Engine Mechanical: Overhaul — Toyota Corolla IX (2000-2004)

REASSEMBLY

Note. Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace oil seals with new ones.

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Scheme 266: REASSEMBLY

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Install Water Hose Unions. Mark the standard position away from the edge, onto the water hose union. Apply adhesive to the water hose union hole of the cylinder head. Adhesive: Part No. 08833-00070, Three Bond 1324 or equivalent . NOTE: Avoid pressing a new water hose union in too far by measuring the amount of protrusion while pressing. Using a press, press in a new water hose union until there is protruding from the cylinder head. Standard protrusion: A: 29 mm (1.14 in.). B: 66.5 mm (2.618 in.). C: 24 mm (0.95 in.).
Install Valves. CAUTION: Pay much attention assembling the oil seal for intake and exhaust. Assembling the wrong one may cause a failure. Using SST, push in a new oil seal. The intake valve oil seal is light brown and the exhaust valve oil seal is gray. SST 09201-41020. Install the valve (1), spring (2), valve spring (3) and spring retainer (4). Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202-70020 (092002-00010). CAUTION: Be careful not to damage the valve stem tip. Using a plastic-faced hammer and the valve stem (not in use) tip wound with vinyl tape, lightly tap the valve stem tip to ensure a proper fit.
Install Valve Lifters. Install the valve lifter. Check that the valve lifter rotates smoothly by hand.

Note. Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace all gaskets, O-rings and oil seals with new parts.

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Scheme 274: REASSEMBLY

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Assemble Piston And Connecting Rod. NOTE: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. Using a small screwdriver, install a new snap ring at one end of the piston pin hole. Gradually heat the piston to 80 - 90°C (176 - 194°F). Coat the piston pin with engine oil. Align the front marks on the piston and connecting rod, and push in the piston with your thumb. NOTE: Be sure that end gap of the snap ring is not as aligned with the pin hole cutout portion of the piston. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.
Install Piston Rings. Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Code mark (No. 2 only): T or 2R . CAUTION: Do not align the ring ends. Position the piston rings so that the ring ends are as shown.
Install Connecting Rod Bearings. Align the bearing claw with the groove of the connecting rod or connecting cap. Install the bearings in the connecting rod and connecting rod cap.
Install Main Bearings. NOTE: Install the bearing with the oil hole in the cylinder block. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings. Align the bearing claw with the claw grove of the main bearing cap, and push in the 5 lower bearings.
Install The 2 Thrust Washers Under The No. 3 Journal Position Of The Cylinder Block With The Oil Grooves Facing Outward.
Place Crankshaft On Cylinder Block. .
Place Bearing Cap Subassembly On Cylinder Block. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap subassembly and cylinder block. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. throughly clean all components to remove all the loose material. Using a non-reusable solvent, clean both sealing surfaces. NOTE: Avoid applying an excessive amount to the surface. Apply seal packing to the bearing cap subassembly as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent . Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 in.) opening. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Using a plastic-faced hammer, lightly tap the bearing cap subassembly to ensure a proper fit.
Install 12 Pointed Head Bearing Cap Subassembly Bolts. The bearing cap subassembly bolts are tightened in 3 progressive steps (steps ( b ), ( c ) and ( e )). If any of the bearing cap subassembly bolts is broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the bearing cap subassembly bolts. Install and uniformly tighten the 10 bearing cap subassembly bolts, in several passes, in the sequence shown. Torque: 22 N.m (225 kgf.cm, 16 ft.lbf) . Retighten the bearing cap subassembly bolts, in several passes, in the sequence shown. Torque: 44 N.m (449 kgf.cm, 32 ft.lbf) . If any of the bearing cap sub-assembly bolts does not meet the torque specification, replace the bearing cap subassembly bolt. Mark the front of the bearing cap subassembly bolts with paint. Retighten the bearing cap subassembly bolts by 45° and 45° in the numerical order shown. Check that the painted mark is now at a 90° angle to the front.
Install Hexagon Head Bearing Cap Subassembly Bolts. Install and uniformly tighten the 10 bearing cap subassembly bolts in several passes. Torque: 18.5 N.m (189 kgf.cm, 14 ft.lbf) . Check that the crankshaft turns smoothly.
Check Crankshaft Thrust Clearance. See 21 in DASSASSEMBLY under CYLINDER BLOCK.
Install piston and connecting rod assembles : Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.
Place Connecting Rod Cap On Connecting Rod. Match the numbered connecting rod cap with the connecting rod. Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the connecting rod. Check that the protrusion of the connecting rod cap is facing in the correct direction.
Install Connecting Rod Cap Bolts. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. Install and alternately tighten the 2 connecting rod cap bolts in several passes. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) . If any of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts. Mark the front of the connecting cap bolts with paint. Retighten the cap bolts by 90° as shown. Check that the painted mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly.
Check Connecting Rod Thrust Clearance. See 17 In DISASSEMBLY Under CYLINDER BLOCK .
Install Rear Crankshaft Oil Seal. See Step 2 In Replacement.
Install a new gasket and the oil strainer with the 2 nuts and bolt. Torque: 9 N.m (92 kgf.cm, 80 in..lbf) .
Install Oil Pan. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the main bearing cap and oil pan. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces. NOTE: Avoid applying an excessive amount to the surface. Apply seal packing to the oil pan as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent . Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 in.) opening. Parts must be assembled within 3 minutes of application. Otherwise the material must be remove and reapplied. Immediately remove nozzle from the tube and reinstall cap. Install the oil pan with the 14 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 9 N.m (92 kgf.cm, 80 in..lbf) .
Install Oil Filter Union. Torque: 30 N.m (306 kgf.cm, 21 ft.lbf)
Install Oil Filter . .
Install Oil Pump . .
Install Engine Coolant Drain Union. Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833-00080, Three Bond 1344, LOCTITE 242 or equivalent . NOTE: After applying the specified torque, rotate the drain union clockwise until its drain port is facing downward. Install the drain union. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) .
Install Knock Sensor. . Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
Install Thermostat.
Install Water Bypass Pipe. Torque: 9 N.m (92 kgf.cm, 80 in..lbf) .
Install Oil Dipstick And Guide. Install a new O-ring on the dipstick guide. Apply soapy water on the O-ring. Connect the dipstick guide end to the main bearing cap. Install the dipstick guide with the bolt. Torque: 11 N.m (113 kgf.cm, 8 ft.lbf) .
Install Engine Wire .
Install Cylinder Head. See «INSTALLATION»(ref-163214-S16781007412005011900000) .
Install Timing Sprockets And Timing Chain. See «INSTALLATION»(ref-163214-S30615584612005011900000) .
Remove Engine Stand. .
M/T: Install Flywheel. Install and uniformly tighten the 8 mounting bolts, in several passes, in the sequence shown. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) . Mark the flywheel bolt with paint. Retighten the flywheel bolts by an additional 90°. Check that the painted mark in now at a 90° angle to ( b ).
A/T: Install Drive Plate. Install the front spacer, drive plate and rear plate on the crankshaft. Apply adhesive to 2 or 3 threads of the mounting bolt end, Adhesive: Part No. 08833-00070, Three Bond or equivalent . Install and uniformly tighten the 8 mounting bolts, in several passes, in the sequence shown. Torque: 83 N.m (850 kgf.cm, 61 ft.lbf) .

Engine Mechanical: Overhaul Toyota Corolla IX