Cylinder block 1GR-FE Disassembly

1. INSPECT CONNECTING ROD THRUST CLEARANCE

1. 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. If necessary, replace the crankshaft.

2. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD

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

2. Uniformly loosen the connecting rod bolts, and remove the connecting rod cap with bearing.

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

   HINT:

   1. Keep the bearings, connecting rod and cap together.
   2. Arrange the piston and connecting rod assemblies in the correct order.

3. REMOVE CONNECTING ROD BEARING

4. REMOVE PISTON RING SET

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

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

5. REMOVE PISTON PIN HOLE SNAP RING

1. Using a screwdriver, pry out the 2 snap rings.

6. REMOVE PISTON WITH PIN SUB-ASSEMBLY

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

2. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.

   HINT:

   1. The piston and pin are a matched set.
   2. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

7. INSPECT CRANKSHAFT THRUST CLEARANCE

1. 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. REMOVE CRANKSHAFT

1. Using several steps, loosen and remove the 8 bearing cap bolts and seal washers uniformly in the sequence shown in the illustration.

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

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

   NOTICE:

   1. Push up on the cap little by little, alternating from the right and left side until the cap can be removed.
   2. Be careful not to damage the joint surfaces of the cylinder block and bearing cap.

9. REMOVE CRANKSHAFT BEARING

10. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

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