БЛОК ЦИЛИНДРОВ ПОВТОРНАЯ СБОРКА

PROCEDURE


  1. INSTALL STUD BOLT

    Note

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


    1. Install the stud bolts as shown in the illustration.

      A01XJ86E05
      Text in Illustration
      *a Right Side *b Thread diameter: 8 mm
      Torque:
      15 N*m  { 148 kgf*cm, 11 ft.*lbf }

  2. INSTALL NO. 1 TAPER SCREW PLUG


    1. Apply adhesive to 2 or 3 threads of the screw plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. A01XEBH

      Install the screw plug.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

  3. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. Apply adhesive to 2 or 3 threads of the water drain cock.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      Text in Illustration
      *1 Adhesive
    2. A01XFOBE04
      Text in Illustration
      *1 Port
      *a Downward

      Install the water drain cock.

      Torque:
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }

      Tech Tips


      • After tightening the drain cock to 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.

  4. INSTALL CYLINDER BLOCK OIL ORIFICE


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

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

  5. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

    Note

    Use the same procedure for all oil nozzle No. 1 sub-assemblies.


    1. A01XKNX

      Align the pin of the oil nozzle with the one of the pin holes of the cylinder block.

    2. Install the oil nozzle with the check valve.

      Torque:
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }

  6. INSTALL PISTON SUB-ASSEMBLY


    1. Assemble the piston and connecting rod.


      1. A01XJ6B

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

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

      3. Coat the piston pin with engine oil.

      4. A01XJ8VE01
        Text in Illustration
        *1 Front Mark

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

      5. Check the fitting condition between the piston and piston pin. Try to move the piston back and forth on the piston pin.

      6. A01XMA2

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

  7. INSTALL PISTON RING SET


    1. Install the piston rings.


      1. A01XHNAE07
        Text in Illustration
        *1 Coil Joint
        *2 Oil Ring Ends

        Install the coil and oil ring by hand.

        Tech Tips

        Make sure the end gap of the oil ring faces the opposite direction of the coil joint.

      2. A01XLFKE05
        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
        Item Code Mark
        No. 1 piston ring 1N
        No. 2 piston ring 2N
      3. A01XDPJE04
        Text in Illustration
        *1 No. 1 Compression Ring
        *2 No. 2 Compression Ring
        *3 Oil Ring
        *4 Coil
        *5 Front Mark

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

        Note

        Do not align the ring ends.

  8. INSTALL CONNECTING ROD BEARING


    1. A01XDTH

      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.

  9. INSTALL CRANKSHAFT BEARING

    Tech Tips

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


    1. A01XEC9

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

    2. A01XHUN

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

  10. INSTALL CRANKSHAFT THRUST WASHER SET


    1. A01XHSNE03
      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. A01XCX5E03
      Text in Illustration
      *1 Oil Groove

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

  11. INSTALL CRANKSHAFT


    1. Place the crankshaft on the cylinder block.

    2. A01XC9B

      Install the 5 crankshaft bearing caps in their proper locations.

    3. Install the crankshaft bearing cap bolts.


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

      2. A01XKJPE04

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

        Torque:
        105 N*m  { 1071 kgf*cm, 77 ft.*lbf }

    4. Check that the crankshaft turns smoothly.

    5. Check the crankshaft thrust clearance Click here.

  12. INSTALL PISTON AND CONNECTING ROD


    1. A01XG1C

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

    2. A01XH22E01
      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.

    3. Place the connecting rod cap on the connecting rod.


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

      2. A01XL26E07
        Text in Illustration
        *1 Front Mark

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

    4. Install the connecting rod cap nuts.

      Note

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

      Tech Tips

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

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

    6. Step 1:


      1. A01XGZ0

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

        Torque:
        54 N*m  { 551 kgf*cm, 40 ft.*lbf }

        Tech Tips

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

    7. Step 2:


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

      2. Tighten the connecting rod cap nuts 90° in the shown step 1.

    8. Check that the painted marks are now at a 90° angle to the front.

    9. Check that the crankshaft turns smoothly.

    10. Check the connecting rod thrust clearance Click here.