Cylinder Block ASSY: Overhaul

HINT:

Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
Replace all gaskets, O-rings and oil seals with new parts.

REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
REMOVE WATER SEAL PLATE
1. Remove the 2 nuts.
2. Pry out the seal plate.
Fig 1: Measuring Thrust Clearance Moving Connecting Rod Back And Forth
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CONNECTING ROD THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
  Standard thrust clearance:
  
  0.160 - 0.290 mm (0.0063 - 0.0138 in.)
  
  Maximum thrust clearance: 0.35 mm (0.0138 in.)
  
  If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
  
  Connecting rod thickness:
  
  22.880 - 22.920 mm (0.9008 - 0.9024 in.)
INSPECT CONNECTING ROD OIL CLEARANCE
1. Check the matchmarks on the connecting rod and cap ensure correct reassembly.
2. Remove the 2 connecting rod cap bolts.
  
  Fig 2: Locating Matchmarks On Connecting Rod And Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using the removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.
  HINT:
  
  Keep the lower bearing inserted with the connecting rod cap.
4. Clean the crank pin and bearing.
5. Check the crank pin and bearing for pitting and scratches.
  If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
  
  Fig 3: Removing Connecting Rod Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Lay a strip of Plastigage across the crank pin.
  
  Fig 4: Inserting Plastigage Strip To Crank Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the connecting rod cap with the 2 bolts.
8. Remove the 2 bolts, connecting rod cap and lower bearing (See steps b and c above).
  
  Fig 5: Installing Connecting Rod Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Measure the Plastigage at its widest point.
  Standard oil clearance:
  
  0.021 - 0.047 mm (0.0008 - 0.0019 in.)
  
  Maximum oil clearance: 0.065 mm (0.0026 in.)
  
  If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.
  
  Fig 6: Measuring Plastigage At Its Widest Point
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the connecting rod cap and crankshaft, then selecting the bearing with the same number as the total. There are 6 sizes of standard bearings, marked 2, 3, 4, 5, 6 and 7.
  
  Fig 7: Identifying 6 Sizes Of Standard Bearings (Marked 2, 3, 4, 5, 6 & 7)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 8: Bearing Number Marks Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  EXAMPLE:
  
  Connecting rod cap "3" + Crankshaft "1" = Total number 4 (Use bearing "4")
  
  Reference
  
  Connecting rod big end inside diameter:
  
  Fig 9: Matching Connecting Rod Cap Number With Connecting Rod Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 10: Connecting Rod Big End Inside Diameter Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 11: Crankshaft Crank Pin Diameter Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 12: Standard Sized Bearing Center Wall Thickness Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Completely remove the Plastigage.
Fig 13: Removing Carbon From Top Of Cylinder
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PISTON AND CONNECTING ROD
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
HINT:
- Keep the bearings, connecting rod and cap together.
- Arrange the piston and connecting rod assemblies in correct order.
REMOVE W/PIN PISTON SUB-ASSY
1. Check fit between the piston and piston pin.
  1. Try to move the piston back and forth on the piston pin.
    If any movement is felt, replace the piston and pin as a set.
  Fig 14: Moving Piston Back And Forth On Piston Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a piston ring expander, remove the 2 compression rings.
3. Remove the 2 side rails and oil ring by hand.
  HINT:
  
  Arrange the piston rings in correct order only.
  
  Fig 15: Removing Compression Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a small screwdriver, pry out the 2 snap rings.
  
  Fig 16: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Gradually heat the piston to approx. 60°C (140°F).
  
  Fig 17: Heating Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and pin and remove the connecting rod.
  HINT:
  - The piston and pin are a matched set.
  - Arrange the pistons, pins, rings, connecting rods and bearings in correct order.
Fig 18: Removing Connecting Rod
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
  Standard thrust clearance:
  
  0.020 - 0.220 mm (0.0008 - 0.0087 in.)
  
  Maximum thrust clearance: 0.30 mm (0.0118 in.)
  
  If the thrust clearance is greater than maximum, replace the thrust washers as a set.
  
  Fig 19: Measuring Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Thrust washer thickness:
  
  2.440 - 2.490 mm (0.0961 - 0.0980 in.)
INSPECT CRANKSHAFT OIL CLEARANCE
1. Remove the 10 crankshaft bearing cap bolts.
  
