Contents: L-series engines ↓ KZ series engines ↓
Check piston protrusion and select cylinder head gasket thickness.
A. Check the protrusion of pistons No.1 and No.4.
a) Align the TDC mark on the crankshaft pulley with the reference mark.
L-series engines
Engine 1KZ-T
b) Install the dial indicator on the cylinder block, place the tip of the indicator on the piston bottom.
c) Slowly turn the crankshaft clockwise and counterclockwise to find the point where the piston crown protrudes the maximum distance.
d) Set the dial indicator to zero - 0 mm.
d) Measure the piston protrusion from the cylinder block by moving the dial indicator.
Protrusion - 0.68 - 0.97 mm
Note: Check the protrusion at least at two points.
If the protrusion is not as specified, remove the connecting rod and piston group and replace it.
B. Check the protrusion of pistons No.2 and No.3.
a) Turn the crankshaft half a turn (180°).
b) Measure the piston protrusion as described above.
B. Select a new cylinder head gasket. When selecting a new cylinder head gasket, use the largest protrusion value.
L-series engines
Please note: Cylinder head gaskets come in three sizes, which are marked with either the letters "B", "D" or "F", or the location of the cutout.
Note: There are 6 types of cylinder head gaskets installed at the factory (marked from A to F), but only three types are supplied as spare parts (B, D and F), so when replacing the gasket you need to choose from the three types listed above.
Thickness of new cylinder head gasket:
- Marking B - 1.40 - 1.50 mm
- Marking D - 1.50-1.60 mm
- Marking F - 1.60 - 1.70 mm
| Piston protrusion | Gasket type |
| 0,68-0,77 | "IN" |
| 0,78 - 0,87 | "D" |
| 0,88-0,97 | "R" |
KZ series engines
Please note: Cylinder head gaskets are available in three sizes, each marked with the number of holes.
Note: There are 5 types of head gaskets installed at the factory, but only three types are available as replacement parts (one, three and five holes), therefore, when replacing the gasket, you need to choose from the three types listed above.
Thickness of new cylinder head gasket:
- Marking 1 - 0.8 - 0.9 mm
- Marking 3 - 0.9 -1.0 mm
- Marking 5 - 1.0 -1.1 mm
| Piston protrusion | Gasket type |
| 0,08-0,12 | "1" |
| 0,13-0,22 | "3" |
| 0,23-0,33 | "5" |
2. (L only): Set the piston of cylinder No.1 to TDC.
a) Install the camshaft with the keyway facing up.
b) Align the TDC mark on the crankshaft pulley with the reference mark.
Install the cylinder head.
A. (ALL ENGINES) Install the head onto the cylinder block.
a) Place the new one on the cylinder block.
Note: Orient the gasket correctly.
b) Install the cylinder head on the pins.
B. Install the cylinder head bolts.
Note: The cylinder head bolts are tightened in three successive stages.
If any of the bolts are broken or deformed, replace them.
a) Apply a thin coat of engine oil to the threads and caps of the cylinder head bolts.
b) First, install and tighten the eighteen cylinder head bolts uniformly in several passes, in the sequence shown in the figure, to a torque of 78 N·m (L series) or 39 N·m (KZ series).
Note: L series engine cylinder head bolts of two types A and B:
- Type A - 107 mm
- Type B - 127 mm
c) Mark the cylinder head bolts.
d) On the second pass, tighten the cylinder head bolts by an additional 90° in the same sequence as described above.
d) On the third pass, tighten the cylinder head bolts an additional 90°.
e) The mark should now be facing the back side.
