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EM-117
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
EM1Y0-01
INSPECTION
1. INSPECT CYLINDER BLOCK FOR FLATNESS
Using a precision straight edge and feeler gauge, measure the
flatness of the surface that is in contact with the cylinder head
gasket.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than the maximum, replace the cylinder
block.
A23039
2. INSPECT CYLINDER BORE
Using a cylinder gauge, measure the cylinder bore diameter at
positions A and B in the thrust and axial directions.
Standard diameter:
94.000 to 94.012 mm (3.7008 to 3.7013 in.)
Maximum diameter: 94.132mm (3.7060 in.)
If the average diameter of the 4 positions is greater than the
maximum, replace the cylinder block.
Thrust Direction
Front
Axial Direction
A 10 mm
B
A23040
3. INSPECT PISTON
Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 27.7 mm (1.091 in.) from the
piston head.
Piston diameter:
93.910 to 93.940 mm (3.6972 to 3.6984 in.)
27.7 mm
(1.091 in.)
A23041
EM-118
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
4. INSPECT PISTON OIL CLEARANCE
Subtract the piston diameter measurement from the cylinder
bore diameter measurement.
Standard oil clearance:
0.060 to 0.102 mm (0.0024 to 0.0040 in.)
Maximum oil clearance: 0.13 mm (0.0051 in.)
If the oil clearance is greater than the maximum, replace all the
6 pistons. If necessary, replace the cylinder block.
5. INSPECT CONNECTING ROD
Using a rod aligner and feeler gauge, check the connecting rod
alignment.
(1) Check for misalignment.
Maximum misalignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If misalignment is greater than the maximum, replace the con-
necting rod assembly.
Z00064
(2) Check twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than the maximum, replace the connecting rod
assembly.
Z00065
6. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
piston pin hole.
Piston pin hole inside diameter:
22.001 to 22.010 mm (0.8662 to 0.8665 in.)
HINT:
Piston pin hole inside diameter
Mark mm (in.)
A13490 A 22.001 to 22.004 (0.8662 to 0.8663)
B 22.005 to 22.007 (0.8663 to 0.8664)
C 22.008 to 22.010 (0.8665 to 0.8665)
EM-119
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 to 22.006 mm (0.8660 to 0.8664 in.)
HINT:
Piston pin diameter
Mark mm (in.)
A 21.997 to 22.000 (0.8660 to 0.8661)
B 22.001 to 22.003 (0.8661 to 0.8663)
EM0227 C 22.004 to 22.006 (0.8663 to 0.8664)
(c) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
22.005 to 22.014 mm (0.8663 to 0.8667 in.)
HINT:
Bushing inside diameter
Mark mm (in.)
A 22.005 to 22.008 (0.8663 to 0.8665)
EM6525 B 22.009 to 22.011 (0.8665 to 0.8666)
C 22.012 to 22.014 (0.8666 to 0.8667)
(d) Subtract the piston pin diameter measurement from the
piton pin hole diameter measurement.
Standard oil clearance:
0.001 to 0.007 mm (0.00004 to 0.00028 in.)
Maximum oil clearance: 0.040 mm (0.0016 in.)
(e) If the oil clearance is greater than the maximum, replace
the bushing. If necessary, replace the piston and piston
pin together.
(f) Subtract the piston pin diameter measurement from the
bushing inside diameter measurement.
Standard oil clearance:
Front Mark 0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance: 0.050 mm (0.0020 in.)
Piston Pin Hole
Inside Diameter
(g) If the oil clearance is greater than the maximum, replace
Mark the bushing. If necessary, replace the connecting rod and
piston pin together.
Front Mark
Connecting Rod
Bushing Inside
Diameter Mark
A23042
EM-120
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
7. INSPECT RING GROOVE CLEARANCE
Using a feeler gauge, measure the clearance between the new
piston ring and the wall of the ring groove.
Ring groove clearance:
No.1: 0.02 to 0.07 mm (0.0008 to 0.0028 in.)
No.2: 0.02 to 0.06 mm (0.0008 to 0.0024 in.)
Oil: 0.07 to 0.15 mm (0.0028 to 0.0060 in.)
A23044
8. INSPECT PISTON RING END GAP
(a) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 110 mm (4.33 in.) from the top of the
cylinder block.
110 mm
A23045
(b) Using a feeler gauge, measure the end gap.
Standard end gap:
No. 1: 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
No. 2: 0.40 to 0.50 mm (0.0157 to 0.0197 in.)
Oil (Side rail): 0.10 to 0.40 mm (0.0039 to 0.0157 in.)
Maximum end gap:
No. 1: 1.0 mm (0.039 in.)
No. 2: 1.1 mm (0.043 in.)
EM7639 Oil (Side rail): 1.0 mm (0.039 in.)
9. INSPECT CONNECTING ROD BOLT
Using a vernier caliper, measure the tension portion diameter
of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter: 7.0 mm (0.276 in.)
If the diameter is less than the minimum, replace the bolt.
A23046
10. INSPECT CRANKSHAFT BEARING CAP SET BOLT
Using a vernier caliper, measure the tension portion diameter
of the bolt.
Standard diameter:
10.0 to 10.2 mm (0.393 to 0.402 in.)
If the diameter is less than the minimum, replace the bolt.
A23046
EM-121
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
11. INSPECT CRANKSHAFT
(a) Using a dial indicator and V-blocks, measure the runout
as shown in the illustration.
Maximum circle runout: 0.06 mm (0.0024 in.)
A23047
(b) Using a micrometer, measure the diameter of each main
journal.
Diameter: 71.988 to 72.000 mm (2.8342 to 2.8346 in.)
(c) Check each main journal for taper and out-of-round as
shown in the illustration.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
A23048
(d) Using a micrometer, measure the diameter of each crank
pin.
