БЛОК ДВИГАТЕЛЯ ПОВТОРНАЯ СБОРКА

INSTALL STRAIGHT PIN

1. 

   Using a plastic-faced hammer, tap in new straight pins to the cylinder block.

   Table 3. Text in Illustration

   *a	Height	*b	Wide
   *c	Protrusion Height	*d	Rear Side

   Standard Straight Pin
   Item Height Width Protrusion Pin A 22 mm (0.866 in.) 10 mm (0.394 in.) 13 mm (0.512 in.) Pin B 14 mm (0.551 in.) 6.0 mm (0.236 in.) 5.5 mm (0.217 in.)

INSTALL RING PIN

1. 

   Using a plastic-faced hammer, tap in new ring pins to the cylinder block.

   Table 4. Text in Illustration

   *a	Front Side	*b	Lower Side
   *c	Upper Side	*d	Height
   *e	Width	*f	Protrusion

   Standard Ring Pin
   Item Height Width Protrusion Pin A 9.0 mm (0.354 in.) 11 mm (0.433 in.) 3.5 to 4.5 mm (0.138 to 0.177 in.) Pin B 20 mm (0.787 in.) 14 mm (0.511 in.) 7.0 to 9.0 mm (0.276 to 0.354 in.) Pin C 14 mm (0.511 in.) 15 mm (0.591 in.) 7.5 to 9.5 mm (0.295 to 0.374 in.)

INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

1. Apply adhesive to the cylinder block water drain cock sub-assembly.

   Adhesive
   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

2. 

   Install the cylinder block water drain cock sub-assembly as shown in the illustration.

   25 N*m

   250 kgf*cm

   18 ft.*lbf

   Table 5. Text in Illustration

   *a	Allowable Range
   *b	Target Direction
   *c	Upper Side
   *d	Front

   Note:
   

   • Do not rotate the cylinder block water drain cock sub-assembly more than 1 revolution (360°) after tightening the cylinder block water drain cock sub-assembly to the specified torque.

   • Do not loosen the cylinder block water drain cock sub-assembly to adjust it. If an adjustment is necessary, remove the cylinder block water drain cock sub-assembly and reinstall it.

3. Install the water drain cock plug to the cylinder block water drain cock sub-assembly.

   13 N*m

   130 kgf*cm

   9 ft.*lbf

INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

1. Using an E7 "TORX" socket wrench, install the 4 No. 1 oil nozzle sub-assemblies.

   7.0 N*m

   71 kgf*cm

   62 in.*lbf

INSTALL CONNECTING ROD SMALL END BUSH

1. 

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

   Table 6. Text in Illustration

   *a

   Oil Hole

2. 

   Using SST and a press, press in the connecting rod small end bush.

   09222-30010

3. 

   Using a pin hole grinder, hone the connecting rod small end bush to obtain the standard specified clearance (Click here) between the connecting rod small end bush and piston pin.

4. Check that the piston pin fits at normal room temperature.

   
   

   1. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

INSTALL PISTON WITH PIN SUB-ASSEMBLY

1. Assemble the piston and connecting rod.

   
   
   1. 

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

      Table 7. Text in Illustration

      *a	Service Hole Cutout Portion

      Tip:

      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. 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.

      Table 8. Text in Illustration

      *a	Front Mark

      Tip:

      The piston and pin are a matched set.

   5. 

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

      Table 9. Text in Illustration

      *a	Service Hole Cutout Portion

      Tip:

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

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

INSTALL PISTON RING SET

1. 

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

   Table 10. Text in Illustration

   *1	Upper Oil Ring Side Rail
   *2	Oil Ring Expander
   *3	Lower Oil Ring Side Rail

2. 

   Using a piston ring expander, install the 2 compression rings with the code mark as shown in the illustration.

   Table 11. Text in Illustration

   *1	No. 2 Compression Ring
   *a	Code Mark (2N)
   	Upward

   Note:
   

   • The No. 1 compression ring is reversible.

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

3. 

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

   Table 12. Text in Illustration

   *1	No. 1 Compression Ring
   *2	No. 2 Compression Ring
   *3	Oil Ring Expander
   *4	Upper Oil Ring Side Rail
   *5	Lower Oil Ring Side Rail
   *a	Front Mark

   Note:

   Do not align the compression ring ends.

INSTALL CRANKSHAFT BEARING

1. Clean the main journal, and both surfaces of the crankshaft bearing.

2. Install the upper crankshaft bearing.

   
   
   1. 

      Install the upper crankshaft bearing to the cylinder block as shown in the illustration.

      Reference (Difference in Dimension of Cylinder Block and Crankshaft Bearing)
      Item Specified Condition # 1, 5 journal 3.83 mm (0.151 in.) # 3 journal 1.74 mm (0.0685 in.) # 2, 4 journal 2.75 mm (0.1083 in.)

