БЛОК ЦИЛИНДРОВ ПОВТОРНАЯ СБОРКА

CAUTION / NOTICE / HINT

Note:

Before performing the installation procedure, sufficiently clean and remove any foreign matter from the cylinder block sub-assembly, connecting rods and other parts.

PROCEDURE

  1. INSTALL OIL REFLECTOR PLATE

    1. Using a 5 mm hexagon wrench, install the 3 oil reflector plates with the 3 bolts.

      Момент затяжки
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

    1. Using a 5 mm hexagon wrench, install the 4 No. 1 oil nozzle sub-assemblies with the 4 bolts.

      A012H6U
      Момент затяжки
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  3. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    1. Install the No. 1 crankshaft position sensor plate by fitting the straight pin of the crankshaft into the hole on the No. 1 crankshaft position sensor plate.

      A012GY3C03
      *a Straight Pin

    2. Using a T30 "TORX" socket wrench, install the 3 bolts.

      Момент затяжки
      10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }
      Note:

      Make sure that the No. 1 crankshaft position sensor plate is not tilted.

  4. INSTALL PISTON WITH PIN SUB-ASSEMBLY

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

      A012II1C03
      *a Cutout
      Tip:

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

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

    3. Coat the piston pin with engine oil.

    4. Align the front marks of the piston and connecting rod, install the connecting rod to the piston and push in the piston pin with your thumb until the piston pin comes into contact with the snap ring.

      A012IP8C04
      *a Front Mark
      Tip:

      The piston and piston pin are a matched set.

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

      A012H29

      If abnormal movement is felt, replace the piston and piston pin as a set.

    6. Using a screwdriver, install a new snap ring on the other end of the piston pin hole.

      A012M4MC07
      *a Cutout
      Tip:

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

  5. INSTALL PISTON RING SET

    1. Install the oil ring expander by hand.

      A012G7E

    2. Using a piston ring expander, install the oil ring rail.

      A012I8HC05
      *a Coil Joint
      *b Oil Ring Rail End Gap
      Tip:

      Face the end gap of the oil ring rail in the opposite direction of the coil joint.

    3. Using a piston ring expander, install the No. 1 and No. 2 compression rings so that the code marks are positioned as shown in the illustration.

      A012I2CC02
      *a Code Mark (T1)
      *b Code Mark (2FTE)
      A012M0O Upward
      Code Mark
      Ring Code Mark
      No. 1 T1
      No. 2 2FTE
      Tip:

      • Install the No. 1 compression ring with the code mark facing upward.

      • Install the No. 2 compression ring with the code mark facing upward.

    4. Position the piston ring set so that the end gaps are as shown in the illustration.

      A012KJCC07
      *a Front Mark
      *b No. 1 Compression Ring End Gap
      *c No. 2 Compression Ring End Gap
      *d Oil Ring Rail End Gap
      *e Coil Joint
      A012M0O Front
      Note:

      Do not align the end gaps.

  6. INSTALL CONNECTING ROD BEARING

    Note:

    Apply oil to the inner surface of each connecting rod bearing (the surface which contacts the crankshaft), but not to the outer surface (the surface which contacts the connecting rod or connecting rod cap).

    1. Install the connecting rod bearings to the connecting rod and connecting rod cap.

      A012J46N01

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

      Dimension A - B or B - A
      0 to 0.7 mm (0 to 0.0276 in.)
      Note:

      Clean the backside of the connecting rod bearing and the connecting rod bearing contact surfaces of the connecting rod and connecting rod cap.

  7. INSTALL CRANKSHAFT BEARING

    Note:

    • Apply oil to the inner surface of each crankshaft bearing (the surface which contacts the crankshaft), but not to the outer surface (the surface which contacts the crankshaft bearing cap or cylinder block sub-assembly).

    • When replacing a crankshaft bearing, also replace the corresponding upper or lower bearing.

    1. Clean each crankshaft main journal and bearing.

    2. Align each bearing claw with the claw groove of the cylinder block sub-assembly, and push in the 5 upper crankshaft bearings to install them.

      A012LBJ
      Note:

      • Clean the contact surfaces of the bearing and cylinder block sub-assembly.

