Part 1

4GR-FSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

Part 1 of 3

1. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, tap in new straight pins to the cylinder block.

Standard protrusion:

2. INSTALL STUD BOLT
(a) Using an E8 "TORX" socket, install the stud bolts.

Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL TIGHT PLUG
NOTE:
If water leaks from the tight plug or the plug is corroded, replace it.

(a) Apply adhesive around the tight plugs.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Using SST and a hammer, tap in new tight plugs as shown in the illustration.

(1) Using SST, tap in the 2 tight plugs A.
SST: 09950-60010
09951-00340
SST: 09950-70010
09951-07100
(2) Using SST, tap in the tight plug B.
SST: 09950-60010
09951-00200
SST: 09950-70010
09951-07100
4. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, install the oil nozzles.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
5. INSTALL CONNECTING ROD SMALL END BUSH

(a) Align the oil holes of a new bush and the connecting rod.

(b) Using SST and a press, press in the bush.
SST: 09222-30010

(c) Using a pin hole grinder, hone the bush to obtain the specified clearance between the bush and piston pin.
Standard oil clearance:
-0.002 to 0.004 mm (-0.00007 to 0.0001 in.)

(d) Check that the piston pin fits at normal room temperature.
(e) Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
6. INSTALL PISTON SUB-ASSEMBLY WITH PIN

(a) Using a screwdriver, install a new snap ring at one end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

(b) Gradually heat the piston to approximately 80°C (176°F).
(c) Coat the piston pin with engine oil.

(d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
Front Mark:

HINT:
The piston and pin are a matched set.

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

(f) Using a screwdriver, install a new snap ring at the other end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

7. INSTALL PISTON RING SET
(a) Install the oil ring expander by hand.

(b) Using a piston ring expander, install the oil ring rail and 2 compression rings as shown in the illustration.

(c) Position the piston rings so that the ring ends are as shown in the illustration.
NOTE:
Do not align the ring ends.

8. INSTALL CRANKSHAFT BEARING

(a) Clean the main journal and the both surfaces of the bearing.
NOTE:
Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

(b) Install the upper bearing.
(1) Install the upper bearings to the cylinder block as shown in the illustration.
NOTICE:
- Do not apply engine oil to the bearings or the contact surfaces.
- Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal.

(c) Install the lower bearing.
(1) Install the lower bearings to the bearing caps.
(2) Using vernier calipers, measure the distance between the bearing cap's edge and the lower bearing's edge.
Dimension (A - B):
0.7 mm (0.0276 in.) or less
NOTE:
Do not apply engine oil to the bearings or the contact surfaces.

9. INSTALL CRANKSHAFT THRUST WASHER SET
(a) Apply engine oil to the crankshaft thrust washer.

(b) Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.
10. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.

(b) Confirm the projection and numbers of the main bearing caps and install the bearing caps on the cylinder block.
HINT:
A number is marked on each main bearing cap to indicate the installation position.

(c) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
(d) Temporarily install the 8 main bearing cap bolts to the inside positions.

(e) Insert the main bearing cap by hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.
Bolt length:
100 to 102 mm (3.94 to 4.02 in.)

(f) Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.
(g) Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.

(h) Install the 8 main bearing cap bolts to the outside positions.
Bolt length:

(i) Install the crankshaft bearing cap bolts.
HINT:
The main bearing cap bolts are tightened in 2 progressive steps.

(j) Step 1

(1) Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.
Torque: 61 Nm (622 kgf-cm, 45 ft-lbf)
If any of the main bearing cap bolts does not meet the torque specified, replace it.
(k) Step 2

(1) Mark the front of the bearing cap bolts with paint.
(2) Retighten the bearing cap bolts by 90° in the order above.
(3) Check that the painted mark is now at a 90° angle to the front.

(l) Install 8 new seal washers and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in the illustration.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)
Bolt length:

(m) Check that the crankshaft turns smoothly.
(n) Check the crankshaft thrust clearance Inspection.
11. INSTALL CONNECTING ROD BEARING
(a) Install the connecting rod bearing to the connecting rod and bearing cap.

(b) Using vernier calipers, measure the distance between the connecting rod's and bearing cap's edges and the connecting rod bearing's edge.
Dimension (A - B):
0.7 mm (0.0276 in.) or less
NOTE:
Do not apply engine oil to the bearings or the contact surfaces.

12. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
(a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.

(b) Position the piston rings so that the ring ends are as shown in the illustration.
NOTE:
Do not align the ring ends.

(c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.
NOTE:
Match the numbered connecting rod cap with the connecting rod.

Front Mark:

(d) Check that the front mark of the connecting rod cap is facing forward.
(e) Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
(f) Install the connecting rod cap bolts.
HINT:
The connecting rod cap bolts are tightened in 2 progressive steps.

