Cylinder Block: Reassembly

WARNING: This page is about a different car, the 2008 Lexus LS 600hL. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side.

INSTALL STUD BOLT
NOTE: If a stud bolt is deformed or the threads are damaged, replace it.
1. Using an E8 and E10 "TORX" socket wrench, install the stud bolts.
  
  Fig 1: Identifying Stud Bolt Dimensions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: for stud bolt A
  
  10 N.m (102 kgf/cm, 7 ft.lbf)
  
  for stud bolt B
  
  9.0 N.m (92 kgf/cm, 80 in.lbf)
INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a 5 mm hexagon wrench, install the 4 oil nozzles with the 4 bolts.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
  
  Fig 2: Locating Oil Nozzle Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL PISTON WITH PIN SUB-ASSEMBLY

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
Coat the piston pin and connecting rod with engine oil

Fig 3: Installing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

FRONT MARKS REFERENCE

Item	Front Mark
Bank 1 Piston	1
Bank 2 Piston	2

NOTE: For bank 1, perform the assembly so that the front marks of the piston and connecting rod are on the same side. For bank 2, perform the assembly so that the front marks of the piston and connecting rod are on opposite sides.

HINT:

The piston and pin are a matched set.

Fig 4: Aligning Front Marks Of Piston And Connecting Rod

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Move the connecting rod back and forth on the piston pin Check the fitting condition.
Rotate the piston back and forth on the piston pin. Check the fitting condition.

Fig 5: Checking Fitting Condition Of Connecting Rod
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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
  HINT:
  
  Arrange the oil ring ends and coil joint as shown in the illustration
  
  Fig 7: Installing Piston Ring Set
  Courtesy 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
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT BEARING
1. Clean the main journal and both surfaces of the bearing.
2. Install the upper bearing.
  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 crankshaft 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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Install the upper bearing to the cylinder block as shown in the illustration.
    NOTE:
    Do not apply engine oil to the bearings and the contact surface.
    
    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 Bearing To Cylinder Block
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the lower bearing.
  NOTE:
  - Be sure to install the selected bearing.
  - 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 crankshaft 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 crankshaft bearing caps
  2. Using a vernier caliper, measure the distance between the crankshaft 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 bearings and the contact surface.
    
    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 Bearing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 crankshaft bearing cap with the oil grooves facing outward.
INSTALL CRANKSHAFT
1. Apply engine oil to the upper bearing and lower bearing, then place the crankshaft on the cylinder block.
  
  Fig 12: Locating Crankshaft Thrust Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Confirm the front marks and numbers of the crankshaft bearing caps, and install the crankshaft bearing caps on the cylinder block.
  HINT:
  
  A number is marked on each crankshaft 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 crankshaft bearing cap bolts to the inside positions.
  
  Fig 13: Identifying Front Marks And Numbers On Crankshaft Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Push the crankshaft bearing cap by hand until the clearance between the crankshaft bearing cap and cylinder block is less than 6 mm (0.236 in).
  Bolt length:
  
  91 mm (3.58 in.)
  
  Fig 14: Identifying Clearance Between Crankshaft Bearing Cap And Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a plastic-faced hammer, lightly tap the crankshaft 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 crankshaft bearing cap bolts.
  
  Fig 15: Tapping Crankshaft Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Temporarily install the 10 crankshaft bearing cap bolts to the outside positions
  Bolt length:
  
  79.5 mm (3.13 in.)
  
  HINT.
  
  The crankshaft bearing cap bolts are tightened in 2 progressive steps.
  
  Fig 16: Identifying Crankshaft Bearing Cap Bolt Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Step 1:
  1. Uniformly tighten the 20 crankshaft bearing cap bolts in the sequence shown in the illustration.
    Torque: for inside position
    
    61 N.m (622 kgf/cm, 45 ft.lbf)
    
    for outside position
    
    27 N.m (275 kgf/cm, 20 ft.lbf)
    
    If a crankshaft bearing cap bolt does not meet the specified torque, replace it.
    
    Fig 17: Identifying Tightening Sequence Of Crankshaft Bearing Cap Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Step 2:
  1. Mark the front of the bearing cap bolts with paint.
  2. Tighten the bearing cap bolts 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 Tightening Angle Of Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Install and uniformly tighten the 10 crankshaft 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: Identifying Tightening Sequence Of Crankshaft Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONNECTING ROD BEARING
1. Install the connecting rod bearings to the connecting rods and bearing caps.
2. Using a vernier caliper, measure the distance between the connecting rod's and bearing cap's edges, and each connecting rod 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 bearings and the contact surface.
  - 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.

INSTALL PISTON AND CONNECTING ROD

Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.

Fig 20: Installing Connecting Rod Bearings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Rings Ends
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a hammer handle and piston ring compressor, press a piston and connecting rod into each cylinder with the front mark of the piston facing forward.

NOTE: Match the numbered connecting rod cap with the connecting rod.

FRONT MARK

FRONT MARKS REFERENCE

Item	Front Mark
Bank 1	1
Bank 2	2

Fig 22: Pressing Piston And Connecting Rod Into Cylinder

Check that the front mark of the connecting rod cap is facing forward.

FRONT MARK

FRONT MARKS REFERENCE

Item	Front Mark
Bank 1	Front Side
Bank 2	Rear Side

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

Fig 23: Identifying Front Mark Of Connecting Rod Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Temporarily install the connecting rod cap bolts.
HINT:

The connecting rod cap bolts are tightened in 2 progressive steps.
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: Installing Connecting Rod Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Step 2:
1. Mark the front side of each connecting rod cap bolt with paint.
2. Tighten the cap bolts 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.
Check that the crankshaft turns smoothly.

Fig 25: Identifying Tightening Angle Of Connecting Rod Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002