БЛОК ДВИГАТЕЛЯ ПОВТОРНАЯ СБОРКА

INSTALL TIGHT PLUG

Tech Tips

If coolant leaks from a tight plug or a plug is corroded, replace it.

Text in Illustration

*a	Front Side	*b	Intake Side
*c	Rear Side	*d	Exhaust Side
*e	1.0 mm (0.0394 in.)	-	-

1. Apply adhesive to new tight plugs.

   Adhesive
   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

2. Using SST, tap in the tight plug labeled A.

   SST

   09950-60010   ( 09951-00300 )

   09950-70010   ( 09951-07100 )

3. Using SST, tap in the 8 tight plugs labeled B and D.

   SST

   09950-60010   ( 09951-00350 )

   09950-70010   ( 09951-07100 )

4. Using SST, tap in the tight plugs labeled C.

   SST

   09950-60010   ( 09951-00400 )

   09950-70010   ( 09951-07100 )

INSTALL STUD BOLT

Tech Tips

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

Text in Illustration

*a	Front Side	*b	Lower Side
*c	Exhaust Side	*d	12 mm (0.472 in.)
*e	85 mm (3.35 in.)	*f	37 mm (1.46 in.)
*g	13 mm (0.512 in.)	*h	20 mm (0.787 in.)
*i	35 mm (1.38 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. Apply adhesive to the hole for the stud bolt labeled B in the cylinder block. Install the stud bolt labeled B.

   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

3. Using an E7 "TORX" socket wrench, install the stud bolts labeled C.

   Torque:

   7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

INSTALL STRAIGHT PIN

INSTALL RING PIN

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. 

   Text in Illustration

   *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:

   25 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:

   13 N*m  { 130 kgf*cm, 9 ft.*lbf }

INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

1. Using an E7 "TORX" socket wrench, install the 4 No. 1 oil nozzle sub-assemblies.

   Torque:

   7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

INSTALL CONNECTING ROD SMALL END BUSH

INSTALL PISTON WITH PIN SUB-ASSEMBLY

1. Assemble the piston and connecting rod.

   
   
   1. 

      Text in Illustration

      *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).

   3. Coat the piston pin with engine oil.

   4. 

      Text in Illustration

      *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. 

      Text in Illustration

      *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.

INSTALL PISTON RING SET

1. 

   Text in Illustration

   *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. 

   Text in Illustration

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

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

   Note

   
   

   • The No. 1 compression ring is reversible.

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

3. 

   Text in Illustration

   *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.

INSTALL CRANKSHAFT BEARING

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

2. Install the upper crankshaft bearing.

   
   
   1. 

      Text in Illustration

      *a	CORRECT
      *b	INCORRECT
      *c	Oil Groove

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

      Reference (Difference in Dimension of Cylinder Block and Crankshaft Bearing)
      Item Specified Condition # 1, 5 journal 3.83 mm (0.151 in.) # 3 journal 1.74 mm (0.0685 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. Install the lower crankshaft bearing.

   
   

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

   2. 

      Text in Illustration

      *1	Lower Crankshaft Bearing
      *2	Crankshaft Bearing Cap

      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 3.83 mm (0.151 in.) # 3 journal 1.74 mm (0.0685 in.) # 2, 4 journal 2.75 mm (0.108 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. 

   Text in Illustration

   *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. 

   Text in Illustration

   *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.

   
   

   1. 

      Text in Illustration

      *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.

9. Apply engine oil to the lower crankshaft bearing.

INSTALL CRANKSHAFT

INSTALL CONNECTING ROD BEARING

1. 

   Text in Illustration

   *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.

INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

INSTALL INTAKE VALVE GUIDE BUSH

INSTALL EXHAUST VALVE GUIDE BUSH

INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

Note

It is not necessary to remove a ring pin unless it is being replaced.

1. Remove the ring pins.

2. Using a plastic-faced hammer, tap in a new ring pin until the pin stops.

   Standard Ring Pin
   Item Height Width Protrusion Height Ring pin 7 mm (0.276 in.) 10 mm (0.394 in.) 2.5 to 3.8 mm (0.0984 to 0.150 in.)

   Text in Illustration

   *a	Height
   *b	Width
   *c	Protrusion Height

INSTALL STUD BOLT

Note

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

Text in Illustration

*a	Cylinder Head Upper Side	*b	Intake Side
*c	Front Side	*d	Exhaust Side
*e	21 mm (0.827 in.)	*f	9 mm (0.354 in.)
*g	34 mm (1.34 in.)	*h	18 mm (0.709 in.)
*i	13 mm (0.512 in.)	*j	44 mm (1.73 in.)
*k	20 mm (0.787 in.)	*l	35 mm (1.38 in.)
*m	14 mm (0.551 in.)	*n	63 mm (2.48 in.)
*o	12 mm (0.472 in.)	-	-

