CYLINDER BLOCK REASSEMBLY

CAUTION / NOTICE / HINT

Tip:

Perform "Inspection After Repairs" after replacing the piston or piston ring.

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PROCEDURE

  1. INSTALL STUD BOLT

    Note:

    If a stud bolt is deformed or the threads are damaged, replace it.

    Tip:

    This procedure is for type A.

    1. A205577C01

      *a

      LH Side

      *b

      16 mm (0.630 in.)

      *c

      9.0 mm (0.354 in.)

      *d

      27 mm (1.06 in.)

      Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

  2. INSTALL NO. 1 TAPER SCREW PLUG

    1. Clean the No. 1 taper screw plug and plug hole.

    2. Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug. Then install the No. 1 taper screw plug.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      43 N*m

      438 kgf*cm

      32 ft.*lbf

      Note:

      • Install the plug within 3 minutes of applying adhesive.

      • Do not start the engine within 1 hour of installing the plug.

  3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

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

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  4. INSTALL PISTON

    Tip:

    Perform "Inspection After Repairs" after replacing the piston.

    Click here

    1. A151020C08

      *1

      Service Hole Cutout

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

      Tip:

      Make sure that the end gap of the snap ring is not aligned with the service hole cutout of the piston.

    2. Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).

    3. A151021C08

      *1

      Front Mark

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

      Tip:

      The piston and pin are a matched set.

    4. Using a screwdriver, install a new snap ring on the other end of the piston pin hole.

      Tip:

      Make sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

    5. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

  5. INSTALL PISTON RING SET

    Tip:

    • Perform "Inspection After Repairs" after replacing the piston ring.

      Click here

    • A336801C01

      *a

      for Type A

      *b

      for Type B

      Type A and type B can be distinguished by the shape of the oil ring.

    1. A146333C17

      *1

      Oil Ring Expander

      *2

      Oil Ring

      *3

      Coil Joint

      *4

      Oil Ring End

      for Type A:

      Install the oil ring expander and oil ring by hand.

      Note:

      • Install the expander and oil ring so that their ring ends are at opposite sides.

      • Securely install the expander to the inner groove of the oil ring.

    2. A164414C10

      *1

      Side Rail (Upper)

      *2

      Oil Ring Expander

      *3

      Side Rail (Lower)

      for Type B:

      Install the oil ring expander and 2 side rails by hand.

    3. Using a piston ring expander, install the 2 compression rings so that the paint marks are positioned as shown in the illustration.

      A297216C01

      *1

      Paint Mark

      *2

      Code Mark (T)

      *3

      Code Mark (2T)

      *4

      No. 1 Compression Ring

      *5

      No. 2 Compression Ring

      -

      -
      V100135

      Upward

      -

      -
      Note:

      • Install the No. 1 compression ring with the code mark (T) facing upward.

      • Install the No. 2 compression ring with the code mark (2T) facing upward.

      • Paint marks can only be checked on new piston rings. When reusing piston rings, check each piston ring profile in order to install them into the correct positions.

    4. A332625C04

      *1

      No. 1 Compression Ring

      *2

      No. 2 Compression Ring and Oil Ring Expander (for Type A)

      *3

      Side Rail (Upper)

      *4

      Side Rail (Lower)

      *a

      for Type B
      V100136

      Engine Front

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

      Tip:

      for Type B:

      The location of the oil ring expander end gap is free.

  6. INSTALL CRANKSHAFT BEARING

    1. A151015C11

      *1

      Scale

      Install the upper bearing (except No. 3 journal).

      1. Install the upper bearing to the cylinder block assembly.

        Tip:

        Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal.

      2. Using a scale, measure the distance between the cylinder block edge and the upper bearing edge.

        Dimension (A)

        0.5 to 1.0 mm (0.0197 to 0.0394 in.)

        Note:

        Do not apply engine oil to the bearings or the contact surfaces.

    2. A162987C09

      *1

      Vernier Caliper

      Install the upper bearing (for No. 3 journal).

      1. Install the upper bearing to the cylinder block assembly.

        Tip:

        Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal.

      2. Using a vernier caliper, measure the distance between the cylinder block edge and the upper bearing edge.

        Dimension (A - B) or (B - A)

        0 to 0.5 mm (0 to 0.0197 in.)

        Note:

        Do not apply engine oil to the bearing or the contact surfaces.

    3. Install the lower bearing.

      1. Install the lower bearing to the bearing cap.

      2. A151016C10

        *1

        Vernier Caliper

        *2

        Mark 1, 2, 3, 4 and 5

        Using a vernier caliper, measure the distance between the bearing cap edge and lower bearing edge.

        Dimension (A - B) or (B - A)

        0 to 0.5 mm (0 to 0.0197 in.)

        Note:

        Do not apply engine oil to the bearings or the contact surfaces.

