Engine Mechanical (2TR-FE) (Service Information): Removal & Installat… — Engine Mechanical (2TR-FE) (Service Information) — Mechanical

INSTALLATION

INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH Install the engine mounting bracket with the 4 bolts. Torque: 51 N*m (520 kgf*cm, 38 ft.*lbf)
INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH Install the engine mounting bracket with the 4 bolts. Torque: 51 N*m (520 kgf*cm, 38 ft.*lbf)
INSTALL FRONT ENGINE MOUNTING INSULATOR Install the 2 mounting insulators with the 2 nuts. Torque: 46 N*m (469 kgf*cm, 34 ft.*lbf)
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Install the oil level dipstick guide with the bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
INSTALL NO. 1 WATER BY-PASS PIPE Install a new gasket and the water by-pass pipe with the 2 nuts. Torque: 18 N*m (178 kgf*cm, 13 ft.*lbf)
INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY . Refer to «INSTALLATION - Step 13»(ref-422097-S00540834262011092600000)
INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET . Refer to «INSTALLATION - Step 16»(ref-422097-S00540834262011092600000)
INSTALL INTAKE MANIFOLD . Refer to «INSTALLATION - Step 1»(ref-422105-S17442334332011092600000)
INSTALL PURGE VSV . Refer to «INSTALLATION - Step 1»(ref-422150-S40670765682011092600000)
INSTALL FUEL DELIVERY PIPE WITH FUEL INJECTOR Install the fuel delivery pipe with fuel injector, refer to «INSTALLATION»(ref-422143-S20836050792011092600000) .
INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-421955-S14816338192011092600000)
INSTALL EXHAUST MANIFOLD . Refer to «INSTALLATION - Step 1»(ref-422105-S42274534812011092600000)
INSTALL AIR SWITCHING VALVE ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-422150-S23175575242011092600000)
INSTALL NO. 4 INTAKE PIPE . Refer to «INSTALLATION - Step 2»(ref-422150-S23175575242011092600000)
INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR . Refer to «INSTALLATION - Step 3»(ref-422150-S23175575242011092600000)
INSTALL GENERATOR ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-422158-S08245780152011092600000)
INSTALL IGNITION COIL ASSEMBLY . Refer to «INSTALLATION - Step 2»(ref-421955-S07606354592011092600000)

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Scheme 580: ILLUSTRATION

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Scheme 581: DISASSEMBLY

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REMOVE INTAKE VALVE Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks. SST: 09202-70020 09202-00010 Remove the retainer, compression spring and valve. HINT: Arrange the removed parts in the correct order.
REMOVE EXHAUST VALVE Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks. SST: 09202-70020 09202-00010 Remove the retainer, compression spring and valve. HINT: Arrange the removed parts in the correct order.
REMOVE VALVE STEM OIL SEAL Using needle-nose pliers, remove the 16 oil seals.
REMOVE VALVE SPRING SEAT Remove the 16 valve spring seats from the cylinder head.
REMOVE NO. 1 HEAD STRAIGHT SCREW PLUG NOTE: If coolant leaks from the No. 1 head straight screw plug or the plug is corroded, replace it. Using a 10 mm hexagon wrench, remove the 3 screw plugs and 3 gaskets.
REMOVE NO. 2 HEAD STRAIGHT SCREW PLUG NOTE: If coolant leaks from the No. 2 head straight screw plug or the plug is corroded, replace it. Using a 19 mm hexagon wrench, remove the screw plug and gasket.
REMOVE STUD BOLT NOTE: If a stud bolt is deformed or its threads are damaged, replace it.

