Cylinder Block: Reassembly

INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a socket hexagon wrench 5, install the oil nozzles with the bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 1: Locating Bolts And Oil Nozzles
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON SUB-ASSEMBLY WITH PIN
1. Using a screwdriver, install a new snap ring at one end of the piston pin hole.
  HINT:
  
  Make sure that the end gap of the snap ring is not aligned with the service hole on the piston.
  
  Fig 2: Identifying Piston Pin Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Gradually heat the piston to between 80 and 90°C (176 to 194°F).
3. Align the front marks of the piston and connecting rod, and push in the piston by hand.
  HINT:
  
  The piston and pin are a matched set.
  
  Fig 3: Identifying Front Marks Of Piston And Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a screwdriver, install a new snap ring on the other end of the piston pin hole.
  HINT:
  
  Make sure that the end gap of the snap ring is not aligned with the service hole on the piston.
5. Check the fitting condition between the piston and piston pin by moving the piston back and forth on the piston pin.
  
  Fig 4: Checking Fitting Condition Between Piston And Piston Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON RING SET
1. Install the oil ring expander and oil ring rail by hand.
  NOTE:
  - Install the expander and oil ring so that their ring ends are at opposite sides.
  - Securely install the expander onto the inner groove of the oil ring.
    
    Fig 5: Identifying Oil Ring Expander And Oil Ring Rail
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a piston ring expander, install the 2 compression rings so that the paint marks are positioned as shown in the illustration.
  NOTE:
  - Install the compression ring No. 1 with the code mark (A1) facing upward.
  - Install the compression ring No. 2 with the code mark (A2) 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.
    
    Fig 6: Installing Piston Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Position the piston rings so that the ring ends are as shown in the illustration.
INSTALL CRANKSHAFT BEARING
1. Install the upper bearing (for except No. 3 journal).
  1. Install the upper bearing with the oil groove on the cylinder block.
  2. Using vernier calipers, measure the distance between the cylinder block edge and the upper bearing edge.
    NOTE: Do not apply engine oil to the bearings or the contact surfaces.
    
    Dimension (A): 0.5 to 1.0 mm (0.020 to 0.039 in.)
    
    Fig 8: Identifying Distance Between Cylinder Block Edge And Upper Bearing Edge
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the upper bearing (for No. 3 journal).
  1. Install the upper bearing with an oil groove on the cylinder block.
  2. Using vernier calipers, measure the distance between the cylinder block edge and the upper bearing's edge.
    NOTE: Do not apply engine oil to the bearings or the contact surfaces.
    
    Dimension (A - B): 0.5 mm (0.0196 in.) or less
    
    Fig 9: Identifying Distance Between Cylinder Block Edge And Upper Bearing's Edge
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the lower bearing.
  1. Install the lower bearing onto the bearing cap.
  2. Using vernier calipers, measure the distance between the bearing cap edge and the lower bearing edge.
    Dimension (A - B): 0.5 mm (0.0196 in.) or less
    
    NOTE: Do not apply engine oil to the bearings and the contact surfaces.
    
    Fig 10: Identifying Distance Between Bearing Cap Edge And Lower Bearing Edge
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UPPER CRANKSHAFT THRUST WASHER
1. Install the 2 thrust washers under the No. 3 journal of the cylinder block with the oil grooves facing outward.
2. Apply engine oil to the crankshaft thrust washer.
INSTALL CRANKSHAFT
1. Apply engine oil to the upper bearing and install the crankshaft on the cylinder block.
2. Apply engine oil to the lower bearing.
3. Examine the front marks and install the bearing caps on the cylinder block.
4. Apply a light coat of engine oil to the threads and under the bearing cap bolts.
5. Temporarily install the 10 main bearing cap bolts.
  
  Fig 13: Locating Main Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Insert the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block is less than 5 mm (0.20 in.).
  
  Fig 14: Identifying Clearance Between Main Bearing Cap And Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.
8. Install the crankshaft bearing cap bolts.
  NOTE: The main bearing cap bolts are tightened in 2 progressive steps.
9. Step 1
  1. Install and uniformly tighten the 10 main bearing cap bolts in the sequence shown in the illustration.
    Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
    
    Fig 16: Locating Main Bearing Cap Bolts And Tightening Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Step 2
  1. Mark the front of the bearing cap bolts with paint.
  2. Further tighten the bearing cap bolts by 90° in the numerical order shown in the previous illustration.
11. Check that the paint mark is now at a 90° angle to the front.
12. Check that the crankshaft turns smoothly.
13. Check the crankshaft thrust clearance (See INSPECTION ).
INSTALL CONNECTING ROD BEARING
1. Install the connecting rod bearing onto the connecting rod and bearing cap.
2. Using vernier calipers, measure the distance between the connecting rod and connecting rod bearing, and the connecting rod cap and connecting rod bearing.
  Dimension (A - B): 0.7 mm (0.0276 in.) or less
  
  NOTE: Do not apply engine oil to the bearings or the contact surfaces.
  
  Fig 18: Identifying Distance Between Connecting Rod And Connecting Rod Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
2. Position the piston rings so that the ring ends are as shown in the illustration.
  NOTE: Do not align the ring ends.
  
  Fig 19: Identifying Piston Ring Gap Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly 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.
    
    Fig 20: Pushing Piston And Connecting Rod Assembly Into Cylinder
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check that the protrusion of the connecting rod cap is facing in the correct direction.
5. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
6. Install the connecting cap bolts.
  NOTE: The connecting cap bolts should be tightened in 2 progressive steps.
7. Step 1
  1. Using SST, install and alternately tighten the bolts of the connecting rod cap in several steps.
    SST 09205-16010
    
    Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
    
    Fig 22: Tightening Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Step 2
  1. Mark the front of the connecting rod cap bolts with paint.
  2. Further tighten the cap bolts by 90° as shown in the illustration.
9. Check that the crankshaft turns smoothly.
10. Check the connecting rod thrust clearance (See INSPECTION ).
INSTALL NO. 1 VENTILATION CASE
1. Apply seal packing in a continuous line as shown in the illustration.
  Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter: 2.0 mm (0.0787 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan 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 installing.
    
    Fig 24: Applying Seal Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 1 ventilation case with the 6 bolts and 2 nuts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 25: Locating No. 1 Ventilation Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002