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14-172
ENGINE MECHANICAL - CYLINDER BLOCK ASSY
OVERHAUL
1. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
2. REMOVE WATER SEAL PLATE
3. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG
(a) Using a 10 mm socket hexagon wrench, remove the screw plug. 1405L-06
4. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.2 PLUG
(a) Using a 10 mm socket hexagon wrench, remove the screw plug.
5. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG
(a) Using a 10 mm socket hexagon wrench, remove the screw plug.
6. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.
Standard thrust clearance:
0.15 to 0.30 mm (0.0059 to 0.0118 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
7. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check the matchmarks on the connecting rod and the cap
P12695 are aligned to ensure correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(c) Clean the crank pin, the bearing and the connecting rod.
(d) Check the crank pin and the bearing for pitting and
scratches.
(e) Lay a strip of plastigage across the crank pin.
Plastigage
A78793
(f) Check that the protrusion of the connecting rod cap is fac-
Front ing in the correct direction.
(g) Apply a light coat of engine oil on the threads of the con-
necting rod cap bolts.
Protrusion
A78794
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Author : Date : 2471
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
(h) Tighten the bolts in several steps by the specified torque.
Torque: 25 Nm (250 kgfcm, 18 ftlbf)
P12697
(i) Mark the front side of the each connecting cap bolt with
Painted Mark
paint.
90_ (j) Retighten the cap bolts by 90_ as shown in the illustration.
90_
NOTICE:
Front
Do not turn the crankshaft.
(k) Remove the 2 bolts, the connecting rod cap and the lower
bearing.
A78795
(l) Measure the plastigage at its widest point.
Standard oil clearance:
0.038 to 0.066 mm (0.0015 to 0.0026 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
NOTICE:
Completely remove the plastigage.
P12698
If replacing the bearing, replace it with one having the same
number as marked on the connecting rod. There are 4 sizes of
Number Mark standard bearings, marked "1 ", "2", "3" and "4" accordingly.
HINT:
Standard bearing center wall thickness
Mark mm (in.)
"1" 1.484 to 1.487 (0.0584 to 0.0585)
"2" 1.487 to 1.490 (0.0585 to 0.0587)
A79803 "3" 1.490 to 1.493 (0.0587 to 0.0588)
"4" 1.493 to 1.496 (0.0588 to 0.0589)
8. REMOVE PISTON SUB-ASSY W/CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push out the piston and the connecting rod assembly
from the top of the cylinder block.
HINT:
S Keep the bearings, the connecting rod and the cap to-
gether.
A05258 S Arrange the piston and the connecting rod assemblies in
correct order.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2472
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
9. REMOVE CONNECTING ROD BEARING
10. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and the oil ring by hand.
A78315
11. REMOVE PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, pry out the 2 snap rings.
P12403
12. REMOVE W/PIN PISTON SUB-ASSY
80_C (176_F)
(a) Gradually heat the piston to approx. 80_C (176_F).
A78797
(b) Using a plastic-faced hammer and a brass bar, lightly tap
out the piston pin and remove the connecting rod.
HINT:
S The piston and pin are a matched set.
S Store the pistons, the pins, the rings, the connecting rods
and the bearings in correct order so that they can be re-
turned to the original locations when re-assembling.
P12415
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Author : Date : 2473
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
13. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.04 to 0.24 mm (0.0016 to 0.0094 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set. Check the crankshaft for wear, repair
P12799 or replace if necessary.
HINT:
Thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780
in.)
14. REMOVE CRANKSHAFT
5 (a) Using several steps, loosen and remove the 8 main bear-
8 ing cap bolts and seal washers uniformly in the sequence
7
shown in the illustration.
6 2
3
4
1 A78798
(b) Using several steps, loosen and remove the 16 main
bearing cap bolts uniformly in the sequence shown in the
illustration.
4 12
8 11
6 16 3
2 14 15
7
10 13
9 5
1 A78799
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
(c) Using a screwdriver, pry out the main bearing caps. Re-
move the 4 main bearing caps and the lower bearings.
