Part 1
ENGINE UNITCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
COMPONENTS (Part 6):
COMPONENTS (Part 7):
REASSEMBLY
1. INSTALL TIGHT PLUG
NOTICE: If water leaks from the tight plug or the plug corrodes, replace it.
(a) Apply adhesive around the tight plugs.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Using SST and a hammer, tap in new tight plugs as shown in the illustration.
(c) Using SST, tap in the 8 tight plugs A and C.
SST 09950-60010 (09951-00350), 09950-70010 (09951-07100)
(d) Using SST, tap in the tight plug B.
SST 09950-60010 (09951-00300), 09950-70010 (09951-07100)
(e) Using SST, tap in the 3 tight plugs D.
SST 09950-60010 (09951-00400), 09950-70010 (09951-07100)
2. INSTALL STUD BOLT
(a) Using an E7 "torx" socket wrench, install the stud bolts B and D.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.) for stud bolts B and D
(b) Using an E8 "torx" socket wrench, install the stud bolts A.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.) for stud bolts A
(c) Apply adhesive to the hole for the stud bolt C on the cylinder block. Using an E7 "torx" socket wrench, install the stud bolts C.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.) for stud bolt C
NOTICE: If the stud bolt is deformed or the threads are damaged, replace it.
3. INSTALL STRAIGHT PIN
(a) Using a plastic-faced hammer, tap in new straight pins to the cylinder block.
4. INSTALL RING PIN
(a) Using a plastic-faced hammer, tap in new ring pins to the cylinder block.
5. INSTALL NO. 2 BALANCE SHAFT DRIVEN GEAR
(a) Mount the head portion of the balance shaft in a vise.
NOTICE: Be careful not to damage the balance shaft.
(b) Install the balance shaft thrust washer No.2 (* 1) and balance shaft driven gear No.2 (* 2).
(c) Install and torque the bolt.
Torque: 36 Nm (365 kgf-cm, 26 ft. lbs.)
6. INSTALL NO.2 BALANCE SHAFT
(a) Install the balance shaft to the cylinder block.
NOTICE: When installing the balance shaft, make sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block side.
(b) Install and torque the 2 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
7. INSTALL NO. 1 BALANCE SHAFT DRIVEN GEAR
(a) Mount the head portion of the balance shaft in a vise.
NOTICE: Be careful not to damage the balance shaft.
(b) Install the balance shaft thrust spacer (* 1), balance shaft thrust washer No.1 (* 2), sliding key (* 3) and balance shaft driven gear No.1 (* 4).
(c) Install and torque the bolt.
Torque: 36 Nm (365 kgf-cm, 26 ft. lbs.)
8. INSTALL NO.1 BALANCE SHAFT
(a) Install the No.1 balance shaft to the cylinder block.
NOTICE: When installing the balance shaft, make sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block side.
(b) Install and torque the bolt.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
9. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Apply adhesive around the drain cock.
(b) Install the cylinder block water drain cock as shown in the illustration.
Torque: 25 Nm (250 kgf-cm, 18 ft.lbs.)
(c) Install the water drain cock plug to the water drain cock sub-assembly.
Torque: 13 Nm (130 kgf-cm, 9 ft.lbs.)
10. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using an E7 "torx" socket wrench, install the oil nozzles.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
11. INSTALL WITH PIN PISTON SUB-ASSEMBLY
(a) Assemble the piston and connecting rod.
(1) Using a screwdriver, install a new snap ring at one end of the piston pin hole.
(2) Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).
(3) Coat the piston pin with engine oil.
(4) 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.
(5) Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
(6) Using a screwdriver, install a new snap ring at the other end of the piston pin hole.
12. INSTALL PISTON RING SET
(a) Install the oil ring expander by hand.
(b) Using a piston ring expander, install the oil ring rail.
(c) Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration.
HINT:
^ Install the compression ring No.1 with the code mark (1N) facing upward.
^ Install the compression ring No.2 with the code mark (2N) facing upward.
(d) Position the piston rings so that the ring ends are as shown in the illustration.
NOTICE: Do not align the ring ends.
13. INSTALL CRANKSHAFT BEARING
NOTICE:
^ Do not apply engine oil to the bearing's contact area and backside.