1. Using E6, E7 and E8 "TORX" socket wrenches, install the stud bolts.

   Torque:

   for stud bolt A

   3.0 N*m  { 31 kgf*cm, 27 in.*lbf }

   for stud bolt B and C

   7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

INSTALL NO. 1 HEAD STRAIGHT SCREW PLUG

1. Using a 10 mm hexagon wrench, install 3 new gaskets and the No. 1 head straight screw plugs.

   Torque:

   44 N*m  { 449 kgf*cm, 32 ft.*lbf }

INSTALL NO. 2 HEAD STRAIGHT SCREW PLUG

1. Using a 19 mm hexagon wrench, install a new gasket and the No. 2 head straight screw plug.

   Torque:

   140 N*m  { 1428 kgf*cm, 103 ft.*lbf }

INSTALL OIL CONTROL VALVE FILTER

1. Check that no foreign matter is on the mesh part of the filter.

   If foreign objects are present, clean the part thoroughly.

2. Using an 8 mm hexagon wrench, install a new gasket and the oil control valve filter with the screw plug.

   Torque:

   30 N*m  { 306 kgf*cm, 22 ft.*lbf }

INSTALL VALVE SPRING SEAT

1. Install the 16 valve spring seats to the cylinder head sub-assembly.

INSTALL VALVE STEM OIL SEAL

1. 

   Text in Illustration

   *a	Intake Side
   *b	Exhaust Side
   *c	Gray
   *d	Black

   Apply a light coat of engine oil to new valve stem oil seals.

   Note

   Pay attention when installing the intake and exhaust valve stem oil seals. Installing an intake valve stem oil seal to the exhaust side or installing an exhaust valve stem oil seal to the intake side can cause installation problems later.

   Tech Tips

   The intake valve stem oil seals are gray and the exhaust valve stem oil seals are black.

2. 

   Text in Illustration

   *1	Valve Stem Oil Seal

   Using SST, push in the 16 valve stem oil seals to install them.

   SST

   09201-41020

   Note

   Failure to use SST will cause the valve stem oil seal to be damaged or improperly seated.

INSTALL INTAKE VALVE

INSTALL EXHAUST VALVE

INSTALL OIL FILTER BRACKET SUB-ASSEMBLY

1. Install 2 new gaskets and 2 straight screw plugs to the oil filter bracket sub-assembly.

   Torque:

   27 N*m  { 275 kgf*cm, 20 ft.*lbf }

2. Install 2 new O-rings, gasket and oil filter bracket with the union bolt and nut.

   Torque:

   for union bolt

   69 N*m  { 699 kgf*cm, 51 ft.*lbf }

   for nut

   25 N*m  { 255 kgf*cm, 18 ft.*lbf }

   Note

   Apply a light coat of engine oil to the new O-rings.

INSTALL REAR CRANKSHAFT OIL SEAL

1. 

   Text in Illustration

   *a	Wooden Block

   Place the rear engine oil seal retainer on wooden blocks.

2. Using SST, tap in a new rear crankshaft oil seal until its surface is flush with the rear engine oil seal retainer edge.

   SST

   09223-15030

   09950-70010   ( 09951-07150 )

   Note

   Do not tap the rear crankshaft oil seal at an angle.

3. Apply a light coat of MP grease to the lip of a new rear crankshaft oil seal.

   Note

   
   

   • Do not allow foreign matter to contact the lip of the rear crankshaft oil seal.

   • Do not allow MP grease to contact the dust seal.

INSTALL REAR ENGINE OIL SEAL RETAINER

1. 

   Text in Illustration

   *a	Seal Packing

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

   Seal packing
   Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
   Standard seal width
   2.5 to 3.5 mm (0.0984 to 0.138 in.)

   Note

   
   

   • Remove any oil from the contact surface.

   • Install the crankcase within 3 minutes after applying seal packing.

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

2. Install the rear engine oil seal retainer with the 6 bolts.

   Torque:

   13 N*m  { 133 kgf*cm, 10 ft.*lbf }

   Note

   Wipe off any seal packing that has leaked out within 10 minutes.

INSTALL OIL JET

1. Install a new gasket and oil jet with the bolt.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

INSTALL CRANKSHAFT PULLEY SET KEY

1. Install the 2 crankshaft pulley set keys to the crankshaft.

INSTALL CRANK POSITION SENSOR ROTOR

1. 

   Text in Illustration

   *1	Crankshaft Pulley Set Key
   *a	Front Mark
   *b	Key Groove

   Install the crankshaft position sensor rotor with the front mark facing forward.

INSTALL ENGINE WATER PUMP ASSEMBLY

1. Install a new gasket and the engine water pump assembly with the 8 bolts.

   Torque:

   8.9 N*m  { 91 kgf*cm, 79 in.*lbf }

INSTALL OIL STRAINER SUB-ASSEMBLY

INSTALL NO. 1 VENTILATION CONNECTOR

1. Install the No. 1 ventilation connector to the cylinder head cover sub-assembly with the 2 bolts.

   Torque:

   9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

INSTALL OIL FILLER CAP SUB-ASSEMBLY