Cylinder Block: Reassembly

WARNING: This page is about a different car, the 2004 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace all gaskets, O-rings and oil seals with new parts.

Assemble Piston & Connecting Rod
1. Using a small screwdriver, install a new snap ring at one end of the piston pin hole.
  NOTE: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
  
  Fig 1: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Gradually heat the piston to 80-90°C (176-194°F).
  
  Fig 2: Heating Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the piston pin with engine oil.
4. Align the front marks on the piston and connecting rod, and push in the piston with your thumb.
  
  Fig 3: Aligning Front Marks On Piston & Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.
  NOTE: Be sure that end gap of the snap ring is not as aligned with the pin hole cutout portion of the piston.
  
  Fig 4: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install Piston Rings

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

Using a piston ring expander, install the 2 compression rings with the code mark facing upward. See CODE MARK table.

Code Mark

Piston Ring	Code
No. 1	None
No. 2	2N

Fig 5: Installing Compression Rings

Position the piston rings so that the ring ends are as shown in Fig 6.
NOTE: Do not align the ring ends.

Fig 6: Positioning Piston Rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install Connecting Rod Bearings
1. Align the bearing claw with the groove of the connecting rod or connecting cap.
2. Install the bearings in the connecting rod and connecting rod cap.
  
  Fig 7: Installing Connecting Rod Bearings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Main Bearings
HINT: Upper bearings have an oil groove and oil holes; Lower bearings do not.
1. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.
  NOTE:
  - Install the bearing with the oil hole in the cylinder block.
  - Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick.
  Fig 8: Aligning Bearing Claw With Claw Groove Of Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
  NOTE: Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick.
  
  Fig 9: Aligning Bearing Claw With Claw Groove Of Main Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Thrust Washers
Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.

Fig 10: Installing Thrust Washers
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Place Crankshaft On Cylinder Block
Install Main Bearing Caps
1. Install the 5 main bearing caps in their proper locations.
  
  Fig 11: Installing Main Bearing Caps In Proper Locations
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Spread engine oil around the bolt threads of each bearing cap bolt.
3. Install and tighten the 10 bearing cap bolts.
  Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
  
  NOTE: These bearing cap bolts must be tightened uniformly in several passes, in the sequence shown in the illustration
  
  Fig 12: Main Bearing Cap Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Retighten the 10 bolts.
  Torque: 40 N.m (48 kgf.cm, 30 ft.lbf)
5. Mark the front of the main bearing cap bolt with paint.
6. Retighten the 10 bolts by 90°.
  
  Fig 13: Retightening Main Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Check that the crankshaft turns smoothly.
Check Crankshaft Thrust Clearance See DISASSEMBLY .
Install Piston & Connecting Rod Assembles
Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.

Fig 14: Installing Piston & Connecting Rod Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Connecting Rod Cap
NOTE: Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick.
1. Confirm that the connecting rod cap number matches the connecting rod.
  
  Fig 15: Matching Numbered Connecting Rod Cap With Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install on the connecting rod.
3. Check that the protrusion of the connecting rod cap is facing in the correct direction.
  
  Fig 16: Checking Protrusion Of Connecting Rod Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Spread engine oil around the bolt threads of each connecting rod cap bolts.
5. Install and tighten the 2 bolts.
  Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf)
  
  NOTE: The bolts must be tightened uniformly in several passes.
  
  Fig 17: Tightening Connecting Rod Cap Bolts Alternately
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Mark the front of the connecting cap bolts with paint.
7. Retighten the bolts by 90°
  
  Fig 18: Retightening Cap Bolts By 90°
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Check that the crankshaft turns smoothly.
Check Connecting Rod Thrust Clearance See INSPECTION .
Install Rear Crankshaft Oil Seal See REPLACEMENT .
HINT: Wipe seal packing away from the contact surface of the cylinder block assembly and oil seal.
Install Stiffening Crankcase Assembly
1. Install a new O-ring to the cylinder block.
  
  Fig 19: Installing O-Ring To Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Temporarily tighten the pulley set bolt.
3. Turn the crankshaft so that the key groove is facing downward.
  
  Fig 20: Location of Key Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Apply seal packing in a continuous bead (diameter 2.5 to 3.0 mm (.098 to 0.118 in.)) to the places shown in the illustration.
  
