Reassembly

2ZR-FXE ENGINE MECHANICAL: CYLINDER BLOCK: REASSEMBLY

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.

(a) Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.

Text in Illustration

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

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

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

3. INSTALL PISTON

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

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HINT
Make sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

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

(c) 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.

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HINT
The piston and pin are a matched set.

(d) 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.

(e) 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

(a) Install the oil ring expander and oil ring by hand.

Text in Illustration

NOTICE:
* 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.

(b) 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

NOTICE:
* 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.

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

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5. INSTALL CRANKSHAFT BEARING

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

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(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.

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

Text in Illustration

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

(a) Install the 2 thrust washers to the No. 3 journal position of the cylinder block with the oil grooves facing outward.

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(b) Apply engine oil to the crankshaft thrust washer.

7. INSTALL CRANKSHAFT

(a) Apply engine oil to the upper bearings and install the crankshaft to the cylinder block.

(b) Apply engine oil to the lower bearings.

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

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

(e) Temporarily install the 10 crankshaft bearing cap bolts.

(f) 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.).

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

(h) Install the crankshaft bearing cap bolts.

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

(i) Step 1:

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

Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)

(j) Step 2:

(1) Mark the front of the bearing cap bolts with paint.

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

(k) Check that the paint marks are now at a 90° angle to the front.

(l) Check that the crankshaft turns smoothly.

(m) Check the crankshaft thrust clearance Disassembly.

8. INSTALL CONNECTING ROD BEARING

(a) Install the connecting rod bearings to the connecting rods and connecting rod caps.

(b) 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

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

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

Text in Illustration

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

NOTICE:
Do not align the ring ends.

(c) 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.

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NOTICE:
* 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.

(d) Check that the front mark of the connecting rod cap is facing in the correct direction.

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

(f) Install the connecting rod cap bolts.

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

(g) Step 1:

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

SST : 09205-16011

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

(h) Step 2:

(1) Mark the front of the connecting rod cap bolts with paint.

Text in Illustration

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

(i) Check that the crankshaft turns smoothly.

(j) Check the connecting rod thrust clearance Disassembly.

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.

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

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Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Application Specification:

NOTICE:
* 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.

(b) Type A:

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

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(c) Type B:

(1) Install the ventilation case with the 8 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)