Cylinder Block: Reassembly: Reassembly

WARNING: This page is about a different variant/trim than selected.

INSTALL STUD BOLT
NOTE:
If a stud bolt is deformed or the threads are damaged, replace it.

HINT:

There are 2 installation types for the No. 1 ventilation case.

This procedure is for type A.
1. Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.
  
  Fig 1: Identifying Stud Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a LH Side
  
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a 5 mm socket hexagon wrench, install the 4 oil nozzles with the 4 bolts.
  
  Fig 2: Identifying Bolts And Oil Nozzles
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL PISTON
1. Using a screwdriver, install a new snap ring at one end of the piston pin hole.
  
  Fig 3: Identifying Piston Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Service 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).
3. 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 pin comes into contact with the snap ring.
  
  Fig 4: Identifying Piston Front Marks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a Front Mark
  
  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.
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 5: Checking Fitting Condition Between Piston And Piston Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL PISTON RING SET

Install the oil ring expander and oil ring by hand.

Fig 6: Installing Piston Ring Set

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Oil Ring Expander
*2	Oil Ring
*3	Coil Joint
*4	Oil Ring End

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.

Using a piston ring expander, install the 2 compression rings so that the paint marks are positioned as shown in the illustration.

Fig 7: Installing Compression Rings

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

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

NOTE:

Install the No. 1 compression ring with the code mark (1R) facing upward.
Install the No. 2 compression ring with the code mark (2R) 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.

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

Fig 8: Positioning Piston Rings

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	No. 1 Compression Ring and Oil Ring
*2	No. 2 Compression Ring and Oil Ring Expander
	Engine Front

INSTALL CRANKSHAFT BEARING

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

Fig 9: Installing Crankshaft Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEXT IN ILLUSTRATION

*1 Vernier Caliper
1. Install the upper bearing to the cylinder block.
  HINT:
  
  Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the 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 edge and the upper bearing edge.
  Standard dimension (A)
  
  0.5 to 1.0 mm (0.0197 to 0.0394 in.)
  
  NOTE:
  Do not apply engine oil to the bearings or the contact surfaces.
Install the upper bearing (for No. 3 journal).

Fig 10: Installing Upper Bearing (For No. 3 Journal)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEXT IN ILLUSTRATION

*1 Vernier Caliper
1. Install the upper bearing to the cylinder block.
  HINT:
  
  Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the 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 edge and the upper bearing edge.
  Standard dimension (A - B)
  
  0.7 mm (0.0276 in.) or less
  
  NOTE:
  Do not apply engine oil to the bearing or the contact surfaces.

Install the lower bearing.

Install the upper bearing to the cylinder block.
HINT:

Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal.

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

Fig 11: Measuring Distance Between Bearing Cap Edge And Lower Bearing Edge

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

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

Standard dimension (A - B)

0.7 mm (0.0276 in.) or less

NOTE:

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

INSTALL UPPER CRANKSHAFT THRUST WASHER
1. Install the 2 thrust washers to the No. 3 journal position of the cylinder block with the oil grooves facing outward.
  
  Fig 12: Identifying Upper Crankshaft Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Oil Groove
2. Apply engine oil to the crankshaft thrust washer.

INSTALL CRANKSHAFT

Apply engine oil to the upper bearings and install the crankshaft to the cylinder block.
Apply engine oil to the lower bearings.

Examine the number marks and install the bearing caps to the cylinder block.

Fig 13: Identifying Number Marks On Bearing Caps

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*a	Number Mark
	Engine Front

Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
Temporarily install the 10 crankshaft bearing cap bolts.

Fig 14: Identifying Crankshaft Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Push on the crankshaft bearing caps with your hand until the clearance between the crankshaft bearing caps and cylinder block is less than 5 mm (0.197 in.).

Fig 15: Identifying Clearance Between The Crankshaft Bearing Caps And Cylinder Block
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEXT IN ILLUSTRATION

*a Less than 5 mm
Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.

Fig 16: Tapping Bearing Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the crankshaft bearing cap bolts.
NOTE:
The crankshaft bearing cap bolts are tightened in 2 progressive steps.
Step 1:
1. Install and uniformly tighten the 10 crankshaft bearing cap bolts in the sequence shown in the illustration.
  
  Fig 17: Identifying Crankshaft Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)

Step 2:

Mark the front of the bearing cap bolts with paint.

Fig 18: Identifying Front Of Bearing Cap Bolt And Mark

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*a	Paint Mark
	Engine Front

Tighten the bearing cap bolts 90° in the sequence shown in step 1.

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 See step 9.

INSTALL CONNECTING ROD BEARING
1. Install the connecting rod bearings to the connecting rods and connecting rod caps.
2. 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.
  
  Fig 19: Installing Connecting Rod Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Vernier Caliper
  
  Standard dimension A - B or B - A
  
  0 to 0.7 mm (0 to 0.0276 in.)
  
  NOTE:
  Do not apply engine oil to the 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.

Fig 20: Positioning Piston Rings

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	No. 1 Compression Ring and Oil Ring
*2	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.
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.

Fig 21: Identifying Front Mark And Piston Installation Procedure
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEXT IN ILLUSTRATION

*a Front Mark
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.
Check that the front mark of the connecting rod cap is facing in the correct direction.

Fig 22: Checking That Front Mark Of Connecting Rod Cap Is Facing In Correct Direction
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEXT IN ILLUSTRATION

*a Front Mark
Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
Install the connecting rod cap bolts.
NOTE:
The connecting rod cap bolts should be tightened in 2 progressive steps.
Step 1:
1. Using SST, install and alternately tighten the bolts of the connecting rod cap in several steps.
  
  Fig 23: Identifying Connecting Rod Cap Bolts And SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09205-16011
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)

Step 2:

Mark the front of the connecting rod cap bolts with paint.

Fig 24: Rotating Bolt Clockwise to 90Degrees

TEXT IN ILLUSTRATION

*a	Paint Mark
	Engine Front

Tighten the cap bolts 90° as shown in the illustration.

Check that the crankshaft turns smoothly.
Check the connecting rod thrust clearance See step 3.

INSTALL NO. 1 VENTILATION CASE

HINT:

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.

Apply seal packing in a continuous line as shown in the illustration.

Fig 25: Identifying Seal Packing Application

TEXT IN ILLUSTRATION

*a	Seal Packing
*b	Seal Packing Diameter

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 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:
1. Install the ventilation case with the 6 bolts and 2 nuts.
  
  Fig 26: Identifying No. 1 Ventilation Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
Type B:
1. Install the ventilation case with the 8 bolts.
  
  Fig 27: Identifying Ventilation Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)