Reassembly [04/2013 - 08/2015]: Procedure

WARNING: This page is about a different car, the 2015 Lexus IS 250 and 2014 Lexus IS 250. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a 5 mm hexagon wrench, install the 3 No. 1 oil nozzle sub-assemblies with the 3 bolts.
  Torque: 9.0 N.m (92 kgf/cm, 80 in.lbf)

INSTALL CONNECTING ROD SMALL END BUSH

Align the oil holes of a new connecting rod small end bush and the connecting rod sub-assembly.

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Oil Hole

Using SST and a press, press in the connecting rod small end bush.

SST: 09222-30010

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HINT:

Make sure that the oil holes are aligned.

Using a pin hole grinder, hone the bush to obtain the specified clearance between the connecting rod small end bush and piston pin.

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Standard oil clearance

-0.002 to 0.004 mm (-0.00008 to 0.00016 in.)

Check that the piston pin fits at normal room temperature.

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Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

INSTALL PISTON SUB-ASSEMBLY WITH PIN

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

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*1	Cutout Portion

HINT:

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

Gradually heat the piston to approximately 80°C (176°F).
WARNING:
Be sure to wear protective gloves.
Coat the piston pin with engine oil.

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

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*1	Front Mark
*a	for Bank 1
*b	for Bank 2

HINT:

The piston and piston pin are a matched set.

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

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

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*1	Cutout Portion

HINT:

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

Check that the piston moves smoothly.

INSTALL PISTON RING SET

Install the oil ring expander by hand.

Using a piston ring expander, install the No. 1 compression ring, No. 2 compression ring and oil ring as shown in the illustration.

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*1	Piston Ring Expander
*2	No. 1 Compression Ring
*3	No. 2 Compression Ring
*4	Oil Ring
*5	Oil Ring Expander
*6	Cutout

NOTE:

The No. 1 compression ring can be installed with either side facing upward.
Install the No. 2 compression ring with the cutout facing downward.

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

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*1	Oil Ring End
*2	No. 1 Compression Ring End
*3	No. 2 Compression Ring End
*4	Oil Ring Expander End
*5	Front Mark
*a	for Bank 1
*b	for Bank 2
	Engine Front

NOTE:

Do not align the ring ends.

INSTALL CRANKSHAFT BEARING

Clean the main journal and both surfaces of the bearings.

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*1	No. 1 and No. 4 Journal Bearing
*2	No. 2 and No. 3 Journal Bearing
*a	21.0 mm (0.827 in.)
*b	18.0 mm (0.709 in.)

NOTE:

Crankshaft bearings come in widths between 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 crankshaft bearing cap.

Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

Install the upper crankshaft bearing.

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*1	Oil Groove
*2	Oil Feed Hole
*a	CORRECT
*b	INCORRECT

Install the upper crankshaft bearings to the cylinder block as shown in the illustration.
NOTE:
- Do not apply engine oil to the crankshaft bearings and the 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 crankshaft bearing inner surface, replace the crankshaft bearing with a new one.

Install the lower crankshaft bearing.

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*1	Journal Number
*2	Vernier Caliper

Install the lower crankshaft bearings to the crankshaft bearing caps.
Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the lower crankshaft bearing edge.
Standard Dimension (A - B or B - A)

0 to 0.7 mm (0 to 0.0276 in.)
NOTE:
- Do not apply engine oil to the crankshaft bearings and the contact surfaces.
- Do not allow coolant to come into contact with the crankshaft bearing inner surface.
- If any coolant comes into contact with the crankshaft bearing inner surface, replace the crankshaft bearing with a new one.

INSTALL CRANKSHAFT THRUST WASHER SET

Apply engine oil to the crankshaft thrust washer set.

Install the crankshaft thrust washer set under the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

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*1	Oil Groove

NOTE:

Be sure not to install the crankshaft thrust washer set the wrong way around.

INSTALL CRANKSHAFT

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

Confirm the projections and numbers on the crankshaft bearing caps and install the crankshaft bearing caps on the cylinder block sub-assembly.

