EM-40 ENGINE MECHANICAL - Cylinder Head (2L-T)

INSTALLATION OF CYLINDER HEAD

(See page EM-35)
CHECK PISTON PROTRUSION AND SELECT
CYLINDER HEAD GASKET

Check protrusions of No. 1 and No. 4 pistons

(a) Align the timing marks of the crankshaft timing
pulley and timing belt case.

(b) Place a dial indicator on the cylinder block, and set

the dial indicator needle on the piston measuring
point.

(c) Find where the piston head protrudes most by slowly

turning the crankshaft clockwise and counterclock-
wise.

(d) Set the dial indicator a t 0 mm (0in.).

(e) Measure the piston protrusion from the cylinder

block by sliding the dial indicator.
Protrusion: 0.68 - 0.97 rnrn
(0.0268 - 0.0382 in.)
HINT: For each piston, measure the piston protrusion a t
two measuring points.
(When removing piston and connecting rod assembly)
I f the protrusion is not as specified, remove the piston and
connecting rod assembly and reinstall it.

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 ENGINE MECHANICAL - Cylinder Head (2L-T) EM-41

B. Check protrusions of No. 2 and No. 3 pistons

(a) Turn the crankshaft 112 of a revolution (180").
(b) Measure the piston protrusions.
(See procedure steps A (b) to (e))

C. Select new cylinder head gasket

Cutout
HINT: There are three sizes of new cylinder head gasket,
marked either "B", "D" or "F", or indicated by a cutout
Mark
0, D or F mark.
New cylinder head gasket thickness:
-
Mark 5 1.40 1.SO mm
(0.0551 - 0.0591 in.)
Mark D 1.50 - 1.60 mm
Front (0.0591 - 0.0630 in.)
Mark F 1.60 - 1.70 mm
(0.0630 - 0.0669 in.)
When selecting a new cylinder head gasket, use the largest
I Piston protrusion
mm (in.)
Gasket size
I value from the eight measurements made of the piston

1 0.68 - 0.77
(0.0268 - 0.0303)
I use 8 1 protrusion.
HINT: There are 6 types of cylinder head gasket (marks
A to F) installed a t the factory, but only 3 types for sup-
ply parts (mark B, D and F), so when replacing the gasket,
choose from one of the 3 types above.
0.88 - 0.97
(0.03 16 - 0.0382)
I use F I
SET NO. 1 CYLINDER TO TDCICOMPRESSION
HINT: Set the No. 1 cylinder to TDC/compression to
avoid interference with the piston top and valve head.
(a) (Camshaft Position)
Set the camshaft by turning the hexagonal wrench
head portion, facing the key groove upward.

(b) (Crankshaft Position)

Using the crankshaft pulley bolt, align the timing
marks of the timing pulley and timing belt case by
turning the crankshaft.

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 EM-42 ENGINE MECHANICAL - Cylinder Head (2L-T)

INSTALL CYLINDER HEAD

Place cylinder head on cylinder block

(a) Place a new cylinder head gasket in position on the
cylinder block.
NOTICE: Be careful of the installation direction.
(b) Place the cylinder head in position on the cylinder
head gasket.

Install cylinder head bolts

HINT:
The cylinder head bolts are tightened in three progres-
sive steps.
I f any of bolts break or deform, replace them.
(a) Apply a light coat of engine oil on the threads and
under the heads of the cylinder head bolts.
(b) First, install and uniformly tighten the eighteen cy-
linder head bolts in several passes in the sequence
shown.
Torque: 800 kg-cm (58 ft-lb, 78 N-m)
HINT: The bolt lengths for bolt types A and B shown in
the illustration are:
A 107 mm (4.12 in.)
B 127 mm (5.00 in.)
I f any one of the bolts does not meet the torque specifica-
tion, replace the bolt.

(c) Mark the front of the cylinder head bolt with paint.

