Engine Unit: Reassembly

1. Using a small screwdriver, install a new snap ring onto one end of the piston pin hole.

   HINT:

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

2. Gradually heat the piston up to 80 to 90°C (176 to 194°F).
   Fig 1: Installing Piston Pin Snap Ring

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3. Align the front marks of the piston and connecting rod, then push in the piston pin with your thumb until the pin comes into contact with the snap pin hole.

   HINT:

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

   Fig 2: Aligning Front Marks Of Piston & Connecting Rod

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1. Install the expander and oil ring by hand.
   Fig 3: Installing Expander And Oil Ring

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2. Using a piston ring expander, install the 2 compression rings with the paint mark as shown in the illustration.
   NOTE: Install the No. 2 compression ring with the code mark (2N) facing upward.
   Fig 4: Identifying Compression Rings With Paint Mark

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3. Position the piston rings so that the ring ends are as shown in the illustration.
   Fig 5: Locating Position Of Piston Rings

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1. Install the 4 oil nozzles with the 4 bolts.

   Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

   Fig 6: Identifying No. 1 Oil Nozzle Sub-Assembly

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1. Install the upper bearing with an oil groove onto the cylinder block.
   NOTE: Do not apply engine oil to the contact surfaces of the cylinder block and crankshaft bearing.
   Fig 8: Identifying Crankshaft Bearing

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1. Install the lower bearing onto the bearing cap.
   NOTE: Do not apply engine oil to the contact surfaces of the cylinder block and crankshaft bearing cap.
   Fig 9: Installing Lower Bearing Onto Bearing Cap

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1. Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil groove facing outward.
   Fig 10: Identifying Crankshaft Thrust Washer Upper

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1. Apply engine oil to the upper bearing, and install the crankshaft onto the cylinder block.
2. Examine the front marks and numbers, and install the bearing caps onto the cylinder block in the order shown in the illustration.
3. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
   Fig 11: Identifying Bearing Caps Onto Cylinder Block

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4. Using several steps, uniformly install and tighten the 10 bearing cap bolts in the sequence shown in the figure below.

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

   Fig 12: Tightening Bearing Cap Bolts In Sequence

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5. Mark the front of the bearing cap bolts with paint.
6. Retighten the 10 bearing cap bolts by 90° in the same sequence.
   Fig 13: Retightening Bearing Cap Bolts By 90°

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7. Check that the paint marks are now at a 90° angle to the front.
8. Check that the crankshaft turns smoothly.

1. Align the bearing claw with the oil groove of the connecting rod or connecting rod cap.
   NOTE:

   • Do not apply engine oil to the contact surfaces of the connecting rod cap and bearing.
   • Do not apply engine oil to the contact surfaces of the connecting rod and bearing.
   Fig 14: Aligning Bearing Claw With Oil Groove Of Connecting Rod Cap And Bearing

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1. Apply engine oil to the cylinder walls, pistons, and surfaces of connecting rod bearings.
2. Check the position of the piston ring ends.
   Fig 15: Checking Position Of Piston Ring Ends

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3. Using a hammer handle and piston ring compressor, press a piston and connecting rod into each cylinder with the front mark of the piston facing forward.
   Fig 16: Pressing Piston And Connecting Rod Into Each Cylinder

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4. Check that the front mark of the connecting rod cap is facing in the correct direction.
   NOTE: Match the numbered connecting rod cap with the connecting rod.
5. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
6. Using a 12 mm socket wrench, tighten the bolts in several passes to the specified torque.

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

   Fig 17: Checking Front Mark Of Connecting Rod Cap

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7. Mark the front of the connecting rod bolts with paint.
8. Retighten the cap bolts 90° as shown in the illustration.
9. Check that the crankshaft turns smoothly.
   Fig 18: Retightening Connecting Rod Bolts By 90°

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1. Align the bearing claw with the claw groove, and push in the 8 bearings (see the illustration below).
   NOTE:

   • Do not apply engine oil to the contact surfaces of the balance shaft bearing and balance shaft housing.
   • Do not apply engine oil to the contact surfaces of the balance shaft bearing and stiffening crankcase.
2. Apply light coat of engine oil to the bearings.
   Fig 19: Aligning Bearing Claw With Claw Groove

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1. Rotate the No. 1 driven gear of the No. 1 balance shaft in the rotating direction until it hits the stopper.
   Fig 20: Identifying Balance Shaft

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2. Confirm that the timing marks on the No. 1 and No. 2 driven gears are aligned.
   Fig 21: Identifying Timing Marks On Driven Gears

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3. Align the timing marks of the No. 1 and No. 2 balance shafts as shown in the illustration.
4. Place the No. 1 and No. 2 balance shafts onto the crankcase.
5. Apply a light coat of engine oil to the threads and under the heads of the bolts.
   Fig 22: Aligning Timing Marks Of Balance Shafts

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6. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the figure below.