  Fig 20: Removing Crankshaft Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen and remove the 20 crankshaft bearing cap bolts in several passes, in the sequence shown.
  
  Fig 21: Loosening And Removing Crankshaft Bearing Cap Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using 2 screwdrivers, pry out the crankshaft bearing cap, and remove the 5 crankshaft bearing caps, 5 lower bearings and 2 lower thrust washers (No. 3 crankshaft bearing cap only).
  NOTE: Be careful not to damage the cylinder block.
  
  Fig 22: Removing Crankshaft Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  - Keep the lower bearing and bearing cap together.
  - Arrange the bearing caps and lower thrust washers in correct order.
4. Lift out the crankshaft.
5. Remove the 2 upper thrust washers.
  HINT:
  - Arrange the upper thrust washers in correct order.
  - Keep the upper bearings together with the cylinder block.
6. Clean each crankshaft journal and bearing.
7. Check each crankshaft journal and bearing for pitting and scratches.
  If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
8. Install the 10 crankshaft bearings and 5 crankshaft bearing caps with the 30 bolts (See step 26.) Do not install the crankshaft.
  
  Fig 23: Installing Crankshaft Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Using a cylinder gauge, measure the inside diameter of the crankshaft bearing.
  Bearing inside diameter:
  
  66.986 - 67.000 mm (2.6372 - 2.6378 in.)
10. Measure the diameter of the crankshaft journal (See step 17.)
11. Subtract the crankshaft journal diameter measurement from the crankshaft bearing inside diameter measurement.
  
  Fig 24: Measuring Inside Diameter Of Crankshaft Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 25: Standard Clearance Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 26: Maximum Clearance Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.
  
  HINT:
  
  If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of the standard bearings. For No. 1 and No. 5 position bearings, use bearings marked 3,4,5,6 and 7. For others position bearings, use bearings marked 1, 2, 3, 4 and 5.
  
  No. 1, No. 5:
  
  Fig 27: Identifying Bearing Sizes By Matching Connecting Rod Bearing Number With Crankshaft Number
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 28: No. 1 And No. 5 Position Bearing Specifications (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  EXAMPLE:
  
  Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "4" (Upper), "5" (Lower))
  
  Fig 29: No. 1 And No. 5 Position Bearing Specifications (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  EXAMPLE:
  
  Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "2" (Upper), "3" (Lower))
  
  Reference
  
  Fig 30: Cylinder Block Crankshaft Journal Bore Diameter (A) Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 31: Cylinder Block Crankshaft Journal Bore Diameter (B) Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 32: Standard Bearing Center Wall Thickness Specifications (No. 1 And No. 5)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 33: Standard Bearing Center Wall Thickness Specifications (Others)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Remove the 10 bolts, 20 nuts, 5 crankshaft bearing caps and 5 lower crankshaft bearing.
13. Remove the 5 upper crankshaft bearings from the cylinder block.
  HINT:
  
  Arrange the bearing caps, bearings and thrust washers in correct order.
Fig 34: Removing Crankshaft Bearing Caps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER BLOCK SUB-ASSY
1. Clean the cylinder block.
  1. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
  2. Using a soft brush and solvent, thoroughly clean the cylinder block.
    NOTE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash the cylinder block at a temperature of 45° or less.
  Fig 35: Removing Gasket Material From Top Surface Of Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect for flatness.
  1. Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head and main bearing cap for warpage.
    Maximum warpage: 0.07 mm (0.0028 in.)
    
    If warpage is greater than maximum, replace the cylinder block sub-assy.
  Fig 36: Measuring Cylinder Head Contacting Surface And Bearing Cap Warpage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Visually check the cylinder for vertical scratches.
  If deep scratches are present, replace the cylinder block sub-assy.
  
  Fig 37: Checking Cylinder For Vertical Scratches (Visually)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Inspect the cylinder bore diameter.
  HINT:
  
  There are 3 sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the top of the cylinder block.
  
  If deep scratches are present, replace the cylinder block sub-assy.
  
  Fig 38: Inspecting Cylinder Bore Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.
  Fig 39: Standard Cylinder Bore Diameter Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum diameter: 91.229 mm (3.5917 in.)
  
