Part 1

CYLINDER BLOCK ASSEMBLY (1GR-FE)

COMPONENTS

OVERHAUL

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 (0.0059 to 0.0118 inch)
Maximum thrust clearance: 0.35 mm (0.0138 inch)
2. INSPECT CONNECTING ROD OIL CLEARANCE
a. Check the matchmarks on the connecting rod and cap are aligned to ensure correct assembly.
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 any pits and scratches.

e. Lay a strip of plastigage across the crank pin.

f. Check that the protrusion of the connecting rod cap is facing in the correct direction.
g. Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

h. Using SST, tighten the bolts alternately to the specified torque.
SST 09011-38121
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

i. Mark the front side of the each connecting cap bolt with paint.
j. Retighten the cap bolts 90° as shown in the illustration.

NOTICE: Do not turn the crankshaft.

k. Remove the 2 bolts, connecting rod cap and lower bearing.

l. Measure the plastigage at its widest point.
Standard oil clearance: 0.026 to 0.046 mm (0.0010 to 0.0018 inch)
Maximum oil clearance: 0.066 mm (0.0025 inch)

NOTICE: Completely remove the plastigage.

m. When replacing the bearing, replace it with one with the same number as 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

3. REMOVE PISTON SUB-ASSEMBLY W/CONNECTING ROD
a. Using a ridge reamer, remove all the carbon from the top of the cylinder.
b. Push in the piston, connecting rod assembly 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 in the correct order.

4. REMOVE CONNECTING ROD BEARING

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 by hand.

6. REMOVE RING, HOLE SNAP
a. Using a small screwdriver, pry out the 2 snap rings.

7. REMOVE W/PIN PISTON SUB-ASSEMBLY
a. Gradually heat the piston to approximately 80°C (176° F).

b. 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.

8. 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 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than the maximum, replace the pair of the thrust washers or crankshaft.

HINT: Thrust washer thickness: 1.93 to 1.98 mm (0.0760 to 0.0780 inch)

9. REMOVE CRANKSHAFT
a. Using several steps, uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the sequence shown in the illustration.

b. Using several steps, uniformly loosen and remove the 16 main bearing cap bolts in the sequence shown in the illustration.

c. Using a screwdriver, pry out the main bearing caps. Remove the 4 main bearing caps and lower bearings.

NOTICE:
- Pull up the main bearing cap by turning it to the right and left little by little.
- Be careful not to damage the joint surfaces of the cylinder block and the main bearing cap.

10. REMOVE CRANKSHAFT THRUST WASHER SET
11. REMOVE CRANKSHAFT BEARING

12. REMOVE SUB-ASSEMBLY OIL NOZZLE NO.1
a. Using a 5 mm socket hexagon wrench, remove the 3 oil nozzles.

13. CHECK CYLINDER BLOCK FOR WARPAGE
a. Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.
Maximum warpage: 0.05 mm (0.0020 inch)
If the warpage is greater than the maximum, replace the cylinder block.

14. INSPECT CYLINDER BORE
a. 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 inch)
Maximum diameter: 94.132 mm (3.7060 inch)
If the average diameter of 4 positions is greater than the maximum, replace the cylinder block.

15. INSPECT W/PIN PISTON SUB-ASSEMBLY
a. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 27.7 mm (1.091 inch) from the piston head.
Piston diameter: 93.910 to 93.940 mm (3.6972 to 3.6984 inch)
16. INSPECT PISTON OIL CLEARANCE
a. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.060 to 0.102 mm (0.0031 to 0.0040 inch)
Maximum oil clearance: 0.13 mm (0.0051 inch)
If the oil clearance is greater than the maximum, replace all the 6 pistons. If necessary, replace the cylinder block.

17. INSPECT ROD SUB-ASSEMBLY, CONNECTING
a. Using a rod aligner and feeler gauge, check the connecting rod alignment.
(1) Check for misalignment.
Maximum misalignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If misalignment is greater than the maximum, replace the connecting rod assembly.

(2) Check the twist.
Maximum twist: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch)
If the twist is greater than the maximum, replace the connecting rod assembly.

18. INSPECT PISTON PIN OIL CLEARANCE
a. Using a caliper gauge, measure the internal diameter of the piston pin hole.
Piston pin hole internal diameter: 22.001 to 22.010 mm (0.8662 to 0.8665 inch)

HINT: Piston pin hole inside diameter:

b. Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 inch)

HINT: Piston pin diameter:

c. Using a caliper gauge, measure the internal diameter of the connecting rod bushing.
Bushing internal diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 inch)

HINT: Bushing internal diameter:

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 inch)
Maximum oil clearance: 0.040 mm (0.0016 inch)

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: 0.005 to 0.011 mm (0.0002 to 0.0004 inch)
Maximum oil clearance: 0.050 mm (0.0020 inch)
g. If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin together.

19. REMOVE CONNECTING ROD SMALL END BUSH
a. Using SST and a press, press out the bushing.
SST 09222-30010

20. INSTALL CONNECTING ROD SMALL END BUSH
a. Align the oil holes of a new bushing and the connecting rod.

b. Using SST and a press, press in the bushing.
SST 09222-30010

c. Using a pin hole grinder, hone the bushing to the standard specified clearance between the bushing and piston pin.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 inch)

HINT: Check the measurement at room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with a thumb.

21. INSPECT RING GROOVE CLEARANCE
a. Using a feeler gauge, measure the clearance between a 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 inch)
No.2 0.02 to 0.06 mm (0.0008 to 0.0024 inch)
Oil 0.07 to 0.15 mm (0.0028 to 0.0060 inch)

22. INSPECT PISTON RING END GAP
a. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 inch) from the top of the cylinder block.

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 inch)
No.2 0.40 to 0.50 mm (0.0157 to 0.0197 inch)
Oil (Side rail) 0.10 to 0.40 mm (0.0039 to 0.0157 inch)
Maximum end gap:
No.1 1.0 mm (0.039 inch)
No.2 1.1 mm (0.043 inch)
Oil (Side rail) 1.0 mm (0.039 inch)