1 GR
1 GR
1 GR
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PROCEDURE
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 (0.00591 to 0.0118 in.)
If the thrust clearance is more than the maximum, replace one or more connecting rods as necessary.
Standard connecting rod thickness:
20.80 to 20.85 mm (0.819 to 0.821 in.)
a.
Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
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c.
Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT:
Keep the lower bearing and connecting rod cap together.
e. Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
f.
g. Install the connecting rod cap (See page Engine / Hybrid System>1GR-FE ENGINE MECHANICAL>CYLINDER
BLOCK>REASSEMBLY).
NOTICE:
Do not turn the crankshaft.
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i.
Text in Illustration
*1 Plastigage
If the oil clearance is more than the maximum, replace the bearings. If necessary, inspect the crankshaft.
HINT:
If replacing a bearing, replace it with one that has the same number as the number marked on the connecting rod.
There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.
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Text in Illustration
*1 Number Mark
a.
Using a ridge reamer, remove all the carbon from the top of the cylinder.
b. Push out the piston with connecting rod 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 assemblies in the correct order.
a. Remove the connecting rod bearings from the connecting rods and connecting rod caps.
HINT:
Arrange the removed parts in the correct order.
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a.
ii.
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iii.
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.
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 (0.00157 to 0.00945 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.)
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a.
Uniformly loosen and remove the 8 bearing cap bolts and 8 seal washers in several steps in the sequence shown in the
illustration.
b.
Uniformly loosen and remove the 16 bearing cap bolts in several steps in the sequence shown in the illustration.
c.
Using a screwdriver, pry out the bearing caps. Remove the 4 bearing caps and lower bearings.
NOTICE:
· Push up on the cap little by little, alternating between the right and left side until the cap can be removed.
· Be careful not to damage the joint surfaces of the cylinder block or bearing cap.
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f.
h. Check each crankshaft journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
j.
k. Install the crankshaft bearing cap (See page Engine / Hybrid System>1GR-FE ENGINE MECHANICAL>CYLINDER
BLOCK>REASSEMBLY).
NOTICE:
Do not turn the crankshaft.
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m.
Maximum clearance:
0.080 mm (0.00315 in.)
If the oil clearance is more than the maximum, replace the bearings. If necessary, replace the crankshaft.
n.
If replacing a bearing, replace it with one that has the same number. If the number of the bearing cannot be determined,
select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, and then refer
to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4"
and "5" accordingly.
New Bearing:
Item Specified Condition
Cylinder block main
journal bore
diameter (A)
6 to 12 to 18 to 24 to
0 to 5
+
11 17 23 28
Crankshaft main
journal diameter (B)
Use bearing 1 2 3 4 5
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Text in Illustration
*1 Number Mark
EXAMPLE:
Cylinder block "11" (A) + Crankshaft "06" (B) = Total number 17 (Use bearing "3")
Cylinder Block Main Journal Bore Diameter (A):
Mark Specified Condition
Mark 00 77.000 mm (3.03149 in.)
Mark 01 77.001 mm (3.03152 in.)
Mark 02 77.002 mm (3.03156 in.)
Mark 03 77.003 mm (3.03160 in.)
Mark 04 77.004 mm (3.03164 in.)
Mark 05 77.005 mm (3.03168 in.)
Mark 06 77.006 mm (3.03172 in.)
Mark 07 77.007 mm (3.03176 in.)
Mark 08 77.008 mm (3.03180 in.)
Mark 09 77.009 mm (3.03184 in.)
Mark 10 77.010 mm (3.03188 in.)
Mark 11 77.011 mm (3.03192 in.)
Mark 12 77.012 mm (3.03196 in.)
Mark 13 77.013 mm (3.03200 in.)
Mark 14 77.014 mm (3.03204 in.)
Mark 15 77.015 mm (3.03208 in.)
Mark 16 77.016 mm (3.03211 in.)
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9.REMOVE CRANKSHAFT
a. Remove the crankshaft bearings from the bearing caps and cylinder block.
HINT:
Arrange the removed parts in the correct order.
a.
Using a 5 mm hexagon socket wrench, remove the 3 bolts and 3 oil nozzles.
NOTICE:
If a stud bolt is deformed or its threads are damaged, replace it.
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