Cylinder block (3S-GTE)¶

Components¶

Removal of engine¶

Disconnect cable from negative terminal of battery.

Caution

Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative (–) terminal cable is disconnected from the battery.
Remove engine hood.
Remove engine hood side panels.
Remove engine under covers.
Drain engine coolant. (See page CO-6)
Drain engine oil. (See page LU-7)
Drain transaxle oil.
Remove suspension upper brace.

Remove the two bolts, two nuts and upper brace.
Remove air cleaner.
1. Disconnect the air flow meter connector.
2. Disconnect the four air cleaner cap clips.
3. Disconnect the following hoses:
  1. Air cleaner hose from turbocharger
  2. PCV hose from cylinder head cover
  3. Air hose from No.2 air tube
  4. Air hose from air by-pass valve
4. Remove the air cleaner cap, air flow meter assembly and element.
5. Remove the three bolts and air cleaner case.
Remove No.1 air intake connector.
Remove No.2 air intake connector.
Disconnect accelerator cable from throttle body.
Remove cruise control actuator (w/ cruise control system) and linkage.
1. Remove the two screws and actuator cover.
2. Remove the screw and accelerator linkage cover.
3. Remove the three bolts and actuator.
4. Disconnect the actuator connector.
5. Remove the three bolts and accelerator linkage.
6. Disconnect the cable from the accelerator linkage.
Disconnect brake booster vacuum hose.
Disconnect ground strap connector.
Remove check connector and turbocharging pressure sensor.
Remove injector solenoid resistor, fuel pump relay, fuel pump resistor and A/C VSV.
1. Disconnect the following connectors:
  - Solenoid resistor connector
  - Fuel pump relay connector
  - Fuel pump resistor connector
  - A/C VSV connector
2. Disconnect the following hoses:
  1. A/C VSV air hose from No.2 air tube
  2. A/C VSV vacuum hose from intake manifold
3. Remove the two bolts, A/C VSV, the solenoid resistor and fuel pump relay, fuel pump resistor assembly.
Remove water filler.
1. Disconnect the following hose:
  1. Water filler hose
  2. Coolant reservoir hose
2. Remove the two bolts and water filler.
Remove charcoal canister.
1. Disconnect the three vacuum hoses.
2. Remove the two bolts and charcoal canister.
Remove engine relay box, and disconnect engine wire.
1. Remove the two bolts and relay box. Disconnect the luggage compartment striker cable.
2. Remove the upper and lower covers from the relay box.
3. Disconnect the positive (+) cable and two connectors of the engine wire from the relay box.
Remove ignition coil and igniter.
1. Disconnect the ignition coil connector.
2. Disconnect the igniter connector.
3. Disconnect the high-tension cord.
4. Remove the two bolts, the ignition coil and igniter assembly. Disconnect the noise filter.
Disconnect engine wire from luggage compartment.
1. Disconnect the following connectors:
  1. Two engine ECU connectors
  2. Starter relay connector
  3. Engine compartment cooling fan relay connector
  4. Engine compartment wire connector
2. Pull out the engine wire from the luggage compartment.
Disconnect starter cable.
Disconnect radiator hose from water inlet.
Disconnect fuel inlet hose.

Caution

Catch leaking fuel in a container.
Disconnect fuel return hose.

Caution

Catch leaking fuel in a container.
Disconnect radiator hose from water outlet housing.
Disconnect heater hoses.
Disconnect transaxle control cables from transaxle.
Remove tailpipe.
1. Remove the two bolts holding the front exhaust pipe to the tailpipe stopper bracket.
2. Remove the two bolts holding the front exhaust pipe to the tailpipe. Remove the gasket.
3. Remove the two through bolts holding the tailpipe to the tailpipe bracket.
Remove front exhaust pipe.
1. Remove the two bolts and damper.
2. Remove the two bolts and support bracket.
3. Using a 14 mm deep socket wrench, remove the three nuts, exhaust pipe and gasket.
  
  Hint
  
  Passing the exhaust pipe rear side between the body and suspension crossmember is not easy, so follow the method shown in the illustration.
Remove engine compartment cooling fan. (See steps 4 and 5 on page CO-34)
Remove idler pulley bracket and A/C compressor without disconnecting hoses.
1. Disconnect the idler pulley bolt and adjusting bolt, and remove the drive belt.
2. Disconnect the A/C compressor connector.
3. Remove the bolt and the wire clamp of the A/C compressor.
4. Remove the three bolts and idler pulley bracket.
5. Remove the two bolts, and disconnect the A/C compressor from the engine.
  
  Hint
  
  Put aside the compressor, and suspend it to the radiator support with a string.
Remove intercooler. (See steps 8 to 12 (a) and 13 on Intercooler › Removal of intercooler)
Remove rear engine mounting insulator.
1. Remove the through bolt holding the mounting insulator to the mounting bracket.
2. Remove the three bolts and mounting insulator.
Disconnect speedometer cable.
Remove rear suspension crossmember.
1. Remove the nut, and disconnect the stabilizer link from the shock absorber.
2. Remove the bolt, and disconnect the wire clamp of the ABS speed sensor from the body.
3. Remove the lower suspension arms. (See page SA-76)
4. Remove the drive shafts. (See page SA-53 and 54)
1. Remove the four bolts and lower crossmember.
Remove front engine mounting insulator.
1. Remove the through bolt and nut holding the mounting insulator to the mounting bracket.
2. Remove the four bolts and mounting insulator.
Remove front engine mounting bracket and clutch release cylinder.
1. Remove the bolt and nut holding the clutch release cylinder to the transaxle.
2. Remove the two bolts and mounting bracket.
3. Disconnect the clutch release cylinder without disconnecting the tubes.
Remove RH engine mounting stay.

Remove the two bolts, nut and mounting stay.
Remove LH engine mounting stay.

Remove the two bolts, speedometer cable clamp and mounting stay.
Remove lateral control rod and air cleaner case bracket.

Remove the five bolts, the control rod and case bracket. Disconnect the charcoal canister tube and ground strap (from the transaxle).
Remove engine and transaxle assembly from vehicle.
1. Attach the engine chain hoist to the engine hangers.
2. Remove the through bolt, nut, three bolts and LH mounting insulator.
3. Remove the through bolt, two nuts and RH mounting insulator.
4. Lower the engine out of the vehicle slowly and carefully, and raise the engine.
  
  Hint
  
  Make sure the engine is clear of all wiring, hoses and cables.
5. Place the engine and transaxle assembly onto the stand.
Remove rear engine mounting bracket.

Remove the six bolts and mounting bracket.
Remove LH engine mounting bracket.

Remove the three bolts and mounting bracket.
Remove starter. (See Starter › Removal of starter)
Separate engine and transaxle. (See pages MT-5 and 6)

Preparation for disassembly¶

Remove clutch cover and disc.
Remove flywheel.
Remove rear end plate.

Remove the bolt and end plate.
Install engine to engine stand for disassembly.
Remove alternator. (See Alternator)
Remove alternator bracket.

Remove the three bolts, two nuts and mounting bracket.
Remove RH engine mounting bracket.

Remove the four bolts and mounting bracket.
Remove timing belt and pulleys. (See Timing belt (3S-GTE) › Removal of timing belt)
Remove turbocharger. (See Turbocharger › Removal of turbocharger)
Remove cylinder head. (See Cylinder head (3S-GTE) › Removal of cylinder head)
Remove water pump. (See page CO-11)
Remove oil pan and oil pump. (See pages LU-11 and 12)
Remove oil filter. (See page LU-7)
Remove oil cooler. (See page LU-19)
Remove knock sensor.

Using SST, remove the knock sensor.

SST 09816-30010

Disassembly of cylinder block¶

(See Cylinder block (3S-GTE))

Remove rear oil seal retainer.

Remove the six bolts, retainer and gasket.
Check connecting rod thrust clearance.

Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

Standard thrust clearance: 0.160 – 0.312 mm (0.0063 – 0.0123 in.)

Maximum thrust clearance: 0.35 mm (0.0138 in.)

If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
Remove connecting rod caps and check oil clearance.
1. Using a punch or numbering stamp, place the matchmarks on the connecting rod and cap to ensure correct reassembly.
2. Remove the connecting rod cap nuts.
3. Using a plastic-faced hammer, lightly tap the connecting rod bolts and lift off the connecting rod cap.
  
  Hint
  
  Keep the lower bearing inserted with the connecting cap.
4. Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.
5. Clean crank pin and bearing.
6. Check the crank pin and bearing for pitting and scratches.
  
  If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.
7. Lay a strip of Plastigage across the crank pin.
8. Install the connecting rod cap. (See Assembly of cylinder block, step 7)
  
  Torque: 680 kg-cm (49 ft-lb, 67 N·m)
  
  Notice
  
  Do not turn the crankshaft.
9. Remove the connecting rod cap. (See procedures (b) and © above)
10. Measure the Plastigage at its widest point.
  
  Standard oil clearance:
  - STD – 0.024 – 0.055 mm (0.0009 – 0.0022 in.)
  - U/S 0.25 – 0.023 – 0.069 mm (0.0009 – 0.0027 in.)
  Maximum oil clearance: 0.08 mm (0.0031 in.)
  
  If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.
  Hint
  
  If using a standard bearing, replace it with one having the same number marked on the connecting rod cap. There are three sizes of standard bearings, marked "1", "2" and "3" accordingly.
  
