CYLINDER BLOCK(w/ DPF) REASSEMBLY

PROCEDURE


  1. INSTALL OIL JET


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

      A01VDTCE10
      Text in Illustration
      *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.

  2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01VHAO

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

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  3. INSTALL CRANKSHAFT


    1. Install the crankshaft bearing (upper) with the oil groove onto the cylinder block sub-assembly, crankshaft bearing (lower) onto the crankshaft bearing cap.

      A01VIXHE14
      Text in Illustration
      *a Oil Groove *b Cylinder Block Side
      *c Crankshaft Bearing Cap Side - -

      Note

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

      Tech Tips

      Mass production parts do not have identification marks. If reusing a mass production 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 = within 0.8 mm (0.032 in.)
    2. A01VE6XE05
      Text in Illustration
      *a Oil Groove

      Install the upper crankshaft thrust washer onto the cylinder block sub-assembly and front and backside of No. 3 crankshaft bearing cap with the oil groove facing outward.

    3. Apply engine oil to the crankshaft bearing (upper), and then install the crankshaft onto the cylinder block sub-assembly.

    4. A01VJFS

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

      Text in Illustration
      A01VL3H Engine Front

    5. Apply a light coat of engine oil to the threads and contact surface of the crankshaft bearing cap set bolt.

    6. A01VDPXE04

      Temporarily tighten the crankshaft bearing cap set bolts in several steps in the order shown in the illustration, and tighten them to the specified torque (step "f").

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Tech Tips

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

    7. A01VDQPE02
      Text in Illustration
      *a Paint Mark
      A01VL3H Engine Front

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

    8. Retighten the crankshaft bearing cap set bolts by 90° in the same order as step "f".

    9. Check that each paint mark is now at the 90° angle from the front.

  4. INSTALL PISTON


    1. A01VJ1Z

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

      Note

      Securely assemble the snap ring to the snap ring installation groove.

    2. A01VF7VE01
      Text in Illustration
      *a Front Mark

      Align the front marks of the piston and connecting rod cap.

    3. Apply a light coat of engine oil to the piston pin, and then push the piston pin into the hole of the piston and connecting rod cap.

    4. 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 assemble the snap ring to the snap ring installation groove.

  5. INSTALL CONNECTING ROD BEARING


    1. A01VDM9E04
      Text in Illustration
      *a Oil Groove

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

      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.

  6. INSTALL PISTON RING SET


    1. A01VI6Y

      Install oil ring (expander) by hand.

    2. A01VDTGE01
      Text in Illustration
      *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.

    3. A01VK2JE01
      Text in Illustration
      *a Code Mark
      A01VL3H Upward

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

      Part Code Mark
      No. 1 Compression Ring FTE
      No. 2 Compression Ring 2T
      Oil Ring -
    4. A01VKHHE01
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 Oil Ring (Side Rail)
      *3 Oil Ring (Expander)
      *4 No. 2 Compression Ring
      A01VL3H 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 placed at either position "side rail END" or "expander END".

  7. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD


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

    2. Check that the gap in the piston ring is located correctly.

    3. A01VF2PE06
      Text in Illustration
      *a Front Mark

      Check the front marks. Using a piston ring compressor, install the piston sub-assembly with connecting rod.

      Note

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

    4. A01VIEKE05
      Text in Illustration
      *a Front Mark

      Check that the connecting rod and its connecting rod cap are in the correct combination and that the front marks are facing correctly, and then install the connecting rod cap onto the connecting rod.

      Note

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

    5. Apply a light coat of engine oil to the threads and contact surface of the connecting rod bolts.

    6. A01VF9WE01

      Using SST, temporarily tighten the connecting rod bolts in several steps, and then retighten them to the specified torque.

      SST
      09205-16011
      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }
    7. A01VDQPE02
      Text in Illustration
      *a Paint Mark
      A01VL3H Engine Front

      Mark the front of the connecting rod bolts with paint.

    8. Retighten the connecting rod bolts by 90° as shown in the illustration.

    9. Check that the crankshaft turns smoothly.

  8. INSTALL TUBE CONNECTOR


    1. A01VGWWE06
      Text in Illustration
      *a Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. A01VIJOE02
      Text in Illustration
      *a 14 mm Deep Socket Wrench

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

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }