CYLINDER BLOCK REASSEMBLY

Tech Tips


  • Thoroughly clean all parts to be assembled.

  • Before installing the parts, apply new engine oil to all sliding and rotating surfaces.

  • Replace all gaskets, O-rings and oil seals with new parts.


  1. INSTALL TIGHT PLUG


    1. A01KGGAE01
      Text in Illustration
      *1 Adhesive

      Apply adhesive to a new tight plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

    2. Using SST and a hammer, tap in the tight plug as shown in the illustration.

      Position A:

      SST
      09950-60010   ( 09951-00250 )
      09950-70010   ( 09951-07100 )

      Position B:

      SST
      09950-60010   ( 09951-00350 )
      09950-70010   ( 09951-07100 )

      Position C:

      SST
      09950-60010   ( 09951-00500 )
      09950-70010   ( 09951-07100 )
      A01KFR8E01
      Text in Illustration
      *a Right Side *b Rear Side
      *c Left Side *d Stops

  2. INSTALL STUD BOLT

    A01KIL0E01
    Text in Illustration
    *a Right Side *b Thread diameter: 8 mm
    Torque:
    14.5 N*m  { 150 kgf*cm, 11 ft.*lbf }

  3. INSTALL STRAIGHT PIN

    A01KI5SE01
    Text in Illustration
    *a Right Side *b Until pin stops

  4. INSTALL RING PIN

    A01KGA5E01
    Text in Illustration
    *a Rear Side *b Front Side
    *c Cylinder Head Side *d Until pin stops

  5. INSTALL OIL LEVEL GAGE GUIDE


    1. A01KEIRE01
      Text in Illustration
      *1 Adhesive

      Apply adhesive to the surface of the guide contacting the cylinder block.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent
    2. A01KGLRE01
      Text in Illustration
      *a Front
      *b Painted Mark

      Using a bass bar and hammer, tap in the hexagon wrench head portion of the level gauge guide with the painted mark facing forward.

  6. INSTALL W/HEAD TAPER SCREW PLUG NO.1


    1. A01KF05E01
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

    2. Install the screw plug.

      Torque:
      19.5 N*m  { 200 kgf*cm, 14 ft.*lbf }

  7. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A01KGT6E01
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent
    2. A01KIOLE01
      Text in Illustration
      *a Port
      *b Downward

      Install the drain union.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

      Tech Tips


      • After applying the specified torque, rotate the drain union clockwise until its drain port is facing downward.

      • The drain port may be set within 45° of either side of the prescribed position.

  8. INSTALL CYLINDER BLOCK OIL ORIFICE


    1. Using a 6 mm hexagon wrench, install the oil orifice.

      Torque:
      Reference
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

  9. INSTALL SUB-ASSEMBLY OIL NOZZLE NO. 1


    1. A01KFA8

      Align the pin of the oil nozzle with the pin hole of the cylinder block.

    2. Install the oil nozzle with the check valve. Install the 4 oil nozzles and check valves.

      Torque:
      25 N*m  { 260 kgf*cm, 18 ft.*lbf }

  10. INSTALL CONNECTING ROD SMALL END BUSH


    1. A01KEQJ

      Using a round file, lightly file off any roughness from the small end of the connecting rod.

    2. A01KHTWE01
      Text in Illustration
      *1 Oil Hole
      *2 Ball

      Attach a new bush to SST with the ball of SST inside the oil hole of the bush.

      SST
      09222-54011   ( 09222-03021 )
    3. A01KF25E01
      Text in Illustration
      *1 Oil Hole

      Align the oil holes of the bush and connecting rod.

    4. A01KF78E01
      Text in Illustration
      *1 Bushing

      Using SST and a press, press in the bush.

      SST
      09222-54011   ( 09222-03016, 09222-03021, 09222-03026 )
    5. A01KIHK

      Using a pin hole grinder, hone the bush to obtain the standard specified clearance (See step Click here) between the bush and piston pin.

    6. A01KENW

      Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

  11. INSTALL W/PIN PISTON SUB-ASSEMBLY


    1. A01KG12

      Assemble the piston and connecting rod.