  Standard sized bearing center wall thickness:
  - Mark "1" – 1.484 – 1.488 mm (0.0584 – 0.0586 in.)
  - Mark "2" – 1.488 – 1.492 mm (0.0586 – 0.0587 in.)
  - Mark "3" – 1.492 – 1.496 mm (0.0587 – 0.0589 in.)
11. Completely remove the Plastigage.
Remove piston and connecting rod assemblies.
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Cover the connecting rod bolts. (See Disassembly of cylinder block)
3. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
Hint
- Keep the bearings, connecting rod and cap together.
- Arrange the piston and connecting rod assemblies in correct order.
Check crankshaft thrust clearance.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

Standard thrust clearance: 0.020 – 0.220 mm (0.0008 – 0.0087 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.

Thrust washer thickness: 2.440 – 2.490 mm (0.0961 – 0.0980 in.)
Remove main bearing caps and check oil clearance.
1. Remove the main bearing cap bolts.
2. Using the removed main bearing cap bolts, pry the main bearing cap back and forth, and remove the main bearing caps, lower bearings and lower thrust washers (No.3 main bearing cap only).
  Hint
  - Keep the lower bearing and main bearing cap together.
  - Arrange the main bearing caps and lower thrust washers in correct order.
3. Lift out the crankshaft.
  
  Hint
  
  Keep the upper bearing and upper thrust washers together with the cylinder block.
4. Clean each main journal and bearing.
5. Check each main journal and bearing for pitting and scratches.
  
  If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.
6. Place the crankshaft on the cylinder block.
7. Lay a strip of Plastigage across each journal.
8. Install the main bearing caps. (See Assembly of cylinder block, step 5)
  
  Torque: 600 kg-cm (43 ft-lb, 59 N·m)
  
  Notice
  
  Do not turn the crankshaft.
9. Remove the main bearing caps. (See procedures (a) and (b) above)
10. Measure the Plastigage at its widest point.
  
  Standard clearance:
  - No.3
    - STD – 0.025 – 0.044 mm (0.0010 – 0.0017 in.)
    - U/S 0.25 – 0.021 – 0.061 mm (0.0008 – 0.0024 in.)
  - Others
    - STD – 0.015 – 0.034 mm (0.0006 – 0.0013 in.)
    - U/S 0.25 – 0.029 – 0.069 mm (0.0011 – 0.0027 in.)
  Maximum clearance: 0.08 mm (0.0031 in.)
  Hint
  
  If replacing the cylinder block subassembly, the bearing standard clearance will be:
  - No.3 – 0.027 – 0.054 mm (0.0011 – 0.0021 in.)
  - Others – 0.017 – 0.044 mm (0.0007 – 0.0017 in.)
  If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.
  
  Hint
  
  If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then select the bearing with the same number as the total. There are five sizes of standard bearings, marked "1," "2," "3," "4" and "5" accordingly.
  
  Cylinder block Crankshaft Bearing
  
  1 0 1
  
  1 1 2
  
  1 2 3
  
  2 0 1
  
  2 1 2
  
  2 2 3
  
  3 0 1
  
  3 1 2
  
  3 2 3
  
  Example: Cylinder block "2" + Crankshaft "1" = Bearing "3"
  
  (Reference)
  
  Cylinder block main journal bore diameter:
  - Mark "1" – 59.020 – 59.026 mm (2.3236 – 2.3239 in.)
  - Mark "2" – 59.026 – 59.032 mm (2.3239 – 2.3241 in.)
  - Mark "3" – 59.032 – 59.038 mm (2.3241 – 2.3243 in.)
  Crankshaft journal diameter:
  - Mark "0" – 54.998 – 55.003 mm (2.1653 – 2.1655 in.)
  - Mark "1" – 54.993 – 54.998 mm (2.1651 – 2.1653 in.)
  - Mark "2" – 54.988 – 54.993 mm (2.1649 – 2.1651 in.)
  Standard sized bearing center wall thickness:
  - No.3
    - Mark "1" – 1.992 – 1.995 mm (0.0784 – 0.0785 in.)
    - Mark "2" – 1.995 – 1.998 mm (0.0785 – 0.0787 in.)
    - Mark "3" – 1.998 – 2.001 mm (0.0787 – 0.0788 in.)
    - Mark "4" – 2.001 – 2.004 mm (0.0788 – 0.0789 in.)
    - Mark "5" – 2.004 – 2.007 mm (0.0789 – 0.0790 in.)
  - Others
    - Mark "1" – 1.997 – 2.000 mm (0.0786 – 0.0787 in.)
    - Mark "2" – 2.000 – 2.003 mm (0.0787 – 0.0789 in.)
    - Mark "3" – 2.003 – 2.006 mm (0.0789 – 0.0790 in.)
    - Mark "4" – 2.006 – 2.009 mm (0.0790 – 0.0791 in.)
    - Mark "5" – 2.009 – 2.012 mm (0.0791 – 0.0792 in.)
11. Completely remove the Plastigage.
Remove crankshaft.
1. Lift out the crankshaft.
2. Remove the upper bearings and upper thrust washers from the cylinder block.
Hint

Arrange the main bearing caps, bearings and thrust washers in correct order.
Remove oil nozzles. (See page LU-26)

Inspection of cylinder block¶

Clean cylinder block.
1. Remove gasket material
  
  Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block
  
  Using a soft brush and solvent, thoroughly clean the cylinder block.
Inspect top surface of cylinder block for flatness.

