Cylinder Block: Overhaul

NOTE:

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.
INSPECT CONNECTING ROD THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
  
  Fig 1: Measuring Thrust Clearance Moving Connecting Rod Back & Forth
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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

Check the matchmarks on the connecting rod and cap ensure correct reassembly.
Remove the 2 connecting rod cap bolts.

Fig 2: Locating Matchmarks On Connecting Rod & Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using the removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.
NOTE: Keep the lower bearing inserted with the connecting rod cap.
Clean the crank pin and bearing.
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
Lay a strip of Plastigage across the crank pin.

Fig 4: Inserting Plastigage Strip To Crank Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the connecting rod cap with the 2 bolts (See step 30).
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

Measure the Plastigage at its widest point.

Fig 6: Measuring Plastigage At Widest Point

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.

NOTE: 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.

BEARING NUMBER MARKS SPECIFICATIONS

Item	Number Mark
Connecting rod	1		2	1	2	3	2	3	4	3	4
Crankshaft	1	2	1	3	2	1	3	2	1	3	2	3
Use bearing	2	3		4			5			6		7

EXAMPLE:

Connecting rod cap "3" + Crankshaft "1" =

Total number 4 (Use bearing "4")

Reference
Connecting rod big end inside diameter:

CONNECTING ROD BIG END INSIDE DIAMETER SPECIFICATIONS

Mark 1	55.000 - 55.006 mm (2.1654 - 2.1656 in.)
Mark 2	55.006 - 55.012 mm (2.1656 - 2.1658 in.)

Fig 7: Matching Connecting Rod Cap Number With Connecting Rod Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

CRANKSHAFT CRANK PIN DIAMETER SPECIFICATIONS

Mark 3	55.012 - 55.018 mm (2.1658 - 2.1661 in.)
Mark 4	55.018 - 55.024 mm (2.1661 - 2.1663 in.)

Crankshaft crank pin diameter:

STANDARD SIZED BEARING CENTER WALL THICKNESS SPECIFICATIONS

Mark 1	51.994 - 52.000 mm (2.0470 - 2.0472 in.)
Mark 2	51.988 - 51.994 mm (2.0468 - 2.0470 in.)
Mark 3	51.982 - 51.988 mm (2.0465 - 2.0468 in.)

Standard sized bearing center wall thickness:

STANDARD SIZED BEARING CENTER WALL THICKNESS SPECIFICATIONS

Mark 2	1.487 -1.490 mm (0.0585 - 0.0587 in.)
Mark 3	1.490 -1.493 mm (0.0587 - 0.0588 in.)
Mark 4	1.493 -1.496 mm (0.0588 - 0.0589 in.)
Mark 5	1.496 -1.499 mm (0.0589 - 0.0590 in.)
Mark 6	1.499 -1.502 mm (0.0590 - 0.0591 in.)
Mark 7	1.502 -1.505 mm (0.0591 - 0.0593 in.)

Completely remove the Plastigage.

REMOVE PISTON AND CONNECTING ROD
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
  
  Fig 8: Removing Carbon From Top Of Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
NOTE:
- 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.
2. Using a piston ring expander, remove the 2 compression rings.
3. Remove the 2 side rails and oil ring by hand.
  NOTE: Arrange the piston rings in correct order only.
4. Using a small screwdriver, pry out the 2 snap rings.
  
  Fig 11: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Gradually heat the piston to approx. 60°C (140°F).
  
  Fig 12: 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.
NOTE:
- The piston and pin are a matched set.
- Arrange the pistons, pins, rings, connecting rods and bearings in correct order.
Fig 13: 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.
  
  Fig 14: Measuring Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.)

INSPECT CRANKSHAFT OIL CLEARANCE

Remove the 10 crankshaft bearing cap bolts.

Fig 15: Removing Crankshaft Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Uniformly loosen and remove the 20 crankshaft bearing cap bolts in several passes, in the sequence shown.

Fig 16: Loosening & Removing Crankshaft Bearing Cap Bolts In Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
NOTE:
- Keep the lower bearing and bearing cap together.
- Arrange the bearing caps and lower thrust washers in correct order.
Fig 17: Removing Crankshaft Bearing Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Lift out the crankshaft.
Remove the 2 upper thrust washers.
NOTE:
- Arrange the upper thrust washers in correct order.
- Keep the upper bearings together with the cylinder block
Clean each crankshaft journal and bearing.
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.
Install the 10 crankshaft bearings and 5 crankshaft bearing caps with the 30 bolts (See step 26). Do not install the crankshaft.

Fig 18: Installing Crankshaft Bearing Caps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.)
Measure the diameter of the crankshaft journal (See step 17).

Subtract the crankshaft journal diameter measurement from the crankshaft bearing inside diameter measurement.

Fig 19: Measuring Inside Diameter Of Crankshaft Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard clearance:

STANDARD CLEARANCE SPECIFICATIONS

No. 1 & No. 5	0.017 - 0.033 mm (0.0007 - 0.0013 in.)
Others	0.029 - 0.045 mm (0.0011 - 0.0018 in.)

Maximum clearance:

MAXIMUM CLEARANCE SPECIFICATIONS

No. 1 & No. 5	0.043 mm (0.0017 in.)
Others	0.055 mm (0.0022 in.)

If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.

NOTE: 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:

NO. 1 & NO. 5 POSITION BEARING SPECIFICATIONS

-		Use bearing
Cylinder block (A) + Crankshaft (B)	A) + (B)	Upper	Lower
	0 - 5	3	3
	6 - 8	3	4
	9 - 11	4	4
	12 - 14	4	5
	15 - 17	5	5
	18 - 20	5	6
	21 - 23	6	6
	24 - 26	6	7
	27 - 28	7	7

Fig 20: Matching Connecting Rod Bearing Number With Crankshaft Number

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

EXAMPLE:

Cylinder block "08" + Crankshaft "06" =

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

Others:

OTHERS POSITION BEARING SPECIFICATIONS

-		Use Bearing
Cylinder block (A) + Crankshaft (B)	A) + (B)	Upper	Lower
	0 - 5	1	1
	6 - 8	1	2
	9 - 11	2	2
	12 - 14	2	3
	15 - 17	3	3
	18 - 20	3	4
	21 - 23	4	4
	24 - 26	4	5
	27 - 28	5	5

EXAMPLE:

Cylinder block "08" + Crankshaft "06" =

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

Reference

Cylinder block crankshaft journal bore diameter (A):

CYLINDER BLOCK CRANKSHAFT JOURNAL BORE DIAMETER (A) SPECIFICATIONS

Mark 00	72.000 mm (2.8346 in.)
Mark 01	72.001 mm (2.8347 in.)
Mark 02	72.002 mm (2.8347 in.)
Mark 03	72.003 mm (2.8348 in.)
Mark 04	72.004 mm (2.8348 in.)
Mark 05	72.005 mm (2.8348 in.)
Mark 06	72.006 mm (2.8349 in.)
Mark 07	72.007 mm (2.8349 in.)
Mark 08	72.008 mm (2.8350 in.)
Mark 09	72.009 mm (2.8350 in.)
Mark 10	72.010 mm (2.8350 in.)
Mark 11	72.011 mm (2.8351 in.)
Mark 12	72.012 mm (2.8351 in.)
Mark 13	72.013 mm (2.8352 in.)
Mark 14	72.014 mm (2.8352 in.)
Mark 15	72.015 mm (2.8352 in.)
Mark 16	72.016 mm (2.8353 in.)

Crankshaft journal diameter (B):

CRANKSHAFT JOURNAL DIAMETER (B) SPECIFICATIONS

Mark 00	67.000 mm (2.6378 in.)
Mark 01	66.999 mm (2.6378 in.)
Mark 02	66.998 mm (2.6377 in.)
Mark 03	66.997 mm (2.6377 in.)
Mark 04	66.996 mm (2.6376 in.)
Mark 05	66.995 mm (2.6376 in.)
Mark 06	66.994 mm (2.6376 in.)
Mark 07	66.993 mm (2.6375 in.)
Mark 08	66.992 mm (2.6375 in.)
Mark 09	66.991 mm (2.6374 in.)
Mark 10	66.990 mm (2.6374 in.)
Mark 11	66.989 mm (2.6374 in.)
Mark 12	66.988 mm (2.6373 in.)

