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Cylinder Block: Reassembly

HINT:

  1. ASSEMBLE PISTON AND CONNECTING ROD 
    1. Using a small screwdriver, install a new snap ring on one side of the piston pin hole.

      HINT:

      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 about 80°C (176°F).
      Fig 1: Installing Snap Ring To Piston Pin Hole
      G00889489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the piston pin with engine oil.
    4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
      Fig 2: Aligning Front Marks Of Piston And Connecting Rod
      G00889490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install a new snap ring at the other end of the piston pin hole.

      HINT:

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

  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 with the code mark facing up.
      Fig 3: Installing Piston Rings With Code Marks Facing Up
      G00889491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Code mark: 

      Fig 4: Piston Rings Code Mark Chart
      G00889492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Position the piston rings so that the ring ends are as shown in Fig 5.
      NOTE: Do not align the piston ring ends.
    Fig 5: Identifying Positions Of Piston Ring Ends
    G00889493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL BEARINGS 
    1. Align the bearing claw with the groove of the connecting rod and connecting cap.
      Fig 6: Aligning Bearing Claw With Groove
      G00889494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bearings in the connecting rod and connecting rod cap.
  4. INSTALL MAIN BEARINGS 

    HINT:

    • Main bearings come in widths of 20.0 mm (0.787 in.) and 23.0 mm (0.906 in.). Install the 23.0 mm bearings in the No.1 cylinder block journal position with the main bearing cap. Install the 20.0 mm bearings in the other positions.
    • Upper bearings have an oil groove and oil holes; lower bearings do not.
      Fig 7: Installing Main Bearings
      G00889495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Align the bearing claw with the claw groove of the main bearing cap or cylinder block.
      NOTE: Install the bearing with the oil hole in the cylinder block.
      Fig 8: Aligning Bearing Claw With Claw Groove
      G00889496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bearings in the cylinder block and main bearing caps.
      Fig 9: Installing Bearings In Cylinder Block And Main Bearing Caps
      G00889497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL UPPER THRUST WASHERS 

    Install the 2 thrust washers under the No.4 main journal position of the cylinder block with the oil grooves facing outward.

    Fig 10: Installing Upper Thrust Washers
    G00889498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. PLACE CRANKSHAFT ON CYLINDER BLOCK 
  7. PLACE MAIN BEARING CAP AND LOWER THRUST WASHERS ON CYLINDER BLOCK 
    1. Install the lower thrust washers on the No.4 main bearing with the grooves facing outward.
      Fig 11: Installing Lower Thrust Washers On No. 4 Main Bearing With Grooves Facing Outward
      G00889499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the main bearing caps in numerical order with the arrows facing forward.
      Fig 12: Installing Main Bearing Caps In Numerical Order
      G00889500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL MAIN BEARING CAP BOLTS 

    HINT:

    • The main bearing cap bolts are tightened in 2 progressive steps (steps  b and  d).
    • If any of the main bearing bolts break or deform, replace them.
    1. Apply a light coat of engine oil on the threads and under the heads of the main bearing cap bolts.
    2. Install and uniformly tighten the 14 main bearing cap bolts, in several passes, in the sequence shown in Fig 13.
      1. Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) 
      Fig 13: Tightening Main Bearing Cap Bolts In Sequence
      G00889501Courtesy 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.

    3. Mark the front of the main bearing cap bolt head with paint.
    4. Retighten the main bearing cap bolts 90° in the numerical order shown in Fig 13.
      Fig 14: Retightening Main Bearing Cap Bolts
      G00889502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Check that the painted mark is now at a 90° angle to the front.
    6. Check that the crankshaft turns smoothly.
  9. CHECK CRANKSHAFT THRUST CLEARANCE (See  DISASSEMBLY   ) 
  10. INSTALL PISTON AND CONNECTING ROD ASSEMBLIES 