Using a precision straight edge and feeler gauge, measure the surfaces 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.
Inspect cylinder for vertical scratches.

Visually check the cylinder for vertical scratches.

If deep scratches are present, replace the cylinder block.
Inspect cylinder bore diameter.

Hint

There are three sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the top of the cylinder block.

Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust axial directions.

Standard diameter:
- Mark "1" – 86.000 – 86.010 mm (3.3858 – 3.3862 in.)
- Mark "2" – 86.010 – 86.020 mm (3.3862 – 3.3866 in.)
- Mark "3" – 86.020 – 86.030 mm (3.3866 – 3.3870 in.)
Maximum diameter: 86.23 mm (3.3949 in.)

If the diameter is greater than maximum, replace the cylinder block.
Remove cylinder ridge.

If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.

Disassembly of piston and connecting rod assemblies¶

Check fit between piston and piston pin.

Try to move the piston back and forth on the piston pin.

If any movement is felt, replace the piston and pin as a set.
Remove piston rings.
1. Using a piston ring expander, remove the two compression rings.
2. Remove the two side rails and oil ring expander by hand.
Hint

Arrange the rings in correct order only.
Disconnect connecting rod from piston.
1. Using a small screwdriver, pry out the two snap rings.
2. Gradually heat the piston to 80 – 90°C (176 – 194°F).
3. Using plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.
Hint
- The piston and pin are a matched set.
- Arrange the pistons, pins, rings, connecting rods and bearings in correct order.

Inspection of piston and connecting rod assemblies¶

Clean piston.
1. Using a gasket scraper, remove the carbon from the piston top.
2. Using a groove cleaner or broken ring, clean the piston ring grooves.
3. Using solvent and a brush, thoroughly clean the piston.
  
  Notice
  
  Do not use a wire brush.
Inspect piston.
1. Inspect piston oil clearance
  
  Hint
  
  There are three sizes of the standard piston diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the piston top.
  1. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.1 mm (1.185 in.) from the piston head.
    
    Piston diameter:
    - Mark "1" – 85.920 – 85.930 mm (3.3827 – 3.3831 in.)
    - Mark "2" – 85.930 – 85.940 mm (3.3831 – 3.3835 in.)
    - Mark "3" – 85.940 – 85.950 mm (3.3835 – 3.3839 in.)
  2. Measure the cylinder bore diameter in the thrust directions. (See step 4 on page EM-152)
  3. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
    
    Standard oil clearance: 0.070 – 0.090 mm (0.0028 – 0.0035 in.)
    
    Maximum oil clearance: 0.110 mm (0.0043 in.)
    
    If the oil clearance is greater than maximum, replace all the four pistons. If necessary, replace the cylinder block.
    
    Hint
    
    (Use new cylinder block) Use a piston with the same number mark as the cylinder bore diameter marked on the cylinder block.
2. Inspect piston ring groove clearance
  
  Using a feeler gauge, measure the clearance between new piston ring and the wall of the piston ring groove.
  
  Ring groove clearance:
  - No.1 – 0.040 – 0.080 mm (0.0016 – 0.0031 in.)
  - No.2 – 0.030 – 0.070 mm (0.0012 – 0.0028 in.)
  If the clearance is greater than maximum, replace the piston.
3. Inspect piston ring end gap
  1. Insert the piston ring into the cylinder bore.
  2. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 115 mm (4.53 in.) from the top of the cylinder block.
  3. Using a feeler gauge, measure the end gap.
    
    Standard end gap:
    - No.1 – 0.330 – 0.550 mm (0.0130 – 0.0217 in.)
    - No.2 – 0.450 – 0.670 mm (0.0177 – 0.0264 in.)
    - Oil (Side rail) – 0.200 – 0.600 mm (0.0079 – 0.0236 in.)
    Maximum end gap:
    - No.1 – 0.85 mm (0.0335 in.)
    - No.2 – 0.97 mm (0.0382 in.)
    - Oil (Side rail) – 0.90 mm (0.0354 in.)
    If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block.
4. Inspect piston pin fit
  
  At 60°C (140°F), you should be able to push the piston pin into the piston pin hole with your thumb.
Inspect connecting rod.
1. Inspect connecting rod alignment
  
  Using rod aligner and feeler gauge, check the connecting rod alignment.
  - Check for bending.
  Maximum bending: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
  
  If bend is greater than maximum, replace the connecting rod assembly.
  - 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 assembly.
2. Inspect piston pin oil clearance
  1. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
    
    Bushing inside diameter: 22.005 – 22.017 mm (0.8663 – 0.8668 in.)
  2. Using a micrometer, measure the piston pin diameter.
    
