Reassembly [10/2015 - ]: Procedure

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INSTALL STUD BOLT

NOTE:

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

Using E6 and E8 "TORX" socket wrenches, install the 4 stud bolts.

Courtesy 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)

INSTALL OIL PIPE SUB-ASSEMBLY

Install a new oil pipe gasket to the oil pipe sub-assembly.

Temporarily install the oil pipe sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

	Hexagon Socket Head Cap Bolt
	Bolt

Temporarily install the 3 bolts in the order shown in the illustration.
Using a 5 mm hexagon wrench, temporarily install the 4 hexagon socket head cap bolts in the order shown in the illustration.

Tighten the oil pipe sub-assembly.

Fig 1: Hexagon Socket Head Cap Bolts Tightening Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

	Hexagon Socket Head Cap Bolt
	Bolt

Using a 5 mm hexagon wrench, tighten the 4 hexagon socket head cap bolts in the order shown in the illustration.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
Tighten the 3 bolts in the order shown in the illustration.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

INSTALL PISTON

HINT:

Perform "Inspection After Repairs" after replacing the piston.

Refer to INITIALIZATION [10/2015 - 10/2018] , or refer to INITIALIZATION [10/2018 - 11/2019] , or refer to INITIALIZATION [11/2019 - ]

Using a small screwdriver, install a new piston pin hole snap ring at one end of the piston pin hole.
Gradually heat the piston to between 80 and 90°C (176 to 194°F).
Coat the piston, piston pin and connecting rod with engine oil.

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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Front Mark

HINT:

The piston and piston pin are a matched set.

Using a small screwdriver, install a new piston pin hole snap ring on the other side of the piston pin hole.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Piston Pin Hole Snap Ring
*a	Cutout

HINT:

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

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.

INSTALL PISTON RING SET

HINT:

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

Refer to INITIALIZATION [10/2015 - 10/2018] , or refer to INITIALIZATION [10/2018 - 11/2019] , or refer to INITIALIZATION [11/2019 - ]

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Upper Oil Ring Side Rail
*2	Oil Ring Expander
*3	Lower Oil Ring Side Rail

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.

Courtesy 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.

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	Upper Oil Ring Side Rail
*4	Lower Oil Ring Side Rail
*5	Oil Ring Expander
*a	Front Mark
	Front of Engine

HINT:

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

INSTALL CRANKSHAFT PULLEY SET KEY
1. Install the 2 crankshaft pulley set keys to the crankshaft.

INSTALL CRANKSHAFT BEARING

Clean the main journal and both surfaces of the crankshaft bearing.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Correct
*b	Incorrect

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.

HINT:

The colors of the crankshaft bearing and No. 2 crankshaft bearing differ depending on the journal position.

Journal Position	Crankshaft Bearing	No. 2 Crankshaft Bearing
No. 1	Black	Black
No. 2	Silver	Silver
No. 3	Black	Silver
No. 4	Silver	Silver
No. 5	Silver	Black

Install the No. 2 crankshaft bearing to the crankshaft bearing cap.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Vernier Caliper

Using a vernier caliper, measure the distance between the edges of the crankshaft bearing cap and No. 2 crankshaft bearing.
Difference between (A) and (B)

0 to 0.7 mm (0 to 0.0276 in.)
NOTE:
- Do not apply engine oil to the No. 2 crankshaft bearings or 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.

INSTALL CRANKSHAFT THRUST WASHER

Apply engine oil to the 2 crankshaft thrust washers.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Oil Groove

Install the 2 crankshaft thrust washers to the No. 3 journal of the cylinder block sub-assembly with the oil grooves facing outward.

INSTALL CRANKSHAFT

Apply engine oil to the crankshaft bearing, and then install the crankshaft to the cylinder block sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Front Mark

Confirm the front marks and numbers, and then install the crankshaft bearing caps to the cylinder block sub-assembly with the front marks positioned as shown in the illustration.
Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts.
Tighten the crankshaft bearing cap bolts.
HINT:

The crankshaft bearing cap bolts are tightened in 3 progressive steps.
1. Fig 2: Crankshaft Bearing Cap Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Step 1:
  
  Install and uniformly tighten the 10 crankshaft bearing cap bolts in several steps in the order shown in the illustration.
  
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
2. Step 2:
  Further tighten the 10 crankshaft bearing cap bolts in the order shown in the illustration.
  
  Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)
  
  If a crankshaft bearing cap bolt cannot be tightened to the specified torque, replace it.
3. Mark the front of each crankshaft bearing cap bolt with paint.
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 of the engine.
Check that the crankshaft turns smoothly.

INSTALL CONNECTING ROD BEARING

Clean the connecting rod bearing contact surface of the connecting rod and connecting rod cap, and both surfaces of both connecting rod bearings.

*a	Vernier Caliper

Install the connecting rod bearings to the connecting rods and connecting rod caps.
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.
Difference between (A) and (B)

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.

INSTALL PISTON WITH CONNECTING ROD

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

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

*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 of Engine

HINT:

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

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 the front of the engine.

*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.

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

*a	Front Mark

NOTE:

Match the connecting rod cap with the correct connecting rod.

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

Install the connecting rod bolts.

HINT:

The connecting rod bolts are tightened in 2 progressive steps.

Step 1:
Install and alternately tighten the connecting rod bolts in several steps.

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

Mark the front of each connecting rod bolt with paint.

*a	Paint Mark
*b	90°
	Front of Engine

Step 2:
Tighten the connecting rod cap bolts 90°.
Check that the paint marks are now at a 90° angle to the front of the engine.

Check that the crankshaft turns smoothly.