      1. Using snap ring pliers, install a new snap ring on one side of the piston pin hole.

      2. A01KEXE

        Gradually heat the piston to about 60°C (140°F).

      3. A01KI6XE01
        Text in Illustration
        *a Front Mark (Arrow)
        *b Front Mark (Protrusion)

        Coat the piston pin with engine oil.

      4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

      5. A01KGPD

        Check fit between the piston and piston pin.


        • Try to move the piston back and forth on the piston pin.

      6. A01KFHS

        Using snap ring pliers, install a new snap ring on the other side of the piston pin hole.

    2. A01KH26E01
      Text in Illustration
      *1 Oil Ring Ends
      *2 Coil Joint

      Install the piston rings.


      1. Install the coil and oil ring by hand.

        Tech Tips

        Face the end gap of the oil ring in the opposite direction coil joint.

      2. A01KIHNE01
        Text in Illustration
        *1 No. 1
        *2 No. 2
        *3 Code Mark

        Using a piston ring expander, install the No. 1 and No. 2 piston rings with the code mark facing upward.

        Code mark
        No. 1 1N
        No. 2 2N
      3. A01KEKLE01
        Text in Illustration
        *1 Oil Ring
        *2 Coil
        *3 No.1 Ring
        *4 No.2 Ring
        *a Front Mark (Arrow)

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

        Note

        Do not align the ring ends.

  12. INSTALL CONNECTING ROD BEARING


    1. A01KGZ2

      Align the bearing claw with the groove of the connecting rod or connecting cap.

    2. Install the bearings in the connecting rod and connecting rod cap.

  13. INSTALL CRANKSHAFT BEARING

    A01KG14

    Tech Tips

    Upper bearings have an oil groove and oil hole; lower bearings do not.


    1. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.

    2. A01KI9D

      Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings.

  14. INSTALL CRANKSHAFT THRUST WASHER SET


    1. A01KH2S

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

    2. A01KEKC

      Install the 2 thrust washers on the No. 3 crankshaft bearing cap with the grooves facing outward.

  15. INSTALL CRANKSHAFT


    1. A01KFM1

      Place the crankshaft on the cylinder block.

    2. Install the 5 crankshaft bearing caps in their proper locations.

    3. A01KIJRE01

      Install the crankshaft bearing cap bolts.


      1. Apply a light coat of the engine oil on the threads and under the bolt heads of the crankshaft bearing caps.

      2. Install and uniformly tighten the 10 bolts of the crankshaft bearing caps, in several passes, in the sequence shown.

        Torque:
        105 N*m  { 1050 kgf*cm, 77 ft.*lbf }

    4. Check that the crankshaft turns smoothly.

    5. Check the crankshaft thrust clearance (See step Click here).

  16. INSTALL PISTON AND CONNECTING ROD


    1. A01KHQ7

      Cover the connecting rod bolts with a short piece of hose to protect the crankshaft and cylinder bore from damage.

    2. A01KEJ8E01
      Text in Illustration
      *a Front Mark (Arrow)

      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.

    3. A01KHLZE01
      Text in Illustration
      *a Front Mark (Protrusion)

      Place the connecting rod cap on the connecting rod.


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

      2. Install the connection rod cap with the front mark facing forward.

    4. A01KI4D

      Install the connecting rod cap nuts.

      Tech Tips


      • The connecting rod cap nuts are tightened in 2 progressive steps (steps (2) and (4)).

      • If any connecting rod bolt is broken or deformed, replace it.


      1. Apply a light of engine oil on the threads and under the heads of the connecting rod cap nuts.

      2. Install and alternately tighten the nuts of the connecting rod cap in several passes.

        Torque:
        54 N*m  { 550 kgf*cm, 40 ft.*lbf }

        If any one of the connecting rod cap nuts does not meet the torque specification, replace the cap nuts.

      3. A01KFGEE01
        Text in Illustration
        *a Front
        *b Painted Mark

        Mark the front of the connecting rod cap nuts with paint.

      4. Retighten the connecting rod cap nuts 90° as shown.

      5. Check that the painted mark is now at a 90° angle to the front.

    5. Check that the crankshaft turns smoothly.

    6. Check the connecting rod thrust clearance (See step Click here).