EM-98

ENGINE MECHANICAL (5VZ-FE) - CYLINDER BLOCK

EM020-07

REASSEMBLY
HINT:

Thoroughly clean all parts to be assembled.

Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.

Replace all gaskets, O-rings and oil seals with new parts.

1. ASSEMBLE PISTON AND CONNECTING ROD

(a) Using a small screwdriver, install a new snap ring at one
end of the piston pin hole.
HINT:
Be sure that end gap of the snap ring is not aligned with the pin
hole cutout portion of the piston.
(b) Gradually heat the piston to about 60°C (140°F).

P21452

(c) Coat the piston pin with engine oil.

Front Mark (d) Align the front marks of the piston and connecting rod,
(Cavity) and push in the piston pin with your thumb.
(e) Using a small screwdriver, install a new snap ring on the
other end of the piston pin hole.
Front Mark
(Mold) HINT:
Be sure that end gap of the snap ring is not aligned with the pin
hole cutout portion of the piston.
P21462

No.1 Code Mark 2. INSTALL PISTON RINGS

(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
No.2 Code Mark Code mark:
No.1 1R or T
No.2 2R or T

Z14706

Upper Side Compression (c) Position the piston rings so that the ring ends are as
Rail Ring No.1 shown.
NOTICE:
Do not align the ring ends.
Expander Front Mark
(Cavity)

Compression Lower Side

Ring No.2 Rail P21438

2002 4RUNNER (RM887U)

Author
: Date
: 910

 EM-99
ENGINE MECHANICAL (5VZ-FE) - CYLINDER BLOCK

3. INSTALL BEARINGS
(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.

P00592

4. INSTALL MAIN BEARINGS

No.1 Others HINT:

Main bearings come in widths of 20 mm (0.79 in.) and 22
mm (0.87 in.). Install the 22 mm (0.87 in.) bearings in the
No.1 cylinder block journal position with the main bearing
caps. Install the 20 mm (0.79 in.) bearings in the other
positions.

Upper bearings have an oil holes; lower bearings do not.
22 mm 20 mm
P10205

(a) Align the bearing claw with the claw groove of the main
bearing cap or cylinder block.
(b) Install the bearings in the cylinder block and main bearing
cap.

P10214

5. INSTALL UPPER THRUST WASHERS

Install the thrust washers under the No.2 journal position of the
cylinder block with the oil grooves facing outward.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK

P10215

7. PLACE MAIN BEARING CAP AND LOWER THRUST

WASHERS ON CYLINDER BLOCK
(a) Install the thrust washers on the No.2 journal position of
the bearing cap with the grooves facing outward.

EM5354

2002 4RUNNER (RM887U)

Author
: Date
: 911

EM-100
ENGINE MECHANICAL (5VZ-FE) - CYLINDER BLOCK

Front Mark (b) Install the main bearing cap with the front mark facing for-
(Arrow) ward.
8. INSTALL MAIN BEARING CAP BOLTS
HINT:

The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).

If any main bearing cap bolt is broken or deformed, re-
place it.
P20861

(a) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(b) Install and uniformly tighten the 8 main bearing cap bolts
7 in several passes, in the sequence shown.
4
1 Torque: 61 N·m (625 kgf·cm, 45 ft·lbf)
5 If any one of the main bearing cap bolts does not meet the
6 2
3 torque specification, replace the cap bolt.
8
EM5368

(c) Mark the front of the main bearing cap bolt with paint.
Front
Painted Mark

EM5369

(d) Retighten the main bearing cap bolts by 90° in the numer-
Painted Mark ical order shown.
90° (e) Check that the painted mark is now at a 90° angle to the
90° front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance.
(See page EM-88 )

EM5370

9. INSTALL PISTON AND CONNECTING ROD AS-

SEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.

P00591

2002 4RUNNER (RM887U)

Author
: Date
: 912

 EM-101
ENGINE MECHANICAL (5VZ-FE) - CYLINDER BLOCK

(b) Using a piston ring compressor, push the correctly num-

Front bered piston and connecting rod assemblies into each
Mark
(Cavity) cylinder with the front mark of the piston facing forward.

Front

Z14819

Front Mark 10. PLACE CONNECTING ROD CAP ON CONNECTING

(Protrusion) ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Install the connecting rod cap with the front mark facing
forward.