    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 And Connecting Rod Assemblies
    G00889503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. PLACE CONNECTING ROD CAP ON CONNECTING ROD 
    1. Match the numbered connecting rod cap with the connecting rod.
    2. Install the connecting rod cap with by aligning the dowel pin to the corresponding hole.
    Fig 16: Placing Connecting Rod Cap On Connecting Rod
    G00889504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL CONNECTING ROD CAP BOLTS 

    HINT:

    • The connecting rod cap bolts are tightened in 2 progressive steps (steps  b and  d).
    • If any of the connecting rod bolts break or deform, replace them.
    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 bolts of the connecting rod cap in several passes.
      1. Torque: 30 N.m (300 kgf.cm, 22 ft.lbf) 
        Fig 17: Installing Connecting Rod Cap Bolts
        G00889505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Mark the front of the connecting rod cap bolt with paint.
    4. Retighten the connecting rod cap bolts 90° in the numerical order shown.
      Fig 18: Tightening Connecting Rod Cap Bolts An Additional 90°
      G00889506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Check that the painted mark is now at a 90° angle to the front.
    6. Check that the crankshaft turns smoothly.
  13. CHECK CONNECTING ROD THRUST CLEARANCE (See  DISASSEMBLY   ) 
  14. INSTALL REAR OIL SEAL RETAINER 
    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the retainer 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 debris.
      • Using a non-residue solvent, clean both sealing surfaces.
    2. Apply seal packing to the retainer as shown in Fig 19 .
      1. 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.
      Fig 19: Applying Seal Packing To Retainer
      G00889507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the retainer with the 6 bolts.
      1. Torque: 6.0 N.m (60 kgf.cm, 53 in..lbf) 
  15. INSTALL OIL PUMP (See  OIL AND FILTER  ) 
  16. INSTALL RH ENGINE MOUNTING BRACKET AND INSULATOR ASSEMBLY 

    Install the mounting bracket with the 4 bolts.

    1. Torque: 59 N.m (590 kgf.cm, 44 ft.lbf) 
  17. INSTALL LH ENGINE MOUNTING BRACKET AND INSULATOR ASSEMBLY 

    Install the mounting bracket with the 4 bolts.

    1. Torque: 59 N.m (590 kgf.cm, 44 ft.lbf) 
  18. INSTALL FUEL INLET PIPE 

    Install the fuel inlet pipe with the 2 bolts.

    1. Torque: 29 N.m (290 kgf.cm, 21 ft.lbf) 
  19. INSTALL NO. 1 OIL PIPE 

    Install the oil pipe with 2 new gaskets and the union bolt.

    1. Torque: 55 N.m (550 kgf.cm, 41 ft.lbf) 
  20. INSTALL OIL FILTER AND BRACKET ASSEMBLY 
    1. Install a new O-ring to the oil filter bracket.
    2. Install a new gasket to the union bolt.
    3. Install the oil filter bracket with the union bolt.
      1. Torque: 90 N.m (900 kgf.cm, 65 ft.lbf) 
  21. INSTALL OIL PRESSURE SWITCH (See  OIL AND FILTER  ) AND KNOCK SENSORS (See  KNOCK SENSOR  ) 
  22. INSTALL CYLINDER HEAD (See  INSTALLATION   ) 
  23. INSTALL WATER PUMP (See  INSTALLATION  ) 
  24. INSTALL NO. 2 WATER BYPASS PIPE WITH HOSE 
    1. Install the water bypass pipe with the bolt and 2 nuts.
      1. Torque: 21 N.m (210 kgf.cm, 15 ft.lbf) 
    2. Connect the water bypass hose to the hose clamp.
  25. INSTALL TIMING PULLEYS AND BELT (See  INSTALLATION   ) 
  26. INSTALL GENERATOR 

    Install the generator and pipe bracket with the bolt and nut.

    1. Torque: 40 N.m (400 kgf.cm, 30 ft.lbf) 
  27. REMOVE ENGINE STAND FROM ENGINE 
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