Reassembly

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

REASSEMBLY

1. INSTALL STUD BOLT

2. INSTALL STRAIGHT PIN

3. INSTALL RING PIN

4. INSTALL PISTON SUB-ASSEMBLY WITH PIN

(a) Using a small screwdriver, install a new snap ring on one side of the piston pin hole.

(b) Gradually heat the piston to about 60°C (140°F).

(c) Coat the piston pin with engine oil.
(d) The piston's front mark and the connecting rod's outside mark should face the same direction, as shown in the illustration.

NOTICE: The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with a "3L" and the RH piston is marked with a "3R".

(e) Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.

(f) Check the fit between the piston and piston pin.
(1) Try to move the piston back and forth on the piston pin.

(g) Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.

(h) Install the oil ring expander and 2 side rails by hand.
(i) Using a piston ring expander, install the No. 1 and No. 2 piston rings with the code mark facing upward.

Code mark:

(j) Position the piston rings so that the ring ends are as shown in the illustration.

NOTICE: Do not align the ring ends.

5. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the connecting rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting rod cap.

6. INSTALL CRANKSHAFT BEARING

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 crankshaft 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.

(a) Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.

(b) Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings.

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

7. INSTALL CRANKSHAFT THRUST WASHER

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

(b) Install the 2 thrust washers on the No. 3 bearing cap with the grooves facing outward.

8. INSTALL CRANKSHAFT

(a) Place the crankshaft on the cylinder block.

(b) Install the 5 crankshaft bearing caps in their proper locations.

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

NOTICE: Do not install the bearing cap by tapping it.

(c) Install the crankshaft bearing cap bolts.

HINT: If any one of the bearing cap bolts is broken or deformed, replace it.

(1) Apply a light coat of engine oil on the threads and under the crankshaft bearing cap bolts.
(2) Install and uniformly tighten the 20 crankshaft bearing cap bolts in several passes in the sequence shown in the illustration.
Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
If any of the bearing cap bolts cannot meet the torque specification, replace the bearing cap bolt.

(3) Mark the front of each crankshaft bearing cap bolt's head with paint.
(4) Tighten the crankshaft bearing cap bolts another 90° as shown in the illustration.
(5) Check that the painted mark is now at a 90° angle to the front.

(6) Install a new seal washer to the crankshaft bearing cap bolt.
(7) Install and uniformly tighten the 10 crankshaft bearing cap bolts.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
(d) Check that the crankshaft turns smoothly.
(e) Check the crankshaft thrust clearance.

9. INSTALL PISTON AND CONNECTING ROD

(a) 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.

NOTICE: The shape of the piston varies for the LH and RH banks. The LH piston is marked with a "3L" and the RH piston is marked with a "3R".

(b) Place the connecting rod cap on the 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.

(3) Check that the outside mark of the connecting rod cap is facing in the correct direction.

(c) Install the connecting rod cap bolts.

HINT: If any one of the connecting rod cap bolts is broken or deformed, replace it.

(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 of the connecting rod cap bolts cannot meet the torque specification, replace the connecting rod cap bolts.

(3) Mark the front of each connecting cap bolt with paint.
(4) Tighten the cap bolts another 90° as shown in the illustration.
(5) Check that the painted mark is now at a 90° angle to the front.
(d) Check that the crankshaft turns smoothly.
(e) Check the connecting rod thrust clearance.

10. INSTALL WATER SEAL PLATE
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the seal plate as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1324 or equivalent
Seal diameter: 2 to 3 mm (0.08 to 0.12 in.)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the seal plate within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing the seal plate.

(c) Install the seal plate with the 2 nuts. Alternately tighten the nuts in several passes.
Torque: 14 N*m (142 kgf*cm, 10 ft.*lbf)

11. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply seal packing to 2 or 3 threads.
Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent

(b) Install the RH and LH drain cocks.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)

HINT: After applying the specified torque, rotate each drain cock clockwise until its drain port is facing forward.