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Scheme 585: INSPECTION

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INSPECT CYLINDER HEAD SUB-ASSEMBLY Using a precision straightedge and feeler gauge, measure the warpage of the surfaces that contact the cylinder block and manifolds. Maximum warpage 0.05 mm (0.00197 in.) TEXT IN ILLUSTRATION *a Cylinder Head Lower Side *b Intake Manifold Side *c Exhaust Manifold Side If the warpage is more than the maximum, replace the cylinder head. Using a dye penetrant, check the intake ports, exhaust ports and cylinder head surface for cracks. If cracked, replace the cylinder head.
INSPECT INNER COMPRESSION SPRING Using a vernier caliper, measure the free length of the inner compression spring. Standard free length 48.53 mm (1.91 in.) If the free length is not as specified, replace the spring. Using a steel square, measure the deviation of the inner compression spring. Maximum deviation 1.5 mm (0.0591 in.) Maximum angle 2° TEXT IN ILLUSTRATION *a Deviation If the deviation is more than the maximum, replace the spring.
INSPECT INTAKE VALVE Using a vernier caliper, measure the overall length of the valve. Standard overall length 106.26 mm (4.18 in.) Minimum overall length 105.96 mm (4.17 in.) If the overall length is less than the minimum, replace the intake valve. Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter 5.470 to 5.485 mm (0.215 to 0.216 in.) Using a vernier caliper, measure the valve head margin thickness. Standard margin thickness 1.05 to 1.45 mm (0.0413 to 0.0571 in.) Minimum margin thickness 0.50 mm (0.0197 in.) TEXT IN ILLUSTRATION *a Margin Thickness If the margin thickness is less than the minimum, replace the intake valve.
INSPECT EXHAUST VALVE Using a vernier caliper, measure the overall length of the valve. Standard overall length 106.74 mm (4.20 in.) Minimum overall length 106.44 mm (4.19 in.) If the overall length is less than the minimum, replace the exhaust valve. Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter 5.465 to 5.480 mm (0.215 to 0.216 in.) Using a vernier caliper, measure the valve head margin thickness. Standard margin thickness 1.2 to 1.6 mm (0.0472 to 0.0630 in.) Minimum margin thickness 0.50 mm (0.0197 in.) TEXT IN ILLUSTRATION *a Margin Thickness If the margin thickness is less than the minimum, replace the exhaust valve.
INSPECT VALVE SEAT Apply a light coat of Prussian blue to the valve face. Lightly press the valve face against the valve seat. HINT: Do not rotate the valve while pressing the valve against the valve seat. Check the valve face and valve seat by using the following procedure. Check that Prussian blue appears around the entire valve face. If not, replace the valve. If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat. Check that the valve seat contacts the middle of the valve face with the width between 1.1 and 1.4 mm (0.0433 and 0.0551 in.). TEXT IN ILLUSTRATION *a Width
INSPECT CAMSHAFT THRUST CLEARANCE Install the camshafts See step 7 . Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance 0.10 to 0.24 mm (0.00394 to 0.00945 in.) Maximum thrust clearance 0.26 mm (0.0102 in.) If the thrust clearance is more than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.
INSPECT CAMSHAFT OIL CLEARANCE Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. Lay a strip of Plastigage across each of the camshaft journals. TEXT IN ILLUSTRATION *1 Plastigage Install the bearing caps See step 7 . NOTE: Do not turn the camshafts. Remove the bearing caps See step 13 . Measure the Plastigage at its widest point. Standard Oil Clearance Item Specified Condition No. 1 journal 0.035 to 0.072 mm (0.00138 to 0.00283 in.) Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.) Maximum oil clearance 0.08 mm (0.00315 in.) TEXT IN ILLUSTRATION *1 Plastigage If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the cylinder head sub-assembly. Completely remove the Plastigage.
INSPECT VALVE GUIDE BUSH OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the guide bush. Standard bush inside diameter 5.51 to 5.53 mm (0.217 to 0.218 in.) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard Oil Clearance Item Specified Condition Intake 0.025 to 0.060 mm (0.000984 to 0.00236 in.) Exhaust 0.030 to 0.065 mm (0.00118 to 0.00256 in.) Maximum Oil Clearance Item Specified Condition Intake 0.08 mm (0.00315 in.) Exhaust 0.10 mm (0.00397 in.) If the clearance is more than the maximum, replace the valve and valve guide bush.

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Scheme 595: REPLACEMENT

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Scheme 601

REPLACE INTAKE VALVE GUIDE BUSH Heat the cylinder head to 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST and a hammer, tap out the guide bush. SST: 09201-01055 SST: 09950-70010 09951-07100 Using a caliper gauge, measure the bush bore diameter of the cylinder head. Standard Bush Bore Diameter Item Specified Condition STD 10.285 to 10.306 mm (0.405 to 0.406 in.) O/S 0.05 10.335 to 10.356 mm (0.407 to 0.408 in.) Select a new valve guide bush. New Valve Guide Bush Item Specified Condition Bush bore diameter 10.285 to 10.306 mm (0.405 to 0.406 in.) 10.335 to 10.356 mm (0.407 to 0.408 in.) Use bush STD O/S 0.05 If the bush bore diameter of the cylinder head is more than 10.306 mm (0.406 in.), machine the bush bore so that the diameter is between 10.335 and 10.356 mm (0.407 and 0.408 in.). If the bush bore diameter of the cylinder head is more than 10.356 mm (0.408 in.), replace the cylinder head. New Guide Bush Diameter Item Specified Condition STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.) O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.) HINT: Different bushes are used for the intake and exhaust. Standard bush length 43.0 to 44.0 mm (1.69 to 1.73 in.) Heat the cylinder head to 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST and a hammer, tap in a new valve guide bush to the specified protrusion height. SST: 09201-01055 SST: 09950-70010 09951-07100 Standard protrusion height 9.8 to 10.2 mm (0.386 to 0.402 in.) TEXT IN ILLUSTRATION *a Height Using a sharp 5.5 mm reamer, ream the valve guide bush to obtain the standard clearance between the guide bush and valve stem. Standard oil clearance 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
REPLACE EXHAUST VALVE GUIDE BUSH Heat the cylinder head to 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST and a hammer, tap out the guide bush. SST: 09201-01055 SST: 09950-70010 09951-07100 Using a caliper gauge, measure the bush bore diameter of the cylinder head. Standard Bush Bore Diameter Item Specified Condition STD 10.285 to 10.306 mm (0.405 to 0.406 in.) O/S 0.05 10.335 to 10.356 mm (0.407 to 0.408 in.) Select a new valve guide bush. New Valve Guide Bush Item Specified Condition Bush bore diameter 10.333 to 10.344 mm (0.4068 to 0.4072 in.) 10.383 to 10.394 mm (0.4088 to 0.4092 in.) Use bush STD O/S 0.05 If the bush bore diameter of the cylinder head is more than 10.306 mm (0.406 in.), machine the bush bore so that the diameter is between 10.335 and 10.356 mm (0.407 and 0.408 in.). If the bush bore diameter of the cylinder head is more than 10.356 mm (0.408 in.), replace the cylinder head. New Guide Bush Diameter Item Specified Condition STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.) O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.) HINT: Different bushes are used for the intake and exhaust. Standard bush length 43.0 to 44.0 mm (1.69 to 1.73 in.) Heat the cylinder head to 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST and a hammer, tap in a new valve guide bush to the specified protrusion height. SST: 09201-01055 SST: 09950-70010 09951-07100 Standard protrusion height 7.6 to 8.0 mm (0.299 to 0.315 in.) TEXT IN ILLUSTRATION *a Height Using a sharp 5.5 mm reamer, ream the valve guide bush to obtain the standard clearance between the guide bush and valve stem. Standard oil clearance 0.030 to 0.065 mm (0.00118 to 0.00256 in.)
REPLACE CAMSHAFT BEARING CAP SETTING RING PIN NOTE: It is not necessary to remove a ring pin unless it is being replaced. Remove the ring pins. Using a plastic-faced hammer, tap in a new ring pin until the pin stops. Standard Ring Pin Item Height Width Protrusion Height Ring pin 7 mm (0.276 in.) 10 mm (0.394 in.) 2.5 to 3.8 mm (0.0984 to 0.150 in.) TEXT IN ILLUSTRATION *1 Height *2 Width *3 Protrusion Height

