NR Series ENGINE MECHANICAL  CYLINDER BLOCK  REASSEMBLY  

2.667,3 2.885,2.75 false 2.5,2.24 2.833,2.406 false 2.479,2.906 2.792,3.063 0.313,0.156 10 false *1 2.302,2.146 2.615,2.302 0.313,0.156 10 false *2 1.583,2.063 1.896,2.219 0.313,0.156 10 false *a 2.031,2.979 2.344,3.146 0.313,0.167 10 false 5°

*1	Cylinder Block Sub-assembly
*2	Spool
*a	Upward

Install a new oil jet as shown in the illustration.

NOTICE:

Do not tap the tip of the oil jet.

HINT:

Press in the oil jet until the spool contacts the cylinder block sub-assembly.

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

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf)

0.781,0.969 0.906,0.208 0.906,0.208 1,0.969 false 0.813,0.021 1.125,0.219 0.313,0.198 10 false *a

*a

End Gap

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

HINT:

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

1.271,0.885 2.24,0.375 2.24,0.375 2.646,2.219 false 0.708,2.469 2.229,0.385 2.229,0.385 2.635,2.833 false 2.229,0.208 2.542,0.406 0.313,0.198 10 false *a

*a	Front Mark

Align the front marks of the piston and connecting rod, insert the connecting rod into the piston, and then push in the piston pin with your thumb until the piston pin comes into contact with the snap ring.

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.

0.375,2.583 3.156,4.417 2.781,1.833 2.354,1.031 2.5,0.885 2.5,0.885 2.646,0.885 false 2.813,1.354 2.667,1.354 false 2.563,1.813 2.448,1.813 2.448,1.813 2.333,1.646 false 0.958,3.521 1.115,3.521 1.115,3.521 1.333,3.729 false 2.125,3.604 2.292,3.938 2.292,3.938 2.427,3.938 false 2.688,0.792 3,0.99 0.313,0.198 10 false *a 2.885,1.25 3.198,1.448 0.313,0.198 10 false *b 2.635,1.719 2.948,1.917 0.313,0.198 10 false *c 0.427,2.677 0.74,2.875 0.313,0.198 12 false *A 2.49,3.865 2.802,4.063 0.313,0.198 10 false *d 0.573,3.417 1.396,3.646 0.823,0.229 10 false *a, *c

*A	When using new parts
*a	Upper Side Rail
*b	Oil Ring Expander
*c	Lower Side Rail
*d	Paint (Pink)
	Upper Side

Install the oil ring expander, upper side rail and lower side rail.

NOTICE:

Make sure that the oil ring expander ends do not overlap each other.

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.

1.615,0.552 1.927,0.75 0.313,0.198 10 false *a 4.229,1.792 4.542,1.99 0.313,0.198 10 false *b 3.51,0.708 3.823,0.906 0.313,0.198 10 false *c 3.521,2.135 3.833,2.333 0.313,0.198 10 false *d

*a	Press around the circumference	*b	Ring End
*c	Correct	*d	Incorrect (Ends of the oil ring expander are overlapping)

NOTICE:

·

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.

1.198,2.635 1.531,2.333 1.531,2.333 1.75,2.333 false 1.188,3.219 1.594,2.844 1.594,2.844 1.74,2.844 false 0.479,2.531 0.635,2.531 0.635,2.531 0.729,2.823 false 0.49,3.177 0.646,3.177 0.646,3.177 0.729,3.396 false 1.073,4.469 1.073,4.302 false 2.302,4.479 2.302,4.313 false 1.813,2.24 2.125,2.438 0.313,0.198 10 false *a 1.802,2.75 2.115,2.948 0.313,0.198 10 false *b 0.302,2.427 0.615,2.625 0.313,0.198 10 false *1 0.302,3.083 0.615,3.281 0.313,0.198 10 false *2 1.01,4.5 1.333,4.667 0.323,0.167 10 false *2 2.229,4.5 2.542,4.667 0.313,0.167 10 false *1

*1	No. 1 Compression Ring
*2	No. 2 Compression Ring
*a	Code Mark (1R)
*b	Code Mark (2R)
	Upward

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.

NOTICE:

·

Install the No. 1 compression ring with the code mark (1R) facing upward.

·

Install the No. 2 compression ring with the code mark (2R) facing upward.

1.646,0.708 1.958,0.906 0.313,0.198 10 false *a 2.563,1.635 2.875,1.833 0.313,0.198 10 false *c 1.656,2.542 1.969,2.74 0.313,0.198 10 false *b 0.74,1.615 1.052,1.813 0.313,0.198 10 false *d

*a	No. 1 Compression Ring and Oil Ring Expander
*b	No. 2 Compression Ring
*c	Upper Side Rail
*d	Lower Side Rail
	Front of Engine

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

1.438,3.125 1.75,3.281 0.313,0.156 10 false *a 2.323,3.125 2.635,3.281 0.313,0.156 10 false *b

*a	Correct
*b	Incorrect
	Front of Engine

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

NOTICE:

·

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 bearings. The amount visible on each side of the holes should be equal.

2.073,2.5 2.49,2.083 false 2.49,1.917 2.802,2.073 0.313,0.156 10 false *a 0.74,2.948 0.896,3.146 0.156,0.198 10 false A 2.063,2.948 2.219,3.146 0.156,0.198 10 false B

*a	Vernier Caliper

Install the lower crankshaft bearings to the No. 1 crankshaft bearing caps.

1.74,1.135 1.802,0.479 1.802,0.479 1.938,1.229 true 1.719,0.323 2.031,0.521 0.313,0.198 10 true *a

*a	Oil Groove

Install the 2 upper crankshaft thrust washers to the No. 3 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

0.594,2.635 1.854,3.073 1.854,3.073 3.146,2.625 false 1.24,2.635 1.854,3.063 1.854,3.063 2.49,2.635 false 1.854,3.073 1.854,2.635 false 1.76,3.125 2.073,3.281 0.313,0.156 10 false *a

*a	Front Mark and Number

Confirm the front marks and numbers, and place the 5 No. 1 crankshaft bearing caps on the cylinder block sub-assembly.

1.896,2.5 2.208,2.656 0.313,0.156 10 false *a

*a	Less than 5 mm

Temporarily install the 10 crankshaft bearing cap set bolts.

Using a plastic hammer, lightly tap the No. 1 crankshaft bearing caps to ensure a proper fit.

Step 1:

i.

1.76,0.333 1.917,0.531 0.156,0.198 10 true 1 1.771,1.813 1.927,2.01 0.156,0.198 10 true 2 1.24,1.813 1.396,2.01 0.156,0.198 10 true 3 2.281,0.365 2.438,0.563 0.156,0.198 10 true 6 1.26,0.333 1.417,0.531 0.156,0.198 10 true 4 2.271,1.833 2.427,2.031 0.156,0.198 10 true 5 0.719,0.365 0.875,0.563 0.156,0.198 10 true 8 0.729,1.833 0.885,2.031 0.156,0.198 10 true 7 2.781,0.375 3.146,0.563 0.365,0.188 10 true 10 2.781,1.833 2.938,2.031 0.156,0.198 10 true 9

Uniformly tighten the 10 crankshaft bearing cap set bolts in the order shown in the illustration.

Torque:

40 N*m (408 kgf*cm, 30 ft.*lbf)

HINT:

If a crankshaft bearing cap set bolt cannot be tightened to the specified torque, replace it.

Step 2:

i.

2.083,0.75 2.625,0.479 true 2.719,0.333 3.031,0.49 0.313,0.156 10 false *a 1.198,0.5 1.51,0.656 0.313,0.156 10 false *b

*a	Paint Mark
*b	90°
	Front of Engine

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

0.49,2.073 0.667,2.073 0.667,2.073 0.792,2.635 false 0.292,2 0.604,2.156 0.313,0.156 10 false *a 1.813,2.625 1.969,2.823 0.156,0.198 10 false A 3.135,2.625 3.292,2.823 0.156,0.198 10 false B

*a	Vernier Caliper

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

Difference between (A) and (B):

0.5 mm (0.0197 in.) or less

NOTICE:

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

1.646,0.708 1.958,0.906 0.313,0.198 10 false *a 2.563,1.635 2.875,1.833 0.313,0.198 10 false *c 1.656,2.542 1.969,2.74 0.313,0.198 10 false *b 0.74,1.615 1.052,1.813 0.313,0.198 10 false *d

*a	No. 1 Compression Ring and Oil Ring Expander
*b	No. 2 Compression Ring
*c	Upper Side Rail
*d	Lower Side Rail
	Front of Engine

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

Confirm 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.

1.615,0.552 1.927,0.75 0.313,0.198 10 false *a 4.229,1.792 4.542,1.99 0.313,0.198 10 false *b 3.51,0.708 3.823,0.906 0.313,0.198 10 false *c 3.521,2.135 3.833,2.333 0.313,0.198 10 false *d

*a	Press around the circumference	*b	Ring End
*c	Correct	*d	Incorrect (Ends of the oil ring expander are overlapping)

NOTICE:

·

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.

0.792,3.833 0.75,2.979 0.75,2.979 2.5,3.094 false 0.76,3 2.458,4.073 false 0.594,2.854 0.906,3.052 0.313,0.198 10 false *a

*a	Front Mark

Using a piston ring compressor, push the correctly numbered piston sub-assembly with pin with connecting rod into the cylinder with the front marks of the piston sub-assembly with pin with connecting rod facing the front of the engine.

NOTICE:

·

When inserting the piston sub-assembly with connecting rod, do not allow it to make contact with the No. 1 oil nozzle sub-assembly.

·

Match each connecting rod bearing cap to the correct connecting rod.

0.833,1.094 1.979,1.094 true 0.656,1.01 0.969,1.167 0.313,0.156 10 false *a

*a	Front Mark

Check that the front mark of the connecting rod bearing cap is facing in the correct direction.

Step 1:

i.

0.927,0.958 1.688,0.958 false 0.646,0.906 1.104,1.104 0.458,0.198 10 false SST

Using SST, alternately tighten the connecting rod bolts of the connecting rod bearing cap in several steps.

SST

09205-16011  

Torque:

15 N*m (153 kgf*cm, 11 ft.*lbf)

Step 2:

i.

2.083,0.708 2.5,0.292 true 2.542,0.177 2.854,0.333 0.313,0.156 10 false *a 1.229,0.438 1.542,0.594 0.313,0.156 10 false *b

*a	Paint Mark
*b	90°
	Front of Engine

Mark the front of the connecting rod bolts with paint.

Install the case separator to the No. 1 ventilation case with the 2 bolts.

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf)

Install 2 new oil separator gaskets to the case separator.

1.865,0.74 2.375,0.74 true 1.104,2.813 1.521,3.177 1.521,3.177 1.698,3.177 true 2.448,0.667 2.76,0.823 0.313,0.156 10 false *a 1.771,3.104 2.083,3.26 0.313,0.156 10 false *b 0.979,0.635 1.135,0.833 0.156,0.198 10 true A 0.115,0.646 0.271,0.844 0.156,0.198 10 false A 1.083,2.073 1.854,2.271 0.771,0.198 10 false A - A 1.719,2.271 2.635,2.469 0.917,0.198 10 false *c

*a	Seal Packing
*b	2.0 to 3.0 mm
*c	4.5 mm

Apply seal packing in a continuous line as shown in the illustration.

Seal Packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Application Specifications:

Seal Packing Diameter	Distance from Inside Edge of Cover to Center of Seal Packing
2.0 to 3.0 mm (0.0787 to 0.118 in.)	4.5 mm (0.177 in.)

NOTICE:

·

Remove any oil from the contact surfaces.

·

Install the No. 1 ventilation case within 3 minutes and tighten the bolts and nuts within 15 minutes of applying seal packing.

·

Do not start the engine for at least 2 hours after installation.

0.917,0.458 1.073,0.656 0.156,0.198 10 true 1 1.24,0.448 1.396,0.646 0.156,0.198 10 true 2 1.531,0.042 1.688,0.24 0.156,0.198 10 true 3 2.875,0.063 3.031,0.26 0.156,0.198 10 true 4 3.073,0.813 3.229,1.01 0.156,0.198 10 true 5 2.948,1.281 3.104,1.479 0.156,0.198 10 true 6 1.833,1.885 1.99,2.083 0.156,0.198 10 true 7 0.979,1.781 1.135,1.979 0.156,0.198 10 true 8

Install the No. 1 ventilation case to the cylinder block sub-assembly with the 8 bolts in the order shown in the illustration.

Torque:

21 N*m (214 kgf*cm, 15 ft.*lbf)