Page 1337 of 2389
B. If oil pump is installed to the cylinder block:
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE: Be careful not to damage the crankshaft.
Tape the screwdriver tip.
(b) Using SST and a hammer, tap in a new oil seal until its
surface is flush with the oil pump case edge.
SST 09309±37010
(c) Apply MP grease to the oil seal lip.
(c) Apply IMP grease to a new oil seal lip.
(d) Using SST and a hammer, tap in the oil seal until its sur-
face is flush with the oil pump case edge.
SST 09309±37010 1. REPLACE CRANKSHAFT FRONT OIL SEAL
A. If Oil Pump 1s removed from cylinder block:
(a) Using a screwdriver and hammer, tap out the oil seal.
REPLACEMENT OF CRANKSHAFT OIL
SEALS
HINT: There are two methods (A an B) to replace the oil
seal as follows:
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±160
Page 1338 of 2389
6. If rear oil seal retainer is installed to cylinder block:
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE: Be careful not to damage the crankshaft.
Tape the screwdriver tip.
2. REPLACE CRANKSHAFT REAR OIL SEAL
A. If rear oil seal retainer is removed from cylinder block:
(a) Using a screwdriver and hammer, tap out the oil seal.
(b) Using SST and a hammer, tap in a new oil seal until its
surface is flush with the rear oil seal edge.
SST 09223±56010
(c) Apply MP grease to the oil seal lip.
(c) Apply MP grease to a new oil seal lip.
(d) Using SST and a hammer, tap in the oil seal until its sur-
face is flush with the rear oil seal retainer edge.
SST 09223±56010
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±161
Page 1339 of 2389
ASSEMBLY OF PISTON AND CONNECTING
ROD ASSEMBLIES
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Align the front marks of the piston and connecting rod.
Connecting rod front (mold) mark:
B6, 1 B, 8A, C3 or etc.
(b) Coat the piston pin and piston hole of the piston with
engine oil. .
(c) Using SST, press in the piston pin.
SST 09221±25024 (09221±00020, 09221±00030,
09221±00181, 09221±00190, 09221±00200)
(d) Check that the piston smoothly moves back and forth
on the piston pin.
(b) Using a piston ring expander, install the two com-
pression rings with the code mark facing upward.
Code mark: No.1 T or 1R
No.2 T2 or 2R 2. INSTALL PISTON RINGS
(a) Install the oil ring expander and two side rails by hand.
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE: Do not align the ring ends.
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±162
Page 1340 of 2389

1. INSTALL MAIN BEARINGS
HINT:
wMain 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 posi-
tions.
wUpper bearings have on oil groove and oil holes; lower bear-
ings do not.
(a) Align the bearing claw with the claw groove of the main bear-
ing cap or cylinder block.
(b) Install the bearings in the cylinder block and main bearing
cap.
NOTICE: Install the bearing with the oil hole in the cylinder
block.
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the con±
necting rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting rod
cap.
NOTICE: Install the bearing with the oil hole in the connect-
ing rod.
ASSEMBLY OF CYLINDER BLOCK
(See page EM±139)
HINT:
wThoroughly clean all parts to be assembled.
wBefore installing the parts, apply new engine oil to all
sliding and rotating surfaces.
wReplace all gaskets. 0±rings and oil seals with new parts.
2. INSTALL UPPER THRUST WASHERS
Install the thrust washers under the No.2 journal position of
the block with the oil grooves facing outward.
3. PLACE CRANKSHAFT ON CYLINDER BLOCK
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±163
Page 1341 of 2389

