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Reassembly [08/2015 - ]: Procedure

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  1. INSTALL STUD BOLT 
    NOTE:

    If a stud bolt is deformed or its threads are damaged, replace it.

    1. Using E6 and E8 "TORX" socket wrenches, install the 4 stud bolts.
      GTY619683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Side *b LH Side
      *c RH Side *d 9 mm (0.354 in.)
      *e 12 mm (0.472 in.) *f 16 mm (0.630 in.)
      *g 21 mm (0.827 in.) *h 24 mm (0.945 in.)
      *i 34 mm (1.34 in.) *j 52 mm (2.05 in.)

      for stud bolt A 

      Torque: 4.0 N.m (41 kgf/cm, 35 in.lbf) 

      for stud bolt B, C 

      Torque: 9.0 N.m (92 kgf/cm, 80 in.lbf) 

  2. INSTALL OIL PIPE SUB-ASSEMBLY 
    1. Install a new oil pipe gasket to the oil pipe sub-assembly.
    2. Temporarily install the oil pipe sub-assembly.
      Fig 1: Oil Pipe Sub-Assembly Tightening Sequence
      GTY510965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Hexagon Socket Head Cap Bolt
      Bolt
      1. Temporarily install the 3 bolts in the sequence shown in the illustration.
      2. Using a 5 mm hexagon wrench, temporarily install the 4 hexagon socket head cap bolts in the sequence shown in the illustration.
    3. Tighten the oil pipe sub-assembly.
      Fig 2: Oil Pipe Sub-Assembly Tightening Sequence
      GTY510966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Hexagon Socket Head Cap Bolt
      Bolt
      1. Using a 5 mm hexagon wrench, tighten the 4 hexagon socket head cap bolts in the sequence shown in the illustration.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      2. Tighten the 3 bolts in the sequence shown in the illustration.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  3. INSTALL PISTON 

    HINT: 

    Perform "Inspection After Repairs" after replacing the piston.

    Refer to INITIALIZATION [08/2015 - 09/2018] , or refer to INITIALIZATION [09/2018 - 09/2019] , or refer to INITIALIZATION [09/2019 - ]

    1. Using a small screwdriver, install a new piston pin hole snap ring at one end of the piston pin hole.
    2. Gradually heat the piston up to 80 to 90°C (176 to 194°F).
    3. Coat the piston, piston pin and connecting rod with engine oil.
    4. Align the front marks of the piston and connecting rod, insert the connecting rod into the piston, and then push in the piston pin with your thumb until the piston pin comes into contact with the piston pin hole snap ring.
      GTY513439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark

      HINT: 

      The piston and piston pin are a matched set.

    5. Using a small screwdriver, install a new piston pin hole snap ring on the other side of the piston pin hole.
      GTY515562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Piston Pin Hole Snap Ring
      *a Service Hole Cutout Portion

      HINT: 

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

    6. Check the fitting condition between the piston and piston pin.
      1. Move the connecting rod back and forth on the piston pin. Check the fitting condition.

        If abnormal movement is felt, replace the piston and piston pin as a set.

      2. Rotate the piston back and forth on the piston pin. Check the fitting condition.

        If abnormal movement is felt, replace the piston and pin as a set.

  4. INSTALL PISTON RING SET 

    HINT: 

    Perform "Inspection After Repairs" after replacing the piston ring.

    Refer to INITIALIZATION [08/2015 - 09/2018] , or refer to INITIALIZATION [09/2018 - 09/2019] , or refer to INITIALIZATION [09/2019 - ]

    1. Install the oil ring expander and 2 oil ring side rails by hand.
      GTY481306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Upper Oil Ring Side Rail
      *2 Oil Ring Expander
      *3 Lower Oil Ring Side Rail
    2. Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring with the code mark positioned as shown in the illustration.
      GTY498027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a Paint Mark
      *b Code Mark (2T)
      Upward
      NOTE:

      Install the No. 2 compression ring with the code mark facing upward.

    3. Position the piston rings so that the ring ends are as shown in the illustration.
      GTY508883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Upper Oil Ring Side Rail
      *4 Lower Oil Ring Side Rail
      *5 Oil Ring Expander
      *a Front Mark
      Front Side

      HINT: 

      The oil ring expander can be installed with the ring ends in either of the directions shown in the illustration.

  5. INSTALL CRANKSHAFT PULLEY SET KEY 
    1. Install the 2 crankshaft pulley set keys to the crankshaft.
  6. INSTALL CRANKSHAFT BEARING 
    1. Clean the main journal and both surfaces of the crankshaft bearing.
      GTY627509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a CORRECT
      *b INCORRECT
    2. Install the crankshaft bearing to the cylinder block sub-assembly as shown in the illustration.
      NOTE:
      • Do not apply engine oil to the crankshaft bearings or their contact surfaces.
      • Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the crankshaft bearing. The amount visible on each side of the holes should be equal.
      • Do not allow coolant to come into contact with the crankshaft bearing inner surface. If any coolant comes into contact with the crankshaft bearing inner surface, replace the crankshaft bearing with a new one.
    3. Install the No. 2 crankshaft bearing to the crankshaft bearing cap.
      GTY502853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Vernier Caliper
    4. Using a vernier caliper, measure the distance between the edges of the crankshaft bearing cap and No. 2 crankshaft bearing.