  If the diameter is greater than maximum, replace the cylinder block sub-assy.
  
  Fig 40: Measuring Cylinder Bore Diameter At Positions A, B And C
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the cylinder ridge.
  If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.
Fig 41: Removing Cylinder Ridge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT W/PIN PISTON SUB-ASSY
1. Clean the piston.
  1. Using a gasket scraper, remove the carbon from the piston top.
    
    Fig 42: Removing Carbon From Piston Top
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
    
    Fig 43: Cleaning Piston Ring Groove
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Using solvent and a brush, thoroughly clean the piston.
  NOTE: Do not use a wire brush.
  
  Fig 44: Cleaning Piston Thoroughly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect the piston oil clearance.
  HINT:
  
  There are 3 sizes of the standard piston diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the piston top.
  1. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 28.1 mm (1.106 in.) from the piston head.
    
    Fig 45: Piston Diameter Specifications
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Measure the cylinder bore diameter in the thrust directions (See step d above).
  3. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
    Standard oil clearance:
    
    0.080 - 0.101 mm (0.0031 - 0.0040 in.)
    
    Maximum oil clearance: 0.121 mm (0.0048 in.)
    
    Fig 46: Measuring Piston Diameter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If the oil clearance is greater than maximum, replace all the 8 pistons. If necessary, replace the cylinder block sub-assy.
    
    HINT:
    
    Use a new cylinder block:
    - Use a piston with the same number mark as the cylinder diameter marked on the cylinder block.
    - The shape of the piston varies for the LH and RH banks. The LH piston is marked with "3L", the RH piston with "3R".
  Fig 47: Identifying Location Of Piston Number
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Inspect the piston pin fit.
  1. At 60°C (140°F), you should be able to push the piston pin into the piston pin hole with your thumb.
  Fig 48: Inspecting Piston Pin Fit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a micrometer, measure the piston pin diameter.
  Piston pin diameter:
  
  21.997 - 22.006 mm (0.8660 - 0.8664 in.)
Fig 49: Measuring Piston Pin Diameter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PISTON RING SET
1. Inspect the piston ring groove clearance.
  1. Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.
    
    Fig 50: Ring Groove Clearance Specifications
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If the clearance is not as specified, replace the piston.
2. Inspect the piston ring end gap.
  1. Insert the piston ring into the cylinder bore.
  2. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 105 mm (4.13 in.) from the top of the cylinder block.
    
    Fig 51: Pushing Piston Ring From Top Of Cylinder Block
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Fig 52: Measuring Clearance Between New Piston Ring And Wall Of Ring Groove
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Using a feeler gauge, measure the end gap.
    
    Fig 53: Measuring End Gap
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Fig 54: Standard End Gap Specifications
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Fig 55: Maximum End Gap Specifications
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block sub-assy.
INSPECT CONNECTING ROD SUB-ASSY
1. Using a rod aligner and feeler gauge, check the connecting rod alignment.
  1. Check for bend.
    Maximum bend:
    
    0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
    
    If bend is greater than maximum, replace the connecting rod sub-assy.
    
    Fig 56: Checking Connecting Rod Alignment
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Check for twist
    Maximum twist:
    
    0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
  If twist is greater than maximum, replace the connecting rod sub-assy.
Fig 57: Checking Connecting Rod Twist
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PISTON PIN OIL CLEARANCE
1. Inspect the piston pin oil clearance.
  1. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
    Bushing inside diameter:
    
    22.005 - 22.014 mm (0.8663 - 0.8667 in.)
  2. Subtract the piston pin diameter measurement (See step d) from the bush inside diameter measurement.
    Standard oil clearance:
    
    0.005 - 0.011 mm (0.0002 - 0.0004 in.)
    
    Maximum oil clearance: 0.05 mm (0.0020 in.)
  If the oil clearance is greater than maximum, replace the bush. If necessary, replace the piston and piston pin as a set.
Fig 58: Measuring Inside Diameter Of Connecting Rod Bushing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONNECTING ROD SMALL END BUSH
1. Using SST and a press, press out the bush.
  SST 09222-30010
Fig 59: Removing Connecting Rod Small End Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CONNECTING ROD BOLT
1. Using vernier calipers, measure the tension portion of the connecting rod bolt.
  Standard diameter:
  
  7.200 - 7.300 mm (0.2835 - 0.2874 in.)
  
