CYLINDER BLOCK REASSEMBLY
CAUTION / NOTICE / HINT
PROCEDURE
INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
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Using a 5 mm socket hexagon wrench, install the 4 No. 1 oil nozzle sub-assemblies with the 4 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
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INSTALL PISTON
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*a
Cutout
Using a screwdriver, install a new piston pin hole snap ring at one end of the piston pin hole.
Tip:Make sure that the end gap of the piston pin hole snap ring is not aligned with the cutout of the piston.
Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).
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*a
Front Mark
Align the front marks of the piston and connecting rod, insert the connecting rod into the piston, and then push in the piston pin with your thumb until the piston pin comes into contact with the piston pin hole snap ring.
Tip:The piston and piston pin are a matched set.
Using a screwdriver, install a new piston pin hole snap ring on the other end of the piston pin hole.
Tip:Make sure that the end gap of the piston pin hole snap ring is not aligned with the cutout of the piston.
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Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
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INSTALL PISTON RING SET
for 2-piece Type:
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*1
Oil Ring Expander
*2
Oil Ring
*a
Coil Joint
*b
Oil Ring End
Install the oil ring expander and oil ring by hand.
Note:Install the oil ring expander and oil ring so that their ring ends are at opposite sides.
Securely install the oil ring expander to the inner groove of the oil ring.
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for 3-piece Type:
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*1
Upper Side Rail
*2
Oil Ring Expander
*3
Lower Side Rail
Install the oil ring expander and 2 side rails by hand.
Note:When installing the upper side rail and lower side rail, the ends of the oil ring expander may overlap. If it occurs, the upper side rail or lower side rail may move out of its groove.
Check that the ends of the oil ring expander are not overlapping and that the upper side rail and lower side rail are securely installed into the groove.
*a
Press around the circumference
*b
Ring End
*c
Correct
*d
Incorrect (Ends of the oil ring expander are overlapping)
Note:After installing the oil ring expander, upper side rail and lower side rail, press around the circumference with a finger to check that they are securely installed into the groove.
If the oil ring expander is not securely installed into the groove, check that the ends of the oil ring expander are not overlapping.
If the ends of the oil ring expander are overlapping, remove the upper side rail and lower side rail and realign the oil ring expander using a screwdriver.
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Using a piston ring expander, install the 2 compression rings so that the paint marks are positioned as shown in the illustration.
*1
No. 1 Compression Ring
*2
No. 2 Compression Ring
*3
Piston Ring Expander
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-
*a
Code Mark (T) or (FTE)
*b
Code Mark (2T) or (FTE2)
*c
Paint Mark
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-
Upward
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-
Note:Install the No. 1 compression ring with the code mark (T) or (FTE) facing upward.
Install the No. 2 compression ring with the code mark (2T) or (FTE2) facing upward.
Paint marks can only be checked on new piston rings. When reusing piston rings, check each piston ring profile in order to install them into the correct positions.
for 2-piece Type:
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*a
No. 1 Compression Ring and Oil Ring
*b
No. 2 Compression Ring and Oil Ring Expander
Engine Front
Position the piston rings so that the ring ends are as shown in the illustration.
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for 3-piece Type:
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*1
No. 1 compression ring and Oil Ring Expander
*2
No. 2 compression ring
*3
Upper Side Rail
*4
Lower Side Rail
*a
Engine Front
Position the piston rings so that the ring ends are as shown in the illustration.
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INSTALL CRANKSHAFT BEARING
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*1
Vernier Caliper
Install the upper crankshaft bearing (except No. 3 journal).
Install the upper crankshaft bearing to the cylinder block sub-assembly.
Tip:Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the crankshaft bearing. The amount visible on each side of the holes should be equal.
Using a vernier caliper, measure the distance between the cylinder block sub-assembly edge and the upper crankshaft bearing edge.
Dimension (A)
0.5 to 1.0 mm (0.0197 to 0.0394 in.)
Note:Do not apply engine oil to the crankshaft bearings or the contact surfaces.
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*1
Vernier Caliper
Install the upper crankshaft bearing (for No. 3 journal).
Install the upper crankshaft bearing to the cylinder block sub-assembly.
Tip:Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the crankshaft bearing. The amount visible on each side of the holes should be equal.
Using a vernier caliper, measure the distance between the cylinder block sub-assembly edge and upper bearing edge.
Dimension (A) and (B)
0.5 mm (0.0197 in.) or less
Note:Do not apply engine oil to the crankshaft bearings or the contact surfaces.
Install the lower crankshaft bearing.
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*1
Vernier Caliper
*a
Mark 1, 2, 3, 4 or 5
Install the upper crankshaft bearing to the crankshaft bearing cap.
Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the lower crankshaft bearing edge.
Dimension (A) and (B)
0.5 mm (0.0197 in.) or less
Note:Do not apply engine oil to the crankshaft bearings or the contact surfaces.
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INSTALL UPPER CRANKSHAFT THRUST WASHER
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*1
Oil Grooves
Install the 2 upper crankshaft thrust washers to the No. 3 journal position of the cylinder block sub-assembly with the oil grooves facing outward.