      Dimension A - B or B - A

      0 to 0.7 mm (0 to 0.0276 in.)

      NOTE:
      • Do not apply engine oil to the No. 2 crankshaft bearings and the contact surfaces.
      • Do not allow coolant to come into contact with the No. 2 crankshaft bearing inner surface. If any coolant comes into contact with the No. 2 crankshaft bearing inner surface, replace the No. 2 crankshaft bearing with a new one.
  7. INSTALL CRANKSHAFT THRUST WASHER 
    1. Apply engine oil to the 2 crankshaft thrust washers.
      GTY637888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil Groove
    2. Install the 2 crankshaft thrust washers to the No. 3 journal position of the cylinder block sub-assembly with the oil grooves facing outward.
  8. INSTALL CRANKSHAFT 
    1. Apply engine oil to the crankshaft bearing, and then install the crankshaft to the cylinder block sub-assembly.
      GTY679455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark
    2. Examine the front marks and numbers, and then install the crankshaft bearing caps to the cylinder block sub-assembly with the front marks as shown in the illustration.
    3. Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts.
    4. Tighten the crankshaft bearing cap bolts.

      HINT: 

      The crankshaft bearing cap bolts are tightened in 3 progressive steps.

      1. Fig 3: Crankshaft Bearing Cap Tightening Sequence
        GTY658946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Step 1:

        Using several steps, install and uniformly tighten the 10 crankshaft bearing cap bolts in the sequence shown in the illustration.

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

      2. Step 2:

        Tighten the 10 crankshaft bearing cap bolts again in the sequence shown in the illustration.

        Torque: 61 N.m (622 kgf/cm, 45 ft.lbf) 

        If a crankshaft bearing cap bolt does not meet the specified torque, replace it.

      3. Mark the front side of each crankshaft bearing cap bolt with paint.
        GTY621658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Paint Mark
        *b 90°
        Engine Front Side
      4. Step 3:

        Tighten the 10 crankshaft bearing cap bolts 90° in the order shown in step 1.

      5. Check that the paint marks are now at a 90° angle to the front.
    5. Check that the crankshaft turns smoothly.
  9. INSTALL CONNECTING ROD BEARING 
    1. Clean the connecting rod bearing contact surface of the connecting rod and connecting rod cap, and both surfaces of both connecting rod bearings.
      GTY612375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Vernier Caliper
    2. Install the connecting rod bearings to the connecting rods and connecting rod caps.
    3. Using a vernier caliper, measure the distance between the edges of the connecting rod and connecting rod bearing, and the edges of the connecting rod cap and connecting rod bearing.

      Dimension A - B or B - A

      0 to 0.7 mm (0 to 0.0276 in.)

      NOTE:
      • Do not apply engine oil to the connecting rod bearings or the contact surfaces.
      • Do not allow coolant to come into contact with the connecting rod bearing inner surface. If any coolant comes into contact with the connecting rod bearing inner surface, replace the connecting rod bearing with a new one.
  10. INSTALL PISTON WITH CONNECTING ROD 
    1. Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.
    2. Position the piston rings so that the ring ends are as shown in the illustration.
      GTY508883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Upper Oil Ring Side Rail
      *4 Lower Oil Ring Side Rail
      *5 Oil Ring Expander
      *a Front Mark
      Front Side

      HINT: 

      The oil ring expander can be installed with the ring ends in either of the directions shown in the illustration.

    3. Using a hammer handle and piston ring compressor, press a piston with connecting rod into each cylinder with the front mark of the piston facing forward.
      GTY654629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark
      NOTE:

      When inserting the piston with connecting rod into the cylinder block sub-assembly, make sure the oil pipe sub-assembly does not interfere with the connecting rod.

    4. Check that the front mark of the connecting rod cap is facing in the correct direction.
      GTY663388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark
      NOTE:

      Match the numbered connecting rod cap with the correct connecting rod.

    5. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
    6. Install the connecting rod bolts.

      HINT: 

      The connecting rod bolts are tightened in 2 progressive steps.

      1. Step 1:

        Install and alternately tighten the connecting rod bolts of each connecting rod cap in several steps.

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

      2. Mark the front side of each connecting rod bolt with paint.
        GTY632766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Paint Mark
        *b 90°
        Engine Front Side
      3. Step 2:

        Tighten the connecting rod cap bolts 90°.

      4. Check that the paint marks are now at a 90° angle to the front.
    7. Check that the crankshaft turns smoothly.
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