Cylinder Block ASSY (3MZ-FE): Overhaul

WARNING: This page is about a different car, the 2004 Lexus ES 330. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
REMOVE WATER SEAL PLATE
REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO. 1 PLUG
1. Using a socket hexagon wrench 10, remove the screw plug.
REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO. 2 PLUG
1. Using a socket hexagon wrench 10, remove the screw plug.
REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO. 3 PLUG
1. Using a socket hexagon wrench 10, remove the screw plug.
INSPECT CONNECTING ROD THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
  
  Fig 1: Measuring Thrust Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard thrust clearance:
  
  0.15 to 0.30 mm (0.0059 to 0.0118 in.)
  
  Maximum thrust clearance: 0.35 mm (0.0138 in.)
  - If the thrust clearance is greater than maximum, replace the connecting rod.
  - If necessary, replace the crankshaft.
INSPECT CONNECTING ROD OIL CLEARANCE
1. Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
2. Remove the cap bolts.
3. Clean the crank pin, bearing and connecting rod.
4. Check the crank pin and bearing for pitting and scratches.
5. Lay a strip of Plastigage across the crank pin.
  
  Fig 2: Identifying Plastigage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Check that the protrusion of the cap is facing the correct direction.
7. Apply a light coat of engine oil to the threads of the cap bolts.
  
  Fig 3: Checking Protrusion Of Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Tighten the cap bolts in several steps by the specified torque.
  Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)
  
  Fig 4: Tightening Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Mark the front side of each cap bolt with paint.
10. Retighten the cap bolts by 90° as shown in the illustration.
  NOTE: Do not turn the crankshaft.
11. Remove the cap bolts, cap and lower bearing.
  
  Fig 5: Retightening Cap Bolts By 90deg
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Measure the Plastigage at its widest point.
  Standard oil clearance:
  
  0.038 to 0.066 mm (0.0015 to 0.0026 in.)
  
  Maximum oil clearance: 0.08 mm (0.0031 in.)
  
  Fig 6: Measuring Plastigage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Completely remove the Plastigage.
  - If the oil clearance is greater that maximum, replace the bearing.
  - If necessary, grind or replace the crankshaft.
  HINT:
  
  Fig 7: Locating Number Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If replacing the bearing, replace it with one having the same number as marked on the connecting rod. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.
  
  Reference:
  
  Standard bearing center wall thickness:
  
  Fig 8: Thickness Specification Chart
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PISTON SUB-ASSY W/CONNECTING ROD
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Push out the piston and connecting rod assembly from the top of the cylinder block.
  HINT:
  - Keep the bearings, connecting rod and cap together.
  - Arrange the piston and connecting rod assemblies in the correct order so they can be returned to the original locations when reassembling.
    
    Fig 9: Removing Carbon From Top Of Cylinder Using Ridge Remover
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONNECTING ROD BEARING
REMOVE PISTON RING SET
1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the 2 side rails and expander by hand.
  
  Fig 10: Removing Compression Rings Using Piston Ring Expander
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PISTON PIN HOLE SNAP RING
1. Using a small screwdriver, pry out the 2 snap rings.
  
  Fig 11: Prying Out Snap Rings Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE W/PIN PISTON SUB-ASSY
1. Gradually heat the piston up to approximately 80°C (176°F).
  
  Fig 12: Removing Piston Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin, then remove the connecting rod.
  HINT:
  - The piston and piston pin are a matched set.
  - Store the pistons, piston pins, rings, connecting rods and bearings in the correct order so that they can be returned to the original locations when reassembling.
    
    Fig 13: Lightly Taping Out Piston Pin Using Hammer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
  Standard thrust clearance:
  
  0.04 to 0.24 mm (0.0016 to 0.0094 in.)
  
  Maximum thrust clearance: 0.30 mm (0.0118 in.)
  
  If the thrust clearance is greater than maximum, replace the thrust washers as a set.
  
  HINT:
  
  The thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 in.).
  
  Fig 14: Measuring Thrust Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT
1. Using several steps, loosen and remove the 8 bearing cap bolts and 8 seal washers uniformly in the sequence shown in the illustration.
  
  Fig 15: Identifying Loosening Sequence Of Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence shown in the illustration.
  
  Fig 16: Identifying Loosening Sequence Of Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, pry out the bearing caps. Remove the 4 bearing caps and 4 lower bearings.
  NOTE:
  - Carefully pry out the main bearing cap by alternately lifting each end of the bearing cap little by little.
  - Be careful not to damage the joint surface of the cylinder block and bearing cap.
    
    Fig 17: Prying Out Bearing Caps Using Screwdriver
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Fig 18: Identifying Joint Surface
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT THRUST WASHER SET
REMOVE CRANKSHAFT BEARING
INSPECT CYLINDER BLOCK FOR FLATNESS
1. Using a precision straight edge and feeler gauge, measure the warpage on the surface which contacts the cylinder head gasket.
  Maximum warpage: 0.05 mm (0.0020 in.)
  
  If the warpage is greater than maximum, replace the cylinder block.
  
  Fig 19: Inspecting Cylinder Block For Flatness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER BORE
1. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
  Standard diameter:
  
  92.000 to 92.012 mm (3.6220 to 3.6225 in.)
  
  Maximum diameter: 92.132 mm (3.6272 in.)
  
  If the average diameter of 4 positions is greater than maximum, replace the cylinder block.
  
  Fig 20: Measuring Cylinder Bore Diameter Using Cylinder Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT W/PIN PISTON SUB-ASSY
1. Using a micrometer, measure the diameter of the piston. Align the micrometer so it is 13.0 mm (0.512 in.) from the bottom of the piston and at a right angle (90°) to the piston pin holes as illustrated.
  Piston diameter:
  
  91.953 to 91.967 mm (3.6202 to 3.6207 in.)
  
  Fig 21: Measuring Diameter Of Piston Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PISTON OIL CLEARANCE
1. Substract the piston diameter measurement from the cylinder bore diameter measurement.
  Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.)
  
  Maximum oil clearance: 0.13 mm (0.0051 in.)
  - If the oil clearance is greater than maximum, replace all the 6 pistons.
  - If necessary, replace the cylinder block.
INSPECT CONNECTING ROD SUB-ASSY
1. Using a rod aligner and feeler gauge, check the connecting rod alignment.
  1. Inspect for misalignment.
    Maximum misalignment:
    
    0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
    
    If misalignment is greater than maximum, replace the connecting rod assembly.
    
    Fig 22: Inspecting Connecting Rod Misalignment
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Inspect for twist.
    Maximum twist:
    
    0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
    
    If the twist is greater than maximum, replace the connecting rod assembly.
    
    Fig 23: Inspecting For Twist
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PISTON PIN OIL CLEARANCE
1. Using a caliper gauge, measure the inside diameter of the bushing.
  Bushing inside diameter:
  
  22.005 to 22.014 mm (0.8663 to 0.8667 in.)
  
  Fig 24: Measuring Inside Diameter Of Bushing Using Caliper Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the piston pin diameter.
  Piston pin diameter:
  
  21.997 to 22.006 mm (0.8660 to 0.8664 in.)
3. Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
  Standard oil clearance:
  
  0.005 to 0.011 mm (0.0002 to 0.0004 in.)
  
  Maximum oil clearance: 0.05 mm (0.0020 in.)
  - If the oil clearance is greater than maximum, replace the bushing.
  - If necessary, replace the piston and piston pin together.
    
    Fig 25: Measuring Piston Pin Diameter Using Micrometer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONNECTING ROD SMALL END BUSHING
1. Using SST and a press, press out the bushing.
  SST 09222-30010
  
  Fig 26: Pressing Out Bushing Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONNECTING ROD SMALL END BUSHING
1. Align the oil holes of a new bushing and the connecting rod.
  
  Fig 27: Identifying Oil Holes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in the bushing.
  SST 09222-30010
  
  Fig 28: Pressing In Bushing Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a pin hole grinder, hone the bushing to obtain the standard specified clearance between the bushing and piston pin.
  Standard oil clearance:
  
  0.005 to 0.011 mm (0.0002 to 0.0004 in.)
  
  Fig 29: Honing Bushing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, then push it into the connecting rod with your thumb.
  
  Fig 30: Checking Piston Pin Fit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT RING GROOVE CLEARANCE
1. Using a feeler gauge, measure the clearance between the new piston ring and wall of the ring groove.
  Ring groove clearance:
  
  0.03 to 0.08 mm (0.0012 to 0.0031 in.) for No. 1 ring
  
  0.02 to 0.06 mm (0.0008 to 0.0024 in.) for No. 2 ring
  
  0.03 to 0.11 mm (0.0012 to 0.0043 in.) for oil ring
  
  If the groove clearance is not as specified, replace the piston ring.
  
  Fig 31: Measuring Clearance Between New Piston Ring And Wall Of Ring Groove Using Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PISTON RING END GAP
1. Using a piston, push the piston ring which it is a little below the bottom of the ring travel, where is 110 mm (4.33 in.) from the top of the cylinder block.
  