Apply engine oil to the upper crankshaft thrust washers.
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INSTALL CRANKSHAFT
Apply engine oil to the upper crankshaft bearings and install the crankshaft to the cylinder block sub-assembly.
Apply engine oil to the lower crankshaft bearings.
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*a
Number Mark
Front Mark
Examine the number marks and install the crankshaft bearing caps to the cylinder block sub-assembly.
Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap set bolts.
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Temporarily install the 10 crankshaft bearing cap set bolts.
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*a
Less than 5 mm
Push on the crankshaft bearing caps with your hand until the clearance between the crankshaft bearing caps and cylinder block sub-assembly is less than 5 mm (0.197 in.).
-
Using a plastic-faced hammer, lightly tap the crankshaft bearing cap to ensure a proper fit.
Install the crankshaft bearing cap set bolts.
Note:The crankshaft bearing cap set bolts are tightened in 2 progressive steps.
Step 1
-
Install and uniformly tighten the 10 main bearing cap bolts in the order shown in the illustration.
40 N*m
408 kgf*cm
30 ft.*lbf
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Step 2
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*a
Paint Mark
Engine Front
Mark the front of the crankshaft bearing cap set bolts with paint.
Tighten the crankshaft bearing cap set bolts by 90° in the order shown in step 1.
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Check that the paint marks are now at a 90° angle to the front.
Check that the crankshaft turns smoothly.
Check the crankshaft thrust clearance.
INSTALL CONNECTING ROD BEARING
Install the connecting rod bearings to the connecting rods and connecting rod caps.
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*1
Vernier Caliper
Using a vernier caliper, measure the distance between the edges of the connecting rods and connecting cap bearings, and the connecting rod caps and the connecting rod bearings.
Dimension (A) and (B)
0.7 mm (0.0276 in.) or less
Note:Do not apply engine oil to the connecting rod bearings or the contact surfaces.
INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
Apply engine oil to the cylinder walls, pistons, and the surfaces of the connecting rod bearings.
for 2-piece Type:
-
*a
No. 1 Compression Ring and Oil Ring
*b
No. 2 Compression Ring and Oil Ring Expander
Engine Front
Position the piston rings so that the ring ends are as shown in the illustration.
Note:Do not align the ring ends.
-
for 3-piece Type:
-
*1
No. 1 compression ring and Oil Ring Expander
*2
No. 2 compression ring
*3
Upper Side Rail
*4
Lower Side Rail
*a
Engine Front
Position the piston rings so that the ring ends are as shown in the illustration.
Confirm that the ends of the oil ring expander are not overlapping and that the upper side rail and lower side rail are securely installed into the groove.
*a
Press around the circumference
*b
Ring End
*c
Correct
*d
Incorrect (Ends of the oil ring expander are overlapping)
Note:After installing the oil ring expander, upper side rail and lower side rail, press around the circumference with a finger to check that they are securely installed into the groove.
If the oil ring expander is not securely installed into the groove, check that the ends of the oil ring expander are not overlapping.
If the ends of the oil ring expander are overlapping, remove the upper side rail and lower side rail and realign the oil ring expander using a screwdriver.
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-
*a
Front Mark
Using a piston ring compressor, push the correctly numbered piston and connecting rod into the cylinder with the front mark of the piston facing forward.
Note:When inserting the piston with connecting rod, do not allow it to make contact with the oil nozzle.
Match the numbered connecting rod cap with the connecting rod.
-
*a
Front Mark
Check that the front mark of the connecting rod cap is facing in the correct direction.
Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
Install the connecting rod bolts.
Note:The connecting rod bolts are should be tightened in 2 progressive steps.
Step 1:
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Using SST, install and alternately tighten the connecting rod bolts of the connecting rod cap in several steps.
09205-16011
20 N*m
204 kgf*cm
15 ft.*lbf
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Step 2:
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*a
Paint Mark
Engine Front
Mark the front of the connecting rod bolts with paint.
Tighten the connecting rod bolts by 90° as shown in the illustration.
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Check that the crankshaft turns smoothly.
Check the connecting rod thrust clearance.
INSTALL NO. 1 VENTILATION CASE
Tip:There are 2 installation types for the No. 1 ventilation case.
Depending on the installation type, the number of bolts, nuts and stud bolts used will vary.
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*a
Seal Packing
*b
Seal Packing Diameter
Apply seal packing in a continuous line as shown in the illustration.
Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Application Specification
Seal Packing Diameter
Distance from Inside Edge of Cover to Center of Seal Packing
2.0 to 3.0 mm (0.0787 to 0.118 in.)
3.0 mm (0.118 in.)
Note:Remove any oil from the contact surfaces.
Install the No. 1 ventilation case within 3 minutes and tighten the bolts and nuts within 15 minutes of applying seal packing.
Do not start the engine for at least 2 hours after installation.
Type A:
-
Install the No. 1 ventilation case with the 6 bolts and 2 nuts.
10 N*m
102 kgf*cm
7 ft.*lbf
-
Type B:
-
Install the No. 1 ventilation case with the 8 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
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