Part 1

ENGINE UNIT





































REASSEMBLY





1. 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 inch)





(d) Check that the piston pin fits at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
2. INSTALL STUD BOLT





3. INSTALL STRAIGHT PIN





4. INSTALL RING PIN





(a) Install ring pin.





5. INSTALL PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, install a new 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.





6. INSTALL W/PIN PISTON SUB-ASSEMBLY
(a) Gradually heat the piston to about 80°C (176°F).





(b) Coat the piston pin with engine oil.
(c) 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.





7. INSTALL PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.

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





8. INSTALL PISTON RING SET
(a) Install the oil ring expander and the 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression rings.

HINT: The compression ring No. 2 is installed with code mark "2A" faced upward as shown in the illustration.





(c) Position the piston rings so that the ring ends are arranged as shown in the illustration.

NOTICE: Do not align the ring ends.





9. INSTALL CONNECTING ROD BEARING
(a) Align the key of the bearing with the keyway of the connecting rod or connecting cap.

NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oils.





10. INSTALL CRANKSHAFT BEARING
(a) Install crank shaft bearing.

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





(b) Align the key of the bearing with the keyway of the cylinder block, and push in the 4 upper bearings.

NOTICE: 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.

NOTICE: 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.





11. 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.
12. 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 on 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 using the inner bolt as a guide. Stop the main bearing cap is about 6 mm (0.23 inch) away from contacting with the block.





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





(h) Uniformly install and tighten the 16 main bearing cap bolts in the sequence shown in the illustration.
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)





(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 a 90° angle to the front.
(l) Check that the crankshaft turns smoothly.
(m) Install a new seal washer to the main bearing cap bolt.





(n) Uniformly install and tighten the 8 main bearing cap bolts in the sequence shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)

HINT: Use the short bolt for the marked position (arrow).





13. INSTALL PISTON AND CONNECTING ROD
(a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of 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.

NOTICE: 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 on the threads of the connecting rod cap bolts.





(f) Tighten the bolts in several steps by the specified torque.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)





(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.





14. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 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. lbs.)





15. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.2 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. lbs.)





16. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 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. lbs.)





17. INSTALL WATER SEAL PLATE
(a) Remove any old seal packing from the contact surface.
(b) Apply a continuous bead of seal packing (diameter 3 to 5 mm (0.12 to 0.20 inch)) as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

NOTICE:
^ 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 for at least 2 hours after installing.

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

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





19. INSTALL SPARK PLUG TUBE GASKET
(a) Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover.
SST 09950-60010 (09951-00430), 09950-70010 (09951-07100)
(b) Return the ventilation plate tab to its original position.
(c) Apply a light coat of MP grease to the gasket lip.





20. INSTALL ENGINE REAR OIL SEAL
(a) Using SST and a hammer, a tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)

NOTICE:
^ Be careful not to tap the oil seal at an angle.
^ Keep the gap between the rear oil seal retainer edge and the oil seal free of foreign matter.

(b) Apply MP grease to the oil seal lip.
21. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Remove any old packing material from the contact surface.





(b) Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 inch)) as show in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil seal retainer within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing.

(c) Install the oil seal retainer. Tighten the 6 bolts uniformly.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)





22. INSTALL OIL PUMP SEAL
(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
SST 09223-00010

NOTICE:
^ Be careful not to tap the oil seal at an angle.
^ Keep the gap between the oil pump body edge and the oil seal free of foreign matter.

(b) Apply MP grease to the oil seal lip.





23. INSTALL OIL PUMP ASSEMBLY
(a) Remove any old packing material from the contact surface.
(b) Apply a light coat of engine oil to a new O-ring and place it on the cylinder block.





(c) Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 inch)) as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the inner side of the bolt holes.
^ Install the oil pump within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing the oil pump.





(d) Align the key of the oil pump drive gear with the keyway located on the crankshaft, and slide the oil pump into place.





(e) Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque:
Bolt A 8.0 Nm (82 kgf-cm, 71 inch lbs.)
Bolt B 20 Nm (204 kgf-cm, 15 ft. lbs.)
Bolt C 43 Nm (439 kgf-cm, 32 ft. lbs.)
24. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
25. INSTALL OIL PAN BAFFLE PLATE
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
26. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old seal packing from the contact surface.





(b) Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 inch)) as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the outer side of the bolt holes in region "X".
^ Apply seal packing to the inner side of the bolt holes in region "Y".
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing.

(c) Install the oil pan No. 1 with the 15 bolts and 2 nuts. Tighten the bolts uniformly in several steps.
Torque:
10 mm head 8.0 Nm (82 kgf-cm, 71 inch lbs.)
12 mm head 20 Nm (199 kgf-cm, 14 ft. lbs.)
27. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
28. INSTALL NO.2 OIL PAN SUB-ASSEMBLY
(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 inch)) as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

HINT:
^ Remove any oil from the contact surface.
^ Apply seal packing to the inner side of the bolt holes.
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing.

(c) Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
29. INSTALL OIL PAN DRAIN PLUG
(a) Install the drain plug with a new gasket.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.)
30. INSTALL WATER INLET HOUSING
(a) Remove any old packing material from the contact surface.





(b) Apply a continuous bead of seal packing (diameter 3 to 5 mm (0.12 to 0.20 inch)) as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the water inlet housing within 3 minutes after applying seal packing.
^ Do not expose the seal to coolant for at least 2 hours after installing.





(c) Install the water inlet housing with the 8 bolts and 2 nuts. Uniformly tighten the bolts and nuts in the sequence shown in the illustration.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)





31. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block with the R mark upside down, as shown in the illustration.

NOTICE:
^ Remove any oil from the contact surface.
^ Make sure the cylinder head gasket is facing in the correct direction.

32. INSTALL CYLINDER HEAD SUB-ASSEMBLY

NOTICE:
^ To prevent damage to the block, place the gasket carefully.
^ The cylinder head bolts are tightened in 2 successive steps.





(a) Apply a light coat of engine oil on the threads of the cylinder head bolts.
(b) Install the plate washers to the cylinder head bolts.
(c) Uniformly install and tighten the 8 cylinder head bolts in the sequence shown in the illustration (Procedure "A").
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)





(d) Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
(e) Retighten the cylinder head bolts by 90° in the same sequence as (Procedure "A").
(f) Check that each painted mark is now at a 90° angle to the front.





(g) Using an 8 mm socket hexagon wrench, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)





33. INSTALL CYLINDER HEAD GASKET NO.2
(a) Place a new cylinder head gasket on the cylinder block with the L mark as shown in the illustration.

NOTICE:
^ Remove any oil from the contact surface.
^ Make sure the cylinder head gasket is facing in the correct direction.

34. INSTALL CYLINDER HEAD LH

NOTICE:
^ To prevent damage to the block, place the gasket carefully.
^ The cylinder head bolts are tightened in 2 successive steps.

(a) Apply a light coat of engine oil on the threads of the cylinder head bolts.
(b) Install the plate washers to the cylinder head bolts.





(c) Uniformly install and tighten the 8 cylinder head bolts in the sequence shown in the illustration.
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)





(d) Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
(e) Retighten the cylinder head bolts by 90° in the same sequence as step (c).
(f) Check that each painted mark is now at a 90° angle to the front.





(g) Using an 8 mm socket hexagon wrench, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)





35. INSTALL OIL CONTROL VALVE FILTER
(a) Check that no foreign matter is on the mesh part of the filter.
(b) Assemble the valve filter and the plug.
(c) Install a new gasket and the plug.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.)