CYLINDER BLOCK > REASSEMBLY

for Preparation Click here



1. INSTALL STUD BOLT

NOTICE:
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.



    A151026E08

  1. Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.
    Text in Illustration 
    *a
    		LH Side

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }



2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    A151001

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

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



3. INSTALL PISTON


    A151020E02

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

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



    A151021E05

  1. 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.
    Text in Illustration 
    *a
    		Front Mark

    HINT:
    The piston and pin are a matched set.

  1. 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.



    A152651

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



4. INSTALL PISTON RING SET


    A146333E03

  1. Install the oil ring expander and oil ring by hand.
    Text in Illustration 
    *1
    		Oil Ring Expander
    *2
    		Oil Ring
    *3
    		Coil Joint
    *4
    		Oil Ring End

    NOTICE:
    1. Install the expander and oil ring so that their ring ends are at opposite sides.
    2. Securely install the expander to the inner groove of the oil ring.



    A216967E02

  1. Using a piston ring expander, install the 2 compression rings so that the paint marks are positioned as shown in the illustration.
    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
    V100135
    		Upward

    NOTICE:
    1. Install the No. 1 compression ring with the code mark (1R) facing upward.
    2. Install the No. 2 compression ring with the code mark (2R) facing upward.
    3. 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.



    A151018E04

  1. Position the piston rings so that the ring ends are as shown in the illustration.
    Text in Illustration 
    *1
    		No. 1 Compression Ring and Oil Ring
    *2
    		No. 2 Compression Ring and Oil Ring Expander
    V100135
    		Engine Front



5. INSTALL CRANKSHAFT BEARING


    A151015E04

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

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



    A162987E04

  1. Install the upper bearing (for No. 3 journal).
    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

      NOTICE:
      Do not apply engine oil to the bearing or the contact surfaces.



  1. Install the lower bearing.

    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. A151016E06

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

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



6. INSTALL UPPER CRANKSHAFT THRUST WASHER


    A150982E06

  1. Install the 2 thrust washers to the No. 3 journal position of the cylinder block with the oil grooves facing outward.
    Text in Illustration 
    *1
    		Oil Groove

  1. Apply engine oil to the crankshaft thrust washer.



7. INSTALL CRANKSHAFT

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

  1. Apply engine oil to the lower bearings.



    A151013E02

  1. Examine the number marks and install the bearing caps to the cylinder block.
    Text in Illustration 
    *a
    		Number Mark
    V100135
    		Engine Front

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



    A205910

  1. Temporarily install the 10 crankshaft bearing cap bolts.



    A205917E02

  1. 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.).
    Text in Illustration 
    *a
    		Less than 5 mm



    A151024

  1. Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.

  1. Install the crankshaft bearing cap bolts.

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



  1. Step 1:



      A205910E03

    1. Install and uniformly tighten the 10 crankshaft bearing cap bolts in the sequence shown in the illustration.

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



  1. Step 2:



      A050671E15

    1. Mark the front of the bearing cap bolts with paint.
      Text in Illustration 
      *a
      		Paint Mark
      V100135
      		Engine Front

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

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

  1. Check that the crankshaft turns smoothly.

  1. Check the crankshaft thrust clearance (Click here).



8. INSTALL CONNECTING ROD BEARING

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



    A151017E05

  1. 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.
    Text in Illustration 
    *1
    		Vernier Caliper

    Standard dimension A - B or B - A:
    0 to 0.7 mm (0 to 0.0276 in.)

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



9. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    A151018E04

  1. Apply engine oil to the cylinder walls, pistons, and the surfaces of the connecting rod bearings.
    Text in Illustration 
    *1
    		No. 1 Compression Ring and Oil Ring
    *2
    		No. 2 Compression Ring and Oil Ring Expander
    V100135
    		Engine Front

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

    NOTICE:
    Do not align the ring ends.



    A151019E05

  1. 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.
    Text in Illustration 
    *a
    		Front Mark

    NOTICE:
    1. When inserting the piston with connecting rod, do not allow it to make contact with the oil nozzle.
    2. Match the numbered connecting rod cap with the connecting rod.



    A205918E06

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

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

  1. Install the connecting rod cap bolts.

    NOTICE:
    The connecting rod cap bolts should be tightened in 2 progressive steps.



  1. Step 1:



      A205915E01

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

      SST
      09205-16011  

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



  1. Step 2:



      A101478E14

    1. Mark the front of the connecting rod cap bolts with paint.
      Text in Illustration 
      *a
      		Paint Mark
      V100136
      		Engine Front

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

  1. Check that the crankshaft turns smoothly.

  1. Check the connecting rod thrust clearance (Click here).



10. 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.



    A158007E08

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

    NOTICE:
    1. Remove any oil from the contact surfaces.
    2. Install the ventilation case within 3 minutes and tighten the bolts and nuts within 15 minutes of applying seal packing.
    3. Do not start the engine for at least 2 hours after installation.



  1. Type A:



      A150902

    1. Install the ventilation case with the 6 bolts and 2 nuts.

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



  1. Type B:



      A221752

    1. Install the ventilation case with the 8 bolts.

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