Cylinder Block: Reassembly

WARNING: This page is about a different variant/trim than selected.

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.

Assemble piston and connecting rod .
1. Using a small screwdriver, install a new snap ring at one end of the piston pin hole.
  
  Fig 1: Installing New Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
2. Gradually heat the piston to 80 - 90°C (176 - 194°F).
  
  Fig 2: Heating Piston To Appropriate Temperature
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the piston pin with engine oil.
4. Align the front marks on the piston and connecting rod, and push in the piston with your thumb.
  
  Fig 3: Aligning Piston & Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.
NOTE: Be sure that end gap of the snap ring is not as aligned with the pin hole cutout portion of the piston.
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.
  
  Fig 5: Displaying Compressor Rings Installation
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Code mark:
  
  Fig 6: Displaying Code Mark Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Position the piston rings so that the ring ends are as shown.
  
  Fig 7: Displaying Piston Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE: Do not align the ring ends.
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.
Install main bearings .
NOTE: Upper bearings have an oil groove and oil holes; Lower bearings do not.
1. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.
  
  Fig 9: Installing Main Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Install the bearing with the oil hole in the cylinder block.
  - Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick.
2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
NOTE: Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick.

Fig 10: Aligning Bearing Claw
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install thrust washers .
Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.
Install main bearing caps .
1. Install the 5 main bearing caps in their proper locations.
  
  Fig 12: Installing Main Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: A number is marked on each main bearing cap to indicate the installation position.
2. Install the main bearing cap bolts.
  NOTE:
  - The main bearing cap bolts are tightened in 2 progressive steps (steps (2), (3) and (5)).
  - If any one of the main bearing cap bolts is broken or deformed, replace it.
  1. Apply a light coat of engine oil on the threads and under the main bearing cap bolts.
  2. Install and uniformly tighten the 10 main bearing cap bolts in several passes, in the sequence shown.
    1. Torque: 20 N.m (205 kgf. cm, 15 ft. lbf)
  3. Retighten the 10 main bearing cap bolts in several passes, in the sequence shown.
    1. Torque: 40 N.m (410 kgf. cm, 30 ft. lbf)
      
      Fig 13: Tightening Main Bearing Cap Bolts
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    If any one of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.
  4. Mark the front of the main bearing cap bolt with paint.
  5. Retighten the main bearing cap bolts by 90° in the numerical order shown.
  6. Check that the painted mark is now at a 90° angle to the front.
3. Check that the crankshaft turns smoothly.
Check crankshaft thrust clearance (See DISASSEMBLY ) .

Fig 14: Marking Front Part Of Main Bearing Cap Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.

Fig 15: Installing Piston & Connecting Rod Assembles
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install connecting rod cap .
1. Place the connecting rod cap on the connecting rod.
  
  Fig 16: Install Connecting Rod Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
    NOTE: Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick.
  3. Check that the protrusion of the connecting rod cap is facing in the correct direction.
    
    Fig 17: Identifying Front Direction
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Install the connecting rod cap bolts.
    NOTE: The connecting rod cap bolts are tightened in 2 steps (steps (3) and (4)).
    
    If any of the connecting rod cap bolts is broken or deformed, replace it.
  5. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
    
    Fig 18: Tightening Connecting Rod Cap Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. 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 of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.
  7. Mark the front of the connecting cap bolts with paint.
    
    Fig 19: Locating Front Part & Retightening Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Retighten the cap bolts by 90° as shown.
  9. Check that the painted mark is now at a 90° angle to the front.
2. Check that the crankshaft turns smoothly.
Check connecting rod thrust clearance (See INSPECTION ) .
Install rear crankshaft oil seal (See REPLACEMENT ) .
NOTE: Wipe seal packing away from the contact surface of the cylinder block assembly and oil seal.
Install crank case .
1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the crank case 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 crank case or cylinder block as shown in the illustration.
  1. Seal packing: Part No. 08826-00080 or equivalent
  - Install a nozzle that has been cut to a 2.5 - 3.0 mm (0.10 - 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 a new O-ring to the cylinder block.
  
  Fig 21: Installing O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily install the crank case with the 11 bolts.
  
  Fig 22: Installing Crank Case With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Each bolt length is indicated in the illustration.
  1. Bolt length: 112 mm (4.41 in.) for A of 12 mm head, 35 mm (1.38 in.) for B of 12 mm head
5. Uniformly tighten the bolts, stud bolts and nuts in several passes.
  1. Torque: 32.5 N.m (330 kgf. cm, 24 ft. lbf)
Install oil filter union .

Fig 23: Installing Oil Filter Union
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a 12 mm hexagon wrench, install the oil filter union.
1. Torque: 29.5 N.m (300 kgf. cm, 22 ft. lbf)
Install oil filter (See REPLACEMENT ) .
Install oil pump (See INSTALLATION ) .
Install water by-pass pipe .

Fig 24: Installing Water By-Pass Pipe
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install a new gasket, the water bypass pipe with the 2 nuts.
1. Torque: 9 N.m (90 kgf. cm, 80 in. lbf)
Install oil dipstick and guide .
1. Install a new O-ring to the dipstick guide.
2. Apply soapy water to the O-ring.
3. Push in the dipstick guide end into the guide hole of the No. 1 oil pan.
4. Install the dipstick guide with the bolt.
  1. Torque: 9 N.m (90 kgf. cm, 80 in. lbf)
5. Install the dipstick.
Install engine coolant drain union .
1. Apply adhesive to 2 or 3 threads.
  1. Seal packing: Part No. 08826-00100 or equivalent
2. Install the drain union.
  1. Torque: 25 N.m (255 kgf. cm, 18 ft. lbf) or more
  NOTE: After applying the specified torque, rotate the drain union clockwise until its drain port is facing downward.
Install thermostat (See INSTALLATION ) .
Install plug .
Install wire clamps .
Install knock sensor (See KNOCK SENSOR ) .
Install water pump (See INSTALLATION ) .
Install OCV filter

Fig 27: Installing OCV Filter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a 12 mm hexagon wrench, install the OCV filter with a new gasket and the plug.
1. Torque: 30 N.m (305 kgf. cm, 22 ft. lbf)
Install cylinder head (See INSTALLATION ) .
Install timing chain (See INSTALLATION ) .
Remove engine stand .