Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 467

 

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Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 467

 

 

SS–6

SERVICE SPECIFICATIONS  –  1GR-FE ENGINE MECHANICAL

SS

1GR-FE ENGINE MECHANICAL

SERVICE DATA

Ignition timing

Terminals TC and CG of

DLC3 connected

8 to 12

° BTDC @ idle (Transmission in neutral 

position)

Terminals TC and CG of

DLC3 disconnected

7 to 24

° BTDC @ idle (Transmission in neutral 

position)

Idle speed

650 to 750 rpm (Transmission in neutral position)

Compression

Compression pressure

1,300 kPa (13.3 kgf/cm

2

, 189 psi) or more

Minimum pressure

1,000 kPa (10.2 kgf/cm

2

, 145 psi)

Difference between each

cylinder

100 kPa (1.0 kgf/cm

2

, 15 psi) or less

Valve clearance

Intake

(cold)

0.15 to 0.25 mm (0.006 to 0.010 in.)

Exhaust

0.29 to 0.39 mm (0.011 to 0.015 in.)

Intake manifold

Intake air 
surge tank 
side 
warpage

Maximum

0.8 mm (0.031 in.)

Cylinder 
head side 
warpage

0.2 mm (0.008 in.)

Exhaust manifold

Warpage

Maximum

0.7 mm (0.028 in.)

Camshaft timing gear assembly

Diameter 
(with chain)

Large gear

115.5 mm (4.547 in.)

Small gear

73.1 mm (2.878 in.)

Camshaft timing gear or sprocket

Diameter (with chain)

73.1 mm (2.878 in.)

Crankshaft timing gear or sprocket

Diameter (with chain)

61.0 mm (2.402 in.)

Idle sprocket

Diameter (with chain)

61.0 mm (2.402 in.)

Cylinder head set bolt

Outer 
diameter

Standard

10.85 to 11.00 mm (0.4272 to 0.4331 in.)

Minimum

10.7 mm (0.421 in.)

Chain sub-assembly

Length

Maximum

146.8 mm (5.780 in.)

No. 2 chain sub-assembly

Length

Maximum

146.8 mm (5.780 in.)

Idle gear shaft

Diameter

22.987 to 23.000 mm (0.9050 to 0.9055 in.)

Internal diameter

23.02 to 23.03 mm (0.9063 to 0.9067 in.)

Oil 
clearance

Standard

0.020 to 0.043 mm (0.0008 to 0.0017 in.)

Maximum

0.093 mm (0.0037 in.)

Chain tensioner assembly No. 2

Wear

Maximum

1.0 mm (0.039 in.)

Chain tensioner assembly No. 3

Wear

Maximum

1.0 mm (0.039 in.)

Chain tensioner slipper

Wear

Maximum

1.0 mm (0.039 in.)

Chain vibration damper No. 1

Wear

Maximum

1.0 mm (0.039 in.)

Chain vibration damper No. 2

Wear

Maximum

1.0 mm (0.039 in.)

Cylinder head sub-assembly

Warpage

Maximum

0.10 mm (0.0039 in.)

Intake valve

Valve stem diameter

5.470 to 5.485 mm (0.2154 to 0.2159 in.)

Valve face angle

45.5

°

Margin 
thickness

Standard

1.0 mm (0.039 in.)

Minimum

0.5 mm (0.020 in.)

Overall 
length

Standard

106.95 mm (4.2106 in.)

Minimum

106.70 mm (4.2008 in.)

SERVICE SPECIFICATIONS  –  1GR-FE ENGINE MECHANICAL

SS–7

SS

Exhaust valve

Valve stem diameter

5.465 to 5.480 mm (0.2152 to 0.2158 in.)

Valve face angle

45.5

°

Margin 
thickness

Standard

1.0 mm (0.039 in.)

Minimum

0.5 mm (0.020 in.)

Overall 
length

Standard

105.80 mm (41654 in.)

Minimum

105.55 mm (4.1555 in.)

Inner compression spring

Deviation

Maximum

2.0 mm (0.079 in.)

Free length

Maximum

47.80 mm (1.8819 in.)

Tension

at 33.3 mm (1.311 in.)

186.2 to 205.8 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf)

Intake valve guide bush

Inside diameter

5.51 to 5.53 mm (0.2169 to 0.2177 in.)

Oil 
clearance

Standard

0.025 to 0.060 mm (0.0010 to 0.0024 in.)

