2NZ-FE ENGINE MECHANICAL CYLINDER BLOCK REASSEMBLY

Hide Display 1.INSTALL OIL JET

a.

1.969,0.615 2.281,0.813 0.313,0.198 10 false *a

*a

Align

Align the groove on the cylinder block sub-assembly with the oil jet positioning bracket and tap in the oil jet.

NOTICE:: Do not tap the tip of the oil jet.

Hide Display 11432A 2.INSTALL NO. 1 WITH HEAD TAPER SCREW PLUG

a.

Clean and degrease the No. 1 with head taper screw plug and installation hole.

b.

2.25,1.406 2.031,1.052 false 2.198,1.427 2.51,1.583 0.313,0.156 10 false *a

*a

Adhesive

Apply adhesive to the end 2 or 3 threads of the No. 1 with head taper screw plug.

Adhesive:: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:: To prevent contamination by foreign matter, install immediately after applying adhesive.

c.

Install the No. 1 with head taper screw plug to the cylinder block sub-assembly.

Torque:: 30 N*m (306 kgf*cm, 22 ft.*lbf)

NOTICE:: Do not add engine coolant for at least 1 hour after installation.

Hide Display 11711 3.INSTALL CRANKSHAFT BEARING

1.656,3.875 1.969,4.031 0.313,0.156 10 false *a 2.594,3.917 2.906,4.073 0.313,0.156 10 false *b

*a	Correct
*b	Incorrect

a.

Align the upper crankshaft bearings with the oil hole of the cylinder block sub-assembly and install the upper crankshaft bearings.

NOTICE:: Do not apply engine oil to the crankshaft bearings or the contact surfaces.

b.

2.104,3.229 2.333,2.813 2.333,2.813 2.521,2.813 false 2.573,2.729 2.885,2.885 0.313,0.156 10 false *a 0.531,3.719 0.688,3.917 0.156,0.198 10 false A 2.208,3.719 2.365,3.917 0.156,0.198 10 false B

*a	Vernier Caliper

Install the lower crankshaft bearings to the crankshaft bearing caps.

c.

Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the lower crankshaft bearing edge.

Difference between (A) and (B):: 0.7 mm (0.0276 in.) or less

NOTICE:: Do not apply engine oil to the crankshaft bearings or the contact surfaces.

Hide Display 11791 4.INSTALL UPPER CRANKSHAFT THRUST WASHER

1.375,1.25 1.781,0.24 1.781,0.24 1.646,1.531 false 1.76,0.094 2.073,0.292 0.313,0.198 10 false *a

*a	Oil Grooves

a.

Install the 2 upper crankshaft thrust washers to the No. 3 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

b.

Apply engine oil to the upper crankshaft thrust washers.

Hide Display 13411 5.INSTALL CRANKSHAFT

a.

Install the crankshaft to the cylinder block sub-assembly.

b.

0.281,1.458 0.646,0.865 false 1.01,0.958 1.385,0.74 false 1.917,1.469 2.281,0.875 false 0.844,0.229 1.156,0.385 0.313,0.156 10 false *a 2.531,0.229 2.844,0.385 0.313,0.156 10 false *b 0.167,1.469 0.479,1.625 0.313,0.156 10 false *c 1.438,0.656 1.75,0.813 0.313,0.156 10 false *d 1.833,1.479 2.146,1.635 0.313,0.156 10 false *e

*a	No. 3 Crankshaft Bearing Cap
*b	No. 1, 2, 4, 5 Crankshaft Bearing Cap
*c	Front Mark
*d	Number
*e	Front Mark and Number

Examine the front marks and numbers and install the crankshaft bearing caps onto the cylinder block sub-assembly.

c.

Apply a light coat of engine oil to the threads of the crankshaft bearing cap set bolts.

d.

1.563,0.406 1.75,0.573 0.188,0.167 10 true 1 0.958,0.396 1.167,0.552 0.208,0.156 10 true 5 0.26,0.375 0.469,0.552 0.208,0.177 10 true 9 2.813,0.417 3.021,0.594 0.208,0.177 10 true 7 2.198,0.385 2.406,0.563 0.208,0.177 10 true 3 1.573,1.677 1.729,1.865 0.156,0.188 10 true 2 0.927,1.656 1.083,1.844 0.156,0.188 10 true 6 0.271,1.656 0.479,1.844 0.208,0.188 10 true 10 2.833,1.656 3.042,1.844 0.208,0.188 10 true 8 2.208,1.667 2.417,1.854 0.208,0.188 10 true 4

Step 1

i.

Uniformly tighten the 10 crankshaft bearing cap set bolts in the order shown in the illustration.

Torque:: 22 N*m (224 kgf*cm, 16 ft.*lbf)

NOTICE:: Check that the crankshaft turns smoothly.

e.

2.26,0.51 2.646,0.25 true 2.688,0.177 2.927,0.354 0.24,0.177 10 false *a 1.177,0.24 1.417,0.417 0.24,0.177 10 false 90°

*a	Paint Mark
	Engine Front

Step 2

i.

Mark the front of the crankshaft bearing cap set bolts with paint.

ii.

Further tighten the crankshaft bearing cap set bolts by 90° in the order shown in step 1.

f.

