Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 182

 

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Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 182

 

 

1GR-FE ENGINE MECHANICAL  –  ENGINE UNIT

EM–159

EM

27. CHECK CYLINDER BLOCK FOR WARPAGE

(a) Using a precision straight edge and feeler gauge, 

measure the warpage of the contact surface of the 
cylinder head gasket.
Maximum warpage:

0.05 mm (0.0020 in.)

If the warpage is greater than the maximum, replace 
the cylinder block.

28. INSPECT CYLINDER BORE

(a) Using a cylinder gauge, measure the cylinder bore 

diameter at positions A and B in the thrust and axial 
directions.
Standard diameter:

94.000 to 94.012 mm (3.7008 to 3.7013 in.)

Maximum diameter:

94.132mm (3.7060 in.)

If the average diameter of the 4 positions is greater 
than the maximum, replace the cylinder block.

29. INSPECT WITH PISTON SUB-ASSEMBLY

(a) Using a micrometer, measure the piston diameter at 

right angles to the piston pin center line, 27.7 mm 
(1.091 in.) from the piston head.
Piston diameter:

93.910 to 93.940 mm (3.6972 to 3.6984 in.)

If the result is not as specified, replace the with 
piston sub-assembly.

A076052E01

Thrust Direction

Axial Direction

10 mm

A

B

Front

A092877E02

27.7 mm

A076054E01

EM–160

1GR-FE ENGINE MECHANICAL  –  ENGINE UNIT

EM

30. INSPECT PISTON OIL CLEARANCE

(a) Subtract the piston diameter measurement from the 

cylinder bore diameter measurement.
Standard oil clearance:

0.060 to 0.102 mm (0.0031 to 0.0040 in.)

Maximum oil clearance:

0.13 mm (0.0051 in.)

If the oil clearance is greater than the maximum, 
replace all the 6 pistons. If necessary, replace the 
cylinder block.

31. INSPECT CONNECTING ROD SUB-ASSEMBLY

(a) Using a rod aligner and feeler gauge, check the 

connecting rod alignment.
(1) Check for misalignment.

Maximum misalignment:

0.05 mm (0.0020 in.) per 100 mm (3.94 in.)

If misalignment is greater than the maximum, 
replace the connecting rod assembly.

(2) Check the twist.

Maximum twist:

0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

If the twist is greater than the maximum, 
replace the connecting rod assembly.

32. INSPECT PISTON PIN OIL CLEARANCE

(a) Using a caliper gauge, measure the internal 

diameter of the piston pin hole.
Piston pin hole internal diameter:

22.001 to 22.010 mm (0.8662 to 0.8665 in.)

Piston pin hole inside diameter

(b) Using a micrometer, measure the piston pin 

diameter.
Piston pin diameter:

21.997 to 22.006 mm (0.8660 to 0.8664 in.)

Piston pin diameter

Z000064E01

Z000065E01

A013490E01

Mark

mm (in.)

A

22.001 to 22.004 (0.8662 to 0.8663)

B

22.005 to 22.007 (0.8663 to 0.8664)

C

22.008 to 22.010 (0.8665 to 0.8665)

EM00227E01

Mark

mm (in.)

A

21.997 to 22.000 (0.8660 to 0.8661)

B

22.001 to 22.003 (0.8661 to 0.8663)

C

22.004 to 22.006 (0.8663 to 0.8664)

1GR-FE ENGINE MECHANICAL  –  ENGINE UNIT

EM–161

EM

(c) Using a caliper gauge, measure the internal 

diameter of the connecting rod bushing.
Bushing internal diameter:

22.005 to 22.014 mm (0.8663 to 0.8667 in.)

Bushing internal diameter

(d) Subtract the piston pin diameter measurement from 

the piton pin hole diameter measurement.
Standard oil clearance:

0.001 to 0.007 mm (0.00004 to 0.00028 in.)

Maximum oil clearance:

0.040 mm (0.0016 in.)

(e) If the oil clearance is greater than the maximum, 

replace the bushing. If necessary, replace the piston 
and piston pin together.

(f)

Subtract the piston pin diameter measurement from 
the bushing inside diameter measurement.
Standard oil clearance:

0.005 to 0.011 mm (0.0002 to 0.0004 in.)

Maximum oil clearance:

0.050 mm (0.0020 in.)

(g) If the oil clearance is greater than the maximum, 

replace the bushing. If necessary, replace the 
connecting rod and piston pin together.

33. INSPECT RING GROOVE CLEARANCE

(a) Using a feeler gauge, measure the clearance 

between a new piston ring and the wall of the ring 
groove.
Ring groove clearance

A076055E01

Mark

mm (in.)

A

22.005 to 22.008 (0.8663 to 0.8665)

B

22.009 to 22.011 (0.8665 to 0.8666)

C

22.012 to 22.014 (0.8666 to 0.8667)

Front Mark

Piston Pin 
Hole Inside 
Diameter 
Mark

Front Mark

Connecting Rod 
Bushing Inside 
Diameter Mark

A076391E02

A076056E01

Piston ring

Specification

No. 1

0.02 to 0.07 mm (0.0008 to 0.0028 in.)

No. 2

0.02 to 0.06 mm (0.0008 to 0.0024 in.)

Oil

0.07 to 0.15 mm (0.0028 to 0.0060 in.)

EM–162

1GR-FE ENGINE MECHANICAL  –  ENGINE UNIT

EM

34. INSPECT PISTON RING END GAP

(a) Using a piston, push the piston ring a little beyond 

the bottom of the ring travel, 110 mm (4.33 in.) from 
the top of the cylinder block.

(b) Using a feeler gauge, measure the end gap.

Standard end gap

Maximum end gap

35. INSPECT CONNECTING ROD BOLT

(a) Using vernier calipers, measure the diameter of the 

elongated portion of the bolt.
Standard diameter:

7.2 to 7.3 mm (0.283 to 0.287 in.)

Minimum diameter:

7.0 mm (0.276 in.)

If the diameter is less than the minimum, replace the 
bolt.

36. INSPECT CRANKSHAFT BEARING CAP SET BOLT

(a) Using vernier calipers, measure the diameter of the 

elongated portion of the bolt.
Standard diameter:

10.0 to 10.2 mm (0.393 to 0.402 in.)

If the diameter is less than the minimum, replace the 
bolt.

110 mm

A076057E02

A037355E01

Piston ring

Specification

No. 1

0.30 to 0.40 mm (0.0118 to 0.0157 in.)

No. 2

0.40 to 0.50 mm (0.0157 to 0.0197 in.)

Oil (Side rail)

0.10 to 0.40 mm (0.0039 to 0.0157 in.)

Piston ring

Specification

No. 1

1.0 mm (0.039 in.)

No. 2

1.1 mm (0.043 in.)

Oil (Side rail)

1.0 mm (0.039 in.)

A015065E01

A015065E01

 

 

 

 

 

 

 

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