Cylinder block 1GR-FE Replacement

1. REPLACE STUD BOLT

NOTICE:

If a stud bolt is deformed or its threads are damaged, replace it.

  1. Remove the stud bolts.

  1. Install new stud bolts.

    Torque:

    for stud bolt A and B:

    11 N*m{ 112 kgf*cm , 8 ft.*lbf }

    for stud bolt C:

    4.0 N*m{ 41 kgf*cm , 35 in.*lbf }

    Cylinder block 1GR-FE Replacement. Replace stud bolt.

2. REPLACE STRAIGHT PIN

NOTICE:

It is not necessary to remove the straight pin unless it is being replaced.

  1. Remove the straight pins.

  1. Using a plastic-faced hammer, tap in new straight pins to the cylinder block.

    Standard Protrusion Height:

    Item Specified Condition
    Pin "A" 22.5 to 23.5 mm (0.889 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.)
    Cylinder block 1GR-FE Replacement. Replace straight pin

3. REPLACE CYLINDER BLOCK TIGHT PLUG

NOTICE:

If water leaks from the tight plug or the plug corrodes, replace it.

  1. Remove the tight plugs.

Cylinder block 1GR-FE Replacement. Apply adhesive around new tight plugs.

  1. Apply adhesive around new tight plugs.

    Adhesive:

    Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

  1. Using SST and a hammer, tap in the tight plugs to the standard depth.

    SST

    09950-60010 (09951-00350) 09950-70010 (09951-07150)

    Standard depth:

    0.2 to 1.2 mm (0.00787 to 0.0472 in.)

    Cylinder block 1GR-FE Replacement. Using SST and a hammer, tap in the tight plugs to the standard depth.

4. REPLACE OIL JET

NOTICE:

It is not necessary to remove the oil jet unless it is being replaced.

  1. Using a screwdriver and hammer, tap out the oil jet.

Cylinder block 1GR-FE Replacement. Using a screwdriver and hammer, tap in a new oil jet as shown in the illustration.

  1. Using a screwdriver and hammer, tap in a new oil jet as shown in the illustration.

5. REPLACE CONNECTING ROD SMALL END BUSH

Cylinder block 1GR-FE Replacement. Using SST and a press, press out the bush.

  1. Using SST and a press, press out the bush.

    SST

    09222-30010

Cylinder block 1GR-FE Replacement. Align the oil holes of a new bush and the connecting rod.

  1. Align the oil holes of a new bush and the connecting rod.

Cylinder block 1GR-FE Replacement. Using SST and a press, press in the bush.

  1. Using SST and a press, press in the bush.

    SST

    09222-30010

Cylinder block 1GR-FE Replacement. Using a pin hole grinder, hone the bush to obtain the standard oil clearance between the bush and piston pin.

  1. Using a pin hole grinder, hone the bush to obtain the standard oil clearance between the bush and piston pin.

    Standard oil clearance:

    0.005 to 0.011 mm (0.000197 to 0.000433 in.)

    HINT:

    Check that the piston pin fits at a normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with a thumb.