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EM-128
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
EM1Y2-01
REASSEMBLY
1. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.
Torque:
Stud bolt A: 11 Nm (112 kgfcm, 8.1 ftlbf)
Stud bolt B: 4.5 Nm (46 kgfcm, 40 in.lbf)
Stud bolt C: 4.0 Nm (41 kgfcm, 35 in.lbf)
Front Side Upper Side
C
42 mm C
(1.65 in.)
A 23 mm
A (0.91 in.)
M6
Lower Side
56 mm
(2.20 in.)
B B
A23062
EM-129
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
2. INSTALL STRAIGHT PIN
(a) Using a plastic-faced hammer, tap in the straight pin.
Standard protrusion:
Pin A: 22.5 to 23.5 mm (0.886 to 0.925 in.)
Pin B: 10.5 to 11.5 mm (0.413 to 0.453 in.)
Pin C: 8.5 to 9.5 mm (0.335 to 0.374 in.)
Pin D: 5.5 to 6.5 mm (0.217 to 0.256 in.)
Front Side Front Side
10 mm
(0.39 in.)
A 4 mm
(0.16 in.)
D
36 mm D
(1.42 in.)
Protrusion Height: 5.5 to 6.5 mm 12 mm
Protrusion Height: 22.5 to 23.5 mm
(0.886 to 0.925 in.) Rear Side (0.217 to 0.256 in.) (0.47 in.)
Rear Side
B
10 mm
(0.39 in.) 4 mm
(0.16 in.)
22 mm D
B (0.87 in.)
12 mm
Protrusion Height: 10.5 to 11.5 mm Protrusion Height: 5.5 to 6.5 mm (0.47 in.)
(0.217 to 0.256 in.)
(0.413 to 0.453 in.) Lower Side
D
Upper Side
8 mm 4 mm
(0.31 in.) (0.16 in.)
18 mm
C C (0.71 in.)
C C 12 mm
D (0.47 in.)
Protrusion Height: 5.5 to 6.5 mm
(0.217 to 0.256 in.)
Protrusion Height: 8.5 to 9.5 mm (0.335 to 0.374 in.) A23063
EM-130
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
3. INSTALL TIGHT PLUG
(a) Apply adhesive around the tight plugs.
Adhesive: Part No. 08833-00070, THREE BOND 1324
or equivalent.
(b) Using SST, install the tight plugs as shown in the illustra-
tion.
SST 09950-60010 (09951-00350), 09950-70010
(09951-07150)
Standard depth: 0.2 to 1.2 mm (0.008 to 0.047 in.)
Right Side Left Side
0.2 to 1.2 mm
(0.008 to 0.047 in.)
A23064
4. INSTALL OIL JET
Using a screwdriver and hammer, tap in an oil jet.
26.5_"5_
A23065
5. INSTALL OIL NOZZLE
Using a 5 mm socket hexagon wrench, install the 3 oil nozzles.
Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)
A23038
EM-131
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
6. INSTALL PISTON PIN HOLE SNAP RING
Using a screwdriver, install a new snap ring at one side of the
piston pin hole.
HINT:
Check that the end gap of the snap ring does not overlap the
pin hole cutout portion of the piston.
A23066
7. INSTALL PISTON
(a) Gradually heat the piston to about 80_C (176_F).
P12417
(b) Coat the piston pin with engine oil.
Front Mark (c) Align the front marks of the piston and connecting rod,
and push in the piston pin with a thumb.
Front
Mark
A23067
8. INSTALL PISTON PIN HOLE SNAP RING
Using a screwdriver, install a new snap ring on the other side
of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring does not overlap the
pin hole cutout portion of the piston.
A23066
9. INSTALL PISTON RING SET
(a) Install the oil ring expander and 2 side rails by hand.
Upward (b) Using a piston ring expander, install the 2 compression
rings.
NOTICE:
Install the compression ring No. 2 with the painted mark
facing upward.
Painted Mark
A23068
EM-132
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
No. 2 Lower side rail (c) Position the piston rings so that the ring ends are as
Compression shown in the illustration.
Front Mark
Expander Side Rail
No. 1
Compression
Upper side rail A23069
10. INSTALL CONNECTING ROD BEARING
Align the bearing claw with the groove of the connecting rod or
connecting cap.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the connecting rod and prevent oil from adhering to
them.
A23070
11. INSTALL CRANKSHAFT BEARING
No. 1 and No. 4 No. 2 and No. 3 HINT:
Upper 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
Lower bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No.
2 and No. 3 positions.
22.4 mm 19.0 mm (a) Clean each main journal and bearing.
