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Cylinder Block: Reassembly

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon wrench, install the 4 No. 1 oil nozzles assembly with the 4 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    Fig 1: Locating Oil Nozzle Bolt
    G04943515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL PISTON WITH PIN SUB-ASSEMBLY 
    1. Using a screwdriver, install a new snap ring at one end of the piston pin hole

      HINT

      Be sure that the end gap of the snap ring is not aligned with the service hole of the piston.

      Fig 2: Installing Snap Ring
      G04943562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Gradually heat the piston to approximately 80°C (176°F).
    3. Coat the piston pin and connecting rod with engine oil.
      Fig 3: Heating Piston
      G04943563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the front marks of the piston and connecting rod as shown in the illustration Then push in the piston pin with your thumb until the piston pin contacts the snap ring.

      Front Mark 

      PISTON FRONT MARKS REFERENCE

      Item Front Mark
      Bank 1 piston 1 mark
      Bank 2 piston 2 marks
      NOTE: For bank 1, assemble the piston and connecting rod so that the front mark of the piston and mark of the connecting rod face the same direction. For bank 2, assemble so that the front mark of the piston and mark of the connecting rod face the opposite direction.

      HINT

      The piston and pin are a matched set.

      Fig 4: Identifying Front Marks Of Piston And Connecting Rod
      G05749875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Move the connecting rod back and forth on the piston pin. Check the fitting condition
    6. Rotate the piston back and forth on the piston pin Check the fitting condition.
      Fig 5: Checking Fitting Condition Of Connecting Rod And Piston
      G04943565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a screwdriver, install a new snap ring at the other end of the piston pin hole.

      HINT.

      Be sure that the end gap of the snap ring is not aligned with the service hole of the piston.

      Fig 6: Installing Snap Ring
      G04943562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL PISTON RING SET 
    1. Install the oil ring expander by hand
    2. Using a piston ring expander, install the oil ring as shown in the illustration.
      Fig 7: Installing Oil Ring
      G04943567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a piston ring expander, install the 2 compression rings so that the code marks are positioned as shown in the illustration

      HINT:

      • Install the No 1 compression ring with the code mark (1N) facing upward.
      • Install the No 2 compression ring with the code mark (2N) facing upward.
      Fig 8: Identifying Code Marks On Compression Rings
      G04943568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL CRANKSHAFT BEARING 
    1. Clean the main journals and both surfaces of the bearings.
    2. Install the upper bearings
      NOTE: Main bearings come in widths of 21 mm (0.827 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the main bearing caps. Install the 21 mm (0.827 in.) bearings in the No. 2, No. 3 and No. 4 positions.
      Fig 9: Identifying Main Bearings Widths
      G05749880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the upper bearings to the cylinder block as shown in the illustration.
        NOTE:
        • Do not apply engine oil to the bearing inner surfaces or main journal contact surfaces.
        • 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.
        • Do not allow coolant to come into contact with the bearing inner surface.
        • If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
        Fig 10: Installing Upper Bearings To Cylinder Block
        G04943570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the lower bearings.
      NOTE:
      • Be sure to install the selected bearings.
      • Main bearings come in widths of 21 mm (0.827 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the main bearing caps. Install the 21 mm (0.827 in.) bearings in the No. 2, No. 3 and No. 4 positions.
      1. Install the lower bearings to the bearing caps
      2. Using a vernier caliper, measure the distance between the bearing cap's edge and the lower bearing's edge.

        Dimension A - B or B - A: 

        0 to 0.7 mm (0 to 0.0276 in.) 

        NOTE:
        • Do not apply engine oil to the bearing inner surfaces or bearing cap contact surfaces.
        • Do not allow coolant to come into contact with the bearing inner surface.
        • If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
        Fig 11: Installing Lower Bearings To Bearing Caps
        G04943571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL CRANKSHAFT THRUST WASHER SET 
    1. Apply engine oil to the thrust washer set.
    2. Install the 4 thrust washers to the No 3 journal position of the cylinder block and bearing cap with the oil grooves facing outward.
  6. INSTALL CRANKSHAFT 
    1. Apply engine oil to the upper and lower bearings, then place the crankshaft on the cylinder block.
      Fig 12: Locating Crankshaft Thrust Washers
      G05749831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Confirm the front marks and numbers of the main bearing caps, and install the bearing caps onto the cylinder block.

