Cylinder Block: 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.

1. 1. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY 
2. 2. REMOVE WATER SEAL PLATE 
   1. Remove the 2 nuts.
   2. Pry out the seal plate.
3. 3. 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.) 

      Fig 1: Measuring Connecting Rod Thrust (Side) Clearance Using Dial Indicator

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 4. 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 Connecting Rod Cap Bolts & Matchmarks

      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.

      Fig 3: Removing Connecting Rod Cap

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.

   6. Lay a strip of Plastigage across the crank pin.
      Fig 4: Laying Strip Of Plastigage Across Crank Pin

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   7. Install the connecting rod cap with the 2 bolts (See step 30).
   8. Remove the 2 bolts, connecting rod cap and lower bearing (See steps ( b and  c above).
      Fig 5: Installing Bolts Connecting Rod Cap & Lower Bearing

      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 Widest Point Of Crankshaft Journal

      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: Crankshaft/Camshaft Number Mark Table

      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 8: Connecting Rod Big End Inside Diameter Table

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 9: Identifying Crankshaft Number Mark

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 10: Connecting Rod Big End Inside Diameter Table

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Crankshaft crank pin diameter: 

      Fig 11: Crankshaft Crank Pin Diameter Table

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard sized bearing center wall thickness: 

      Fig 12: Standard Sized Bearing Center Wall Thickness Table

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   10. Completely remove the Plastigage.
5. 5. REMOVE PISTON AND CONNECTING ROD 
   1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
      Fig 13: Removing Carbon From Top Of Cylinder Using Ridge Reamer

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.
6. 6. 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: Checking Fit Between Piston & 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 Rings Using Piston Ring Expander

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Using a small screwdriver, pry out the 2 snap rings.
      Fig 16: Prying Out Piston Pin Snap Rings Using Screwdriver

      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: Lightly Taping Out Piston Pin Using Hammer

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. 7. 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.

      Thrust washer thickness: 

      2.440 - 2.490 mm (0.0961 - 0.0980 in.) 

      Fig 19: Measuring Crankshaft Thrust Clearance Using Dial Indicator

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. 8. INSPECT CRANKSHAFT OIL CLEARANCE 
   1. Remove the 10 crankshaft bearing cap bolts.
      Fig 20: Locating Crankshaft Bearing Cap Side 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 in Fig 21.
      Fig 21: Identifying Crankshaft Bearing Cap Loosening 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).
      Fig 22: Prying Out Crankshaft Bearing Cap Using Screwdriver

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to damage the cylinder block. 

      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 Bearings And 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.) 

      Fig 24: Measuring Inside Diameter Of Crankshaft Bearing Using Dial Indicator

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.

       Standard clearance: 

       Fig 25: Crankshaft Bearing Standard Clearance Table

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       Maximum clearance: 

       Fig 26: Crankshaft Bearing Maximum Clearance Table

       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 Fig 27 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.

       Fig 27: Crankshaft Bearing Position Table

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       No. 1, No. 5: 

       Fig 28: Identifying Crankshaft Bearing Number Mark - No. 1, No. 5

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       EXAMPLE:

       Cylinder block "08" + Crankshaft "06" =

       Total number 14 (Use bearing "4" (Upper), "5" (Lower))

       Others: 

       Fig 29: Identifying Crankshaft Bearing Number Mark - Except No. 1, No. 5

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       EXAMPLE:

       Cylinder block "08" + Crankshaft "06" =

       Total number 14 (Use bearing "2" (Upper), "3" (Lower))

       Reference 

       Cylinder block crankshaft journal bore diameter (A): 

       Fig 30: Cylinder Block Crankshaft Journal Bore Diameter (A) Table

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       Crankshaft journal diameter (B): 

       Fig 31: Crankshaft Journal Diameter (B) Table

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       Standard bearing center wall thickness: 

       No. 1 and No. 5 

       Fig 32: Standard Bearing Center Wall Thickness Table - No. 1 & No. 5

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       Others 

       Fig 33: Standard Bearing Center Wall Thickness Table - Except No. 1 & No. 5 (1 Of 2)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       Fig 34: Standard Bearing Center Wall Thickness Table - Except No. 1 & No. 5 (2 Of 2)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   12. Remove the 10 bolts, 20 nuts, 5 crankshaft bearing caps and 5 lower crankshaft bearing (See steps  a to  c above).
       Fig 35: Removing Upper Crankshaft Bearing Caps From Cylinder Block

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   13. Remove the 5 upper crankshaft bearings from the cylinder block.

       HINT:

       Arrange the bearing caps, bearings and thrust washers in correct order.

9. 9. 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 36: Cleaning Cylinder Block Using Soft Brush & Solvent

         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 37: Measuring Cylinder Block Surfaces Contacting Cylinder Head & Main Bearing Cap For 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 38: Checking Cylinder For Vertical Scratches

      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.

      Fig 39: Identifying Cylinder Bores

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If deep scratches are present, replace the cylinder block sub-assy.

      1. Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.

         Standard diameter: 

         Fig 40: Cylinder Bore Standard Diameter Table - Marks 1, 2 & 3

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
         Fig 41: Measuring Cylinder Bore Diameter Using Cylinder Gauge

         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.

