Page 3489 of 5135
A77477
Back Side
BB
A8
15
B 10
22A
Bottom Side
7.5 (Pin A)
12 (Pin B)
A
A
Front Side
A
A13857
A77478
Front Mark
Front Mark
± ENGINE MECHANICALCYLINDER BLOCK ASSY
14±65
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
28. INSTALL STRAIGHT PIN
(a) Using a plastic±faced hammer, tap into the straight pin.
Standard protrusion
Pin A 7.5 mm (0.295 in.)
Pin B 12 mm (0.472 in.)
29. INSTALL PISTON
(a) Using a small screwdriver, install a new snap ring at one
end of the piston pin hole.
(b) Gradually heat the piston to 80 to 90C (176 to 194F).
(c) Align the front mark of the piston with the front mark lo-
cated on the connecting rod, and push in the piston with
your thumb.
(d) Using a small screwdriver, install a new snap ring on the
other end of the piston pin hole.
Page 3490 of 5135
A77479
Upward
No. 1
No. 2
Painted Mark
Code Mark (2T)
A77480
Front
Side Rail UpperSide Rail Lower
No. 2 Expander
Compression No. 1 and
A53029
A33379
14±66
± ENGINE MECHANICALCYLINDER BLOCK ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
30. 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 with the painted mark facing right side.
NOTICE:
Install the compression ring No. 2 with the code mark (2T)
upward.
(c) Position the piston rings so that the ring ends are as
shown.
31. INSTALL CRANKSHAFT BEARING
(a) Install the upper bearing with an oil groove on cylinder
block.
NOTICE:
Clean the back side of the bearing and the bearing surface
of the cylinder block and keep them free of oils.
32. INSTALL CRANKSHAFT BEARING NO.2
(a) Install the lower bearing on bearing cap.
NOTICE:
Clean the back side of the bearing and the bearing surface
of the cylinder block and keep them free of oils.
Page 3491 of 5135

A13501
A77275Front Mark and Journal Number
A77475
10
A77470
90
Engine FrontPaint
Mark
A77481
Claw
± ENGINE MECHANICALCYLINDER BLOCK ASSY
14±67
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
33. INSTALL CRANKSHAFT THRUST WASHER UPPER
(a) Install the 2 thrust washers under the No. 3 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.
34. INSTALL CRANKSHAFT
(a) Apply engine oil on the upper bearing and install the
crankshaft on the cylinder block.
(b) Apply engine oil on the lower bearing.
(c) Examine the front marks and install the bearing caps to
the cylinder block.
(d) Apply a light coat of engine oil on the threads of the bear-
ing cap bolts.
(e) Using several steps, tighten the bolts with the specified
torque in the sequence shown in the illustration.
Torque: 20 Nm (204 kgfcm, 15 ftlbf)
(f) Retighten the bolts in the same way as above with the
specified torque.
Torque: 40 Nm (408 kgfcm, 29 ftlbf)
(g) Place the front mark on each bearing cap bolt head with
paint.
(h) Retighten the bearing cap bolts by 90 in the same se-
quence as step (e).
(i) Check that each painted mark is now at a 90angle to
the front.
(j) Check that the crankshaft turns smoothly.
35. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
NOTICE:
Clean the back side of the bearing and the bearing surface
of the bearing cap and keep them free of oils.
36. INSTALL PISTON SUB±ASSY W/CONNECTING ROD
NOTICE:
The connecting rod cap bolts are tightened in 2 progres-
sive steps.
Page 3492 of 5135

