Reassembly
2UR-GSE ENGINE MECHANICAL: CYLINDER BLOCK: REASSEMBLY
1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, install the 4 No. 1 oil nozzles assembly with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
2. INSTALL PISTON WITH PIN SUB-ASSEMBLY
(a) 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.
(b) Gradually heat the piston to approximately 80°C (176°F).
(c) Coat the piston pin and connecting rod with engine oil.
(d) 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:
NOTICE:
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.
(e) Move the connecting rod back and forth on the piston pin. Check the fitting condition.
(f) Rotate the piston back and forth on the piston pin. Check the fitting condition.
(g) 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.
3. INSTALL PISTON RING SET
(a) Install the oil ring expander by hand.
(b) Using a piston ring expander, install the oil ring as shown in the illustration.
(c) 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.
4. INSTALL CRANKSHAFT BEARING
(a) Clean the main journals and both surfaces of the bearings.
(b) Install the upper bearings.
NOTICE:
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 upper bearings to the cylinder block as shown in the illustration.
NOTICE:
* 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.
(c) Install the lower bearings.
NOTICE:
* 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.)
NOTICE:
* 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.
5. INSTALL CRANKSHAFT THRUST WASHER SET
(a) Apply engine oil to the thrust washer set.
(b) 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
(a) Apply engine oil to the upper and lower bearings, then place the crankshaft on the cylinder block.
(b) 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.
(c) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
(d) Temporarily install the 10 main bearing cap bolts to the inside positions.
(e) 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.)
(f) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
(g) Apply a light coat of engine oil to the threads and under the heads of the 10 main bearing cap bolts.
(h) 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.
(i) Step 1:
(1) Install and uniformly tighten the 20 main bearing cap bolts in the sequence shown in the illustration.
Torque : 61 Nm (622 kgf-cm, 45 ft-lbf) for inside position
Torque : 27 Nm (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.
(j) 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.
(k) Check that the crankshaft turns smoothly.
(l) 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 Nm (459 kgf-cm, 33 ft-lbf)
(m) Check that the crankshaft turns smoothly.
7. INSTALL CONNECTING ROD BEARING
(a) Install the connecting rod bearing to the connecting rod and bearing cap.
(b) 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.)
NOTICE:
* 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.
8. INSTALL PISTON AND CONNECTING ROD
(a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
(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 into the cylinder with the front mark of the piston facing forward.
NOTICE:
Match the numbered connecting rod cap with the connecting rod.
Front Mark:
(d) Check that the mark of the connecting rod cap is facing the correct side.
Front Mark:
(e) Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
(f) Temporarily install the connecting cap bolts.
HINT
The connecting cap bolts are tightened in 2 progressive steps.
(g) Step 1:
(1) Install and alternately tighten the bolts of the connecting rod cap in several steps.
Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
(h) 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.
(i) Check that the crankshaft turns smoothly.