Engine Unit: Reassembly

1. Using a small screwdriver, install a new snap ring on one side of the piston pin hole.
   Fig 4: Installing Piston Sub-Assembly With Pin

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2. Gradually heat the piston to about 60°C (140°F).
   Fig 5: Heating Piston

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3. Coat the piston pin with engine oil.
4. The piston's front mark and the connecting rod's outside mark should face the same direction, as shown in the illustration.
   NOTE: The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with a "3L" and the RH piston is marked with a "3R".
5. Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.
   Fig 6: Identifying Piston Front Mark

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6. Check the fit between the piston and piston pin.
   1. Try to move the piston back and forth on the piston pin.
      Fig 7: Checking Piston And Piston Pin

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7. Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.
   Fig 8: Installing Snap Ring On Other Side Of Piston Pin Hole

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8. Install the oil ring expander and 2 side rails by hand.
9. Using a piston ring expander, install the No. 1 and No. 2 piston rings with the code mark facing upward.

   Code mark 

   CODE MARK SPECIFICATION
   
   

   Piston Ring	Code Mark
   No. 1	1R
   No. 2	2R

   Fig 9: Installing Oil Ring Expander And 2 Side Rails By Hand

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   Fig 10: Identifying Piston Rings Installing Positions

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10. Position the piston rings so that the ring ends are as shown in the illustration.
    NOTE: Do not align the ring ends.

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 11: Aligning Bearing Claw With Groove Of Connecting Cap

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HINT:

• 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 12: Identifying Ring Code Mark

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1. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.
   Fig 13: Identifying Piston Code Mark Specification

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2. Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings.

   HINT:

   A number is marked on each bearing cap to indicate the installation position.

   Fig 14: Aligning Bearing Claw With Claw Groove Of Crankshaft Bearing Cap

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1. Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.
   Fig 15: Installing Thrust Washers Under No 3 Journal Position Of Cylinder Block

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2. Install the 2 thrust washers on the No. 3 bearing cap with the grooves facing outward.
   Fig 16: Installing Thrust Washers On No 3 Bearing Cap With Grooves

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1. Place the crankshaft on the cylinder block.
   Fig 17: Placing Crankshaft On Cylinder Block

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2. Install the 5 crankshaft bearing caps in their proper locations.

   HINT:

   Place the bearing caps level and let them return to their original positions by their own weight.

   NOTE: Do not install the bearing cap by tapping it.
   Fig 18: Installing Crankshaft Bearing Caps

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3. Install the crankshaft bearing cap bolts.

   HINT:

   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 in the illustration.

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

      If any of the bearing cap bolts cannot meet the torque specification, replace the bearing cap bolt.

      Fig 19: Identifying Tightening Sequence Of Crankshaft Bearing Cap Bolts

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   3. Mark the front of each crankshaft bearing cap bolt's head with paint.
   4. Tighten the crankshaft bearing cap bolts another 90° as shown in the illustration.
   5. Check that the painted mark is now at a 90° angle to the front.
      Fig 20: Retightening Crankshaft Bearing Cap Bolts By 90°

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   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.
   Fig 21: Locating Crankshaft Bearing Cap Bolts

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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 a "3L" and the RH piston is marked with a "3R".
   Fig 22: Installing Piston And Connecting Rod

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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 23: Placing Connecting Rod Cap On Connecting Rod

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   3. Check that the outside mark of the connecting rod cap is facing in the correct direction.
      Fig 24: Checking Outside Mark Of Connecting Rod Cap

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3. Install the connecting rod cap bolts.

   HINT:

   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 of the connecting rod cap bolts cannot meet the torque specification, replace the connecting rod cap bolts.

      Fig 25: Installing Connecting Rod Cap Bolts

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   3. Mark the front of each connecting cap bolt with paint.
   4. Tighten the cap bolts another 90° as shown in the illustration.
   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.

1. Remove any old packing (FIPG) material.
   Fig 26: Retightening Cap Bolts 90°

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2. Apply seal packing to the seal plate as shown in the illustration.

   Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1324 or equivalent 

   Seal diameter: 2 to 3 mm (0.08 to 0.12 in.) 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the seal plate within 3 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installing the seal plate.
     Fig 27: Identifying Seal Packing To Seal Plate

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3. Install the seal plate with the 2 nuts. Alternately tighten the nuts in several passes.