      Table 13. Text in Illustration

      *a	CORRECT
      *b	INCORRECT
      *c	Oil Groove

      Note:
      

      • Do not apply engine oil to the upper crankshaft bearings or their contact surfaces.

      • 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.

3. Install the lower crankshaft bearing.

   
   

   1. Install the lower crankshaft bearing to the crankshaft bearing cap.

   2. 

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

      Dimension (A - B) or (B - A)
      0.3 mm (0.0118 in.) or less

      Reference (Dimension of (A) or (B))
      Item Specified Condition # 1, 5 journal 3.83 mm (0.151 in.) # 3 journal 1.74 mm (0.0685 in.) # 2, 4 journal 2.75 mm (0.108 in.)

      Table 14. Text in Illustration

      *1	Lower Crankshaft Bearing
      *2	Crankshaft Bearing Cap

      Note:

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

4. With the upper crankshaft bearing and lower crankshaft bearing installed, use a plastic-faced hammer to install the crankshaft bearing caps to the cylinder block.

   Note:

   Make sure that the crankshaft bearing caps are installed in the correct positions and facing in the correct direction.

5. 

   Using a vernier caliper, measure the amount of misalignment between the upper crankshaft bearing and lower crankshaft bearing as shown in the illustration.

   Standard misalignment
   0.9 mm (0.0354 in.) or less

   Table 15. Text in Illustration

   *a	Misalignment

6. Remove the crankshaft bearing cap.

7. Apply engine oil to the upper crankshaft thrust washers.

8. 

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

   Table 16. Text in Illustration

   *a	Oil Groove

   Note:

   Be careful when installing the upper and lower crankshaft thrust washers as they are similar but cannot be interchanged.

   
   
   1. 

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

      Table 17. Text in Illustration

      *a	Claw
      *b	Oil Groove

      Note:

      Be careful when installing the upper and lower crankshaft thrust washers as they are similar but cannot be interchanged. The lower crankshaft thrust washers have a claw as shown in the illustration.

9. Apply engine oil to the lower crankshaft bearing.

INSTALL CRANKSHAFT

1. Apply engine oil to the upper crankshaft bearing, and then place the crankshaft on the cylinder block.

2. 

   Install the 5 crankshaft bearing caps to their proper locations.

3. Install the crankshaft bearing cap bolts.

   
   

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

   2. Temporarily install the crankshaft bearing cap bolts.

      Tip:

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

   3. 

      Step 1:

      Uniformly tighten the 10 crankshaft bearing cap bolts in the sequence shown in the illustration.

      39 N*m

      398 kgf*cm

      29 ft.*lbf

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

   4. Mark the front of the bearing cap bolts with paint.

   5. Step 2:

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

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

4. Check that the crankshaft turns smoothly.

INSTALL CONNECTING ROD BEARING

1. 

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

   Table 18. Text in Illustration

   *a

   Claw

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

   Note:

   Clean the backside of the bearing and the bearing surface of the connecting rod.

INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

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

2. 

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

   Table 19. Text in Illustration

   *1	No. 1 Compression Ring
   *2	No. 2 Compression Ring
   *3	Oil Ring Expander
   *4	Upper Oil Ring Side Rail
   *5	Lower Oil Ring Side Rail
   *a	Front Mark

   Note:

   Do not align the compression ring ends.

3. 

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

   Table 20. Text in Illustration

   *a	Front
   *b	Front Mark

4. Match the numbered connecting rod cap with the correct connecting rod.

5. 

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

   Table 21. Text in Illustration

   *a	Front Mark

6. Install the connecting rod cap bolts.

   Tip:

   The connecting rod cap bolts are tightened in 2 progressive steps.

   
   

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

   2. 

      Step 1:

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

      25 N*m

      250 kgf*cm

      18 ft.*lbf

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

   4. Step 2:

      Tighten the cap bolts 90° as shown.

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

7. Check that the crankshaft turns smoothly.

INSTALL INTAKE VALVE GUIDE BUSH

1. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

   Standard Bush Bore Diameter
   Item Specified Condition STD 10.285 to 10.306 mm (0.405 to 0.406 in.) O/S 0.05 10.335 to 10.356 mm (0.407 to 0.408 in.)

   If the bush bore diameter of the cylinder head is more than 10.306 mm (0.406 in.), machine the bush bore so that the diameter is between 10.335 and 10.356 mm (0.407 and 0.408 in.).

   If the bush bore diameter of the cylinder head is more than 10.356 mm (0.408 in.), replace the cylinder head sub-assembly.

2. Select a new intake valve guide bush.

   New Valve Guide Bush
   Item Specified Condition Bush Diameter 10.333 to 10.344 mm (0.4068 to 0.4072 in.) 10.383 to 10.394 mm (0.4088 to 0.4092 in.) Bush to be Used STD O/S 0.05

   Tip:

   Standard intake valve guide bush length: 43.0 to 44.0 mm (1.69 to 1.73 in.)

