CYLINDER BLOCK REASSEMBLY

PROCEDURE


  1. INSTALL CONNECTOR TUBE


    1. Apply adhesive to 2 or 3 threads on the end of the connector tube and install the connector tube.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note


      • Install the connector tube within 3 minutes of applying adhesive.

      • Do not start the engine within 1 hour of installing the connector tube.

  2. INSTALL OIL JET


    1. A005H8PE02
      *1 Align

      Align the groove on the cylinder block with the oil jet positioning bracket and tap in the new oil jet.

      Note

      Do not tap the tip of the oil jet.

  3. INSTALL STRAIGHT PIN


    1. Using a plastic-faced hammer, tap in the straight pin.

      A005GE9E06
      Text in Illustration
      *a Upper Side *b Front Side
      *c Lower Side *d Rear Side
      Standard protrusion
      Pin A
      8.5 to 9.5 mm (0.335 to 0.374 in.)
      Pin B
      8.5 to 9.5 mm (0.335 to 0.374 in.)
      Pin C
      18.5 to 19.5 mm (0.728 to 0.768 in.)
      Pin D
      11.5 to 12.5 mm (0.453 to 0.492 in.)

  4. INSTALL OIL PUMP SET RING PIN


    1. A005JL4E01
      *1 3.5 to 4.5 mm

      Using a plastic-faced hammer, tap in a new oil pump set ring pin.

      Standard protrusion
      3.5 to 4.5 mm (0.138 to 0.177 in.)

  5. INSTALL STUD BOLT


    1. Using an E5 and E7 "TORX" socket wrench, install the 7 stud bolts.

      A005H73E05
      Torque:
      Stud bolts A, B and D
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      Stud bolt C
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      Note

      The lower threads of the bolt are installed into the cylinder block.

  6. INSTALL CRANKSHAFT BEARING

    A005M08E02

    1. Align the crankshaft bearing (upper) with the oil hole of the cylinder block and install the bearing.

      Text in Illustration
      *a Incorrect
      *b Correct

      Note

      Do not apply engine oil to the bearing or its contact surface.

    2. A005HKNE01

      Align the crankshaft bearing (lower) with the bearing cap and install the crankshaft bearing cap.

      Note


      • Install the bearing cap so that the gap between A and B is 0 to 0.7 mm (0 to 0.028 in.).

      • Do not apply engine oil to the bearing or its contact surface.

  7. INSTALL UPPER CRANKSHAFT THRUST WASHER


    1. A005J8V

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

    2. Apply engine oil to the upper bearing and install the crankshaft onto the cylinder block.

  8. INSTALL CRANKSHAFT

    A005K5JE01
    Text in Illustration
    *1 No. 3 Bearing Cap
    *2 No. 1, 2, 4, 5 Bearing Cap
    *a Front Mark
    *b Number
    *c Front Mark and Number

    1. Examine the front marks and numbers and install the bearing caps onto the cylinder block.

    2. Apply a light coat of engine oil to the threads of the bearing cap bolts.

    3. A005HETE01

      Tighten the 10 crankshaft bearing cap set bolts in several steps to the specified torque in the sequence shown in the illustration (*1).

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

      Note

      Check that the crankshaft turns smoothly.

    4. A005M3IE01
      Text in Illustration
      *a Paint Mark
      A005IBX Engine Front

      Mark the front of the bearing cap bolts with paint.

    5. Further tighten the 10 crankshaft bearing cap set bolts by 90° in the same sequence as step (*1).

    6. Check that the painted mark is now at a 90° angle from the front.

  9. INSTALL PISTON WITH PIN SUB-ASSEMBLY


    1. A005K7VE01
      Text in Illustration
      *a Front Mark

      Coat the piston pin and pin holes in the piston with engine oil.

    2. Align the cavity of the piston with the protruding portion on the connecting rod sub-assembly.

    3. A005KAXE01
      Text in Illustration
      *1 Connecting Rods
      *2 Piston Pin
      *3 Piston

      Using SST, press in the piston pin.

      SST
      09221-25026   ( 09221-00021, 09221-00030, 09221-00150, 09221-00090, 09221-00100 )

  10. INSTALL CONNECTING ROD BEARING


    1. A005KQWE01
      Text in Illustration
      *a Claw

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

      Note

      Clean the back side of the bearing and the bearing surface of the connecting rod and keep them free of oil.

  11. INSTALL PISTON RING SET

    A005GEME01
    Text in Illustration
    *a Upward

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

    2. Using a piston ring expander, install the 2 compression rings.

      Tech Tips

      When reusing the piston rings, install them onto the matched pistons with the surfaces facing correctly.

    3. A005K59E01
      Text in Illustration
      *a No. 1 Compression and Expander
      *b Lower Side Rail
      *c Upper Side Rail
      *d No. 2 Compression
      A005GO2 Engine Front

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

  12. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD


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

    2. Check the position of the piston ring ends.

    3. A005K1YE01
      Text in Illustration
      *a Front Mark

      Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark on the piston facing forward.

      Note


      • Clean the back side of the bearing and the bearing surface of the connecting rod cap and keep them free of oil.

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

    4. A005K8AE02
      Text in Illustration
      *a Front Mark

      Make sure that the connecting rod and cap are in the correct combination and that the front mark of the cap is facing in the correct mounting orientation, then install the cap onto the connecting rod.

    5. Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

    6. A005ICSE01

      Using SST, tighten the 8 connecting rod cap bolts in several steps to the specified torque.

      SST
      09205-16011
      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }
    7. A005M3IE03
      Text in Illustration
      *a Paint Mark
      A005IBX Engine Front

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

    8. Further tighten the connecting rod cap bolts by 90° as shown.

    9. Check that the crankshaft turns smoothly.