CYLINDER BLOCK REASSEMBLY

PROCEDURE


  1. INSTALL STUD BOLT

    Note

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

    A01LEA6C01
    *a Front Side *b Lower Side
    *c Exhaust Side *d 12 mm (0.472 in.)
    *e 81 mm (3.19 in.) *f 25 mm (0.984 in.)
    *g 56 mm (2.20 in.) *h 18 mm (0.709 in.)
    *i 60 mm (2.36 in.) *j 20 mm (0.787 in.)
    *k 35 mm (1.38 in.) *l 13 mm (0.512 in.)

    1. Using an E8 "TORX" socket wrench, install the stud bolts labeled A.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Using an E7 "TORX" socket wrench, install the stud bolts labeled B and labeled D.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    3. Apply adhesive to the hole for the stud bolt labeled C on the cylinder block. Using an E7 "TORX" socket wrench, install the stud bolts labeled C.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

      Tech Tips

      When reusing a stud bolt, apply adhesive to the bolt before installing it.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

  2. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. Apply adhesive to the cylinder block water drain cock sub-assembly.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. A01LDFJC06
      *a Allowable Range
      *b Target Direction
      *c Upper Side
      *d Front

      Install the cylinder block water drain cock sub-assembly as shown in the illustration.

      Torque:
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

      Note


      • Do not rotate the cylinder block water drain cock sub-assembly more than 1 revolution (360°) after tightening the cylinder block water drain cock sub-assembly to the specified torque.

      • Do not loosen the cylinder block water drain cock sub-assembly to adjust it. If an adjustment is necessary, remove the cylinder block water drain cock sub-assembly and reinstall it.

    3. Install the water drain cock plug to the cylinder block water drain cock sub-assembly.

      Torque:
      12.7 N*m  { 130 kgf*cm, 9 ft.*lbf }

  3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


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

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  4. INSTALL NO. 2 BALANCESHAFT DRIVEN GEAR


    1. Mount the head portion of the No. 2 balanceshaft in a vise.

      Note

      Do not damage the balanceshaft.

    2. Install the No. 2 balanceshaft thrust washer and No. 2 balanceshaft driven gear.

    3. Install the bolt.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  5. INSTALL NO. 2 BALANCESHAFT


    1. Install the No. 2 balanceshaft to the cylinder block.

      Note

      When installing the No. 2 balanceshaft, make sure to support the No. 2 balanceshaft with both hands and avoid scratching the No. 2 balanceshaft bearing on the cylinder block side.

    2. Install the 2 bolts.

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

  6. INSTALL NO. 1 BALANCESHAFT DRIVEN GEAR


    1. Mount the head portion of the No. 1 balanceshaft in a vise.

      Note

      Do not damage the No. 1 balanceshaft.

    2. Install the balanceshaft thrust spacer, balanceshaft thrust washer, sliding key and No. 1 balanceshaft driven gear.

    3. Install the bolt.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  7. INSTALL NO. 1 BALANCESHAFT


    1. Install the No. 1 balanceshaft to the cylinder block.

      Note

      When installing the No. 1 balanceshaft, make sure to support the No. 1 balanceshaft with both hands and avoid scratching the No. 1 balanceshaft bearing on the cylinder block side.

    2. Install the bolt.

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

  8. INSTALL PISTON WITH PIN SUB-ASSEMBLY

    Tech Tips

    Perform "Inspection After Repairs" after replacing the piston sub-assembly.

    Click here


    1. Assemble the piston and connecting rod.


      1. A01L978C01
        *a Service Hole Cutout Portion

        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 portion of the piston.

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

        CAUTION:

        Be sure to wear protective gloves.

      3. Coat the piston pin with engine oil.

      4. A01LAXDC01
        *a Front Mark

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

        Tech Tips

        The piston and pin are a matched set.

      5. A01LBNCC01
        *a Service Hole Cutout Portion

        Using a screwdriver, install a new snap ring at 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 service hole cutout portion of the piston.

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

  9. INSTALL PISTON RING SET

    Tech Tips

    Perform "Inspection After Repairs" after replacing the piston ring.

    Click here


    1. A01LAAWC15
      *1 Upper Oil Ring Side Rail
      *2 Oil Ring Expander
      *3 Lower Oil Ring Side Rail

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

    2. A01L85GC01
      *1 No. 2 Compression Ring
      *a Code Mark (2N)
      B0068HS Upward

      Using a piston ring expander, install the 2 compression rings with the code mark as shown in the illustration.

      Tech Tips


      • The No. 1 compression ring is reversible.

