Cylinder block. 1 - union bolt (M3=34 Nm); 2 - nipple gaskets; 3 - oil pipe fitting of the oil radiator; 4 - oil drain plug (M3=34 Nm); 5 - plug gasket; 6 - bolt (M3=4.9 Nm); 7 - Oil pan (4A-FE); B - bolts (M3=9.3 Nm); 9 - oil receiver with mesh filter; 10 - oil receiver gasket; 11 - main bearing cap mounting bolt (M3=60 Nm); 12 - crankshaft main bearing caps; 13 - thrust half rings; 14 - crankshaft bearing shells; 15 - crankshaft; 16 - oil pump housing mounting bolt (M3=21 Nm); 17 and 18 - oil pump housing and housing gasket; 19 - crankshaft nose seal; 20 - right engine support mounting bolt (M3=51 Nm); 21 - right engine support; 22 - bolt (M3=14 Nm); 23 - Coolant pump; 24 - sealing ring; 25 - knock sensor (M3=37 Nm); 26 - cylinder block; 27 - connecting rod; 28 - piston; 29 - oil scraper ring expander; 30 - compression ring No.2; 31 - compression ring No.1; 32 - oil scraper ring scrapers; 33 - piston pin; 34 - crankshaft connecting rod bearing shells; 35 - connecting rod crank cap; 36-nut for fixing the crank head cover (first stage M3=29 Nm; then turn it another 90°); 37 - flywheel; 38 - flywheel mounting bolt (M3=78 Nm); 39 - rear plate (cover) of the cylinder block (clutch housing cover); 40 - crankshaft tailstock seal; 41 - Crankshaft tailstock oil seal holder; 42 - Crankshaft tailstock oil seal holder gasket; 43 - Oil filter bracket gasket; 44 - Oil filter bracket; 45 - flat washer; 46 - bolt-nipple (bypass bolt); 47 - oil filter; 48 - plug for draining coolant from the cylinder block (M3=34 Nm); 49 - oil pressure sensor; 51 - rear plate (cover) of the cylinder block; 52 - Front spacer bushing; 53 - leading plate of the torque converter; 54 - rear spacer sleeve; 55 - bolt (M3=64 Nm); 56 - oil separator (7A-FE); 57 - nut (M3=7.8 Nm); 58 - Lower part of oil pan (7A-FE); 59 - bolt (M3=4.9 Nm); 60 - Upper part of oil pan (7A-FE).
Preparing for disassembling the cylinder block
1. (Models with manual transmission)
- a) Remove the clutch housing and clutch disc
- b) Remove the flywheel by unscrewing 6 bolts.
Note: Before removing the flywheel or torque converter drive plate, place marks to avoid disturbing the balance when installing them.
(Models with automatic transmission)
(See the source on the internet resource: «TOYOTAMAN»)
Remove the torque converter drive plate together with the front and rear spacers by unscrewing the 6 bolts.
2. Remove the rear plate (cover) of the cylinder block by unscrewing 2 bolts.
3. Install the engine on a stand (machine) for disassembly.
4. (Models with air conditioning) Remove the air conditioning compressor.
5. Remove the timing belt and timing pulleys (see "Removal the timing belt").
6. Remove the cylinder head (see "Removal the cylinder head").
7. Remove the generator and generator tension bar by unscrewing 2 bolts.
8. Remove the right engine mount by unscrewing 3 bolts
9. Remove the coolant pump by unscrewing the 3 bolts and removing the O-ring seal (see chapter "Cooling system").
10. Remove the oil filter using a suitable wrench as shown in the figure.
11. (Only for engines with oil cooler)
Remove the oil filter bracket by unscrewing the bypass bolt, removing the flat washer and (after removing the bracket): O-ring seal and bolt guide.
 |  |
12. Remove the plug or tap to drain the coolant from the cylinder block.
13. Using a suitable tool, remove the oil pressure switch or oil pressure sensor.
14. Using a suitable tool, remove the knock sensor.
15. (4A-FE)
Remove the oil pan and oil receiver with mesh filter
- a) (Only for engines with oil cooler) Remove the oil cooler oil line fitting.
- b) Remove the pan by unscrewing 19 bolts and 2 nuts.
- c) Insert a sharp blade between the mating surfaces of the cylinder block and the oil pan, cut off the seal and remove the oil pan.
Notes:
- Be careful not to damage the tray flange.
- Do not use this method when removing the oil pump and crankshaft end seal holder
- d) After unscrewing 2 bolts and 2 nuts, remove the oil receiver with the mesh filter.
(7A-FE)
Remove the lower part of the oil pan, the oil baffle, the oil pickup with the mesh filter and the upper part of the oil pan.
- a) (Engines with oil cooler) Remove the oil cooler oil line fitting.
- b) Remove the lower part of the oil pan by unscrewing 13 bolts and 2 nuts.
- c) Insert a sharp blade between the mating surfaces, cut the seal and remove the lower part of the oil pan.
Notes:
- Be careful not to damage the tray flange.
- Do not use this method when removing the upper part of the oil pan, oil pump and crankshaft end oil seal holder.
- d) After unscrewing 2 bolts and 2 nuts, remove the oil receiver with the mesh filter.
- d) After unscrewing 3 nuts, remove the oil receiver with the mesh filter and gasket.
- e) Remove 6 bolts. Using the special tool, remove 14 bolts and remove the upper part of the oil pan.
