CYLINDER BLOCK REASSEMBLY

CAUTION / NOTICE / HINT

Note:

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

PROCEDURE

  1. INSTALL CYLINDER BLOCK STUD BOLT

    Tip:

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

    1. Apply adhesive to the holes for the stud bolts labeled A on the cylinder block sub-assembly. Install the cylinder block stud bolts labeled A.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      20 N*m

      204 kgf*cm

      15 ft.*lbf

    2. Using an E5 "TORX" socket wrench, install the cylinder block stud bolts labeled B and C.

      for stud bolt B

      3.0 N*m

      31 kgf*cm

      27 in.*lbf

      for stud bolt C

      2.0 N*m

      20 kgf*cm

      18 in.*lbf

      A298155C01

      *a

      Intake Side

      *b

      Exhaust Side

      *c

      22 mm (0.866 in.)

      *d

      73 mm (2.87 in.)

      *e

      30 mm (1.18 in.)

      *f

      9 mm (0.354 in.)

      *g

      49 mm (1.93 in.)

      *h

      12 mm (0.472 in.)

      *i

      23 mm (0.906 in.)

      -

      -
    3. A206565

      Apply adhesive to the holes for the stud bolts on the crankshaft bearing cap. Install the 2 cylinder block stud bolts to the crankshaft bearing cap.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

  2. INSTALL OIL REFLECTOR PLATE

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

      9.0 N*m

      92 kgf*cm

      80 in.*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 with the 4 bolts.

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

  4. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    1. A203725C02

      *1

      Straight Pin

      Install the No. 1 crankshaft position sensor plate by fitting the straight pin of the crankshaft into the hole on the No. 1 crankshaft position sensor plate.

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

      11 N*m

      107 kgf*cm

      8 ft.*lbf

      Note:

      Make sure that the No. 1 crankshaft position sensor plate is not slanted.

  5. INSTALL PISTON WITH PIN SUB-ASSEMBLY

    1. A293308C04

      *1

      Service Hole

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

      Tip:

      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 with pin sub-assembly to approximately 80 to 90°C (176 to 194°F).

    3. Coat the piston pin with engine oil.

    4. A111361C05

      *1

      Front Mark

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

      Tip:

      The piston and pin are a matched set.

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

    6. A111320C09

      *1

      Service Hole

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

      Tip:

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

  6. INSTALL PISTON RING SET

    1. A111363

      Install the oil ring expander by hand.

    2. A111364C04

      *1

      Coil Joint

      *2

      Oil Ring End

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

      Tip:

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

    3. A273383C02

      *1

      Code Mark (T1)

      *2

      Code Mark (FTE2 or 2T)
      V100135

      Upward

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

      Code Mark

      Item

      Code Mark

      No. 1 Compression Ring

      T1

      No. 2 Compression Ring

      FTE2 or 2T
      Tip:

      Install the No. 1 compression ring and No. 2 compression ring with the code mark facing upward.

    4. A111366C05

      *1

      No. 1 Compression Ring

      *2

      No. 2 Compression Ring

      *3

      Oil Ring

      *4

      Coil

      *5

      Front Mark
      V100135

      Front

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

      Note:

      Do not align the ring ends.

  7. INSTALL CONNECTING ROD BEARING

    Note:

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

    1. A293307N02

      Install the connecting rod bearings to the connecting rod sub-assembly and connecting rod cap.

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

      Dimension A - B or B - A

      0 to 0.7 mm (0 to 0.0276 in.)

      Note:

      Clean the backside of the connecting rod bearing and the connecting bearing surface of the connecting rod sub-assembly.

  8. INSTALL CRANKSHAFT BEARING

    Note:

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

    • When replacing a crankshaft bearing, also replace the corresponding crankshaft bearing or No. 2 crankshaft bearing.

    1. Clean each main journal, crankshaft bearing and No. 2 crankshaft bearing.

    2. A101023

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

      Note:

      • Clean the contact surface of the crankshaft bearing and cylinder block sub-assembly.

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

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

    3. A111367C05

      *1

      Claw

      Align the No. 2 crankshaft bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 No. 2 crankshaft bearings to install them.

      Note:

      • Clean the contact surface of the No. 2 crankshaft bearing and crankshaft bearing cap.

      • Apply oil to the inner surface of each No. 2 crankshaft bearing (the surface which contacts the crankshaft), but not to the outer surface (the surface which contacts the crankshaft bearing cap).

  9. INSTALL UPPER CRANKSHAFT THRUST WASHER

    Note:

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

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

    2. A111365

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

  10. INSTALL CRANKSHAFT

    1. A111382C04

      *1

      Groove C
      V100135

      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 sub-assembly.

    3. Install the crankshaft bearing cap bolts.

      Tip:

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

    4. A293320N04

      Step 1:

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

        60 N*m

        612 kgf*cm

        44 ft.*lbf

        Tip:

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

    5. Step 2:

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

      2. Tighten the crankshaft 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. A203717N03

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

      18 N*m

      184 kgf*cm

      13 ft.*lbf

  11. 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. A111366C06

      *1

      No. 1 Compression Ring

      *2

      No. 2 Compression Ring

      *3

      Oil Ring

      *4

      Coil

      *5

      Front Mark
      V100135

      Front

      Check the positions of the piston ring ends.

      Note:

      Do not align the ring ends.

    3. A294396C04

      *1

      Front Mark
      V100135

      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. A111307C04

      *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. A203712

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

      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.

  12. INSPECT CONNECTING ROD THRUST CLEARANCE

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