Standard bearing center wall thickness:

No. 1 & No. 5

STANDARD BEARING CENTER WALL THICKNESS SPECIFICATIONS (NO. 1 AND NO. 5)

Mark 3	2.492 - 2.495 mm (0.0981 - 0.0982 in.)
Mark 4	2.495 - 2.498 mm (0.0982 - 0.0983 in.)
Mark 5	2.498 - 2.501 mm (0.0983 - 0.0985 in.)
Mark 6	2.501 - 2.504 mm (0.0985 - 0.0986 in.)
Mark 7	2.504 - 2.507 mm (0.0986 - 0.0987 in.)

Others

STANDARD BEARING CENTER WALL THICKNESS SPECIFICATIONS (OTHERS POSITION BEARING)

Mark 1	2.486 - 2.489 mm (0.0979 - 0.0980 in.)
Mark 2	2.489 - 2.492 mm (0.0980 - 0.0981 in.)
Mark 3	2.492 - 2.495 mm (0.0981 - 0.0982 in.)
Mark 4	2.495 - 2.498 mm (0.0982 - 0.0983 in.)
Mark 5	2.498 - 2.501 mm (0.0983 - 0.0985 in.)

Remove the 10 bolts, 20 nuts, 5 crankshaft bearing caps and 5 lower crankshaft bearing (See steps a to c above).
Remove the 5 upper crankshaft bearings from the cylinder block.

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

Fig 21: Removing Crankshaft Bearing Caps

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CYLINDER BLOCK SUB-ASSY

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 22: Removing Gasket Material From Top Surface Of Cylinder Block
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 23: Measuring Cylinder Head Contacting Surface & Bearing Cap Warpage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Maximum warpage: 0.07 mm (0.0028 in.)

If warpage is greater than maximum, replace the cylinder block sub-assy.
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block sub-assy.

Fig 24: Checking Cylinder For Vertical Scratches (Visually)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the cylinder bore diameter.

NOTE: 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 25: Inspecting Cylinder Bore Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard diameter:

STANDARD DIAMETER SPECIFICATIONS

Mark 1	91.000 - 91.008 mm (3.5827 - 3.5830 in.)
Mark 2	91.008 - 91.021 mm (3.5830 - 3.5835 in.)
Mark 3	91.021 - 91.029 mm (3.5835 - 3.5838 in.)

Maximum diameter: 91.229 mm (3.5917 in.)

If the diameter is greater than maximum, replace the cylinder block sub-assy.

Fig 26: Measuring Cylinder Bore Diameter At Positions A, B & C

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 27: Removing Cylinder Ridge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT W/PIN PISTON SUB-ASSY

[ 13101 / 98-11 ]

Clean the piston.
1. Using a gasket scraper, remove the carbon from the piston top.
  
  Fig 28: 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 29: 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 30: Cleaning Piston Thoroughly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the piston oil clearance.

NOTE: There are 3 sizes of the standard piston diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the piston top.

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:

PISTON DIAMETER SPECIFICATIONS

Mark 1	90.910 - 90.920 mm (3.5791 - 3.5795 in.)
Mark 2	90.920 - 90.928 mm (3.5795 - 3.5798 in.)
Mark 3	90.928 - 90.938 mm (3.5798 - 3.5802 in.)

Measure the cylinder bore diameter in the thrust directions (See step 2 above).
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 31: Measuring Piston Diameter

If the oil clearance is greater than maximum, replace all the 8 pistons. If necessary, replace the cylinder block sub-assy.

NOTE: 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 32: Identifying Piston Number Mark

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 33: Inspecting Piston Pin Fitting
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a micrometer, measure the piston pin diameter.
Piston pin diameter:

21.997 - 22.006 mm (0.8660 - 0.8664 in.)

Fig 34: Measuring Piston Pin Diameter

INSPECT PISTON RING SET

[ 13011 / 98-11 ]

Inspect the piston ring groove clearance.

Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.

Fig 35: Measuring Piston Ring Clearance

Ring groove clearance:

RING GROOVE CLEARANCE SPECIFICATIONS

No.1	0.030 - 0.080 mm (0.0012 - 0.0031 in.)
No.2	0.020 - 0.060 mm (0.0008 - 0.0024 in.)

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

Inspect the piston ring end gap.

Insert the piston ring into the cylinder bore.
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 36: Pushing Piston Ring Down Through Cylinder
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard end gap:

STANDARD END GAP SPECIFICATIONS

No. 1	0.300 - 0.500 mm (0.0118 - 0.0197 in.)
No. 2	0.400 - 0.600 mm (0.0157 - 0.0236 in.)
Oil (Side rail)	0.150 - 0.500 mm (0.0059 - 0.0197 in.)