Scheme 602

Scheme 602: REASSEMBLY

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INSTALL STUD BOLT NOTE: If a stud bolt is deformed or its threads are damaged, replace it. TEXT IN ILLUSTRATION *a Cylinder Head Upper Side *b Intake Side *c Front Side *d Exhaust Side Using E6, E7 and E8 "TORX" socket wrenches, install the stud bolts. for stud bolt A Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) for stud bolt B Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) for stud bolt C Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
INSTALL NO. 1 HEAD STRAIGHT SCREW PLUG NOTE: If coolant leaks from the No. 1 head straight screw plug or the plug is corroded, replace it. Using a 10 mm hexagon wrench, install 3 new gaskets and the straight screw plugs. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
INSTALL NO. 2 HEAD STRAIGHT SCREW PLUG NOTE: If coolant leaks from the No. 2 head straight screw plug or the plug is corroded, replace it. Using a 19 mm hexagon wrench, install a new gasket and the straight screw plug. Torque: 140 N*m (1428 kgf*cm, 103 ft.*lbf)
INSTALL VALVE SPRING SEAT Install the 16 valve spring seats to the cylinder head.
INSTALL VALVE STEM OIL SEAL Apply a light coat of engine oil to new oil seals. TEXT IN ILLUSTRATION *A Intake Side *B Exhaust Side *1 Gray *2 Black NOTE: Pay attention when installing the intake and exhaust oil seals. For example, installing an intake oil seal to the exhaust side or installing an exhaust oil seal to the intake side can cause installation problems later. HINT: The intake valve oil seals are gray and the exhaust valve oil seals are black. Using SST, push in the 16 oil seals to install them. SST: 09201-41020 TEXT IN ILLUSTRATION *1 Valve Stem Oil Seal NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.
INSTALL INTAKE VALVE Apply plenty of engine oil to the tip area of the intake valve shown in the illustration. TEXT IN ILLUSTRATION *a 30 mm (1.18 in.) or more Install the valve, compression spring and spring retainer to the cylinder head. NOTE: Install the same parts in the same combination to the original locations. Using SST and wooden blocks, compress the spring and install the 2 retainer locks. SST: 09202-70020 09202-00010 Using a 5 mm pin punch and plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit. TEXT IN ILLUSTRATION *1 5 mm Pin Punch NOTE: Do not damage the valve stem tip.
INSTALL EXHAUST VALVE Apply plenty of engine oil to the tip area of the intake valve shown in the illustration. TEXT IN ILLUSTRATION *a 30 mm (1.18 in.) or more Install the valve, compression spring and spring retainer to the cylinder head. NOTE: Install the same parts in the same combination to the original locations. Using SST and wooden blocks, compress the spring and install the 2 retainer locks. SST: 09202-70020 09202-00010 Using a 5 mm pin punch and plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit. TEXT IN ILLUSTRATION *1 5 mm Pin Punch NOTE: Do not damage the valve stem tip.

Scheme 609

Scheme 609: REPAIR

Scheme 610

REPAIR INTAKE VALVE SEAT NOTE: Repair the seat while checking the seating position. Keep the lip free of foreign matter. Take off the cutter gradually to make the intake valve seat smooth. If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat. TEXT IN ILLUSTRATION *1 Width If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat. TEXT IN ILLUSTRATION *1 Width Hand-lap the valve and valve seat with an abrasive compound. Check the valve seating position. Standard width 1.1 to 1.4 mm (0.0433 to 0.0551 in.)
REPAIR EXHAUST VALVE SEAT NOTE: Repair the seat while checking the seating position. Keep the lip free of foreign matter. Take off the cutter gradually to make the exhaust valve seat smooth. If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat. TEXT IN ILLUSTRATION *1 Width If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat. TEXT IN ILLUSTRATION *1 Width Hand-lap the valve and valve seat with an abrasive compound. Check the valve seating position. Standard width 1.1 to 1.4 mm (0.0433 to 0.0551 in.)

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Scheme 611: ILLUSTRATION

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Scheme 612: ILLUSTRATION

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Scheme 613: DISASSEMBLY

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INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance 0.15 to 0.35 mm (0.00591 to 0.0138 in.) Maximum thrust clearance 0.40 mm (0.0157 in.) If the thrust clearance is more than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
INSPECT CONNECTING ROD OIL CLEARANCE Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. HINT: The matchmarks on the connecting rods and caps are for ensuring correct reassembly. Remove the 2 connecting rod cap bolts. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing installed to the connecting rod cap. Clean the crank pin and bearing. Check the crank pin and bearing for pitting and scratches. Lay a strip of Plastigage on the crank pin. TEXT IN ILLUSTRATION *1 Plastigage Check that the front mark of the connecting rod cap is facing forward. TEXT IN ILLUSTRATION *1 Front Mark Install the connecting rod cap See step 13 . NOTE: Do not turn the crankshaft. Remove the 2 bolts and connecting rod cap (refer to the steps above). Measure the Plastigage at its widest point. Standard oil clearance 0.039 to 0.066 mm (0.00154 to 0.00260 in.) Maximum oil clearance 0.066 mm (0.00260 in.) TEXT IN ILLUSTRATION *1 Plastigage *2 4, 5 or 6 Mark If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft. If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. The standard thickness of each bearing is indicated by a 4, 5 or 6 mark on its surface. Standard crankshaft pin diameter 52.989 to 53.002 mm (2.086 to 2.087 in.) Standard Bearing Center Wall Thickness Item Specified Condition Mark 4 1.484 to 1.487 mm (0.05843 to 0.05854 in.) Mark 5 1.488 to 1.490 mm (0.05858 to 0.05866 in.) Mark 6 1.491 to 1.493 mm (0.05870 to 0.05878 in.) Completely remove the Plastigage. Perform the inspection above for each crank pin.
REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD Using a ridge reamer, remove all the carbon from the top of the cylinder. TEXT IN ILLUSTRATION *1 Ridge Reamer Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: Keep the bearing, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.
REMOVE CONNECTING ROD BEARING Remove the connecting rod bearings from the connecting rods and connecting rod caps. HINT: Arrange the removed parts in the correct order.
INSPECT CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance 0.02 to 0.22 mm (0.000787 to 0.00866 in.) Maximum thrust clearance 0.30 mm (0.0118 in.) If the thrust clearance is more than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft. Thrust washer thickness 2.440 to 2.490 mm (0.0961 to 0.0980 in.)
REMOVE CRANKSHAFT Uniformly loosen the 10 bearing cap bolts in several steps in the sequence shown in the illustration. HINT: Keep the lower bearings and crankshaft bearing caps together. Arrange the thrust washers in the correct order. Lift out the crankshaft to remove it. Remove the upper thrust washers from the cylinder block. HINT: Arrange the main bearing caps, bearings and thrust washers in the correct order.
REMOVE CRANKSHAFT BEARING Remove the crankshaft bearings from the cylinder block and bearing caps. HINT: Arrange the removed parts in the correct order.
REMOVE PISTON RING SET Using a piston ring expander, remove the 2 compression rings. Using a piston ring expander, remove the oil ring rail. Remove the oil ring expander by hand. HINT: Arrange the piston rings in the correct order.
REMOVE PISTON WITH PIN SUB-ASSEMBLY Check the fitting condition between the piston and piston pin. Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. Disconnect the connecting rod from the piston. Using a screwdriver, pry off the snap rings from the piston. TEXT IN ILLUSTRATION *1 Snap Ring Gradually heat the piston to approximately 80 to 90°C (176 to 194°F). Using a brass bar and plastic-faced hammer, lightly tap out the piston pin and remove the connecting rod. HINT: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
CLEAN PISTON WITH PIN SUB-ASSEMBLY Using a gasket scraper, remove the carbon from the piston top. Using a groove cleaning tool or broken ring, clean the piston ring grooves. Using solvent and a brush, thoroughly clean the piston. NOTE: Do not use a wire brush.
REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, remove the oil nozzles.
INSPECT BALANCE SHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth. Standard thrust clearance 0.07 to 0.13 mm (0.00276 to 0.00512 in.) Maximum thrust clearance 0.20 mm (0.00787 in.) If the thrust clearance is more than the maximum, replace the balance shaft thrust washer. If necessary, replace the balance shaft.
REMOVE NO. 1 BALANCE SHAFT Remove the bolt. Remove the balance shaft from the cylinder block. NOTE: When removing the balance shaft, be sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block.
REMOVE NO. 1 BALANCE SHAFT DRIVEN GEAR Mount the head portion of the balance shaft in a vise. NOTE: Do not damage the balance shaft. Remove the bolt. Remove the No. 1 balance shaft driven gear, sliding key, balance shaft thrust washer and balance shaft thrust spacer. TEXT IN ILLUSTRATION *1 No. 1 Balance Shaft Driven Gear *2 Sliding Key *3 Balance Shaft Thrust Washer *4 Balance Shaft Thrust Spacer
REMOVE NO. 2 BALANCE SHAFT Remove the 2 bolts. Remove the balance shaft from the cylinder block. NOTE: When removing the balance shaft, be sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block.
REMOVE NO. 2 BALANCE SHAFT DRIVEN GEAR Mount the head portion of the balance shaft in a vise. NOTE: Do not damage the balance shaft. Remove the bolt. Remove the No. 2 balance shaft driven gear and No. 2 balance shaft thrust washer. TEXT IN ILLUSTRATION *1 No. 2 Balance Shaft Driven Gear *2 No. 2 Balance Shaft Thrust Washer
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY Remove the water drain cock from the cylinder block. Remove the water drain cock plug from the water drain cock.
REMOVE STUD BOLT NOTE: If a stud bolt is deformed or its threads are damaged, replace it.

