CYLINDER BLOCK REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing the piston or piston ring.

Click here

PROCEDURE


  1. INSTALL STUD BOLT

    Note

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

    Tech Tips

    This procedure is for type A.


    1. A01HESOC02
      *a LH Side
      *b 16 mm (0.630 in.)
      *c 9 mm (0.354 in.)
      *d 27 mm (1.063 in.)

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

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

  2. INSTALL NO. 1 TAPER SCREW PLUG


    1. Clean the No. 1 taper screw plug and plug hole.

    2. Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug. Then install the No. 1 taper screw plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Note


      • Install the No. 1 taper screw plug within 3 minutes of applying adhesive.

      • Do not start the engine within 1 hour of installing the No. 1 taper screw plug.

  3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. Using a 5 mm hexagon socket wrench, install the 4 No. 1 oil nozzle sub-assemblies with the 4 bolts.

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

  4. INSTALL PISTON

    Tech Tips

    Perform "Inspection After Repair" after replacing the piston or piston ring.

    Click here


    1. A01HIS6C15
      *a Service Hole Cutout

      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 of the piston.

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

    3. A01HFIRC15
      *a 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 piston pin comes into contact with the snap ring.

      Tech Tips

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

  5. INSTALL PISTON RING SET


    1. A01HF48C35
      *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. A01HGD7C13
      *1 Side Rail (Upper)
      *2 Oil Ring Expander
      *3 Side Rail (Lower)

      for Type Y:

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

    3. A01HE2MC01
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a Piston Ring Expander
      *b Code Mark (2T)
      *c Paint Mark
      B0057RX Upward

      Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring so that the paint marks are positioned as shown in the illustration.

      Note


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

      • Paint marks can only be checked on new compression rings. When reusing compression rings, check each compression ring profile in order to install them into the correct positions.

    4. A01HETYC13
      *1 No. 1 Compression Ring and Oil Ring
      *2 No. 2 Compression Ring and Oil Ring Expander
      B0059IK Engine Front

      for Type X:

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

    5. A01HH0KC03
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Side Rail (Upper)
      *4 Side Rail (Lower)
      B0059IK Engine Front

      for Type Y:

      Position the piston ring set 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.

  6. INSTALL CRANKSHAFT BEARING


    1. A01HFGMC03
      *a Vernier Caliper

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


      1. Install the crankshaft bearing to the cylinder block sub-assembly.

        Tech Tips

        Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the crankshaft 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 sub-assembly edge and the crankshaft bearing edge.

        Dimension A
        0.5 to 1.0 mm (0.0197 to 0.0394 in.)

        Note

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

    2. A01HI9RC16
      *a Vernier Caliper

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


      1. Install the crankshaft bearing to the cylinder block sub-assembly.

        Tech Tips

        Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the crankshaft 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 sub-assembly edge and the crankshaft 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 crankshaft bearings or the contact surfaces.

    3. Install the crankshaft bearing.


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

      2. A01HE74C19
        *a Mark 1, 2, 3, 4 and 5
        *b Vernier Caliper

        Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the crankshaft 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 crankshaft bearings or the contact surfaces.

  7. INSTALL UPPER CRANKSHAFT THRUST WASHER


    1. A01HE22C09
      *a Oil Groove

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

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

  8. INSTALL CRANKSHAFT


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

    2. Apply engine oil to the lower crankshaft bearings.

    3. A01HFQFC05
      *a Number mark
      B0057RX Engine Front

      Examine the number marks and install the crankshaft bearing caps to the cylinder block sub-assembly.

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

    5. A01HJZE

      Temporarily install the 10 crankshaft bearing cap bolts.

    6. A01HDT3C01
      *a Less than 5.0 mm (0.197 in.)

      Push on the crankshaft bearing caps with your hand until the clearance between the crankshaft bearing caps and cylinder block sub-assembly is less than 5.0 mm (0.197 in.).

    7. A01HHO9

      Using a plastic-faced hammer, lightly tap the crankshaft 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. A01HFXDN02

        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 }

      2. Mark the front side of the crankshaft bearing cap set bolts with paint.

    10. Step 2:


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

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

    11. Check that the crankshaft turns smoothly.

    12. Check the crankshaft thrust clearance.

      Click here

  9. INSTALL CONNECTING ROD BEARING


    1. Install the connecting rod bearings to the connecting rods and connecting rod caps.

    2. A01HGKYC15
      *a Vernier Caliper

      Using a vernier caliper, measure the distance between the edges of the connecting rod and connecting rod bearing, and the edges of the connecting rod cap and connecting rod bearing.

      Dimension A - B or B - A
      0 to 0.7 mm (0 to 0.0276 in.)

      Note

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

  10. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD


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

    2. A01HETYC14
      *1 No. 1 Compression Ring and Oil Ring
      *2 No. 2 Compression Ring and Oil Ring Expander
      B0059IK Engine Front

      for Type X:

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

    3. A01HH0KC03
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Side Rail (Upper)
      *4 Side Rail (Lower)
      B0059IK Engine Front

      for Type Y:

      Position the piston ring set 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. A01HFPYC04
      *a Front Mark

      Using a piston ring compressor, push the correctly numbered piston and connecting rod 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 No. 1 oil nozzle sub-assembly.

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

    5. A01HH5HC10
      *a 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 bolts.

    7. Install the connecting rod bolts.

      Note

      The connecting rod bolts are tightened in 2 progressive steps.

    8. Step 1:


      1. A01HFLEN05

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

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

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

    9. Step 2:


      1. Tighten the connecting rod bolts 90°.

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

    10. Check that the crankshaft turns smoothly.

    11. Check the connecting rod thrust clearance.

      Click here

  11. INSTALL NO. 1 VENTILATION CASE

    Tech Tips

    There are 2 installation types for the No. 1 ventilation case. Depending on the installation type, the number of bolts, nuts and stud bolts used will vary.


    1. A01HJF5C02
      *a Seal Packing Diameter
      *b 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      *c 5.0 mm (0.197 in.)

      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 surfaces.

      • Install the No. 1 ventilation case within 3 minutes and tighten the bolts and nuts within 15 minutes of applying seal packing.

      • Do not start the engine for at least 2 hours after installation.

    2. for Type A:


      1. Install the No. 1 ventilation case with the 6 bolts and 2 nuts.

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

    3. for Type B:


      1. Install the No. 1 ventilation case with the 8 bolts.

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