P00655

11. INSTALL CONNECTING ROD CAP NUTS

HINT:

The connecting rod cap nuts are tightened in 2 progres-
sive steps (steps (b) and (d)).

If any connecting rod bolt is broken or deformed, replace
it.
(a) Apply a light of engine oil on the threads and under the
nuts of the connecting rod cap.
EM5345 (b) Install and alternately tighten the nuts of the connecting
rod cap in several passes.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
If any one of the connecting rod cap nuts does not meet the
torque specification, replace the cap nut.

Front (c) Mark the front of the connecting rod cap nut and bolt with
Painted Mark
paint.

P02237

2002 4RUNNER (RM887U)

Author
: Date
: 913

EM-102
ENGINE MECHANICAL (5VZ-FE) - CYLINDER BLOCK

Painted Mark (d) Retighten the connecting rod cap nuts 90° as shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
90° (f) Check that the crankshaft turns smoothly.
90°
(g) Check the connecting rod thrust clearance.
(See page EM-88 )
12. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
P02238 not to drop any oil on the contact surfaces of the retainer
and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.

B A (b) Apply seal packing to the oil seal retainer as shown in the
A
illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal Width
Install a nozzle that has been cut to a 2 - 3 mm (0.08
2 - 3 mm - 0.12 in.) opening.

Parts must be assembled within 5 minutes of ap-
B plication. Otherwise the material must be removed
and reapplied.
EM5292
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the oil seal retainer with the 6 bolts.
Torque: 8 N·m (80 kgf·cm, 71 in.·lbf)
13. INSTALL OIL PUMP (See page LU-15 )
14. INSTALL OIL COOLER (See page LU-21 )
15. INSTALL COOLANT DRAIN COCK
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
16. INSTALL RH AND LH ENGINE MOUNTING BRACKET
Torque: 44 N·m (440 kgf·cm, 32 ft·lbf)
17. INSTALL OIL FILTER UNION
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
18. INSTALL OIL FILTER (See page LU-3 )

2002 4RUNNER (RM887U)

Author
: Date
: 914

 EM-103
ENGINE MECHANICAL (5VZ-FE) - CYLINDER BLOCK

19. INSTALL OIL PRESSURE SWITCH

Adhesive (a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833 - 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Using SST, install the oil pressure switch.
SST 09816-30010
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
A01580 20. INSTALL GENERATOR ADJUSTING BAR
Torque: 42 N·m (420 kgf·cm, 31 ft·lbf)
21. INSTALL WATER PUMP (See page CO-8 )
22. INSTALL KNOCK SENSORS (See page SF-49 )
23. INSTALL NO.2 IDLER PULLEY BRACKET
Torque: 38 N·m (380 kgf·cm, 28 ft·lbf)
24. INSTALL WATER BYPASS PIPE WITH KNOCK SEN-
SOR WIRE
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the bypass
and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.

(b) Apply seal packing to the groove of the bypass pipe.

Seal packing: Part No. 08826 - 00100 or equivalent

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
Seal Width
2 - 3 mm (c) Install the bypass pipe with the 2 bolts and nut.
Torque: 8.5 N·m (85 kgf·cm, 75 in.·lbf)
(d) Connect the 2 knock sensor connectors.
25. INSTALL CYLINDER HEADS (See page EM-52 )
26. INSTALL PULLEYS AND TIMING BELT
(See page EM-19 )
27. REMOVE ENGINE STAND
P10226 28. INSTALL REAR END PLATE
Torque: 7.5 N·m (75 kgf·cm, 66 in.·lbf)
2002 4RUNNER (RM887U)

Author
: Date
: 915

EM-104
ENGINE MECHANICAL (5VZ-FE) - CYLINDER BLOCK

29. A/T:
INSTALL DRIVE PLATE
Adhesive (a) Apply adhesive to 2 or 3 threads of the mount bolt end.
Adhesive:
Part No. 08833 - 00070, THREE BOND 1324 or equiva-
lent
(b) Install the front spacer, drive plate and rear spacer on the
crankshaft.
P00601

(c) Install and uniformly tighten the 8 mount bolts in several

1 passes, in the sequence shown.
8
5 Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)
30. M/T:
4 3 INSTALL FLYWHEEL (See step 29)
Torque: 85 N·m (850 kgf·cm, 63 ft·lbf)
6
7
2
P21461

2002 4RUNNER (RM887U)

Author
: Date
: 916