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Cylinder Block: Reassembly

NOTE:
  • Thoroughly clean all parts to be assembled.
  • Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
  • Replace all gaskets, O-rings and oil seals with new parts.
  1. ASSEMBLE PISTON AND CONNECTING ROD 
    Fig 1: Assembling Piston And Connecting Rod
    G02810789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Gradually heat the piston side of connecting rod to 80-90°C (176-194°F).
    2. Coat the piston pin and pin holes of the piston with engine oil.
    3. Align the cavity on the piston with the protrusion on the connecting rod.
    4. Using SST, press in the piston pin.

      SST 09221-25026 (09221-00021, 09221-00030, 09221-00190, 09221-00141, 09221-00150)

  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.
      Fig 2: Installing Compression Rings
      G02810790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. NOTE: Do not align the ring ends.
      Fig 3: Positioning Piston Rings
      G02810791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Position the piston rings so that the ring ends are as shown in Fig 3.
  3. Supply Parts: 

    INSTALL MAIN BEARINGS 

    NOTE: Upper bearings have an oil groove and oil holes; Lower bearings do not.
    Fig 4: Installing Main Bearings
    G02810792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Install the bearing with the oil hole in the cylinder block.
    1. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.
    2. Align the bearing claw with the claw grove of the main bearing cap, and push in the 5 lower bearings.
  4. Manufacture Parts: 

    INSTALL MAIN BEARINGS 

    Fig 5: Identifying Block And Cap Side Of Main Bearing
    G02810793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Specified clearance: 

    NOTE:

    Upper bearings have an oil groove and oil holes; Lower bearings do not.

    Measure the clearance on both sides of the bearing and install it so that the difference between measured values will be within the specified bellow.

    A - B = 0.8 mm (0.032 in.) 

    C - D = 0.4 mm (0.016 in.) 

  5. PLACE CRANKSHAFT ON CYLINDER BLOCK 
  6. INSTALL BEARING CAPS  .
      NOTE: Each bearing cap has a number and front mark.
    1. Install the 5 bearing caps.
    2. Apply a light coat of engine oil on the threads and under the head of the bearing cap bolts.
    3. Install and uniformly tighten the 10 bolts of the bearing cap is several passes, in the sequence shown. See Fig 6.

      Torque: 

      1ST: 22 N.m (220 kgf.cm, 16 ft.lbf) 

      2ND: Turn 90° 

      Fig 6: Installing Sequence Of Bearing Cap
      G02810794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Check that the crankshaft turns smoothly.
  7. CHECK CRANKSHAFT THRUST CLEARANCE  . See DISASSEMBLY .
  8. 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.

  9. 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 7: Installing Piston And Connecting Rod Assemblies
      G02810795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check that the protrusion of the connecting rod cap is facing in the correct direction.
  10. INSTALL CONNECTING ROD CAP BOLTS  .
    NOTE:
    • 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.
    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: 

      1ST: 15 N.m (150 kgf.cm, 11 ft.lbf) 

      2ND: Turn 90° 

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

  11. CHECK CONNECTING ROD THRUST CLEARANCE  . See DISASSEMBLY .
    Fig 8: Locating Connecting Rod Cap Bolts
    G02810796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL OIL PAN NO. 1  .
    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the oil pan No. 1 and cylinder block.
      • 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. NOTE: Avoid applying an excessive amount to the surface.
      Fig 9: Applying Seal Packing To Oil Pan No. 1
      G02810797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing to the oil pan No. 1 as shown in the illustration. See Fig 9.

      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 new O-rings to the cylinder block.
    4. Using a plastic-faced hammer, lightly tap the oil pan No. 1 to ensure a proper fit.
      5. NOTE:

      Each bolt length in indicated in the illustration. See Fig 10.

      A: 49 mm (1.929 in.)

      B: 88 mm (3.465 in.)

      C: 144 mm (5.669 in.)

      Fig 10: Identifying Tightening Sequence Of Bolts
      G02810798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install and uniformly tighten the 13 bolts, in several passes, in the sequence shown.

      Torque: 24 N.m (245 kgf.cm, 18 ft.lbf) 

  13. INSTALL REAR CRANKSHAFT OIL SEAL  . See REPLACE CRANKSHAFT REAR OIL SEAL  under REPLACEMENT.
    NOTE: Wipe seal packing away from the contact surface of the cylinder block assembly and oil seal.
  14. INSTALL OIL STRAINER  .

    Install a new gasket, and oil strainer with the bolt and 2 nuts.

    Torque: 11 N.m (112 kgf.cm, 8 ft.lbf) 

    Fig 11: Installing Oil Strainer
    G02810799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL OIL PAN  .
    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the main bearing cap and oil pan.
      • 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.
        • NOTE: Do not use a solvent which will affect the painted surfaces.
      • Using a non-residue solvent, clean both sealing surfaces.
      2. NOTE: Avoid applying an excessive amount to the surface.
      Fig 12: Applying Seal Packing To Oil Pan
      G02810800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing to the oil pan as shown in the illustration.

      Seal packing: Part No. 08826-00080 or equivalent 

      • Install a nozzle that has been cut to a 2.5 - 3.5 mm (0.098 - 0.138 in.) opening.
      • Parts must be assembled within 3 minutes of application. Otherwise the material must be remove d and reapplied.
      • Immediately remove nozzle from the tube and reinstall cap.
    3. Install the oil pan with the 9 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

      Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

      Fig 13: Locating Oil Pan Bolts And Nuts
      G02810801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL OIL FILTER UNION 

    Torque: 30 N.m (306 kgf.cm, 21 ft.lbf) 

  17. INSTALL OIL FILTER  . Refer to INSTALL OIL FILTER .
  18. INSTALL ENGINE COOLANT DRAIN UNION 
    1. Apply adhesive to 2 or 3 threads.

      Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Fig 14: Applying Adhesive To Threads
      G02810802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. NOTE: After applying the specified torque, rotate the drain union clockwise until its drain port is facing downward.
    2. Install the drain union.

      Torque: 35 N.m (350 kgf.cm, 25 ft.lbf) 

  19. INSTALL KNOCK SENSOR 

    Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

  20. INSTALL OIL PRESSURE SWITCH  . Refer to INSTALL OIL PRESSURE SWITCH .
  21. INSTALL THERMOSTAT  . Refer to INSTALL THERMOSTAT .
  22. INSTALL WATER BYPASS PIPE  .

    Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

    Fig 15: Installing Water Bypass Pipe
    G02810803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL ENGINE WIRE  .
  24. INSTALL CYLINDER HEAD  . Refer to INSTALLATION .
  25. INSTALL TIMING SPROCKETS AND TIMING CHAIN  . Refer to INSTALL TIMING CHAIN .
  26. REMOVE ENGINE STAND 
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