Cylinder Block: Reassembly

INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a 5 mm socket hexagon wrench, install the oil nozzles with the bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 1: Locating No. 1 Oil Nozzle Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON
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 pin hole cutout portion of the piston.
2. Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).
  
  Fig 2: Identifying Piston Service Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
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 pin hole cutout portion of the piston.
  
  Fig 3: Identifying Piston And Connecting Rod Front Mark Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
Fig 4: Checking Fitting Condition Between Piston And Piston Pin
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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 to the inner groove of the oil ring.
  Fig 5: Identifying Expander And Oil Ring
  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 (T) facing upward.
  - Install the compression ring No. 2 with the code mark (2T) 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: Identifying Compression Ring No. 2 With Code Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Position the piston rings so that the ring ends are as shown in the illustration.
Fig 7: Identifying Piston Rings Position
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INSTALL CRANKSHAFT BEARING
1. Install the upper bearing (for except No. 3 journal).
  1. Install the upper bearing with an oil groove on the cylinder block.
  2. Using a scale, measure the distance between the cylinder block edge and the upper bearing edge.
  NOTE: Do not apply engine oil to the bearing inner surface or journal contact surfaces.
  
  Dimension (A):
  
  0.5 to 1.0 mm (0.020 to 0.039 in.)
  
  Fig 8: Installing Upper Bearing Oil Groove On Cylinder Block
  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 a vernier caliper, measure the distance between the cylinder block edge and the upper bearing edge.
  NOTE: Do not apply engine oil to the bearing inner surface or journal contact surfaces.
  
  Dimension (A - B):
  
  0.5 mm (0.0197 in.) or less
  
  Fig 9: Measuring Distance Between Cylinder Block Edge And Upper Bearing Edge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the lower bearing.
  1. Install the lower bearing onto the bearing cap.
  2. Using a vernier caliper, measure the distance between the bearing cap edge and the lower bearing edge.
    Dimension (A - B):
    
    0.5 mm (0.0197 in.) or less
    
    NOTE: Do not apply engine oil to the bearing inner surface or bearing cap contact surfaces.
    
    Fig 10: Measuring 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.
  
  Fig 11: Locating Upper Crankshaft Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 number 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.
  
  Fig 12: Identifying Number Marks On Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 by hand until the clearance between the main bearing cap and the cylinder block is less than 5 mm (0.20 in.) using the 2 internal bearing cap bolts as guides.
  
  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: Tighten the main bearing cap bolts in 2 progressive steps.
  
  Fig 15: Tapping Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Bearing Cap Bolts Location
    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 an additional 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 ).
Fig 17: Identifying Bearing Cap Bolt Paint Mark
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONNECTING ROD BEARING
1. Install the connecting rod bearing to the connecting rod and bearing cap.
2. Using a vernier caliper, measure the distance between the connecting rod and bearing cap edges and the connecting rod bearing edge.
  Dimension (A - B):
  
  0.7 mm (0.0276 in.) or less
  
  NOTE: Do not apply engine oil to the bearing inner surface or connecting rod contact surfaces.
  
  Fig 18: Installing 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: Positioning Piston Rings
  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: Identifying Piston Front Marl Location
  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 rod cap bolts.
  NOTE: Tighten the connecting rod cap bolts in 2 progressive steps.
  
  Fig 21: Installing Connecting Rod Cap Correct Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Installing Connecting Rod Cap 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 an additional 90° as shown in the illustration.
9. Check that the crankshaft turns smoothly.
10. Check the connecting rod thrust clearance (See INSPECTION ).
Fig 23: Identifying Connecting Rod Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 VENTILATION CASE
1. Apply seal packing in a continuous bead as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Bead diameter:
  
  2.0 mm (0.0787 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the No. 1 ventilation case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
  Fig 24: Identifying No. 1 Ventilation Case
  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