INSTALLATION — Part 2 Toyota Corolla IX

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1. M/T: Remove Flywheel.
2. A/T: Remove Drive Plate.
3. Install Engine To Engine Stand For Disassembly.
4. Remove Timing Chain And Sprockets. . See «REMOVAL»(ref-163214-S35448928722005011900000) under TIMING CHAIN
5. Remove Cylinder Head. See 24 in REMOVAL under CYLINDER HEAD.
6. Remove Engine Wire.
7. Remove Oil Dipstick And Guide. Remove the 2 bolts and oil dipstick and guide. Remove the O-ring from the dipstick.
8. Remove The 2 Nuts, Bolt And Water Bypass Pipe.
9. Remove Thermostat.
10. Remove Knock Sensor.
11. Remove Engine Coolant Drain Union.
12. Remove Oil Pump
13. Remove Oil Filter
14. Using A 12-mm Hexagon Wrench, Remove The Oil Filter Union.
15. Remove Oil Pan. Remove the 14 bolts and 2 nuts. CAUTION: Be careful not to the damage the oil pan contact surface of the bearing cap subassembly. Be careful not to damage the oil pan flange. Insert the blade of SST between the bearing cap subassembly and oil pan, and cut off applied sealer and remove the oil pan. SST 09032-00100 .
16. Remove The 2 Nuts, Bolt, Oil Strainer And Gasket.
17. Using A Dial Indicator, Measure The Thrust Clearance While Moving The Connecting Rod Back And Forth. Standard thrust clearance: 0.160 - 0.342 mm (0.0063 - 0.0135 in.) . Maximum thrust clearance: 0.342 mm (0.0135 in.) . If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. Connecting rod thickness: 19.788 - 19.840 mm (0.0779 - 0.0781 in.) .
18. Remove Connecting Rod Caps And Check Oil Clearance. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. Remove the 2 connecting rod cap bolts. NOTE: Keep the lower bearing inserted with the connecting rod cap. 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. Clean the crank pin and bearing. Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. Lay a strip of Plastigage the crank pin. Install the connecting rod cap with the 2 bolts. See step 12 - 14 under REASSEMBLY. NOTE: Do not turn the crankshaft. Remove the 2 bolts, connecting rod cap and lower bearing (See steps ( b ) and ( c )). Measure the Plastigage at its widest point. Standard oil clearance: 0.028 - 0.060 mm (0.0011 - 0.0024 in.) . Maximum oil clearance: 0.08 mm (0.0031 in.) . NOTE: If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly. If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft. Completely remove the Plastigage.
19. Remove Piston And Connecting Rod Assembles. Using a ridge reamer, remove all the carbon from the top of the cylinder. NOTE: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
20. Remove Bearing Cap Subassembly And Crankshaft Rear Oil Seal, And Check Oil Clearance. Remove the 10 hexagon head bearing cap subassembly bolts. Uniformly loosen and remove the 10 bearing cap subassembly bolts, in several passes, in the sequence shown. CAUTION: Be careful not to damage the contact surfaces of the cylinder block and bearing cap subassembly. Keep the lower bearing and bearing cap subassembly together. Using a screwdriver, remove the bearing cap subassembly by prying the portions between the cylinder block and bearing cap subassembly. Remove the 5 lower main bearings. Remove the crankshaft rear oil seal. NOTE: Keep the upper bearings together with the cylinder block. Lift out the crankshaft. 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 bearings. If necessary, replace the crankshaft. Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. NOTE: Do not turn the crankshaft. Install the bearing cap subassembly. See 8 in REASSEMBLY. Remove the bearing cap subassembly (See steps ( a ) to ( e )). Measure the Plastigage at its widest point. If the oil clearance is greater then maximum, replace the bearings. If necessary, replace the crankshaft. Standard oil clearance: 0.015 - 0.032 mm (0.0006 - 0.0013 in.) . Maximum oil clearance: 0.050 mm (0.0020 in.) . NOTE: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then selecting the bearing with the same number as the total. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly. EXAMPLE: Cylinder block "4" (A) + Crankshaft "3" (B) = Total number 7 (Use bearing "3") Completely remove the Plastigage.
21. Check Crankshaft Thrust Clearance. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04 - 0.24 mm (0.0016 - 0.0094 in.) . Maximum thrust clearance: 0.30 mm (0.0118 in.) . If the thrust clearance is greater than maximum, replace the thrust washers as a set. Thrust washer thickness: 2.430 - 2.480 mm (0.0957 - 0.0976 in.) .
22. Remove Crankshaft. Lift out the crankshaft. NOTE: Arrange the main bearings and thrust washers in the correct order. Remove the 5 upper main bearings and 2 thrust washers from the cylinder block.
23. Check Fit Between 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.
24. Remove Piston Rings. Using a piston ring expander, remove the 2 compression rings. NOTE: Arrange the piston rings in the correct order only. Remove the 2 side rails and oil ring by hand.
25. Disconnect Connecting Rod From Piston. Using a small screwdriver, pry out the 2 snap rings. Gradually heat the piston to 80 - 90°C (176 - 194°F). NOTE: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.

