CYLINDER BLOCK(w/o DPF) REASSEMBLY

PROCEDURE

1. INSTALL OIL JET

   
   

   1. Tap in a new oil jet with the tip of the oil jet aligned with the cylinder block alignment mark.

      

      Text in Illustration

      *1

      Oil Jet

      *2

      Alignment Mark

      Note

      Do not tap the tip of the oil jet.

2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

   
   

   1. 

      Using a 5 mm hexagon wrench, install the 4 oil nozzles with the 4 bolts.

      Torque:

      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

3. INSTALL CRANKSHAFT

   
   

   1. Install the upper bearing with the oil groove onto the cylinder and the lower bearing onto the bearing cap.

      

      Text in Illustration

      *1	Oil Groove	-	-
      *a	Upper Bearing	*b	Block Side
      *b	Lower Bearing	*d	Cap Side

      Note

      Do not apply engine oil to the contact surface of the cylinder block or the back side of the bearing.

      Tech Tips

      Mass production parts do not have identification marks. If reusing a mass production part, measure the clearance of both sides so that the bearing is in the center of the crankshaft bearing cap.

      Specified clearance
      A - B = within 0.8 mm (0.032 in.)

   2. 

      Text in Illustration

      *1	Oil Groove

      Install the thrust washer onto the cylinder block and the front and backside of bearing cap No. 3 with the oil groove facing outward.

   3. Apply engine oil to the upper bearing, and then install the crankshaft onto the cylinder block.

   4. 

      Examine the front marks and numbers and check that the sequence is as shown in the illustration. Then, install the bearing caps onto the cylinder block.

      Text in Illustration

      Engine Front

   5. 

      Apply a light coat of engine oil to the threads and contact surface of the bolt.

   6. Temporarily tighten the bolts in several steps in the order shown in the illustration, and tighten them to the specified torque (step "f").

      Torque:

      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Tech Tips

      Check that the crankshaft turns smoothly while tightening the bolts.

   7. 

      Text in Illustration

      *a	Paint Mark
      	Engine Front

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

   8. Retighten the bearing cap bolts by 90° in the same order as step "f".

   9. Check that each paint mark is now at the 90° angle from the front.

4. INSTALL WITH PIN PISTON SUB-ASSEMBLY

   
   

   1. 

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

   2. 

      Text in Illustration

      *1	Front Mark

      Align the front marks of the piston and connecting rod cap.

   3. Apply a light coat of engine oil to the piston pin, and then push the piston pin into the hole of the piston and connecting rod cap.

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

      Note

      Do not change the combinations of the pistons and piston pins so that they can be returned to their original location when reassembled.

5. INSTALL CONNECTING ROD BEARING

   
   
   1. 

      Text in Illustration

      *1	Oil Groove

      Align the connecting rod bearing and oil grooves, and then install the bearing onto the connecting rod.

      Note

      Do not apply engine oil to the contact surfaces of the connecting rod, connecting rod cap or the back side of the connecting rod bearing.

6. INSTALL PISTON RING SET

   
   

   1. 

      Install oil ring (Expander) by hand.

   2. 

      Text in Illustration

      *a	Expander End
      *b	Side Rail End

      Using a piston ring expander, install the oil ring (side rail) as shown in the illustration.

   3. 

      Text in Illustration

      *1	Code Mark
      *a	Upward

      Using a piston ring expander, install No. 1 and No. 2 compression rings with the code marks as shown in the illustration.

      Part	Code Mark
      No. 1 Compression Ring	1R
      No. 2 Compression Ring	2R
      Oil Ring	-

   4. 

      Text in Illustration

      *1	No. 1 Compression Ring
      *2	Oil Ring (Side Rail END)
      *3	Oil Ring (Expander END)
      *4	No. 2 Compression Ring
      *a	Engine Front

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

      Note

      Make sure that the gap in the oil ring is placed at either position "side rail END" or "expander END".

7. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

   
   

   1. 

      Text in Illustration

      *1	Front Mark

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

   2. Check that the gap in the piston ring is located correctly.

   3. Check the front marks. Using a piston ring compressor, install the piston with connecting rod.

   4. 

      Text in Illustration

      *1	Front Mark

      Check that the connecting rod and its cap are in the correct combination and that the front marks are facing correctly, and then install the connecting rod cap onto the connecting rod.

      Note

      The connecting rods and their caps should be reinstalled in their original combinations.

   5. 

      Apply a light coat of engine oil to the threads and contact surface of the bolts.

      SST

      09205-16011

   6. Using several steps, temporarily tighten the bolts in the order shown in the illustration, and tighten them to the specified torque.

      Torque:

      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

   7. 

      Text in Illustration

      *a	Paint Mark
      	Engine Front

      Mark the front of the bolts with paint.

   8. Retighten the bolts by additional 90°.

   9. Check that the crankshaft turns smoothly.

8. INSTALL TUBE CONNECTOR

   

   Text in Illustration

   *1

   Adhesive

   
   

   1. Apply adhesive to 2 or 3 threads of the tube connector.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

   2. 

      Text in Illustration

      *1	14 mm Deep Socket Wrench

      Using a 14 mm deep socket wrench, install the tube connector.

      Torque:

      25 N*m  { 255 kgf*cm, 18 ft.*lbf }