Maximum

0.08 mm (0.0031 in.)

Bore diameter

10.295 to 10.315 mm (0.4053 to 0.4061 in.)

Protrusion height

9.3 to 9.7 mm (0.366 to 0.382 in.)

Exhaust valve guide bush

Inside diameter

5.51 to 5.53 mm (0.2169 to 0.2177 in.)

Oil 
clearance

Standard

0.030 to 0.065 mm (0.0012 to 0.0026 in.)

Maximum

0.10 mm (0.0039 in.)

Bore diameter

10.295 to 10.315 mm (0.4053 to 0.4061 in.)

Protrusion height

9.3 to 9.7 mm (0.366 to 0.382 in.)

Valve lifter

Diameter

30.966 to 30.976 mm (1.2191 to 1.2195 in.)

Bore diameter

31.009 to 31.025 mm (1.2208 to 1.2215 in.)

Oil 
clearance

Standard

0.033 to 0.059 mm (0.0013 to 0.0023 in.)

Maximum

0.08 mm (0.0031 in.)

No. 1 camshaft

Journal 
diameter

No. 1 journal

35.971 to 35.985 mm (1.4162 to 1.4167 in.)

Other journals

22.959 to 22.975 mm (0.9039 to 0.9045 in.)

Circle 
runout

Maximum

0.06 mm (0.0024 in.)

Cam lobe 
height

Standard

44.168 to 44.268 mm (1.7389 to 1.7428 in.)

Minimum

44.018 mm (1.7330 in.)

Oil 
clearance

No. 1

journal

Standard

0.008 to 0.038 mm (0.0003 to 0.0015 in.)

Other journals

0.025 to 0.062 mm (0.0010 to 0.0024 in.)

No. 1

journal

Maximum

0.07 mm (0.0028 in.)

Other journals

0.10 mm (0.0039 in.)

Thrust 
clearance

Standard

0.04 to 0.09 mm (0.016 to 0.035 in.)

Maximum

0.11 mm (0.0043 in.)

No. 2 camshaft

Journal 
diameter

No. 1 journal

35.971 to 35.985 mm (1.4162 to 1.4167 in.)

Other journals

22.959 to 22.975 mm (0.9039 to 0.9045 in.)

Circle 
runout

Maximum

0.06 mm (0.0024 in.)

Cam lobe 
height

Standard

44.580 to 44.680 mm (1.7551 to 1.7591 in.)

Minimum

44.430 mm (1.7492 in.)

Oil 
clearance

No. 1

journal

Standard

0.040 to 0.079 mm (0.0016 to 0.0031 in.)

Other journals

0.025 to 0.062 mm (0.0010 to 0.0024 in.)

Maximum

0.10 mm (0.0039 in.)

Thrust 
clearance

Standard

0.04 to 0.09 mm (0.016 to 0.035 in.)

Maximum

0.11 mm (0.0043 in.)

SS–8

SERVICE SPECIFICATIONS  –  1GR-FE ENGINE MECHANICAL

SS

No. 3 camshaft sub-assembly

Journal 
diameter

No. 1 journal

35.971 to 35.985 mm (1.4162 to 1.4167 in.)

Other journals

22.959 to 22.975 mm (0.9039 to 0.9045 in.)

Circle 
runout

Maximum

0.06 mm (0.0024 in.)

Cam lobe 
height

Standard

44.168 to 44.268 mm (1.7389 to 1.7428 in.)

Minimum

44.018 mm (1.7330 in.)

Oil 
clearance

No. 1

journal

Standard

0.008 to 0.038 mm (0.0003 to 0.0015 in.)

Other journals

0.025 to 0.062 mm (0.0010 to 0.0024 in.)

Maximum

0.10 mm (0.0039 in.)

Thrust 
clearance

Standard

0.04 to 0.09 mm (0.016 to 0.035 in.)

Maximum

0.11 mm (0.0043 in.)

No. 4 camshaft sub-assembly

Journal 
diameter

No. 1 journal

35.971 to 35.985 mm (1.4162 to 1.4167 in.)

Other journals

22.959 to 22.975 mm (0.9039 to 0.9045 in.)

Circle 
runout

Maximum

0.06 mm (0.0024 in.)

Cam lobe 
height

Standard

44.580 to 44.680 mm (1.7551 to 1.7591 in.)

Minimum

44.430 mm (1.7492 in.)

