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Home >> Toyota >> 2016 >> Highlander LE Plus, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2GR-FE) (Service Information) (Except Hybrid) (2 Of 2) >> Cylinder Block >> Reassembly [12/2013 - 11/2016] >> Procedure

Reassembly [12/2013 - 11/2016]: Procedure

  1. 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.
      GTY293631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

  2. INSTALL PISTON 
    1. Using a screwdriver, install a new piston pin hole snap ring at one end of the piston pin hole.
      GTY423123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cutout

      HINT: 

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

    2. Gradually heat the piston to approximately 80°C (176°F).
      GTY189941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the piston pin with engine oil.
      WARNING:

      Be sure to wear protective gloves.

    4. Align the front marks of the piston and connecting rod sub-assembly, and push in the piston pin with your thumb.
      GTY430650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark

      HINT: 

      The piston and piston pin are a matched set.

    5. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
      GTY145469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole.
      GTY435635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cutout

      HINT: 

      • Confirm that the end gap of the snap ring is not aligned with the cutout of the piston pin hole.
      • Perform "Inspection After Repair" after replacing the piston.

        Refer to INITIALIZATION [12/2013 - 11/2016]

  3. INSTALL PISTON RING SET 
    1. Install the oil ring expander and 2 side rails by hand.
    2. Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring as shown in the illustration.
      GTY426148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring
      *a Piston Ring Expander
      *b Upper Side Rail
      *c Oil Ring Expander
      *d Lower Side Rail
      *e 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.
    3. Position the piston ring set so that the ring ends are as shown in the illustration.
      GTY443748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a Front Mark
      *b Lower Side Rail
      *c Oil Ring Expander
      *d Upper Side Rail
      NOTE:

      Do not align the ring ends.

      HINT: 

      Perform "Inspection After Repair" after replacing the piston ring.

      Refer to INITIALIZATION [12/2013 - 11/2016]

  4. INSTALL CRANKSHAFT BEARING 
    1. Clean the main journals and both surfaces of the crankshaft bearings.
      GTY440707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No. 1 and No. 4 Crankshaft Bearing
      *b No. 2 and No. 3 Crankshaft Bearing
      NOTE:

      Crankshaft 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.) crankshaft bearings to the No. 1 and No. 4 cylinder block journal positions. Install the 18.0 mm (0.709 in.) crankshaft bearings to the No. 2 and No. 3 positions.

    2. Install the upper crankshaft bearing.
      GTY426208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Upper Crankshaft Bearing
      *b Correct
      *c Incorrect
      1. Install the upper crankshaft bearings to the cylinder block sub-assembly 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 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.
    3. Install the lower crankshaft bearing.
      GTY437082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Vernier Caliper
      *b Mark 1, 2, 3, 4 or 5
      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.

        Difference Between (A) and (B)

        0.7 mm (0.0276 in.) or less

        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.
  5. INSTALL CRANKSHAFT THRUST WASHER SET 
    1. Apply engine oil to the crankshaft thrust washer set.
    2. Install the crankshaft thrust washer set under the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward.
      GTY442349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil Grooves
  6. INSTALL CRANKSHAFT 
    1. Apply engine oil to the crankshaft bearings, then place the crankshaft on the cylinder block sub-assembly.
    2. Confirm the projections and numbers on the crankshaft bearing caps and install the 4 crankshaft bearing caps on the cylinder block sub-assembly.
      GTY439600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Projection
      *b Number Mark

      HINT: 

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

    3. Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts.
    4. Temporarily install the 8 crankshaft bearing cap bolts to the inside positions.
    5. Push the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and the cylinder block sub-assembly is less than 6 mm (0.236 in.) by using the 2 inside crankshaft bearing cap bolts as a guide.
      GTY440364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Less than 6 mm
      *b Bolt Length 100 to 102 mm

      Bolt Length

      100 to 102 mm (3.94 to 4.02 in.)

    6. Using a plastic hammer, lightly tap the crankshaft bearing cap to ensure a proper fit.
      GTY146649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Apply a light coat of engine oil to the threads and under the heads of the 8 crankshaft bearing cap bolts.
    8. Temporarily install the 8 crankshaft bearing cap bolts to the outside positions.
      GTY432780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt Length

      Bolt Length

      105.5 to 107.5 mm (4.15 to 4.23 in.)

    9. Install the crankshaft bearing cap bolts.

      HINT: 

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

    10. Step 1:
      1. Uniformly tighten the 16 crankshaft bearing cap bolts in several steps in the order shown in the illustration.
        Fig 1: Tightening Sequence Of 16 Crankshaft Bearing Cap Bolts
        GTY438840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) 

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

    11. Step 2:
      1. Mark the front of the crankshaft bearing cap bolts with paint.
        GTY455009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Paint Mark
        *b Turn 90°
        Engine Front
      2. Tighten the crankshaft bearing cap bolts by 90° in the order shown in the illustration.
      3. Check that the paint marks are now at a 90° angle to the front.
    12. Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap bolts in several steps in the order shown in the illustration.
      Fig 2: Tightening Sequence Of 8 Crankshaft Bearing Cap Bolts
      GTY440518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 51.5 N*m (525 kgf*cm, 38 ft.*lbf) 

      Bolt Length

      Item Length
      Bolt (A) 45 mm (1.77 in.)
      Except bolt (A) 30 mm (1.18 in.)
    13. Check that the crankshaft turns smoothly.
    14. Check the crankshaft thrust clearance.

      See step  10

  7. INSTALL CONNECTING ROD BEARING 
    1. Install the connecting rod bearings to the connecting rod sub-assembly and connecting rod cap.
    2. Using a vernier caliper, measure the distance between the connecting rod sub-assembly and connecting rod cap edges and the connecting rod bearing edge.
      GTY454422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Vernier Caliper

      Difference Between (A) and (B)

      0.7 mm (0.0276 in.) or less

      NOTE:

      Do not apply engine oil to the connecting rod bearings and the contact surfaces.

  8. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD 
    1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
    2. Position the piston rings so that the ring ends are as shown in the illustration.
      GTY443748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a Front Mark
      *b Lower Side Rail
      *c Oil Ring Expander
      *d Upper Side Rail
      NOTE:

      Do not align the ring ends.

    3. Using a piston ring compressor, push the correctly matched piston and connecting rod sub-assembly into the cylinder with the front mark of the piston facing the front.
      GTY433337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark
      Engine Front
      NOTE:

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

    4. Check that the front mark of the connecting rod cap is facing the front.
      GTY437126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark
      Engine Front
    5. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
    6. Install the 2 connecting rod cap bolts.

      HINT: 

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

    7. Step 1:
      1. Alternately tighten the 2 connecting rod cap bolts in several steps.
        GTY104958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

    8. Step 2:
      GTY438153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b Turn 90°
      Engine Front
      1. Mark the front of each connecting rod cap bolt with paint.
      2. Further tighten the connecting rod cap bolts by 90° as shown in the illustration.
      3. Check that the paint marks are now at a 90° angle to the front.
    9. Confirm that the crankshaft turns smoothly.
    10. Check the connecting rod thrust clearance.

      See step  1

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