  Fig 32: Inspecting Piston Ring End Gap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a feeler gauge, measure the end gap.
  Standard end gap:
  
  0.30 to 0.40 mm (0.0118 to 0.0157 in.) for No. 1 ring
  
  0.50 to 0.60 mm (0.0197 to 0.0236 in.) for No. 2 ring
  
  0.15 to 0.40 mm (0.0059 to 0.0157 in.) for oil (side rail) ring
  
  Maximum end gap:
  
  0.95 mm (0.0374 in.) for No. 1 ring
  
  1.05 mm (0.0413 in.) for No. 2 ring
  
  1.00 mm (0.0394 in.) for oil (side rail) ring
  - If the end gap is greater than maximum, replace the piston ring.
  - If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block.
    
    Fig 33: Measuring End Gap Using Feeler Gauge
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CONNECTING ROD BOLT
1. Using vernier calipers, measure the tension portion diameter of the bolt.
  Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.)
  
  Minimum diameter: 7.0 mm (0.276 in.)
  
  If the diameter is less than minimum, replace the bolt.
  
  Fig 34: Measuring Tension Portion Diameter Of Bolt Using Vernier Caliper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT BEARING CAP SET BOLT
1. Using vernier calipers, measure the tension portion diameter of the bolt.
  Standard diameter: 7.5 to 7.6 mm (0.295 to 0.299 in.)
  
  Minimum diameter: 7.2 mm (0.283 in.)
  
  If the diameter is less than minimum, replace the bolt.
  
  Fig 35: Measuring Tension Portion Diameter Of Bolt Using Vernier Caliper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT
1. Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration.
  Maximum circle runout: 0.06 mm (0.0024 in.)
  
  If the circle runout is greater than maximum, replace the crankshaft.
  
  Fig 36: Measuring Circle Runout Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the diameter of each main journal.
  Diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 in.)
  
  If the diameter is not as specified, check the crankshaft oil clearance
3. Check each main journal for taper and out-of-round as shown.
  Maximum taper and out-of-round:
  
  0.02 mm (0.0008 in.)
  
  If the taper and out-of-round is greater than maximum, replace the crankshaft.
  
  Fig 37: Checking Main Journal For Taper And Out-Of-Round
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a micrometer, measure the diameter of each crank pin.
  Diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
  
  If the diameter is not as specified, check the connecting rod oil clearance.
5. Check each crank pin for taper and out-of-round as shown.
  Maximum taper and out-of-round:
  
  0.02 mm (0.0008 in.)
  
  If the taper and out-of-round is greater than maximum, replace the crankshaft.
  
  Fig 38: Checking Crank Pin For Taper And Out-Of-Round
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT OIL CLEARANCE
HINT:

Crankshaft bearings come in widths of 22.4 mm (0.882 in.) and 19.0 mm (0.748 in.). Install the 22.4 mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the bearing caps. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions.
1. Clean each main journal and bearing.
  
  Fig 39: Inspecting Crankshaft Oil Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the key of the bearing with the keyway of the cylinder block, then push in the 4 upper bearings.
  NOTE: Do not apply engine oil to the bearing and its contact surface.
  
  Fig 40: Aligning Key Of Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the key of the bearing with the keyway of the bearing cap, then push in the 4 lower bearings.
  NOTE: Do not apply engine oil to the bearing and its contact surface.
  
  HINT:
  
  A number is marked on each bearing cap to indicate the installation position.
4. Place the crankshaft on the cylinder block.
  
  Fig 41: Identifying Mark Of Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Lay a strip of Plastigage across each journal.
  
  Fig 42: Laying Strip Of Plastigage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Examine the front marks and numbers, then install the bearing caps on the cylinder block.
7. Apply a light coat of engine oil to the threads of the bearing cap bolts.
  
  Fig 43: Applying Light Coat Of Engine Oil To Threads Of Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Temporarily install the 8 bearing cap bolts to the inside positions.
9. Install the bearing cap by hand using the inner bolt as a guide. Stop when the bearing cap is about 6 mm (0.23 in.) away from contact with the cylinder block.
  
  Fig 44: Installing Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Using a plastic-faced hammer, lightly tap the bearing cap to ensure proper fit.
11. Apply a light coat of engine oil to the threads of the bearing cap bolts.
  