^ The crankshaft bearing cap bolt is tightened in 2 progressive steps.
(a) Clean the main journal, and the both surfaces of the bearing.
(b) Install the upper bearing.
(1) Install the upper bearing to the cylinder block as shown in the illustration.
NOTICE: Do not apply engine oil to the bearing's contact area and backside.
(c) Install the lower bearing.
(1) Install the lower bearing to the bearing cap.
(2) Using vernier calipers, measure the distance between the bearing cap's edge and the lower bearing's edge.
Dimension (A - B): 0.3 mm (0.0118 inch) or less
HINT:
NOTICE: Do not apply engine oil to the bearing's contact area and backside.
(d) With the upper bearing and lower bearing installed, use a plastic-faced hammer to install the bearing caps to the cylinder block.
NOTICE: Make sure that the bearing caps are installed in the correct positions and direction.
(e) Using vernier calipers, measure the amount of misalignment between the upper bearing and lower bearing, as shown in the illustration.
Standard: 0.9 mm (0.035 inch) or less
(f) Remove the bearing cap.
(g) Install the crankshaft thrust washer upper to the cylinder block.
(1) Install the 2 thrust washers under the No.3 journal position of the cylinder block with the oil grooves facing outward.
NOTICE: Be careful when installing the thrust bearing upper and lower as they are similar but cannot be interchanged.
(h) Install the 2 thrust washers on the No.3 bearing cap with the grooves facing outward.
NOTICE: Be careful when installing the thrust bearing upper and lower as they are similar but cannot be interchanged. The bearing lower has a claw as shown in the illustration.
(i) Apply engine oil to the lower bearing.
14. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.
(b) Install the 5 crankshaft bearing caps in their proper locations.
(c) Install the crankshaft bearing cap bolts.
HINT: The main bearing cap bolts are tightened in 2 progressive steps.
(d) Step 1
(1) Install and uniformly tighten the 10 main bearing cap bolts in the sequence shown in the illustration.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.
(e) Step 2
(1) Mark the front of the bearing cap bolts with paint.
(2) Retighten the bearing cap bolts by 90° in the order above.
(3) Check that the painted mark is now at a 90° angle to the front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance (see step 5).
15. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the connecting rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting rod cap.
NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod.
16. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
(a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings.
(b) Position the piston rings so that the ring ends are as shown in the illustration.
CAUTION: 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.
(d) Match the numbered connecting rod cap with the connecting rod.
NOTICE:
^ Match the numbered connecting rod cap with the connecting rod.
(e) Check that the front mark of the connecting rod cap is facing forward.
(f) Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
(g) Install and alternately tighten the bolts of the connecting rod cap in several steps.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
(h) Mark the front side of each connecting cap bolt with paint.
(i) Retighten the cap bolts by 90° as shown.
(j) Check that the painted mark is now at a 90° angle to the front.
(k) Check that the crankshaft turns smoothly.
(l) Check the connecting rod thrust clearance (see step 1).
17. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN
NOTICE: It is not necessary to remove with head pin unless it is being replaced.
(a) Using a plastic-faced hammer, tap in a new ring pin until the pin stops.
18. INSTALL NO. 1 TIGHT PLUG
NOTICE: If water leaks from the tight plug or the plug corrodes, replace it.
(a) Apply adhesive to the tight plug hole of the cylinder head.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Using SST, tap in a new tight plug to the cylinder head as shown in the illustration.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)
19. INSTALL STUD BOLT
NOTICE: If the stud bolt is deformed or the threads are damaged, replace it.
(a) Using E6 and E7 "torx" socket wrenches, install the stud bolts.
Torque:
3.0 Nm (31 kgf-cm, 27 inch lbs.) for stud bolt A
7.5 Nm (76 kgf-cm, 66 inch lbs.) for stud bolt B
9.5 Nm (97 kgf-cm, 84 inch lbs.) for stud bolt C
20. INSTALL NO. 1 WITH HEAD STRAIGHT SCREW PLUG
(a) Using a 10 mm hexagon wrench, install 3 new gaskets and the straight screw plugs.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)