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 the end of 1 new tight plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

    2. Position A:

      Using 14mm steel bar and a hammer, tap in the tight plug as shown in the illustration.

    3. Other Positions:

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

      Position B:

      SST
      09950-60010   ( 09951-00180 )
      09950-70010   ( 09951-07100 )

      Position C:

      SST
      09950-60010   ( 09951-00190 )
      09950-70010   ( 09951-07100 )

      Position D:

      SST
      09950-60010   ( 09951-00200 )
      09950-70010   ( 09951-07100 )

      Position E:

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

      Position F:

      SST
      09950-60010   ( 09951-00400 )
      09950-70010   ( 09951-07100 )

      Position G:

      SST
      09950-60010   ( 09951-00450 )
      09950-70010   ( 09951-07100 )
      A01KF75E01
      Text in Illustration
      *a Front Side *b Left Side
      *c Rear Side *d Stops

  2. INSTALL STUD BOLT

    A01KHDFE01
    Text in Illustration
    *a Cylinder Head Side *b Oil Pan Side
    *c Left Side *d Front Side
    Torque:
    A and B
    7.0 N*m  { 70 kgf*cm, 62 in.*lbf }
    C
    8.0 N*m  { 80 kgf*cm, 71 in.*lbf }
    D and E
    4.0 N*m  { 40 kgf*cm, 35 in.*lbf }

  3. INSTALL STRAIGHT PIN

    A01KGOKE01
    Text in Illustration
    *a Front Side *b Rear Side
    *c Until pin stops - -

  4. INSTALL RING PIN

    A01KI0KE01
    Text in Illustration
    *a Cylinder Head Side *b Until pin stops

  5. INSTALL W/HEAD STRAIGHT SCREW PLUG NO.1


    1. Install a new gasket and the screw plug.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  6. INSTALL SUB-ASSEMBLY OIL NOZZLE NO.1


    1. A01KF2Z

      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:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  7. INSTALL CONNECTING ROD SMALL END BUSH


    1. A01KGAYE01
      Text in Illustration
      *1 Oil Hole

      Align the oil holes of a new bush and the connecting rod.

    2. A01KHYXE02

      Using SST and a press, press in the bush.

      SST
      09222-76012

      1. A01KHG2

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

      2. A01KI3AE01
        Text in Illustration
        *a Piston Pin

        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.

  8. INSTALL W/PIN PISTON SUB-ASSEMBLY


    1. A01KGTR

      Assemble the piston and connecting rod.


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

      2. A01KIJD

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

      3. A01KF4DE01
        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. A01KHGU

        Check fit between the piston and piston pin.


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

      6. A01KGC7

        Using a small screwdriver, 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. A01KFFFE01
        Text in Illustration
        *a Code Mark
        *b No. 1
        *c No. 2

        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. A01KF3IE01
        Text in Illustration
        *1 Oil
        *2 Coil
        *a No. 1
        *b No. 2
        *c Front Mark

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

        Note

        Do not align the ring ends.

  9. INSTALL CONNECTING ROD BEARING


    1. A01KFBK

      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.

  10. INSTALL CRANKSHAFT BEARING

    A01KH45

    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. A01KEA9

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

  11. INSTALL CRANKSHAFT


    1. A01KF4U

      Place the crankshaft on the cylinder block.

    2. Install the 2 upper thrust washers to the No. 5 journal position of the cylinder block.


      1. Push the crankshaft toward the front (rear) side.

      2. Install the 2 thrust washers with the oil grooves facing outward.

    3. A01KIFM

      Install the 2 thrust washers on the No. 5 bearing cap with the grooves facing outward.

    4. A01KGG6

      Install the 5 crankshaft bearing caps in their proper locations.

    5. A01KI9ME02

      Install the crankshaft bearing cap bolts.

      Tech Tips


      • The main bearing cap bolts are tightened in 2 progressive steps (steps (b) and (d)).

      • If any one of the main bearing cap bolt is broken or deformed, replace it.


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

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

        Torque:
        50 N*m  { 510 kgf*cm, 37 ft.*lbf }

        If any one of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.

      3. A01KEOEE01
        Text in Illustration
        *a Front
        *b Painted Mark

        Mark the front of the main bearing cap bolt with paint.

      4. Retighten the main bearing cap bolts 90 ° in the numerical order shown above.

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

    6. Check that the crankshaft turns smoothly.

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

  12. INSTALL PISTON AND CONNECTING ROD


    1. A01KFYWE01
      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.

    2. A01KHQY

      Place the connecting rod cap on the connecting rod.


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

      2. Align the pins of the connecting rod cap with the pin holes of the connecting rod, and install the connecting rod cap.

      3. A01KG4DE01
        Text in Illustration
        *a Front
        *b Front Mark (Protrusion)

        Check that the front mark of the connecting rod cap is facing forward.

    3. A01KFJJ

      Install the connecting rod cap bolts.

      Tech Tips


      • The connecting rod cap bolts 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 bolts.

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

        Torque:
        35 N*m  { 357 kgf*cm, 26 ft.*lbf }

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

      3. A01KI1EE01
        Text in Illustration
        *a Front
        *b Painted Mark

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

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

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

    4. Check that the crankshaft turns smoothly.

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

  13. INSTALL CYLINDER BLOCK OIL ORIFICE