Reassembly [12/2019 - 10/2022]: Procedure

INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

Using a 5 mm hexagon socket wrench, install the 3 No. 1 oil nozzle sub-assemblies to the cylinder block sub-assembly with the 3 bolts.

Torque: 9.0 N.m (92 kgf/cm, 80 in.lbf)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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°C (176°F).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the piston pin with engine oil.
WARNING:
Be sure to wear protective gloves.

Align the front marks of the piston and connecting rod sub-assembly, and push in the piston pin with your thumb.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*A	for Bank 1
*B	for Bank 2
*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 piston pin hole snap ring is not aligned with the cutout of the piston pin hole.

Check the fitting condition between the piston and piston pin.

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Move the connecting rod back and forth on the piston pin. Check the fitting condition.
HINT:

If abnormal movement is felt, replace the piston and piston pin as a set.
Rotate the piston back and forth on the piston pin. Check the fitting condition.
HINT:
- If abnormal movement is felt, replace the piston and piston pin as a set.
- Perform Inspection After Repair after replacing the piston.
  Refer to INITIALIZATION [12/2019 - 10/2022]

INSTALL PISTON RING SET

Install the oil ring expander and 2 side rails by hand.

Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	No. 1 Compression Ring
*b	No. 2 Compression Ring
*c	Oil Ring
*d	Piston Ring Expander
*e	Upper Side Rail
*f	Oil Ring Expander
*g	Lower Side Rail
*h	Code Mark

NOTE:

Install the No. 1 compression ring with the code mark (T1) facing upward.
Install the No. 2 compression ring with the code mark (T2) facing upward.

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*A	for Bank 1
*B	for Bank 2
*a	No. 1 Compression Ring
*b	No. 2 Compression Ring
*c	Front Mark
*d	Lower Side Rail
*e	Oil Ring Expander
*f	Upper Side Rail

NOTE:

Do not align the ring ends.

HINT:

Perform Inspection After Repair after replacing the piston ring.

Refer to INITIALIZATION [12/2019 - 10/2022]

INSTALL CRANKSHAFT BEARING

Clean the main journals and both surfaces of the crankshaft bearings.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	No. 1 and No. 4 Crankshaft Bearing
*b	No. 2 and No. 3 Crankshaft Bearing
*c	20.9 mm
*d	17.9 mm

NOTE:

Crankshaft bearings come in widths of 17.9 mm (0.705 in.) and 20.9 mm (0.823 in.). Install the 20.9 mm (0.823 in.) crankshaft bearings to the No. 1 and No. 4 cylinder block journal positions. Install the 17.9 mm (0.705 in.) crankshaft bearings to the No. 2 and No. 3 positions.

Install the upper crankshaft bearings.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Upper Crankshaft Bearing
*b	Correct
*c	Incorrect

Install the upper crankshaft bearings to the cylinder block sub-assembly as shown in the illustration.
NOTE:
- Do not apply engine oil to the crankshaft bearings or the contact surfaces.
- 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.
- Do not allow coolant to come into contact with the crankshaft bearing inner surface.
- If any coolant comes into contact with the crankshaft bearing inner surface, replace the crankshaft bearing with a new one.

Install the lower crankshaft bearings.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Vernier Caliper
*b	Number Mark

Install the lower crankshaft bearings to the crankshaft bearing caps.
Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and lower crankshaft bearing edge.
Difference Between (A) and (B)

0.7 mm (0.0276 in.) or less
NOTE:
- Do not apply engine oil to the crankshaft bearings or the contact surfaces.
- Do not allow coolant to come into contact with the crankshaft bearing inner surface.
- If any coolant comes into contact with the crankshaft bearing inner surface, replace the crankshaft bearing with a new one.

INSTALL CRANKSHAFT THRUST WASHER SET

Apply engine oil to the crankshaft thrust washer set.

Install the crankshaft thrust washer set under the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Oil Groove

INSTALL CRANKSHAFT

Apply engine oil to the crankshaft bearings, then place the crankshaft on the cylinder block sub-assembly.

Confirm the projections and numbers of the crankshaft bearing caps and install the 4 crankshaft bearing caps to the cylinder block sub-assembly.

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*a	Projection
*b	Number Mark

HINT:

A number is marked on each crankshaft bearing cap to indicate its installation position.

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

Temporarily install the 8 crankshaft bearing cap set bolts to the inside positions.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Less than 6 mm
*b	Bolt Length

Bolt Length

100 to 102 mm (3.94 to 4.02 in.)

Push the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and the cylinder block sub-assembly is less than 6 mm (0.236 in.) by using the 2 inside crankshaft bearing cap set bolts as a guide.

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Apply a light coat of engine oil to the threads and under the heads of the 8 crankshaft bearing cap set bolts.

Temporarily install the 8 crankshaft bearing cap set bolts to the outside positions.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Bolt Length

Bolt Length

105.5 to 107.5 mm (4.15 to 4.23 in.)

Install the crankshaft bearing cap set bolts.
HINT:

The crankshaft bearing cap set bolts are tightened in 2 progressive steps.
Step 1:
1. Uniformly tighten the 16 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.
  
  Fig 1: Crankshaft Bearing Cap Set Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 61 N.m (622 kgf/cm, 45 ft.lbf)
  
  HINT:
  
  If a crankshaft bearing cap bolt cannot be tightened to the specified torque, replace it.

Step 2:

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

*a	Paint Mark
*b	Turn 90°
	Front of Engine

Tighten the crankshaft bearing cap set bolts 90° in the order shown in the illustration.
Check that the paint marks are now at a 90° angle to the front.

Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.

Fig 2: Crankshaft Bearing Cap Set Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 51.5 N.m (525 kgf/cm, 38 ft.lbf)
Check that the crankshaft turns smoothly.
Check the crankshaft thrust clearance.
See step 10

INSTALL CONNECTING ROD BEARING

Install the connecting rod bearings to the connecting rod sub-assembly and connecting rod cap.

Using a vernier caliper, measure the distance between the connecting rod sub-assembly, connecting rod cap edges and the connecting rod bearing edge.

*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, the pistons, and the surfaces of the connecting rod bearings.

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

NOTE:

Do not align the ring ends.

*A	for Bank 1
*B	for Bank 2
*a	No. 1 Compression Ring
*b	No. 2 Compression Ring
*c	Front Mark
*d	Lower Side Rail
*e	Oil Ring Expander
*f	Upper Side Rail

Using a piston ring compressor, push the piston and connecting rod sub-assembly into the cylinder with the front mark of the piston facing the front of the engine.

*A	for Bank 1	*B	for Bank 2
*a	Front Mark	-	-
	Front of Engine	-	-

NOTE:

Match the connecting rod cap with the connecting rod sub-assembly.

Check that the front mark of the connecting rod cap is facing the front of the engine.

*a	Front Mark
	Front of Engine

Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
Install the 2 connecting rod bolts.
HINT:

The connecting rod bolts are tightened in 2 progressive steps.

Step 1:

Alternately tighten the 2 connecting rod bolts in several steps.

Torque: 24.5 N.m (250 kgf/cm, 18 ft.lbf)

Step 2:

*a	Paint Mark
*b	Turn 90°
	Front of Engine

Mark the front of each connecting rod bolt with paint.
Further tighten the connecting rod bolts 90° as shown in the illustration.
Check that the paint marks are now at a 90° angle to the front.

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