Cylinder Block: Reassembly

HINT:

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

1. ASSEMBLE PISTON AND CONNECTING ROD 
   1. Using a small screwdriver, install a new snap ring on one side of the piston pin hole.
      Fig 1: Installing Snap Ring Using Small Screwdriver

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   2. Gradually heat the piston to about 60°C (140°F).
      Fig 2: Heating Piston

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   3. Coat the piston pin with engine oil.
   4. Position the piston front mark with respect to the outside mark on the connecting rod as shown in the diagram.
      NOTE: The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with "3L", the RH piston with "3R".
   5. Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.
      Fig 3: Positioning Pistons

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   6. Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.
   Fig 4: Installing Snap Ring

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2. INSTALL PISTON RINGS 
   1. Install the oil ring expander and 2 side rails by hand.
   2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
      Fig 5: Installing Compression Rings

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      Code mark: 

      COMPRESSION RING SPECIFICATION
      
      

      No.1	1R
      No.2	2R

   3. Position the piston rings so that the ring ends are as shown in Fig 6.
   NOTE: Do not align the ring ends.
   Fig 6: Positioning Piston Rings

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3. INSTALL BEARINGS 
   1. Align the bearing claw with the groove of the connecting rod or connecting cap.
   2. Install the bearings in the connecting rod and connecting rod cap.
   Fig 7: Installing Bearings

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4. INSTALL MAIN BEARINGS 

   HINT:

   • Main bearings come in widths of 19.5 mm (0.768 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No.1 and No.5 cylinder block journal positions with the main bearing cap. Install the 19.5 mm (0.768 in.) bearings in the other positions.
   • Upper bearings have an oil groove and oil holes; lower bearings do not.
   Fig 8: Installing Main Bearing

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   1. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.
      Fig 9: Pushing In Upper Bearings

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   2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.

   HINT:

   A number is marked on each main bearing cap to indicate the installation position.

   Fig 10: Aligning Bearing Claw

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5. INSTALL UPPER THRUST WASHERS 

   Install the 2 thrust washers under the No.3 journal position of the cylinder block with the oil grooves facing outward.

   Fig 11: Installing Upper Thrust Washers

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6. PLACE CRANKSHAFT ON CYLINDER BLOCK 
7. PLACE MAIN BEARING CAPS AND LOWER THRUST WASHERS ON CYLINDER BLOCK 
   1. Install the 2 thrust washers on the No.3 bearing cap with the grooves facing outward.
      Fig 12: Installing Lower Thrust Washers

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   2. Install the 5 main bearing caps in their proper locations.
   Fig 13: Installing Main Bearing Caps

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   HINT:

   Place the bearing caps level and let them return to their original position by their own weight.

   Fig 14: Placing Bearing Caps Level

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   NOTE: Do not install the main bearing cap by tapping it.
8. INSTALL MAIN BEARING CAP BOLTS 

   HINT:

   • The main bearing cap bolts are tightened in 2 progressive steps (steps  b and  d).
   • If any one of the main bearing cap bolts is broken or deformed, replace it.
   1. Apply a light coat of engine oil on the threads and under the main bearing cap bolts.
   2. Install and uniformly tighten the 20 main bearing cap bolts in several passes, in the sequence shown in Fig 15.

      Torque: 27 N.m (275 kgf.cm, 20 ft.lbf) 

      If any one of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.

      Fig 15: Installing And Tightening Main Bearing Caps Bolts In Sequence

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Mark the front of the main bearing cap bolt with paint.
   4. Retighten the main bearing cap bolts by 90° in the numerical order shown in Fig 16.
      Fig 16: Retighten Main Bearing Cap Bolts Additional 90°

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Check that the painted mark is now at a 90° angle to the front.
   6. Install a new seal washer to the main bearing cap bolt.
   7. Install and uniformly tighten the 10 main bearing cap bolts.

      Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

      Fig 17: Installing Main Bearing Cap Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   8. Check that the crankshaft turns smoothly.
9. CHECK CRANKSHAFT THRUST CLEARANCE (See  DISASSEMBLY   ) 
10. 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.

    NOTE: The shape of the piston varies for the LH and RH banks. The LH piston is marked with "3L", the RH piston with "3R".
    Fig 18: Installing Piston And Connecting Rod

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11. PLACE CONNECTING ROD CAP ON CONNECTING ROD 
    1. Match the numbered connecting rod cap with the connecting rod.
    2. Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.
       Fig 19: Placing Connecting Rod Cap On Connecting Rod

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check that the outside mark of the connecting rod cap is facing in correct direction.
12. INSTALL CONNECTING ROD CAP BOLTS 

    HINT:

    • The connecting rod cap bolts are tightened in 2 progressive steps (steps  b and  d).
    • If any one of the connecting rod cap bolts is broken or deformed, replace it.
    Fig 20: Installing Connecting Rod Cap Bolts

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    1. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
    2. Install and alternately tighten the 2 connecting rod cap bolts in several passes.

       Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) 

       If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.

       Fig 21: Installing And Tightening Connecting Rod Cap Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Mark the front of the connecting cap bolt with paint.
    4. Retighten the cap bolts 90° as shown in Fig 22.
       Fig 22: Tightening Connecting Rod Cap Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Check that the painted mark is now at a 90° angle to the front.
    6. Check that the crankshaft turns smoothly.
13. CHECK CONNECTING ROD THRUST CLEARANCE (See  DISASSEMBLY   ) 
14. INSTALL REAR OIL SEAL RETAINER 
    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.
       • Using a razor blade and gasket scraper, remove all the oil 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.
    2. Apply seal packing to the oil seal retainer as shown in Fig 23 .

       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 5 minutes of application. Otherwise the material must be removed and reapplied.
       • Immediately remove nozzle from the tube and reinstall cap.
       Fig 23: Applying Seal Packing To Oil Seal Retainer

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new O-ring to the cylinder block.
    4. Install the oil seal retainer with the 7 bolts.

       Torque: 8.0 N.m (80 kgf.cm, 71 in..lbf) 

    Fig 24: Installing O-Ring And Oil Seal Retainer Bolts

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15. INSTALL ENGINE COOLANT DRAIN UNIONS 
    1. Apply seal packing to 2 or 3 threads.

       Seal packing: Part No. 08826-00100 or equivalent 

       Fig 25: Applying Seal Packing To Threads

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the RH and LH drain unions.

       Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

       Fig 26: Installing RH And LH Drain Unions

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    HINT:

    After applying the specified torque, rotate the drain union clockwise until its drain port is facing forward.

16. INSTALL WATER SEAL PLATE 
    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the seal plate and cylinder block.
       • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
       • Thoroughly clean all components to remove all the loose material.
       • Using a non-residue solvent, clean both sealing surfaces.
    2. Apply seal packing to the seal plate as shown in Fig 27 .

       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 5 minutes of application. Otherwise the material must be removed and reapplied.
       • Immediately remove nozzle from the tube and reinstall cap.
         Fig 27: Applying Seal Packing To Seal Plate

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the seal plate with the 2 nuts. Alternately tighten the nuts in several passes.

       Torque: 14 N.m (145 kgf.cm, 10 ft.lbf) 

17. INSTALL OIL PUMP (See  INSTALLATION  ) 
18. INSTALL OIL STRAINER (See  INSTALLATION  ) 
19. INSTALL NO.1 OIL PAN (See  INSTALLATION  ) 
20. INSTALL OIL PAN BAFFLE PLATE (See  INSTALLATION  ) 
21. INSTALL NO.2 OIL PAN (See  INSTALLATION  ) 
22. INSTALL WATER PUMP (See  INSTALLATION  ) 
23. INSTALL ENGINE WIRE 
    1. Install the engine wire to the LH side of the cylinder block with the 4 bolts.
    2. Install the engine wire cover with the 2 bolts.
       Fig 28: Installing Engine Wire (LH)

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    3. Install the 2 brackets on the engine wire to the RH side of the cylinder block with the 2 bolts.
       Fig 29: Installing Engine Wire (RH)

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    4. Connect the crankshaft position sensor connector.
24. INSTALL KNOCK SENSORS (See  KNOCK SENSOR  ) 
25. INSTALL STARTER (See  REMOVAL & INSTALLATION (GS430)  ) 
26. INSTALL LH ENGINE MOUNTING BRACKET 

    Install the mounting bracket with the 4 bolts.

    Torque: 36 N.m (370 kgf.cm, 27 ft.lbf) 

    HINT:

    The LH mounting bracket is marked with "L".

    Fig 30: Installing Engine Mounting Bracket (LH)

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27. INSTALL RH ENGINE MOUNTING BRACKET 

    Install the mounting bracket with the 4 bolts.

    Torque: 36 N.m (370 kgf.cm, 27 ft.lbf) 

    HINT:

    The RH mounting bracket is marked with "R".

    Fig 31: Installing Engine Mounting Bracket (RH)

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28. INSTALL CYLINDER HEADS (See  INSTALLATION   ) 
29. INSTALL TIMING BELT AND PULLEYS (See  INSTALLATION   ) 
30. DISCONNECT ENGINE FROM ENGINE STAND