CYLINDER BLOCK REASSEMBLY

PROCEDURE


  1. INSTALL STUD BOLT

    Note

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

    Tech Tips

    This procedure is for type A.

    A00564LE04
    LH Side
    *1 16 mm (0.630 in.)
    *2 27 mm (1.06 in.)
    *3 9 mm (0.354 in.)

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

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A0052IK

      Using a 5 mm socket hexagon wrench, install the 4 oil nozzles with the 4 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  3. INSTALL PISTON


    1. A0057JSE02
      Text in Illustration
      *1 Service Hole

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

      Tech Tips

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

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

    3. A0058UCE21
      Text in Illustration
      *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.

      Tech Tips

      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.

      Tech Tips

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

    5. A0054AJ

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

  4. INSTALL PISTON RING SET

    Tech Tips

    Type X and type Y can be distinguished by the shape of the oil ring.

    A00597GE01
    *1 for Type X:
    *2 Oil Ring
    *3 for Type Y:

    1. A0053O6E22
      Text in Illustration
      *1 Oil Ring Expander
      *2 Oil Ring
      *3 Coil Joint
      *4 Oil Ring End

      for Type X:

      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. A005632E19
      Text in Illustration
      *1 Oil Ring Side Rail Upper
      *2 Oil Ring Side Rail Lower
      *3 Oil Ring Expander

      for Type Y:

      Install the oil ring expander and 2 oil ring 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.

      A0058H0E01

      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. A00592ZE03
      *1 No. 2 Compression Ring and Oil Ring Expander
      *2 Front
      *3 Rear
      *4 No. 1 Compression Ring and Oil Ring

      for Type X:

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

    5. A00545GE02

      for Type Y:

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

      Tech Tips

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

  5. INSTALL CRANKSHAFT BEARING


    1. A0052D0E04
      Text in Illustration
      *1 Scale

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


      1. Install the upper bearing to the cylinder block.

        Tech Tips

        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. A00561QE04
      Text in Illustration
      *1 Vernier Caliper

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


      1. Install the upper bearing to the cylinder block.

        Tech Tips

        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 onto the bearing cap.

      2. A0058P8E05
        Text in Illustration
        *1 Vernier Caliper

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

  6. INSTALL UPPER CRANKSHAFT THRUST WASHER


    1. A0059KNE04
      Text in Illustration
      *1 Oil Groove

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

    2. Apply engine oil to the crankshaft thrust washers.

  7. INSTALL CRANKSHAFT


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

    2. Apply engine oil to the lower bearings.

    3. A0054W0E06
      *1 Front
      *2 Number Mark

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

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

    5. A0053OC

      Temporarily install the 10 crankshaft bearing cap bolts.

    6. A0052O0E08
      *1 Less than 5 mm

      Push on the crankshaft bearing caps with your hand until the clearance between the crankshaft bearing caps and cylinder block is less than 5 mm (0.197 in.).

    7. A0056MH

      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. A00547LE03

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

        Torque:
        40 N*m  { 408 kgf*cm, 30 ft.*lbf }

    10. Step 2:


      1. A0054U5E01
        *1 Paint Mark
        *2 Engine Front

        Mark the front of the bearing cap bolts with paint.

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

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

    12. Check that the crankshaft turns smoothly.

    13. Check the crankshaft thrust clearance Click here.

  8. INSTALL CONNECTING ROD BEARING


    1. A0055K8E05
      Text in Illustration
      *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.

  9. 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. A00592ZE03
      *1 No. 2 Compression Ring and Oil Ring Expander
      *2 Front
      *3 Rear
      *4 No. 1 Compression Ring and Oil Ring

      for Type X:

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

      Note

      Do not align the ring ends.

    3. A00545GE02

      for Type Y:

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

      Note

      Do not align the ring ends.

      Tech Tips

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

    4. A0055XBE03
      Text in Illustration
      *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.

    5. A0054OGE01
      Text in Illustration
      *1 Front Mark

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

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

    7. Install the connecting rod cap bolts.

      Note

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

    8. Step 1:


      1. A0052QAE01

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

        SST
        09205-16011
        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    9. Step 2:


      1. A0057CSE51
        *1 Paint Mark
        *2 Engine Front

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

      2. Tighten the cap bolts 90° as shown in the illustration.

    10. Check that the crankshaft turns smoothly.

    11. Check the connecting rod thrust clearance Click here.

  10. INSTALL NO. 1 VENTILATION CASE


    1. A0056T2E13
      *1 Seal Packing
      *2 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 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. A00555P

      for Type A:


      1. Install the ventilation case with the 6 bolts and 2 nuts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. A0056YT

      for Type B:


      1. Install the ventilation case with the 8 bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }