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Cylinder Block: Reassembly

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HINT:

  1. ASSEMBLE PISTON AND CONNECTING ROD 
    1. Using a small screwdriver, install a new snap ring at one end of the piston pin hole.

      HINT:

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

      Fig 1: Installing A New Snap Ring At One End Of Piston Pin Hole
      G01331951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Gradually heat the piston to about 60°C (140°F).
      Fig 2: Identifying Heat Piston
      G01331952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the piston pin with engine oil.
    4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
    5. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.

      HINT:

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

      Fig 3: Coating Piston Pin With Engine Oil
      G01331953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL PISTON RINGS 
    1. Install the oil ring expander and 2 side rails by hand.
    2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
      • Code mark: No.1: 1R or T No.2: 2R or 2T 
      Fig 4: Installing Piston Rings
      G01331954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Position the piston rings so that the ring ends are as shown.
      NOTE: Do not align the ring ends.
      Fig 5: Positioning Piston Rings
      G01331955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. INSTALL CONNECTING ROD BEARINGS 
      1. Align the bearing claw with the groove of the connecting rod or connecting cap.
      2. Install the bearings in the connecting rod and connecting rod cap.
        Fig 6: Installing Bearings In Connecting Rod
        G01331956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. INSTALL MAIN BEARINGS 

      HINT:

      • Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the No.1 and No.4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions.
      • Upper bearings have an oil groove and oil holes; lower bearings do not.
      Fig 7: Installing Main Bearings
      G01331957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings.
        NOTE: Install the bearing with the oil hole in the cylinder block.
        Fig 8: Installing Bearing With Oil Hole In Cylinder Block
        G01331958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings.

        HINT:

        A number is marked on each main bearing cap to indicate the installation position.

        Fig 9: Aligning Bearing Claw With Claw Groove Of Main Bearing Cap
        G01331959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. INSTALL UPPER THRUST WASHERS 

      Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.

      Fig 10: Installing Upper Thrust Washers
      G01331960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. PLACE CRANKSHAFT ON CYLINDER BLOCK 
      Fig 11: Placing Crankshaft On Cylinder Block
      G01331961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. PLACE MAIN BEARING CAPS AND LOWER THRUST WASHERS ON CYLINDER BLOCK 
      1. Install the 2 thrust washers on the No. 2 bearing cap with the grooves facing outward.
        Fig 12: Installing Thrust Washers On Bearing Cap
        G01331962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Temporarily place the 4 main bearing caps level and let them in their proper locations.
        Fig 13: Placing Main Bearing Caps Level
        G01331963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Apply a light coat of engine oil on the threads and under the main bearing cap bolts for the 12 pointed head.
      4. Temporarily install the 8 main bearing cap bolts to the inside positions.
      5. Insert the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block will become less than 6 mm (0.23 in.) by making the 2 internal main bearing cap bolts as a guide.
        Fig 14: Inserting Main Bearing Cap
        G01331964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
    9. INSTALL 12 POINTED HEAD MAIN BEARING CAP BOLTS 

      HINT:

      • The main bearing cap bolts are tightened in 2 progressive steps (steps (b) and (d)).
      • If any of the main bearing cap bolts is broken or deformed, replace it.
      Fig 15: Installing Pointed Head Main Bearing Cap Bolts
      G01331965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply a light coat of engine oil on the threads and under the main bearing cap bolts.
      2. Install and uniformly tighten the 16 main bearing cap bolts in several passes, in the sequence shown.
        • Torque: 22 N.m (225 kgf.cm, 16 ft.lbf) 

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

        Fig 16: Applying A Light Coat Of Engine Oil On Threads
        G01331966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Mark the front of the main bearing cap bolts with paint.
      4. Retighten the main bearing cap bolts by 90° in the numerical order shown.
      5. Check that the painted mark is now at a 90° angle to the front.
        Fig 17: Installing Main Bearing Cap Bolts
        G01331967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. INSTALL HEXAGON HEAD MAIN BEARING CAP BOLTS 
      1. Install a new seal washer to the main bearing cap bolt.
      2. Install and uniformly tighten the 8 main bearing cap bolts in several passes, in the sequence shown.
        • Torque: 27 N.m (275 kgf.cm, 20 ft.lbf) 
      3. Check that the crankshaft turns smoothly.
    11. CHECK CRANKSHAFT THRUST CLEARANCE (See  DISASSEMBLY  ) 
      Fig 18: Checking Crankshaft Thrust Clearance
      G01331968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. INSTALL PISTON AND CONNECTING ROD ASSEMBLES 

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

      HINT:

      The shape of the piston varies for the RH and LH banks. The RH piston is marked with "R", the LH piston with "L".

      Fig 19: Installing Piston And Connecting Rod Assembles
      G01331969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. PLACE CONNECTING ROD CAP ON CONNECTING ROD 
      1. Match the numbered connecting rod cap with the connecting rod.
      2. Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the connecting rod.
        Fig 20: Placing Connecting Rod Cap On Connecting Rod
        G01331970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Check that the protrusion of the connecting rod cap is facing in the correct direction.
    14. INSTALL CONNECTING ROD CAP BOLTS 

      HINT:

      • The connecting rod cap bolts are tightened in 2 progressive steps (steps (b) and (d)).
      • If any of the connecting rod cap bolts is broken or deformed, replace it.
      Fig 21: Installing Connecting Rod Cap
      G01331971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
      2. Install and alternately tighten the 2 connecting rod cap bolts in sever
        • Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) 

        If any of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.

        Fig 22: Applying A Light Coat Of Engine Oil On Threads
        G01331972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Mark the front of the connecting cap bolts with paint.
      4. Retighten the cap bolts by 90° as shown.
      5. Check that the painted mark is now at a 90° angle to the front.
      6. Check that the crankshaft turns smoothly.
    15. CHECK CONNECTING ROD THRUST CLEARANCE (See  DISASSEMBLY  ) 
      Fig 23: Identifying Connecting Cap Bolts With Paint
      G01331973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    16. INSTALL REAR OIL SEAL RETAINER 
      1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.
        • Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing grooves.
        • Thoroughly clean all components to remove all the loose material.
        • Using a non-residue solvent, clean both sealing surfaces.
        Fig 24: Installing Rear Oil Seal Retainer
        G01331974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Apply seal packing to the oil seal retainer as shown in the illustration.
        • Seal packing: Part No. 08826-00080 or equivalent 
        • Install a nozzle that has been cut to a 2 - 3 mm (0.08 -0.12 in.) opening.
        • Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
        • Immediately remove nozzle from the tube and reinstall cap.
      3. Install the oil seal retainer with the 6 bolts Uniformly tighten the bolt in several passes, in the sequence shown.
        • Torque: 8 N.m (80 kgf.cm, 69 in..lbf) 
    17. 2WD: INSTALL CYLINDER BLOCK SIDE COVER 

      Install a new gasket and the cylinder block side cover with the 3 bolts and 2 nuts.

      • Torque: 9 N.m (90 kgf.cm, 78 in..lbf) 
    18. INSTALL ENGINE COOLANT DRAIN UNION(S) 
      1. Apply seal packing to 2 or 3 threads.
        • Seal packing: Part No. 08826-00100 or equivalent 
      2. Install the drain union.
        • Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

        HINT:

        After applying the specified torque, rotate the drain union clockwise until its drain port is facing downward.

    19. INSTALL WATER SEAL PLATE 
      1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the seal plate and cylinder block.
        • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
        • Thoroughly clean all components to remove all the loose material.
        • Using a non-residue solvent, clean both sealing surfaces.
      2. Apply seal packing to the seal plate as shown in the illustration.
        • Seal packing: Part No. 08826-00100 or equivalent 
        • Install a nozzle that has been cut to a 3 - 5 mm (0.12 - 0.20 in.) opening.
        • Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
        • Immediately remove nozzle from the tube and reinstall cap.
        Fig 25: Installing Water Seal Plate
        G01331975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Install the seal plate with the 2 nuts.
        • Torque: 18 N.m (180 kgf.cm, 13 ft.lbf) 
    20. INSTALL OIL FILTER UNION 
      • Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) 
    21. INSTALL OIL FILTER (See  OIL AND FILTER  ) 
    22. INSTALL OIL PUMP (See  OIL PUMP  ) 
    23. INSTALL NO.1 OIL PAN (See  OIL PUMP  ) 
    24. INSTALL OIL STRAINER (See  OIL PUMP  ) 
    25. INSTALL No. 2 OIL PAN (See  OIL PUMP  ) 
    26. INSTALL WATER PUMP (See  WATER PUMP  ) 
    27. INSTALL WATER INLET HOUSING 
      1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water inlet housing and cylinder block.
        Fig 26: Installing Oil Filter Union
        G01331976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
        • Thoroughly clean all components to remove all the loose material.
        • Using a non-residue solvent, clean both sealing surfaces.
      2. Apply seal packing to the water inlet housing as shown in the illustration.
        • Seal packing: Part No. 08826-00100 or equivalent 
        • Install a nozzle that has been cut to a 3 - 5 mm (0.12 - 0.20 in.) opening.

        HINT:

        Avoid applying an excessive amount to the surface.

        • Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
        • Immediately remove nozzle from the tube and reinstall cap.
        Fig 27: Applying Seal Packing To Water Inlet Housing
        G01331977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Install the water inlet housing with the 8 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes, in the sequence shown.
        • Torque: 8 N.m (80 kgf.cm, 69 in..lbf) 
      4. Connect the No. 2 ECT switch connector.
      5. Connect the engine wire clamp to the water inlet.
      6. Install the engine wire band.
      7. Install the engine wire clamp.
        Fig 28: Installing Engine Wire Band
        G01331978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    28. INSTALL KNOCK SENSORS 
      1. Using SST, install the 2 knock sensors.
        • SST 09816-30010
        • Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 
      2. Connect the 2 knock sensor connectors.
    29. INSTALL No. 2 IDLER PULLEY BRACKET 
      • Torque: 28 N.m (290 kgf.cm, 21 ft.lbf) 
    30. INSTALL A/C COMPRESSOR HOUSING BRACKET 
      • Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 
      Fig 29: Installing A/C Compressor Housing Bracket
      G01331979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    31. INSTALL OIL PRESSURE SWITCH (See  OIL AND FILTER  ) 
    32. INSTALL GENERATOR, BRACKET AND ADJUSTING BAR ASSEMBLY 
      • Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) 
    33. CONNECT OIL PRESSURE SWITCH CONNECTOR 
    34. CONNECT CRANKSHAFT POSITION SWITCH CONNECTOR 
    35. INSTALL CYLINDER HEAD (See  INSTALLATION  ) 
    36. INSTALL TIMING PULLEYS AND BELT (See  INSTALLATION  ) 
    37. REMOVE ENGINE STAND 
    38. INSTALL DRIVE PLATE 
      1. Apply adhesive to 2 or 3 threads of the bolt end.
        • Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent 
        Fig 30: Installing Timing Pulleys And Belt
        G01331980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Install the front spacer, drive plate and rear plate on the crankshaft.
      3. Install and uniformly tighten the 8 bolts in several passes, in the sequence shown.
        • Torque: 83 N.m (850 kgf.cm, 61 ft.lbf) 
        Fig 31: Installing Front Spacer, Drive Plate
        G01331981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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