      HINT:

      A number is marked on each main bearing cap to indicate the installation position

    3. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
    4. Temporarily install the 10 main bearing cap bolts to the inside positions.
      Fig 13: Identifying Front Marks And Numbers Of Main Bearing Caps
      G04943547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Insert the main bearing cap by hand until the clearance between the main bearing cap and cylinder block is less than 6 mm (0.236 in.) by marking the 2 internal bearing cap bolts as a guide

      Bolt length: 

      91 mm (3.58 in.) 

      Fig 14: Identifying Main Bearing Cap Bolt Length
      G04943548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit
    7. Apply a light coat of engine oil to the threads and under the heads of the 10 main bearing cap bolts.
      Fig 15: Tapping Bearing Cap
      G04943549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Temporarily install the 10 main bearing cap bolts to the outside positions

      Bolt length: 

      79.5 mm (3.13 in.) 

      HINT:

      Tighten the main bearing cap bolts in 2 progressive steps

      Fig 16: Identifying Main Bearing Cap Bolt Length
      G04943550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Step 1.
      1. Install and uniformly tighten the 20 main bearing cap bolts in the sequence shown in the illustration.

        Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) for inside position 

        27 N*m (275 kgf*cm, 20 ft.*lbf) for outside position 

        If any of the main bearing cap bolts does not meet the specified torque, replace it.

        Fig 17: Locating Tightening Sequence Of Main Bearing Cap Bolts
        G04943577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Step 2.
      1. Mark the front of each bearing cap bolt with paint.
      2. Tighten the bearing cap bolts another 90° in the order shown in step 1
      3. Check that the painted marks are now at a 90° angle to the front.
    11. Check that the crankshaft turns smoothly.
      Fig 18: Identifying Retightening Angle Of Main Bearing Cap Bolts
      G04943552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Install and uniformly tighten the 10 main bearing cap bolts and 10 seal washers in several steps, in the sequence shown in the illustration.

      Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) 

    13. Check that the crankshaft turns smoothly.
    Fig 19: Tightening Main Bearing Cap Bolts
    G04943553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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 each connecting rod bearing edge

      Dimension A - B or B - A: 

      0 to 0.7 mm (0 to 0.0276 in.) 

      NOTE:
      • Do not apply engine oil to the bearing inner surfaces or connecting rod contact surfaces.
      • Do not allow coolant to come into contact with the bearing inner surface.
      • If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
      Fig 20: Installing Connecting Rod Bearing To Connecting Rod And Bearing Cap
      G05749891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL PISTON AND 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 21: Identifying Piston Ring Ends
      G05749892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a piston ring compressor, push the correctly numbered piston and connecting rod into the cylinder with the front mark of the piston facing forward
      NOTE: Match the numbered connecting rod cap with the connecting rod. Front Mark
      CONNECTING ROD FRONT MARKS REFERENCE

      Item Front Mark
      Bank 1 1 mark
      Bank 2 2 marks
      Fig 22: Pushing Piston And Connecting Rod Into Cylinder
      G05749893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Check that the mark of the connecting rod cap is facing the correct side.

      Front Mark 

      CONNECTING ROD CAP MARKS REFERENCE

      Item Mark
      Bank 1 Front Side
      Bank 2 Rear Side
    5. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
      Fig 23: Identifying Mark On Connecting Rod Cap
      G05749894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Temporarily install the connecting cap bolts

      HINT

      The connecting cap bolts are tightened in 2 progressive steps

    7. Step 1
      1. Install and alternately tighten the bolts of the connecting rod cap in several steps.

        Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

      Fig 24: Tightening Connecting Cap Bolts
      G05749895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Step 2
      1. Mark the front side of each connecting cap bolt with paint
      2. Tighten the cap bolts another 90° as shown in the illustration in the order in step 1
      3. Check that the painted marks are now at a 90° angle to the front
      4. When using new connecting rod cap bolts, loosen each bolt once after tightening it 90° and perform steps 1 and 2 again
    9. Check that the crankshaft turns smoothly
    Fig 25: Identifying Retightening Angle Of Connecting Cap Bolts
    G04943585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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