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 or its contact surface.
A23071
(c) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 4 lower bearings.
NOTICE:
Do not apply engine oil to the bearing or its contact surface.
HINT:
The number marked on each main bearing cap indicates the
Mark
1, 2, 3 or 4 installation position.
A23052
EM-133
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
12. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing and install the crank-
shaft on the cylinder block.
(b) Install the 2 upper thrust washers to the No. 2 journal posi-
tion of the cylinder block.
(1) Push the crankshaft toward the front (rear) side.
(2) Install the 2 upper thrust washers with the oil
grooves facing outward.
A23072
(c) Install the 2 lower thrust washers on the No. 2 bearing cap
with the grooves facing outward.
A23073
(d) Examine the front marks and numbers and install the
bearing caps on the cylinder block.
(e) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(f) Temporarily install the 8 main bearing cap bolts to the in-
side positions.
A23054
(g) 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
EM-134
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
(h) Using a plastic-faced hammer, lightly tap the bearing cap
to ensure a proper fit.
(i) Apply a light coat of engine oil to the threads of the main
bearing cap bolts.
A23056
(j) Install the 16 main bearing cap bolts. Using several steps,
uniformly tighten the bolts in the sequence shown in the
13 illustration.
9 5 6
Torque: 61 Nm (622 kgfcm, 45 ftlbf)
1 2 14
11
3 4
10
15 7 8 12
16
A23057
Painted Mark (k) Mark the front side of the bearing cap bolts with paint.
90_ (l) Retighten the bearing cap bolts 90_ in the sequence as
shown in the illustration.
Front (m) Check that the painted mark is now at a 90_ angle to the
90_
front.
(n) Check that the crankshaft turns smoothly.
A23058
(o) Using several steps, uniformly tighten the 8 main bearing
4
1 cap bolts in the sequence as shown in the illustration.
2 Torque: 25 Nm (255 kgfcm, 18 ftlbf)
3 7
6
5
8
A23059
EM-135
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
13. INSTALL PISTON W/CONNECTING ROD
Front Mark (a) Apply engine oil to the cylinder walls, the pistons, and the
surfaces of the connecting rod bearings.
(b) Check the position of the piston ring ends.
(c) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
NOTICE:
A23074 S Clean the backside of the bearing and the bearing
surface of the connecting rod cap and prevent oil
from adhering to them.
S Match the numbered connecting rod cap with the con-
necting rod.
(d) Check that the protrusion of the connecting rod cap is fac-
ing the correct direction.
(e) Apply a light coat of engine oil to the threads of the con-
necting rod cap bolts.
Protrusion
A23023
(f) Using SST, tighten the bolts alternately to the specified
torque.
SST 09011-38121
Torque: 25 Nm (250 kgfcm, 18 ftlbf)
A23024
Painted Mark (g) Mark the front side of each connecting cap bolt with paint.
90_ (h) Retighten the cap bolts 90_ as shown.
(i) Check that the crankshaft turns smoothly.
Front 90_ 14. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Remove any old packing material (FIPG) and be careful
not to drop any oil on the contact surfaces of the oil seal
retainer and cylinder block.
A23025
EM-136
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
Seal Packing (b) Apply a continuous bead of seal packing (diameter 2 to
3 mm (0.08 to 0.12 in.)) to the oil seal retainer as shown
in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Parts must be assembled within 3 minutes of application.
Otherwise the seal packing must be removed and reap-
plied.
Seal Width: 2 to 3 mm (0.08 to 0.12 in.)
A23004 (c) Install the oil seal retainer with the 5 bolts and 2 nuts.
Torque:
Bolt: 10 Nm (102 kgfcm, 7 ftlbf)
Nut: 9.0 Nm (92 kgfcm, 80 in.lbf)
15. INSTALL WATER DRAIN COCK
Adhesive (a) Apply adhesive to 2 or 3 threads of the drain cock ends.
Adhesive: Part No. 08833-00070, THREE BOND 1324
or equivalent
A23018
(b) After tightening the drain cocks to the specified torque, ro-
tate them clockwise as shown in the illustration.
Torque: 25 Nm (255 kgfcm, 18 ftlbf)
NOTICE:
S Do not rotate the drain cocks more than 1 complete
45_ 15_
revolution (360_) after tightening the drain cocks to
the specified torque.
S Do not loosen the drain cocks after setting them cor-
45_ 45_
A23019 rectly.
EM-137
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
16. INSTALL KNOCK SENSOR
LH Bank Upper (a) Install the 2 knock sensors with the 2 bolts within a 15◦ Jabse Service Manual Search 2026 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo