Reassembly [10/2022 - ]: Procedure

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a plastic hammer, install 13 new ring pins.

   Standard Protrusion Height

   Ring Pin	Specified Condition
   (A)	5.0 to 7.0 mm (0.197 to 0.276 in.)
   (B)	3.0 to 5.0 mm (0.118 to 0.197 in.)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.)
   (C)	6.0 to 8.0 mm (0.236 to 0.315 in.)

Courtesy 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) 

Courtesy 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) 

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 with pin sub-assembly.

   2. Rotate the piston back and forth on the piston pin. Check the fitting condition.

   If abnormal movement is felt, replace the piston with pin sub-assembly.

Refer to INITIALIZATION [10/2022 - ]

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	No. 1 Compression Ring	*2	No. 2 Compression Ring
*a	Code Mark	*b	Paint Mark
*c	Front Mark	*d	No. 1 Compression Ring End Gap
*e	No. 2 Compression Ring End Gap	*f	Oil Ring Expander End Gap
*g	Upper Side Rail End Gap	*h	Lower Side Rail 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	T	White
   No. 2 Compression Ring	2T	Sky Blue

2. Position the piston rings so that the ring ends are as shown in the illustration.

Refer to INITIALIZATION [10/2022 - ]

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Clean the main journal, crankshaft bearing cap and both surfaces of the crankshaft bearings and No. 2 crankshaft bearings.
2. Install the 5 crankshaft bearings to the cylinder block sub-assembly as shown in the illustration.
   NOTE:

   • Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the crankshaft bearings. The amount visible on each side of the holes should be equal.
   • Do not apply engine oil to the 5 crankshaft bearings or the contact surfaces.
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.)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 5 No. 2 crankshaft bearings to the crankshaft bearing cap.
   NOTE:

   • The No. 3 journal and No. 2 crankshaft bearing has a groove.
   • Do not apply engine oil to the No. 2 crankshaft bearings or the contact surfaces.
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 0.7 mm (0 to 0.0276 in.)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply engine oil to the 5 crankshaft bearings.
2. Install the crankshaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply engine oil to the 2 crankshaft thrust washer uppers.
2. Install the 2 crankshaft thrust washer uppers to the No. 3 journal position of the cylinder block sub-assembly with the oil grooves facing outward.
   NOTE:

   Make sure the crankshaft thrust washer uppers are installed correctly.

3. After installation, make sure the identification grooves of the crankshaft thrust washer uppers are positioned as shown in the illustration.

Fig 1: Crankshaft Bearing Cap Set Bolts Tightening Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Seal Packing	*b	Paint Mark
*c	Turn 45°	-	-
	Front of Engine	-	-

1. Apply engine oil to the 5 No. 2 crankshaft bearings.
2. Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap set bolts (A).

   HINT: 

   The shank length of crankshaft bearing cap set bolt (A) is 111.5 to 112.9 mm (4.39 to 4.44 in.).

3. Clean and degrease the installation surfaces of the crankshaft bearing cap and cylinder block sub-assembly.
4. Apply seal packing in a continuous line as shown in the illustration.

   Seal Packing

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

   Standard Seal Packing Diameter

   2.5 to 3.5 mm (0.0984 to 0.138 in.)

   NOTE:

   • Install the crankshaft bearing cap within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
   • Clean and inspect the bolts and bolt holes.
   • Do not add engine oil for at least 2 hours after the installation.
   • Do not start the engine for at least 2 hours after installation.
   • Make sure that the diameter at the start and end of each line of seal packing is 3 to 7 mm (0.118 to 0.276 in.).
   • After installation, if the seal packing has seeped out, wipe it off within 10 minutes.
5. Uniformly install and tighten the 10 crankshaft bearing cap set bolts (A) in several steps in the order shown in the illustration.

   Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

   NOTE:

   • As the length of the crankshaft bearing cap set bolts differ, make sure to confirm when installing.
   • While performing tightening, check that the crankshaft continues to turn smoothly.
6. Once again, tighten the 10 crankshaft bearing cap set bolts to the specified torque in the order shown in the illustration.

   Torque: 75 N.m (765 kgf/cm, 55 ft.lbf) 

   NOTE:

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

7. Mark the front of the crankshaft bearing cap set bolts (A) with paint.
8. Tighten the 10 crankshaft bearing cap set bolts (A) 45° as shown in the illustration.
9. Tighten the 10 crankshaft bearing cap set bolts (A) an additional 45° in the order shown in the illustration.
10. Check that the paint marks are now at a 90° angle to the front.

Fig 2: Crankshaft Bearing Cap Set Bolts Tightening Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Uniformly install and tighten the bolt (B) and 7 bolts (C) in the order shown in the illustration.

   Torque: 46 N.m (469 kgf/cm, 34 ft.lbf) 

   Bolt Length

   Item	Length
   Bolt (B)	40 mm (1.57 in.)
   Bolt (C)	70 mm (2.76 in.)

2. After installation, if the seal packing has seeped out, wipe it off within 10 minutes.

   HINT: 

   Install the rear engine oil seal within 10 minutes.

3. Check that the crankshaft turns smoothly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 8 connecting rod bearings to the 4 connecting rods and 4 connecting rod caps.
2. 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 bearings or the bearing contact surfaces of the connecting rod.
   • This measurement is performed to ensure that the connecting rod bearing is centered in the connecting rod.
3. 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 bearings or the bearing contact surfaces of the connecting rod.
   • This measurement is performed to ensure that the connecting rod bearing is centered in the connecting rod cap.

Courtesy 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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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. 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.

Courtesy 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.
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, alternately tighten the 8 connecting rod bolts in several steps.

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

4. Mark the front of the connecting rod bolts with paint.
5. Tighten the connecting rod bolts 90° as shown in the illustration.
6. Check that the paint marks are now at a 90° angle to the front.
7. Check that the crankshaft turns smoothly.