Scheme 635

Scheme 635: INSPECTION

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INSPECT CYLINDER BLOCK FOR WARPAGE Using a precision straightedge and feeler gauge, measure the warpage of the surface that contacts the cylinder head gasket. Maximum warpage 0.05 mm (0.00197 in.) If the warpage is more than the maximum, replace the cylinder block. Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all 4 cylinders. If necessary, replace the cylinder block.
INSPECT CYLINDER BORE Using a cylinder gauge, measure the cylinder bore diameter at position A in the thrust and axial directions. Standard diameter 94.990 to 95.003 mm (3.7398 to 3.7403 in.) Maximum difference in diameter 0.2 mm (0.00787 in.) Measurement position 70 mm (2.76 in.) TEXT IN ILLUSTRATION *1 Thrust Direction *2 Axial Direction Engine Front If the diameter is more than the maximum, rebore all 4 cylinders. If necessary, replace the cylinder block. Inspect the cylinder ridge. TEXT IN ILLUSTRATION *1 Ridge Reamer If the wear is less than 0.2 mm (0.00787 in.), using a ridge reamer, grind the top of the cylinder.
INSPECT PISTON DIAMETER Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the piston end is as specified. Distance 13.8 mm (0.543 in.) Standard diameter 94.941 to 94.971 mm (3.738 to 3.739 in.) TEXT IN ILLUSTRATION *a Distance
INSPECT PISTON OIL CLEARANCE Measure the cylinder bore diameter in the thrust direction. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance 0.019 to 0.052 mm (0.000748 to 0.00205 in.) If the oil clearance is more than the standard, replace all the pistons and rebore all the cylinders. If necessary, replace the cylinder block.
INSPECT RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. Standard Ring Groove Clearance Item Specified Condition No. 1 compression ring 0.020 to 0.075 mm (0.000787 to 0.00295 in.) No. 2 compression ring 0.020 to 0.065 mm (0.000787 to 0.00256 in.) Oil ring 0.020 to 0.070 mm (0.000787 to 0.00276 in.) If the groove clearance is not as specified, replace the piston with pin.
INSPECT PISTON RING END GAP Insert the piston ring into the cylinder bore. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. Using a feeler gauge, measure the end gap. Standard End Gap Item Specified Condition No. 1 compression ring 0.26 to 0.38 mm (0.0102 to 0.0150 in.) No. 2 compression ring 0.59 to 0.71 mm (0.0232 to 0.0280 in.) Oil ring 0.10 to 0.40 mm (0.00394 to 0.0157 in.) Maximum End Gap Item Specified Condition No. 1 compression ring 0.90 mm (0.0354 in.) No. 2 compression ring 1.36 mm (0.0535 in.) Oil ring 0.75 mm (0.0295 in.) If the end gap is more than the maximum, replace the piston ring. If the end gap is less than the standard, even with a new piston ring, rebore all 4 cylinders or replace the cylinder block.
INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the piston pin hole. Standard piston pin hole inside diameter 22.001 to 22.010 mm (0.866 to 0.867 in.) If the diameter is not as specified, replace the piston with pin. Using a micrometer, measure the piston pin diameter. Measurement Position Measurement Position Piston Pin Position a 31 mm (1.22 in.) b 6 mm (0.24 in.) Standard piston pin diameter 21.997 to 22.009 mm (0.8660 to 0.8665 in.) If the diameter is not as specified, replace the piston with pin. Subtract the piston pin diameter measurement from the piston pin hole diameter measurement. Standard oil clearance 0.001 to 0.007 mm (0.0000394 to 0.000276 in.) Maximum oil clearance 0.010 mm (0.000394 in.) If the oil clearance is more than the maximum, replace the piston and piston pin as a set. Using a caliper gauge, measure the inside diameter of the connecting rod bush. Standard bush inside diameter 22.005 to 22.014 mm (0.866 to 0.867 in.) If the diameter is not as specified, replace the connecting rod small end bush. Subtract the piston pin diameter measurement from the bush inside diameter measurement. Standard oil clearance 0.005 to 0.011 mm (0.000197 to 0.000433 in.) Maximum oil clearance 0.025 mm (0.000984 in.) TEXT IN ILLUSTRATION *1 Piston Pin Hole Inside Diameter Mark *2 Connecting Rod Bushing Inside Diameter Mark *3 Front Mark If the oil clearance is more than the maximum, replace the connecting rod small end bush. If necessary, replace the connecting rod and piston pin as a set.
INSPECT CONNECTING ROD SUB-ASSEMBLY Using a rod aligner and feeler gauge, check the connecting rod alignment. Check for bend. Maximum bend 0.03 mm (0.00118 in.) per 100 mm (3.94 in.) If the bend is more than the maximum, replace the connecting rod sub-assembly. Check for twist. Maximum twist 0.15 mm (0.00591 in.) per 100 mm (3.94 in.) If the twist is more than the maximum, replace the connecting rod sub-assembly.
INSPECT CRANKSHAFT Inspect the circle runout. Place the crankshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout 0.03 mm (0.00118 in.) If the circle runout is more than the maximum, replace the crankshaft. Inspect the main journals. Using a micrometer, measure the diameter of each main journal. Standard Journal Diameter Item Specified Condition No. 3 journal 59.981 to 59.994 mm (2.361 to 2.362 in.) Except No. 3 journal 59.987 to 60.000 mm (2.3617 to 2.3622 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. Check each main journal for taper and out-of- round as shown in the illustration. Maximum taper and out-of-round 0.005 mm (0.000197 in.) If the taper and out-of-round is more than the maximum, replace the crankshaft. Inspect the crank pin. Using a micrometer, measure the diameter of each crank pin. Standard diameter 52.989 to 53.002 mm (2.086 to 2.087 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. Check each crank pin for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round 0.003 mm (0.000118 in.) If the taper and out-of-round is more than the maximum, replace the crankshaft.
INSPECT CRANKSHAFT OIL CLEARANCE HINT: Keep the lower bearings and crankshaft bearing caps together. Arrange the thrust washers in the correct order. Keep the upper crankshaft bearings and upper thrust washers together with the cylinder block. Clean each main journal and bearing. Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearing. Install the crankshaft bearings and upper crankshaft thrust washers. Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. TEXT IN ILLUSTRATION *1 Plastigage Install the 5 crankshaft bearing caps with the 10 bolts See step 11 . NOTE: Do not turn the crankshaft. Remove the 10 bolts and 5 crankshaft bearing caps See step 6 . Measure the Plastigage at its widest point. Standard Oil Clearance Item Specified Condition No. 3 journal 0.036 to 0.067 mm (0.00142 to 0.00264 in.) Other journals 0.030 to 0.061 mm (0.00118 to 0.00240 in.) Maximum oil clearance 0.10 mm (0.00394 in.) TEXT IN ILLUSTRATION *1 Plastigage *2 No. 1 Journal *3 No. 2 Journal *4 No. 3 Journal *5 No. 4 Journal *6 No. 5 Journal *7 Mark 1, 2 or 3 If the oil clearance is more than the maximum, replace the crankshaft bearing. If replacing the cylinder block, measure the bearing standard clearance. If replacing a bearing, first check the number on the cylinder block for the journal of the bearing. Then replace the bearing with one that has the same number. The standard thickness of each bearing is indicated by a 1, 2 or 3 mark on its surface. Standard Cylinder Block Main Journal Bore Diameter Item Specified Condition Mark 1 64.004 to 64.010 mm (2.51984 to 2.52007 in.) Mark 2 64.011 to 64.016 mm (2.52011 to 2.52031 in.) Mark 3 64.017 to 64.022 mm (2.52035 to 2.52055 in.) Standard Bearing Center Wall Thickness Item Specified Condition Mark 1 1.987 to 1.990 mm (0.07823 to 0.07835 in.) Mark 2 1.991 to 1.993 mm (0.07839 to 0.07846 in.) Mark 3 1.994 to 1.996 mm (0.07850 to 0.07858 in.) Completely remove the Plastigage. Perform the inspection above for each journal.
INSPECT NO. 1 BALANCE SHAFT Inspect the diameter of the journal. Using a micrometer, measure the diameter of the balance shaft main journals. Standard Main Journal Diameter Item Specified Condition A 37.969 to 37.985 mm (1.49 to 1.50 in.) B 37.449 to 37.465 mm (1.474 to 1.475 in.) Inspect the diameter of the bearing. Using a cylinder gauge, measure the inside diameter of the balance shaft bearing. Standard Bearing Inside Diameter Item Specified Condition A 38.025 to 38.045 mm (1.497 to 1.498 in.) B 37.525 to 37.545 mm (1.477 to 1.478 in.) Inspect the oil clearance. Subtract the balance shaft main journal diameter measurement from the balance shaft bearing inside diameter measurement. Standard Oil Clearance Item Specified Condition A 0.040 to 0.076 mm (0.00157 to 0.00299 in.) B 0.060 to 0.096 mm (0.00236 to 0.00378 in.) Maximum oil clearance 0.15 mm (0.00591 in.) If the oil clearance is more than the maximum, replace the cylinder block and balance shaft.
INSPECT NO. 2 BALANCE SHAFT Inspect the diameter of the journal. Using a micrometer, measure the diameter of the balance shaft main journals. Standard Main Journal Diameter Item Specified Condition A 37.969 to 37.985 mm (1.49 to 1.50 in.) B 37.449 to 37.465 mm (1.474 to 1.475 in.) Inspect the diameter of the bearing. Using a cylinder gauge, measure the inside diameter of the balance shaft bearing. Standard Bearing Inside Diameter Item Specified Condition A 38.025 to 38.045 mm (1.497 to 1.498 in.) B 37.525 to 37.545 mm (1.477 to 1.478 in.) Inspect the oil clearance. Subtract the balance shaft main journal diameter measurement from the balance shaft bearing inside diameter measurement. Standard Oil Clearance Item Specified Condition A 0.040 to 0.076 mm (0.00157 to 0.00299 in.) B 0.060 to 0.096 mm (0.00236 to 0.00378 in.) Maximum oil clearance 0.15 mm (0.00591 in.) If the oil clearance is more than the maximum, replace the cylinder block and balance shaft.
INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY Push the check valve with a pin to check if it is stuck. TEXT IN ILLUSTRATION Push If the check valve is stuck, replace the No. 1 oil nozzle. Push the check valve with a pin to check if it moves smoothly. If the check valve does not move smoothly, clean or replace the No. 1 oil nozzle. Apply air into A. Check that air does not leak through B. TEXT IN ILLUSTRATION Air If air leaks, clean or replace the No. 1 oil nozzle. Push the check valve while applying air into A. Check that air passes through B. TEXT IN ILLUSTRATION Air Push If air does not pass through B, clean or replace the No. 1 oil nozzle.
INSPECT CRANKSHAFT BEARING CAP SET BOLT Using a vernier caliper, measure the diameter of the most elongated threads in the measuring area. Distance 64 mm (2.52 in.) Standard diameter 10.76 to 10.97 mm (0.424 to 0.432 in.) Minimum diameter 10.66 mm (0.420 in.) TEXT IN ILLUSTRATION *a Distance *b Measuring Area If the diameter is less than the minimum, replace the crankshaft bearing cap bolt.
INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter 7.2 to 7.3 mm (0.283 to 0.287 in.) Minimum diameter 7.0 mm (0.276 in.) TEXT IN ILLUSTRATION *1 Tension Portion If the diameter is less than the minimum, replace the connecting rod bolt.

