Engine Mechanical: Overhaul — Toyota MR2 W30 (1999-2007)

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.

Scheme 272

Scheme 272: REASSEMBLY

Scheme 273

Scheme 274

Scheme 275

Scheme 276

Scheme 277

Scheme 278

Scheme 279

INSTALL WATER HOSE UNIONS NOTE: When using a new cylinder head, water hose unions must be installed. 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 Using a press, press in a new water hose union until it is protruding from the cylinder head. Standard protrusion: 29 mm (1.14 in.) for A 66.5 mm (2.618 in.) for B 24 mm (0.95 in.) for C NOTE: Avoid pressing a new water hose union in too far by measuring the amount of protrusion while pressing.
INSTALL VALVES Using SST, push in a new oil seal. SST 09201-41020 NOTE: The intake valve oil seal is light brown and the exhaust valve oil seal is gray. NOTE: Pay much attention to assemble the oil seal for intake and exhaust. Assembling the wrong one may cause a failure. 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) 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. NOTE: Be careful not to damage the valve stem tip.
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.

Scheme 280

Scheme 280: REASSEMBLY

Scheme 281

Scheme 282

Scheme 283

Scheme 284

Scheme 285

Scheme 286

Scheme 287

Scheme 288

Scheme 289

Scheme 290

Scheme 291

Scheme 292

Scheme 293

Scheme 294

Scheme 295

Scheme 296

Scheme 297

Scheme 298

Scheme 299

Scheme 300

Scheme 301

Scheme 302

Scheme 303

ASSEMBLE PISTON AND CONNECTING ROD Using a small screwdriver, install a new snap ring at one end of the piston pin hole. NOTE: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. 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. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole. NOTE: Be sure that end gap of the snap ring is not as aligned with the pin hole cutout portion of the piston.
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 Position the piston rings so that the ring ends are as shown. NOTE: Do not align the ring ends.
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: Upper bearings have an oil groove and oil holes; Lower bearings do not. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings. NOTE: Install the bearing with the oil hole in the cylinder block. Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings. NOTE: Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick.
INSTALL THRUST WASHERS 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. Thoroughly clean all components to remove all the loose material. Using a non-reusable solvent, clean both sealing surfaces. Apply seal packing to the bearing cap subassembly. Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that has been cut to an 1 - 2 mm (0.004 - 0.08 in.) opening. NOTE: Avoid applying an excessive amount to the surface. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove the 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 NOTE: The bearing cap subassembly bolts are tightened in 3 steps (steps b, c and e ). If any of the bearing cap subassembly bolts are broken or deformed, replace them. 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. Torque: 22 N.m (225 kgf.cm, 16 ft.lbf) Tighten the bearing cap subassembly bolts in several passes. (Scheme 292) Torque: 44 N.m (449 kgf.cm, 32 ft.lbf) If any of the bearing cap subassembly 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 degrees and additional 45 degrees in the numerical order shown. Check that the painted mark is now at a 90 degree 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 step 16 under DISASSEMBLY.
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. NOTE: Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick. Check that the protrusion of the connecting rod cap is facing in the correct direction.
INSTALL CONNECTING ROD CAP BOLTS NOTE: The connecting rod cap bolts are tightened in 2 steps (steps b and d ). If any of the connecting rod cap bolts is broken or deformed, replace it. 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 degrees as shown. Check that the painted mark is now at a 90 degree angle to the front. Check that the crankshaft turns smoothly.
CHECK CONNECTING ROD THRUST CLEARANCE. See 12 under DISASSEMBLY.
INSTALL REAR CRANKSHAFT OIL SEAL. See step 2 under REPLACEMENT. NOTE: Wipe seal packing away from the contact surface of the cylinder block assembly and oil seal.
INSTALL OIL STRAINER 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: Do not use a solvent which will affect the painted surfaces. Apply seal packing to the oil pan as shown. 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. NOTE: Avoid applying an excessive amount to the surface. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove the nozzle from the tube and reinstall the 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. See «OIL AND FILTER»(ref-172852-S06015286812005030700000).
INSTALL OIL PUMP. See «OIL PUMP»(ref-172852-S30963328042005030700000)
INSTALL ENGINE COOLANT DRAIN UNION Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Install the drain union. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) HINT: After applying the specified torque, rotate the drain union clockwise until its drain port is facing downward.
INSTALL KNOCK SENSOR Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
INSTALL THERMOSTAT. See «INSTALLATION»(ref-172848-S12970190572005030400000).
INSTALL WATER BYPASS PIPE Torque: 9 N.m (92 kgf.cm, 80 in.lbf)
INSTALL CYLINDER HEAD. See «INSTALLATION»(ref-163243-S07096500512005030400000).
INSTALL TIMING SPROCKETS AND TIMING CHAIN. See «INSTALLATION»(ref-163243-S38459488852005030400000).
REMOVE ENGINE STAND

Engine Mechanical: Overhaul Toyota MR2 W30