CYLINDER BLOCK REASSEMBLY

CAUTION / NOTICE / HINT

Note

Before performing these installation procedures, sufficiently clean and remove any foreign matter from the cylinder block, connecting rod and other parts.

PROCEDURE


  1. INSTALL OIL REFLECTOR PLATE


    1. Using a 5 mm hexagon wrench, install the 3 oil reflector plates with the 3 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A004PBXE01
      Text in Illustration
      *A for CCo
      *B for DPF

      Using a 5 mm hexagon wrench, install the 4 oil nozzles with the 4 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  3. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A004R5WE01
      Text in Illustration
      *1 Straight Pin

      Install the sensor plate by fitting the straight pin of the crankshaft into the hole on the sensor plate.

    2. Using a T30 "TORX" socket wrench, install the 3 bolts.

      Torque:
      11 N*m  { 107 kgf*cm, 8 ft.*lbf }

      Note

      Make sure that the sensor plate is not slanted.

  4. INSTALL PISTON WITH PIN SUB-ASSEMBLY


    1. A004NFRE01
      Text in Illustration
      *1 Service Hole

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

      Tech Tips

      Be 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. A004SKUE05
      Text in Illustration
      *1 Front Mark

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

      Tech Tips

      The piston and pin are a matched set.

    5. A004RB5

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

    6. A004RICE05
      Text in Illustration
      *1 Service Hole

      Using a screwdriver, install a new snap ring at the other end of the piston pin hole.

      Tech Tips

      Be sure that the end gap of the snap ring is not aligned with the service hole cutout portion of the piston.

  5. INSTALL PISTON RING SET


    1. A004P5U

      Install the oil ring expander by hand.

    2. A004NNKE05
      Text in Illustration
      *1 Coil Joint
      *2 Oil Ring End

      Using a piston ring expander, install the oil ring rail.

      Tech Tips

      Face the end gap of the oil ring in the opposite direction of the coil joint.

    3. A004U5JE02
      Text in Illustration
      *1 Code Mark (T1)
      *2 Code Mark (FTE2)
      *a Upward

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

      Code Mark
      Ring Code Mark
      No. 1 T1
      No. 2 FTE2

      Tech Tips


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

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

    4. A004TMUE10
      Text in Illustration
      *1 No. 1
      *2 No. 2
      *3 Oil
      *4 Coil
      *5 Front Mark
      *a Front

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

      Note

      Do not align the ring ends.

  6. INSTALL CONNECTING ROD BEARING

    Note

    Apply oil to the inner surface of each bearing (the surface which contacts the crankshaft), but not to the outer surface (the surface which contacts the connecting rod or connecting rod cap).


    1. A004RISE01

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

    2. Using a vernier caliper, measure the distance between the bearing cap edge and bearing edge.

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

      Note

      Clean the backside of the bearing and the bearing surface of the connecting rod.

  7. INSTALL CRANKSHAFT BEARING

    Note


    • Apply oil to the inner surface of each bearing (the surface which contacts the crankshaft), but not to the outer surface (the surface which contacts the bearing cap or cylinder block).

    • When replacing a bearing, also replace the corresponding upper or lower bearing.


    1. Clean each main journal and bearing.

    2. A004RBN

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

      Note


      • Clean the contact surface of the bearing and cylinder block.


      • Apply oil to the inner surface of each bearing (the surface which contacts the crankshaft), but not to the outer surface (the surface which contacts the cylinder block).


      • Make sure both sides of the oil groove in the cylinder block are visible through the oil feed holes in the bearing. Make sure the amount visible on each side of the holes is equal.

    3. A004Q9QE06
      Text in Illustration
      *1 Claw

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

      Note


      • Clean the contact surface of the bearing and crankshaft bearing cap.


      • Apply oil to the inner surface of each bearing (the surface which contacts the crankshaft), but not to the outer surface (the surface which contacts the bearing cap).

  8. INSTALL UPPER CRANKSHAFT THRUST WASHER

    Note

    When replacing a thrust washer, replace both thrust washers together as a set.


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

    2. A004N67

      Push the crankshaft in one direction and install one thrust washer to the No. 4 journal position with the oil groove facing outward.

    3. Push the crankshaft in the opposite direction and install the other thrust washer to the No. 4 journal position with the oil groove facing outward.

  9. INSTALL CRANKSHAFT


    1. A004QMLE02
      Text in Illustration
      *1 Groove C
      *a Front

      Apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal diameter
      2.0 to 4.0 mm (0.0787 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the crankshaft bearing cap within 3 minutes after applying seal packing.

      • Do not start the engine for at least 4 hours after installation.

      • Do not overlap seal packing in area ● in the illustration.

      • Do not apply seal packing in groove C.

    2. Apply engine oil to the crankshaft bearings, and then place the crankshaft bearing cap on the cylinder block.

    3. Temporarily install the crankshaft bearing cap bolts.

      Tech Tips

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

    4. A004TV2E02

      Step 1:


      1. Uniformly tighten the 10 main bearing cap bolts in several steps, in the sequence shown in the illustration.

        Torque:
        60 N*m  { 612 kgf*cm, 44 ft.*lbf }

        Tech Tips

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

    5. Step 2:


      1. Mark the front of the bearing cap bolts with paint.

      2. Tighten the bearing cap bolts by 90°.

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

    6. Check that the crankshaft turns smoothly.

    7. A004RCXE02

      Install and uniformly tighten the 10 bolts in several passes in the sequence shown.

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

  10. 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. A004TMUE10
      Text in Illustration
      *1 No. 1
      *2 No. 2
      *3 Oil
      *4 Coil
      *5 Front Mark
      *a Front

      Check the positions of the piston ring ends.

      Note

      Do not align the ring ends.

    3. A004PZOE02
      Text in Illustration
      *1 Front Mark
      *a Front

      Using a hammer handle and piston ring compressor, press a piston and connecting rod assembly into each cylinder with the front mark of the piston facing forward.

    4. A004SRJE03
      Text in Illustration
      *1 Front Mark

      Install the connecting rod cap so that its front mark (protrusion) is facing the correct direction.

      Note


      • Make sure that the front mark of the connecting rod cap is facing forward.


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

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

    6. A004S5L

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

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

    7. Mark the front side of each connecting cap bolt with paint.

    8. Tighten the cap bolts by 90°.

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

    10. Check that the crankshaft turns smoothly.

  11. INSPECT CONNECTING ROD THRUST CLEARANCE

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