    Piston pin diameter: 21.997 – 22.009 mm (0.8660 – 0.8665 in.)
  3. Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
    
    Standard oil clearance: 0.005 – 0.011 mm (0.0002 – 0.0004 in.)
    
    Maximum oil clearance: 0.05 mm (0.0020 in.)
    
    If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set.
3. If necessary, replace connecting rod bushing
  1. Using SST and a press, press out the bushing.
    
    SST 09222-30010
  2. Align the oil holes of a new bushing and the connecting rod.
  3. Using SST and a press, press in the bushing.
    
    SST 09222-30010
  4. Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (see step B above) between the bushing and piston pin.
  5. Check the piston pin fit at normal room temperature.
    
    Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

Inspection and repair of crankshaft¶

Inspect crankshaft for runout.
1. Place the crankshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)

If the circle runout is greater than maximum, replace the crankshaft.
Inspect main journals and crank pins.
1. Using a micrometer, measure the diameter of each main journal and crank pin.
  
  Main journal diameter:
  - STD size – 54.988 – 55.003 mm (2.1653 – 2.1655 in.)
  - U/S 0.25 – 54.745 – 54.755 mm (2.1553 – 2.1557 in.)
  Crank pin diameter:
  - STD size – 47.985 – 48.000 mm (1.8892 – 1.8898 in.)
  - U/S 0.25 – 47.745 – 47.755 mm (1.8797 – 1.8801 in.)
  If the diameter is not as specified, check the oil clearance (See Disassembly of cylinder block). If necessary, grind or replace the crankshaft.
2. Check each main journal and crank pin for taper and out-of-round as shown.
  
  Maximum taper and out-of-round: 0.02 mm (0.0008 in.)
  
  If the taper and out-of-round is greater than maximum, replace the crankshaft.
If necessary, grind and hone main journals and/or crank pins.

Grind and hone the main journals and/or crank pins to the finished undersized diameter (See procedure step 2).

Install new main journal and/or crank pin undersized bearings.

Replacement of crankshaft oil seals¶

Hint

There are two methods (A and B) to replace the oil seal which are as follows:

Replace crankshaft front oil seal.
1. If oil pump is removed from cylinder block:
  1. Using a screwdriver and hammer, tap out the oil seal.
  2. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump case edge.
    
    SST 09226-10010
  3. Apply MP grease to the oil seal lip.
2. If oil pump is installed to the cylinder block:
  1. Using a knife, cut off the oil seal lip.
  2. Using a screwdriver, pry out the oil seal.
    
    Notice
    
    Be careful not to damage the crankshaft. Tape the screwdriver tip.
  3. Apply MP grease to a new oil seal lip.
  4. Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump case edge.
    
    SST 09226-10010
Replace crankshaft rear oil seal.
1. If rear oil seal retainer is removed from cylinder block:
  1. Using screwdriver and hammer, tap out the oil seal.
  2. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal edge.
    
    SST 09223-63010
  3. Apply MP grease to the oil seal lip.
2. If rear oil seal retainer is installed to cylinder block:
  1. Using a knife, cut off the oil seal lip.
  2. Using a screwdriver, pry out the oil seal.
    
    Notice
    
    Be careful not to damage the crankshaft. Tape the screwdriver tip.
  3. Apply MP grease to a new oil seal lip.
  4. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
    
    SST 09223-63010

Assembly of piston and connecting rod assemblies¶

Assemble piston and connecting rod.
1. Install a new snap ring on one side of the piston pin hole.
  
  Hint
  
  Be sure the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
2. Gradually heat the piston to 80 – 90°C (176 – 194°F).
3. Coat the piston pin with engine oil.
4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
5. Install a new snap ring on the other side of the piston pin hole.
  
  Hint
  
  Be sure the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
Install piston rings.
1. Install the oil ring expander and two side rails by hand.
2. Using a piston ring expander, install the two compression rings with the code mark facing upward.
  
  Code mark: R
3. Position the piston rings so that the ring ends are as shown.
  
  Notice
  
  Do not align the ring ends.
Install bearings.
1. Align the bearing claw with the groove of the connecting rod or connecting cap.
2. Install the bearings in the connecting rod and connecting rod cap.

Assembly of cylinder block¶

(See Cylinder block (3S-GTE))

Hint

Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
Replace all gaskets, O-rings and oil seals with new parts.

Install oil nozzles. (See page LU-14)
Install main bearings.
Hint
- Main bearings come in widths of 19.2 mm (0.756 in.) and 23.0 mm (0.906 in.). Install the 23.0 mm (0.906 in.) bearings in the No.3 cylinder block journal position with the main bearing cap. Install the 19.2 mm (0.756 in.) bearings in the other positions.
- Upper bearings have an oil groove and oil holes; lower bearings do not.
1. Align the bearing claw with the claw groove of the cylinder block, and push in the five upper bearings.
2. Align the bearing claw with the claw groove of the main bearing cap, and push in the five lower bearings.
  