   Torque: 14 N*m (142 kgf*cm, 10 ft.*lbf) 

1. Apply seal packing to 2 or 3 threads.

   Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent 

   Fig 28: Applying Seal Packing To 2 Or 3 Threads

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2. Install the RH and LH drain cocks.
   Fig 29: Installing RH And LH Drain Cocks

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   Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

   HINT:

   After applying the specified torque, rotate each drain cock clockwise until its drain port is facing forward.

1. Remove any oil packing (FIPG) material.
2. Apply seal packing to the oil seal retainer as shown in the illustration.

   Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1324 or equivalent 

   Seal diameter: 3 to 4 mm (0.12 to 0.16 in.) 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil seal within 3 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installing the oil seal retainer.
     Fig 30: Identifying Seal Packing To Oil Seal Retainer

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3. Install a new O-ring to the cylinder block.
4. Install the oil seal retainer with the 7 bolts.

   Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

1. Place a new cylinder head gasket on the cylinder block.

   HINT:

   The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A "3R" mark is on the RH bank's gasket.

   NOTE: Be careful of the installation direction.
2. Place the cylinder head on the cylinder head gasket.
   Fig 33: Placing Cylinder Head Gasket In Position On Cylinder Block

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3. Install the cylinder head bolts.

   HINT:

   If any cylinder head bolt is broken or deformed, replace it.

   1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
   2. Install the plate washer to the cylinder head bolt.
      Fig 34: Identifying Installing Sequence Of Cylinder Head Bolt (RH)

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   3. Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes in the sequence shown.

      Torque: 59 N*m (602 kgf*cm, 44 ft.*lbf) 

      If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

      NOTE: Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
      Fig 35: Identifying Portion A (RH Bank)

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   4. Mark the front of each cylinder head bolt's head with paint.
   5. Tighten the cylinder head bolts another 90° in the sequence shown in the illustration.
   6. Check that the painted mark is now at a 90° angle to the front.
      Fig 36: Retightening Cylinder Head Bolts By 90°

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1. Place a new cylinder head gasket on the cylinder block.

   HINT:

   The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A "3L" mark is on the LH bank's gasket.

   NOTE: Be careful of the installation direction.
2. Place the cylinder head on the cylinder head gasket.
   Fig 37: Placing Cylinder Head Gasket In Position On Cylinder Block

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3. Install the cylinder head bolts.

   HINT:

   If any cylinder head bolt is broken or deformed, replace it.

   1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
   2. Install the plate washer to the cylinder head bolt.
      Fig 38: Identifying Tightening Sequence Of Cylinder Head Bolts

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   3. Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes in the sequence shown.

      Torque: 59 N*m (602 kgf*cm, 44 ft.*lbf) 

      If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

      NOTE: Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
      Fig 39: Identifying Portion A (LH Bank)

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   4. Mark the front of each cylinder head bolt's head with paint.
   5. Tighten the cylinder head bolts another 90° in the sequence shown in the illustration.
      Fig 40: Retightening Cylinder Head Bolts By 90°

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   6. Check that the painted mark is now at a 90° angle to the front.

1. Align the timing pulley set key with the key groove of the pulley.
2. Using SST and a hammer, tap in the timing pulley, facing the flange side inward.

   SST 09223-46011 

1. Install the idler with the bolt.

   Torque: 34.5 N*m (352 kgf*cm, 25 ft.*lbf) 

2. Check that the idler moves smoothly.
   Fig 41: Taping Timing Pulley

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1. Apply adhesive to 2 or 3 threads of the pivot bolt.

   Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

2. Using a 10 mm hexagon wrench, install the plate washer and idler with the pivot bolt.

   Torque: 34.5 N*m (352 kgf*cm, 25 ft.*lbf) 

3. Check that the idler bracket moves smoothly.
   Fig 42: Installing Plate Washer And Idler With Pivot Bolt

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1. Remove any old packing (FIPG) material.
2. Apply seal packing to the semicircular plug grooves.

   Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1324 or equivalent 

   Fig 43: Applying Seal Packing To Semicircular Plug Grooves

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3. Install the 4 semicircular plugs to the cylinder heads as shown in the illustration.
   Fig 44: Locating Semicircular Plugs To Cylinder Heads

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