ПРОКЛАДКА ГОЛОВКИ БЛОКА ЦИЛИНДРОВ УСТАНОВКА

PROCEDURE


  1. INSTALL CYLINDER HEAD GASKET


    1. Check the piston protrusion for each cylinder.


      1. A01XGN3E03
        Text in Illustration
        *a Measuring Tip
        *b Protrusion

        Find where the piston head protrudes most by slowly turning the crankshaft clockwise and counterclockwise.

      2. A01XLCKE05
        Text in Illustration
        *a Measuring Point
        B001CHY Front

        Measure the protrusion of each cylinder at 2 places as shown in the illustration, making a total of 8 measurements.

      3. For the piston protrusion value of each cylinder, use the average of the 2 measurements of that cylinder.

        Standard protrusion
        0.68 to 0.98 mm (0.0268 to 0.0386 in.)

        After installing the piston and connecting rod assembly, if the protrusion is not as specified, remove the piston and connecting rod assembly and reinstall them.

    2. A01XKWTE05
      Text in Illustration
      *1 Cutout Mark
      B001CHY Front

      Select a new cylinder head gasket.

      Tech Tips

      There are 3 sizes of new cylinder head gaskets, marked "B", "D" or "F" accordingly.

      New Cylinder Head Gasket Thickness
      Item Specified Condition
      Mark B 1.40 to 1.50 mm (0.0551 to 0.0591 in.)
      Mark D 1.50 to 1.60 mm (0.0591 to 0.0630 in.)
      Mark F 1.60 to 1.70 mm (0.0630 to 0.0669 in.)

      1. Select the largest piston protrusion value from the measurements made, then select a new appropriate gasket according to the table below.

        Gasket Size
        Piston Protrusion Gasket Size
        0.68 to 0.78 mm (0.0268 to 0.0307 in.) Use B
        0.78 to 0.88 mm (0.0307 to 0.0346 in.) Use D
        0.88 to 0.98 mm (0.0346 to 0.0385 in.) Use F
    3. A01XFPV

      Install the selected cylinder head gasket to the cylinder block.

      Note

      Make sure that the gasket is installed facing the proper direction.

      Be careful of the installation direction.

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips


    • The cylinder head bolts are tightened in 3 progressive steps.

    • Set the No. 1 cylinder to 90° BTDC/compression to avoid interference with the piston top and valve head.

    • If any bolt is broken or deformed, replace it.


    1. A01XFMR

      Using the crankshaft pulley bolt, turn the crankshaft 90° counterclockwise, and align the timing mark of the crankshaft timing pulley with the protrusion of the timing belt case.

      Text in Illustration
      B001CHY Turn

    2. Place the cylinder head on the cylinder block.

      Note


      • Make sure that no oil is on the mounting surface of the cylinder head.

      • Place the cylinder head on the cylinder block gently in order not to damage the gasket with the bottom part of the head.

    3. Install the plate washers to the cylinder head bolts.

    4. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

    5. Step 1:


      1. A01XL8IE03

        Install and uniformly tighten the 18 cylinder head bolts, in several steps, in the sequence shown in the illustrations.

        Torque:
        78 N*m  { 795 kgf*cm, 58 ft.*lbf }

        Tech Tips

        Each bolt length is indicated below.

        Standard Bolt
        Item Length
        Bolt A 107 mm (4.21 in.)
        Bolt B 127 mm (5.00 in.)

        If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder set head bolt.

    6. Step 2:


      1. Mark the front side of each cylinder head bolt head with paint.

      2. Tighten the cylinder head bolts 90° in the sequence shown in step 1.

    7. Step 3:


      1. Tighten the cylinder head bolts another 90° in the sequence shown in step 1.

    8. Check that the paint marks are now at a 180° angle to the front.

  3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  4. INSTALL WIRING HARNESS CLAMP BRACKET (for LHD)

    Click here

  5. CONNECT WIRE HARNESS


    1. A01XHZPE01
      Text in Illustration
      *1 Nut
      *2 Washer
      *3 No. 2 Glow Plug Resistor Insulator
      *4 Engine Wire
      *5 No. 1 Glow Plug Connector
      *6 No. 1 Glow Plug Resistor Insulator
      *7 Bolt

      Connect the engine wire and install the No. 2 glow plug resistor insulator and washer with the nut.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    2. A01XERT

      Attach the 4 wire harness clamps.

    3. Install the generator wire with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    4. Install the terminal cap.

    5. Connect the generator connector and cooler compressor connector.

    6. for RHD:


      1. A01XCE0

        Attach the 5 wire harness clamps.

    7. for LHD:


      1. A01XJOY

        Attach the 4 wire harness clamps.

      2. A01XFRC

        Attach the 3 wire harness clamps.

  6. INSTALL INJECTION PIPE SET

    Click here

  7. INSTALL HEATER WATER HOSE SUB-ASSEMBLY

    Click here

  8. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  9. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  10. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


    1. Install the No. 1 compressor mounting bracket with the 4 bolts.

      Torque:
      81 N*m  { 829 kgf*cm, 60 ft.*lbf }

    2. Connect the generator with the bolt.

  11. CONNECT COOLER COMPRESSOR ASSEMBLY

    Click here

  12. INSTALL DIESEL THROTTLE BODY ASSEMBLY


    1. Install the diesel throttle body Click here.

  13. INSTALL TIMING BELT


    1. Install the timing belt Click here.

  14. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for Long Wheelbase)

    Click here

  15. BLEED AIR FROM FUEL SYSTEM

    Click here

  16. ADD ENGINE COOLANT

    Click here

  17. BLEED INJECTION PIPE

    Click here

  18. INSPECT FOR COOLANT LEAK

    Click here

  19. INSPECT FOR FUEL LEAK

    Click here

  20. INSPECT FOR EXHAUST GAS LEAK

  21. INSPECT ENGINE IDLE SPEED

    Click here

  22. INSPECT MAXIMUM ENGINE SPEED

    Click here