NOTICE:
S Carefully pry out the main bearing cap by alternating
lifting a little at a time on each end the cap.
S Be careful not to damage the joint surface of the cylin-
der block and the main bearing cap.
P12603
Joint Surface
A78800
15. REMOVE CRANKSHAFT THRUST WASHER SET
16. REMOVE CRANKSHAFT BEARING
17. INSPECT CYLINDER BLOCK FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, mea-
sure the surface contacting the cylinder head gasket for
warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder block.
Z09222
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
18. INSPECT CYLINDER BORE
(a) Using a cylinder gauge, measure the cylinder bore diame-
ter at positions A, B and C in the thrust and axial direc-
tions.
Standard diameter:
92.000 to 92.012 mm (3.6220 to 3.6225 in.)
Maximum diameter: 92.080 mm (3.6252 in.)
If the diameter is greater than maximum, replace the cylinder
block.
Thrust Direction
Front Axial Direction
A 10 mm
B
C 10 mm
A78801
19. INSPECT W/PIN PISTON SUB-ASSY
(a) Using a micrometer, measure a diameter of the piston.
When you measure the diameter, attach the micrometer
to a location where 13.0 mm (0.512 in.) above from the
piston bottom and meets at the right angles to the piston
pin hole.
Piston diameter:
13.0 mm 91.953 to 91.967 mm (3.6202 to 3.6207 in.)
A78316
20. INSPECT PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.)
Maximum oil clearance: 0.13 mm (0.0051 in.)
If the oil clearance is greater than maximum, replace all the 6 pistons. If necessary, replace the cylinder block.
21. INSPECT CONNECTING ROD SUB-ASSY
(a) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Check for misalignment.
Maximum misalignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If misalignment is greater than maximum, replace the connect-
ing rod assembly.
Z00064
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
(2) Check for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
Z00065
22. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
22.005 to 22.014 mm (0.8663 to 0.8667 in.)
EM6525
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 to 22.006 mm (0.8660 to 0.8664 in.)
(c) Subtract the piston pin diameter measurement from the
bushing inside diameter measurement.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)
EM0227 If the oil clearance is greater than maximum, replace the bush-
ing. If necessary, replace the piston and the piston pin together.
23. REMOVE CONNECTING ROD SMALL END BUSH
(a) Using SST and a press, press out the bushing.
SST SST 09222-30010
A78803
24. INSTALL CONNECTING ROD SMALL END BUSH
(a) Align the oil holes of a new bushing and the connecting
rod.
Oil Hole
A78804
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
(b) Using SST and a press, press in the bushing.
SST 09222-30010
SST
A78803
(c) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance between the bushing and
the piston pin.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
EM6535
HINT:
Check the piston pin fit at normal room temperature. Coat the
piston pin with engine oil, and push it into the connecting rod
with thumb.
P00326
25. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between
new piston ring and the wall of the ring groove.
Ring groove clearance:
No.1 0.03 to 0.08 mm (0.0012 to 0.0031 in.)
No.2 0.02 to 0.06 mm (0.0008 to 0.0024 in.)
Oil 0.03 to 0.11 mm (0.0012 to 0.0043 in.)
A78317
26. INSPECT PISTON RING END GAP
(a) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 110 mm (4.33 in.) from the top of the
cylinder block.
110 mm
A78805
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
(b) Using a feeler gauge, measure the end gap.
Standard end gap:
No. 1 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
No. 2 0.50 to 0.60 mm (0.0197 to 0.0236 in.)
Oil (Side rail) 0.15 to 0.40 mm (0.0059 to 0.0157 in.)
Maximum end gap:
No. 1 0.95 mm (0.0374 in.)
No. 2 1.05 mm (0.0413 in.)
A37355 Oil (Side rail) 1.00 mm (0.0394 in.)
27. INSPECT CONNECTING ROD BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter: 7.0 mm (0.276 in.)
If the diameter is less than minimum, replace the bolt.
