Cylinder Block: Reassembly

WARNING: This page is about a different variant/trim than selected.

INSTALL RING PIN

Using a plastic hammer, tap in the ring pins.

Fig 1: Identifying Ring Pins

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Standard Protrusion

ITEM PROTRUSION

Item	Protrusion
A	6 mm (0.236 in.)
B	5 mm (0.197 in.)

INSTALL STUD BOLT
1. Install the stud bolts as shown in the illustration.
Fig 2: Identifying Stud Bolts
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Torque: Stud Bolt A

22 N*m (220 kgf*cm, 16 ft.*lbf)

Stud Bolt B

5.0 N*m (51 kgf*cm, 44 in.*lbf)

Stud Bolt C

9.5 N*m (97 kgf*cm, 84 in.*lbf)

Stud Bolt D

5.0 N*m (51 kgf*cm, 44 in.*lbf)

INSTALL STRAIGHT PIN

Using a plastic hammer, tap in the straight pins.

Fig 3: Identifying Straight Pin

Standard Protrusion

ITEM PROTRUSION

Item	Protrusion
A	8 mm (0.315 in.)
B	7.5 mm (0.295 in.)
C	12 mm (0.472 in.)
D	5 mm (0.197 in.)

INSPECT CRANKSHAFT OIL CLEARANCE (See INSPECTION )
INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a 5 mm hexagon wrench, install the oil nozzles with the bolts.
  Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
  
  Fig 4: Locating Bolts And Oil Nozzles
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON
1. Using a screwdriver, install a new snap ring at one end of the piston pin hole.
  HINT:
  
  Make sure that the end gap on the snap ring is not aligned with the pin hole cutout portion of the piston.
2. Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).
  
  Fig 5: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the front marks on the piston and connecting rod, and push in the piston with a thumb.
4. Using a screwdriver, install a new snap ring on the other end of the piston pin hole.
  HINT:
  
  Make sure that the end gap on the snap ring is not aligned with the pin hole cutout portion of the piston.
  
  Fig 6: Aligning Front Marks On Piston And Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
  
  Fig 7: Checking Fitting Condition Between Piston And Piston Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON RING SET
1. install the oil ring expander and oil ring rail by hand.
  NOTE:
  - Install the expander and oil ring so that their ring ends are at opposite sides.
  - Securely install the expander into the inner groove of the oil ring.
  Fig 8: Identifying Oil Ring Expander And Oil Ring Rail
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a piston ring expander, install the 2 compression rings so that the paint marks are positioned as shown in the illustration.
  NOTE: Install compression ring No. 2 with the code mark (2N or 2A) facing upward.
  
  HINT:
  
  Supply part compression springs (No. 1 and No. 2) do not have paint marks.
  
  Fig 9: Installing Compression Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Position the piston rings so that the ring ends are as shown in the illustration.
Fig 10: Identifying Piston Rings Ends Direction
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INSTALL CRANKSHAFT BEARING
1. Install the upper bearing with an oil groove on the cylinder block.
NOTE: Do not apply engine oil to the bearing inner surface or bearing cap contact surfaces.

Fig 11: Installing Upper Bearing
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INSTALL NO. 2 CRANKSHAFT BEARING
1. Install the No. 2 crankshaft bearing on the bearing cap.
NOTE: Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oils.

Fig 12: Identifying No. 2 Crankshaft Bearing On Bearing Cap
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INSTALL UPPER CRANKSHAFT THRUST WASHER
1. Install the 2 thrust washers under the No. 3 journal of the cylinder block with the oil grooves facing outward.
  NOTE: Make sure to install the proper thrust washers.
2. Apply engine oil to the crankshaft thrust washers.
INSTALL CRANKSHAFT
1. Apply engine oil to the upper bearings and place the crankshaft on the cylinder block.
  
  Fig 13: Identifying Oil Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply engine oil to the lower bearings.
3. Examine the front marks and install the bearing caps on the cylinder block.
4. Apply a light coat of engine oil to the threads and under the bearing cap bolts.
5. Install the crankshaft bearing cap bolts.
  NOTE: The main bearing cap bolts are tightened in 2 progressive steps.
  
  Fig 14: Identifying Crankshaft Bearing Cap Mark And Numbers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Step 1
  1. Install and uniformly tighten the 10 main bearing cap bolts in the sequence shown in the illustration.
    Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
    
    Fig 15: Identifying Bearing Caps Bolts In Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Retighten the 10 main bearing cap bolts in the sequence shown in the illustration.
    Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
    
    Fig 16: Identifying Bearing Caps Bolts In Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Step 2
  1. Mark the front of the bearing cap bolts with paint.
  2. Retighten the bearing cap bolts 90° in the numerical order shown in the illustration.
8. Check that the paint mark is now at a 90° angle to the front.
9. Check that the crankshaft turns smoothly.
10. Check the crankshaft thrust clearance (See INSPECTION ).
  
  Fig 17: Tightening Bearing Cap Bolts 90°
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONNECTING ROD BEARING
1. Align the bearing claw with the groove on the connecting rod or connecting cap.
  NOTE: Do not apply engine oil to the bearing inner surface or connecting rod contact surface.
INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
NOTE: The connecting rod cap bolts are tightened in 2 progressive steps.

Fig 18: Aligning Bearing Claw With Groove On Connecting Rod Or Connecting Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings.
2. Check the position of the piston ring ends.
  
  Fig 19: Identifying Piston Ring Ends Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.
  NOTE: Match the numbered connecting rod cap with the connecting rod.
  
  Fig 20: Pushing Piston And Connecting Rod Assemblies Into Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check that the protrusion on the connecting rod cap is facing in the correct direction.
5. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
6. Install the connecting cap bolts.
  NOTE: The connecting cap bolts should be tightened in 2 progressive steps.
  
  Fig 21: Installing Connecting Rod Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Step 1
  1. Install and alternately tighten the bolts of the connecting rod cap in several steps.
    Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
    
    Fig 22: Locating Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Step 2
  1. Mark the front of the connecting rod cap bolts with paint.
  2. Retighten the cap bolts 90° as shown in the illustration.
9. Check that the crankshaft turns smoothly.
10. Check the connecting rod thrust clearance (See INSPECTION ).
  
  Fig 23: Tightening Cap Bolts 90°
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002