Part 1
ENGINE UNITCOMPONENTS (Part 1) (Bank 1):
COMPONENTS (Part 2) (Bank 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
COMPONENTS (Part 6):
COMPONENTS (Part 7):
COMPONENTS (Part 8) (Bank 1):
COMPONENTS (Part 9) (Bank 2):
COMPONENTS (Part 10):
COMPONENTS (Part 11):
COMPONENTS (Part 12):
REASSEMBLY
1. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, tap in new straight pins to the cylinder block.
Standard Protrusion:
2. INSTALL STUD BOLT
(a) Using E8 and E10 "TORX" sockets, install the stud bolts.
Torque:
10 Nm (102 kgf-cm, 7 ft. lbs.) for bolt A
17 Nm (173 kgf-cm, 13 ft. lbs.) for bolt B
3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, install the No. 1 oil nozzle sub-assembly.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
4. INSTALL PISTON SUB-ASSEMBLY WITH PIN
(a) Using a screwdriver, install a new piston pin hole 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 portion of the piston.
(b) Gradually heat the piston to approximately 80°C (176°F).
(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
HINT: The piston and pin are a matched set.
(e) Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
(f) Using a screwdriver, install a new piston pin hole snap ring at the other 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 portion of the piston.
5. INSTALL PISTON RING SET
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the compression ring as shown in the illustration.
(c) Position the piston rings so that the ring ends are as shown in the illustration.
NOTICE: Do not align the ring ends.
6. INSTALL CRANKSHAFT BEARING
(a) Clean the main journal and both surfaces of the bearing.
NOTICE: Main bearings come in widths between 18.0 mm (0.709 inch) and 21.0 mm (0.827 inch). Install the 21.0 mm (0.827 inch) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 inch) bearings in the No. 2 and No. 3 positions.
(b) Install the upper bearing.
(1) Install the upper crankshaft bearings to the cylinder block as shown in the illustration.
NOTICE:
^ Do not apply engine oil to the bearings and the contact surfaces.
^ Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal.
(c) Install the lower crankshaft bearing.
(1) Install the lower crankshaft bearings to the crankshaft bearing caps.
(2) Using vernier calipers, measure the distance between the crankshaft bearing cap's edge and the lower crankshaft bearing's edge.
Dimension (A - B): 0.7 mm (0.0276 inch) or less
NOTICE: Do not apply engine oil to the crankshaft bearings and the contact surfaces.
7. INSTALL CRANKSHAFT THRUST WASHER SET
(a) Apply engine oil to the crankshaft thrust washer.
(b) Install the 2 upper crankshaft thrust washers under the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward.
8. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.
(b) Confirm the projection and numbers of the main bearing caps and install the bearing caps on the cylinder block.
HINT: A number is marked on each main bearing cap to indicate the installation position.
(c) Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts.
(d) Temporarily install the 8 crankshaft bearing cap bolts to the inside positions.
(e) Insert the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and the cylinder block is less than 6 mm (0.23 inch) by marking the 2 internal crankshaft bearing cap bolts as a guide.
Bolt length: 100 to 102 mm (3.94 to 4.02 inch)
(f) Using a plastic hammer, lightly tap the crankshaft bearing cap to ensure a proper fit.
(g) Apply a light coat of engine oil to the threads and under the heads of the 8 crankshaft bearing cap bolts.
(h) Install the 8 crankshaft bearing cap bolts to the outside positions.
(i) Install the crankshaft bearing cap bolts.
HINT: The crankshaft bearing cap bolts are tightened in 2 progressive steps.
(j) Step 1
(1) Install and uniformly tighten the 16 crankshaft bearing cap bolts in the sequence shown in the illustration.
Torque: 61 Nm (622 kgf-cm, 45 ft. lbs.)
If any of the crankshaft bearing cap bolts does not meet the torque specified, replace it.
(k) Step 2
(1) Mark the front of the bearing cap bolts with paint.
(2) Retighten the bearing cap bolts 90° in the order above.
(3) Check that the painted mark is now at a 90° angle to the front.
(l) Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.
Torque: 52 Nm (525 kgf-cm, 38 ft. lbs.)
Bolt Length:
(m) Check that the crankshaft turns smoothly.
(n) Check the crankshaft thrust clearance.
9. INSTALL CONNECTING ROD BEARING
(a) Install the connecting rod bearing to the connecting rod and connecting rod cap.
(b) Using vernier calipers, measure the distance between the connecting rod's and bearing cap's edges and the connecting rod bearing's edge.
Dimension (A - B): 0.7 mm (0.0276 inch) or less
NOTICE: Do not apply engine oil to the bearings and the contact surfaces.
10. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
(a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
(b) Position the piston rings so that the ring ends are as shown in the illustration.
NOTICE: Do not align the ring ends.
(c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.
NOTICE: Match the numbered connecting rod cap with the connecting rod.
(d) Check that the front mark of the connecting rod cap is facing forward.
(e) Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
(f) Install the connecting cap bolts.
HINT: The connecting cap bolts are tightened in 2 progressive steps.