EM6347 A15065
28. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolt.
Standard diameter:
7.5 to 7.6 mm (0.295 to 0.299 in.)
Minimum diameter: 7.2 mm (0.283 in.)
If the diameter is less than minimum, replace the bolt.
EM6347 A15065
29. INSPECT CRANKSHAFT
(a) Using a dial indicator and V-blocks, measure the runout
as shown in the illustration.
Maximum circle runout: 0.06 mm (0.0024 in.)
P12406
(b) Using a micrometer, measure the diameter of each main
journal.
Diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 in.)
(c) Check each main journal for taper and out-of-round as
shown.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
A37157
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
(d) Using a micrometer, measure the diameter of each crank
pin.
Diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
(e) Check each crank pin for taper and out-of-round as
shown.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
ZF6928
30. INSPECT CRANKSHAFT OIL CLEARANCE
No. 1 and No. 4 No. 2 and No. 3 HINT:
Main bearings come in widths of 22.4 mm (0.882 in.) and 19.0
Upper
mm (0.748 in.). Install the 22.4mm (0.882 in.) bearings in the
No. 1 and No. 4 cylinder block journal positions with the main
Lower
bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No.
2 and No. 3 positions.
19.0 mm (a) Clean each main journal and bearing.
22.4 mm
A78806
(b) Align the bearing key with the keyway of the cylinder
block, and push in the 4 upper bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
P12599
(c) Align the bearing key with the keyway of the main bearing
cap, and push in the 4 lower bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
HINT:
Mark A number is marked on each main bearing cap to indicate the
1, 2, 3 or 4
installation position.
A78807 (d) Place the crankshaft on the cylinder block.
Plastigage (e) Lay a strip of plastigage across each journal.
A78808
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
(f) Examine the front marks and numbers and install the
bearing caps on the cylinder block.
(g) Apply a light coat of engine oil on the threads of the bear-
ing cap bolts.
(h) Temporarily install the 8 main bearing cap bolts to the in-
side positions.
A10530
(i) Install the main bearing cap by hand, using the inner bolt
as a guide. Stop the main bearing cap is about 6 mm (0.23
in.) away from mating with the block.
Less than 6 mm
A78809
(j) Using a plastic-faced hammer, lightly tap the bearing cap
to ensure a proper fit.
(k) Apply a light coat of engine oil on the threads of the main
bearing cap bolts.
A10529
(l) Using several steps, install and tighten the 16 main bear-
ing cap bolts uniformly in the sequence shown in the il-
lustration.
13 5 Torque: 22 Nm (224 kgfcm, 16 ftlbf)
9 6
11 2
1 14
15 3 10
7 4 12
8 16
A78810
(m) Mark the front side of the bearing cap bolts with paint.
Painted Mark
(n) Retighten the bearing cap bolts by 90_ in the same se-
90_
quence shown as step (l).
Front 90_ (o) Check that the painted mark is now at a 90_ angle to the
front.
NOTICE:
Do not turn the crankshaft.
A78811
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
(p) Using several steps, install and tighten the 8 main bearing
4
1 cap bolts uniformly in the sequence shown in the illustra-
2 tion.
3 7 Torque: 27 Nm (275 kgfcm, 20 ftlbf)
HINT:
6 Use the short bolt for the marked position (arrow)
5 (q) Remove the main bearing caps.
8
A78812
(r) Measure the plastigage at its widest point.
Standard oil clearance:
No. 1 and No. 2 journals
0.014 to 0.031 mm (0.0006 to 0.0012 in.)
No. 3 and No. 4 journals
0.028 to 0.041 mm (0.0011 to 0.0016 in.)
Maximum clearance:
No. 1 and No. 2 journals 0.05 mm (0.0020 in.)
P12993 No. 3 and No. 4 journals 0.06 mm (0.0024 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, replace the crankshaft.
NOTICE:
Completely remove the plastigage.