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

    3. A01LEARC01
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring Expander
      *4 Upper Oil Ring Side Rail
      *5 Lower Oil Ring Side Rail
      *a Front Mark

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

      Note

      Do not align the compression ring ends.

  10. INSTALL CRANKSHAFT BEARING

    Note

    Do not apply engine oil to the contact area or backside of the crankshaft bearing.

    Tech Tips

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


    1. Clean the main journal and both surfaces of the crankshaft bearing.

    2. A01L9S5C04
      *a CORRECT
      *b INCORRECT
      *c Oil Groove

      Install the upper crankshaft bearing.


      1. Install the upper crankshaft bearing to the cylinder block as shown in the illustration.

        Reference (Difference in Dimension of Cylinder Block and Bearing)
        Item Specified Condition
        # 1, 5 journal 3.75 mm (0.1476 in.)
        # 3 journal 1.75 mm (0.0689 in.)
        # 2, 4 journal 2.75 mm (0.1083 in.)

        Note


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

        • 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.

    3. A01LA6NC06
      *1 Lower Crankshaft Bearing
      *2 Crankshaft Bearing Cap

      Install the lower crankshaft bearing.


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

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

        Dimension (A - B) or (B - A)
        0.3 mm (0.0118 in.) or less
        Reference (Dimension of (A) or (B))
        Item Specified Condition
        # 1, 5 journal 3.75 mm (0.1476 in.)
        # 3 journal 1.75 mm (0.0689 in.)
        # 2, 4 journal 2.75 mm (0.1083 in.)

        Note

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

    4. With the upper crankshaft bearing and lower crankshaft bearing installed, use a plastic-faced hammer to install the crankshaft bearing caps to the cylinder block.

      Note

      Make sure that the crankshaft bearing caps are installed in the correct positions and facing in the correct direction.

    5. A01LDRUC06
      *a Misalignment

      Using a vernier caliper, measure the amount of misalignment between the upper crankshaft bearing and lower crankshaft bearing as shown in the illustration.

      Standard misalignment
      0.9 mm (0.0354 in.) or less

    6. Remove the crankshaft bearing cap.

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

    8. A01LCZ4C05
      *a Oil Groove

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

      Note

      Be careful when installing the upper and lower crankshaft thrust washers as they are similar but cannot be interchanged.

    9. A01LG2CC08
      *a Claw
      *b Oil Groove

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

      Note

      Be careful when installing the upper and lower crankshaft thrust washers as they are similar but cannot be interchanged. The lower crankshaft thrust washers have a claw as shown in the illustration.

    10. Apply engine oil to the lower crankshaft bearing.

  11. INSTALL CRANKSHAFT


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

    2. A01LFRM

      Install the 5 crankshaft bearing caps to their proper locations.

    3. Install the crankshaft bearing cap bolts.


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

      2. Temporarily install the crankshaft bearing cap bolts.

        Tech Tips

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

      3. A01LCTHN02

        Step 1:

        Uniformly tighten the 10 crankshaft bearing cap bolts in the sequence shown in the illustration.

        Torque:
        39 N*m  { 398 kgf*cm, 29 ft.*lbf }

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

      4. Mark the front of the crankshaft bearing cap bolts with paint.

      5. Step 2:

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

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

    4. Check that the crankshaft turns smoothly.

  12. INSPECT CRANKSHAFT THRUST CLEARANCE

    Click here

  13. INSTALL CONNECTING ROD BEARING


    1. A01LG8WC07
      *a Claw

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

    2. Install the bearings in the connecting rod and connecting rod cap.

      Note

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

  14. 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. A01LEARC01
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring Expander
      *4 Upper Oil Ring Side Rail
      *5 Lower Oil Ring Side Rail
      *a Front Mark

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

      Note

      Do not align the compression ring ends.

    3. A01LCI4C01
      *a Front
      *b Front Mark

      Using a piston ring compressor, push the numbered piston and connecting rod assembly into the correct cylinder with the front mark of the piston facing forward.

    4. Match the numbered connecting rod cap with the correct connecting rod.

    5. A01LD1PC09
      *a Front Mark

      Check that the front mark of the connecting rod cap is facing forward.

    6. Install the connecting rod cap bolts.

      Tech Tips

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


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

      2. A01LFYJ

        Step 1:

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

        Torque:
        24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

      3. Mark the front of each connecting rod cap bolt with paint.

      4. Step 2:

        Tighten the connecting rod cap bolts 90° as shown.

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

    7. Check that the crankshaft turns smoothly.

  15. INSPECT CONNECTING ROD THRUST CLEARANCE

    Click here