirculation valve, tubing, valve adapter and check valve assembly.
A) Put a new gasket on the intake manifold.
b) Secure the recirculation valve and tube with two nuts. Tightening torque 13 Nm.
V) Secure the recirculation check valve assembly with three bolts.
G) Connect the connectors of the shut-off and vacuum control valves.
d) (2L-T) Install two new gaskets, recirculation valve adapter and air tube and secure with four nuts.
Tightening torque 19 N.m
6. (2L-T) Install the throttle assembly.
A) Install the wire holder on the two bolts.
b) Install a new gasket and throttle assembly.
V) Connect the connector and vacuum tubes to the vacuum shutoff valve.
7. Install the left motor hanger.
Tightening torque 37 N.m
8. Install the water tube and water tube housing.
A) Install a new gasket, water tube and water tube housing.
Tightening torque 19 N.m.
b) (With heating control). Connect the bypass hose to the temperature control unit.
9. Install the top timing belt cover with four bolts.
Tightening torque 18 N.m
10. Install the camshaft pulley.
11. Install nozzles.
12. (For 2L-T) Install injection pump (see related section).
13. Install the timing belt (see related section).
14. Install the turbocharger (only for 2L-T engines).
15. Fill the engine with coolant (see related section).
16. Start the engine and check for leaks.
17. Check coolant and oil levels.
KZ series
1. Install the camshaft with the keyway up.
A) Install five camshaft bearing caps.
b) Tighten the cover bolts in the sequence shown in the figure in several stages up to a torque of 18 Nm.
2. Installing the rear belt cover
A) Thoroughly clean the mating surfaces of the cover and block head.
b) Apply sealant to the cover as shown.
V) Apply locking adhesive to the threads of the mounting bolts and tighten the bolts to 9 Nm.
3. Install the gears and camshaft drive belt.
4. Check and adjust valve clearances.
b. Valve cover installation
A) Apply sealant in the places shown in the picture.
b) Place the gasket on the cylinder head cover.
V) Reinstall the head cover. Tighten 10 mounting bolts to 9 Nm.
6. Install a new gasket, secure the fluid outlet pipe from the heater with two bolts and nuts.
7. Install vacuum tubes and hoses. Connect the hoses to the injection pump and the block head.
8. Install a new gasket, fix 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, screw in the injectors by hand, tighten to 64 N.m
Note: Exceeding the torque of the nozzle will result in deformation of the body and hanging of the atomizer needle.
10. Install new sealing washers and drain tube on the injectors. Tighten the tube fastening nuts to a torque of 30 Nm, connect the fuel outlet hose.
11. Install a new gasket and coolant outlet pipe to the radiator. Tighten the fastening nuts to 13 Nm.
12. Install new gaskets and intake manifold. Tighten the fastening nuts to a torque of 29 Nm.
A) Connect: wiring clamps; vacuum hose; connectors for boost pressure and coolant temperature sensors.
b) On engines with height compensator, connect two vacuum hoses to the compensator actuator
13. Install the oil dipstick tube, tighten the tube mounting nut to 29 Nm.
14. Install the high pressure pipes, tighten the tube nuts to 15 Nm.
15. Establish an arm and draft of a drive of the lever of TNVD.
16. Install the intake duct.
17. Fill the cooling system.
18. Start the engine and check for fluid leaks.
19. Check oil and coolant levels.