Toyota FJ Cruiser (GSJ 10, 15 series). Manual — part 179

1GR-FE ENGINE MECHANICAL – ENGINE UNIT

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(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 in.)

Maximum oil clearance:

0.066 mm (0.0025 in.)

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".
HINT:
Standard bearing center wall thickness

(n) Remove the 2 connecting rod cap bolts.

90°

90°

Front

Painted Mark

A075151E03

A075152E02

Number Mark

A126508E01

Mark

mm (in.)

"1"

1.484 to 1.487 (0.0584 to 0.0585)

"2"

1.487 to 1.490 (0.0585 to 0.0587)

"3"

1.490 to 1.493 (0.0587 to 0.0588)

"4"

1.493 to 1.496 (0.0588 to 0.0589)

A075150E01

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1GR-FE ENGINE MECHANICAL – ENGINE UNIT

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52. REMOVE PISTON SUB-ASSEMBLY WITH

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.

53. REMOVE CONNECTING ROD BEARING

54. 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.

55. REMOVE HOLE SNAP RING

(a) Using a small screwdriver, pry out the 2 snap rings.

56. REMOVE WITH PISTON SUB-ASSEMBLY

(a) Gradually heat the piston to approximately 80

°C

(176

°F).

A076043E01

A076044E01

P012403E01

80°C (176°F)

A076045E07

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(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.

57. 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 in.)

Maximum thrust clearance:

0.30 mm (0.0118 in.)

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 in.)

58. INSPECT CRANKSHAFT OIL CLEARANCE

(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.

A076046E01

A076047E01

6

1

7

8

5

2

3

4

A076048E01

1

3

2

10

9

4

5

6

7

8

13

14

12

11

15

16

A076049E01

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(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.

(d) Lay a strip of plastigage across each journal.

(e) Examine the front marks and numbers, check the

sequence order is as shown and install the bearing
caps onto the cylinder block.

(f)

Apply a light coat of engine oil to the threads of
bearing cap bolts.

(g) Temporarily install the 8 main bearing cap bolts in

the inside positions.

(h) Install the main bearing caps. Tighten the 2 bolts for

each bearing cap until the clearance between the
bearing cap and the cylinder block is under 6 mm
(0.23 in.).

Joint Surface

A121032E01

Plastigage

A076066E02

A076067E01

Less than 6 mm

A076069E02