1. REPLACE STUD BOLT
NOTICE:
If a stud bolt is deformed or its threads are damaged, replace it.
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Remove the stud bolts.
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Install new stud bolts.
Torque:
for stud bolt A and B:
11 N*m{ 112 kgf*cm , 8 ft.*lbf }
for stud bolt C:
4.0 N*m{ 41 kgf*cm , 35 in.*lbf }
2. REPLACE STRAIGHT PIN
NOTICE:
It is not necessary to remove the straight pin unless it is being replaced.
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Remove the straight pins.
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Using a plastic-faced hammer, tap in new straight pins to the cylinder block.
Standard Protrusion Height:
Item Specified Condition Pin "A" 22.5 to 23.5 mm (0.889 to 0.925 in.) Pin "B" 10.5 to 11.5 mm (0.413 to 0.453 in.) Pin "C" 8.5 to 9.5 mm (0.335 to 0.374 in.) Pin "D" 5.5 to 6.5 mm (0.217 to 0.256 in.)
3. REPLACE CYLINDER BLOCK TIGHT PLUG
NOTICE:
If water leaks from the tight plug or the plug corrodes, replace it.
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Remove the tight plugs.
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Apply adhesive around new tight plugs.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
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Using SST and a hammer, tap in the tight plugs to the standard depth.
SST
09950-60010 (09951-00350) 09950-70010 (09951-07150)
Standard depth:
0.2 to 1.2 mm (0.00787 to 0.0472 in.)
4. REPLACE OIL JET
NOTICE:
It is not necessary to remove the oil jet unless it is being replaced.
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Using a screwdriver and hammer, tap out the oil jet.
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Using a screwdriver and hammer, tap in a new oil jet as shown in the illustration.
5. REPLACE CONNECTING ROD SMALL END BUSH
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Using SST and a press, press out the bush.
SST
09222-30010
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Align the oil holes of a new bush and the connecting rod.
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Using SST and a press, press in the bush.
SST
09222-30010
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Using a pin hole grinder, hone the bush to obtain the standard oil clearance between the bush and piston pin.
Standard oil clearance:
0.005 to 0.011 mm (0.000197 to 0.000433 in.)
HINT:
Check that the piston pin fits at a normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with a thumb.