Reassembly [12/2015 - 08/2016]: Procedure

WARNING: This page is about a different car, the 2016 Toyota Sienna. 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 wrench, install the No. 1 oil nozzle sub-assemblies with the 3 bolts.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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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*1	Service Hole

HINT:

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

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

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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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*a	Front Mark

HINT:

The piston and 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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*1	Service Hole

HINT:

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

INSTALL PISTON RING SET

Install the oil ring expander and 2 side rails by hand.

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*1	Piston Ring Expander
*2	Upper Side Rail
*3	Oil Ring Expander
*4	Lower Side Rail
*5	Oil Ring
*6	No. 1 Ring
*7	No. 2 Ring

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

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*1	Lower Side Rail
*2	No. 2 Ring
*3	Oil Ring Expander
*4	No. 1 Ring
*5	Upper Side Rail
*a	Front Mark

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

NOTE:

Main 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 main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

Install the upper crankshaft bearing.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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*1	Upper Bearing
*a	CORRECT
*b	INCORRECT

NOTE:

Do not apply engine oil to the 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.

Install the lower crankshaft bearing.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*1	Vernier Caliper
*a	Mark 1, 2, 3, 4 or 5

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.
Dimension (A - B)

0.7 mm (0.0276 in.) or less

NOTE:
Do not apply engine oil to the crankshaft bearings and the contact surfaces.

INSTALL CRANKSHAFT THRUST WASHER SET

Apply engine oil to the crankshaft thrust washer.

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

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*1	Oil Grooves

INSTALL CRANKSHAFT

Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.

Confirm the projections and numbers on the main bearing caps and install the crankshaft bearing caps on the cylinder block.

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*1	Projection
*a	Number Mark

HINT:

A number is marked on each main 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 bolts.
Temporarily install the 8 crankshaft bearing cap bolts to the inside positions.

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 bolts as a guide.

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*a	Less than 6 mm
*b	Bolt Length 100 to 102 mm

Bolt length

100 to 102 mm (3.94 to 4.02 in.)

Using a plastic 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 bolts.

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

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*a	Bolt Length

Bolt length

105.5 to 107.5 mm (4.15 to 4.23 in.)

Install the crankshaft bearing cap bolts.
HINT:

The crankshaft bearing cap bolts are tightened in 2 progressive steps.
Step 1
1. Install and uniformly tighten the 16 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.
  
  Fig 1: Crankshaft Bearing Cap Bolts Tightening Sequence (1 Of 2)
  Courtesy 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 torque specified, replace it.

Step 2

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*a	Paint Mark
*b	Turn 90°
	Engine Front

Mark the front of the bearing cap bolts with paint.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Retighten the bearing cap bolts 90° in the sequence shown in the illustration.
Check that the painted mark is now at a 90° angle to the front of the engine.

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

Fig 2: Crankshaft Bearing Cap Bolts Tightening Sequence (2 Of 2)

Torque: 52 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.)

Check that the crankshaft turns smoothly.
Check the crankshaft thrust clearance (See step 10).

INSTALL CONNECTING ROD BEARING

Install the connecting rod bearing to the connecting rod and connecting rod cap.

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

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*1	Vernier Caliper

Dimension (A - B)

0.7 mm (0.0276 in.) or less

NOTE:

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

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.

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*1	Lower Side Rail
*2	No. 2 Ring
*3	Oil Ring Expander
*4	No. 1 Ring
*5	Upper Side Rail
*a	Front Mark

NOTE:

Do not align the ring ends.

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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*a	Front Mark
	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.

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*a	Front Mark
	Engine Front

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

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

Step 1

Install and alternately tighten the bolts of the connecting rod cap in several steps.

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

Step 2

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*a	Paint Mark
*b	Turn 90°
	Engine Front

Mark the front side of each connecting rod cap bolt with paint.
Retighten the cap bolts 90° as shown in the illustration.
Check the painted mark is now at a 90° angle to the front.

Confirm that the crankshaft turns smoothly.
Check the connecting rod thrust clearance (See step 1).