Scheme 656

Scheme 656: REPLACEMENT

Scheme 657

Scheme 658

Scheme 659

Scheme 660

Scheme 661

Scheme 662

REPLACE CONNECTING ROD SMALL END BUSH Using SST and a press, press out the bush. SST: 09222-30010 Align the oil holes of a new bush and the connecting rod. TEXT IN ILLUSTRATION *1 Oil Hole Using SST and a press, press in the bush. SST: 09222-30010 Using a pin hole grinder, hone the bush to obtain the standard specified clearance between the bush and piston pin. 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.
REPLACE TIGHT PLUG NOTE: If coolant leaks from the tight plug or the plug is corroded, replace it. TEXT IN ILLUSTRATION *a Front Side *b Intake Side *c Rear Side *d Exhaust Side Apply adhesive to new tight plugs. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. Using SST, tap in the 8 tight plugs labeled A and C. SST: 09950-60010 09951-00350 SST: 09950-70010 09951-07100 Using SST, tap in the tight plug labeled B. SST: 09950-60010 09951-00300 SST: 09950-70010 09951-07100 Using SST, tap in the 3 tight plugs labeled D. SST: 09950-60010 09951-00400 SST: 09950-70010 09951-07100
REPLACE STRAIGHT PIN NOTE: It is not necessary to remove a straight pin unless it is being replaced. Using a plastic-faced hammer, tap in new straight pins to the cylinder block. Standard Straight Pin Item Wide Protrusion Pin A 10 mm (0.394 in.) 13 mm (0.512 in.) Pin B 6.0 mm (0.236 in.) 5.5 mm (0.217 in.) TEXT IN ILLUSTRATION *1 Protrusion *a Rear Side
REPLACE RING PIN NOTE: It is not necessary to remove a ring pin unless it is being replaced. TEXT IN ILLUSTRATION *1 Height *2 Width *3 Protrusion - - *a Front Side *b Lower Side *c Upper Side - - Using a plastic-faced hammer, tap in new ring pins to the cylinder block. Standard Ring Pin Item Height Width Protrusion Pin A 9.0 mm (0.354 in.) 11 mm (0.433 in.) 3.5 to 4.5 mm (0.138 to 0.177 in.) Pin B 14 mm (0.511 in.) 15 mm (0.591 in.) 7.5 to 9.5 mm (0.295 to 0.374 in.) Pin C 20 mm (0.787 in.) 14 mm (0.511 in.) 7.0 to 9.0 mm (0.276 to 0.354 in.)

