Part 1

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6) (RH Side):

COMPONENTS (Part 7) (LH Side):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

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, tap in the tight plugs.
SST 09950-60010 (09951-00340), 09950-70010 (09951-07100)

2. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, tap in new straight pins to the cylinder block.

Standard protrusion:

3. INSTALL STUD BOLT
(a) Using E8 and E10 "TORX" sockets wrench, install the stud bolt.
Torque:
A bolt 10 N*m (102 kgf/cm, 7 ft. lbs.)
B bolt 17 N*m (173 kgf/cm, 13 ft. lbs.)

4. INSTALL SUB-ASSEMBLY OIL NOZZLE NO. 1
(a) Using a 5 mm hexagon wrench, install the 3 oil nozzles with the bolts.
Torque: 9.0 N*m (92 kgf/cm, 80 in. lbs.)

5. INSTALL PISTON SUB-ASSEMBLY WITH PIN

(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 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 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.

6. INSTALL PISTON RING SET

(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned 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.

7. INSTALL CRANKSHAFT BEARING

NOTICE: Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

(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 and its contact surface.

(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): 0.7 mm (0.0276 in.) or less.

NOTICE: Do not apply engine oil to the bearing's contact area and underside.

8. INSTALL CRANKSHAFT

(a) Install the crankshaft thrust washer to the cylinder block.
(1) Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.
(b) Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.

(c) Confirm the front marks 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.

(d) Apply a light coat of engine oil to the threads and under the head of the bearing cap bolts.
(e) Temporarily install the 8 main bearing cap bolts to the inside positions.

(f) Insert the main bearing cap by hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.
Bolt length: 100 to 102 mm (3.94 to 4.02 in.)

(g) Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.
(h) Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.

(i) Install the 8 main bearing cap bolts to the outside positions.
Bolt length: 105.5 to 107.5 mm (4.15 to 4.23 in.)

(j) Install the crankshaft bearing cap bolts.

HINT: The main bearing cap bolts are tightened in 2 progressive steps.

(k) Step 1
(1) Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.
Torque: 61 N*m (622 kgf/cm, 45 ft. lbs.)
If any of the main bearing cap bolts does not meet the torque specified, replace it.

(l) Step 2
(1) Mark the front of the bearing cap bolts with paint.
(2) Tighten the bearing cap bolts another 90° in the order above.
(3) Check that the painted mark is now at a 90° angle to the front.
(m) Check that the crankshaft turns smoothly.
(n) Check the crankshaft thrust clearance.

(o) Install and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in the illustration.
Torque: 52 N*m (525 kgf/cm, 38 ft. lbs.)

HINT:
^ Bolt (A) length: 45 mm (1.77 in.)
^ Except bolt (A) length: 30 mm (1.18 in.)

(p) Check that the crankshaft turns smoothly.
(q) Check the crankshaft thrust clearance.

9. INSTALL CONNECTING ROD BEARING
(a) Install the connecting rod bearing to the connecting rod and bearing cap.
(b) Using vernier calipers, measure the distance between the connecting rod's and bearing cap's edges, and each connecting rod bearing's edge.
Dimension (A - B): 0.7 mm (0.0276 in.) or less

NOTICE: Do not apply engine oil to the bearing's contact area and underside.

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.
(d) 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 the connecting cap bolts.

HINT: The connecting cap bolts are tightened in 2 progressive steps.

(h) Step 1
(1) Install and alternately tighten the bolts of the connecting rod cap in several steps.
Torque: 25 N*m (255 kgf/cm, 18 ft. lbs.)

(i) Step 2
(1) Mark the front side of each connecting cap bolt with paint.
(2) Tighten the cap bolts another 90° as shown in the illustration.
(3) Check the painted mark is now at a 90° angle to the front.
(j) Check that the crankshaft turns smoothly.
(k) Check the connecting rod thrust clearance.

11. INSTALL RING PIN
(a) Using a plastic hammer, tap in 4 new ring pins to the specified protrusion height.
Specified protrusion height: 2.5 to 3.5 mm (0.098 to 0.138 in.)

12. INSTALL WITH HEAD STRAIGHT SCREW PLUG NO. 1
(a) Using a 10 mm hexagon wrench, install 4 new gaskets and the straight screw plugs.
Torque: 44 N*m (449 kgf/cm, 32 ft. lbs.)

13. INSTALL WITH HEAD STRAIGHT SCREW PLUG NO. 2
(a) Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 straight screw plugs.
Torque: 80 N*m (816 kgf/cm, 59 ft. lbs.)

14. INSTALL STUD BOLT

NOTICE: If the stud bolt is deformed or the threads are damaged, replace it.

(a) Using E6 and E8 "TORX" socket wrenches, install the stud bolts.
Torque:
A and B bolts 10 N*m (102 kgf/cm, 7 ft. lbs.)
C bolt 4.0 N*m (41 kgf/cm, 35 in. lbs.)

15. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, tap in 4 new straight pins as shown in the illustration.
Specified protrusion height: 17.5 to 19.5 mm (0.689 to 0.768 in.)

16. INSTALL VALVE SPRING SEAT
(a) Install the valve spring seats to the cylinder head.

17. INSTALL VALVE STEM OIL SEAL

(a) Apply a light coat of engine oil to new oil seals.

NOTICE: Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later.

HINT: The intake valve oil seals are white 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.

18. INSTALL INTAKE VALVE

(a) Apply a plenty of engine oil to the tip area of the intake valve shown in the illustration.
(b) Install the valve, compression spring and spring retainer to the cylinder head.

NOTICE: Install the same parts in the same combination to the original locations.

(d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE: Be careful not to damage the retainer.

19. INSTALL EXHAUST VALVE

(d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE: Be careful not to damage the retainer.