Maximum end gap:

MAXIMUM END GAP SPECIFICATIONS

No. 1	1.10 mm (0.0433 in.)
No. 2	1.20 mm (0.0472 in.)
Oil (Side rail)	1.10 mm (0.0433 in.)

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.
  
  Fig 38: Checking Connecting Rod Alignment
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
  2. Check for twist
    
    Fig 39: Checking Connecting Rod Twist
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Maximum twist:
    
    0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
  If twist is greater than maximum, replace the connecting sub-assy.
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 40: 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 41: 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.
  
  Fig 42: Measuring Connecting Rod Bolt Tension Portion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
INSPECT CRANKSHAFT BEARING CAP BOLT
1. Using vernier calipers, measure the tension portion diameter of the main bearing cap bolt.
  
  Fig 43: Measuring Tension Portion Diameter Of Main Bearing Cap Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
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.
    
    Fig 44: Measuring Crankshaft Circle Runout At Center Journal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  Maximum circle runout: 0.08 mm (0.0031 in.)
  
  If the circle runout is greater than maximum, replace the crankshaft.
2. Inspect the main journals and crank pins.
  1. Using a micrometer, measure the diameter of each main journal and crank pin.
    
    Fig 45: Measuring Diameter Of Each Crankshaft Journal & Crank Pin
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    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.
INSTALL STUD BOLT

Fig 46: Locating Stud Bolt Installation Point & Stud Bolt Specifications
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RING PIN

Fig 48: Locating Ring Pin Installation Point & 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 49: Aligning Oil Holes Of Bushing & Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in the bushing.
  SST 09222-30010
  
  Fig 50: 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 51: 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 52: Pushing Piston Pin Into Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL W/PIN PISTON SUB-ASSY

Using a small screwdriver, install a new snap ring on one side of the piston pin hole.

Fig 53: Installing New Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Coat the piston pin with engine oil.
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".
Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.

Fig 55: Identifying Piston Front & Outside Marks
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check fit between the piston and piston pin.
1. Try to move the piston back and forth on the piston pin.
Fig 56: Moving Piston Back & Forth On Piston Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.

Fig 57: Installing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the oil ring expander and 2 side rails by hand.

Using a piston ring expander, install the 2 compression rings with the code mark facing upward.

Code mark:

COMPRESSION RING CODE MARK SPECIFICATIONS

No. 1	1R
No. 2	2R

Fig 58: Identifying Compression Ring Code Mark

Position the piston rings so that the ring ends are as shown.

NOTE: Do not align the ring ends.

Fig 59: Identifying Piston Ring End Positions

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 60: Installing Bearings In Connecting Rod & Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT BEARING
NOTE:
- 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 61: Identifying No. 1, No. 5 & Other Upper & Lower Bearings
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 62: 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.
NOTE: A number is marked on each bearing cap to indicate the installation position.

Fig 63: Identifying Bearing Cap Number Mark 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 64: Installing Thrust Washers Under No. 3 Journal Position Of Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 thrust washers on the No. 3 bearing cap with the grooves facing outward.
  
  Fig 65: 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 66: Installing Crankshaft Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: 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 67: Installing Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the crankshaft bearing cap bolts.
  NOTE:
  - The bearing cap bolts are tightened in 2 progress 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.
    
    Fig 68: Torquing Crankshaft Bearing Cap Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    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.
  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.
    
    Fig 69: Identifying Bearing Cap Bolts Painted Mark Position
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Check that the painted mark is now at a 90° angle to the front.
  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 70: Installing & 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 71: Pushing Correctly Numbered Piston & 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 72: 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 73: Identifying Outside Mark Of Connecting Rod Cap
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the connecting rod cap bolts.
  NOTE:
  - 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 74: Torquing 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.
    
    Fig 75: Identifying Bearing Cap Bolts Painted Mark Position
    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).
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 pi 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 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.
  Fig 76: Applying Seal Packing To Seal Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the seal plate with the 2 nuts. Alternately tighten' nuts in several passes.
  Torque: 14 N.m (145 kgf.cm, 10 ft.lbf)
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 77: 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)
NOTE: After applying the specified torque, rotate the drain union clockwise until its drain port is facing forward.

Fig 78: Identifying Drain Port Position
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002