Toyota Venza: Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

HINT:

Perform "Inspection After Repair" after replacing the piston or piston ring (See page ).

PROCEDURE

1. INSTALL STUD BOLT

NOTICE:

If a stud bolt is deformed or the threads are damaged, replace it.

(a) Using an E8 and E10 "TORX" socket wrenches, install the stud bolts.

Torque:

for stud bolt A :

6.5 N·m {66 kgf·cm, 58 in·lbf}

for stud bolt B :

21 N·m {214 kgf·cm, 15 ft·lbf}

2. INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, install the 4 oil nozzles with the 4 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, install the 2 oil nozzles with the 2 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

4. INSTALL PISTON

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

(b) Gradually heat the piston up to 80 to 90°C (176 to 194°F).

(c) Coat the piston, piston pin and connecting rod with engine oil.

(d) 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 pin comes into contact with the snap ring. Text in Illustration *1 Front Mark HINT: The piston and pin are a matched set.

(e) Using a small screwdriver, install a new snap ring on the other side of the piston pin hole. Text in Illustration *1 Service Hole HINT: Be sure that the end gap of the snap ring is not aligned with the service hole cutout portion of the piston.

(f) Check the fitting condition between the piston and piston pin. (1) Move the connecting rod back and forth on the piston pin. Check the fitting condition. If abnormal movement is felt, replace the piston and pin as a set. (2) Rotate the piston back and forth on the piston pin. Check the fitting condition. If abnormal movement is felt, replace the piston and pin as a set. HINT: Perform "Inspection After Repair" after replacing the piston (See page ).

5. INSTALL PISTON RING SET

(a) Install the oil ring expander and oil ring by hand. Text in Illustration *1 Oil Ring *2 Oil Ring Expander *3 Coil Joint *4 Oil Ring End HINT: Arrange the oil ring ends and coil joint as shown in the illustration.

(b) Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring with the code mark positioned as shown in the illustration.

*1	No. 1 Compression Ring
*2	No. 2 Compression Ring
*a	Piston Ring Expander
*b	Code Mark (N1)
*c	Code Mark (N2)
*d	Paint Mark
	Upward

Piston Ring Mark:

NOTICE:

Install the compression ring with the code mark facing upward.

HINT:

Perform "Inspection After Repair" after replacing the piston, piston ring (See page ).

6. INSTALL CRANKSHAFT PULLEY KEY

(a) Install the 2 crankshaft pulley keys to the crankshaft.

7. INSTALL CRANKSHAFT BEARING

(a) Clean the main journal and both surfaces of the bearing. Text in Illustration *1 CORRECT *2 INCORRECT

(b) Install the upper bearing to the cylinder block as shown in the illustration.

(c) Install the lower bearing onto the bearing cap.

(d) Using a vernier caliper, measure the distance between the crankshaft bearing cap's edge and the lower bearing's edge.

Standard dimension A - B or B - A:

0 to 0.7 mm (0 to 0.0276 in.)

8. INSTALL CRANKSHAFT THRUST WASHER

(a) Apply engine oil to the thrust washers. Text in Illustration *1 Oil Groove

(b) Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward.

9. INSTALL CRANKSHAFT

(a) Apply engine oil to the upper bearing, and install the crankshaft onto the cylinder block. Text in Illustration *1 Front Mark

(b) Examine the front marks and numbers, and install the bearing caps onto the cylinder block with the front marks as shown in the illustration.

HINT:

The crankshaft bearing cap bolts are tightened in 3 progressive steps.

(c) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(d) Step 1:

(1) Using several steps, uniformly install and tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 20 N·m {204 kgf·cm, 15 ft·lbf}

(e) Step 2:

(1) Tighten the 10 bearing cap bolts again in the sequence shown in the illustration.

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

If a crankshaft bearing cap bolt does not meet the specified torque, replace it.

(f) Step 3:

(1) Mark the front of the bearing cap bolts with paint.

(2) Tighten the 10 bearing cap bolts 90° in the same sequence.

(3) Check that the paint marks are now at a 90° angle to the front.

(g) Check that the crankshaft turns smoothly.

10. INSTALL CONNECTING ROD BEARING

(a) Clean the bearing contact surface of the connecting rod and cap, and both surfaces of both bearings.

(b) Install the connecting rod bearings to the connecting rods and connecting rod caps.

(c) Using a vernier caliper, measure the distance between the edges of the connecting rod and connecting rod bearing, and the edges of the bearing cap and connecting rod bearing.

Standard dimension A - B or B - A:

0 to 0.7 mm (0 to 0.0276 in.)

11. INSTALL PISTON WITH CONNECTING ROD

(a) Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings. Text in Illustration *1 Front Mark *2 No. 1 Compression Ring *3 No. 2 Compression Ring *4 Oil Ring Rail *5 Oil Ring Expander *6 Front

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

(c) Using a hammer handle and piston ring compressor, press a piston with connecting rod into each cylinder with the front mark of the piston facing forward. Text in Illustration *1 Front Mark NOTICE: When inserting the piston with connecting rod into the cylinder block, make sure the oil nozzle does not interfere with the connecting rod. HINT: The front mark is "1L" printed in raised letters.

(d) Check that the front mark of the connecting rod cap is facing in the correct direction. Text in Illustration *1 Front Mark NOTICE: Match the numbered connecting rod cap with the connecting rod.

(e) Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.

(f) Temporarily install the connecting rod bolts.

HINT:

The connecting rod bolts are tightened in 2 progressive steps.

(g) Step 1:

(1) Alternately tighten the connecting rod bolts in several steps.

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

(h) Step 2: (1) Mark the front of the connecting rod bolts with paint. (2) Tighten the bolts 90° as shown in the illustration. (3) Check that the paint marks are now at a 90° angle to the front.

(i) Check that the crankshaft turns smoothly.