Part 1

1ZZ-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

1. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, install 9 new straight pins into the cylinder block.
Standard protrusion:

2. INSTALL RING PIN
(a) Using a plastic hammer, install 5 new ring pins into the cylinder block.
Standard protrusion:

3. INSTALL STUD BOLT
(a) Using "TORX" socket wrenches E5 and E7, install 9 stud bolts into the cylinder block.
Torque:

4. INSTALL W/PIN PISTON SUB-ASSEMBLY

(a) Using a small screwdriver, install a new snap ring onto one end of the piston pin hole.

HINT: Make sure that the end gap of the snap ring is aligned with the pin hole cutout portion of the piston.

(b) Gradually heat the piston up to 80 to 90°C (176 to 194°F).

(d) Using a small screwdriver, install a new snap ring onto one end of the piston pin hole.

HINT: Make sure that the end gap of the snap ring is aligned with the pin hole cutout portion of the piston.

5. INSTALL PISTON RING SET

HINT: If reusing the piston rings, install them onto the matched pistons with the surfaces facing correctly.

(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
Code mark (No. 2 only):
2R

(a) Install the upper bearing with an oil groove onto the cylinder block.

NOTE: Do not apply engine oil to the bearing and its contact surface.

(b) Install the lower bearing onto the bearing cap.

NOTE: Do not apply engine oil to the bearing and its contact surface.

7. INSTALL CRANKSHAFT THRUST WASHER UPPER

(a) Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward.
8. INSTALL CRANKSHAFT

(a) Apply engine oil to the upper bearing, then install the crankshaft onto the cylinder block.
(b) Apply a light coat of engine oil to the bolt threads, bolt seats, and bearings of the bearing cap.

(c) Apply a continuous bead of seal packing (Diameter 2.5 to 3.5 mm (0.098 to 0.138 in.)) as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

- Remove any oil from the contact surface.
- Install the bearing cap sub-assembly within 3 minutes of applying seal packing.
- Do not put in engine oil for at least 2 hours after installation.

(d) Tighten the bolts to the specified torque in several passes in the sequence shown.
Torque: 44 Nm (449 kgf-cm, 33 ft-lbf)

(e) Mark the front of the bearing cap bolts with paint.
(f) Retighten the bearing cap bolts by 90° as shown in the illustration.
(g) Check that the painted mark of each bolt is now at a 90° angle to the front.

(h) Tighten the 10 other bolts for the bearing cap.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
9. INSTALL CONNECTING ROD BEARING

(a) Align the connecting rod bearing claw with the oil groove of the connecting rod cap.
(b) Install the connecting rod bearing onto the connecting rod cap.

NOTE: Do not apply engine oil to the bearing and its contact surface.

(c) Align the connecting rod bearing claw with the oil groove of the connecting rod.
(d) Install the connecting rod bearing onto the connecting rod.

NOTE: Do not apply engine oil to the bearing and its contact surface.

10. INSTALL CONNECTING ROD SUB-ASSEMBLY

(a) Position the piston rings so that the ring ends are as shown.
(b) Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.

(c) Using a piston ring compressor, correctly push into the numbered piston and connecting rod assemblies each cylinder with the front mark of the piston facing forward.

(d) Align the pin dowels of the connecting rod cap with the pins of the connecting rod, then install the connecting rod.

NOTE: Match the numbered connecting rod cap with the same numbered connecting rod.

(e) Check that the protruding portion of the connecting rod.
(f) Apply a light coat of engine oil to the threads and the bottom of the heads of the connecting rod cap bolts.

(g) Using SST, tighten the bolts in several passes to the specified torque.
SST: 09205-16010
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)

(h) Mark the front of the connecting cap bolts with paint.
(i) Retighten the cap bolts by an additional 90° as shown in the illustration.
(j) Check that the crankshaft turns smoothly.
11. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive to 2 or 3 threads of the cylinder block water drain cock, then install it within 3 minutes of applying as shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(b) After tightening the drain cock to the specified torque, turn the cylinder block water drain cock clockwise until its drain port faces downward (Procedure "A").

- Do not put in coolant for at least an hour after installation.
- Do not turn the drain union more than 360° in procedure "A", and never loosen it after setting the union correctly.

12. INSTALL OIL STRAINER FLANGE GASKET

(a) Install a new gasket onto the cylinder block.
13. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Install the oil strainer with the 2 nuts and bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
14. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material from the contact surface and thread holes.

(b) Apply a continuous bead of seal packing (Diameter 3.5 to 4.5 mm (0.138 to 0.177 in.)) as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

- Remove any oil from the contact surface.
- Install the oil pan within 3 minutes of applying seal packing.
- Do not put in engine oil for at least 2 hours after installing the oil pan.

(c) Install the oil pan with the 14 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

- Tighten the bolts and nuts to the specified torque in two passes.
- Tighten the bolts and nuts within 15 minutes of applying sealant (if possible within 3 minutes).

15. INSTALL OIL PAN DRAIN PLUG

(a) Place a new gasket on the oil pan drain plug, then install it onto the oil pan.
Torque: 37 Nm (377 kgf-cm, 27 ft-lbf)
16. INSTALL ENGINE REAR OIL SEAL
(a) Apply a light coat of multi-purpose grease to a new oil seal lip.

NOTE: Keep the lip free of foreign objects.

(b) Using SST and a hammer, tap the new oil seal in until its surface is flush with the rear oil seal retainer edge.
SST: 09223-15020
SST: 09950-70010
09951-07100

- Tap the oil seal in a vertical position.
- Wipe any extra grease off the crankshaft.

17. INSTALL OIL FILTER UNION

(a) Using a socket hexagon wrench 12, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
18. INSTALL OIL FILTER SUB-ASSEMBLY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, then tighten it until the gasket comes into contact with the seat.

(d) Using SST, tighten it an additional 3/4 turn.
SST: 09228-06501
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
19. INSTALL CYLINDER HEAD GASKET

(a) Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

- Make sure that the cylinder head gasket is mounted in the correct direction.
- Place the cylinder head gently in order to avoid damaging the gasket.

20. INSTALL CYLINDER HEAD SUB-ASSEMBLY

(a) Place the cylinder head on the cylinder block.
(b) Apply a light coat of engine oil to the threads and the bottom of the heads of the cylinder head bolts.

(c) Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)

(d) Mark the front of the cylinder head bolts with paint.
(e) Retighten the cylinder head bolts by 90° in the sequence order shown.
(f) Check that the paint mark of each bolt is at 90° angle to the front.
21. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

(a) Put the camshaft timing gear together with the camshaft with the straight pin off the key groove.
(b) Turn the camshaft timing gear in the left as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.

CAUTION: Be sure not to turn the camshaft timing gear to the retard angle side (the right angle).

(c) Check that there is no clearance between the gear fringe and camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
(e) Check that the camshaft timing gear can move to the retard angle side (the right angle), and is locked in the most retarded position.
22. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET

(a) Clamp the camshaft in a vise, then install the camshaft timing gear with the bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)

NOTE: Be careful not to damage the camshaft.