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Reassembly [11/2021 - ]: Procedure

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  1. INSTALL RING PIN 
    1. GTY1075678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Top Side *b Bottom Side
      *c Protrusion Height *d 14 mm (0.551 in.)
      *e 12 mm (0.472 in.) - -
      1. Using a plastic hammer, install 12 new ring pins.

        Standard Protrusion Height

        5.0 to 7.0 mm (0.197 to 0.276 in.)

  2. INSTALL STRAIGHT PIN 
    1. GTY1204703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Side *b Rear Side
      *c LH Side *d Bottom Side
      *e RH Side *f Protrusion Height
      *g 22 mm (0.866 in.) *h 10 mm (0.394 in.)
      *i 14 mm (0.551 in.) *j 6.0 mm (0.236 in.)
      *k 7.4 mm (0.291 in.) - -
      1. Using a plastic hammer, install 10 new straight pins.

        Standard Protrusion Height

        Straight Pin Specified Condition
        (A) 11.0 to 13.0 mm (0.433 to 0.512 in.)
        (B) 5.0 to 7.0 mm (0.197 to 0.276 in.)
  3. INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY 
    1. GTY1075940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 5 mm hexagon socket wrench, install the 4 No. 2 oil nozzle sub-assemblies to the cylinder block sub-assembly with the 4 bolts.

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

  4. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. GTY1075883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 5 mm hexagon socket wrench, install the 4 No. 1 oil nozzle sub-assemblies to the cylinder block sub-assembly with the 4 bolts.

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

  5. INSTALL PISTON PIN 
    1. GTY1074911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Piston Pin Hole Snap Ring - -
      *a Cutout *b Front Mark
      1. Using a screwdriver with its tip wrapped with protective tape, install a new piston pin hole snap ring to the piston pin hole on the rear side of the piston.
      2. Gradually heat the piston to between 80 and 90°C (176 and 194°F).
        WARNING:

        Be sure to wear protective gloves.

      3. Apply a light coat of engine oil to the piston pin and connecting rod.
      4. Align the cutout of the piston and front mark of the 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.
        NOTE:

        Do not change the combination of the pistons and piston pins.

      5. Using a screwdriver with its tip wrapped with protective tape, install a new piston pin hole snap ring to the piston pin hole on the front side of the piston.
        NOTE:

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

    2. Perform "Inspection After Repair" after replacing the piston.

      Refer to INITIALIZATION [11/2021 - ]

  6. INSTALL PISTON RING SET 
    1. GTY1075435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Upper Side Rail *2 Lower Side Rail
      *3 Oil Ring Expander - -
      *a Ring End *b Correct
      *c Incorrect *d Paint (Orange)
      *e Paint (Light Blue) *f Upward
      *g Press around the circumference *h Push with Thumb
      1. Install the oil ring expander by hand.
      2. Install upper side rail and lower side rail to the piston.
        NOTE:

        Make sure to install the upper side rail and lower side rail in the correct direction. Also, when installing the upper side rail and lower side rail, the oil ring expander may move and overlap. If this occurs, part of the side rail may greatly protrude.

      3. Check that the ends of the oil ring expander are not overlapping and that the upper side rail and lower side rail are securely installed into the groove.
        NOTE:
        • After installing the oil ring expander, upper side rail and lower side rail, press around the circumference with a finger to check that they are securely installed into the groove.
        • If the oil ring expander is not securely installed into the groove, check that the ends of the oil ring expander are not overlapping.
        • If the ends of the oil ring expander are overlapping, remove the upper side rail and lower side rail and realign the oil ring expander using a screwdriver.
    2. GTY1075418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Compression Ring *2 No. 2 Compression Ring
      *a Code Mark *b Paint Mark
      *c Oil Ring Expander End Gap *d Upper Side Rail End Gap
      *e Lower Side Rail End Gap *f Front Mark
      *g No. 1 Compression Ring End Gap *h No. 2 Compression Ring End Gap
      Upward Front of Engine
      1. 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.

        Piston Ring Mark

        Item Code Mark Paint Mark
        No. 1 Compression Ring 1N Orange
        No. 2 Compression Ring 2N Pink
      2. Position the piston rings so that the ring ends are as shown in the illustration.
    3. Perform "Inspection After Repair" after replacing the piston and piston ring.

      Refer to INITIALIZATION [11/2021 - ]

  7. INSTALL CRANKSHAFT BEARING 
    1. GTY1075173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Clean the main journal and both surfaces of the crankshaft bearings, No. 2 crankshaft bearings and crankshaft bearing cap.
    2. GTY1075830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Correct *b Incorrect
      *c Vernier Caliper - -
      1. Type A:

        HINT: 

        For type A, the same color is used for all of the crankshaft bearings.

        1. Install the 5 crankshaft bearings to the cylinder block sub-assembly as shown in the illustration.
          NOTE:

          Do not apply engine oil to the 5 crankshaft bearings or the contact surfaces.