Scheme 663

Scheme 663: REASSEMBLY

Scheme 664

Scheme 665

Scheme 666

Scheme 667

Scheme 668

Scheme 669

Scheme 670

Scheme 671

Scheme 672

Scheme 673

Scheme 674

Scheme 675

Scheme 676

Scheme 677

Scheme 678

INSTALL STUD BOLT NOTE: If a stud bolt is deformed or its threads are damaged, replace it. TEXT IN ILLUSTRATION *a Front Side *b Lower Side *c Exhaust Side - - Using an E8 "TORX" socket wrench, install the stud bolts labeled A. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Using an E7 "TORX" socket wrench, install the stud bolts labeled B and D. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Apply adhesive to the hole for the stud bolt labeled C in the cylinder block. Using an E7 "TORX" socket wrench, install the stud bolt labeled C. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) HINT: When reusing a stud bolt, apply adhesive to the bolt before installing it. Adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY Apply adhesive to the drain cock. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the cylinder block water drain cock as shown in the illustration. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) TEXT IN ILLUSTRATION *a Upper Side *b Front *c Allowable Range *d Target Direction NOTE: 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 to adjust it. If an adjustment is necessary, remove the drain cock and reinstall it. Install the water drain cock plug to the water drain cock sub-assembly. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, install the oil nozzles. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
INSTALL NO. 2 BALANCE SHAFT DRIVEN GEAR Mount the head portion of the balance shaft in a vise. NOTE: Do not damage the balance shaft. Install the No. 2 balance shaft thrust washer and No. 2 balance shaft driven gear. TEXT IN ILLUSTRATION *1 No. 2 Balance Shaft Driven Gear *2 No. 2 Balance Shaft Thrust Washer Install the bolt. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
INSTALL NO. 2 BALANCE SHAFT Install the balance shaft to the cylinder block. NOTE: When installing the balance shaft, be sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block. Install the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
INSTALL NO. 1 BALANCE SHAFT DRIVEN GEAR Mount the head portion of the balance shaft in a vise. NOTE: Do not damage the balance shaft. Install the No. 1 balance shaft thrust washer, balance shaft thrust spacer, sliding key and No. 1 balance shaft driven gear. TEXT IN ILLUSTRATION *1 No. 1 Balance Shaft Driven Gear *2 Sliding Key *3 Balance Shaft Thrust Washer *4 Balance Shaft Thrust Spacer Install the bolt. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
INSTALL NO. 1 BALANCE SHAFT Install the No. 1 balance shaft to the cylinder block. NOTE: When installing the balance shaft, be sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block. Install the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
INSTALL PISTON WITH PIN SUB-ASSEMBLY Assemble the piston and connecting rod. Using a screwdriver, install a new snap ring at one end of the piston pin hole. TEXT IN ILLUSTRATION *1 Service Cutout HINT: Make sure that the end gap of the snap ring is not aligned with the service cutout of the piston. Gradually heat the piston to approximately 35 to 45°C (95 to 113°F). Coat the piston pin with engine oil. Align the front marks of the piston and connecting rod and push in the piston pin with your thumb. TEXT IN ILLUSTRATION *1 Front Mark HINT: The piston and pin are a matched set. Using a screwdriver, install a new snap ring at the other end of the piston pin hole. TEXT IN ILLUSTRATION *1 Service Cutout HINT: Make sure that the end gap of the snap ring is not aligned with the service cutout of the piston. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
INSTALL PISTON RING SET Install the oil ring expander by hand. Using a piston ring expander, install the oil ring rail. Using a piston ring expander, install the 2 compression rings so that the cord marks are positioned as shown in the illustration. HINT: Install the No. 1 compression ring with the code mark (1N) facing upward. Install the No. 2 compression ring with the code mark (2N) facing upward. TEXT IN ILLUSTRATION *1 Code Mark *2 No. 1 Compression Ring *3 No. 2 Compression Ring Position the piston rings so that the ring ends are as shown in the illustration. TEXT IN ILLUSTRATION *1 No. 1 Compression Ring *2 No. 2 Compression Ring *3 Oil Ring *4 Oil Ring Expander *5 No. 1 Compression Ring and Oil Ring Engine Front NOTE: Do not align the compression ring ends.
INSTALL CRANKSHAFT BEARING NOTE: Do not apply engine oil to the contact area or backside of the bearing. Clean the main journal and both surfaces of the bearing. Install the upper bearing. Install the upper bearing to the cylinder block. Reference (Difference in Dimension of Cylinder Block and Bearing) Item Specified Condition # 1, 5 journal 3.75 mm (0.148 in.) # 3 journal 1.74 mm (0.0684 in.) # 2, 4 journal 2.75 mm (0.108 in.) NOTE: Do not apply engine oil to the bearings or their contact surfaces. Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal. TEXT IN ILLUSTRATION *1 Oil Groove *a CORRECT *b INCORRECT Install the lower bearing. Install the lower bearing to the bearing cap. Using a vernier caliper, measure the distance between the bearing cap edge and lower bearing edge. Dimension A - B or B - A 0.3 mm (0.0118 in.) or less Reference (Dimension of A or B) Item Specified Condition # 1, 5 journal 3.75 mm (0.148 in.) # 3 journal 1.75 mm (0.0689 in.) # 2, 4 journal 2.75 mm (0.108 in.) NOTE: Do not apply engine oil to the bearings or their contact surfaces. With the upper bearing and lower bearing installed, use a plastic-faced hammer to install the bearing caps to the cylinder block. NOTE: Make sure that the bearing caps are installed in the correct positions and facing in the correct direction. Using a vernier caliper, measure the amount of misalignment between the upper bearing and lower bearing as shown in the illustration. Standard misalignment 0.9 mm (0.0354 in.) or less TEXT IN ILLUSTRATION *a Misalignment Remove the bearing cap. Apply engine oil to the thrust washers. Install the 2 thrust washers to the No. 3 journal position of the cylinder block with the oil grooves facing outward. TEXT IN ILLUSTRATION *1 Oil Groove NOTE: Be careful when installing the upper and lower thrust washers as they are similar but cannot be interchanged. Install the 2 thrust washers to the No. 3 bearing cap with the grooves facing outward. TEXT IN ILLUSTRATION *1 Claw *2 Oil Groove NOTE: Be careful when installing the thrust bearing upper and lower as they are similar but cannot be interchanged. The bearing lower has a claw as shown in the illustration. Apply engine oil to the lower bearing.
INSTALL CRANKSHAFT Apply engine oil to the upper bearing, and then place the crankshaft on the cylinder block. Install the 5 crankshaft bearing caps in their proper locations. Install the crankshaft bearing cap bolt. HINT: The main bearing cap bolts are tightened in 2 progressive steps. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Temporarily install the crankshaft bearing cap bolts. Step 1: Uniformly tighten the 10 main bearing cap bolts in the sequence shown in the illustration. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt. Mark the front of the bearing cap bolts with paint. Step 2: Tighten the bearing cap bolts 90° in the sequence shown in step 1. Check that the paint marks are now at a 90° angle to the front. Check that the crankshaft turns smoothly. Check the crankshaft thrust clearance See step 5 .
INSTALL CONNECTING ROD BEARING Align the bearing claw with the groove of the connecting rod or connecting rod cap. TEXT IN ILLUSTRATION *1 Claw Install the bearings to the connecting rod and connecting rod cap. NOTE: Clean the backside of the bearing and the surface of the connecting rod or connecting rod cap that contacts the bearing.
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 rings so that the ring ends are as shown in the illustration. TEXT IN ILLUSTRATION *1 No. 1 Compression Ring *2 No. 2 Compression Ring *3 Oil Ring *4 Oil Ring Expander *5 No. 1 Compression Ring and Oil Ring Engine Front NOTE: Do not align the compression ring ends. Using a piston ring compressor, push the numbered piston and connecting rod assembly into the correct cylinder with the front mark of the piston facing forward. TEXT IN ILLUSTRATION *1 Front Mark *a Engine Front Match the numbered connecting rod cap with the correct connecting rod. Check that the front mark of the connecting rod cap is facing forward. TEXT IN ILLUSTRATION *1 Front Mark Install the connecting rod cap bolts. HINT: The connecting rod cap bolts are tightened in 2 progressive steps. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts. Step 1: Install and alternately tighten the bolts of the connecting rod cap in several steps. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) Mark the front of each connecting rod cap bolt with paint. Step 2: Tighten the cap bolts 90° as shown. Check that the painted marks are now at a 90° angle to the front. Check that the crankshaft turns smoothly. Check the connecting rod thrust clearance See step 1 .

Engine Mechanical (2TR-FE) (Service Information): Removal & Installation Toyota 4Runner V