Disassembly

1GR-FE 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 0.30 mm (0.00591 to 0.0118 in.)

Maximum thrust clearance:

0.35 mm (0.0138 in.)

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

Standard connecting rod thickness:

20.80 to 20.85 mm (0.819 to 0.821 in.)

If necessary, replace the crankshaft.

2. INSPECT CONNECTING ROD OIL CLEARANCE

Check the matchmarks on the connecting rod and cap to ensure correct reassembly.

(a) Remove the 2 connecting rod cap bolts.

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 and connecting rod cap together.

(b) Clean the crank pin and bearing.

(c) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.

(d) Lay a strip of Plastigage across the crank pin.

Text in Illustration

(e) Install the connecting rod cap Reassembly.

NOTICE:
Do not turn the crankshaft.

(f) Remove the 2 bolts, connecting rod cap and lower bearing.

(g) Measure the Plastigage at its widest point.

Standard oil clearance:

0.040 to 0.066 mm (0.00157 to 0.00260 in.)

Maximum oil clearance:

0.086 mm (0.00339 in.)

Text in Illustration

If the oil clearance is more than the maximum, replace the bearings. If necessary, inspect the crankshaft.

HINT

If replacing a bearing, replace it with one that has the same number as the number marked on the connecting rod. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.

Connecting Rod Diameter:

Standard Bearing Center Wall Thickness:

Standard crankshaft pin diameter:

55.992 to 56.000 mm (2.2044 to 2.2047 in.)

Text in Illustration

(h) Completely remove the Plastigage.

3. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD

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

(b) Push out the piston with connecting rod and upper bearing through the top of the cylinder block.

HINT
* Keep the bearings, connecting rod and cap together.
* Arrange the piston and connecting rod assemblies 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. REMOVE PISTON RING SET

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

(b) Remove the 2 side rails and oil ring (expander) by hand.

6. REMOVE PISTON WITH PIN SUB-ASSEMBLY

(a) Disconnect the connecting rod from the piston.

Using a screwdriver, pry out the 2 snap rings.

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

Using a plastic-faced hammer and brass bar, 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.

7. 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:

0.04 to 0.24 mm (0.00157 to 0.00945 in.)

Maximum thrust clearance:

0.30 mm (0.0118 in.)

If the thrust clearance is more than the maximum, replace the thrust washers as a set.

Standard thrust washer thickness:

1.93 to 1.98 mm (0.0760 to 0.0780 in.)

If necessary, replace the crankshaft.

8. INSPECT CRANKSHAFT OIL CLEARANCE

(a) Uniformly loosen and remove the 8 bearing cap bolts and 8 seal washers in several steps in the sequence shown in the illustration.

(b) Uniformly loosen and remove the 16 bearing cap bolts in several steps in the sequence shown in the illustration.

NOTICE:
* Push up on the cap little by little, alternating between the right and left side until the cap can be removed.
* Be careful not to damage the joint surfaces of the cylinder block or bearing cap.

(d) Remove the 2 lower crankshaft thrust washers.

HINT
* Keep the lower bearing and crankshaft bearing cap together.
* Arrange the removed parts in the correct order.
* Be sure to arrange the bearing caps and lower thrust washers in such a way that they can be reinstalled exactly as before.

(e) Lift out the crankshaft.

Remove the 2 upper thrust washers.

HINT
* Be sure to arrange the removed upper thrust washers in such a way that they can be reinstalled exactly as before.
* Keep the upper bearings together with the cylinder block.

(f) Clean each crankshaft journal and bearing.

(g) Check each crankshaft journal and bearing for pitting and scratches.

If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.

(h) Place the crankshaft on the cylinder block.

Lay a strip of Plastigage across each journal.

Text in Illustration

(i) Install the crankshaft bearing cap Reassembly.

NOTICE:
Do not turn the crankshaft.

(j) Remove the crankshaft bearing cap.

(k) Measure the Plastigage at its widest point.

Standard oil clearance:

0.026 to 0.046 mm (0.00102 to 0.00181 in.)

Maximum clearance:

0.080 mm (0.00315 in.)

If the oil clearance is more than the maximum, replace the bearings. If necessary, replace the crankshaft.

(l) If replacing a bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, and then refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

New Bearing:

Text in Illustration

EXAMPLE:

Cylinder block "11" (A) + Crankshaft "06" (B) = Total number 17 (Use bearing "3")

Cylinder Block Main Journal Bore Diameter (A):

Crankshaft Main Journal Diameter (B):

Standard Bearing Center Wall Thickness:

(m) Completely remove the Plastigage.

9. REMOVE CRANKSHAFT

(a) Lift out the crankshaft.

(b) Remove the 2 upper thrust washers.

10. REMOVE CRANKSHAFT BEARING

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

HINT
Arrange the removed parts in the correct order.

11. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon socket wrench, remove the 3 bolts and 3 oil nozzles.

12. REMOVE STUD BOLT

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