A77482
Front Mark
Front
A77483
Front Mark
A77470
90
Engine FrontPaint
Mark 14±68
± ENGINE MECHANICALCYLINDER BLOCK ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(a) Apply engine oil on the cylinder walls, the pistons, and the
surfaces of connecting rod bearings.
(b) Check the position of the piston ring ends.
(c) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
NOTICE:
Match the numbered connecting rod cap with the connect-
ing rod.
(d) Check that the protrusion of the connecting rod cap is fac-
ing the correct direction.
(e) Apply a light coat of engine oil on the threads of the con-
necting rod cap bolts.
(f) Using a 12 mm socket wrench, tighten the bolts in several
steps with the specified torque.
Torque: 25 Nm (250 kgfcm, 18 ftlbf)
SST 09011±38121
(g) Place the front mark on each connecting cap bolt head
with paint.
(h) Retighten the cap bolts by 90 as shown in the illustration.
(i) Check that each painted mark is at a 90 angle to the
front.
(j) Check that the crankshaft turns smoothly.
Page 3493 of 5135
141BT±01
A77367
Piston Ring Set
Snap Ring
Piston Pin
Piston
Connecting Rod
Connecting Rod Bearing
Cylinder Block Assy
Crankshaft Thrust Washer
Crankshaft Bearing
Crankshaft
Crankshaft Bearing
Ring Pin
Crankshaft Bearing Cap BoltConnecting Rod Bearing
Connecting Rod Bearing 14±52
± ENGINE MECHANICALCYLINDER BLOCK ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
CYLINDER BLOCK ASSY
COMPONENTS
Page 3494 of 5135

141BW±01
A77455
SST
Wooden Blocks
A77456
SST
Wooden Blocks
A14202
± ENGINE MECHANICALCYLINDER HEAD ASSY
14±39
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
OVERHAUL
1. REMOVE VALVE LIFTER
HINT:
Store the valve liters in correct order, so that they can be returned to the original locations when re±assem-
bling.
2. REMOVE INTAKE VALVE
(a) Using SST and wooden blocks, compress and remove
the 8 valve spring retainer locks.
SST 09202±70020 (09202±00010)
(b) Remove the parts below from the cylinder head.
1Retainer
2Valve spring
3Intake valve
HINT:
Store the removed parts in correct order, so that they can be re-
turned to the original locations when re±assembling.
3. REMOVE EXHAUST VALVE
(a) Using SST and wooden blocks, compress and remove
the 8 valve spring retainer locks.
SST 09202±70020 (09202±00010)
(b) Remove the parts below from the cylinder head.
1Retainer
2Valve spring
3Intake valve
HINT:
Store the removed parts in correct order, so that they can be re-
turned to the original locations when re±assembling.
4. REMOVE VALVE STEM OIL O SEAL OR RING
(a) Using needle±nose pliers, remove the oil seals.
Page 3495 of 5135
A14192
A77255
Cylinder Block Side
Intake Manifold Side
Exhaust Manifold Side 14±40
± ENGINE MECHANICALCYLINDER HEAD ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
5. REMOVE VALVE SPRING SEAT
(a) Using compressed air and a magnetic finger, remove the
spring seat by blowing air.
HINT:
Store the removed parts in correct order, so that they can be re-
turned to the original locations when re±assembling.
6. REMOVE STUD BOLT
7. INSPECT CYLINDER HEAD FOR FLATNESS
(a) Using a precision straight edge and a feeler gauge, mea-
sure the surface contacting the cylinder block and the
manifolds for warpage.
Maximum warpage:
Cylinder block side 0.05 mm (0.0020 in.)
Intake manifold side 0.08 mm (0.0031 in.)
Exhaust manifold side 0.08 mm (0.0031 in.)
If warpage is greater than maximum, replace the cylinder head.
Page 3496 of 5135

A14180
A77457
Width
A775021.0 to 1.4mm45
30
± ENGINE MECHANICALCYLINDER HEAD ASSY
14±41
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
8. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrate, check the intake ports, exhaust
ports and cylinder surface for cracks.
9. INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the
valve face.
(b) Lightly press the valve against the seat.
(c) Check the valve face and seat according to the following
procedure.
(1) If blue appears 360 around the face, the valve is
concentric. If not, replace the valve.
(2) If blue appears 360 around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the
valve face with the width between 1.0 to 1.4 mm
(0.039 to 0.055 in.).
10. REPAIR VALVE SEATS
NOTICE:
Releasing the seat±cutter pressure gradually helps to
make smoother valve seat faces.
(a) Using a 45 cutter, cut valve face of the cylinder head a
little wider than the specified valve seating width.
(b) Confirm that the valve fits the valve seat center portion.
If not, re±cut the valve face with the 45 cutter.
(c) Adjust valve face with a 30 or 60 cutter to accurately fit
the valve seat center portion.
(1) If the seating is too high on the valve face, use 30
and 45 cutters to correct the seat.