CYLINDER BLOCK REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing the piston or piston ring.

Click here

PROCEDURE


  1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A001WT1

      Using a 5 mm hexagon socket wrench, install the 4 No. 1 oil nozzle sub-assemblies with the 4 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  2. INSTALL PISTON


    1. A001XG9C10
      *a Cutout

      Using a screwdriver, install a new snap ring at one end of the piston pin hole.

      Tech Tips

      Make sure that the end gap of the snap ring is not aligned with the cutout of the piston.

    2. Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).

    3. A001X8OC01
      *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 snap ring.

      Tech Tips

      The piston and piston pin are a matched set.

    4. Using a screwdriver, install a new snap ring on the other end of the piston pin hole.

      Tech Tips

      Make sure that the end gap of the snap ring is not aligned with the cutout of the piston.

    5. A001TT2

      Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

      Tech Tips

      Perform "Inspection After Repair" after replacing the piston.

      Click here

  3. INSTALL PISTON RING SET


    1. A001TACC01
      *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.

    2. 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.

      A001YDEC02
      *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.

    3. A001VSQC07
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Piston Ring Expander
      *a Code Mark (T)
      *b Code Mark (2T)
      *c Paint Mark
      B008MD9 Upward

      Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring so that the paint marks are positioned as shown in the illustration.

      Note


      • Install the No. 1 compression ring with the code mark (T) facing upward.

      • Install the No. 2 compression ring with the code mark (2T) facing upward.

      • Paint marks can only be checked on new compression rings. When reusing compression rings, check each compression ring profile in order to install them into the correct positions.

    4. A001WFZC02
      *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 ring set so that the ring ends are as shown in the illustration.

      Tech Tips

      Perform "Inspection After Repair" after replacing the piston ring.

      Click here

  4. INSTALL CRANKSHAFT BEARING


    1. A001U9FC04
      *a Vernier Caliper

      Install the crankshaft bearing (except No. 3 journal).


      1. Install the crankshaft bearing to the cylinder block sub-assembly.

        Tech Tips

        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.

      2. Using a vernier caliper, measure the distance between the cylinder block sub-assembly edge and the 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.

    2. A001VILC20
      *a Vernier Caliper

      Install the crankshaft bearing (for No. 3 journal).


      1. Install the crankshaft bearing to the cylinder block sub-assembly.

        Tech Tips

        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.

      2. Using a vernier caliper, measure the distance between the cylinder block sub-assembly edge and the crankshaft bearing edge.

        Difference between (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.

    3. Install the crankshaft bearing.


      1. Install the crankshaft bearing to the crankshaft bearing cap.

      2. A001WTFC13
        *a Mark 1, 2, 3, 4 or 5
        *b Vernier Caliper

        Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the crankshaft bearing edge.

        Difference between (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.

  5. INSTALL UPPER CRANKSHAFT THRUST WASHER


    1. A001XMFC09
      *a Oil Groove

      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.

    2. Apply engine oil to the upper crankshaft thrust washers.

  6. INSTALL CRANKSHAFT


    1. Apply engine oil to the upper crankshaft bearings and install the crankshaft to the cylinder block sub-assembly.

    2. Apply engine oil to the lower crankshaft bearings.

    3. A001SEYC02
      *a Number mark
      B008MD9 Engine Front

      Examine the number marks and install the crankshaft bearing caps to the cylinder block sub-assembly.

    4. Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap set bolts.

    5. A001UBA

      Temporarily install the 10 crankshaft bearing cap set bolts.

    6. A001WZ4C01
      *a Less than 5 mm (0.197 in.)

      Push on the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and cylinder block sub-assembly is less than 5 mm (0.197 in.).

    7. A001U1A

      Using a plastic hammer, lightly tap the crankshaft bearing cap to ensure a proper fit.

    8. Install the crankshaft bearing cap set bolts.

      Note

      The crankshaft bearing cap set bolts are tightened in 2 progressive steps.

    9. Step 1:


      1. A001SNAN02

        Uniformly tighten the 10 crankshaft bearing cap set bolts in the order shown in the illustration.

        Torque:
        40 N*m  { 408 kgf*cm, 30 ft.*lbf }

    10. Step 2:


      1. A001WTOC79
        *a Paint Mark
        *b 90°
        B008LL0 Engine Front

        Mark the front of the crankshaft bearing cap set bolts with paint.

      2. Tighten the crankshaft bearing cap set bolts by 90° in the order shown in step 1.

    11. Check that the paint marks are now at a 90° angle to the front.

    12. Check that the crankshaft turns smoothly.

    13. Check the crankshaft thrust clearance.

      Click here

  7. INSTALL CONNECTING ROD BEARING


    1. Install the connecting rod bearings to the connecting rods and connecting rod caps.

    2. A001T28C19
      *a Vernier Caliper

      Using a vernier caliper, measure the distance between the edges of the connecting rod and connecting rod bearing, and the connecting rod cap and the connecting rod bearing.

      Difference between (A) and (B)
      0 to 0.7 mm (0 to 0.0276 in.)

      Note

      Do not apply engine oil to the connecting rod bearings or the contact surfaces.

  8. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.

    2. A001WFZC02
      *1 No. 1 compression ring and Oil Ring Expander
      *2 No. 2 compression ring
      *3 Upper Side Rail
      *4 Lower Side Rail
      *a Front of Engine

      Position the piston ring set so that the ring ends are as shown in the illustration.

    3. 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.

      A001YDEC02
      *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.

    4. A001YFPC02
      *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 sub-assembly with connecting rod, do not allow it to make contact with the No. 1 oil nozzle sub-assembly.

      • Match the numbered connecting rod cap with the connecting rod.

    5. A001T0UC03
      *a Front Mark

      Check that the front mark of the connecting rod cap is facing in the correct direction.

    6. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.

    7. Install the connecting rod bolts.

      Note

      The connecting rod bolts are tightened in 2 progressive steps.

    8. Step 1:


      1. A001XU1E04

        Using SST, alternately tighten the connecting rod bolts of the connecting rod cap in several steps.

        SST
        09205-16011
        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    9. Step 2:


      1. A001WTOC80
        *a Paint Mark
        *b 90°
        B008LL0 Engine Front

        Mark the front of the connecting rod bolts with paint.

      2. Tighten the connecting rod bolts by 90° as shown in the illustration.

    10. Check that the crankshaft turns smoothly.

    11. Check the connecting rod thrust clearance.

      Click here

  9. INSTALL NO. 1 VENTILATION CASE


    1. A001UWCC02
      *a Seal Packing
      *b 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      *c 5.0 mm (0.118 in.)

      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.) 5.0 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.

    2. for Type A:


      1. A001Y83

        Install the No. 1 ventilation case with the 6 bolts and 2 nuts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. for Type B:


      1. A001WKY

        Install the No. 1 ventilation case with the 8 bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }