Note:
- Thoroughly clean all parts to be assembled.
- Apply engine oil to all mating surfaces before installing parts.
- Replace all gaskets and oil seals with new ones.
(Only for 2L-T and 1KZ-T engines)
1. Install the semi-circular plug.
A) Remove old sealant.
b) Apply sealant to the plug.
V) Install the plug in the cylinder head.
2. Install combustion chambers
A) Align the combustion chamber pin with the recess in the head of the block.
b) Using a plastic mallet, lightly tap the gaskets and combustion chambers into place.
V) Using a dial gauge, measure the distance the combustion chamber protrudes from the cylinder head (within±0.03mm).
If the protrusion distance is out of range, adjust it with shims.
Gasket thickness:
- 0.03, 0.05 and 0.1 mm
Note: two gaskets cannot be installed.
3. Install valves.
A) Install the following parts:
- (1) oil cap,
- (2) valve,
- (3) spring seat,
- (4) valve spring,
- (5) spring plate.
b) Using the special tool, compress the valve spring and install two cotters on the valve stem.
V) Using a plastic sheathed hammer, lightly tap the valve face to ensure alignment.
4. Establish pushers and adjusting washers. Check that the pusher rotates easily by hand.
5. (L series only): Install the camshaft.
Note: Keep in mind that journal #1 and other journals use different bearing shells.
A) Install ten bearing shells in the bearing caps and cylinder head.
b) Install the camshaft onto the cylinder head with the keyway facing up.
V) Reinstall the five bearing caps.
G) Apply a light coat of engine oil to the threads and bolt heads of the bearing caps.
d) Install and evenly tighten the ten bearing cap bolts to 25 Nm in several passes in the sequence shown.
6. Carry out adjustment of a thermal backlash of valves.
Thermal gap:
- intake valve - 0.20 - 0.30 mm
- exhaust valve - 0.40 - 0.50 mm
7. Install a new gasket and camshaft oil seal retainer. Tighten the four bolts to 18 Nm.