  7. INSTALL UPPER CRANKSHAFT THRUST WASHER

    1. A150982C07

      *1

      Oil Groove

      Install the 2 thrust washers to the No. 3 journal of the cylinder block assembly with the oil grooves facing outward.

    2. Apply engine oil to the crankshaft thrust washers.

  8. INSTALL CRANKSHAFT

    1. Apply engine oil to the upper bearings and install the crankshaft to the cylinder block assembly.

    2. Apply engine oil to the lower bearings.

    3. A297217C01

      *1

      Number Mark
      V100135

      Engine Front

      Examine the number marks and install the bearing caps to the cylinder block assembly.

    4. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

    5. A205924

      Temporarily install the 10 crankshaft bearing cap bolts.

    6. A235755C01

      *a

      Less than 5.0 mm (0.197 in.).

      Push on the crankshaft bearing caps with your hand until the clearance between the crankshaft bearing caps and cylinder block is less than 5.0 mm (0.197 in.).

    7. A151024

      Using a plastic-faced hammer, lightly tap the bearing caps to ensure a proper fit.

    8. Install the crankshaft bearing cap bolts.

      Note:

      The crankshaft bearing cap bolts are tightened in 2 progressive steps.

    9. Step 1:

      1. A297212N02

        Install and uniformly tighten the 10 crankshaft bearing cap bolts in several steps in the sequence shown in the illustration.

        40 N*m

        408 kgf*cm

        30 ft.*lbf

      2. Mark the front side of the bearing cap bolts with paint.

    10. Step 2:

      1. Tighten the bearing cap bolts 90° in the sequence shown in step 1.

      2. Check that the paint marks are now at a 90° angle to the front.

    11. Check that the crankshaft turns smoothly.

    12. Check the crankshaft thrust clearance.

      Click here

  9. INSTALL CONNECTING ROD BEARING

    1. A151017C07

      *1

      Vernier Caliper

      Install the connecting rod bearings to the connecting rods and connecting rod caps.

    2. Using a vernier caliper, measure the distance between the edges of the connecting rods and connecting rod caps, and the connecting rod caps and connecting rod bearings.

      Dimension A - B or B - A

      0 to 0.7 mm (0 to 0.0276 in.)

      Note:

      Do not apply engine oil to the bearings or the contact surfaces.

  10. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

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

    2. A332625C04

      *1

      No. 1 Compression Ring

      *2

      No. 2 Compression Ring and Oil Ring Expander (for Type A)

      *3

      Side Rail (Upper)

      *4

      Side Rail (Lower)

      *a

      for Type B
      V100136

      Engine Front

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

      Note:

      Do not align the ring ends.

      A336801C01

      *a

      for Type A

      *b

      for Type B
      Tip:

      • Type A and type B can be distinguished by the shape of the oil ring.

      • for Type B:

        The location of the oil ring expander end gap is free.

    3. A205932C01

      *1

      Front Mark

      Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.

      Note:

      • When inserting the piston with connecting rod, do not allow it to make contact with the oil nozzle.

      • Match the numbered connecting rod cap with the connecting rod.

    4. A208476C02

      *1

      Front Mark

      Check that the front mark of the connecting rod cap is facing in the correct direction.

    5. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.

    6. Install the connecting rod cap bolts.

      Note:

      The connecting rod cap bolts should be tightened in 2 progressive steps.

    7. Step 1:

      1. A208477E01

        Using SST, install and alternately tighten the bolts of the connecting rod cap in several steps.

        09205-16011

        20 N*m

        204 kgf*cm

        15 ft.*lbf

      2. Mark the front side of each connecting rod cap bolt with paint.

    8. Step 2:

      1. Tighten the cap bolts 90°.

      2. Check that the paint marks are now at 90° angle to the front.

    9. Check that the crankshaft turns smoothly.

    10. Check the connecting rod thrust clearance.

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  11. INSTALL NO. 1 VENTILATION CASE

    Tip:

    There are 2 installation types for the No. 1 ventilation case. Depending on the installation type, the number of bolts, nuts and stud bolts used will vary.

    1. A158007C05

      *1

      Seal Packing

      *a

      Distance from Inside Edge of Cover to Center of Seal Packing

      *b

      Seal Packing Diameter

      Apply seal packing in a continuous line as shown in the illustration.

      Seal packing

      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Application Specification

      Seal Packing Diameter

      Distance from Inside Edge of Case to Center of Seal Packing

      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      5.0 mm (0.197 in.)
      Note:

      • Remove any oil from the contact surface.

      • Install the No. 1 ventilation case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installation.

    2. for Type A:

      1. Install the No. 1 ventilation case with the 6 bolts and 2 nuts.

        10 N*m

        102 kgf*cm

        7 ft.*lbf

    3. for Type B:

      1. Install the No. 1 ventilation case with the 8 bolts.

        10 N*m

        102 kgf*cm

        7 ft.*lbf