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EM-112
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
EM1XZ-01

DISASSEMBLY
1. REMOVE WATER OUTLET PIPE NO.1
(a) Separate the knock sensor wire.
(b) Remove the 3 bolts and water outlet pipe.

A22979

2. REMOVE KNOCK SENSOR
(a) Disconnect the knock sensor connectors.
(b) Remove the 2 bolts and 2 knock sensors.
3. REMOVE WATER DRAIN COCK

A22980

4. REMOVE ENGINE REAR OIL SEAL RETAINER
Pry (a) Remove the 5 bolts and 2 nuts.
(b) Using a screwdriver, remove the oil seal retainer by prying
between the oil seal retainer and crankshaft bearing cap.

A22981

5. INSPECT CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back and forth.
Standard thrust clearance:
0.15 to 0.30 mm (0.0059 to 0.0118 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
6. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check that the matchmarks on the connecting rod and
A23021 cap are aligned to ensure correct reassembling.
(b) Using SST, remove the 2 connecting rod cap bolts.
SST 09011-38121
(c) Clean the crank pin, bearing and connecting rod.
(d) Check the crank pin and bearing for pits and scratches.
EM-113
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK

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

A23022

(f) Check that the protrusion of the connecting rod cap is fac-
ing the correct direction.
(g) Apply a light coat of engine oil to the threads of the con-
necting rod cap bolts.

Protrusion

A23023

(h) Using SST, tighten the bolts alternately to the specified
torque.
SST 09011-38121
Torque: 25 Nm (250 kgfcm, 18 ftlbf)

A23024

Painted Mark (i) Mark the front side of each connecting cap bolt with paint.
90_ (j) Retighten the cap bolts 90_ as shown in the illustration.
NOTICE:
Front 90_ Do not turn the crankshaft.
(k) Remove the 2 bolts, connecting rod cap and lower bear-
ing.

A23025

(l) Measure the Plastigage at its widest point.
Standard oil clearance:
0.026 to 0.046 mm (0.0010 to 0.0018 in.)
Maximum oil clearance: 0.066 mm (0.0025 in.)
NOTICE:
Completely remove the Plastigage.

A23026
EM-114
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK

Number Mark (m) If replacing a bearing, replace it with one that has the
Number Mark
same number marked on the connecting rod. There are
4 sizes of standard bearings, marked "1 ", "2", "3" and "4"
accordingly.
HINT:
Standard bearing center wall thickness
Mark mm (in.)
"1" 1.484 to 1.487 (0.0584 to 0.0585)
A23027 "2" 1.487 to 1.490 (0.0585 to 0.0587)
"3" 1.490 to 1.493 (0.0587 to 0.0588)
"4" 1.493 to 1.496 (0.0588 to 0.0589)

7. REMOVE PISTON W/CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push in the piston w/ connecting rod and upper bearing
through the top of the cylinder block.
HINT:
S Keep the bearings, connecting rod and cap together.
S Arrange the piston and connecting rod assemblies in the
A23028 correct order.
8. REMOVE CONNECTING ROD BEARING
9. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.

A23029

10. REMOVE PISTON PIN HOLE SNAP RING
Using a screwdriver, pry out the 2 snap rings.

A23030
EM-115
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK

11. REMOVE PISTON PIN
80_C
(a) Gradually heat the piston to approx. 80_C (176_F).

A23031

(b) Using a plastic-faced hammer and brass bar, lightly tap
out the piston pin and remove the connecting rod.
HINT:
S The piston and pin are a matched set.
S Arrange the pistons, pins, rings, connecting rods and
bearings in the correct order.

A23032

12. 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 (0.0016 to 0.0094 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than the maximum, replace the
pair of the thrust washers or the crankshaft.
A23033 HINT:
Thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780
in.)

13. REMOVE CRANKSHAFT
5
8 (a) Using several steps, uniformly loosen and remove the 8
7 main bearing cap bolts and seal washers in the sequence
2 as shown in the illustration.
3
6
4
1

A23034
EM-116
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK

(b) Using several steps, uniformly loosen and remove the 16
main bearing cap bolts in the sequence as shown in the
4
8 12 illustration.
6 16 11
14 15 3
2 10 13 7
5
9
1

A23035

(c) Using a screwdriver, pry out the main bearing caps. Re-
move the 4 main bearing caps and lower bearings.
NOTICE:
S Pull up the main bearing cap while turning it little by
little to the right and the left.

A23036

S Be careful not to damage the joint surface of the cylin-
der block and the main bearing cap.
Main Bearing Cap 14. REMOVE CRANKSHAFT THRUST WASTER SET
15. REMOVE CRANKSHAFT BEARING

Cylinder
Block
A23037

16. REMOVE OIL NOZZLE
Using a 5 mm socket hexagon wrench, remove the 3 oil
nozzles.

A23038

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