(d) Second, retighten the cylinder head bolts 90" in the

numerical order shown.
(e) Third, retighten cylinder head bolts by an additional
90".
(f) Check that the painted mark is now facing rearward.

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 ENGINE MECHANICAL - Cylinder Head (2L-T) EM-43

- -
:Seal Packing
?
INSTALL CYLINDER HEAD COVER
(a) Apply seal packing to the cylinder heads as shown in
the illustration.
+

Seal packing: Part No. 08826-00080or equivalent

(b) lnstall the gasket to the cylinder head cover.

(c) Install the cylinder head cover with the eight bolts
and two nuts.
Torque: 50 kg-cm (43 in.-lb, 4.9 N-m)

INSTALL RH ENGINE HANGER

Torque: 380 kg-cm (27 ft-lb, 37 N-m)

INSTALL EXHAUST MANIFOLD

(a) Install a new gasket in direction as shown in the illust-
ration.

(b) Install the exhaust manifold with the four nuts and
four bolts.
Torque: 530 kg-cm (38 ft-lb, 52 N-m)

(c) Install the two heat insulators with the four bolts and
nut.
Torque: 120 kg-cm (9 ft-lb, 12 Nmm)

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 EM-44 ENGINE MECHANICAL - Cvlinder Head (2L-T)

INSTALL INTAKE MANIFOLD

(a) lnstall a new gasket and the intake manifold with the
six bolts and two nuts.
Torque: 240 kg-cm (17 ft-lb, 24 N-m)
HINT: Torque the three bolts on the bottom of the
manifold together with the oil level gauge guide support
and the clamp for the engine wires, as shown in the illustra-
tion.
(b) lnstall the insulator and nut to the glow plug resistor.
HINT: lnstall the insulator and engine wire terminals as
shown in the illustration.

(Austria)
INSTALL EGR VALVE, PIPE, VALVE ADAPTOR AND
CONTROL VALVE ASSEMBLY
(a) Place a new gasket in position on the intake manifold.
(b) lnstall the EGR valve and pipe with the two nuts.
Torque: 130 kg-cm (9 in.-lb, 13 N-m)

(c) l nstall the EG R control valve assembly with the three

bolts.
(d) Connect the connectors to the VSV and EVRV.

(e) lnstall two new gaskets, the EGR valve adaptor and
air pipe ( L N only) with the four nuts.
Torque: 195 kg-cm (14 ft-lb, 19 N-m)

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ENGINE MECHANICAL - Cylinder Head (2L-T) EM-45

9. (LN) a
INSTALL VENTURI ASSEMBLY
(a) Install the wire support with the two bolts.
(b) l nstall a new gasket and the venturi assembly.
(c) Connect the connector and vacuum hoses to the VSV.
10. INSTALL LH ENGINE HANGER
Torque: 380 kg-cm (27 ft-lb, 37 Nnm)

INSTALL WATER OUTLET AND OUTLET HOUSING

ASSEMBLY
(a) l nstall a new gasket, the water outlet and outlet hous-
ing assembly with the three bolts.
Torque: 195kg-cm(14ft-lb,19N-m)
(b) Connect the by-pass hose to the thermo wax of the
injection pump.
(c) Connect the water temperature switch connector.

12. INSTALL NO. 2 TIMING BELT COVER

Install the timing belt cover with the four bolts.
Torque: 185 kg-cm (13 ft-lb, 18 N-m)

13. INSTALL CAMSHAFT TIMING PULLEY

14. INSTALL INJECTION NOZZLES

15. INSTALL INJECTION PUMP

(See steps 2 to 11 on pages FU-46 and 47)

16. INSTALL TIMING BELT

(See steps 12 to 18 on page FU-48)

17. INSTALL TURBOCHARGER

(See steps 3 to 8 on pages TC-13 and 14)

18. FILL WITH ENGINE COOLANT (See page CO-5)

19. START ENGINE AND CHECK FOR LEAKS

20. RECHECK ENGINE COOLANT LEVEL AND OIL

LEVEL

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