  Minimum diameter: 7.00 mm (0.2756 in.)
  
  If the diameter is less than minimum, replace the bolt.
Fig 60: Measuring Connecting Rod Bolt Tension Portion
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT BEARING CAP BOLT
1. Using vernier calipers, measure the tension portion diameter of the main bearing cap bolt.
  Standard diameter:
  
  7.500 - 7.600 mm (0.2953 - 0.2992 in.)
  
  Minimum diameter: 7.20 mm (0.2835 in.)
  
  If the diameter is less than minimum, replace the cap bolt.
Fig 61: Measuring Tension Portion Diameter Of Main Bearing Cap Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT
1. Inspect for circle runout.
  1. Place the crankshaft on V-blocks.
  2. Using a dial indicator, measure the circle runout at the center journal.
    Maximum circle runout: 0.08 mm (0.0031 in.)
    
    If the circle runout is greater than maximum, replace the crankshaft.
  Fig 62: Measuring Crankshaft Circle Runout At Center Journal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect the main journals and crank pins.
  1. Using a micrometer, measure the diameter of each main journal and crank pin.
    Main journal diameter:
    
    66.988 - 67.000 mm (2.6373 - 2.6378 in.)
    
    Crank pin diameter:
    
    51.982 - 52.000 mm (2.0465 - 2.0472 in.)
    
    If the diameter is not as specified, check the oil clearance (See steps 4 and 8). If necessary, replace the crankshaft.
  2. Check each main journal and crank pin for taper and out-of-round as shown.
    Maximum taper and out-of-round:
    
    0.02 mm (0.0008 in.)
  If the taper and out-of-round is greater than maximum, replace the crankshaft.
Fig 63: Measuring Diameter Of Each Crankshaft Journal And Crank Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STUD BOLT

Fig 64: Locating Stud Bolt Installation Point And Stud Bolt Specifications
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STRAIGHT PIN

Fig 65: Locating Straight Pin Installation Point And Straight Pin Specifications
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RING PIN

Fig 66: Locating Ring Pin Installation Point And Ring Pin Specifications
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONNECTING ROD SMALL END BUSH
1. Align the oil holes of a new bushing and the connecting rod.
  
  Fig 67: Aligning Oil Holes Of New Bushing And Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in the bushing.
  SST 09222-30010
  
  Fig 68: Installing Bushing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (See step 13) between the bushing and piston pin.
  
  Fig 69: Honing Bushing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
Fig 70: Pushing Piston Pin Into Connecting Rod
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL W/PIN PISTON SUB-ASSY
1. Using a small screwdriver, install a new snap ring on one side of the piston pin hole.
  
  Fig 71: Installing New Snap Ring On One Side Of Piston Pin Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Gradually heat the piston to about 60°C (140°F).
  
  Fig 72: Heating Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the piston pin with engine oil.
4. Position the piston front mark with respect to the outside mark on the connecting rod as shown in the diagram.
  NOTE: The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with "3L", the RH piston with "3R".
5. Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.
  
  Fig 73: Identifying Piston Front And Outside Marks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Check fit between the piston and piston pin.
  1. Try to move the piston back and forth on the piston pin.
  Fig 74: Moving Piston Back And Forth On Piston Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.
  
  Fig 75: Installing New Snap Ring On Other Side Of Piston Pin Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Install the oil ring expander and 2 side rails by hand.
9. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
  
  Fig 76: Compression Ring Code Mark Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 77: Identifying Compression Ring Code Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Position the piston rings so that the ring ends are as shown.
  NOTE: Do not align the ring ends.
Fig 78: Identifying Piston Ring End Positions
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONNECTING ROD BEARING
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 79: Installing Bearings In Connecting Rod And Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT BEARING
HINT:
- Main bearings come in widths of 19.5 mm (0.768 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the crankshaft bearing cap. Install the 19.5 mm (0.768 in.) bearings in the other positions.
- Upper bearings have an oil groove and oil holes; lower bearings do not.
Fig 80: Identifying No. 1, No. 5 And Others Upper Bearing And Lower Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.
  
