L300 Head replacement and timing belt DIY, step by step
Posted: Fri Mar 06, 2015 4:11 pm
Hello Delica.ca,
The head on the ol' L300 cracked about a year ago and I'm finally ready to tackle the job. My van is parked uncovered in the backyard, no hydraulic lift or air tools. Grungy backyard mechanic! I'll be doing the updates in real-time so it might take awhile. I'll endeavor to be as clear and concise as possible. Let me know if you have questions. Best to download the full service manual and refer to the torque specs there.
The following is a step by step head and timing belt replacement for a 4D56 2.5L turbo diesel as found in my 1993 L300 Delica Super Exceed. It has 140,000 kms on the clock and has had a pyrometer since it was imported in 2009 with 56,000 kms. Timing belts and water pump were replaced on import. It's pretty much stock except for EGR blanking plates, pyrometer, K&N filter and stainless 2.5" exhaust. Turbo cartridge was replaced as well as the turbo seals. This is the first time this motor has been torn down. I'll try to upload as many photos as I can and add as much detail as I can. I'm presuming that you have some basic mechanical knowledge, as well as good "feel". I find that this intuitive mechanical skill that some people have is very important when working on a motor. Knowing when to use force, and knowing when to back off before shearing a bolt is the difference between success and frustration. Although I've wrenched on a lot of vehicles, this is the first time I'm tackling this motor, so if there are constructive comments or suggestions from mechanics who have done this before, it would be appreciated.
Tool list (*will be updated as we go*):
- Metric socket set, 3/8" and 1/2" drive
- Metric impact sockets
- Closed end wrenches
- Ratcheting closed end wrenches
- Phillips screwdriver
- Flat head screwdriver
- Lever bars
- Breaker bars, 24" and 30", 1/2" drive
- Trays for collecting parts
- Trays for collection fluids
- Funnel
- Wire brushes
- Needlenose pliers
- Bent needlenose pliers
- Lineman's pliers
- Wire brushes
- Soft mallet
- Soft scraper
- Torque wrench
- Roloc bristle disc
- Cam/Crank removal tool
Supplies (*will be updated as we go*):
- Deep Creep penetrating oil or similar like Liquid Wrench
- Shop rags
- Nitrile gloves
- WD40
- Super Lube silicone grease
- Automotive solvent
- Degreaser
- Brake cleaner, aerosol can
The head on the ol' L300 cracked about a year ago and I'm finally ready to tackle the job. My van is parked uncovered in the backyard, no hydraulic lift or air tools. Grungy backyard mechanic! I'll be doing the updates in real-time so it might take awhile. I'll endeavor to be as clear and concise as possible. Let me know if you have questions. Best to download the full service manual and refer to the torque specs there.
The following is a step by step head and timing belt replacement for a 4D56 2.5L turbo diesel as found in my 1993 L300 Delica Super Exceed. It has 140,000 kms on the clock and has had a pyrometer since it was imported in 2009 with 56,000 kms. Timing belts and water pump were replaced on import. It's pretty much stock except for EGR blanking plates, pyrometer, K&N filter and stainless 2.5" exhaust. Turbo cartridge was replaced as well as the turbo seals. This is the first time this motor has been torn down. I'll try to upload as many photos as I can and add as much detail as I can. I'm presuming that you have some basic mechanical knowledge, as well as good "feel". I find that this intuitive mechanical skill that some people have is very important when working on a motor. Knowing when to use force, and knowing when to back off before shearing a bolt is the difference between success and frustration. Although I've wrenched on a lot of vehicles, this is the first time I'm tackling this motor, so if there are constructive comments or suggestions from mechanics who have done this before, it would be appreciated.
Tool list (*will be updated as we go*):
- Metric socket set, 3/8" and 1/2" drive
- Metric impact sockets
- Closed end wrenches
- Ratcheting closed end wrenches
- Phillips screwdriver
- Flat head screwdriver
- Lever bars
- Breaker bars, 24" and 30", 1/2" drive
- Trays for collecting parts
- Trays for collection fluids
- Funnel
- Wire brushes
- Needlenose pliers
- Bent needlenose pliers
- Lineman's pliers
- Wire brushes
- Soft mallet
- Soft scraper
- Torque wrench
- Roloc bristle disc
- Cam/Crank removal tool
Supplies (*will be updated as we go*):
- Deep Creep penetrating oil or similar like Liquid Wrench
- Shop rags
- Nitrile gloves
- WD40
- Super Lube silicone grease
- Automotive solvent
- Degreaser
- Brake cleaner, aerosol can