          HINT: 

          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.

      2. Type B:

        HINT: 

        For type B, a different color is used for each crankshaft bearing as listed in the below table.

        CRANKSHAFT BEARING COLOR:

        Journal Position Crankshaft Bearing Color
        No. 1 Gray
        No. 2 Silver
        No. 3 Gray
        No. 4 Silver
        No. 5 Gray
        1. Install the 5 crankshaft bearings to the cylinder block sub-assembly as shown in the illustration.
          NOTE:

          Do not apply engine oil to the 5 crankshaft bearings or the contact surfaces.

          HINT: 

          The color of the No. 1, No. 3 and No. 5 journal bearings are different from that of the No. 2 and No. 4 journal bearings. Be sure to check the color before installation.

          CRANKSHAFT BEARING COLOR:

          Journal Position Crankshaft Bearing Color
          No. 1 Gray
          No. 2 Silver
          No. 3 Gray
          No. 4 Silver
          No. 5 Gray
      3. Using a vernier caliper, measure the distance between the cylinder block sub-assembly edge and crankshaft bearing edge.

        Difference between (A) and (B)

        0 to 0.7 mm (0 to 0.0276 in.)

    3. GTY1075245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Vernier Caliper - -
      1. Install the 5 No. 2 crankshaft bearings to the 5 crankshaft bearing caps.
        NOTE:

        Do not apply engine oil to the No. 2 crankshaft bearings or the contact surfaces.

        HINT: 

        The color of the No. 1, No. 3 and No. 5 journal bearings are different from that of the No. 2 and No. 4 journal bearings. Be sure to check the color before installation.

        CRANKSHAFT BEARING COLOR:

        Journal Position Crankshaft Bearing Color
        No. 1 Gray
        No. 2 Silver
        No. 3 Gray
        No. 4 Silver
        No. 5 Gray
      2. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and No. 2 crankshaft bearing edge.

        Difference between (A) and (B)

        0 to 0.9 mm (0 to 0.0354 in.)

  8. INSTALL CRANKSHAFT 
    1. GTY1075566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply engine oil to the 5 No. 2 crankshaft bearings.
      2. Install the crankshaft.
  9. INSTALL CRANKSHAFT THRUST WASHER 
    1. GTY1075785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil Groove - -
      1. Apply engine oil to the 2 crankshaft thrust washers.
      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.
        NOTE:

        Make sure the crankshaft thrust washers are installed correctly.

  10. INSTALL CRANKSHAFT BEARING CAP 
    1. Fig 1: Crankshaft Bearing Cap Bolts Tightening Sequence
      GTY1075690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark *b Paint Mark
      *c 90° *d Front of Engine
      1. Apply engine oil to the 5 No. 2 crankshaft bearings.
      2. Confirm the front marks and numbers, and install the 5 crankshaft bearing caps to the cylinder block sub-assembly with the front marks positioned 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 set bolts.
      4. Uniformly install and tighten the 10 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) 

        NOTE:

        While performing tightening, check that the crankshaft continues to turn smoothly.

      5. Mark the front of the crankshaft bearing cap set bolts with paint.
      6. Tighten the 10 crankshaft bearing cap set bolts 90° as shown in the illustration.
      7. Check that the paint marks are now at a 90° angle to the front.
      8. Check that the crankshaft turns smoothly.
  11. INSTALL CONNECTING ROD BEARING 

    HINT: 

    There are two types of connecting rod sub-assemblies; cracking connecting rods and other than cracking connecting rods.

    GTY1104336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *A except Cracking Connecting Rod *B Cracking Connecting Rod
    *a w/ Pin *b w/o Pin
    1. GTY1132319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Vernier Caliper - -
      1. Clean the connecting rod bearing contact surfaces of the connecting rod and connecting rod cap, and both surfaces of the 2 connecting rod bearings.
      2. Install the 8 connecting rod bearings to the 4 connecting rods and 4 connecting rod caps.
      3. except Cracking Connecting Rod:
        1. Using a vernier caliper, measure the distance between the edges of the connecting rod 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 bearing installation surface of the connecting rod and the connecting rod cap and to the back surface of the connecting rod bearing.
          • Make sure to perform this measurement to determine if the connecting rod bearing is centered in the connecting rod.
        2. Using a vernier caliper, measure the distance between 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 bearing installation surface of the connecting rod and the connecting rod cap and to the back surface of the connecting rod bearing.
          • Make sure to perform this measurement to determine if the connecting rod bearing is centered in the connecting rod cap.
      4. Cracking Connecting Rod:
        NOTE:

        Align the end surfaces of the connecting rod bearing with the V-shaped ends (center of the big end hole) to prevent burrs on the back of the connecting rod bearing from being created after fastening the connecting rod bolt.

