Reassembly

3MZ-FE ENGINE MECHANICAL: CYLINDER BLOCK: REASSEMBLY

REASSEMBLY

1. INSTALL STUD BOLTS
(a) Using E8 and E10 "TORX" sockets, install the stud bolts.





2. INSTALL STRAIGHT PINS
(a) Using a plastic-faced hammer, tap in the straight pins.





3. INSTALL RING PINS
(a) Using a plastic-faced hammer, tap in a new ring pins.





4. INSTALL CONNECTING ROD SMALL END BUSH






(a) Align the oil holes of a new bushing and the connecting rod.






(b) Using SST and a press, press in the bushing.
SST: 09222-30010






(c) Using a pin hole grinder, hone the bushing to obtain the standard specified clearance between the bushing and piston pin.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)






(d) Check the piston pin fit at normal room temperature, coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
5. INSTALL PISTON PIN HOLE SNAP RING






(a) Using a screwdriver, install a new snap ring at one end of the piston pin hole.
HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.





(b) Gradually heat the piston to about 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 until the pin contacts the snap ring.






(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 snap ring on the other end of the piston pin hole.
HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

6. INSTALL PISTON RING SET
(a) Install the oil ring expander by hand.
(b) Using a piston ring expander, install the oil ring side rail.






(c) Using a piston ring expander, install the 2 compression rings.
HINT: The No. 2 compression ring is installed with code mark "2R" facing upward as shown in the illustration.





(d) Position the piston rings so that the ring ends are arranged as shown in the illustration.
NOTE: Do not align the ring ends.

7. INSTALL CONNECTING ROD BEARING






(a) Align the key of the bearing with the keyway of the connecting rod or connecting 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.

8. INSTALL CRANKSHAFT BEARING






(a) Clean each main journal and the bearing.
HINT: Main bearings come in widths of 22.4 mm (0.882 in.) and 19.0 mm (0.748 in.). Install the 22.4 mm (0.882 in.) bearings in the No. 1 and No. 2 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 3 and No. 4 positions.





(b) Align the key of the bearing with the keyway of the cylinder block, and push in the 4 upper bearings.
NOTE: Do not apply engine oil to the bearing and its contact surface.





(c) Align the key of the bearing with the keyway of the main bearing cap, and push in the 4 lower bearings.
NOTE: Do not apply engine oil to the bearing and its contact surface.
HINT: A number is marked on each main bearing cap to indicate the installation position.

9. INSTALL CRANKSHAFT THRUST WASHER SET






(a) Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.






(b) Install the 2 thrust washers on the No. 2 bearing cap with the grooves facing outward.
10. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing and install the crankshaft on the cylinder block.






(b) Examine the front marks and numbers and install the bearing caps on the cylinder block.
(c) Apply a light coat of engine oil to the threads of the bearing cap bolts.
(d) Temporarily install the 8 main bearing cap bolts to the inside positions.






(e) Install the main bearing cap by hand until clearance between the cylinder block and the bearing cap becomes 6 mm (0.23 in.) or less.






(f) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
(g) Apply a light coat of engine oil to the threads of the main bearing cap bolts.






(h) Using several steps, install and tighten the 16 main bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)






(i) Mark the front side of the bearing cap bolts with paint.
(j) Retighten the bearing cap bolts by 90° in the same sequence as step (h).






(k) Check that each painted mark is now at 90° angle to the front.
(l) Check that the crankshaft turns smoothly.






(m) Using several steps, install and tighten the 8 main bearing cap bolts and 8 new seal washers uniformly in the sequence shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
HINT: Use the short bolt for the marked position (arrow).

11. 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) Check the position of the piston ring ends.






(c) 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.





(d) Check that the protrusion of the connecting rod cap is facing the correct direction.
(e) Apply a light coat of engine oil to the threads of the connecting rod cap bolts.






(f) Tighten the bolts in several steps to the specified torque.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)






(g) Mark the front side of each connecting cap bolt with paint.
(h) Retighten the cap bolts by 90° as shown in the illustration.






(i) Check that the crankshaft turns smoothly.
12. INSTALL NO. 3 CYLINDER BLOCK WITH HEAD STRAIGHT SCREW PLUG






(a) Using a 10 mm socket hexagon wrench, install a new gasket and the screw plug.
Torque: 50 Nm (510 kgf-cm, 37 ft-lbf)
13. INSTALL NO. 2 CYLINDER BLOCK WITH HEAD STRAIGHT SCREW PLUG






(a) Using a 10 mm socket hexagon wrench, install a new gasket and the screw plug.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
14. INSTALL NO. 1 CYLINDER BLOCK WITH HEAD STRAIGHT SCREW PLUG






(a) Using a 10 mm socket hexagon wrench, install a new gasket and the screw plug.
Torque: 50 Nm (510 kgf-cm, 37 ft-lbf)
15. INSTALL WATER SEAL PLATE
(a) Remove any old seal packing from the contact surface.






(b) Apply a continuous bead of seal packing (Diameter 4 to 5 mm (0.16 to 0.20 in.)) as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1324 or equivalent

NOTE:
- Remove any oil from the contact surface.
- Install the seal plate within 3 minutes after applying seal packing.
- Do not expose the seal to engine oil within 2 hours after installing.

(c) Install the seal plate with the 2 nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
16. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the drain cock end.
Adhesive:
Toyota Genuine Seal Packing Black, Three Bond 1324 or equivalent






(b) After applying the specified torque, rotate the drain cock clockwise as shown in the illustration.
Torque: 39 Nm (398 kgf-cm, 29 ft-lbf)

NOTE:
- Install the drain cock within 3 minutes after applying adhesive.
- Do not expose the seal to coolant within 1 hour after installing.
- Do not rotate the drain cock more than 1 revolution (360°) after tightening the drain cock to the specified torque.
- Do not loosen the drain cock after setting it correctly.