Part 1

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

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 E8 and E10 "TORX" socket wrenches, install the stud bolt.

Torque: 10 Nm (102 kgf-cm, 7 ft-lbf) for bolt A
Torque: 17 Nm (173 kgf-cm, 13 ft-lbf) for bolt B
3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, install the No. 1 oil nozzle sub-assembly.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
4. INSTALL PISTON SUB-ASSEMBLY WITH PIN

(a) Using a screwdriver, install a new snap ring at one end of the piston pin hole.
HINT: Confirm 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.
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 piston pin hole 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.

5. INSTALL PISTON RING SET
(a) Install the oil ring expander and 2 side rails by hand.

(b) Using a piston ring expander, install the 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.

6. INSTALL CRANKSHAFT BEARING

(a) Clean the main journal and 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 and 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 a vernier caliper, 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 and the contact surfaces.

7. 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.
8. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.

(b) Confirm the projections 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 with your hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by using the 2 internal bearing cap bolts as guides.
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.
(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 specified torque, replace it.
(k) Step 2

(1) Mark the front of the bearing cap bolts with paint.
(2) Retighten the bearing cap bolts 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: 52 Nm (525 kgf-cm, 38 ft-lbf)
Bolt length:

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

(b) Using a vernier caliper, 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 and the contact surfaces.

10. 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.

(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 bolts of the connecting rod cap 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 90° as shown in the illustration.
(3) Check that 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 Engine Unit.
11. 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:
9.30 to 9.70 mm (0.3661 to 0.3819 in.)

(e) Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.
Standard oil clearance:
0.025 to 0.060 mm (0.0010 to 0.0023 in.)
12. INSTALL EXHAUST VALVE GUIDE BUSH

(e) Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.
Standard oil clearance:
0.030 to 0.065 mm (0.0012 to 0.0026 in.)
13. INSTALL RING PIN

(a) Using a plastic hammer, tap in 4 new ring pins to the specified protrusion height.
Specified protrusion height:
2.5 to 3.5 mm (0.098 to 0.138 in.)
14. INSTALL NO. 1 STRAIGHT SCREW PLUG

(a) Using a 10 mm hexagon wrench, install 4 new gaskets and the 4 No. 1 straight screw plugs.
Torque: 44 Nm (449 kgf-cm, 32 ft-lbf)
15. INSTALL NO. 2 STRAIGHT SCREW PLUG

(a) Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 No. 2 straight screw plugs.
Torque: 80 Nm (816 kgf-cm, 59 ft-lbf)
16. INSTALL STUD BOLT
NOTE:
If the stud bolt is deformed or the threads are damaged, replace it.

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

Torque: 10 Nm (102 kgf-cm, 7 ft-lbf) for bolts A and B
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf) for bolt C
17. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, tap in 4 new straight pins as shown in the illustration.

Protrusion height:
17.5 to 19.5 mm (0.689 to 0.768 in.)