3. Heat the cylinder head sub-assembly to 80 to 100°C (176 to 212°F).

4. Place the cylinder head sub-assembly on wooden blocks.

5. 

   Using SST and a hammer, tap in a new intake valve guide bush to the specified protrusion height.

   09201-01055
   09950-70010	09951-07100

   Standard protrusion height
   9.8 to 10.2 mm (0.386 to 0.402 in.)

   Table 22. Text in Illustration

   *a	Protrusion Height

6. 

   Using a sharp 5.5 mm reamer, ream the intake valve guide bush to obtain the standard clearance between the intake valve guide bush and valve stem.

   Standard oil clearance
   0.025 to 0.060 mm (0.000984 to 0.00236 in.)

INSTALL EXHAUST VALVE GUIDE BUSH

1. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

   Standard Bush Bore Diameter
   Item Specified Condition STD 10.285 to 10.306 mm (0.405 to 0.406 in.) O/S 0.05 10.335 to 10.356 mm (0.407 to 0.408 in.)

   If the bush bore diameter of the cylinder head is more than 10.306 mm (0.406 in.), machine the bush bore so that the diameter is between 10.335 and 10.356 mm (0.407 and 0.408 in.).

   If the bush bore diameter of the cylinder head is more than 10.356 mm (0.408 in.), replace the cylinder head sub-assembly.

2. Select a new exhaust valve guide bush.

   New Valve Guide Bush
   Item Specified Condition Bush Diameter 10.333 to 10.344 mm (0.4068 to 0.4072 in.) 10.383 to 10.394 mm (0.4088 to 0.4092 in.) Bush to be Used STD O/S 0.05

   Tip:

   Standard exhaust valve guide bush length: 43.0 to 44.0 mm (1.69 to 1.73 in.)

3. Heat the cylinder head sub-assembly to 80 to 100°C (176 to 212°F).

4. Place the cylinder head sub-assembly on wooden blocks.

5. 

   Using SST and a hammer, tap in a new valve guide bush to the specified protrusion height.

   09201-01055
   09950-70010	09951-07100

   Standard protrusion height
   7.6 to 8.0 mm (0.299 to 0.315 in.)

   Table 23. Text in Illustration

   *a	Protrusion Height

6. 

   Using a sharp 5.5 mm reamer, ream the exhaust valve guide bush to obtain the standard clearance between the exhaust valve guide bush and valve stem.

   Standard oil clearance
   0.030 to 0.065 mm (0.00118 to 0.00256 in.)

INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

Note:

It is not necessary to remove a ring pin unless it is being replaced.

1. Remove the ring pins.

2. Using a plastic-faced hammer, tap in a new ring pin until the pin stops.

   Standard Ring Pin
   Item Height Width Protrusion Height Ring pin 7 mm (0.276 in.) 10 mm (0.394 in.) 2.5 to 3.8 mm (0.0984 to 0.150 in.)

   Table 24. Text in Illustration

   *a	Height
   *b	Width
   *c	Protrusion Height

INSTALL NO. 1 HEAD STRAIGHT SCREW PLUG

1. Using a 10 mm hexagon wrench, install 3 new gaskets and the No. 1 head straight screw plugs.

   44 N*m

   449 kgf*cm

   32 ft.*lbf

INSTALL NO. 2 HEAD STRAIGHT SCREW PLUG

1. Using a 19 mm hexagon wrench, install a new gasket and the No. 2 head straight screw plug.

   140 N*m

   1428 kgf*cm

   103 ft.*lbf

INSTALL OIL CONTROL VALVE FILTER

1. Check that no foreign matter is on the mesh part of the filter.

   If foreign objects are present, clean the part thoroughly.

2. Using an 8 mm hexagon wrench, install a new gasket and the oil control valve filter with the screw plug.

   30 N*m

   306 kgf*cm

   22 ft.*lbf

INSTALL VALVE SPRING SEAT

1. Install the 16 valve spring seats to the cylinder head sub-assembly.

INSTALL VALVE STEM OIL SEAL

1. 

   Apply a light coat of engine oil to new valve stem oil seals.

   Table 26. Text in Illustration

   *a	Intake Side
   *b	Exhaust Side
   *c	Gray
   *d	Black

   Note:

   Pay attention when installing the intake and exhaust valve stem oil seals. Installing an intake valve stem oil seal to the exhaust side or installing an exhaust valve stem oil seal to the intake side can cause installation problems later.

   Tip:

   The intake valve stem oil seals are gray and the exhaust valve stem oil seals are black.

2. 

   Using SST, push in the 16 valve stem oil seals to install them.

