Reassembly [11/2021 - ]: Procedure

WARNING: This page is about a different car, the 2024 Lexus IS 500, 2023 Lexus IS 500, and 2022 Lexus IS 500. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

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

Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL PISTON

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

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Cutout

HINT:

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

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

WARNING:

Be sure to wear protective gloves.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the piston pin and connecting rod sub-assembly with engine oil.

Align the front marks of the piston and connecting rod sub-assembly as shown in the illustration. Then push in the piston pin with your thumb until the piston pin contacts the piston pin hole snap ring.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Front Mark

Item	Number of Front Mark
Bank 1 Piston	1
Bank 2 Piston	2

NOTE:

For bank 2, install the piston to the connecting rod sub-assembly so that the front mark of the piston and that of the connecting rod sub-assembly face the opposite direction.

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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

HINT:

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Cutout

INSTALL PISTON RING SET

for 2-piece Type:

Install the oil ring expander by hand.

Using a piston ring expander, install the oil ring as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Oil Ring	*2	Oil Ring Expander
*a	Front Mark	*b	Oil Ring End
*c	Oil Ring Expander End	*d	for Bank 1
*e	for Bank 2	-	-
	Front of Engine	-	-

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	No. 1 Compression Ring
*2	No. 2 Compression Ring
*a	Code Mark

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.

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Front Mark
*b	No. 1 Compression Ring End
*c	No. 2 Compression Ring End
*d	Oil Ring End
*e	Oil Ring Expander End
*f	for Bank 1
*g	for Bank 2

NOTE:

Do not align the ring ends.

for 3-piece Type:

Install the oil ring expander by hand.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Upper Side Rail
*2	Oil Ring Expander
*3	Lower Side Rail

Install the upper side rail and lower side rail to the piston.

NOTE:

Make sure to install the upper side rail and lower side rail in the correct direction. Also, when installing the upper side rail and lower side rail, the oil ring expander may move and overlap. If this occurs, part of the side rail may greatly protrude.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Upper Side Rail
*2	Lower Side Rail
*a	Paint (Blue)
	Upward

Check that the ends of the oil ring expander are not overlapping and that the upper side rail and lower side rail are securely installed into the groove.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Oil Ring Expander	*b	Correct
*c	Incorrect	*d	Ring End
	Press around the circumference		Push with Thumb

NOTE:

After installing the oil ring expander, upper side rail and lower side rail, press around the circumference with a finger to check that they are securely installed into the groove.
If the oil ring expander is not securely installed into the groove, check that the ends of the oil ring expander are not overlapping.
If the ends of the oil ring expander are overlapping, remove the upper side rail and lower side rail and realign the oil ring expander using a screwdriver.

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	No. 1 Compression Ring
*2	No. 2 Compression Ring
*a	Code Mark

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.

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*A	for Bank 1
*B	for Bank 2
*a	Front Mark
*b	No. 1 Compression Ring End
*c	No. 2 Compression Ring End
*d	Upper Side Rail End
*e	Oil Ring Expander End
*f	Lower Side Rail End
	Front

NOTE:

Do not align the ring ends.

INSTALL CRANKSHAFT BEARING

Clean the main journal and both surfaces of the crankshaft bearings.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	No. 1 and No. 5 Journal Bearing
*2	No. 2, No. 3 and No. 4 Journal Bearing
*a	22.5 mm (0.886 in.)
*b	21 mm (0.827 in.)

NOTE:

Crankshaft bearings come in widths of 22.5 mm (0.886 in.) and 21.0 mm (0.827 in.). Install the 22.5 mm (0.886 in.) bearings to the No. 1 and No. 5 journal positions. Install the 21 mm (0.827 in.) bearings to the No. 2, No. 3 and No. 4 journal positions.

Install the upper crankshaft bearings.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Correct
*b	Incorrect

Install the 5 upper crankshaft bearings to the cylinder block sub-assembly as shown in the illustration.
NOTE:
- Do not apply engine oil to the crankshaft bearings or the contact surfaces.
- Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the crankshaft bearing. The amount visible on each side of the holes should be equal.
- 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 the lower crankshaft bearings.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Vernier Caliper

Install the 5 lower crankshaft bearings to the 5 crankshaft bearing caps.
Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the crankshaft bearing edge.
Difference between (A) and (B)

0 to 0.7 mm (0 to 0.0276 in.)
NOTE:
- Do not apply engine oil to the crankshaft bearing inner surfaces or crankshaft bearing cap 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 to the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CRANKSHAFT

Apply engine oil to the 5 upper crankshaft bearings and 5 lower crankshaft bearings, then place the crankshaft on the cylinder block sub-assembly.

Confirm the front marks and numbers of the crankshaft bearing caps, and install the 5 crankshaft bearing caps to the cylinder block sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

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

Install the crankshaft bearing cap by hand until the clearance between the crankshaft bearing cap and cylinder block sub-assembly is less than 6 mm (0.236 in.)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Apply a light coat of engine oil to the threads and under the heads of the 10 crankshaft bearing cap set bolts.
Temporarily install the 10 crankshaft bearing cap set bolts to the inside positions.
Bolt Length

91 mm (3.58 in.)

HINT:

Tighten the crankshaft bearing cap set bolts in 2 progressive steps.

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Apply a light coat of engine oil to the threads and under the heads of the 10 crankshaft bearing cap set bolts.

Temporarily install the 10 crankshaft bearing cap set bolts to the outside positions.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Bolt Length

Bolt Length

79.5 mm (3.13 in.)

HINT:

Tighten the crankshaft bearing cap set bolts in 2 progressive steps.

Step 1:
1. Install and uniformly tighten the 20 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.
  for Inside Position
  
  Torque: 61 N.m (622 kgf/cm, 45 ft.lbf)
  
  for Outside Position
  
  Torque: 27 N.m (275 kgf/cm, 20 ft.lbf)
  
  NOTE:
  Check that the crankshaft turns smoothly during the procedure.
  
  If any of the crankshaft bearing cap set bolts cannot be tightened to the specified torque, replace it.
  
  Fig 1: Crankshaft Bearing Cap Set Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Step 2:

Mark the front of each crankshaft bearing cap set bolt with paint.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Paint Mark
*b	90°
	Front of Engine

Tighten the crankshaft bearing cap set bolt another 90° in the order shown in step 1.
Check that the paint marks are now at a 90° angle to the front of the engine.

Check that the crankshaft turns smoothly.
Install and uniformly tighten the 10 bolts and 10 new seal washers in several steps in the order shown in the illustration.
Torque: 45 N.m (459 kgf/cm, 33 ft.lbf)

Fig 2: Crankshaft Bearing Cap Side Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check that the crankshaft turns smoothly.
Check the crankshaft thrust clearance.
See step 5

INSTALL CONNECTING ROD BEARING

Install the connecting rod bearings to the connecting rod sub-assembly and connecting rod cap.

Using a vernier caliper, measure the distance between the connecting rod bearing edges and connecting rod sub-assembly edges, and between the connecting rod bearing edges and connecting rod cap edges.

Difference between (A) and (B)

0 to 0.7 mm (0 to 0.0276 in.)

*a	Vernier Caliper

NOTE:

Do not apply engine oil to the connecting rod bearing inner surfaces or connecting rod sub-assembly 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 WITH CONNECTING ROD SUB-ASSEMBLY

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

for 2-piece Type:

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

*a	Front Mark
*b	No. 1 Compression Ring End
*c	No. 2 Compression Ring End
*d	Oil Ring End
*e	Oil Ring Expander End
*f	for Bank 1
*g	for Bank 2

NOTE:

Do not align the ring ends.

for 3-piece Type:

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

*A	for Bank 1
*B	for Bank 2
*a	Front Mark
*b	No. 1 Compression Ring End
*c	No. 2 Compression Ring End
*d	Upper Side Rail End
*e	Oil Ring Expander End
*f	Lower Side Rail End
	Front

NOTE:

Do not align the ring ends.

Check that the ends of the oil ring expander are not overlapping and that the upper side rail and lower side rail are securely installed into the groove.

*a	Oil Ring Expander	*b	Correct
*c	Incorrect	*d	Ring End
	Press around the circumference		Push with Thumb

NOTE:

After installing the oil ring expander, upper side rail and lower side rail, press around the circumference with a finger to check that they are securely installed into the groove.
If the oil ring expander is not securely installed into the groove, check that the ends of the oil ring expander are not overlapping.
If the ends of the oil ring expander are overlapping, remove the upper side rail and lower side rail and realign the oil ring expander using a screwdriver.

Using a piston ring compressor, push the correctly matched piston with connecting rod sub-assembly into the cylinder block sub-assembly with the front mark of the piston facing the front of the engine.

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

NOTE:

Match the connecting rod cap with the connecting rod piston with connecting rod sub-assembly.

Front Mark

Item	Total Number of Front Mark
Bank 1	1
Bank 2	2

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

*a	Front Mark
	Front of Engine

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

Tighten the connecting rod bolts in 2 progressive steps.

Step 1:

Install and alternately tighten the 2 connecting rod bolts.

Torque: 40 N.m (408 kgf/cm, 30 ft.lbf)

Step 2:

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

*a	Paint Mark
	Front of Engine

Tighten the connecting rod bolts another 90° as shown in the illustration.
Check that the paint marks are now at a 90° angle to the front.
When using new connecting rod bolts, loosen each bolt once after tightening it 90° and perform steps 1 and 2 again.

Check that the crankshaft turns smoothly.

INSPECT CONNECTING ROD THRUST CLEARANCE
See step 1