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Reassembly [11/2017 - ]: Procedure

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  1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon socket wrench, install the 3 No. 1 oil nozzle sub-assemblies to the cylinder block sub-assembly with the 3 bolts.

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

  2. INSTALL CONNECTING ROD SMALL END BUSH 
    1. Align the oil hole of a new connecting rod small end bush with the oil hole of the connecting rod.
      GTY801196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil Hole
    2. Using SST and a press, push in the connecting rod small end bush.
      GTY795563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09222-30010 
    3. Using a pin hole grinder, hone the connecting rod small end bush to obtain the standard oil clearance between the connecting rod small end bush and piston pin.
      GTY416665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Oil Clearance

      -0.005 to 0.011 mm (-0.000197 to 0.000433 in.)

    4. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

      HINT: 

      Check that the piston pin fits at a normal room temperature.

  3. INSTALL PISTON SUB-ASSEMBLY WITH PIN 

    HINT: 

    Perform inspection after repairs after replacing the piston.

    Refer to INITIALIZATION [11/2017 - 10/2018] , or refer to INITIALIZATION [10/2018 - 09/2020] , or refer to INITIALIZATION [09/2020 - ]

    1. Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole.
      GTY812021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cutout
      NOTE:

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

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

      Be sure to wear protective gloves.

    4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
      GTY780466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Piston RH
      *b Piston LH
      *c Front Mark

      HINT: 

      The piston and pin are a matched set.

    5. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
    6. Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole.
      GTY825509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cutout
      NOTE:

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

  4. INSTALL PISTON RING SET 

    HINT: 

    Perform inspection after repairs after replacing the piston ring.

    Refer to INITIALIZATION [11/2017 - 10/2018] , or refer to INITIALIZATION [10/2018 - 09/2020] , or refer to INITIALIZATION [09/2020 - ]

    1. Install the oil ring expander and 2 side rails by hand.
    2. Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring as shown in the illustration.
      GTY793435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a Code Mark
      NOTE:
      • 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.
    3. Position the piston ring set so that the ring ends are as shown in the illustration.
      GTY829948Courtesy 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.

  5. INSTALL CRANKSHAFT BEARING 
    1. Clean the main journals and both surfaces of the crankshaft bearings.
      GTY778144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No. 1 and No. 4 Crankshaft Bearing
      *b No. 2 and No. 3 Crankshaft Bearing
      *c 20.9 mm
      *d 17.9 mm
      NOTE:

      Crankshaft bearings come in widths of 17.9 mm (0.705 in.) and 20.9 mm (0.823 in.). Install the 20.9 mm (0.823 in.) crankshaft bearings to the No. 1 and No. 4 cylinder block journal positions. Install the 17.9 mm (0.705 in.) crankshaft bearings to the No. 2 and No. 3 positions.

    2. Install the upper crankshaft bearings.
      GTY786493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Upper Crankshaft Bearing
      *a Correct
      *b Incorrect
      1. Install the upper crankshaft bearings to the cylinder block sub-assembly as shown in the illustration.
        NOTE:
        • Do not apply engine oil to the crankshaft bearings or the 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 lower crankshaft bearings.
      GTY815524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Vernier Caliper
      *b Number Mark
      1. Install the lower crankshaft bearings to the crankshaft bearing caps.
      2. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and lower crankshaft bearing edge.

        Difference Between (A) and (B)

        0.7 mm (0.0276 in.) or less

        NOTE:
        • Do not apply engine oil to the crankshaft bearings or the contact surfaces.
        • 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.
  6. INSTALL CRANKSHAFT THRUST WASHER SET 
    1. Apply engine oil to the crankshaft thrust washer set.
    2. Install the crankshaft thrust washer set under the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward.
      GTY810547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil Grooves
  7. INSTALL CRANKSHAFT 
    1. Apply engine oil to the crankshaft bearings, then place the crankshaft on the cylinder block sub-assembly.
    2. Confirm the projections and numbers of the crankshaft bearing caps and install the 4 crankshaft bearing caps to the cylinder block sub-assembly.
      GTY814133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

    3. Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap set bolts.
    4. Temporarily install the 8 crankshaft bearing cap set bolts to the inside positions.
    5. Push the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and the cylinder block sub-assembly is less than 6 mm (0.236 in.) by using the 2 inside crankshaft bearing cap set bolts as a guide.
      GTY792895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Type A
      *B Type B
      *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
    6. Using a plastic hammer, lightly tap the crankshaft bearing cap to ensure a proper fit.
      GTY552481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Apply a light coat of engine oil to the threads and under the heads of the 8 crankshaft bearing cap set bolts.
    8. Install the crankshaft bearing cap bolt (A) and 7 crankshaft bearing cap bolts (B) to the outside positions.
      GTY800476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

    9. Uniformly tighten the 16 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.
      Fig 1: Crankshaft Bearing Cap Set Bolts Tightening Sequence
      GTY775539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT: 

      If a crankshaft bearing cap bolt cannot be tightened to the specified torque, replace it.

    10. Mark the front of the crankshaft bearing cap set bolts with paint.
      GTY792546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b Turn 90°
      Front of Engine
    11. Tighten the crankshaft bearing cap set bolts 90° in the order shown in the illustration.
    12. Check that the paint marks are now at a 90° angle to the front.
    13. Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.
      Fig 2: Crankshaft Bearing Cap Set Bolts Tightening Sequence
      GTY833947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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.)
    14. Check that the crankshaft turns smoothly.
    15. Check the crankshaft thrust clearance.

      See step  7

  8. INSTALL CONNECTING ROD BEARING 
    1. Install the connecting rod bearings to the connecting rod and connecting rod cap.
    2. Using a vernier caliper, measure the distance between the connecting rod, connecting rod cap edges and the connecting rod bearing edge.
      GTY803566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Vernier Caliper

      Difference Between (A) and (B)

      0.7 mm (0.0276 in.) or less

      NOTE:

      Do not apply engine oil to the connecting rod bearings or the contact surfaces.

  9. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD 
    1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
    2. Position the piston rings so that the ring ends are as shown in the illustration.
      NOTE:

      Do not align the ring ends.

      GTY829948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Lower Side Rail
      *4 Upper Side Rail
      *5 Expander
      *a Front Mark
    3. Using a piston ring compressor, push the piston and connecting rod sub-assembly into the cylinder with the front mark of the piston facing the front of the engine.
      GTY809544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a for Bank 1
      *b for Bank 2
      *c Front Mark
      Front of Engine
      NOTE:

      Match the connecting rod cap with the connecting rod sub-assembly.

    4. Check that the front mark of the connecting rod cap is facing the front of the engine.
      GTY780178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark
      Front of Engine
    5. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
    6. Install the 2 connecting rod bolts.

      HINT: 

      The connecting rod bolts are tightened in 2 progressive steps.

    7. Step 1:
      1. Alternately tighten the 2 connecting rod bolts in several steps.
        GTY125277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    8. Step 2:
      1. Mark the front side of each connecting rod cap bolt with paint.
        GTY792546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Paint Mark
        *b Turn 90°
        Front of Engine
      2. Further tighten the connecting rod bolts 90° as shown in the illustration.
      3. Check that the paint marks are now at a 90° angle to the front.
    9. Confirm that the crankshaft turns smoothly.
    10. Check the connecting rod thrust clearance.

      See step  1

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