6. Install main bearing cap bolts
HINT:
wThe main bearing cap bolts are tightened in two progressive
steps.
wIf any the main bearing cap bolt is broken or deformed,
replace it.
(a) Apply a light coat of engine oil on the threads and under the
heads of the main bearing caps.
(b) 1st, install and uniformly tighten the eight main bearing cap
bolts in several passes in the sequence shown.
Torque: 625 kg±cm (45 ft±lb, 61 N±m)
If any one of the main bearing cap bolts does not meet the
torque specification, replace the cap bolt.
(c) Mark the front of the connecting rod cap nut with paint. 4. INSTALL MAIN SEARING CAP AND LOWER THRUST
WASHERS
A. 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.
(c) 2nd, retighten the main bearing cap bolts 905 and angle
to the front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance.
(See step 5 on page EM±149) (b) Install the main bearing cap with the front mark facing
forward.
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±164
Page 1342 of 2389

B. Install connecting rod cap nuts
HINT:
wThe connecting rod cap nuts are tightened in two progres-
sive steps.
wIf any the connecting rod bolt is broken or deformed, replace
them.
(a) Apply a light of engine oil on the threads and under the nuts
of the connecting rod cap.
(b) 1st, using SST, install and alternately tighten the nuts of the
connecting rod cap in several passes.
SST 09011±38121
Torque: 250 kg±cm(18 ft±Ib, 25 N±m)
6. INSTALL CONNECTING ROD CAPS
A. Place connecting rod cap on connecting rod
(a) Match the numbered connecting rod cap with the connect-
ing rod.
(b) Install the connecting rod cap with the front mark facing for-
ward. 5. INSTALL PISTON AND CONNECTING ROD
ASSEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
If any one of the connecting rod cap nuts does not meet
the torque specification, replace the cap nut.
(c) Mark the front of the connecting rod cap nut with paint.(b) 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.
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±165
Page 1343 of 2389

7. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful not
to drop any oil on the contact surface of the retainer and
cylinder block.
wUsing a razor blade an gasket scraper, remove all the old
packing (FIPG) material from the gasket surfaces and seal-
ing groove.
wThoroughly clean all components to remove all the loose ma-
terial.
wUsing a non±residue solvent, clean both sealing surfaces.
(b) Apply seal packing to the retainer as shown in the figure.
Seal packing: Part No. 08826±00080 or equivalent
wInstall 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.
wParts must be assembled within 5 minutes of
application. Otherwise the material must be removed and
reapplied.
wImmediately remove nozzle from the tube and reinstall cap.
(c) Install the retainer with the six bolts.
Torque: 80 kg±cm (69 in.±lb, 7.8 N±m)
(d) 2nd, retighten the connecting rod cap nuts 90° in the numeri-
cal order shown.
(e) Check that the painted mark is now at a 90° angle to the front.
(f) Check that the crankshaft turns smoothly.
(g) Check the connecting rod thrust clearance.
(See step 2 on page EM±147)
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±166
Page 1344 of 2389

2. INSTALL WATER BY±PASS PIPE
(a) Remove any old packing (FIPG) material and be careful not
to drop any oil on the contact surfaces of the bypass pipe
and cylinder block.
wUsing a razor blade and gasket scraper, remove all the old
packing (FIPG) material from the gasket surfaces and seal-
ing groove.
wThoroughly clean all components to remove all the loose
material.
wUsing a non±residue solvent, clean both sealing surfaces.
(b) Apply seal packing to the groove of the by±pass pipe.
Seal packing: Part No. 08826±00100 or equivalent
wInstall 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.
wParts must be assembled within 5 minutes of application.
Otherwise the material must be removed and reapplied.
wImmediately remove nozzle from the tube and reinstall cap.
(c) Install the by±pass pipe with the two bolts and two nuts.
Torque: 85 kg±cm (74 in.±lb, 8.3 N±m)
POST ASSEMBLY
1. INSTALL NO. 2 IDLER PULLEY BRACKET
Install the pulley bracket with the three bolts. Torque the
bolts.
Torque: 380 kg±cm (27 ft±Ib, 37 N±m)
3. INSTALL KNOCK SENSOR
Using SST, install the knock sensor.
SST 09816±30010
Torque: 450 kg±cm (33 ft±lb, 44 N±m)
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±167