CYLINDER BLOCK REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repairs" after replacing the piston sub-assembly or piston ring Click here.

PROCEDURE


  1. INSTALL STUD BOLT

    Note

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

    A01XCL8E03
    Text in Illustration
    *a Front Side *b Lower Side
    *c Exhaust Side *d 12 mm (0.472 in.)
    *e 85 mm (3.35 in.) *f 25 mm (0.984 in.)
    *g 55 mm (2.17 in.) *h 18 mm (0.709 in.)
    *i 60 mm (2.36 in.) *j 20 mm (0.787 in.)
    *k 35 mm (1.38 in.) *l 13 mm (0.512 in.)

    1. Using an E8 "TORX" socket wrench, install the stud bolts labeled A.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Using an E7 "TORX" socket wrench, install the stud bolts labeled B and D.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    3. Apply adhesive to the hole for the stud bolt labeled C in the cylinder block. Using an E7 "TORX" socket wrench, install the stud bolt labeled C.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

      Tech Tips

      When reusing a stud bolt, apply adhesive to the bolt before installing it.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

  2. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. Apply adhesive to the drain cock.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. A01XG0OE08
      Text in Illustration
      *a Upper Side
      *b Front
      *c Allowable Range
      *d Target Direction

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

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

      Note


      • Do not rotate the drain cock more than 1 revolution (360°) after tightening the drain cock to the specified torque.

      • Do not loosen the drain cock to adjust it. If an adjustment is necessary, remove the drain cock and reinstall it.

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

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01XLWN

      Using a 5 mm hexagon wrench, install the oil nozzles.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  4. INSTALL NO. 2 BALANCESHAFT DRIVEN GEAR


    1. Mount the head portion of the balanceshaft in a vise.

      Note

      Do not damage the balanceshaft.

    2. A01XKQ5E03
      Text in Illustration
      *1 No. 2 Balanceshaft Driven Gear
      *2 No. 2 Balanceshaft Thrust Washer

      Install the No. 2 balanceshaft thrust washer and No. 2 balanceshaft driven gear.

    3. Install the bolt.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  5. INSTALL NO. 2 BALANCESHAFT


    1. A01XEG8

      Install the balanceshaft to the cylinder block.

      Note

      When installing the balanceshaft, be sure to support the balanceshaft with both hands and avoid scratching the balanceshaft bearing on the cylinder block.

    2. A01XKKP

      Install the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  6. INSTALL NO. 1 BALANCESHAFT DRIVEN GEAR


    1. Mount the head portion of the balanceshaft in a vise.

      Note

      Do not damage the balanceshaft.

    2. A01XHU2E09
      Text in Illustration
      *1 No. 1 Balanceshaft Driven Gear
      *2 Sliding Key
      *3 Balanceshaft Thrust Washer
      *4 Balanceshaft Thrust Spacer

      Install the No. 1 balanceshaft thrust washer, balanceshaft thrust spacer, sliding key and No. 1 balanceshaft driven gear.

    3. Install the bolt.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  7. INSTALL NO. 1 BALANCESHAFT


    1. A01XKQC

      Install the No. 1 balanceshaft to the cylinder block.

      Note

      When installing the balanceshaft, be sure to support the balanceshaft with both hands and avoid scratching the balanceshaft bearing on the cylinder block.

    2. A01XLJA

      Install the bolt.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  8. INSTALL PISTON WITH PIN SUB-ASSEMBLY

    Tech Tips

    Perform "Inspection After Repairs" after replacing the piston sub-assembly Click here.


    1. Assemble the piston and connecting rod.


      1. A01XMOUE07
        Text in Illustration
        *a 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. Coat the piston pin with engine oil.

      4. A01XMK5E04
        Text in Illustration
        *a Front Mark

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

        Tech Tips

        The piston and pin are a matched set.

      5. A01XIQXE10
        Text in Illustration
        *a Service Hole

        Using a screwdriver, install a new snap ring at 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 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.

  9. INSTALL PISTON RING SET

    Tech Tips

    Perform "Inspection After Repairs" after replacing the piston ring Click here.


    1. A01XJSQE07
      Text in Illustration
      *1 Upper Oil Ring Side Rail
      *2 Oil Ring Expander
      *3 Lower Oil Ring Side Rail

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

    2. A01XM9JE07
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a Code Mark

      Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration.

      Tech Tips


      • Install the No. 1 compression ring with the code mark (1N) facing upward.

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

    3. A01XHATE02
      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

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

      Note

      Do not align the compression ring ends.

  10. INSTALL CRANKSHAFT BEARING

    Note

    Do not apply engine oil to the contact area or backside of the bearing.

    Tech Tips

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


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

    2. Install the upper bearing.


      1. A01XDP8E09
        Text in Illustration
        *a CORRECT
        *b INCORRECT
        *c Oil Groove

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

        Reference (Difference in Dimension of Cylinder Block and Bearing)
        Item Specified Condition
        # 1, 5 journal 3.75 mm (0.148 in.)
        # 3 journal 1.75 mm (0.0689 in.)
        # 2, 4 journal 2.75 mm (0.108 in.)

        Note


        • Do not apply engine oil to the 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. A01XHAEE04

      Install the lower bearing.


      1. Install the lower bearing to the bearing cap.

      2. Using a vernier caliper, measure the distance between the bearing cap edge and lower 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 3.75 mm (0.148 in.)
        # 3 journal 1.75 mm (0.0689 in.)
        # 2, 4 journal 2.75 mm (0.108 in.)

        Note

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

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

      Note

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

    5. A01XENBE06
      Text in Illustration
      *a Misalignment

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

      Standard misalignment
      0.9 mm (0.0354 in.) or less

    6. Remove the bearing cap.

    7. Apply engine oil to the thrust washers.

    8. A01XL0VE05
      Text in Illustration
      *a Oil Groove

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

      Note

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

    9. A01XH9GE07
      Text in Illustration
      *a Claw
      *b Oil Groove

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

      Note

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

    10. Apply engine oil to the lower bearing.

  11. INSTALL CRANKSHAFT


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

    2. A01XH2J

      Install the 5 crankshaft bearing caps in their proper locations.

    3. Install the crankshaft bearing cap bolt.


      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.

        Tech Tips

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

      3. A01XM22E03

        Step 1:

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

        Torque:
        39 N*m  { 398 kgf*cm, 29 ft.*lbf }

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

    5. Check the crankshaft thrust clearance Click here.

  12. INSTALL CONNECTING ROD BEARING


    1. A01XLQQE06
      Text in Illustration
      *a Claw

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

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

      Note

      Clean the backside of the bearing and the surface of the connecting rod or connecting rod cap that contacts the bearing.

  13. 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. A01XHATE04
      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

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

      Note

      Do not align the compression ring ends.

    3. A01XIKCE07
      Text in Illustration
      *a Front
      *b Front Mark

      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.

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

    5. A01XH2FE07
      Text in Illustration
      *a Front Mark

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

    6. Install the connecting rod cap bolts.

      Tech Tips

      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. A01XFPY

        Step 1:

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

        Torque:
        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 painted marks are now at a 90° angle to the front.

    7. Check that the crankshaft turns smoothly.

    8. Check the connecting rod thrust clearance Click here.