Reassembly

2GR-FXE ENGINE MECHANICAL: CYLINDER BLOCK: REASSEMBLY

1. INSTALL STUD BOLT

NOTICE:
If a stud bolt is deformed or its threads are damaged, replace it.

(a) Using E8 and E10 "TORX" sockets, install the stud bolts.

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

for bolt B - Torque : 17 Nm (173 kgf-cm, 13 ft-lbf)

2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm socket hexagon, install the 3 oil nozzles with the 3 bolts.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

3. INSTALL PISTON WITH PIN SUB-ASSEMBLY

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

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HINT
Be 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°C (176°F).

(c) Coat the piston pin with engine oil.

(d) Align the front marks of the piston and connecting rod and push in the piston pin with your thumb.

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HINT
The piston and pin are a matched set.

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

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

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

4. INSTALL PISTON RING SET

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

(b) Using a piston ring expander, install the compression ring as shown in the illustration.

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NOTICE:
Do not align the ring ends.

5. INSTALL CRANKSHAFT BEARING

HINT
Main bearings come in widths of 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

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(a) Clean the main journal and both surfaces of the bearings.

(b) Install the upper crankshaft bearing.

(1) Install the upper crankshaft bearings to the cylinder block as shown in the illustration.

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NOTICE:
* Do not apply engine oil to the bearings or 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 inner surface of the bearing. If any coolant comes into contact with the inner surface of the bearing, replace the bearing with a new one.

(c) Install the lower crankshaft bearing.

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(1) Install the lower crankshaft bearings to the crankshaft bearing caps.

(2) Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the lower crankshaft 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 bearings or contact surfaces.
* Do not allow coolant to come into contact with the inner surface of the bearing. If any coolant comes into contact with the inner surface of the bearing, replace the bearing with a new one.

6. INSTALL CRANKSHAFT

NOTICE:
Clean the contact surface of each main journal and crank pin.

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

(b) Push the crankshaft in the rear thrust direction to create clearance and install a thrust washer to the No. 2 journal position with the oil groove facing the front of the engine.

(c) Push the crankshaft in the forward thrust direction to create clearance and install a thrust washer to the No. 2 journal position with the oil groove facing the rear of the engine.

(d) Check the projections and numbers on the main bearing caps and install the crankshaft bearing caps to the cylinder block.

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

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

(f) Temporarily install the 8 crankshaft bearing cap bolts to the inside positions.

(g) Insert the crankshaft bearing cap by hand until the clearance between the crankshaft bearing cap and the cylinder block is less than 6 mm (0.236 in.) while marking the 2 internal crankshaft bearing cap bolts as a guide.

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Standard bolt length:

100 to 102 mm (3.94 to 4.02 in.)

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

(i) Apply a light coat of engine oil to the threads and under the heads of the 8 crankshaft bearing cap bolts.

(j) Temporarily install the 8 crankshaft bearing cap bolts to the outside positions.

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Standard bolt length:

105.5 to 107.5 mm (4.15 to 4.23 in.)

(k) Tighten the crankshaft bearing cap bolts.

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

(l) Step 1:

(1) Uniformly tighten the 16 crankshaft bearing cap bolts in several steps in the sequence shown in the illustration.

Torque : 61 Nm (622 kgf-cm, 45 ft-lbf)

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

(m) 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.

(n) Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap bolts in several steps in the sequence shown in the illustration.

Torque : 52 Nm (525 kgf-cm, 38 ft-lbf)

Standard Bolt:

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(o) Check that the crankshaft turns smoothly.

7. INSPECT CRANKSHAFT THRUST CLEARANCE Disassembly

8. INSTALL CONNECTING ROD BEARING

(a) Install the bearing to the connecting rod cap.

NOTICE:
* Clean the contact surfaces of the bearing and connecting rod cap.
* Do not apply engine oil to the bearing or the surface it contacts.

(b) 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.)

Text in Illustration

NOTICE:
* Clean the contact surface of the bearing and connecting rod.
* Do not apply engine oil to the bearing or the surface it contacts.

(d) Using a vernier caliper, measure the distance between the connecting rod edge and connecting rod bearing edge.

Dimension A - B or B - A:

0 to 0.7 mm (0 to 0.0276 in.)

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9. INSTALL PISTON SUB-ASSEMBLY WITH 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.

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

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

(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 rod cap bolts.

HINT
The connecting rod cap bolts are tightened in 2 progressive steps.

(g) Step 1:

(1) Alternately tighten the bolts of the connecting rod cap in several steps.

Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)

(h) Step 2:

(1) Mark the front side of each connecting rod cap bolt with paint.

(2) Tighten the cap bolts 90° the same way as in step 1.

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

(i) Check that the crankshaft turns smoothly

10. INSPECT CONNECTING ROD THRUST CLEARANCE Disassembly