Check that the paint marks are now at a 90° angle to the front.

g.

Check that the crankshaft turns smoothly.

Hide Display 11791 6.INSPECT CRANKSHAFT THRUST CLEARANCE

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Hide Display 13101 7.INSTALL PISTON SUB-ASSEMBLY WITH PIN

a.

Coat the piston pin and pin holes in the piston with engine oil.

b.

1.063,1.51 0.458,0.906 0.458,0.906 1.146,0.354 false 0.25,0.802 0.563,1 0.313,0.198 10 false *a

*a	Front Mark

Align the cavity of the piston with the protruding portion on the connecting rod.

c.

Using SST, press in the piston pin.

1.052,0.854 1.333,0.854 false 1.063,1.438 1.344,1.438 false 0.75,2.146 1.031,2.146 false 3.021,0.635 3.302,0.635 false 3.115,2.125 3.396,2.125 false 5.083,0.938 5.479,0.938 true 5.677,0.521 6.073,0.521 true 5.958,0.958 6.354,0.958 true 4.927,0.854 5.24,1.01 0.313,0.156 10 false *1 6.135,0.458 6.448,0.615 0.313,0.156 10 false *2 6.396,0.885 6.708,1.042 0.313,0.156 10 false *3 0.75,0.771 1.073,0.938 0.323,0.167 10 false SST 0.771,1.344 1.094,1.51 0.323,0.167 10 false SST 0.458,2.063 0.781,2.229 0.323,0.167 10 false SST 3.365,0.563 3.688,0.729 0.323,0.167 10 false SST 3.438,2.052 3.76,2.219 0.323,0.167 10 false SST

*1	Piston Pin	*2	Connecting Rod Sub-assembly
*3	Piston	-	-

SST: 09221-25026 (09221-00021, 09221-00030, 09221-00150, 09221-00090, 09221-00100)

NOTICE:: ·

The piston and piston pin are a matched set.

·

With the connecting rod fully inserted into the piston end, press in the piston pin until it is flush with the piston surface.

d.

Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

Hide Display 13041 8.INSTALL CONNECTING ROD BEARING

a.

2.458,0.573 1.958,0.198 true 1.802,0.094 2.021,0.271 0.219,0.177 10 false *a

*a

Claw

Align the connecting rod bearing claw with the groove of the connecting rod or connecting rod cap.

NOTICE:: Clean the back side of the connecting rod bearing and the connecting rod bearing surface of the connecting rod and keep them free of oil.

Hide Display 13011 9.INSTALL PISTON RING SET

HINT:: When reusing the piston rings, install them onto the matched pistons in the correct orientation.

a.

Install the expander and 2 side rails by hand.

b.

2.781,0.698 3.094,0.896 0.313,0.198 10 false *a

*a	No. 2 Compression Ring

Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring as shown in the illustration.

HINT:: The No. 1 compression ring can be installed with either side facing upward.

c.

2.708,0.177 3.073,0.479 0.365,0.302 10 false *b 2.635,1.719 3.01,2.031 0.375,0.313 10 false *d 1.135,1.74 1.51,2.052 0.375,0.313 10 false *c 1.083,0.188 1.49,0.573 0.406,0.385 10 false *a

*a	No. 1 Compression Ring and Expander
*b	Lower Side Rail
*c	Upper Side Rail
*d	No. 2 Compression Ring
	Engine Front

Position the piston ring set so that the ring ends are as shown in the illustration.

Hide Display 10.INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

a.

Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings.

b.

Check the position of the piston ring ends.

c.

0.458,0.156 0.823,0.635 0.365,0.479 10 false *a

*a	Front Mark

Using a piston ring compressor, push the correctly numbered piston sub-assembly with connecting rod into the cylinder with the front mark of the piston facing forward.

NOTICE:: ·

Clean the back side of the connecting rod bearing and the connecting rod bearing surface of the connecting rod cap and keep them free of oil.

·

Match the numbered connecting rod cap with the connecting rod.

d.

0.948,0.302 1.344,0.573 0.396,0.271 10 false *a

*a	Front Mark

Make sure that the connecting rod and connecting rod cap are in the correct combination and that the front mark of the connecting rod cap is facing in the correct direction, then install the connecting rod cap onto the connecting rod.

e.

Apply a light coat of engine oil to the threads of the connecting rod bolts.

f.

1.125,0.438 1.531,0.438 false 0.823,0.375 1.281,0.573 0.458,0.198 10 false SST

Step 1

i.

Using SST, tighten the connecting rod bolts in several steps to the specified torque.

SST: 09205-16011

Torque:: 15 N*m (153 kgf*cm, 11 ft.*lbf)

g.

2.26,0.51 2.646,0.25 true 2.688,0.177 2.927,0.354 0.24,0.177 10 false *a 1.177,0.24 1.417,0.417 0.24,0.177 10 false 90°

*a	Paint Mark
	Engine Front

Step 2

i.

Mark the front of the connecting rod bolts with paint.

ii.

Further tighten the connecting rod bolts by 90° in the order shown in step 1.

h.

Check that the crankshaft turns smoothly.

Hide Display 11.INSPECT CONNECTING ROD THRUST CLEARANCE

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PROCEDURE