Cylinder Block Reassembly

Using a plastic hammer, tap in the ring pins.

Standard Protrusion:

Item	Protrusion
A	6 mm (0.236 in.)
B	5 mm (0.197 in.)

Install the stud bolts as shown in the illustration.

Torque:

Stud Bolt A:

22 N*m{220 kgf*cm, 16 ft.*lbf}

Stud Bolt B:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Stud Bolt C:

9.5 N*m{97 kgf*cm, 84 in.*lbf}

Stud Bolt D:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Using a plastic hammer, tap in the straight pins.

Standard Protrusion:

Item	Protrusion
A	8 mm (0.315 in.)
B	7.5 mm (0.295 in.)
C	12 mm (0.472 in.)
D	5 mm (0.197 in.)

Check the crank journal and bearing for pitting and scratches.

Install the crankshaft bearing (COROLLA_ZRE142 RM00000224E012X.html).

Place the crankshaft on the cylinder block.

Lay a strip of Plastigage across each journal.

Examine the front marks and numbers and install the bearing caps on the cylinder block.

HINT:

A number is marked on each main bearing cap to indicate the installation position.

Install the main bearing caps (COROLLA_ZRE142 RM00000224E012X.html).

NOTICE:

Do not turn the crankshaft.

Remove the main bearing caps (COROLLA_ZRE142 RM00000224D012X_01_0009.html).

Measure the Plastigage at its widest point.

Standard oil clearance:

0.017 to 0.040 mm (0.000669 to 0.00157 in.)

Maximum oil clearance:

0.060 mm (0.00236 in.)

NOTICE:

Remove the Plastigage completely after the measurement.

HINT:

1. If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft. Then select a new bearing with the calculated number. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.
   
2. EXAMPLE: Cylinder block "3" + Crankshaft "5" = Total number 8 (Use bearing "3")
   

Standard Cylinder Block Journal Bore Diameter:

Mark	Specified Condition
0	59.000 to 59.002 mm (2.32283 to 2.32291 in.)
1	59.003 to 59.004 mm (2.32295 to 2.32299 in.)
2	59.005 to 59.006 mm (2.32303 to 2.32307 in.)
3	59.007 to 59.009 mm (2.32311 to 2.32318 in.)
4	59.010 to 59.011 mm (2.32322 to 2.32326 in.)
5	59.012 to 59.013 mm (2.32330 to 2.32334 in.)
6	59.014 to 59.016 mm (2.32338 to 2.32346 in.)

Standard Crankshaft Journal Diameter:

Mark	Specified Condition
0	54.999 to 55.000 mm (2.16531 to 2.16535 in.)
1	54.997 to 54.998 mm (2.16523 to 2.16527 in.)
2	54.995 to 54.996 mm (2.16515 to 2.16519 in.)
3	54.993 to 54.994 mm (2.16507 to 2.16511 in.)
4	54.991 to 54.992 mm (2.16500 to 2.16504 in.)
5	54.988 to 54.990 mm (2.16488 to 2.16496 in.)

Standard Bearing Center Wall Thickness:

Mark	Specified Condition
1	1.993 to 1.996 mm (0.078464 to 0.078583 in.)
2	1.997 to 1.999 mm (0.078622 to 0.078701 in.)
3	2.000 to 2.002 mm (0.078740 to 0.078819 in.)
4	2.003 to 2.005 mm (0.078858 to 0.078937 in.)

Using a 5 mm hexagon wrench, install the oil nozzles with the bolts.

Torque:

7.0 N*m{71 kgf*cm, 62 in.*lbf}

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

HINT:

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

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

Align the front marks on the piston and connecting rod, and push in the piston with a thumb.

Using a screwdriver, install a new snap ring on the other end of the piston pin hole.

HINT:

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

Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

Install the oil ring expander and oil ring rail by hand.

NOTICE:

1. Install the expander and oil ring so that their ring ends are at opposite sides.
   
2. Securely install the expander into the inner groove of the oil ring.
   

Using a piston ring expander, install the 2 compression rings so that the paint marks are positioned as shown in the illustration.

NOTICE:

Install compression ring No. 2 with the code mark (2N or 2A) facing upward.

HINT:

Supply part compression springs (No. 1 and No. 2) do not have paint marks.

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

Install the upper bearing with an oil groove on the cylinder block.

NOTICE:

Do not apply engine oil to the bearing inner surface or bearing cap contact surfaces.

Install the No. 2 crankshaft bearing on the bearing cap.

NOTICE:

Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oils.

Install the 2 thrust washers under the No. 3 journal of the cylinder block with the oil grooves facing outward.

NOTICE:

Make sure to install the proper thrust washers.

Apply engine oil to the crankshaft thrust washers.

Apply engine oil to the upper bearings and place the crankshaft on the cylinder block.

Apply engine oil to the lower bearings.

Examine the front marks and install the bearing caps on the cylinder block.

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

Install the crankshaft bearing cap bolts.

NOTICE:

The main bearing cap bolts are tightened in 2 progressive steps.

Step 1

1. Install and uniformly tighten the 10 main bearing cap bolts in the sequence shown in the illustration.
   

   Torque:

   20 N*m{204 kgf*cm, 15 ft.*lbf}





2. Further tighten the 10 main bearing cap bolts in the sequence shown in the illustration.
   

   Torque:

   40 N*m{408 kgf*cm, 30 ft.*lbf}

Step 2

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

2. Further tighten the bearing cap bolts 90° in the numerical order shown in the illustration.
   

Check that the paint mark is now at a 90° angle to the front.

Check that the crankshaft turns smoothly.

Check the crankshaft thrust clearance (COROLLA_ZRE142 RM0000026TQ03AX_01_0045.html).

Align the bearing claw with the groove on the connecting rod or connecting cap.

NOTICE:

Do not apply engine oil to the bearing inner surface or connecting rod contact surface.

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

Check the position of the piston ring ends.

Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.

NOTICE:

Match the numbered connecting rod cap with the connecting rod.

Check that the protrusion on the connecting rod cap is facing in the correct direction.

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

Install the connecting cap bolts.

NOTICE:

The connecting cap bolts should be tightened in 2 progressive steps.

Step 1

1. Install and alternately tighten the bolts of the connecting rod cap in several steps.
   

   Torque:

   25 N*m{250 kgf*cm, 18 ft.*lbf}

Step 2

1. Mark the front of the connecting rod cap bolts with paint.
   

2. Further tighten the cap bolts 90° as shown in the illustration.
   

Check that the crankshaft turns smoothly.

Check the connecting rod thrust clearance (COROLLA_ZRE142 RM0000026TQ03AX_01_0043.html).