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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