  Hint
  
  A number is marked on each main bearing cap to indicate the installation position.
Install upper thrust washers.

Install the two thrust washers under the No.3 journal position of the cylinder block with the oil grooves facing outward.
Place crankshaft on cylinder block.
Install main bearing caps and lower thrust washers.
1. Install the two thrust washers on the No.3 bearing cap with the grooves facing outward.
2. Install the five main bearing caps in their proper locations.
  
  Hint
  
  Each bearing cap has a number and front mark.
3. Apply a light coat of engine oil on the threads and under the heads of the main bearing caps.
4. Install and uniformly tighten the ten bolts of the main bearing caps in several passes in the sequence shown.
  
  Torque: 600 kg-cm (43 ft-lb, 59 N·m)
5. Check that the crankshaft turns smoothly.
6. Check the crankshaft thrust clearance. (See Disassembly of cylinder block, step 5)
Install piston and connecting rod assemblies.
1. Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.
2. 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.
Install connecting rod caps.
1. Match the numbered connecting rod cap with the connecting rod.
2. Install the connecting rod cap with the front mark facing forward.
3. Apply a light coat of engine oil on the threads and under the cap nuts.
4. Using SST, install and alternately tighten the cap nuts in several passes.
  
  Torque: 680 kg-cm (49 ft-lb, 67 N·m)
5. Check that the crankshaft turns smoothly.
6. Check the connecting rod thrust clearance. (See Disassembly of cylinder block, step 2)
Install rear oil seal retainer.

Install a new gasket and the retainer with the six bolts.

Torque: 95 kg-cm (82 in.-lb, 9.3 N·m)

Post assembly¶

Install knock sensor.

Using SST, install the knock sensor.

SST 09816-30010

Torque: 450 kg-cm (33 ft-lb, 44 N·m)
Install oil cooler. (See pages LU-21 and 22)
Install oil filter. (See page LU-7)
Install oil pump and oil pan. (See pages LU-15 and 16)
Install water pump. (See pages CO-12 and 13)
Install cylinder head. (See Cylinder head (3S-GTE) › Installation of cylinder head)
Install turbocharger. (See Turbocharger › Installation of turbocharger)
Install pulleys and timing belt. (See Timing belt (3S-GTE) › Installation of timing belt)
Install RH engine mounting bracket.

Install the mounting bracket with the four bolts.

Torque: 620 kg-cm (45 ft-lb, 61 N·m)
Install alternator bracket.

Install the alternator bracket with the three bolts and two nuts.

Torque: 440 kg-cm (32 ft-lb, 43 N·m)
Install alternator. (See Alternator › Assembly of alternator)
Remove engine stand.
Install rear end plate.

Torque: 95 kg-cm (82 in.-lb, 9.3 N·m)
Install flywheel.
1. Apply adhesive to two or three threads of the mount bolt end.
  
  Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
2. Install the flywheel on the crankshaft.
3. Install and uniformly tighten the mount bolts in several passes in the sequence shown.
  
  Torque: 1,100 kg-cm (80 ft-lb, 108 N·m)
Install clutch disc and cover.

Installation of engine¶

Assemble engine and transaxle. (See pages MT-5 and 6)
Install starter. (See Starter › Installation of starter)
Install LH engine mounting bracket.

Install the LH mounting bracket to the transaxle case with the three bolts.

Torque: 530 kg-cm (38 ft-lb, 52 N·m)
Install rear engine mounting bracket.

Install the mounting bracket with the six bolts.

Torque:
- 14 mm head bolt – 530 kg-cm (38 ft-lb, 52 N·m)
- 17 mm head bolt – 790 kg-cm (57 ft-lb, 77 N·m)
Install engine and transaxle assembly in vehicle.
1. Attach the engine chain hoist to the engine hangers.
2. Slowly lower the vehicle, and raise the engine.
3. Keep the engine level, and align RH and LH mountings with the body mountings.
4. Attach the RH mounting insulator to the body, and temporarily install the through bolt.
5. Attach the RH mounting insulator to the mounting bracket, and temporarily install the two nuts.
6. Attach the LH mounting insulator to the body, and temporarily install the through bolt.
7. Attach the LH mounting insulator to the mounting bracket, and install the three bolts.
  
  Torque:
  - A – 650 kg-cm (47 ft-lb, 63 N·m)
  - B – 740 kg-cm (54 ft-lb, 73 N·m)
8. Tighten the through bolt holding the LH mounting insulator to the body.
  
  Torque: 800 kg-cm (58 ft-lb, 78 N·m)
9. Tighten the two nuts holding the RH mounting insulator to the mounting bracket.
  
  Torque: 530 kg-cm (38 ft-lb, 52 N·m)
10. Tighten the through bolt holding the RH mounting insulator to the body.
  
  Torque: 800 kg-cm (58 ft-lb, 78 N·m)
11. Remove the engine chain hoist from the engine.
Install RH engine mounting stay.

Install the mounting stay with the two bolts and nut.

Torque: 740 kg-cm (54 ft-lb, 73 N·m)
Install lateral control rod and air cleaner case bracket.

Install the control rod, case bracket and charcoal canister tube with the five bolts, and connect the ground strap (from transaxle). Do not the tighten the bolt (A).

Torque: 360 kg-cm (26 ft-lb, 35 N·m)
Install LH engine mounting stay.
1. Install the mounting stay and speedometer cable clamp with the two bolts.
  
  Torque:
  - Transaxle side – 250 kg-cm (18 ft-lb, 25 N·m)
  - Mounting insulator side – 740 kg-cm (54 ft-lb, 73 N·m)
2. Tighten the bolt (A) of step 6.
  
  Torque: 380 kg-cm (27 ft-lb, 37 N·m)
Install clutch release cylinder and front engine mounting bracket.
1. Place the release cylinder on the transaxle.
2. Temporarily install the bolt and nut holding the release cylinder to the transaxle.
3. Install the mounting bracket with the two bolts.
  
  Torque: 790 kg-cm (57 ft-lb, 77 N·m)
4. Tighten the bolt and nut holding the clutch release cylinder to the transaxle.
  
  Torque: 120 kg-cm (9 ft-lb, 12 N·m)
Install front engine mounting insulator.
1. Install the mounting insulator to the body with the four bolts.
  
  Torque: 740 kg-cm (54 ft-lb, 73 N·m)
2. Temporarily install the through bolt and nut holding the mounting insulator to the mounting bracket.
Install rear suspension lower crossmember.
1. Install the lower crossmember with the four bolts.
  
  Torque: 1,150 kg-cm (83 ft-lb, 113 N·m)
2. Install the drive shafts. (See pages SA-66 to 68)
3. Install the lower suspension arm. (See page SA-77)
4. Install the stabilizer link to the shock absorber with the nut. Connect the two stabilizer links.
  
  Torque: 500 kg-cm (36 ft-lb, 49 N·m)
5. Install the wire clamp of the speed sensor with the bolt. Install the two wire clamp.
Connect speedometer cable.
Install rear engine mounting insulator.
1. Temporarily install the mounting bracket to the body with the three bolts.
2. Temporarily install the through bolt holding the mounting insulator to the mounting bracket.
3. Install the mounting bracket to the body with the three bolts.
  
  Torque: 650 kg-cm (47 ft-lb, 64 N·m)
1. Tighten the through bolt holding the mounting insulator to the mounting bracket.
  
  Torque: 800 kg-cm (58 ft-lb, 79 N·m)
Tighten front engine mounting through bolt.

Torque: 980 kg-cm (71 ft-lb, 96 N·m)
Install intercooler. (See steps 2, 3 (g) and 4 to 7 on Intercooler › Installation of intercooler)
Install A/C compressor and idler pulley bracket.
1. Temporarily install the compressor with the two bolts.
2. Install the idler pulley bracket with the three bolts.
  
  Torque:
  - A – 275 kg-cm (20 ft-lb, 27 N·m)
  - B – 375 kg-cm (27 ft-lb, 37 N·m)
  - C – 250 kg-cm (18 ft-lb, 25 N·m)
3. Install the wire clamp of the A/C compressor with the bolt.
4. Tighten the two bolts of the lower side holding the A/C compressor to the cylinder block.
  
  Torque: 280 kg-cm (20 ft-lb, 27 N·m)
5. Connect the A/C compressor connector.
6. Install and adjust the drive belt with the idler pulley bolt and adjusting bolt.
Install engine compartment cooling fan. (See steps 1 and 2 on page CO-36)
Install front exhaust pipe.

Hint

Passing the exhaust pipe rear side between the body and suspension crossmember is not easy, so follow the method shown in the illustration.
1. Place a new gasket on the front of the front exhaust pipe.
2. Using a 14 mm deep socket wrench, install the three new nuts holding the exhaust pipe to the catalytic converter.
  
  Torque: 630 kg-cm (46 ft-lb, 62 N·m)
3. Install the support bracket with the two bolts.
  
  Torque: 210 kg-cm (15 ft-lb, 21 N·m)
4. Install the damper with the two bolts.
  
  Torque: 210 kg-cm (15 ft-lb, 21 N·m)
Install tailpipe.
1. Install the tailpipe with the two through bolts.
  
  Torque: 670 kg-cm (48 ft-lb, 66 N·m)
2. Place a new gasket between the front exhaust pipe and tailpipe.
3. Temporarily install the two bolts holding the front exhaust pipe to the tailpipe.
4. Install the two bolts holding the stopper bracket of the front exhaust pipe to the tailpipe stopper bracket.
  