      • Apply oil to the inner surface of each crankshaft bearing (the surface which contacts the crankshaft), but not to the outer surface (the surface which contacts the cylinder block sub-assembly).

      • Make sure both sides of the oil groove in the cylinder block sub-assembly are visible through the oil feed holes in the bearing. Make sure the amount visible on each side of the holes is equal.

    3. Align each bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower crankshaft bearings to install them.

      A012JAEC04
      *a Claw
      Note:

      • Clean the contact surfaces of the lower crankshaft bearing and crankshaft bearing cap.

      • Apply oil to the inner surface of each bearing (the surface which contacts the crankshaft), but not to the outer surface (the surface which contacts the crankshaft bearing cap).

  8. INSTALL UPPER CRANKSHAFT THRUST WASHER

    Note:

    When replacing an upper crankshaft thrust washer, replace both upper crankshaft thrust washers together as a set.

    1. Apply engine oil to the upper crankshaft bearings, and then place the crankshaft on the cylinder block sub-assembly.

    2. Push the crankshaft in one direction and install one upper crankshaft thrust washer to the No. 4 journal position of the cylinder block sub-assembly with the oil groove facing outward.

      A012JZ3

    3. Push the crankshaft in the opposite direction and install the other upper crankshaft thrust washer to the No. 4 journal position of the cylinder block sub-assembly with the oil groove facing outward.

  9. INSTALL CRANKSHAFT

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

      A012K09C01
      *a Groove C
      A012M0O Front
      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal Diameter
      2.0 to 4.0 mm (0.0787 to 0.157 in.)
      Note:

      • Remove any oil from the contact surfaces of the crankshaft bearing cap and cylinder block sub-assembly.

      • Install the crankshaft bearing cap within 3 minutes of applying seal packing.

      • Do not start the engine for at least 4 hours after installation.

      • Do not overlap seal packing in area ● in the illustration.

      • Do not apply seal packing to groove C.

    2. Apply engine oil to the lower crankshaft bearings, and then place the crankshaft bearing cap on the cylinder block sub-assembly.

    3. Install the crankshaft bearing cap set bolts.

      Tip:

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

    4. Step 1:

      A012IPIN02

      1. Uniformly tighten the 10 crankshaft bearing cap set bolts in several steps, in the order shown in the illustration.

        Момент затяжки
        60 N*m  { 612 kgf*cm, 44 ft.*lbf }
        Tip:

        If any of the crankshaft bearing cap set bolt does not meet the torque specification, replace the crankshaft bearing cap set bolt.

    5. Step 2:

      1. Mark the front of the crankshaft bearing cap set bolts with paint.

      2. Further tighten the crankshaft bearing cap set bolts by 90°.

        A012IATC01
        *a Paint Mark
        A012M0O Front

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

        A012LU2C01
        *a Paint Mark
        A012M0O Front

    6. Check that the crankshaft turns smoothly.

    7. Install and uniformly tighten the 10 bolts in several steps, in the order shown in the illustration.

      A012KG6N02
      Момент затяжки
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  10. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

    1. Apply engine oil to the cylinder walls, pistons, and inner surface of the connecting rod bearings.

    2. Check the positions of the end gaps of the piston ring set.

      Note:

      Do not align the end gaps.

      A012KJCC07
      *a Front Mark
      *b No. 1 Compression Ring End Gap
      *c No. 2 Compression Ring End Gap
      *d Oil Ring Rail End Gap
      *e Coil Joint
      A012M0O Front

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

      A012JVQC03
      *a Front Mark
      A012M0O Front

    4. Install the connecting rod cap so that its front mark is facing the correct direction.

      A012LE0C06
      *a Front Mark
      Note:

      • Make sure that the front mark of the connecting rod cap is facing forward.

      • Match the numbered connecting rod cap with the connecting rod.

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

    6. Uniformly tighten the connecting rod bolts of the connecting rod cap in several steps.

      A012HME
      Момент затяжки
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

    7. Mark the front side of each connecting rod bolt with paint.

    8. Further tighten the connecting rod bolts by 90°.

      A012IATC01
      *a Paint Mark
      A012M0O Front

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

      A012LU2C01
      *a Paint Mark
      A012M0O Front

    10. Check that the crankshaft turns smoothly.

  11. INSPECT CONNECTING ROD THRUST CLEARANCE

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