Lexus NX: Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

HINT:

Perform "Inspection After Repairs" after replacing the piston or piston ring.

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PROCEDURE

1. INSTALL STUD BOLT

NOTICE:

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

(a) Using an E8 "TORX" socket wrench, install the stud bolts. Torque: 9.0 N·m {92 kgf·cm, 80 in·lbf}

*a 20 mm (0.787 in.) *b 13 mm (0.512 in.) *c 35 mm (1.38 in.)

2. INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, install the 4 No. 2 oil nozzle sub-assemblies 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 No. 1 oil nozzle sub-assemblies with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

4. INSTALL PISTON

HINT:

Perform "Inspection After Repairs" after replacing the piston.

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(a) Using a small screwdriver, install a new piston pin hole 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 piston pin hole snap ring. HINT: The piston and piston pin are a matched set.

*a Front Mark

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

*a Service Hole Cutout Portion

(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 piston 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.

5. INSTALL PISTON RING SET

HINT:

Perform "Inspection After Repairs" after replacing the piston ring.

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(a) Install the oil ring expander and 2 oil ring side rails by hand.

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

(b) Using a piston ring expander, install the 2 compression rings 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 (1NA)
*c	Code Mark (2N)
*d	Paint Mark
	Upward

NOTICE:

Install the compression ring with the code mark facing upward.

6. INSTALL CRANKSHAFT PULLEY SET KEY

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

7. INSTALL CRANKSHAFT BEARING

(a) Clean the main journal and both surfaces of the bearing.

*a CORRECT *b INCORRECT

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

HINT:

The colors of the crankshat bearing and No. 2 crankshaft bearing differ depending on the installation position.

(c) Install the No. 2 crankshaft bearing to the crankshaft bearing cap.

*a Vernier Caliper

(d) Using a vernier caliper, measure the distance between the edges of the crankshaft bearing cap and No. 2 crankshaft bearing.

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.

*a Oil Groove

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

9. INSTALL CRANKSHAFT

(a) Apply engine oil to the crankshaft bearing, and then install the crankshaft to the cylinder block.

*a Front Mark

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

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

(d) Tighten the crankshaft bearing cap set bolts.

HINT:

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

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

(2) Step 2:

Tighten the 10 crankshaft bearing cap set bolts again in the sequence shown in the illustration.

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

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

(3) Mark the front side of each crankshaft bearing cap set bolt with paint.

(4) Step 3:

Tighten the 10 crankshaft bearing cap set bolts 90° in the order shown in step 1.

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

(e) Check that the crankshaft turns smoothly.

10. INSTALL CONNECTING ROD BEARING

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

*a Vernier Caliper

(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 connecting rod cap and connecting rod bearing.

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.

(b) Position the piston rings so that the ring ends are as shown in the illustration. HINT: The oil ring expander can be installed with the ring ends in either of the directions shown in the illustration.

*1 No. 1 Compression Ring *2 No. 2 Compression Ring *3 Oil Ring Expander *4 Upper Oil Ring Side Rail *5 Lower Oil Ring Side Rail

(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. 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 "2H" printed in raised letters.

*a Front Mark

(d) Check that the front mark of the connecting rod cap is facing in the correct direction. NOTICE: Match the numbered connecting rod cap with the correct connecting rod.

*a Front Mark

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

(f) Install the connecting rod bolts.

HINT:

The connecting rod bolts are tightened in 2 progressive steps.

(1) Step 1:

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

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

(2) Mark the front side of each connecting rod cap bolt with paint.

(3) Step 2:

Tighten the cap bolts 90°.

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

(g) Check that the crankshaft turns smoothly.

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