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Reassembly [12/2023 - ]: Procedure

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  1. INSTALL STRAIGHT PIN 
    1. GTY1233441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Side *b Rear Side
      *c Top Side *d Bottom Side
      *e RH Side *f 23 mm (0.906 in.)
      *g 6 mm (0.236 in.) *h 11 mm (0.433 in.)
      *i 9 mm (0.354 in.) - -
      1. Using a plastic hammer, tap in 15 new straight pins to the cylinder block sub-assembly.

        Standard Protrusion Height

        Item Specified Condition
        Pin (A) 23 mm (0.906 in.)
        Pin (B) 6 mm (0.236 in.)
        Pin (C) 11 mm (0.433 in.)
        Pin (D) 9 mm (0.354 in.)
  2. INSTALL STUD BOLT 
    1. GTY1230943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a LH Side *b 23 mm (0.906 in.)
      *c 15 mm (0.591 in.) *d 40 mm (1.57 in.)
      1. Using an E10 "TORX" socket wrench, install the stud bolt to the cylinder block sub-assembly.

        Torque: 17 N.m (173 kgf/cm, 13 ft.lbf) 

  3. INSTALL CONNECTING ROD SMALL END BUSH 
    1. GTY1235468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil Hole - -
      1. Align the oil hole of a new connecting rod small end bush with the oil hole of the connecting rod.
      2. Using SST and a press, install the connecting rod small end bush.
        • 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.

        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.

  4. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. GTY1239924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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) 

  5. INSTALL PISTON PIN 
    HINT: 
    Perform "Inspection After Repair" after replacing the piston.
    Refer to INITIALIZATION [12/2023 - ]
    1. GTY1238747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 1 *B for Bank 2
      *a Front Mark *b Cutout
      1. Using a screwdriver, install a new piston pin hole snap ring (rear side) at one end of the piston pin hole.

        HINT: 

        Perform this procedure only when replacement of the piston pin hole snap ring (rear side) is necessary.

      2. Gradually heat the piston to approximately 80°C (176°F).
        WARNING:

        Be sure to wear protective gloves.

      3. Coat the piston pin and connecting rod small end bush with engine oil.
      4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

        HINT: 

        The piston and piston pin are a matched set.

      5. Using a screwdriver, install a new piston pin hole snap ring (front side) at the other end of the piston pin hole.
        NOTE:

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

  6. INSTALL PISTON RING SET 
    HINT: 
    Perform "Inspection After Repair" after replacing the piston ring.
    Refer to INITIALIZATION [12/2023 - ]
    1. GTY1238750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Upper Side Rail *2 Oil Ring Expander
      *3 Lower Side Rail *4 No. 1 Compression Ring
      *5 No. 2 Compression Ring - -
      *a Oil Ring *b Code Mark
      1. Install the oil ring expander, upper side rail and lower side rail by hand.
      2. Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring as shown in the illustration.
        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.
    2. GTY1235266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 1 *B for Bank 2
      *1 No. 1 Compression Ring End Gap *2 No. 2 Compression Ring End Gap
      *3 Lower Side Rail End Gap *4 Oil Ring Expander End Gap
      *5 Upper Side Rail End Gap - -
      *a Front Mark - -
      1. Position the piston ring set so that the ring ends are as shown in the illustration.
        NOTE:

        Do not align the ring ends.

  7. INSTALL CRANKSHAFT BEARING 
    1. GTY1231841Courtesy 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 (0.823 in.) *d 17.9 mm (0.705 in.)
      1. Clean the main journals and both surfaces of the crankshaft bearings.
        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. GTY1239396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil Groove *b Upper Crankshaft Bearing
      *c Correct *d Incorrect
      *e Vernier Caliper *f Number Mark
      1. Install the upper crankshaft bearing.
        1. Install the 4 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.
      2. Install the lower crankshaft bearing.
        1. Install the 4 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.
  8. INSTALL CRANKSHAFT THRUST WASHER SET 
    1. GTY1237621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil Groove - -
      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.
  9. INSTALL CRANKSHAFT 
    1. GTY1233991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Projection *b Number Mark
      *c Less than 6 mm (0.236 in.) *d Bolt Length
      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.

        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 8 crankshaft bearing cap set bolts.
      4. Temporarily install the 8 crankshaft bearing cap set bolts to the inside positions.

        Bolt Length

        100 to 102 mm (3.94 to 4.02 in.)

      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.
    2. GTY1230813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt Length - -
      1. Using a plastic hammer, lightly tap the crankshaft bearing cap to ensure a proper fit.
      2. Apply a light coat of engine oil to the threads and under the heads of the 8 crankshaft bearing cap set bolts.
      3. Temporarily install the 8 crankshaft bearing cap set bolts to the outside positions.

        Bolt Length

        105.5 to 107.5 mm (4.15 to 4.23 in.)

    3. Fig 1: Crankshaft Bearing Cap Set Bolts Tightening Sequence
      GTY1228132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Turn 90°
      Front of Engine - -
      1. Install the crankshaft bearing cap set bolts.

        HINT: 

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

      2. Step 1:
        1. Uniformly tighten the 16 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.

        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.

      3. Step 2:
        1. Mark the front of the crankshaft bearing cap set bolts with paint.
        2. Tighten the crankshaft bearing cap set bolts 90° in the order shown in the illustration.
        3. Check that the paint marks are now at a 90° angle to the front.
      4. 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.

        Torque: 51.5 N.m (525 kgf/cm, 38 ft.lbf) 

        Bolt Length

        Bolt Length
        except (A) 30 mm (1.18 in.)
        (A) 45 mm (1.77 in.)
      5. Check that the crankshaft turns smoothly.
      6. Check the crankshaft thrust clearance.

        See step  8

  10. INSTALL CONNECTING ROD BEARING 
    1. GTY1240802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Vernier Caliper - -
      1. Install the connecting rod bearings to the connecting rod and connecting rod bearing cap.
      2. Using a vernier caliper, measure the distance between the connecting rod and connecting rod cap edges and the connecting rod bearing edge.

        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.

  11. INSTALL PISTON WITH CONNECTING ROD 
    1. GTY1235265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 1 *B for Bank 2
      *1 No. 1 Compression Ring End Gap *2 No. 2 Compression Ring End Gap
      *3 Lower Side Rail End Gap *4 Oil Ring Expander End Gap
      *5 Upper Side Rail End Gap - -
      *a Front Mark - -
      1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
      2. Position the piston ring set so that the ring ends are as shown in the illustration.
        NOTE:

        Do not align the ring ends.

    2. GTY1229281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 1 *B for Bank 2
      *a Front Mark - -
      Front of Engine - -
      1. Using a piston ring compressor, push the piston and connecting rod into the cylinder with the front mark of the piston facing the front of the engine.
        NOTE:

        Match the connecting rod bearing cap with the connecting rod.

    3. Fig 2: Connecting Rod Bolts Tightening Sequence
      GTY1238897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark *b Paint Mark
      *c Turn 90° - -
      Front of Engine - -
      1. Check that the front mark of the connecting rod bearing cap is facing the front of the engine.
      2. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
      3. Install the 2 connecting rod bolts.

        HINT: 

        The connecting rod bolts are tightened in 2 progressive steps.

      4. Step 1:
        1. Alternately tighten the 2 connecting rod bolts in several steps.

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

      5. Step 2:
        1. Mark the front of each connecting rod bolt with paint.
        2. 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.
      6. Confirm that the crankshaft turns smoothly.
      7. Check the connecting rod thrust clearance.

        See step  1

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