A. Check protrusion of No. 1 and No. 4 pistons.
A) Align the TDC mark on the crankshaft pulley with the benchmark.
L series engines
Engine 1KZ-T
b) Install a dial indicator on the cylinder block, place the indicator tip on the piston crown.
V) Slowly turning the crankshaft clockwise and counterclockwise, find the point where the piston crown protrudes the maximum distance.
G) Set the dial indicator to zero - 0 mm.
d) Measure the protrusion of the piston 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 protrusion of No. 2 and No. 3 pistons.
A) Rotate the crankshaft half a turn (180°).
b) Measure piston protrusion as described above.
B. Select a new cylinder head gasket. When choosing a new head gasket, use the largest protrusion.
L series engines
Attention: three sizes of cylinder head gaskets are produced, which are marked either with letters "IN", "D" or "F", or the location of the cutout.
Note: There are 6 types of head gaskets installed at the factory (marked from A to F), but only three types are available as spare parts (B, D and F), therefore, when replacing the gasket, you must choose from the three types indicated above.
New cylinder head gasket thickness:
- 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 motors
Attention: three sizes of cylinder head gaskets are produced, which are 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 spare parts (one, three and five holes), therefore, when replacing the gasket, you must choose from the three types indicated above.
New cylinder head gasket thickness:
- 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. (Only L): Set the No. 1 cylinder piston to TDC.
A) Install the camshaft with the keyway up.
b) Align the TDC mark on the crankshaft pulley with the benchmark.
Install the cylinder head.
A. (ALL ENGINES) Install the head to the cylinder block.
A) Put a new one on the cylinder block.
Note: Orient the gasket correctly.
b) Install the cylinder head on the pins.
B. Install the block head bolts.
Note: The cylinder head bolts are tightened in three consecutive steps.
If any of the bolts are broken or deformed, replace them.
A) Apply a light coat of engine oil to the threads and headrests of the cylinder head bolts.
b) First of all, install and evenly tighten the eighteen cylinder head bolts 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 block head bolts of two types A and B:
- Type A - 107 mm
- Type B - 127 mm
V) Mark the cylinder head bolts.
G) On the second pass, turn the cylinder head bolts 90°in the same sequence as above.
d) On the third pass, turn the cylinder head bolts an additional 90°.
e) The label should now be facing the back.