Reassembly [10/2017 - ]: Procedure

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INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a 5 mm hexagon wrench, install the No. 1 oil nozzle sub-assemblies with the 3 bolts.
  Torque: 9.0 N.m (92 kgf/cm, 80 in.lbf)

INSTALL CONNECTING ROD SMALL END BUSH

Align the oil holes of a new connecting rod small end bush and the connecting rod sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Oil Hole

Using SST and a press, press in the connecting rod small end bush.

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SST: 09222-30010

Using a pin hole grinder, hone the bush to obtain the specified clearance between the bush and piston pin.

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Standard oil clearance

-0.005 to 0.011 mm (-0.00019 to 0.00043 in.)

Check that the piston pin fits at normal room temperature.
Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

INSTALL PISTON WITH PIN SUB-ASSEMBLY

HINT:

Perform "Inspection After Repairs" after replacing the piston.

Refer to INITIALIZATION [10/2017 - 09/2018] , or refer to INITIALIZATION [09/2018 - 09/2020] , or refer to INITIALIZATION [09/2020 - ]

Using a screwdriver, install a new piston pin hole snap ring at one end of the piston pin hole.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Cutout Portion

HINT:

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

Gradually heat the piston to approximately 80°C (176°F).
Coat the piston pin with engine oil.

Align the front marks of the piston and connecting rod sub-assembly, and push in the piston pin with your thumb.

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*a	Piston RH
*b	Piston LH
*c	Front Mark

HINT:

The piston and pin are a matched set.

Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole.

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*a	Cutout Portion

HINT:

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

INSTALL PISTON RING SET

HINT:

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

Refer to INITIALIZATION [10/2017 - 09/2018] , or refer to INITIALIZATION [09/2018 - 09/2020] , or refer to INITIALIZATION [09/2020 - ]

Install the oil ring expander and 2 side rails by hand.

Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	No. 1 Compression Ring
*2	No. 2 Compression Ring
*a	Code Mark

HINT:

Install the No. 1 compression ring with the code mark (T1) facing upward.

Install the No. 2 compression ring with the code mark (T2) facing upward.

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	No. 1 Compression Ring
*2	No. 2 Compression Ring
*3	Lower Side Rail
*4	Upper Side Rail
*5	Oil Ring Expander
*a	Front Mark

NOTE:

Do not align the ring ends.

INSTALL CRANKSHAFT BEARING

Clean the main journal and both surfaces of the bearings.

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*a	No. 1 and No. 4 Journal Bearing
*b	No. 2 and No. 3 Journal Bearing
*c	21.0 mm (0.827 in.)
*d	18.0 mm (0.709 in.)

NOTE:

Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

Install the upper crankshaft bearing.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Upper Crankshaft Bearing
*a	Correct
*b	Incorrect

Install the upper crankshaft bearings to the cylinder block as shown in the illustration.
NOTE:
- Do not apply engine oil to the bearings and the contact surfaces.
- Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal.
- Do not allow coolant to come into contact with the bearing inner surface.
- If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.

Install the lower crankshaft bearing.

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*a	Vernier Caliper
*b	Mark 1, 2, 3, 4 or 5

Install the lower crankshaft bearings to the crankshaft bearing caps.
Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the lower crankshaft bearing edge.
Standard dimension (A - B or B - A)

0.7 mm (0.0276 in.) or less
NOTE:
- Do not apply engine oil to the crankshaft bearings and the contact surfaces.
- Do not allow coolant to come into contact with the bearing inner surface.
- If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.

INSTALL CRANKSHAFT THRUST WASHER SET

Apply engine oil to the crankshaft thrust washer.

Install the 2 upper crankshaft thrust washers under the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Oil Grooves

INSTALL CRANKSHAFT

Apply engine oil to the upper bearing, and then place the crankshaft on the cylinder block.

Confirm the projections and numbers on the main bearing caps and install the crankshaft bearing caps on the cylinder block.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

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

Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts.
Temporarily install the 8 crankshaft bearing cap bolts to the inside positions.

Tighten the 2 bolts A for each bearing cap until the clearance between the crankshaft bearing cap and the cylinder block becomes less than 6 mm (0.236 in.).

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*a	Less than 6 mm (0.236 in.)

HINT:

Type A and type B can be distinguished by the shape of the bearing cap bolt.

BOLT TYPE

Type	Shape
A	Without threaded hole
B	With threaded hole

Using a plastic-faced hammer, lightly tap the crankshaft bearing cap to ensure a proper fit.

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Apply a light coat of engine oil to the threads and under the heads of the 8 crankshaft bearing cap bolts.

Install the crankshaft bearing cap bolt A and 7 crankshaft bearing cap bolts B to the outside positions.

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HINT:

The crankshaft bearing cap bolts are tightened in 2 progressive steps.

Install and uniformly tighten the 16 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

Fig 1: Crankshaft Bearing Cap Bolts Tightening Sequence (1 Of 2)
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Torque: 61 N.m (622 kgf/cm, 45 ft.lbf)

If any of the crankshaft bearing cap bolts does not meet the torque specified, replace it.

Mark the front of the bearing cap bolts with paint.

*a	Paint Mark
*b	90°
	Front Side

Tighten the cap bolts another 90°.
Check that the painted marks are now at a 90° angle to the front of the engine.

Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

Fig 2: Crankshaft Bearing Cap Bolts Tightening Sequence (2 Of 2)

*a	Bolt Type
*b	Tightening Order

Torque: 25.7 N.m (262 kgf/cm, 19 ft.lbf)

Bolt Length

Item	Specified Condition
Bolt C	45 mm (1.77 in.)
Bolt D	30 mm (1.18 in.)

Check that the crankshaft turns smoothly.
Check the crankshaft thrust clearance (See step 7).

INSTALL CONNECTING ROD BEARING

Install the connecting rod bearings to the connecting rod sub-assembly and connecting rod cap.

Using a vernier caliper, measure the distance between each connecting rod bearing edge and the connecting rod edges, and the connecting rod cap edges respectively.

*a	Vernier Caliper

Standard dimension (A - B or B - A)

0.7 mm (0.0276 in.) or less

NOTE:

Do not apply engine oil to the bearings and the contact surfaces.

INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.

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

NOTE:

Do not align the ring ends.

*1	No. 1 Compression Ring
*2	No. 2 Compression Ring
*3	Lower Side Rail
*4	Upper Side Rail
*5	Expander
*a	Front Mark

Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.

*a	Piston RH
*b	Piston LH
*c	Front Mark
	Engine Front

NOTE:

Match the numbered connecting rod cap with the connecting rod.

Check that the front mark of the connecting rod cap is facing forward.

*a	Front Mark
	Engine Front

Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
Install the 2 connecting rod cap bolts.
HINT:

The cap bolts are tightened in 2 progressive steps.
Install and alternately tighten the connecting rod cap bolts of each connecting rod cap in several steps.

Fig 3: Tightening Bolts Of Connecting Rod Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 24.5 N.m (250 kgf/cm, 18 ft.lbf)

Mark the front side of each connecting rod cap bolt with paint.

*a	Paint Mark
*b	90°
	Front Side

Tighten the cap bolts 90°.
Check that the paint marks are now at a 90° angle to the front.
Check that the crankshaft turns smoothly.

INSPECT CONNECTING ROD THRUST CLEARANCE
See step 1