No.2 (s) If replacing a bearing, replace it with one having the same
No.1 No.3
No.4 number. If the number of the bearing cannot be deter-
mined, select the correct bearing by adding together the
numbers imprinted on the cylinder block and crankshaft,
then refer to the table below for the appropriate bearing
Number Mark number. The No. 1 and No. 2 journal bearing come in
sizes, marked "3", "4", "5", "6" and "7". The No.3 and No.
4 journal bearings come in 5 standard bearing sizes,
marked "1", "2", "3", "4" and "5".
No.2 No.3 No. 1 and No. 2 journal bearings
No.4
No.1 Cylinder
block (A)
+ 0 to 5 6 to 11 12 to 17 18 to 23 24 to 28
Crankshaft
(B) =
Use
"3" "4" "5" "6" "7"
Bearing
HINT:
Number
Number Mark EXAMPLE
Mark
A78813 Cylinder block "06" (A) + Crankshaft "08" (B)
=Total number 14 (Use bearing "5")
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2482
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
No. 3 and No. 4 journal bearings
Cylinder
block (A)
+ 0 to 5 6 to 11 12 to 17 18 to 23 24 to 28
Crankshaft
(B) =
Use
"1" "2" "3" "4" "5"
Bearing
HINT:
EXAMPLE
Cylinder block "06" (A) + Crankshaft "08" (B)
=Total number 14 (Use bearing "3")
Item Mark mm (in.)
Cylinder block main journal bore diameter (A) "00" 66.000 (2.5984)
"01" 66.001 (2.5985)
"02" 66.002 (2.5985)
"03" 66.003 (2.5985)
"04" 66.004 (2.5986)
"05" 66.005 (2.5986)
"06" 66.006 (2.5987)
"07" 66.007 (2.5987)
"08" 66.008 (2.5987)
"09" 66.009 (2.5988)
"10" 66.010 (2.5988)
"11" 66.011 (2.5989)
"12" 66.012 (2.5989)
"13" 66.013 (2.5989)
"14" 66.014 (2.5990)
"15" 66.015 (2.5990)
"16" 66.016 (2.5990)
Crankshaft main journal diameter (B) "00" 61.000 (2.4016)
"01" 60.999 (2.4015)
"02" 60.998 (2.4015)
"03" 60.997 (2.4015)
"04" 60.996 (2.4014)
"05" 60.995 (2.4014)
"06" 60.994 (2.4013)
"07" 60.993 (2.4012)
"08" 60.992 (2.4012)
"09" 60.991 (2.4012)
"10" 60.990 (2.4012)
"11" 60.989 (2.4011)
"12" 60.988 (2.4011)
Standard bearing center wall thickness "1" 2.486 to 2.489 (0.0979 to 0.0980)
"2" 2.489 to 2.492 (0.0980 to 0.0981)
"3" 2.492 to 2.495 (0.0981 to 0.0982)
"4" 2.495 to 2.498 (0.0982 to 0.0983)
"5" 2.498 to 2.501 (0.0983 to 0.0985)
"6" 2.501 to 2.504 (0.0985 to 0.0986)
"7" 2.504 to 2.507 (0.0986 to 0.0987)
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
31. INSTALL STUD BOLT
Front Side Front Side
99 mm
29 mm
M6 M8
Torque: 6.0 Nm (60 kgfcm, 53 in.lbf) Torque: 15 Nm (145 kgfcm, 11 ftlbf)
Front Side Left Side
80 mm
28.5mm
M10 M8
Torque: 21 Nm (220 kgfcm, 15 ftlbf) Torque: 7.0 Nm (70 kgfcm, 62 in.lbf)
Upper Side Upper Side
52.5 mm
27.5 mm
M6
Torque: 4.0 Nm (40 kgfcm, 35 in.lbf) Torque: 12 Nm (122 kgfcm, 9 ftlbf)
A78318
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Author : Date : 2484
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
32. INSTALL STRAIGHT PIN
Front Side Right Side (FF)
4 mm 4 mm
12 mm 12 mm
Protrusion Height: 6 mm Protrusion Height: 6 mm
Upper Side Lower Side
4 mm 4 mm
12 mm 12 mm
Protrusion Height: 6 mm Protrusion Height: 6 mm
Back Side Back Side
4 mm 10 mm
12 mm 22 mm
Protrusion Height: 6 mm Protrusion Height: 11 mm
A78319
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
33. INSTALL RING PIN
Upper Side
11 mm
16 mm
20 mm 8 mm
Protrusion Height: 10 mm Protrusion Height: 4 mm
A78816
34. INSTALL PISTON PIN HOLE SNAP RING
(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.