  Fig 21: Seal Packing Application Locations
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing: Toyota Genuine Seal Packing Black, Three Bond 120/B or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Ensure that no oil packing enters the oil path. The oil path has a groove to catch excess seal packing. Do not apply seal packing to the oil path side of the groove or the groove itself, or seal packing may enter the oil path.
  - Install the stiffening crankcase assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
  - Do not add engine oil for at least 2 hours after the installation.
5. Install the stiffening crankcase assembly to the cylinder block.
6. Temporarily install the stiffening crankcase assembly with the 11 bolts.
  Bolt length:
  - 112 mm (4.41 in.) for A of 12 mm head
  - 35 mm (1.38 in.) for B of 12 mm head
  Fig 22: Installing Crank Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Uniformly tighten the bolts.
  Torque: 32.5 N.m (331 kgf.cm, 24 ft.lbf)
8. Wipe off the excess seal packing with a clean piece of cloth.
Install No. 1 Balanceshaft Bearing
1. Clean each No. 1 balanceshaft bearing installation surface and inner and outer surfaces of the No. 1 balanceshaft bearing.
2. Align the claw of the No. 1 balanceshaft bearing with the groove of the balanceshaft housing and install the 8 No. 1 balanceshaft bearings.
3. Apply engine oil to the inner surface of the No. 1 balanceshaft bearing.
Install No. 1 and No. 2 Balanceshaft Subassembly
1. Turn the No. 1 gear counterclockwise untill it stops, then align the matchmark of the No. 1 driven gear with that of the No. 2 driven gear.
  
  Fig 24: Aligning The Matchmark Of The No. 1 Driven Gear With That Of The No. 2 Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 1 balanceshaft with the timing mark positioned as shown in illustration. (*1)
  HINT: (A) is not a timing mark.
  
  Fig 25: Positioning of No. 1 Balanceshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the No. 2 balanceshaft with the timing mark positioned as shown in illustration.
  
  Fig 26: Positioning of No. 2 Balanceshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Make sure that the key groove of the crankshaft and timing mark of the balanceshafts are positioned as shown in illustration
  
  Fig 27: Key Groove Of The Crankshaft And Timing Mark Of The Balanceshafts Positioning
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT: (A) is not a timing mark.
4. Apply a light coat of engine oil under the heads of the balanceshaft housing bolts.
5. Install the balanceshaft housing bolts
  NOTE: The balanceshaft housing bolts are tightened in 2 progressive steps.
6. Step 1:
  1. Install and uniformly tighten the 8 bolts in the order shown in the illustration.
  Torque: 21.6 N.m (224 kgf.cm, 16 ft.lbf)
  
  Fig 28: Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Step 2:
  1. Mark the front side of each balanceshaft housing bolt head with paint.
  2. Tighten the blanceshaft housing bolts 90° in the same order.
  NOTE: Check that the paint marks are now at 90° angle to the front.
  
  Fig 29: Checking Paint Marks Are At 90°
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Turn the crankshaft 360° and check that the timing marks of the balanceshafts are positioned as shown in illustration with the key groove of the crankshaft facing downward.
  
  Fig 30: Checking Timing Marks Of The Balanceshafts Positioning
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: If the timing marks are not positioned as shown in the illustration, perform the procedure from step (*1) again.
  
  HINT: (A) is not a timing mark.
9. Remove the pulley set bolt.
Install Oil Filter Union
Using a 12 mm hexagon wrench, install the oil filter union.

Torque: 29.5 N.m (301 kgf.cm, 22 ft.lbf)

Fig 31: Installing Oil Filter Union
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Oil Filter See REPLACEMENT .
Install Oil Pump See INSTALLATION .
Install Water By-Pass Pipe
Install a new gasket, the water bypass pipe with the 2 nuts.

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

Fig 32: Installing Water By-Pass Pipe
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Oil Dipstick & Guide
1. Install a new O-ring to the dipstick guide.
2. Apply soapy water to the O-ring.
3. Push in the dipstick guide end into the guide hole of the No. 1 oil pan.
4. Install the dipstick guide with the bolt.
  Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
  
  Fig 33: Installing Dipstick Guide
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the dipstick.
Install Engine Coolant Drain Union
1. Apply adhesive to 2 or 3 threads.
  Seal packing: Part No. 08826-00100 or equivalent
  
  Fig 34: Applying Adhesive To Threads
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the drain union.
  Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) or more
  
  HINT: After applying the specified torque, rotate the drain union clockwise until its drain port is facing downward.
Install Thermostat See INSTALLATION .
Install Plug
Install Wire Clamps
Install Knock Sensor See KNOCK SENSOR .
Install Water Pump See INSTALLATION .
Install OCV Filter
Using a 12 mm hexagon wrench, install the OCV filter with a new gasket and the plug.

Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)

Fig 35: Installing OCV Filter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Cylinder Head See INSTALLATION .
Install Timing Chain See INSTALLATION .
Remove Engine Stand