  Torque: 190 kg-cm (14 ft-lb, 19 N·m)
1. Tighten the two bolts holding the front exhaust pipe to the tailpipe.
  
  Torque: 440 kg-cm (32 ft-lb, 43 N·m)
Connect transaxle control cables to transaxle.
Connect fuel inlet hose to fuel filter.

Torque: 300 kg-cm (22 ft-lb, 29 N·m)
Connect fuel return hose.
Connect radiator hose to water outlet.
Connect heater hoses.
Connect radiator hose to water inlet.
Connect starter cable.
Connect engine wire to luggage compartment.
1. Push in the engine wire through the luggage compartment.
2. Connect the following connectors:
  1. Two engine ECU connectors
  2. Starter relay connector
  3. Engine compartment cooling fan relay connector
  4. Engine compartment wire connector
Install ignition coil and igniter.
1. Install the ignition coil and igniter assembly with the two bolts. Connect the noise filter.
2. Connect the high-tension cord.
3. Connect the ignition coil connector.
4. Connect the igniter connector.
Connect engine wire, and install engine relay box.
1. Connect the two connectors and positive (+) cable of the engine wire to the relay box.
2. Install the upper and lower covers to the relay box.
1. Install the relay box with the two bolts. Install the luggage compartment striker cable.
Install charcoal canister.
1. Install the charcoal canister with the two bolts.
2. Connect the three hoses.
Install water filler.
1. Install the water filler with the two bolts.
2. Connect the following hoses:
  1. Water filler hose
  2. Coolant reservoir hose
Install injector solenoid resistor, fuel pump relay, fuel pump resistor and A/C VSV.
1. Install the solenoid resistor, fuel pump relay, fuel pump resistor assembly and A/C VSV with the two bolts.
2. Connect the following hoses:
  1. A/C VSV air hose from No.2 air tube
  2. A/C VSV vacuum hose from intake manifold
3. Connect the following connectors:
  - Solenoid resistor connector
  - Fuel pump relay connector
  - Fuel pump resistor connector
  - A/C VSV connector
Install check connector and turbocharging pressure sensor.

Install the check connector and turbocharging pressure sensor with the bolt.
Connect brake booster vacuum hose.
Connect ground strap connector.
Install cruise control actuator (w/ cruise control system) and accelerator linkage.
1. Connect the cable to the accelerator linkage.
2. Install the accelerator linkage with the three bolts.
3. Connect the actuator connector.
4. Install the actuator with the three bolts.
5. Install the accelerator linkage cover with the screw.
6. Install the actuator cover with the two screws.
Install accelerator cable, and adjust it.
Install No.1 air intake connector.
Install No.2 air intake connector.
Install air cleaner.
1. Install the air cleaner case with the three bolts.
2. Install the air cleaner element.
3. Connect the following hose:
  1. Air cleaner hose from turbocharger
  2. PCV hose from cylinder head cover
  3. Air hose from No.2 air tube
  4. Air hose from air by-pass valve
4. Install the air cleaner cap and air flow meter.
5. Connect the air flow meter connector.
Install suspension upper brace.

Install the suspension upper brace with the two bolts and two nuts.

Torque:
- Bolt – 740 kg-cm (54 ft-lb, 73 N·m)
- Nut – 650 kg-cm (47 ft-lb, 64 N·m)
Connect cable to negative terminal of battery.
Fill with engine coolant. (See page CO-7)

Capacity (w/ Heater): 13.6 liters (14.4 US qts, 12.0 Imp. qts)
Fill with engine oil. (See page LU-8)

Capacity:
- Drain and refill
  - w/ Oil filter change – 3.9 liters (4.1 US qts, 3.4 Imp. qts)
  - w/o Oil filter change – 3.6 liters (3.8 US qts, 3.2 Imp. qts)
- Dry fill – 4.3 liters (4.5 US qts, 3.8 Imp. qts)
Start engine and check for leaks.
Perform engine adjustment.
1. Adjust the alternator drive belt. (See On-vehicle inspection)
  
  Drive belt tension:
  - New belt – 120 ± 20 lb
  - Used belt – 104 ± 20 lb
2. Adjust the A/C drive belt.
  
  Drive belt tension:
  - New belt – 160 ± 20 lb
  - Used belt – 100 ± 20 lb
3. Adjust the ignition timing. (See Distributor (3S-GTE) › Installation of distributor, steps 9–13)
  
  Ignition timing: 10° BTDC @ idle (w/ Terminals TE1 and E1 connected)
Install engine under covers.
Install engine hood.
Install engine compartment side panels.
Perform road test.

Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
Recheck engine coolant and oil levels.

Cylinder block	Crankshaft	Bearing
1	0	1
1	1	2
1	2	3
2	0	1
2	1	2
2	2	3
3	0	1
3	1	2
3	2	3