  Fig 81: Aligning Bearing Claw With Claw Groove Of Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings.
  HINT:
  
  A number is marked on each bearing cap to indicate the installation position.
Fig 82: Identifying Bearing Cap Number For Proper Installation
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT THRUST WASHER SET
1. Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.
  
  Fig 83: Installing Thrust Washers Under No. 3 Journal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 thrust washers on the No. 3 bearing cap with the grooves facing outward.
Fig 84: Installing Thrust Washers On No. 3 Bearing Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT
1. Place the crankshaft on the cylinder block.
2. Install the 5 crankshaft bearing caps in their proper locations.
  
  Fig 85: Installing Crankshaft Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Place the bearing caps level and let them return to their original position by their own weight.
  
  NOTE: Do not install the bearing cap by tapping it.
  
  Fig 86: Installing Bearing Caps Level
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the crankshaft bearing cap bolts.
  HINT:
  - The bearing cap bolts are tightened in 2 progressive steps (steps (2) and (4)).
  - If any one of the bearing cap bolts is broken or deformed, replace it.
  1. Apply a light coat of engine oil on the threads and under the crankshaft bearing cap bolts.
  2. Install and uniformly tighten the 20 crankshaft bearing cap bolts in several passes, in the sequence shown.
    Torque: 27 N.m (275 kgf.cm, 20 ft.lbf)
    
    If any one of the bearing cap bolts does not meet the torque specification, replace the bearing cap bolt.
    
    Fig 87: Installing Crankshaft Bearing Cap Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Mark the front of the crankshaft bearing cap bolt with paint.
  4. Retighten the crankshaft 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 88: Identifying Bearing Cap Bolts Painted Mark
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Install a new seal washer to the crankshaft bearing cap bolt.
  7. Install and uniformly tighten the 10 crankshaft bearing cap bolts.
    Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
4. Check that the crankshaft turns smoothly.
5. Check the crankshaft thrust clearance (See step 7).
Fig 89: Installing And Tightening Crankshaft Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON AND CONNECTING ROD
1. 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.
  NOTE: The shape of the piston varies for the LH and RH banks. The LH piston is marked with "3L", the RH piston with "3R".
  
  Fig 90: Pushing Correctly Numbered Piston And Connecting Rod Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place the connecting rod cap on the connecting rod.
  1. Match the numbered connecting rod cap with the connecting rod.
  2. Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.
    
    Fig 91: Matching Connecting Rod Cap Number With Connecting Rod
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Check that the outside mark of the connecting rod cap is facing in correct direction.
  Fig 92: Identifying Outside Mark Of Connecting Rod Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the connecting rod cap bolts.
  HINT:
  - The connecting rod cap bolts are tightened in 2 progressive steps (steps (2) and (4)).
  - If any one of the connecting rod cap bolts is broken or deformed, replace it.
    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 several passes.
      Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf)
      
      If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.
      
      Fig 93: Installing Connecting Rod Cap Bolts
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Mark the front of the connecting cap bolt with paint.
    4. Retighten the cap bolts 90° as shown.
    5. Check that the painted mark is now at a 90° angle to the front.
4. Check that the crankshaft turns smoothly.
5. Check the connecting rod thrust clearance (See step 3.)
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.
  Fig 94: Identifying Bearing Cap Bolts Painted Mark Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing to the seal plate 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 5 minutes of application. Otherwise the material must be removed and reapplied.
  - Immediately remove nozzle from the tube and reinstall cap.
3. Install the seal plate with the 2 nuts. Alternately tighten the nuts in several passes.
  Torque: 14 N.m (145 kgf.cm, 10 ft.lbf)
Fig 95: Applying Seal Packing To Seal Plate
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
1. Apply seal packing to 2 or 3 threads.
  Seal packing: Part No. 08826-00100 or equivalent
  
  Fig 96: Applying Seal Packing To Cylinder Block Water Drain Cock Threads
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the RH and LH drain unions.
  Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
  
  HINT:
  
  After applying the specified torque, rotate the drain union clockwise until its drain port is facing forward.

Fig 97: Identifying Drain Port Location