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Cylinder Block: Reassembly

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL RING PIN 
    1. Using a plastic hammer, tap in the ring pins.
    Fig 1: Identifying Ring Pin Height
    G06008626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Standard Protrusion 

    RING PIN HEIGHT REFERENCE

    Item Protrusion
    A 6 mm (0.236 in.)
    B 5 mm (0.197 in.)
  2. INSTALL STUD BOLT 
    1. Install the stud bolts as shown in the illustration.
      Fig 2: Identifying Stud Bolts Height
      G06008627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: Stud Bolt A 

      22 N*m (220 kgf*cm, 16 ft.*lbf) 

      Stud Bolt B 

      5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      Stud Bolt C 

      9.5 N*m (97 kgf*cm, 84 in.*lbf) 

      Stud Bolt D 

      5.0 N*m (51 kgf*cm, 44 in.*lbf) 

  3. INSTALL STRAIGHT PIN 
    1. Using a plastic hammer, tap in the straight pins.
      Fig 3: Identifying Straight Pin Height
      G06008628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Protrusion 

      STRAIGHT PIN HEIGHT REFERENCE

      Item Protrusion
      A 8 mm (0.315 in.)
      B 7.5 mm (0.295 in.)
      C 12 mm (0.472 in.)
      D 5 mm (0.197 in.)
  4. INSPECT CRANKSHAFT OIL CLEARANCE  (See INSPECTION )
  5. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon wrench, install the oil nozzles with the bolts.

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

      Fig 4: Locating Oil Nozzles With Bolts
      G04974295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL PISTON 
    1. Using a screwdriver, install a new snap ring at one end of the piston pin hole.

      HINT:

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

    2. Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).
      Fig 5: Installing Snap Ring Of Piston Pin Hole
      G04974342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the front marks on the piston and connecting rod, and push in the piston with a thumb.

      HINT:

      Two different engine models manufactured at different factories are available for this vehicle. Referring to the Introduction section, check the engine serial number. Confirm the factory at which the engine was manufactured according to the following table.

      ENGINE SERIAL NUMBER REFERENCE

      Engine Serial Number Factory
      1 ###### TMC made
      2 ###### TMC made
      7 ###### except TMC made
      8 ###### except TMC made
      Fig 6: Aligning Front Marks On Piston And Connecting Rod
      G06008631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a screwdriver, install a new snap ring on the other end of the piston pin hole.

      HINT:

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

    5. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
    Fig 7: Checking Fitting Condition Between Piston And Piston Pin
    G04974344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL PISTON RING SET 
    1. Install the oil ring expander and oil ring rail by hand.
      NOTE:
      • Install the expander and oil ring so that their ring ends are at opposite sides.
      • Securely install the expander into the inner groove of the oil ring.
      Fig 8: Identifying Piston Ring Set
      G06041312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a piston ring expander, install the 2 compression rings so that the paint marks are positioned as shown in the illustration.
      NOTE: Install the No. 2 compression ring with the code mark (2N or 2A) facing upward.

      HINT:

      Supply part compression springs (No. 1 and No. 2) do not have paint marks.

      Fig 9: Identifying Piston Ring Proper Installation Position
      G06008634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Position the piston rings so that the ring ends are as shown in the illustration.

      HINT:

      Two different engine models manufactured at different factories are available for this vehicle. Referring to the Introduction section, check the engine serial number. Confirm the factory at which the engine was manufactured according to the following table.