(g) Step 1
(1) Install and alternately tighten the bolts of the connecting rod cap in several steps.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
(h) Step 2
(1) Mark the front side of each connecting cap bolt with paint.
(2) Retighten the cap bolts 90° as shown in the illustration.
(3) Check the painted mark is now at a 90° angle to the front.
(i) Check that the crankshaft turns smoothly.
(j) Check the connecting rod thrust clearance.
11. INSTALL INTAKE VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the intake valve guide bush bore diameter of the cylinder head.
Cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 inch)
Select a new guide bush (STD or O/S 0.05)
Select A New Guide Bush (STD Or O/S 0.05):
If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 inch), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 inch) to install an O/S 0.05 valve guide bush.
If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 inch), replace the cylinder head.
(b) Heat the cylinder head to 80 to 100°C (176 to 212°F).
(c) Place the cylinder head on wooden blocks.
(d) Using SST, tap in new intake valve guide bushes to the specified protrusion height.
SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)
Protrusion height: 9.30 to 9.70 mm (0.3661 to 0.3819 inch)
(e) Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.
Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0023 inch)
12. INSTALL EXHAUST VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the exhaust valve guide bush bore diameter of the cylinder head.
Cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 inch)
Select a new guide bush (STD or O/S 0.05)
Select A New Guide Bush (STD Or O/S 0.05):
If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 inch), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 inch) to install an O/S 0.05 valve guide bush.
If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 inch), replace the cylinder head.
(b) Heat the cylinder head to 80 to 100°C (176 to 212°F).
(c) Place the cylinder head on wooden blocks.
(d) Using SST, tap in new exhaust valve guide bushes to the specified protrusion height.
SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)
Protrusion height: 9.30 to 9.70 mm (0.3661 to 0.3819 inch)
(e) Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.
Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 inch)
13. INSTALL RING PIN
(a) Using a plastic hammer, tap in new ring pins to the specified protrusion height.
Specified protrusion height: 2.5 to 3.5 mm (0.098 to 0.138 inch)
14. INSTALL NO. 1 STRAIGHT SCREW PLUG
(a) Using a 10 mm hexagon wrench, install 4 new gaskets and the 4 No. 1 straight screw plugs.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
15. INSTALL NO. 2 STRAIGHT SCREW PLUG
(a) Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 No. 2 straight screw plugs.
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
16. INSTALL STUD BOLT
NOTICE: If the stud bolt is deformed or the threads are damaged, replace it.
(a) Using E6 and E8 "TORX" sockets, install the stud bolts.
Torque:
10 Nm (102 kgf-cm, 7 ft. lbs.) for bolts A and B
4.0 Nm (41 kgf-cm, 35 inch lbs.) for bolt C
17. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, tap in new straight pins as shown in the illustration.
Protrusion height: 17.5 to 19.5 mm (0.689 to 0.768 inch)
18. INSTALL VALVE SPRING SEAT
(a) Install the valve spring seats to the cylinder head.
19. INSTALL VALVE STEM OIL SEAL
(a) Apply a light coat of engine oil to new valve stem oil seals.
NOTICE: Pay attention when installing the intake and exhaust valve stem oil seals. For example, installing the intake valve stem oil seal into the exhaust side or installing the exhaust valve stem oil seal to the intake side can cause installation problems later.
HINT: The intake valve oil seals are gray and the exhaust valve oil seals are black.
(b) Using SST, push in the oil seals.
SST 09201-41020
NOTICE: Failure to use SST will cause the seal to be damaged or improperly seated.
20. INSTALL EXHAUST VALVE
(a) Apply a sufficient coat of engine oil to the tip area of the exhaust valve shown in the illustration.
(b) Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head.
NOTICE: Install the same parts in the same combination to the original locations.
(c) Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.
SST 09202-70020 (09202-00010)
(d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
NOTICE: Be careful not to damage the retainer.
21. INSTALL INTAKE VALVE
(a) Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.
(b) Install the intake valve, inner compression spring and valve spring retainer to the cylinder head.
NOTICE: Install the same parts in the same combination to the original locations.
(c) Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.
SST 09202-70020 (09202-00010)
(d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
NOTICE: Be careful not to damage the retainer.
22. INSTALL VALVE STEM CAP
(a) Apply a light coat of engine oil to the valve stem caps.
(b) Install the valve stem caps on the valves.
23. INSTALL ENGINE REAR OIL SEAL
(a) Place the oil seal retainer on wooden blocks.
(b) Using SST, tap in a new engine rear oil seal until its surface is flush with the engine rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)
NOTICE:
^ Keep the lip free of foreign matter.
^ Do not tap on the oil seal at an angle.
24. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Apply seal packing in a continuous line as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal Diameter: 2.0 to 3.0 mm (0.079 to 0.118 inch)
NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil seal retainer within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installation.
(b) Install the engine rear oil seal retainer with the 6 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
NOTICE: Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
25. INSTALL WATER INLET PIPE
(a) Install the water inlet pipe with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
(b) Install the No. 1 water by-pass hose.