   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 42: Grinding Top Of Cylinder Using Ridge Reamer

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. 10. INSPECT W/PIN PISTON SUB-ASSY 
    1. Clean the piston.
       1. Using a gasket scraper, remove the carbon from the piston top.
          Fig 43: Removing Carbon From Piston Top Using Gasket Scraper

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       2. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
          Fig 44: Cleaning Piston Ring Grooves Using Groove Cleaning Tool

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       3. Using solvent and a brush, thoroughly clean the piston.
          NOTE: Do not use a wire brush. 
          Fig 45: Cleaning Piston Using Solvent & Brush

          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.

          Piston diameter: 

          Fig 46: Piston Diameter Table

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          Fig 47: Measuring Piston Diameter Using Micrometer

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       2. Measure the cylinder bore diameter in the thrust directions (See step  2 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.) 

       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 48: Identifying Piston Mark

         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 49: 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 50: Measuring The Piston Pin Diameter Using Micrometer

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. 11. 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.

          Ring groove clearance: 

          Fig 51: Piston Ring Groove Clearance Table

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       If the clearance is not as specified, replace the piston.

       Fig 52: Measuring Clearance Between New Piston Ring & Wall Of Ring Groove

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 53: Inserting Piston Ring Into Cylinder Bore

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       3. Using a feeler gauge, measure the end gap.

          Standard end gap: 

          Fig 54: Standard Piston Ring End Gap Specifications

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

          Maximum end gap: 

          Fig 55: Maximum Piston Ring 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.

       Fig 56: Measuring Piston Ring End Gap Using Feeler Gauge

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. 12. 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 57: 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 58: Checking Connecting Rod For Twist

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. 13. 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  10) 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 59: Measuring Inside Diameter Of Connecting Rod Bushing Using Caliper Gauge

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. 14. REMOVE CONNECTING ROD SMALL END BUSH 
    1. Using SST and a press, press out the bush.

       SST 09222-30010

       Fig 60: Pressing Out Bush Using SST

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. 15. 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 61: Measuring Tension Portion Of Connecting Rod Bolt Using Vernier Calipers

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. 16. 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 62: Measuring Tension Portion Diameter Of Main Bearing Cap Bolt Using Vernier Caliper

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. 17. 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 63: Measuring Circle Runout At Camshaft 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 in Fig 64.

          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 64: Measuring Diameter Of Main Journal & Crank Pin Using Micrometer

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. 18. INSTALL STUD BOLT 
    Fig 65: Identifying Stud Bolt Dimensions

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19. 19. INSTALL STRAIGHT PIN 
    Fig 66: Identifying Straight Pin Dimensions

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. 20. INSTALL RING PIN 
    Fig 67: Identifying Ring Pin Dimensions

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. 21. INSTALL CONNECTING ROD SMALL END BUSH 
    1. Align the oil holes of a new bushing and the connecting rod.
       Fig 68: Locating Connecting Rod Small End Oil Holes

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press in the bushing.

       SST 09222-30010

       Fig 69: Pressing In Connecting Rod Small End Bushing Using SST

       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 70: Honing Connecting Rod Bushing Using Pin Hole Grinder

       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 71: Checking Piston Pin Fit In Connecting Rod

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. 22. 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 72: Installing New Snap Ring On Side Of Piston Pin Hole

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Gradually heat the piston to about 60°C (140°F).
       Fig 73: 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 Fig 74.
       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 74: Identifying Front Mark Of Pistons

       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 75: Checking Fit Between Piston & 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 76: Installing Piston Pin Snap Ring Using Screwdriver

       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.

       Code mark: 

       Fig 77: Compression Ring Code Mark Table

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       Fig 78: Installing Compression Rings Using Piston Ring Expander

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Position the piston rings so that the ring ends are as shown in Fig 79.
        NOTE: Do not align the ring ends. 
        Fig 79: Positioning Piston Rings

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. 23. 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 80: Installing Connecting Rod Bearing

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. 24. 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 81: Identifying Crankshaft Bearing Dimensions

      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 82: Installing Crankshaft Bearing In 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 83: Aligning Crankshaft Bearing Claw With Bearing Cap Claw Groove

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. 25. 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 84: Installing Crankshaft Thrust Washer Set

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 thrust washers on the No. 3 bearing cap with the grooves facing outward.
       Fig 85: Installing Thrust Washers On Bearing Cap

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. 26. INSTALL CRANKSHAFT 
    1. Place the crankshaft on the cylinder block.
    2. Install the 5 crankshaft bearing caps in their proper locations.
       Fig 86: Identifying Crankshaft Bearing Caps

       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 87: Placing Bearing Caps Level In Cylinder Block

       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 in Fig 88.

          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 88: Identifying Bearing Cap Bolt Installion Sequence

          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 in Fig 89.
       5. Check that the painted mark is now at a 90° angle to the front.
          Fig 89: Angle Tightening Crankshaft Bearing Cap Bolts

          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. See Fig 90.

          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 90: Locating Camshaft Bearing Cap Side Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
27. 27. 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 91: Pushing Correctly Numbered Piston & Connecting Rod Assemblies Into Each Cylinder

       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 92: Placing Connecting Rod Cap On 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 93: Checking 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.

       3. Mark the front of the connecting cap bolt with paint.
       4. Retighten the cap bolts 90° as shown in Fig 94.
       Fig 94: Installing Connecting Rod Cap Bolts
       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       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).
28. 28. 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 95: Angle Tightening Connecting Rod Cap Bolts

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing to the seal plate as shown in Fig 96.

       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 2 nuts in several passes.

       Torque: 14 N.m (145 kgf.cm, 10 ft.lbf) 

       Fig 96: Identifying Seal Plate Packing

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
29. 29. 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 97: 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 98: Locating RH & LH Drain Unions

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002