- Lubricate the cylinder bore.
- Lay out all connecting rods by cylinder numbers. The "VORN" mark on the connecting rod and on the piston crown should be directed towards the engine pulleys.
- Distribute the piston ring joints around the piston circumference as shown in Figure 315. Position the three-piece oil scraper ring so that the locks are not located opposite each other.
Fig. 315. Location of piston ring locks around the piston circumference.1. Upper compression ring; 2. Lower side ring of the oil scraper ring; 3. Upper side ring of the oil scraper ring; 4. Middle compression ring.
- Apply piston ring tightening tape to the piston ring installation area and press the rings into the grooves. Check that they are properly seated.
- Place short pieces of rubber or plastic hose on the connecting rod studs to avoid scratching the cylinder bore. The nuts must be replaced, as once installed, the nuts lose their fastening ability.
- Turn the crankshaft until both journals are at bottom dead center.
- Push the connecting rod into the hole from above. To do this, place the engine on its side so that the connecting rod can be guided along the bearing journals and does not scratch the cylinder bore or the connecting rod journal. The connecting rod bearing shells should already be in the connecting rod, with their noses in the cutout.
- When pulling out, check again that the "VORN" marks are positioned correctly relative to each other.
- Push the piston forward until the piston rings are consistently inserted into the cylinder and the connecting rod leg is seated on the shaft journal.
- Place the second bearing shell into the bearing cap, lubricate the shell. Put the cap on the connecting rod studs and tap it lightly. The pieces of rubber hose must be removed beforehand.
- Lubricate the surfaces of the nuts on the connecting rod bearing caps.
- Tighten the new brown nuts alternately to a torque of 65 Nm.
- After installing the connecting rod, turn the crankshaft several times to immediately detect jamming.
- Turn the crankshaft so that the other two journals are positioned at the bottom and install the remaining pistons and connecting rods in the same way.
- Check the position of all markings again and check that the pistons are installed correctly.
- Install a dial indicator on the cylinder block as shown in Figure 21 and measure the clearance between the side surfaces of the connecting rod and crankshaft by moving the connecting rod bearing by hand along the shaft journal in both directions. The axial clearance of the connecting rod bearing should not exceed 0.40 mm.
- To complete the assembly, install the oil pump, gears, front cover and oil pan.
(The original can be read on the website: «ToyotaMAN»)