12. INSTALL CAMSHAFT SUB GEAR
13. INSTALL CAMSHAFT TIMING TUBE ASSEMBLY
14. INSTALL SPARK PLUG TUBE
15. INSTALL NO. 1 TIGHT PLUG
16. INSTALL RING PIN
17. INSTALL STUD BOLT
18. INSTALL VALVE STEM OIL SEAL
19. INSTALL INTAKE VALVE
20. INSTALL EXHAUST VALVE
21. INSTALL VALVE LIFTER
22. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Remove any oil packing (FIPG) material.

(b) Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1324 or equivalent
Seal diameter: 3 to 4 mm (0.12 to 0.16 in.)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil seal within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing the oil seal retainer.

(c) Install a new O-ring to the cylinder block.
(d) Install the oil seal retainer with the 7 bolts.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

23. INSTALL OIL PUMP ASSEMBLY
24. INSTALL OIL STRAINER SUB-ASSEMBLY
25. INSTALL OIL PAN STUD BOLT

26. INSTALL OIL PAN SUB-ASSEMBLY
27. INSTALL OIL PAN BAFFLE PLATE
28. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
29. INSTALL WATER PUMP ASSEMBLY
30. INSTALL CYLINDER HEAD SUB-ASSEMBLY

RH Bank:

(a) Place a new cylinder head gasket on the cylinder block.

HINT: The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A "3R" mark is on the RH bank's gasket.

NOTICE: Be careful of the installation direction.

(b) Place the cylinder head on the cylinder head gasket.

RH Bank:

(c) Install the cylinder head bolts.

HINT: If any cylinder head bolt is broken or deformed, replace it.

(1) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(2) Install the plate washer to the cylinder head bolt.

RH Bank:

(3) Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes in the sequence shown.
Torque: 59 N*m (602 kgf*cm, 44 ft.*lbf)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

NOTICE: Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

RH Bank:

LH Bank:

(a) Place a new cylinder head gasket on the cylinder block.

HINT: The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A "3L" mark is on the LH bank's gasket.

NOTICE: Be careful of the installation direction.

(b) Place the cylinder head on the cylinder head gasket.

LH Bank:

(4) Mark the front of each cylinder head bolt's head with paint.
(5) Tighten the cylinder head bolts another 90° in the sequence shown in the illustration.
(6) Check that the painted mark is now at a 90° angle to the front.

32. INSTALL CAMSHAFT
33. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY
34. INSTALL REAR TIMING BELT PLATE RH
35. INSTALL REAR NO. 2 TIMING BELT PLATE RH
36. INSTALL REAR TIMING BELT PLATE LH
37. INSTALL REAR NO. 2 TIMING BELT PLATE LH
38. INSTALL CAMSHAFT TIMING PULLEY SUB-ASSEMBLY RH
39. INSTALL CAMSHAFT TIMING PULLEY SUB-ASSEMBLY LH

40. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the timing pulley set key with the key groove of the pulley.
(b) Using SST and a hammer, tap in the timing pulley, facing the flange side inward.
SST 09223-46011

41. INSTALL NO. 2 TIMING BELT IDLER SUB-ASSEMBLY
(a) Install the idler with the bolt.
Torque: 34.5 N*m (352 kgf*cm, 25 ft.*lbf)
(b) Check that the idler moves smoothly.

42. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the pivot bolt.
Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Using a 10 mm hexagon wrench, install the plate washer and idler with the pivot bolt.
Torque: 34.5 N*m (352 kgf*cm, 25 ft.*lbf)
(c) Check that the idler bracket moves smoothly.

43. INSTALL TIMING BELT
44. INSTALL CRANKSHAFT POSITION SENSOR PLATE
45. INSTALL TIMING GEAR COVER SPACER
46. INSTALL NO. 1 TIMING BELT COVER
47. INSTALL CRANKSHAFT PULLEY
48. ADJUST VALVE CLEARANCE
49. INSTALL IDLER PULLEY ASSEMBLY
50. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
51. INSTALL NO. 2 TIMING BELT COVER SUB-ASSEMBLY
52. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
53. INSTALL SEMICIRCULAR PLUG

(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semicircular plug grooves.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1324 or equivalent

(c) Install the 4 semicircular plugs to the cylinder heads as shown in the illustration.

54. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
55. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
56. INSTALL SPARK PLUG