        GTY1103046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Connecting Rod *2 Connecting Rod Cap
        *a Alignment surface *b Center of the big end hole
        1. Using a vernier caliper, measure the distance between the edges of the connecting rod 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 bearing installation surface of the connecting rod and the connecting rod cap and to the back surface of the connecting rod bearing.
          • Make sure to perform this measurement to determine if the connecting rod bearing is centered in the connecting rod.
        2. Using a vernier caliper, measure the distance between 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 bearing installation surface of the connecting rod and the connecting rod cap and to the back surface of the connecting rod bearing.
          • Make sure to perform this measurement to determine if the connecting rod bearing is centered in the connecting rod cap.
  12. INSTALL PISTON WITH CONNECTING ROD 

    HINT: 

    There are two types of connecting rod sub-assemblies; cracking connecting rods and other than cracking connecting rods.

    GTY1104336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *A except Cracking Connecting Rod *B Cracking Connecting Rod
    *a w/ Pin *b w/o Pin
    1. GTY1075959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No. 1 Compression Ring End Gap *b No. 2 Compression Ring End Gap
      *c Oil Ring Expander End Gap *d Upper Side Rail End Gap
      *e Lower Side Rail End Gap *f Front Mark
      Front of Engine - -
      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.
    2. GTY1075532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil Ring Expander *b Ring End
      *c Correct *d Incorrect
      *e Front Mark *f Press around the circumference
      *g Push with Thumb - -
      1. Confirm that the ends of the oil ring expander are not overlapping and that the upper side rail and lower side rail are securely installed into the groove.
        NOTE:
        • After installing the oil ring expander, upper side rail and lower side rail, press around the circumference with a finger to check that they are securely installed into the groove.
        • If the oil ring expander is not securely installed into the groove, check that the ends of the oil ring expander are not overlapping.
        • If the ends of the oil ring expander are overlapping, remove the upper side rail and lower side rail and realign the oil ring expander using a screwdriver.
      2. except Cracking Connecting Rod:
        1. Using a piston ring compressor, push the correctly numbered piston with connecting rod into the cylinder with the front marks of each piston with connecting rod facing the front of the engine.
          NOTE:
          • When inserting the piston with connecting rod into the cylinder block sub-assembly, make sure the connecting rod does not contact the No. 1 oil nozzle sub-assembly or No. 2 oil nozzle sub-assembly.
          • Match each connecting rod cap to the correct connecting rod.
      3. Cracking Connecting Rod:
        1. Using a piston ring compressor, push the correctly numbered piston with connecting rod into the cylinder with the front marks of each piston with connecting rod facing the front of the engine.
          NOTE:
          • When inserting the piston with connecting rod into the cylinder block sub-assembly, make sure the connecting rod does not contact the No. 1 oil nozzle sub-assembly or No. 2 oil nozzle sub-assembly.
          • Match each connecting rod cap to the correct connecting rod.
          • As foreign matter may occur from the fractured surface, make sure to remove all foreign matter before installing. Be careful not to damage the fractured surface.
  13. INSTALL CONNECTING ROD BEARING CAP 
    1. except Cracking Connecting Rod:
      GTY1130663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark *b Paint Mark
      *c 90° - -
      Front of Engine - -
      1. Check that the front mark of the connecting rod cap is facing the correct direction, and install the connecting rod cap to the connecting rod.
      2. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
      3. Using an E12 "TORX" socket wrench, install and uniformly tighten the 8 connecting rod bolts.

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

      4. Using an E12 "TORX" socket wrench, alternately tighten the 8 connecting rod bolts.

        Torque: 38 N.m (387 kgf/cm, 28 ft.lbf) 

      5. Mark the front of the connecting rod bolts with paint.
      6. Tighten the connecting rod bolts 90° as shown in the illustration.
      7. Check that the paint marks are now at a 90° angle to the front.
      8. Check that the crankshaft turns smoothly.
    2. Cracking Connecting Rod:
      GTY1130663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark *b Paint Mark
      *c 90° - -
      Front of Engine - -
      1. Check that the front mark of the connecting rod cap is facing the correct direction, and install the connecting rod cap to the connecting rod.
      2. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
      3. Using an E12 "TORX" socket wrench, install and uniformly tighten the 8 connecting rod bolts.

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

        NOTE:

        Do not use electric or air powered tools.

      4. Using an E12 "TORX" socket wrench, alternately tighten the 8 connecting rod bolts.

        Torque: 38 N.m (387 kgf/cm, 28 ft.lbf) 

      5. Mark the front of the connecting rod bolts with paint.
      6. Tighten the connecting rod bolts 90° as shown in the illustration.
      7. Check that the paint marks are now at a 90° angle to the front.
      8. Check that the crankshaft turns smoothly.
  14. INSTALL NO. 1 VENTILATION CASE 
    1. WARNING:
      • When the No. 1 ventilation case is fastened using only bolt A:

        Perform this procedure only when replacement of the No. 1 ventilation case is necessary.

      • When the No. 1 ventilation case is fastened using bolt B:

        Do not remove and install the No. 1 ventilation case.
      GTY1090642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt A *b Bolt B

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

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