   09201-41020

   Table 27. Text in Illustration

   *1	Valve Stem Oil Seal

   Note:

   Failure to use SST will cause the valve stem oil seal to be damaged or improperly seated.

INSTALL INTAKE VALVE

1. 

   Apply plenty of engine oil to the tip area of the intake valve shown in the illustration.

   Table 28. Text in Illustration

   *a	30 mm (1.18 in.) or more

2. 

   Install the intake valve, inner compression spring and valve spring retainer to the cylinder head.

   Table 29. Text in Illustration

   *a	Narrow
   *b	Wide

   Note:

   Install the same parts in the same combination to the original locations.

3. 

   Using SST and wooden blocks, compress the inner compression spring and install the 2 valve spring retainer locks.

   09202-70020

   09202-00021

4. 

   Using a 5 mm pin punch and plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

   Table 30. Text in Illustration

   *a	5 mm Pin Punch

   Note:

   Do not damage the valve stem tip.

INSTALL EXHAUST VALVE

1. 

   Apply plenty of engine oil to the tip area of the exhaust valve shown in the illustration.

   Table 31. Text in Illustration

   *a	30 mm (1.18 in.) or more

2. 

   Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head sub-assembly.

   Table 32. Text in Illustration

   *a	Narrow
   *b	Wide

   Note:

   Install the same parts in the same combination to the original locations.

3. 

   Using SST and wooden blocks, compress the inner compression spring and install the 2 valve spring retainer locks.

   09202-70020

   09202-00021

4. 

   Using a 5 mm pin punch and plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

   Table 33. Text in Illustration

   *a	5 mm Pin Punch

   Note:

   Do not damage the valve stem tip.

INSTALL OIL FILTER BRACKET SUB-ASSEMBLY

1. Install 2 new gaskets and 2 straight screw plugs to the oil filter bracket sub-assembly.

   27 N*m

   275 kgf*cm

   20 ft.*lbf

2. Install 2 new O-rings, gasket and oil filter bracket with the union bolt and nut.

   for union bolt
   69 N*m	699 kgf*cm	51 ft.*lbf
   for nut
   25 N*m	255 kgf*cm	18 ft.*lbf

   Note:

   Apply a light coat of engine oil to the new O-rings.

INSTALL REAR CRANKSHAFT OIL SEAL

1. 

   Place the rear engine oil seal retainer on wooden blocks.

   Table 36. Text in Illustration

   *a	Wooden Block

2. Using SST, tap in a new rear crankshaft oil seal until its surface is flush with the rear engine oil seal retainer edge.

   09223-15030
   09950-70010	09951-07150

   Note:

   Do not tap the rear crankshaft oil seal at an angle.

3. Apply a light coat of MP grease to the lip of a new rear crankshaft oil seal.

   Note:
   

   • Do not allow foreign matter to contact the lip of the rear crankshaft oil seal.

   • Do not allow MP grease to contact the dust seal.

INSTALL REAR ENGINE OIL SEAL RETAINER

1. 

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

   Seal packing
   Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
   Standard seal width
   2.5 to 3.5 mm (0.0984 to 0.138 in.)

   Table 37. Text in Illustration

   *a	Seal Packing

   Note:
   

   • Remove any oil from the contact surface.

   • Install the crankcase within 3 minutes after applying seal packing.

   • Do not start the engine for at least 4 hours after installing.

2. Install the rear engine oil seal retainer with the 6 bolts.

   13 N*m

   133 kgf*cm

   10 ft.*lbf

   Note:

   Wipe off any seal packing that has leaked out within 10 minutes.

INSTALL OIL JET

1. Install a new gasket and oil jet with the bolt.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

INSTALL CRANKSHAFT PULLEY SET KEY

1. Install the 2 crankshaft pulley set keys to the crankshaft.

INSTALL CRANK POSITION SENSOR ROTOR

1. 

   Install the crankshaft position sensor rotor with the front mark facing forward.

   Table 48. Text in Illustration

   *1	Crankshaft Pulley Set Key
   *a	Front Mark
   *b	Key Groove

INSTALL ENGINE WATER PUMP ASSEMBLY

1. Install a new gasket and the engine water pump assembly with the 8 bolts.

   8.9 N*m

   91 kgf*cm

   79 in.*lbf

INSTALL OIL STRAINER SUB-ASSEMBLY

1. 

   Install the oil strainer sub-assembly with the 6 bolts, and tighten the 6 bolts in the sequence shown in the illustration.

   10 N*m

   102 kgf*cm

   7 ft.*lbf

INSTALL NO. 1 VENTILATION CONNECTOR

1. Install the No. 1 ventilation connector to the cylinder head cover sub-assembly with the 2 bolts.

   9.0 N*m

   92 kgf*cm

   80 in.*lbf

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

INSTALL OIL FILLER CAP SUB-ASSEMBLY