P12418 A32958
80_C (176_F)
35. INSTALL W/PIN PISTON SUB-ASSY
(a) Gradually heat the piston to about 80_C (176_F).
A78817
(b) Coat the piston pin with engine oil.
Front Mark (c) Align the front marks of the piston and connecting rod,
Front Mark and push in the piston pin with thumb until the pin contacts
(Mold Mark) the snap ring.
A78376
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
36. INSTALL PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, install a new snap ring on the
other end of the piston pin hole.
HINT:
Be sure that end of gap of the snap ring is not aligned with the
pin hole cutout portion of the piston.
P12418 A32958
37. INSTALL PISTON RING SET
(a) Install the oil ring expander and the 2 side rails by hand.
No. 1 (b) Using a piston ring expander, install the 2 compression
rings.
2A HINT:
No. 2 The compression ring No. 2 is installed with the code mark "2A"
faced upward as shown in the illustration.
A78320
(c) Position the piston rings so that the ring ends are as
Lower Side Rail
No. 2 shown.
Compression Front Mark NOTICE:
Do not align the ring ends.
Expander
No. 1
Compression
Upper Side Rail
A78321
38. INSTALL CONNECTING ROD BEARING
(a) Align the key of the bearing with the keyway of the con-
necting rod or connecting cap.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the connecting rod. The surface should be free of dust
and oils.
P12402
39. INSTALL CRANKSHAFT BEARING
No. 1 and No. 4 No. 2 and No. 3 HINT:
Main bearings come in widths of 22.4 mm (0.882 in.) and 19.0
Upper
mm (0.748 in.). Install the 22.4mm (0.882 in.) bearings in the
No. 1 and No. 4 cylinder block journal positions with the main
Lower
bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No.
2 and No. 3 positions.
19.0 mm (a) Clean each main journal and the bearing.
22.4 mm
A78806
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
(b) Align the key of the bearing with the keyway of the cylinder
block, and push in the 4 upper bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
P12599
(c) Align the key of the bearing with the keyway of the main
bearing cap, and push in the 4 lower bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
HINT:
Mark A number is marked on each main bearing cap to indicate the
1, 2, 3 or 4
installation position.
A78807
40. INSTALL CRANKSHAFT THRUST WASHER SET
(a) Install the 2 thrust washers under the No. 2 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.
P12600
(b) Install the 2 thrust washers on the No. 2 bearing cap with
the grooves facing outward.
41. INSTALL CRANKSHAFT
(a) Apply engine oil to upper bearing and install the crank-
shaft on the cylinder block.
A05264
(b) Examine the front marks and numbers and install the
bearing caps on the cylinder block.
(c) Apply a light coat of engine oil on the threads of bearing
cap bolts.
(d) Temporarily install the 8 main bearing cap bolts to the in-
side positions.
A10530
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
(e) Install the main bearing cap by hand, using the inner bolt
as a guide. Stop the main bearing cap is about 6 mm (0.23
in.) away from mating with the block.
Less than 6 mm
A78809
(f) Using a plastic-faced hammer, lightly tap the bearing cap
to ensure a proper fit.
(g) Apply a light coat of engine oil on the threads of the main
bearing cap bolts.
A10529
(h) Using several steps, install and tighten the 16 main bear-
ing cap bolts uniformly in the sequence shown in the il-
lustration.