Oil 
clearance

No. 1

journal

Standard

0.040 to 0.079 mm (0.0016 to 0.0031 in.)

Other journals

0.025 to 0.062 mm (0.0010 to 0.0024 in.)

Maximum

0.10 mm (0.0039 in.)

Thrust 
clearance

Standard

0.04 to 0.09 mm (0.016 to 0.035 in.)

Maximum

0.11 mm (0.0043 in.)

Ring pin for cylinder head sub-assembly and 
cylinder head LH

Protrusion height

2.7 to 3.3 mm (0.106 to 0.130 in.)

Straight pin for cylinder head sub-assembly 
and cylinder head LH

Protrusion 
height

A

17.5 to 19.5 mm (0.689 to 0.768 in.)

B

7.5 to 8.5 mm (0.295 to 0.335 in.)

C

7.0 to 9.0 mm (0.276 to 0.354 in.)

Tight plug for cylinder head sub-assembly 
and cylinder head LH

Depth

1.5 mm (0.059 in.)

Connecting rod

Thrust 
clearance

Standard

0.15 to 0.30 mm (0.0059 to 0.0118 in.)

Maximum

0.35 mm (0.0138 in.)

Oil 
clearance

Standard

0.026 to 0.046 mm (0.0010 to 0.0018 in.)

Maximum

0.066 mm (0.0025 in.)

Crankshaft thrust clearance

Standard

0.04 to 0.24 mm (0.0016 to 0.0094 in.)

Maximum

0.30 mm (0.0118 in.)

Cylinder block warpage

Maximum

0.05 mm (0.0020 in.)

Cylinder bore diameter

Standard

94.000 to 94.012 mm (3.7008 to 3.7013 in.)

Maximum

94.132 mm (3.7060 in.)

Piston

Diameter

93.910 to 93.940 mm (3.6972 to 3.6984 in.)

Oil 
clearance

Standard

0.060 to 0.102 mm (0.0031 to 0.0040 in.)

Maximum

0.13 mm (0.0051 in.)

Connecting rod out-of alignment

Maximum

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

Connecting rod twist

Maximum

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

Connecting rod bushing

Internal diameter

22.005 to 22.014 mm (0.8662 to 0.8665 in.)

Piston pin

Diameter

21.997 to 22.006 mm (0.8660 to 0.8664 in.)

Oil clearance

Standard

0.005 to 0.011 mm (0.0002 to 0.0004 in.)

Maximum

0.050 mm (0.0020 in.)

Piston ring

Groove 
clearance

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.)

SERVICE SPECIFICATIONS  –  1GR-FE ENGINE MECHANICAL

SS–9

SS

Piston pin

Internal diameter

22.001 to 22.010 mm (0.8662 to 0.8665 in.)

Piston ring

End gap

No. 1

Standard

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.)

No. 1

Maximum

1.0 mm (0.039 in.)

No. 2

1.1 mm (0.043 in.)

Oil (Side

rail)

1.0 mm (0.039 in.)

Connecting rod bolt

Diameter

Standard

7.2 to 7.3 mm (0.283 to 0.287 in.)

Minimum

7.0 mm (0.276 in.)

Thrust 
clearance

Standard

0.15 to 0.30 mm (0.0059 to 0.0118 in.)

Minimum

0.35 mm (0.0138 in.)

Crankshaft bearing cap set bolt

Diameter

Standard

10.0 to 10.2 mm (0.393 to 0.402 in.)

Crankshaft

Circle 
runout

Maximum

0.06 mm (0.0024 in.)

Main journal

Diameter

71.988 to 72.000 mm (2.8342 to 2.8346 in.)

Main journal

Taper and 
out-of-
round

Maximum

0.02 mm (0.0008 in.)

Crank pin

Diameter

55.992 to 56.000 mm (2.2044 to 2.2047 in.)

Crank pin

Taper and 
out-of-
round

Maximum

0.02 mm (0.0008 in.)

Crankshaft

Oil 
clearance

Standard

0.018 to 0.030 mm (0.0007 to 0.0012 in.)

Maximum

0.046 mm (0.0018 in.)

Thrust 
clearance

0.04 to 0.24 mm (0.0016 to 0.0094 in.)

Maximum

0.30 mm (0.0018 in.)

Straight pin

Protrusion

Pin A

Standard

22.5 to 23.5 mm (0.886 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.)

 

 

 

 

 

 

 

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