Disassembly

1UR-FSE ENGINE MECHANICAL: CYLINDER BLOCK: DISASSEMBLY

1. INSPECT CONNECTING ROD THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

Standard thrust clearance:

0.15 to 0.55 mm (0.0059 to 0.0217 in.)

Maximum thrust clearance:

0.70 mm (0.0276 in.)

(a) If the thrust clearance is greater than the maximum, replace one or more connecting rods as necessary.

If necessary, replace the crankshaft.

2. INSPECT CONNECTING ROD OIL CLEARANCE

(a) Check that the front marks on the connecting rod and cap are aligned to ensure correct reassembly.

(b) Remove the 2 connecting rod cap bolts.

(c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

HINT
Keep the lower bearing inserted to the connecting rod cap.

(d) Clean the crank pin and bearing.

NOTICE:
Check the crank pin and bearing for pitting and scratches.

(e) Lay a strip of Plastigage on the crank pin.

(f) Check that the front mark of the connecting rod cap is facing forward.

(g) Install and alternately tighten the bolts of the connecting rod cap in several steps.

Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)

NOTICE:
Do not turn the crankshaft.

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

(i) Retighten the cap bolts 90° as shown.

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

NOTICE:
Do not turn the crankshaft.

(k) Remove the 2 connecting rod cap bolts.

(l) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

HINT
Keep the lower bearing inserted to the connecting rod cap.

(m) Measure the Plastigage at its widest point.

Standard oil clearance:

0.025 to 0.050 mm (0.0010 to 0.0020 in.)

Maximum oil clearance:

0.070 mm (0.0028 in.)

(m) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

HINT
* If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, 3 or 4 mark on its surface.
* Select the correct bearing by adding together the number marks imprinted on the connecting rod big end and crank pin.
* Example:
* Connecting rod "1" + Crank pin "2" = 3 (Use bearing "3")
* Reference:

Standard sized bearing center wall thickness:

Connecting rod big end inside diameter:

Crankshaft pin diameter:

(n) Completely remove the Plastigage.

(o) Perform the inspection above for each cylinder.

3. REMOVE PISTON AND CONNECTING ROD

(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.

(b) Remove the 16 cap bolts and 8 connecting rod caps.

(c) Push the 8 pistons, 8 connecting rods and 8 upper bearings through the top of the cylinder block.

HINT
* Keep each bearing, connecting rod and cap together.
* Arrange the piston and connecting rod in the correct order.
4. REMOVE CONNECTING ROD BEARING

(a) Remove the connecting rod bearings from the connecting rods and connecting rod caps.

HINT
Arrange the removed parts in the correct order.

5. INSPECT CRANKSHAFT THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

Standard thrust clearance:

0.020 to 0.220 mm (0.0008 to 0.0087 in.)

Maximum thrust clearance:

0.30 mm (0.0118 in.)

(a) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft.

Standard thrust washer thickness:

2.44 to 2.49 mm (0.0961 to 0.0980 in.)

6. REMOVE CRANKSHAFT

(a) Uniformly loosen and remove the 10 bearing cap bolts and 10 seal washers in several steps, in the sequence shown the illustration.

(b) Uniformly loosen the 20 bearing cap bolts in several steps, in the sequence shown in the illustration.

HINT
Tape the screwdriver tip before use.

NOTICE:
* Pry up the main beaning caps little by little to the right and left in turns.
* Be careful not to damage the joint surface of the cylinder block and main bearing caps.
(d) Remove the crankshaft.

7. REMOVE CRANKSHAFT BEARING

(a) Remove the crankshaft bearings from the bearing caps and cylinder block.

HINT
Arrange the removed parts in the correct order.

8. REMOVE CRANKSHAFT THRUST WASHER SET

(a) Remove the thrust washer set from the cylinder block and No. 3 bearing cap.

9. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, remove the 4 bolts and 4 oil nozzles.

10. REMOVE PISTON RING SET

HINT
Arrange the piston rings in the correct order.

(a) Using a piston ring expander, remove the 2 compression rings.

(b) Using a piston ring expander, remove the oil ring.

(c) Remove the oil ring expander by hand.

11. REMOVE PISTON WITH PIN SUB-ASSEMBLY

(a) Disconnect the connecting rod from the piston.

(1) Using a screwdriver, pry off the snap rings from the piston.

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

(3) Using a brass bar and plastic-faced hammer, lightly tap out the piston pin and remove the connecting rod.

HINT
* The piston and pin are a matched set.
* Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
(b) Clean the piston.

(1) Using a gasket scraper, remove the carbon from the piston top.

(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.

(3) Using solvent and a brush, thoroughly clean the piston.

NOTICE:
Do not use a wire brush.