Diameter: 55.992 to 56.000 mm (2.2044 to 2.2047 in.)
(e) Check each crank pin for taper and out-of-round as
shownin the illustration.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
A23049
12. INSPECT CRANKSHAFT OIL CLEARANCE
No. 1 and No. 4 No. 2 and No. 3 HINT:
Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4
mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the
No. 1 and No. 4 cylinder block journal positions with the main
bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No.
2 and No. 3 positions.
(a) Clean each main journal and bearing.
22.4 mm 19.0 mm
A23050
(b) Align the bearing claw with the claw groove of the cylinder
block, and push in the 4 upper bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
A23051
EM-122
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
(c) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 4 bottom bearings.
NOTICE:
Do not apply engine oil to the bearing or its contact surface.
HINT:
A number marked on each main bearing cap indicates the
Mark
installation position.
1, 2, 3, or 4
(d) Place the crankshaft on the cylinder block.
A23052
(e) Lay a strip of Plastigage across each journal.
Plastigage
A23053
(f) Examine the front marks and numbers and install the
bearing caps on the cylinder block.
(g) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(h) Temporarily install the 8 main bearing cap bolts to the in-
side positions.
A23054
(i) Install the main bearing caps. Tighten the 2 bolts for each
bearing cap until the clearance between the bearing cap
and the cylinder block becomes less than 6 mm (0.23 in.).
Less than 6 mm
A23055
(j) Using a plastic-faced hammer, lightly tap the bearing cap
to ensure a proper fit.
(k) Apply a light coat of engine oil to the threads of the main
bearing cap bolts.
A23056
EM-123
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
(l) Install the 16 main bearing cap bolts. Using several steps,
uniformly tighten the bolts in the sequence as shown in
13 the illustration.
9 5 6
11 1 2 Torque: 61 Nm (622 kgfcm, 45 ftlbf)
3 4 14
10
15 7 8 12
16
A23057
Painted Mark
(m) Mark the front side of the bearing cap bolts with paint.
90_ (n) Retighten the bearing cap bolts until 90_ in the sequence
as shown in the illustration.
Front
90_
(o) Check that the painted mark is now at a 90_ angle to the
front.
NOTICE:
Do not turn the crankshaft.
A23058
(p) Install the 8 main bearing cap bolts. Using several steps,
4
1 uniformly tighten the bolts in the sequence as shown in
2 the illustration.
7
3 Torque: 25 Nm (255 kgfcm, 18 ftlbf)
6
5
(q) Remove the main bearing caps.
8
A23059
(r) Measure the Plastigage at its widest point.
Standard oil clearance:
0.018 to 0.030 mm (0.0007 to 0.0012 in.)
Maximum clearance: 0.046 mm (0.0018 in.)
If the oil clearance is greater than the maximum, replace the
bearings. If necessary, replace the crankshaft.
NOTICE:
Completely remove the Plastigage.
A23060
EM-124
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
(s) If replacing a bearing, replace it with one that has the
same number. If the number of the bearing cannot be de-
termined, select the correct bearing by adding together
No. 1 the numbers imprinted on the cylinder block and crank-
No. 2 shaft, then refer to the table below for the appropriate
No. 3
No. 4 bearing number. There are 5 sizes of standard bearings,
marked "1", "2", "3", "4" and "5" accordingly
Journal bearings
Number Mark
Cylinder
block (A)
0 to 5 6 to 11 12 to 17 18 to 23 24 to 28
+
Crankshaft
Use
"1" "2" "3" "4" "5"
Bearing
HINT:
No. 1 EXAMPLE
No. 2 Cylinder block "11" (A) + Crankshaft "06" (B)
No. 4 = Total number 17 (Use bearing "3")
Number No. 3
Mark Number MarkA23061
Item Mark mm (in.)
"00" 77.000 (3.0315)
"01" 77.001 (3.0315)
"02" 77.002 (3.0316)
"03" 77.003 (3.0316)
"04" 77.004 (3.0317)
"05" 77.005 (3.0317)
"06" 77.006 (3.0317)
"07" 77.007 (3.0318)
Cylinder block main journal bore diameter (A) "08" 77.008 (3.0318)
"09" 77.009 (3.0319)
"10" 77.010 (3.0319)
"11" 77.011 (3.0319)
"12" 77.012 (3.0320)
"13" 77.013 (3.0320)
"14" 77.014 (3.0320)
"15" 77.015 (3.0321)
"16" 77.016 (3.0321)
EM-125
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
Crankshaft main journal diameter (B)
"00" 71.999 to 72.000 (2.8346 to 2.8346)
"01" 71.998 to 71.999 (2.8346 to 2.8346)
"02" 71.997 to 71.998 (2.8345 to 2.8346)
"03" 71.996 to 71.997 (2.8345 to 2.8346)
"04" 71.995 to 71.996 (2.8344 to 2.8345)
"05" 71.994 to 71.995 (2.8344 to 2.8344)
"06" 71.993 to 71.994 (2.8343 to 2.8344)
"07" 71.992 to 71.993 (2.8343 to 2.8343)
"08" 71.991 to 71.992 (2.8343 to 2.8343)
"09" 71.990 to 71.991 (2.8343 to 2.8343)
"10" 71.989 to 71.990 (2.8342 to 2.8343)
"11" 71.988 to 71.989 (2.8342 to 2.8342)
Standard bearing center wall thickness "1" 2.488 to 2.491 (0.0980 to 0.0981)
"2" 2.491 to 2.494 (0.0981 to 0.0982)
"3" 2.494 to 2.497 (0.0982 to 0.0983)
"4" 2.497 to 2.500 (0.0982 to 0.0984)
"5" 2.500 to 2.503 (0.0984 to 0.0985)
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