13 5 Torque: 22 Nm (224 kgfcm, 16 ftlbf)
9 6
11 2
1 14
15 3 10
7 4 12
8 16
A78810
(i) Mark the front side of the bearing cap bolts with paint.
Painted Mark
(j) Retighten the bearing cap bolts by 90_ in the same se-
90_
quence shown as step (h).
Front 90_ (k) Check that the painted mark is now at a 90_ angle to the
front.
(l) Check that the crankshaft turns smoothly.
A78811
(m) Using several steps, install and tighten the 8 main bearing
4
1 cap bolts uniformly in the sequence shown in the illustra-
2 tion.
3 7 Torque: 27 Nm (275 kgfcm, 20 ftlbf)
HINT:
6 Use the short bolt for the marked position (arrow)
5
8
A78812
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2489
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ENGINE MECHANICAL - CYLINDER BLOCK ASSY
42. INSTALL PISTON SUB-ASSY W/CONNECTING ROD
Front Mark (Cavity)
(a) Apply engine oil to 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
Front
cylinder with the front mark of the piston facing forward.
NOTICE:
A78322 Match the numbered connecting rod cap with the connect-
ing rod.
(d) Check that the protrusion of the connecting rod cap is fac-
Front ing in the correct direction.
(e) Apply a light coat of engine oil on the threads of the con-
necting rod cap bolts.
Protrusion
A78794
(f) Tighten the bolts in several steps by the specified torque.
Torque: 25 Nm (250 kgfcm, 18 ftlbf)
P12697
(g) Mark the front side of the each connecting cap bolt with
Painted Mark
paint.
90_ (h) Retighten the cap bolts by 90_ as shown in the illustration.
90_
(i) Check that the crankshaft turns smoothly.
Front
A78795
Front Side 43. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT
SCREW NO.1 PLUG
(a) Using a 10 mm hexagon wrench, install a new gasket and
the screw plug.
Torque: 30 Nm (306 kgfcm, 22 ftlbf)
A78822
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2490
14-192
ENGINE MECHANICAL - CYLINDER BLOCK ASSY
44. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT
Left Side
SCREW NO.2 PLUG
(a) Using a 10 mm hexagon wrench, install a new gasket and
the screw plug.
Torque: 30 Nm (306 kgfcm, 22 ftlbf)
A78823
Back Side 45. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT
SCREW NO.3 PLUG
(a) Using a 10 mm hexagon wrench, install a new gasket and
the screw plug.
Torque: 50 Nm (510 kgfcm, 37 ftlbf)
46. INSTALL WATER SEAL PLATE
(a) Remove any old seal packing from the contact surface.
A78824
(b) Apply a continuous bead of seal packing (Diameter 3 to
A 5 mm (0.12 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent
A NOTICE:
S Remove any oil from the contact surface.
B
S Install the seal plate within 3 minutes after applying
seal packing.
Seal Width
3 to 5 mm S Do not expose the seal to engine oil within 2 hours af-
B A62377 ter installing.
(c) Install the seal plate with the 2 nuts.
Torque: 18 Nm (184 kgfcm, 13 ftlbf)
47. INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSY
(a) Apply adhesive to 2 or 3 threads of the drain cock end.
Adhesive: Part No. 08833-00070, THREE BOND 1324
or equivalent
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2491
14-193
ENGINE MECHANICAL - CYLINDER BLOCK ASSY
(b) After applying the specified torque, rotate the drain cock
clockwise as shown in the illustration.
Torque: 39 Nm (398 kgfcm, 29 ftlbf)
NOTICE:
S Install the drain cock within 3 minutes after applying
adhesive.
S Do not expose the seal to coolant within an hour after
installing.
S Do not rotate the drain cock more than 1 revolution
(360_) after tightening the drain cock with the speci-
fied torque.
10_ S Do not loosen the drain cock◦ Jabse Service Manual Search 2026 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo