Cylinder Block: Reassembly

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.
  NOTE: Apply a generous amount of oil on the sliding surface of the bearing, and not on the back of it or on the surface to which it is installed.

1. ASSEMBLE PISTON AND CONNECTING ROD 
   1. Using a small screwdriver, install a new snap ring on one side of the piston pin hole.

      HINT:

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

   2. Gradually heat the piston to about 80°C (176°F).
      Fig 1: Installing Snap Ring To Piston Pin Hole

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Coat the piston pin with engine oil.
   4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
      Fig 2: Aligning Front Marks Of Piston And Connecting Rod

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Install a new snap ring at the other end of the piston pin hole.

      HINT:

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

2. INSTALL PISTON RINGS 
   1. Install the oil ring expander and 2 side rails by hand.
   2. Using a piston ring expander, install the 2 compression rings with the code mark facing up.
      Fig 3: Installing Piston Rings With Code Marks Facing Up

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Code mark: 

      Fig 4: Piston Rings Code Mark Chart

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Position the piston rings so that the ring ends are as shown in Fig 5.
      NOTE: Do not align the piston ring ends.
   Fig 5: Identifying Positions Of Piston Ring Ends

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. INSTALL BEARINGS 
   1. Align the bearing claw with the groove of the connecting rod and connecting cap.
      Fig 6: Aligning Bearing Claw With Groove

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Install the bearings in the connecting rod and connecting rod cap.
4. INSTALL MAIN BEARINGS 

   HINT:

   • Main bearings come in widths of 20.0 mm (0.787 in.) and 23.0 mm (0.906 in.). Install the 23.0 mm bearings in the No.1 cylinder block journal position with the main bearing cap. Install the 20.0 mm bearings in the other positions.
   • Upper bearings have an oil groove and oil holes; lower bearings do not.
     Fig 7: Installing Main Bearings

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Align the bearing claw with the claw groove of the main bearing cap or cylinder block.
      NOTE: Install the bearing with the oil hole in the cylinder block.