Lexus ES: Reassembly

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / A25a-fks (engine Mechanical) / Cylinder Block / Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, install the 4 No. 2 oil nozzle sub-assemblies to the cylinder block sub-assembly with the 4 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon 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}

3. INSTALL PISTON

HINT:

Perform "Inspection After Repair" after replacing the piston.

Click here

(a) Using a screwdriver, install a new piston pin hole snap ring to the piston pin hole on the rear side of the piston.

HINT:

Tape the screwdriver tip before use.

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

CAUTION:

Be sure to wear protective gloves.

(d) Align the cutout of the piston and front mark of the 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 piston pin hole snap ring.

NOTICE:

Do not change the combination of the pistons and piston pins.

*a	Cutout
*b	Front Mark

(e) Using a screwdriver, install a new piston pin hole snap ring to the piston pin hole on the front side of the piston.

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

*1	Piston Pin Hole Snap Ring
*a	Cutout
*b	Protective Tape

(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.

HINT:

If abnormal movement is felt, replace the piston and piston pin as a set.

(2) Rotate the piston back and forth on the piston pin. Check the fitting condition.

HINT:

If abnormal movement is felt, replace the piston and piston pin as a set.

4. INSTALL PISTON RING SET

HINT:

Perform "Inspection After Repair" after replacing the piston and piston ring.

Click here

(a) Install the oil ring expander by hand.

*1	Upper Side Rail
*2	Oil Ring Expander
*3	Lower Side Rail

(b) Install the upper side rail and lower side rail to the piston.

*1	Upper Side Rail
*2	Lower Side Rail
*a	Paint (Orange)
*b	Paint (Light Blue)
	Upper Side

NOTICE:

Make sure to install the upper side rail and lower side rail in the correct direction. Also, when installing the upper side rail and lower side rail, the oil ring expander may move and overlap. If this occurs, part of the side rail may greatly protrude.

(c) 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.

*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.

(d) 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	Code Mark
*b	Paint Mark
	Upward

Piston Ring Mark:

Item	Code Mark	Paint Mark
No. 1 Compression Ring	1N	Orange
No. 2 Compression Ring	2N	Pink

NOTICE:

Install the compression rings with the code marks facing upward.

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

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

5. INSTALL CRANKSHAFT BEARING

(a) Clean the main journal and both surfaces of the crankshaft bearings and No. 2 crankshaft bearings.

(b) Install the 5 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.

HINT:

Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the crankshaft bearing. The amount visible on each side of the holes should be equal.
The color of the No. 1, No. 3 and No. 5 journal bearings are different from that of the No. 2 and No. 4 journal bearings. Be sure to check the color before installation. Crankshaft Bearing Color:

Journal Position

Crankshaft Bearing Color

No. 1

Gray

No. 2

Silver

No. 3

Gray

No. 4

Silver

No. 5

Gray

*a	Correct
*b	Incorrect

(c) Using a vernier caliper, measure the distance between the cylinder block sub-assembly edge and the crankshaft bearing edge.

Difference between (A) and (B):

0 to 0.7 mm (0 to 0.0276 in.)

*a	Vernier Caliper

(d) Install the 5 No. 2 crankshaft bearings to the 5 crankshaft bearing caps as shown in the illustration.

NOTICE:

Do not apply engine oil to the No. 2 crankshaft bearings or the contact surfaces.

HINT:

The color of the No. 1, No. 3 and No. 5 journal bearings are different from that of the No. 2 and No. 4 journal bearings. Be sure to check the color before installation.

No. 2 Crankshaft Bearing Color:

Journal Position	No. 2 Crankshaft Bearing Color
No. 1	Gray
No. 2	Silver
No. 3	Gray
No. 4	Silver
No. 5	Gray

*a	Vernier Caliper

(e) Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and No. 2 crankshaft bearing edge.

Difference between (A) and (B):

0 to 0.9 mm (0 to 0.0354 in.)

6. INSTALL CRANKSHAFT THRUST WASHER

(a) Apply engine oil to the crankshaft bearings, and place the crankshaft on the cylinder block sub-assembly.

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

*a	Oil Groove

7. INSTALL CRANKSHAFT

(a) Apply engine oil to the No. 2 crankshaft bearings.

(b) Confirm the front marks and numbers, and install the 5 crankshaft bearing caps to the cylinder block sub-assembly with the front marks positioned as shown in the illustration.

*a	Front Mark

(d) Using a plastic hammer, lightly tap the crankshaft bearing caps to ensure a proper fit.

(e) Install the crankshaft bearing cap set bolts.

NOTICE:

The crankshaft bearing cap set bolts are tightened in 2 progressive steps.

(f) Step 1:

(1) Uniformly install and tighten the 10 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.

Torque:

61 N·m {622 kgf·cm, 45 ft·lbf}

HINT:

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

(g) Step 2:

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

*a	Paint Mark
*b	90°
	Front of Engine

(2) Tighten the 10 crankshaft bearing cap set bolts 90° as shown in the illustration.

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

(h) Check that the crankshaft turns smoothly.

8. INSTALL CONNECTING ROD BEARING

(a) Clean the connecting rod bearing contact surfaces of the connecting rod and connecting rod cap, and both surfaces of the 2 connecting rod bearings.

*a	Vernier Caliper

(b) Install the 8 connecting rod bearings to the 4 connecting rods and 4 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 connecting rod cap and connecting rod bearing.

Difference between (A) and (B):

0 to 0.7 mm (0 to 0.0276 in.)

NOTICE:

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

9. INSTALL PISTON WITH CONNECTING ROD

(a) Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.

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

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

(c) 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.

*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.

(d) Using a piston ring compressor, push the correctly numbered piston with connecting rod into the cylinder with the front marks of each piston with connecting rod facing the front of the engine.

NOTICE:

When inserting the piston with connecting rod into the cylinder block sub-assembly, make sure the connecting rod does not contact the No. 1 oil nozzle sub-assembly or No. 2 oil nozzle sub-assembly.
Match each connecting rod cap to the correct connecting rod.

*a	Front Mark

(e) Check that the front mark of the connecting rod cap is facing the correct direction.

*a	Front Mark

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

(g) Install the 8 connecting rod bolts.

NOTICE:

The connecting rod bolts are tightened in 2 progressive steps.

(h) Step 1:

(1) Using an E12 "TORX" socket wrench, alternately tighten the 2 connecting rod bolts in several steps.

Torque:

38 N·m {387 kgf·cm, 28 ft·lbf}

(i) Step 2:

*a	Paint Mark
*b	90°
	Front of Engine

(1) Mark the front of the connecting rod bolts with paint.

(2) Tighten the connecting rod bolts 90° as shown in the illustration.

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

(j) Check that the crankshaft turns smoothly.

(k) Check the connecting rod thrust clearance.

Click here

10. INSTALL CYLINDER BLOCK WITH HEAD STRAIGHT SCREW PLUG

(a) Using a 10 mm hexagon socket wrench, install the cylinder block with head straight screw plug and a new gasket to the cylinder block sub-assembly.

Torque:

44 N·m {449 kgf·cm, 32 ft·lbf}

11. INSTALL NO. 1 VENTILATION CASE

CAUTION:

Do not disassembly except if the No. 1 ventilation case to be damaged.

(a) Install 3 new oil separator gaskets to the No. 1 ventilation case.

(b) Install the No. 1 ventilation case to the cylinder block sub-assembly with the 4 bolts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

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Lexus ES: Reassembly

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