If the top of the oil pan does not come off, use a screwdriver as a lever as shown in the picture.
16. After unscrewing 7 bolts, remove the oil pump housing together with the gasket.
Final assembly
1. Install the oil pump.
- a) Place a new gasket on the surface of the cylinder block that meets the oil pump housing.
- b) Align the keyway of the pump lead rotor with the large key of the crankshaft and place the pump on the shaft as shown in the figure.
- c) Secure the pump with bolts (M3=21 Nm).
- Please note that bolts of different lengths are used (see pictures):
- long bolts - 35 mm
- other bolts - 25 mm
4A-FE | 
7A-FE |
2. (4A-FE)
Install the oil pan and oil pickup with mesh filter.
- a) Install the oil receiver, first installing a new gasket, and then tighten the mounting bolts and nuts (M3=9.3 Nm).
- b) Remove the old sealant from the surfaces of the oil pan and block joint, being careful not to damage the surfaces of the oil pan and cylinder block, clean the contact surfaces with solvent.
Note: Do not use solvent as it may damage painted surfaces.
- c) Apply fresh sealant to the surface of the pan as shown in the figure.
Notes:
- The hole in the tube should provide a diameter of 3 - 5 mm for the sealant being squeezed out
- The parts must be connected within 5 minutes after applying the sealant, otherwise the sealant must be removed and fresh sealant applied.
- After applying the sealant, the tube nozzle should be removed and cleaned of any traces of sealant, and the tube should be tightly closed.
- d) Secure the tray with bolts and nuts.
- Tightening torque - 5 Nm
- d) (Engines with oil cooler) Install the nipple (with 2 new gaskets) oil cooler hose and bypass bolt, tightening it.
- Tightening torque - 34 Nm
(7A-FE)
Install the lower part of the oil pan, oil separator, oil receiver with mesh filter and the upper part of the oil pan.
- a) Remove old sealant from contact surfaces and clean them with solvent.
- b) Apply sealant (see point "c" of paragraph "2") to the surface of the upper part of the tray, as shown in the figure.
- c) Install the upper part of the oil pan. Using the special tool, secure it with 14 new bolts "A".
- Tightening torque - 16 Nm
- d) Install and tighten the 6 "B" bolts.
- Tightening torque - 8 Nm
- d) Install the oil receiver with a new gasket and secure it with 3 nuts.
- Tightening torque - 9 Nm
- e) Install the oil calmer, securing it with 2 bolts and 2 nuts.
- Tightening torque - 8 Nm
- g) Install the lower part of the oil pan.
- Remove old sealant from contact surfaces and clean them with solvent.
Note: Do not use solvent as it may damage painted surfaces.
- Apply sealant (see point "c" of paragraph "2") to the surface of the tray as shown in the figure.
- Install the lower part of the oil pan, securing it with 13 bolts and 2 nuts (M3=5 Nm).
- e) (Engines with oil cooler) Install the oil cooler hose nipple with 2 new gaskets and tighten the bypass bolt (M3=34 Nm)
3. Install the knock sensor using a suitable tool (M3=37 Nm).
4. Install the oil pressure switch or oil pressure sensor.
- a) Apply glue to 2-3 threads of the sensor
- b) Using a suitable tool, tighten the sensor as shown in the figure.
5. Install the coolant drain plug.
- a) Apply glue to 2-3 threads of the cork (see paragraph 4 of this section).
- b) Tighten the plug (M3=34 Nm).
6. (Engines with oil radiator) Install the oil filter bracket (see chapter "Lubrication system").
- a) Install the bracket guide bolt.
- b) Install a new sealing ring under the oil filter bracket.
- c) Install the oil filter bracket with a flat washer and a bypass bolt (M3=54 Nm).
7. Install the oil filter.
- a) Clean the contact surface on which the oil filter is installed.
- b) Lubricate the rubber gasket of the filter with fresh engine oil.
- c) Screw the filter in by hand until its gasket touches the seating surface. Then, using a suitable tool, screw the filter in an additional 3/4 of a turn.
8. Install the coolant pump.
- a) Install a new seal ring into the cylinder block as shown in the figure.
- b) Secure the coolant pump with bolts (M3=14 Nm).
9. Install the right engine support and secure it with 3 bolts (M3=51 Nm).
10. Install the generator tension bar, securing it with 2 bolts (MZ=39 Nm).
11. Install the cylinder head (see section "Installing the cylinder head").
12. Install the timing belt and pulleys (see section "Installing the timing belt").
13. Install the ignition distributor or combined ignition unit.
14. (Models with air conditioning) Install the air conditioning compressor mounting support.
15. Remove the engine from the mounting stand.
16. Install the rear engine plate and secure it with 2 bolts (M3=5.5 Nm).
17. (Models with manual transmission) Install the flywheels and tighten the flywheel mounting bolts evenly in several passes in the sequence shown in the figure (final M3=78 Nm).
18. (Models with automatic transmission) Install the torque converter drive plate.
- a) Install the front spacer sleeve onto the crankshaft, with the chamfered side of the sleeve facing the shaft, as shown in the figure.
- b) Install the drive plate and rear spacer sleeve onto the crankshaft.
- c) Screw in and tighten the fastening bolts evenly in several passes in the specified sequence (final M3=64 Nm).
19. (Models with manual transmission) Install the clutch disc and housing.
Note: If necessary, check the clutch assembly before installation.