   Torque: 21.6 N*m (220 kgf*cm, 16 ft.*lbf) 

7. Mark the front of the bolts with paint.
8. Retighten the bolts 90° as shown in the illustration.
   Fig 23: Tightening Bolts In Sequence

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9. Check that the paint mark is now at a 90° angle to the front.

1. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and crankcase.
   Fig 24: Removing Any Old Packing Material & O-Rings

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2. Place a new O-ring on the cylinder block as shown in the illustration.
   Fig 25: Placing New O-Ring On Cylinder Block

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3. With the No. 1 crank pin of the crankshaft placed at the 6 o'clock position, install the No. 1 and No. 2 balance shafts and align the adjusting holes as shown in the illustration.
   Fig 26: Identifying Balance Shafts And Align Adjusting Holes

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4. Apply a continuous bead of seal packing (Diameter 2.5 to 3.0 mm (0.098 to 0.118 in.)) as shown in the figure below.

   Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the crankcase within 3 minutes of applying seal packing.
   • Do not add engine oil for at least 2 hours after installing the crankcase.
   Fig 27: Applying Bead Of Seal Packing

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5. Temporarily install the crankcase with the 11 bolts.

   Standard bolt length 

   BOLT LENGTH (STANDARD)
   
   

   Item	Specified Condition
   For bolt A (12 mm head)	112 mm (4.41 in.)
   For bolt B (12 mm head)	35 mm (1.38 in.)

   Fig 28: Identifying Crankcase With Bolts

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6. Uniformly tighten the bolts.

   Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

   Fig 29: Uniformly Tighten Bolts

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7. Confirm that the timing marks of the balance shafts are aligned when the key groove is placed at the 6 o'clock position, as shown in the illustration.
   Fig 30: Identifying Timing Marks Of Balance Shafts

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1. Apply multi-purpose grease to the lip of a new oil seal.
   NOTE: Keep the lip free of foreign object.
2. Using SST and hammer, tap in the new oil seal until its surface is flush with the rear oil seal retainer edge.

   SST 09223-15030, 09950-70010 (09951-07100) 

   NOTE:

   • Wipe any extra grease off the crankshaft.
   • Do not tap the oil seal at an angle.
   Fig 31: Tapping In New Rear Oil Seal

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1. Check that there are no foreign objects on the mesh part of the oil control valve filter.
2. Using a 6 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the plug.

   Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

   Fig 32: Identifying Oil Control Valve Filter

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1. Apply adhesive to 2 or 3 threads of the drain cock.

   Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

   Fig 33: Applying Adhesive To Threads Of Drain Cock

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2. After tightening the drain cock to the specified torque, turn the drain cock clockwise as shown in the figure below.

   Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

   NOTE:

   • Install the drain cock within 3 minutes of applying adhesive.
   • Do not add coolant for at least an hour after installing the drain cock.
   • Do not turn the drain cock by more than 1 revolution (360°) after tightening the drain cock to the specified torque.
   • Do not loosen the drain cock after setting it correctly.
   Fig 34: Identifying Drain Cock

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1. Apply a light coat of engine oil to a new O-ring, then install it onto the camshaft timing oil control valve.
   Fig 35: Applying Light Coat Of Engine Oil To O-Ring

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2. Install the camshaft timing oil control valve with the bolt.

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

   Fig 36: Installing Camshaft Timing Oil Control Valve With Bolt

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1. Place a new gasket on the oil pan drain plug, then install it onto the oil pan.

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

   Fig 38: Identifying Oil Pan Drain Plug

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1. Using a 12 mm hexagon wrench, install the oil filter union.

   Torque: 29.5 N*m (301 kgf*cm, 22 ft.*lbf) 

   Fig 39: Installing Oil Filter Union

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1. Install the gasket onto the cylinder head cover.
   Fig 40: Identifying Cylinder Head Cover Gasket

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1. Install the gasket to the cap.
   Fig 41: Identifying Gasket To Oil Filler Cap

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2. Install the oil filler cap.

   Torque: 3.0 N*m (31 kgf*cm, 26 in.*lbf) 

   Fig 42: Identifying Oil Filler Cap

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Torque: 25 N*m (254 kgf*cm, 18 ft.*lbf) 

Fig 43: Identifying Spark Plug

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1. Apply adhesive to the threads of the ventilation valve.

   Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

   Fig 44: Applying Adhesive To Threads Of Ventilation Valve

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2. Using a 22 mm deep socket wrench, install the ventilation valve.

   Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

   Fig 45: Installing Ventilation Valve

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1. Install a new gasket and pipe with the bolt and 2 nuts.

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

   Fig 46: Identifying Water By-Pass Pipe

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1. Install a new gasket and the pipe with the bolt and 2 nuts.

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

   Fig 47: Identifying No. 1 Water By-Pass Pipe

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