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1. Clean Cylinder Block. Remove the gasket material. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. NOTE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash the cylinder block at a temperature of 45°C (133°F) or less. Clean the cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block.
2. Inspect Cylinder Block. Inspect for flatness. Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) . If warpage is greater than maximum, replace the cylinder block. Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block. Inspect the cylinder bore diameter. Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: 79.000 - 79.013 mm (3.1102 - 3.1107 in.) . Maximum diameter: 79.013 mm (3.1107 in.) . If the diameter is greater than maximum, replace the cylinder block.
3. Remove Cylinder Ridge. If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.
4. Inspect 12 Pointed Head Bearing Cap Subassembly Bolts. : Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.3 - 7.5 mm (0.287 - 0.295 in.) . Minimum diameter: 7.3 mm (0.287 in.) . If the diameter is less than minimum, replace the bolt.
5. Clean Piston. Using a gasket scraper, remove the carbon from the piston top. Using a groove cleaning tool or a broken ring, clean the piston ring grooves. CAUTION: Do not use a wire brush. Using a brush and solvent, thoroughly clean the piston.
6. Inspect Piston. Inspect the piston oil clearance. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 25.6 mm (1.008 in.) from the piston head. Piston diameter: 78.925 - 78.935 mm (3.1073 - 3.1077 in.) . Measure the cylinder bore diameter in the thrust directions. See step 2 c ). Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.065 - 0.088 mm (0.0026 - 0.0035 in.). Maximum oil clearance: 0.10 mm (0.0039 in.) . If the oil clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder block. Inspect the piston ring groove clearance. Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. Ring groove clearance: 0.020 - 0.070 mm (0.0008 - 0.0028 in.) . If the clearance is not as specified, replace the piston. Inspect the piston ring end gap. Insert the piston ring into the cylinder bore. Using the 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. If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block. Inspect the piston pin fit. At 80 - 90°C (176 - 194°F), you should be able to push the piston pin into the piston pin hole with your thumb.
7. Inspect Connecting Rod. Using a rod aligner and a feeler gauge, check the connecting rod alignment. Check for out-of-alignment. Maximum out-of-alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) . If out-of-alignment is greater than maximum, replace the connecting rod assembly. Check for twist. Maximum twist: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) . If twist is greater than maximum, replace the connecting rod assembly. Inspect the piston pin oil clearance. Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 20.012 - 20.021 mm (0.7879 - 0.7882 in.) . Using a micrometer, measure the piston pin diameter. Piston pin diameter: 20.004 - 20.013 mm (0.7876 - 0.7879 in.) . Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 in.) . Maximum oil clearance: 0.05 mm (0.0020 in.) . If the oil clearance is greater than maximum, replace the bushing. See step 1 under REPLACEMENT. If necessary, replace the piston and piston pin as a set.
8. Inspect Connecting Rod Bolts. Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 6.6 - 6.7 mm (0.260 - 0.264 in.) . Minimum diameter: 6.4 mm (0.252 in.) . If the diameter is less than minimum, replace the bolt.
9. Inspect Crankshaft. Inspect for circle runout. Place the crankshaft on V-blocks. Using a dial indicator, measure the circle runout, as shown in the illustration. Maximum circle runout: 0.03 mm (0.0012 in.) . If the circle runout is greater than maximum, replace the crankshaft. Inspect the main journals and crank pins. Using a micrometer, measure the diameter of each main journal and crank pin. If the diameter is not as specified, check the oil clearance. See «DISASSEMBLY»(ref-163214-S42778356062005011900000) . If necessary, replace the crankshaft. Check each main journal and crank pin for taper and out-of-round as shown. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) . If the taper and out-of-round is greater than maximum, replace the crankshaft.

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1. Replace Connecting Rod Bushings. Using SST and a press, press out the bushing. SST 09222-30010 Align the oil hoses of a new bushing and the connecting rod. Using SST and a press, press in the bushing. SST 09222-30010 Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (See page EM-74) between the bushing and piston pin. Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
2. Replace crankshaft rear oil seal : If the rear oil seal is installed to the cylinder block: Using a knife cut off the oil seal lip. CAUTION: Be careful not to damage the crankshaft. Tape the screwdriver tip. Using a screwdriver, pry out the oil seal. Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100)