(g) Step 1

(1) Install and alternately tighten the connecting rod cap bolts in several steps.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
(h) Step 2

(1) Mark the front side of each connecting rod cap bolt with paint.
(2) Retighten the cap bolts by 90° as shown in the illustration.
(3) Check the painted mark is now at a 90° angle to the front.
(i) Check that the crankshaft turns smoothly.
(j) Check the connecting rod thrust clearance Inspection.
13. INSTALL INTAKE VALVE GUIDE BUSH

(a) Using a caliper gauge, measure the bush bore diameter of the cylinder head.
Cylinder bore diameter:
10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Select a new guide bush (STD or O/S 0.05):

If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 valve guide bush.
If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.
(b) Heat the cylinder head to 80 to 100°C (176 to 212°F).
(c) Place the cylinder head on wooden blocks.

(d) Using SST, tap in new valve guide bushes to the specified protrusion height.
SST: 09201-10000
09201-01050
SST: 09950-70010
09951-07100
Protrusion height:
10.20 to 10.24 mm (0.4016 to 0.4031 in.)

(e) Using a sharp 5.5 mm reamer, ream the valve guide bushes to obtain the specified clearance.
Standard oil clearance:
0.030 to 0.060 mm (0.0012 to 0.0023 in.)
14. INSTALL EXHAUST VALVE GUIDE BUSH

(e) Using a sharp 5.5 mm reamer, ream the valve guide bushes to obtain the specified clearance.
Standard oil clearance:
0.025 to 0.065 mm (0.0010 to 0.0026 in.)
15. INSTALL RING PIN

(a) Using a plastic hammer, tap in new ring pins to the specified protrusion height.
Specified protrusion height:
2.5 to 3.8 mm (0.098 to 0.150 in.)
16. INSTALL NO. 1 STRAIGHT SCREW PLUG

(a) Using a 10 mm hexagon wrench, install 4 new gaskets and the straight screw plugs.
Torque: 44 Nm (449 kgf-cm, 32 ft-lbf)
17. INSTALL NO. 2 STRAIGHT SCREW PLUG

(a) Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 straight screw plugs.
Torque: 80 Nm (816 kgf-cm, 59 ft-lbf)
18. INSTALL STUD BOLT
NOTE:
If the stud bolt is deformed or the threads are damaged, replace it.

(a) Using E6 and E8 "TORX" sockets, install the stud bolts.

Torque: 10 Nm (102 kgf-cm, 7 ft-lbf) for bolts A, B and D
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf) for bolt C
19. INSTALL UNION

(a) Apply adhesive to the union of the cylinder head.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Using SST, install the union to the cylinder head as shown in the illustration.

SST: 09023-38201
Torque: 15 Nm (153 kgf-cm, 11 ft-lbf)
20. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, tap in new straight pins as shown in the illustration.

Protrusion height:
17.5 to 19.5 mm (0.689 to 0.768 in.)
21. INSTALL VALVE SPRING SEAT
(a) Install the valve spring seats to the cylinder head.
22. INSTALL VALVE STEM OIL SEAL

(a) Apply a light coat of engine oil to new oil seals.
NOTE:
Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later.
HINT:
The intake valve oil seals are gray and the exhaust valve oil seals are black.

(b) Using SST, push in the oil seals.
SST: 09201-41020
NOTE:
Failure to use SST will cause the seal to be damaged or improperly seated.

23. INSTALL EXHAUST VALVE

(a) Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.
(b) Install the valve, compression spring and spring retainer to the cylinder head.
NOTE:
Install the same parts in the same combination to the original locations.

(d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
NOTE:
Be careful not to damage the retainer.

24. INSTALL INTAKE VALVE

(d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
NOTE:
Be careful not to damage the retainer.

25. INSTALL VALVE STEM CAP
(a) Apply a light coat of engine oil to the valve stem caps.
(b) Install the valve stem caps on the valves.
26. INSTALL ENGINE REAR OIL SEAL
(a) Place the oil seal retainer on wooden blocks.

(b) Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge.
SST: 09223-15030
SST: 09950-70010
09951-07100
- Keep the lip free of foreign matter.
- Do not tap on the oil seal at an angle.

27. INSTALL ENGINE REAR OIL SEAL RETAINER

(a) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter:
2.0 to 3.0 mm (0.079 to 0.118 in.)
- Remove any oil from the contact surface.
- Install the oil seal retainer within 3 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installation.

(b) Install the oil seal retainer with the 6 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTE:
Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.

Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
28. INSTALL WATER OUTLET PIPE SUB-ASSEMBLY

(a) Install the water outlet pipe with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
29. INSTALL KNOCK SENSOR

(a) Install the 2 knock sensors with the 2 bolts as shown in the illustration.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
(b) Connect the 2 knock sensor connectors.
(c) Connect the knock sensor wire clamp.

Continue to Part 2 Part 2