Note:
- Thoroughly clean all parts to be assembled.
- Before installing parts, apply engine oil to all mating surfaces.
- Replace all gaskets and oil seals with new ones.
(For 2L-T and 1KZ-T engines only)
1. Install the semicircular plug.
a) Remove old sealant.
b) Apply sealant to the plug.
c) Install the plug into the cylinder head.
2. Install combustion chambers
a) Align the combustion chamber pin with the cylinder head recess.
b) Using a plastic hammer, lightly tap the gaskets and combustion chambers into place.
c) Using a dial indicator, measure the distance the combustion chamber protrudes from the cylinder head (within ±0.03 mm).
If the protrusion distance is beyond the specified limits, adjust it using shims.
Gasket thickness:
- 0.03, 0.05 and 0.1 mm
Note: Two gaskets cannot be installed.
3. Install the valves.
a) Install the following parts:
- (1) oil seal,
- (2) valve,
- (3) spring seat,
- (4) valve spring,
- (5) spring plate.
b) Using the special tool, compress the valve spring and install two crackers on the valve stem.
c) Using a plastic-tipped hammer, lightly tap the end of the valve to ensure that the parts are aligned.
4. Install the tappets and adjusting washers. Check that the tappet rotates easily by hand.
5. (L series only): Install the camshaft.
Note: Please remember that different bearing shells are used for journal #1 and the other journals.
a) Install ten bearing shells into the bearing caps and cylinder head.
b) Install the camshaft on the cylinder head with the keyway facing upward.
c) Install the five bearing caps into place.
d) Apply a thin coat of engine oil to the threads and heads of the bearing cap bolts.
d) Install and tighten the ten bearing cap bolts uniformly to 25 N·m, in several passes, in the sequence shown in the figure.
6. Adjust the valve clearance.
Thermal clearance:
- inlet valve - 0.20 - 0.30 mm
- outlet valve - 0.40 - 0.50 mm
7. Install a new gasket and camshaft seal retainer. Tighten the four bolts to 18 N·m.
