Reassembly [01/2019 - 03/2019]: Procedure

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INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

Using a 5 mm socket hexagon wrench, install the 4 No. 1 oil nozzle sub-assemblies with the 4 bolts.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

INSTALL PISTON

HINT:

Perform this procedure only when replacement of the piston pin hole snap ring (rear side) is necessary.

Using a screwdriver, install a new piston pin hole snap ring (rear side) at one end of the piston pin hole.
Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).
WARNING:
Be sure to wear protective gloves.

Align the front marks of the piston and 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 snap ring.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Front Mark

HINT:

The piston and piston pin are a matched set.

Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Cutout

NOTE:

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

Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Perform "Inspection After Repair" after replacing the piston.

Refer to INITIALIZATION [01/2019 - 11/2022]

INSTALL PISTON RING SET

Install the oil ring expander, upper side rail and lower side rail to the piston by hand.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Upper Side Rail
*2	Oil Ring Expander
*3	Lower Side Rail

NOTE:

When installing the upper side rail and lower side rail, the ends of the oil ring expander may overlap. If it occurs, the upper side rail or lower side rail may move out of its groove.

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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Press around the circumference	*b	Ring End
*c	Correct	*d	Incorrect (Ends of the oil ring expander are overlapping)

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.

Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring so that the paint marks are positioned as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	No. 1 Compression Ring
*b	No. 2 Compression Ring
*c	Code Mark (2T)
*d	Paint Mark
	Upward

NOTE:

Install the No. 2 compression ring with the code mark (2T) facing upward.
Paint marks can only be checked on new compression rings. When reusing compression rings, check each compression ring profile in order to install them into the correct positions.

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	No. 1 compression ring and Oil Ring Expander
*2	No. 2 compression ring
*3	Upper Side Rail
*4	Lower Side Rail
*a	Front of Engine

HINT:

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

Refer to INITIALIZATION [01/2019 - 11/2022]

INSTALL CRANKSHAFT BEARING

Install the 4 upper crankshaft bearings (except the No. 3 journal).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Scale

Install the 4 upper crankshaft bearings to the cylinder block sub-assembly.
NOTE:
Do not apply engine oil to the 4 upper 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.
Using a scale, measure the distance between the cylinder block sub-assembly edge and the crankshaft bearing edge.
Dimension (A)

0.5 to 1.0 mm (0.0197 to 0.0394 in.)

Install the crankshaft bearing (for No. 3 journal).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Vernier Caliper

Install the crankshaft bearing to the cylinder block sub-assembly.
NOTE:
Do not apply engine oil to the upper crankshaft bearing or the contact surface.

HINT:

Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the upper crankshaft bearing. The amount visible on each side of the holes should be equal.
Using a vernier caliper, measure the distance between the cylinder block sub-assembly edge and the crankshaft bearing edge.
Difference between (A) and (B)

0.5 mm (0.0197 in.) or less

Install the crankshaft bearing.

Install the crankshaft bearing to the cylinder block sub-assembly.
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.

Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the crankshaft bearing edge.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Mark 1, 2, 3, 4 or 5
*b	Vernier Caliper

Difference between (A) and (B)

0.5 mm (0.0197 in.) or less

NOTE:

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

INSTALL UPPER CRANKSHAFT THRUST WASHER

Install the 2 upper crankshaft thrust washers to the No. 3 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Oil Groove

Apply engine oil to the upper crankshaft thrust washers.

INSTALL CRANKSHAFT

Apply engine oil to the upper crankshaft bearings and install the crankshaft to the cylinder block sub-assembly.
Apply engine oil to the lower crankshaft bearings.

Confirm the front marks and numbers, and place the 5 crankshaft bearing caps on the cylinder block sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Number Mark
	Front of Engine

Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap set bolts.

Temporarily install the 10 crankshaft bearing cap set bolts.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Push on the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and cylinder block sub-assembly is less than 5 mm (0.197 in.).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Less than 5 mm

Using a plastic hammer, lightly tap the crankshaft bearing cap to ensure a proper fit.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the crankshaft bearing cap set bolts.
NOTE:
The crankshaft bearing cap set bolts are tightened in 2 progressive steps.
Step 1:
1. Install and uniformly tighten the 10 crankshaft bearing cap set bolts in the sequence shown in the illustration.
  
  Fig 1: Crankshaft Bearing Cap Set Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 40 N.m (408 kgf/cm, 30 ft.lbf)
  
  HINT:
  
  If a crankshaft bearing cap set bolt cannot be tightened to the specified torque, replace it.

Step 2:

Mark the front of the crankshaft bearing cap set bolts with paint.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Paint Mark
	Front of Engine

Tighten the crankshaft bearing cap set bolts by 90° in the order shown in step 1.

Check that the paint marks are now at a 90° angle.
Check that the crankshaft turns smoothly.
Check the crankshaft thrust clearance.
See step 13

INSTALL CONNECTING ROD BEARING

Install the 8 connecting rod bearings to the 4 connecting rods and 4 connecting rod caps.

Using a vernier caliper, measure the distance between the edges of the connecting rod and connecting rod bearing, and the connecting rod cap and the connecting rod bearing.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Vernier Caliper

Difference between (A) and (B)

0.7 mm (0.0276 in.) or less

NOTE:

Do not apply engine oil to the connecting rod bearings or the contact surfaces.

INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.

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

*1	No. 1 compression ring and Oil Ring Expander
*2	No. 2 compression ring
*3	Upper Side Rail
*4	Lower Side Rail
*a	Front of Engine

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.

*a	Press around the circumference	*b	Ring End
*c	Correct	*d	Incorrect (Ends of the oil ring expander are overlapping)

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.

Using a piston ring compressor, push the correctly numbered piston with connecting rod into the cylinder with the front marks of each piston sub-assembly with connecting rod facing the front of the engine.

*a	Front Mark

NOTE:

When inserting the piston sub-assembly with connecting rod, do not allow it to make contact with the No. 1 oil nozzle sub-assembly.
Match the numbered connecting rod cap with the connecting rod.

Check that the front mark of the connecting rod cap is facing in the correct direction.

*a	Front Mark

Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
Install the 8 connecting rod bolts.
NOTE:
The connecting rod bolts are tightened in 2 progressive steps.

Step 1:

Using SST, alternately tighten the connecting rod bolts in several steps.

SST: 09205-16011

Torque: 20 N.m (204 kgf/cm, 15 ft.lbf)

Step 2:

Mark the front of the connecting rod bolts with paint.

*a	Paint Mark
	Front of Engine

Tighten the connecting rod bolts by 90° as shown in the illustration.

Check that the crankshaft turns smoothly.
Check the connecting rod thrust clearance.
See step 1

INSTALL NO. 1 VENTILATION CASE

Apply seal packing in a continuous line as shown in the illustration.

*a	Seal Packing
*b	2.0 to 3.0 mm
*c	5.0 mm

Seal Packing

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

Application Specification

Seal Packing Diameter	Distance from Inside Edge of Cover to Center of Seal Packing
2.0 to 3.0 mm (0.0787 to 0.118 in.)	5.0 mm (0.197 in.)

NOTE:

Remove any oil from the contact surfaces.
Install the No. 1 ventilation case within 3 minutes and tighten the bolts and nuts within 15 minutes of applying seal packing.
Do not start the engine for at least 2 hours after installation.

Type A:

Install the No. 1 ventilation case with the 6 bolts and 2 nuts.

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

Type B:

Install the No. 1 ventilation case with the 8 bolts.

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