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*1	Projection
*2	Number Mark

HINT:

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

Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap set bolts.
Temporarily install the 8 crankshaft bearing cap set bolts to the inside positions.
NOTE:
Confirm the crankshaft bearing cap set bolt length before installing.

Bolt Length

100 to 102 mm (3.94 to 4.02 in.)

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

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*a	Less than 6 mm (0.236 in.)
*b	Bolt Length

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

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

Install the 8 crankshaft bearing cap set bolts to the outside positions.

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*a	Bolt Length

NOTE:

Confirm the crankshaft bearing cap set bolt length before installing.

Bolt Length

Item	Specified Condition
Bolt A	100 to 102 mm (3.94 to 4.02 in.)
Except bolt A	105.5 to 107.5 mm (4.15 to 4.23 in.)

Tighten the crankshaft bearing cap set bolts.
HINT:

The crankshaft bearing cap set bolts are tightened in 2 progressive steps.
Step 1
1. Uniformly tighten the 16 crankshaft bearing cap set bolts in several steps and in the sequence shown in the illustration.
  Torque: 61 N.m (622 kgf/cm, 45 ft.lbf)
  
  NOTE:
  Check that the crankshaft turns smoothly during the procedure.
  
  If any of the crankshaft bearing cap set bolts does not meet the torque specified, replace it.
  
  Fig 1: Crankshaft Bearing Cap Set Bolts Tighten Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Step 2

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

*1	Paint Mark
*a	90°
	Engine Front

Tighten the crankshaft bearing cap set bolts another 90°.
Check that the painted marks are now at a 90° angle to the front of the engine.

Install 8 new seal washers and uniformly tighten the 8 bolts in several steps and in the sequence shown in the illustration.

Torque: 25.7 N.m (262 kgf/cm, 19 ft.lbf)

NOTE:

Check that the crankshaft turns smoothly during the procedure.
Confirm the crankshaft bearing cap set bolt length before installing.

Bolt Length

Item	Specified Condition
Bolt A	45 mm (1.77 in.)
Except bolt A	30 mm (1.18 in.)

Fig 2: Crankshaft Bearing Cap Side Bolts Tighten Sequence

Check that the crankshaft turns smoothly.
Check the crankshaft thrust clearance.
See step 5

INSTALL CONNECTING ROD BEARING

Clean the connecting rod, connecting rod cap and connecting rod bearing.
Install the connecting rod bearings to the connecting rod and connecting rod cap.

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

Standard Dimension (A - B or B - A)

0 to 0.7 mm (0 to 0.0276 in.)

*1	Vernier Caliper

NOTE:

Do not apply engine oil to the connecting rod bearings and the contact surfaces.
Do not allow coolant to come into contact with the connecting rod bearing inner surface.
If any coolant comes into contact with the connecting rod bearing inner surface, replace the connecting rod bearing with a new one.

INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

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

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

*1	Oil Ring End
*2	No. 1 Compression Ring End
*3	No. 2 Compression Ring End
*4	Oil Ring Expander End
*5	Front Mark
*a	for Bank 1
*b	for Bank 2
	Engine Front

NOTE:

Do not align the ring ends.

Using a piston ring compressor, push the correctly numbered piston and connecting rod sub-assembly into the cylinder with the front mark of the piston facing forward.

*1	Front Mark
*a	for Bank 1
*b	for Bank 2
	Engine Front

NOTE:

Match the numbered connecting rod cap with the connecting rod.

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

*1	Front Mark
	Engine Front

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

The connecting rod bolts are tightened in 2 progressive steps.

Step 1

Install and alternately tighten the connecting rod bolts of each connecting rod cap in several steps.
Torque: 24.5 N.m (250 kgf/cm, 18 ft.lbf)

Fig 3: Tightening Bolts Of Connecting Rod Cap
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NOTE:
Check that the crankshaft turns smoothly during the procedure.

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

*1	Paint Mark
*a	90°
	Engine Front

Step 2
1. Tighten the connecting rod bolts 90°.
Check that the paint marks are now at a 90° angle to the front.
Check that the crankshaft turns smoothly.

INSPECT CONNECTING ROD THRUST CLEARANCE
See step 1