Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 181

1GR-FE ENGINE MECHANICAL  –  ENGINE UNIT

EM–155

EM

INSPECTION

1.

INSPECT CAMSHAFTS (See page 

EM-47

)

2.

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY 
(See page 

EM-47

)

3.

INSPECT CYLINDER HEAD SET BOLT (See page 

EM-

75

)

4.

INSPECT CHAIN SUB-ASSEMBLY
(a) Using a spring scale, apply 147 N (15.0 kgf, 33.1 lbf) 

to the chain and measure the length.
Maximum chain length:

146.8 mm (5.780 in.)

NOTICE:
Measure the length in at least 3 places and 
calculate the average length.
If the chain length is greater than the maximum, 
replace the chain.

5.

INSPECT NO. 2 CHAIN SUB-ASSEMBLY
(a) Using a spring scale, apply 147 N (15.0 kgf, 33.1 lbf) 

to the chain and measure the length.
Maximum chain length:

146.8 mm (5.780 in.)

NOTICE:
Measure the length in at least 3 places and 
calculate the average length.
If the chain length is greater than the maximum, 
replace the chain.

6.

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Wrap the chain sub-assembly around the larger 

gear of the timing gear assembly.

(b) Using vernier calipers, measure the timing gear with 

the chain wrapped.
Minimum gear diameter (with chain):

115.5 mm (4.547 in.)

NOTICE:
The vernier calipers must be in contact with the 
chain rollers when measuring.
If the gear diameter is less than the minimum, 
replace the chain sub-assembly and the camshaft 
timing gear assembly.

(c) Wrap the No. 2 chain around the smaller gear of 

timing gear assembly.

(d) Using vernier calipers, measure the timing gear with 

the chain wrapped.
Minimum gear diameter (with chain):

73.1 mm (2.878 in.)

NOTICE:
The vernier calipers must be in contact the 
chain rollers when measuring.

Measuring Area

A053044E02

Measuring Area

A053044E02

A076255E01

A076256E01

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1GR-FE ENGINE MECHANICAL  –  ENGINE UNIT

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If the gear diameter is less than the minimum, 
replace the No. 2 chain and the camshaft timing 
gear assembly.

7.

INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
(a) Wrap the No. 2 chain around the timing gear.
(b) Using vernier calipers, measure the camshaft timing 

gear diameter with the chain wrapped.
Minimum gear diameter (with chain):

73.1 mm (2.878 in.)

NOTICE:
The vernier calipers must be in contact the 
chain rollers when measuring.
If the gear diameter is less than the minimum, 
replace the No. 2 chain and camshaft timing gear.

8.

INSPECT CRANKSHAFT TIMING GEAR OR 
SPROCKET
(a) Wrap the chain sub-assembly around the timing 

gear.

(b) Using vernier calipers, measure the timing gear 

diameter with the chain wrapped.
Minimum gear diameter (with chain):

61.0 mm (2.402 in.)

NOTICE:
The vernier calipers must be in contact with the 
chain rollers when measuring.
If the gear diameter is less than the minimum, 
replace the chain sub-assembly and the crankshaft 
timing gear.

9.

INSPECT IDLE SPROCKET ASSEMBLY
(a) Wrap the chain sub-assembly around the idle 

sprocket.

(b) Using vernier calipers, measure the idle sprocket 

with the chain wrapped.
Minimum gear diameter (with chain):

61.0 mm (2.402 in.)

NOTICE:
The vernier calipers must be in contact with the 
chain rollers when measuring.
If the gear diameter is less than the minimum, 
replace the chain sub-assembly and idle sprocket.

10. INSPECT NO. 1 IDLE GEAR SHAFT

(a) Using a micrometer, measure the idle gear shaft 

diameter.
Idle gear shaft diameter:

22.987 to 23.000 mm (0.9050 to 0.9055 in.)

If the result is not as specified, replace the idle gear 
shaft.

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1GR-FE ENGINE MECHANICAL  –  ENGINE UNIT

EM–157

EM

(b) Using a caliper gauge, measure the internal 

diameter of the idle gear.
Idle gear internal diameter:

23.02 to 23.03 mm (0.9063 to 0.9067 in.)

If the result is not as specified, replace the idle gear.

(c) Subtract the idle gear shaft diameter measurement 

from the idle gear internal diameter measurement.
Standard oil clearance:

0.020 to 0.043 mm (0.0008 to 0.0017 in.)

Maximum oil clearance:

0.093 mm (0.0037 in.)

If the oil clearance is greater than the maximum, 
replace the idle gear or gear shaft.

11. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Check that the plunger moves smoothly when the 

ratchet pawl is raised with finger.

(b) Release the ratchet pawl, then check that the 

plunger is locked in place by the ratchet pawl and 
does not move when pushing it with finger.
If the results are not as specified, replace the No. 1 
chain tensioner assembly.

12. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Check that the plunger moves smoothly.
(b) Measure the wear of the chain tensioner slipper.

Maximum wear:

1.0 mm (0.039 in.)

If the wear is greater than the maximum, replace 
chain tensioner No. 2.

13. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Check that the plunger moves smoothly.
(b) Measure the wear of the chain tensioner slipper.

Maximum wear:

1.0 mm (0.039 in.)

If the wear is greater than the maximum, replace 
chain tensioner No. 3.

A076261E01

Raise

Move

Lock

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Move

Wear

Wear

A076263E02

Move

Wear

Wear

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1GR-FE ENGINE MECHANICAL  –  ENGINE UNIT

EM

14. INSPECT CHAIN TENSIONER SLIPPER

(a) Measure the wear of the tensioner slipper.

Maximum wear:

1.0 mm (0.039 in.)

If the thickness is greater than the maximum, 
replace the tensioner slipper.

15. INSPECT NO. 1 CHAIN VIBRATION DAMPER

(a) Measure the wear of the vibration damper No. 1.

Maximum wear:

1.0 mm (0.039 in.)

If the thickness is greater than the maximum, 
replace vibration damper No. 1.

16. INSPECT NO. 2 CHAIN VIBRATION DAMPER

(a) Measure the wear of the vibration damper No. 2 .

Maximum wear:

1.0 mm (0.039 in.)

If the thickness is greater than the maximum, 
replace vibration damper No. 2.

17. CLEAN CYLINDER HEAD SUB-ASSEMBLY (See page 

EM-75

)

18. INSPECT CYLINDER HEAD SUB-ASSEMBLY (See 

page 

EM-77

)

19. CLEAN VALVE (See page 

EM-77

)

20. INSPECT VALVE (See page 

EM-78

)

21. CLEAN VALVE SEAT (See page 

EM-79

)

22. INSPECT VALVE SEAT (See page 

EM-79

)

23. INSPECT INNER COMPRESSION SPRING (See page 

EM-79

)

24. INSPECT VALVE GUIDE BUSH OIL CLEARANCE 

(See page 

EM-80

)

25. INSPECT VALVE LIFTER (See page 

EM-80

)

26. INSPECT VALVE LIFTER OIL CLEARANCE (See page 

EM-81

)

Wear

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Wear

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Wear

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