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
)
2.
INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(See page
3.
INSPECT CYLINDER HEAD SET BOLT (See page
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
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Measuring Area
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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.
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Raise
Move
Lock
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Move
Wear
Wear
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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
)
18. INSPECT CYLINDER HEAD SUB-ASSEMBLY (See
page
)
19. CLEAN VALVE (See page
20. INSPECT VALVE (See page
21. CLEAN VALVE SEAT (See page
)
22. INSPECT VALVE SEAT (See page
23. INSPECT INNER COMPRESSION SPRING (See page
)
24. INSPECT VALVE GUIDE BUSH OIL CLEARANCE
(See page
)
25. INSPECT VALVE LIFTER (See page
26. INSPECT VALVE LIFTER OIL CLEARANCE (See page
)
Wear
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Wear
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Wear
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