      ENGINE SERIAL NUMBER REFERENCE

      Engine Serial Number Factory
      1 ###### TMC made
      2 ###### TMC made
      7 ###### except TMC made
      8 ###### except TMC made
      Fig 10: Positioning Piston Rings
      G06008635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL CRANKSHAFT BEARING 
    1. Install the upper bearing with an oil groove on the cylinder block.
      NOTE: Do not apply engine oil to the bearing inner surface or bearing cap contact surfaces.
      Fig 11: Installing Upper Bearing With Oil Groove On Cylinder Block
      G06041315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL NO. 2 CRANKSHAFT BEARING 
    1. Install the No. 2 crankshaft bearing on the bearing cap.
      NOTE: Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oils.
      Fig 12: Identifying No. 2 Crankshaft Bearing Claw
      G04974349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL UPPER CRANKSHAFT THRUST WASHER 
    1. Install the 2 thrust washers under the No. 3 journal of the cylinder block with the oil grooves facing outward.
      NOTE: Make sure to install the proper thrust washers.
    2. Apply engine oil to the crankshaft thrust washers.
    Fig 13: Installing Upper Crankshaft Thrust Washer
    G04974350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL CRANKSHAFT 
    1. Apply engine oil to the upper bearings and place the crankshaft on the cylinder block.
    2. Apply engine oil to the lower bearings.
    3. Examine the front marks and install the bearing caps on the cylinder block.
    4. Apply a light coat of engine oil to the threads and under the bearing cap bolts.
    5. Install the crankshaft bearing cap bolts.
      NOTE: The main bearing cap bolts are tightened in 2 progressive steps.
      Fig 14: Identifying Main Bearing Cap Installation Position
      G04974351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Step 1
      1. Install and uniformly tighten the 10 main bearing cap bolts in the sequence shown in the illustration.

        Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

        Fig 15: Identifying Main Bearing Cap Bolts Tightening Sequence
        G04974352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Retighten the 10 main bearing cap bolts in the sequence shown in the illustration.

        Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

        Fig 16: Identifying Main Bearing Cap Bolts Tightening Sequence
        G04974352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Step 2
      1. Mark the front of the bearing cap bolts with paint.
      2. Retighten the bearing cap bolts 90° in the numerical order shown in the illustration.
    8. Check that the paint mark is now at a 90° angle to the front.
    9. Check that the crankshaft turns smoothly.
    10. Check the crankshaft thrust clearance (See INSPECTION ).
    Fig 17: Identifying Bearing Cap Bolts Tightening Angle
    G04974752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL CONNECTING ROD BEARING 
    1. Align the bearing claw with the groove on the connecting rod or connecting cap.
      NOTE: Do not apply engine oil to the bearing inner surface or connecting rod contact surface.
      Fig 18: Aligning Bearing Claw With Groove On Connecting Rod
      G05129132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD 
    NOTE: The connecting rod cap bolts are tightened in 2 progressive steps.
    1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
    2. Check the position of the piston ring ends.

      HINT:

      Two different engine models manufactured at different factories are available for this vehicle. Referring to the Introduction section, check the engine serial number. Confirm the factory at which the engine was manufactured according to the following table.

      ENGINE SERIAL NUMBER REFERENCE

      Engine Serial Number Factory
      1 ###### TMC made
      2 ###### TMC made
      7 ###### except TMC made
      8 ###### except TMC made
      Fig 19: Positioning Piston Rings
      G06008635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. 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: Match the numbered connecting rod cap with the connecting rod.

      HINT:

      Two different engine models manufactured at different factories are available for this vehicle. Referring to the Introduction section, check the engine serial number. Confirm the factory at which the engine was manufactured according to the following table.

      ENGINE SERIAL NUMBER REFERENCE

      Engine Serial Number Factory
      1 ###### TMC made
      2 ###### TMC made
      7 ###### except TMC made
      8 ###### except TMC made
      Fig 20: Pushing Correctly Numbered Piston And Connecting Rod Assemblies
      G06008645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Check that the protrusion on the connecting rod cap is facing in the correct direction.
    5. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
    6. Install the connecting cap bolts.
      NOTE: The connecting cap bolts should be tightened in 2 progressive steps.
      Fig 21: Identifying Connecting Rod Cap Position
      G05387276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Step 1
      1. Install and alternately tighten the bolts of the connecting rod cap in several steps.

        Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) 

        Fig 22: Locating Connecting Rod Cap Bolts
        G05387277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Step 2
      1. Mark the front of the connecting rod cap bolts with paint.
      2. Retighten the cap bolts 90° as shown in the illustration.
    9. Check that the crankshaft turns smoothly.
    10. Check the connecting rod thrust clearance (See INSPECTION ).
    Fig 23: Identifying Connecting Rod Cap Bolts Tightening Angle
    G04974360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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