Perform "Inspection After Repairs" after replacing the piston or piston ring (Click here).
PROCEDURE
INSTALL STUD BOLT
Note:
If the stud bolt is deformed or the threads are damaged, replace it.
Using a "TORX" socket E6, install the stud bolts as shown in the illustration.
5.0 N*m
51 kgf*cm
44 in.*lbf
INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
Using a 5 mm socket hexagon wrench, install the 4 oil nozzles with the 4 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
INSTALL PISTON
Tip:
Perform "Inspection After Repairs" after replacing the piston (Click here).
Using a screwdriver, install a new snap ring at one end of the piston pin hole.
Table 1. Text in Illustration
*1
Service Hole
Tip:
Make sure that the end gap of the snap ring is not aligned with the service hole cutout portion of the piston.
Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).
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 pin comes into contact with the snap ring.
Table 2. Text in Illustration
*1
Front Mark
Tip:
The piston and pin are a matched set.
Using a screwdriver, install a new snap ring on the other end of the piston pin hole.
Tip:
Make sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
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
Note:
During installation, use a type A piston ring set for the type A piston, and a type B piston ring set for the type B piston.
Table 3. Text in Illustration
*A
for Type A
*B
for Type B
*1
Piston
*2
No. 1 Compression Ring
*a
Mark
*b
1.0 mm (0.0394 in.)
*c
1.2 mm (0.0472 in.)
-
-
Tip:
Perform "Inspection After Repairs" after replacing the piston ring (Click here).
Install the oil ring expander and oil ring by hand.
Table 4. Text in Illustration
*1
Side Rail (Upper)
*2
Oil Ring Expander
*3
Side Rail (Lower)
Using a piston ring expander, install the 2 compression rings so that the paint marks are positioned as shown in the illustration.
Table 5. Text in Illustration
*A
for Type A
*B
for Type B
*1
No. 1 Compression Ring
*2
No. 2 Compression Ring
*a
Code Mark
*b
Paint Mark
Upward
-
-
Note:
Install the No. 1 compression ring with the code mark FTE facing upward.
Install the No. 2 compression ring with the code mark FTE2 facing upward.
Paint marks can only be checked on new piston rings. When reusing piston rings, check each piston ring profile in order to install them into the correct positions.
Position the piston rings so that the ring ends are as shown in the illustration.
Table 6. Text in Illustration
*1
No. 1 Compression Ring
*2
No. 2 Compression Ring
*3
Side Rail (Upper)
*4
Side Rail (Lower)
*a
Engine Front
Note:
Do not align the ring ends.
Tip:
The location of the oil ring expander end gap is free.
INSTALL CRANKSHAFT BEARING
Install the upper bearing (except No. 3 journal).
Install the upper bearing to the cylinder block.
Tip:
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.
Using a scale, measure the distance between the cylinder block edge and the upper bearing edge.
Table 7. Text in Illustration
*1
Scale
Dimension (A)
0.5 to 1.0 mm (0.0197 to 0.0394 in.)
Note:
Do not apply engine oil to the bearings or the contact surfaces.
Install the upper bearing (for No. 3 journal).
Install the upper bearing to the cylinder block.
Tip:
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.
Using a vernier caliper, measure the distance between the cylinder block edge and the upper bearing edge.
Table 8. Text in Illustration
*1
Vernier Caliper
Dimension A - B or B - A
0 to 0.5 mm (0 to 0.0197 in.) or less
Note:
Do not apply engine oil to the bearing or the contact surfaces.
Install the lower bearing.
Install the lower bearing onto the bearing cap.
Using a vernier caliper, measure the distance between the bearing cap edge and the lower bearing edge.
Table 9. Text in Illustration
*1
Vernier Caliper
Dimension A - B or B - A
0 to 0.5 mm (0 to 0.0197 in.) or less
Note:
Do not apply engine oil to the bearings or the contact surfaces.
INSTALL UPPER CRANKSHAFT THRUST WASHER
Install the 2 thrust washers to the No. 3 journal position of the cylinder block with the oil grooves facing outward.
Table 10. Text in Illustration
*1
Oil Groove
*a
Resin Coated Upper Crankshaft Thrust Washer
Note:
Install a resin coated upper crankshaft thrust washer only for the rear side of the engine.
Apply engine oil to the crankshaft thrust washers.
INSTALL CRANKSHAFT
Apply engine oil to the upper bearings and install the crankshaft to the cylinder block.
Apply engine oil to the lower bearing.
Examine the number marks and install the bearing caps to the cylinder block.
Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
Temporarily install the 10 crankshaft bearing cap bolts.
Push on the crankshaft bearing caps with your hand until the clearance between the crankshaft bearing caps and cylinder block is less than 5 mm (0.197 in.).
Using a plastic-faced hammer, lightly tap the bearing caps to ensure a proper fit.
Install the crankshaft bearing cap bolts.
Note:
The crankshaft bearing cap bolts are tightened in 2 progressive steps.
Step 1:
Install and uniformly tighten the 10 crankshaft bearing cap bolts in several steps in the sequence shown in the illustration.
40 N*m
408 kgf*cm
30 ft.*lbf
Step 2:
Mark the front of the bearing cap bolts with paint.
Tighten the bearing cap bolts 90° in the sequence shown in step 1.
Check that the paint marks are now at a 90° angle to the front.
Check that the crankshaft turns smoothly.
Check the crankshaft thrust clearance (Click here).
INSTALL CONNECTING ROD BEARING
Install the connecting rod bearings to the connecting rods and connecting rod caps.
Using a vernier caliper, measure the distance between the edges of the connecting rods and connecting rod caps, and the connecting rod caps and connecting rod bearings.
Table 11. Text in Illustration
*1
Vernier Caliper
Dimension A - B or B - A
0 to 0.7 mm (0 to 0.0276 in.)
Note:
Do not apply engine oil to the bearings or the contact surfaces.
INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
Apply engine oil to the cylinder walls, pistons, and the surfaces of the connecting rod bearings.
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
Side Rail (Upper)
*4
Side Rail (Lower)
*a
Engine Front
Note:
Do not align the ring ends.
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.
Table 13. Text in Illustration
*1
Front Mark
Note:
When inserting the piston with connecting rod, do not allow it to make contact with the oil nozzle.
Match the numbered connecting rod cap with the connecting rod.
Check that the front mark of the connecting rod cap is facing in the correct direction.
Table 14. Text in Illustration
*1
Front Mark
Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
Install the connecting rod cap bolts.
Note:
The connecting rod cap bolts should be tightened in 2 progressive steps.
Step 1:
Using SST, install and alternately tighten the bolts of the connecting rod cap in several steps.
09205-16011
20 N*m
204 kgf*cm
15 ft.*lbf
Step 2:
Mark the front of the connecting rod cap bolts with paint.
Tighten the cap bolts 90° as shown in the illustration.
Check that the crankshaft turns smoothly.
Check the connecting rod thrust clearance (Click here).
INSTALL NO. 1 VENTILATION CASE
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 surface.
Install the ventilation case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installation.
Install the ventilation case with the 6 bolts and 2 nuts.
