CYLINDER BLOCK(w/ Glow Plug Controller) REASSEMBLY

INSTALL OIL JET

Tap in a new oil jet with the tip of the oil jet aligned with the cylinder block sub-assembly alignment mark.

*1	Oil Jet	-	-
*a	Alignment Mark	-	-

Note:

Do not tap the tip of the oil jet.
Press in the oil jet until its spool portion contacts the cylinder block sub-assembly.

INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

Using a 5 mm hexagon wrench, install the 4 No. 1 oil nozzle sub-assemblies to the cylinder block sub-assembly with the 4 bolts.

9.0 N*m

92 kgf*cm

80 in.*lbf

INSTALL CRANKSHAFT

Install the crankshaft bearing with the oil grooves to the cylinder block sub-assembly and crankshaft bearing to the crankshaft bearing cap.

*a	Cylinder Block Sub-assembly Side	*b	Crankshaft Bearing Cap Side
*c	Oil Groove	-	-

Note:

Do not apply engine oil to the contact surface of the cylinder block sub-assembly or the back side of the crankshaft bearing.

Tip:

OEM parts do not have identification marks. If reusing an OEM part, measure the clearance of both sides so that the crankshaft bearing is in the center of the crankshaft bearing cap.

Specified Clearance

(A) - (B) = 0.8 mm (0.0315 in.) or less

*a	Oil Groove

Install the upper crankshaft thrust washer to the cylinder block sub-assembly with the oil grooves facing outward.

Apply engine oil to the crankshaft bearings, and then install the crankshaft to the cylinder block sub-assembly.

*a	Front Mark
	Engine Front

Confirm the front marks and numbers and check that the order is as shown in the illustration. Then, install the crankshaft bearing caps to the cylinder block sub-assembly.

Apply a light coat of engine oil to the threads and under the heads of the 10 crankshaft bearing cap set bolts.
Install and uniformly tighten the 10 crankshaft bearing cap bolts in several steps in the order shown in the illustration.

60 N*m

612 kgf*cm

44 ft.*lbf

Tip:
Check that the crankshaft turns smoothly while tightening the 10 crankshaft bearing cap set bolts.

*a	Paint Mark
	Engine Front

Mark the front of the 10 crankshaft bearing cap set bolts with paint.

Tighten the 10 crankshaft bearing cap set bolts by 90° in the same order as in step (*1).
Check that each paint mark is now at a 90° angle from the front.

INSTALL PISTON WITH PIN SUB-ASSEMBLY

Using a small screwdriver, install a new snap ring at one end of the piston pin hole.

Note:
Securely fit the snap ring into the snap ring installation groove.

*a	Front Mark

Align the front marks of the piston and connecting rod, insert the connecting rod to the piston, and then push in the piston pin with your thumb until the piston pin comes into contact with the snap ring.

Using a screwdriver, install a new snap ring on the other end of the piston pin hole.
Note:
- Do not change the combinations of the pistons and piston pins so that they can be returned to their original location when reassembled.
- Securely fit the snap ring onto the snap ring installation groove.

INSTALL CONNECTING ROD BEARING

*a	Oil Groove

Align the connecting rod bearing and oil grooves, and then install the connecting rod bearing to the connecting rod and connecting rod cap.

Note:

Do not apply engine oil to the contact surfaces of the connecting rod, connecting rod cap or the back side of the connecting rod bearing.

INSTALL PISTON RING SET

Install the oil ring (expander) by hand.

*a	Oil Ring (Expander)
*b	Oil Ring (Side Rail)

Using a piston ring expander, install the oil ring (side rail) as shown in the illustration.

*a	Code Mark
	Upward

Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring with the code marks facing as shown in the illustration.


Part	Code Mark
No. 1 Compression Ring	FTE
No. 2 Compression Ring	2T
Oil Ring	-

*a	No. 1 Compression Ring
*b	Oil Ring (Side Rail)
*c	Oil Ring (Expander)
*d	No. 2 Compression Ring
	Engine Front

Position the piston rings so that the ring ends are as shown in the illustration.

Note:

Make sure that the gap in the oil ring is at either the side rail end or the expander end.

INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

*a	Front Mark

Apply engine oil to the cylinder walls, pistons and surfaces of the connecting rod bearings.

Check that the gap in the piston ring is positioned correctly.
Check the front mark. Using a piston ring compressor, install the piston sub-assembly with connecting rod.

Note:
Install the piston sub-assembly with connecting rod so that it does not interfere with the No. 1 oil nozzle sub-assembly.

*a	Front Mark

Check that the connecting rod and its connecting rod cap are in the correct combination and that the front mark is facing in the correct direction, and then install the connecting rod cap to the connecting rod.

Note:

The connecting rods and their caps should be reinstalled in their original combinations.

Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
Temporarily install the 2 connecting rod bolts, then using SST, alternately tighten the connecting rod bolts in several steps.

09205-16011

15 N*m

153 kgf*cm

11 ft.*lbf

*a	Paint Mark
	Engine Front

Mark the front of the connecting rod bolts with paint.

Retighten the connecting rod bolts by 90° as shown in the illustration.
Check that the crankshaft turns smoothly.

INSTALL TUBE CONNECTOR

*a	Adhesive

Apply adhesive to 2 or 3 threads of the tube connector.

Adhesive

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

*a	14 mm Deep Socket Wrench

Using a 14 mm deep socket wrench, install the tube connector to the cylinder block sub-assembly.

25 N*m

255 kgf*cm

18 ft.*lbf