  Fig 45: Taping Bearing Cap Using Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Using several steps, install and tighten the 16 bearing cap bolts uniformly in the sequence shown in the illustration.
  Torque: 22 N.m (224 kgf.cm, 16 ft.lbf)
  
  Fig 46: Identifying Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. Mark the front side of the bearing cap bolts with paint.
14. Retighten the bearing cap bolts by 90° in the same sequence as step (I).
15. Check that each painted mark is now at a 90° angle to the front.
  NOTE: Do not turn the crankshaft.
  
  Fig 47: Retightening Bearing Cap Bolts By 90deg
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. Using several steps, install and tighten the 8 bearing cap bolts uniformly in the sequence shown in the illustration.
  Torque: 27 N.m (275 kgf.cm, 20 ft.lbf)
  
  HINT:
  
  Use the short bolt for the position marked with the arrow.
17. Remove the bearing caps.
  
  Fig 48: Installing And Tightening Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. Measure the Plastigage at its widest point.
  Standard oil clearance:
  
  0.014 to 0.034 mm (0.0006 to 0.0013 in.) for No. 1 and No. 2 journals
  
  0.026 to 0.046 mm (0.0010 to 0.0018 in.) for No. 3 and No. 4 journals
  
  Maximum clearance:
  
  0.05 mm (0.0020 in.) for No. 1 and No. 2 journals
  
  0.06 mm (0.0024 in.) for No. 3 and No. 4 journals
  - If the oil clearance is greater than maximum, replace the bearings.
  - If necessary, replace the crankshaft.
  NOTE: Completely remove the Plastigage.
  
  Fig 49: Measuring Plastigage At Its Widest Point
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. If replacing a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the figure Fig 50 below for the appropriate bearing number. The No. 1 and No. 2 journal bearing come in 5 sizes, marked "3", "4", "5", "6" and "7". The No. 3 and No. 4 journal bearings come in 5 standard bearing sizes, marked "1", "2", "3", "4" and "5".
  
  Fig 50: Identifying Number Marks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  No. 1 and No. 2 journal bearings:
  
  Fig 51: 1-2 Journal Bearings Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  EXAMPLE
  
  Imprinted number on the cylinder block is 06
  
  Imprinted number on the crankshaft is 08
  
  6 + 8 = 14
  
  Select the bearing marked "5"
  
  No. 3 and No. 4 journal bearings:
  
  Fig 52: 3-4Journal Bearings Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  EXAMPLE
  
  Imprinted number on the cylinder block is 06
  
  Imprinted number on the crankshaft is 08
  
  6 + 8 = 14
  
  Select the bearing marked "3"
Fig 53: Bearing Specification Table
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON PIN HOLE SNAP RING
1. Using a small screwdriver, install a new snap ring at one end of the piston pin hole.
  HINT:
  
  Be sure that the end gap of the snap ring is not aligned with the pin hole cutout of the piston.
  
  Fig 57: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL W/PIN PISTON SUB-ASSY
1. Gradually heat the piston up to approximately 80°C (176°F).
  
  Fig 58: Installing W/Pin Piston Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the piston pin with engine oil.
3. Align the front marks of the piston and connecting rod, then push in the piston pin with your thumb until the pin contacts the snap ring.
  
  Fig 59: Identifying Front Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON PIN HOLE SNAP RING
1. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.
  HINT:
  
  Be sure that the end of gap of the snap ring is not aligned with the pin hole cutout of the piston.
  
  Fig 60: Installing Piston Pin Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON RING SET
1. Install the expander and 2 side rails by hand.
  
  Fig 61: Installing Compression Rings Using Piston Ring Expander
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a piston ring expander, install the 2 compression rings.
  HINT:
  
  The No. 2 compression ring is installed with the code mark "2A" facing upward as shown in the illustration.
3. Position the piston rings so that the ring ends are arranged as shown in the illustration.
  NOTE: Do not align the ring ends.
  
  Fig 62: Positioning Piston Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONNECTING ROD BEARING
1. Align the key of the bearing with the keyway of the connecting rod or cap.
  NOTE: Clean the backside of the bearing and bearing surface of the connecting rod. The surface should be free of dust and oils.
  
  Fig 63: Installing Connecting Rod Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT BEARING
HINT:

Crankshaft bearings come in widths of 22.4 mm (0.882 in.) and 19.0 mm (0.748 in.). Install the 22.4 mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing caps. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions.
1. Clean each main journal and the bearing.
  
  Fig 64: Installing Crankshaft Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the key of the bearing with the keyway of the cylinder block, then push in the 4 upper bearings.
  NOTE: Do not apply engine oil to the bearing and its contact surface.
  
  Fig 65: Aligning Key Of Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the key of the bearing with the keyway of the bearing cap, then push in the 4 lower bearings.
  NOTE: Do not apply engine oil to the bearing and its contact surface.
  
  HINT:
  
  A number is marked on each bearing cap to indicate the installation position.
  
  Fig 66: Identifying Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT THRUST WASHER SET
1. Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.
  
  Fig 67: Installing Crankshaft Thrust Washer Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 thrust washers on the No. 2 bearing cap with the grooves facing outward.
INSTALL CRANKSHAFT
1. Apply engine oil to the upper bearing, then install the crankshaft on the cylinder block.
  
  Fig 68: Installing Thrust Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Examine the front marks and numbers, then install the bearing caps on the cylinder block.
3. Apply a light coat of engine oil to the threads of the bearing cap bolts.
  
  Fig 69: Applying Light Coat Of Engine Oil
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily install the 8 bearing cap bolts to the inside positions.
5. Install the bearing cap by hand using the inner bolt as a guide. Stop when the bearing cap is about 6 mm (0.23 in.) away from contact with the cylinder block.
  
  Fig 70: Installing Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a plastic-faced hammer, lightly tap the bearing cap to ensure proper fit.
7. Apply a light coat of engine oil to the threads of the bearing cap bolts.
  
  Fig 71: Taping Bearing Cap Using Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Using several steps, install and tighten the 16 bearing cap bolts uniformly in the sequence shown in the illustration.
  Torque: 22 N.m (224 kgf.cm, 16 ft.lbf)
  
  Fig 72: Tightening Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Mark the front side of the bearing cap bolts with paint.
10. Retighten the bearing cap bolts by 90° in the same sequence as step (h).
11. Check that each painted mark is now at a 90° angle to the front.
12. Check that the crankshaft turns smoothly.
  
  Fig 73: Retightening Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. Using several steps, install and tighten the 8 bearing cap bolts uniformly in the sequence shown in the illustration.
  Torque: 27 N.m (275 kgf.cm, 20 ft.lbf)
  
  HINT:
  
  Use the short bolt for the position marked with the arrow.
  
  Fig 74: Installing And Tightening Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON SUB-ASSY W/CONNECTING ROD
1. Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.
2. Check the position of the piston ring ends.
3. Using a piston ring compressor, push the numbered piston and connecting rod assemblies correctly into each cylinder with the front mark of the piston facing forward.
  NOTE: Match the numbered connecting rod cap with the connecting rod.
  
  Fig 75: Checking Position Of Piston Ring Ends
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check that the protrusion of the cap is facing the correct direction.
5. Apply a light coat of engine oil to the threads of the cap bolts.
  
  Fig 76: Identifying Front End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Tighten the cap bolts in several steps by the specified torque.
  Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)
  
  Fig 77: Tightening Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Mark the front side of each cap bolt with paint.
8. Retighten the cap bolts by 90° as shown in the illustration.
9. Check that the crankshaft turns smoothly.
  
  Fig 78: Retightening Cap Bolts 90deg
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO. 1 PLUG
1. Using a socket hexagon wrench 10, install a new gasket and the screw plug.
  Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)
  
  Fig 79: Installing Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO. 2 PLUG
1. Using a socket hexagon wrench 10, install a new gasket and the screw plug.
  Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)
  
  Fig 80: Installing Cylinder Block W/Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO. 3 PLUG
1. Using a socket hexagon wrench 10, install a new gasket and the screw plug.
  Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
INSTALL WATER SEAL PLATE
1. Remove any old seal packing from the contact surface.
  
  Fig 81: Installing Cylinder Block W/Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a continuous bead of seal packing (Diameter 3 to 5 mm (0.12 to 0.20 in.)) as shown in the illustration.
  Seal packing: Part No. 08826-00100 or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the seal plate within 3 minutes after applying seal packing.
  - Do not expose the seal packing to engine oil within 2 hours after installing.
3. Install the seal plate with the 2 nuts.
  Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
1. Apply adhesive to 2 or 3 threads of the drain cock end.
  Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
  
  Fig 82: Identifying Seal Width
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. After applying the specified torque, rotate the drain cock clockwise as shown in the illustration.
  Torque: 39 N.m (398 kgf.cm, 29 ft.lbf)
  NOTE:
  - Install the drain cock within 3 minutes after applying adhesive.
  - Do not expose the drain cock to coolant within 1 hour after installing.
  - Do not rotate the drain cock by more than 1 revolution (360°) after tightening the drain cock with the specified torque.
  - Do not loosen the drain cock after setting it correctly.
    
    Fig 83: Rotating Drain Cock Clockwise
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002