Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 161

1GR-FE ENGINE MECHANICAL  –  CYLINDER HEAD

EM–77

EM

(c) Using a valve guide bushing brush and solvent, 

clean all the valve guide bushes.

(d) Using a soft brush and solvent, thoroughly clean the 

cylinder head.

3.

INSPECT CYLINDER HEAD SUB-ASSEMBLY
(a) Inspect the cylinder head for warpage.

(1) Using a precision straight edge and feeler 

gauge, measure the warpage on the cylinder 
block side and the intake and exhaust sides.
Maximum warpage:

0.10 mm (0.0039 in.)

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

A075607E01

A075608E01

Cylinder Block Side:

Intake Manifold Side:

Exhaust Manifold Side:

A075609E03

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1GR-FE ENGINE MECHANICAL  –  CYLINDER HEAD

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(b) Inspect the cylinder head for cracks.

(1) Using a dye penetrant, check the combustion 

chamber, intake ports, exhaust ports and 
cylinder block surface for cracks.
If cracked, replace the cylinder head.

4.

CLEAN VALVE
(a) Using a gasket scraper, chip off any carbon from the 

valve head.

(b) Using a wire brush, thoroughly clean the valve.

5.

INSPECT VALVE
(a) Inspect the valve stem diameter.

(1) Using a micrometer, measure the diameter of 

the valve stem.
Valve stem diameter

(b) Inspect the valve face angle.

(1) Grind the valve enough to remove any pits and 

carbon.

(2) Check that the valve is ground to the correct 

valve face angle.
Valve face angle:

45.5

°

(c) Inspect the valve head margin thickness.

(1) Using vernier calipers, check the valve head 

margin thickness.
Standard margin thickness:

1.0 mm (0.039 in.)

Minimum margin thickness:

0.5 mm (0.020 in.)

If the margin thickness is less than the 
minimum, replace the valve.

A075610E01

EM00580E01

A032770E01

Valve Stem

Specification

Intake

5.470 to 5.485 mm (0.2154 to 0.2159 in.)

Exhaust

5.465 to 5.480 mm (0.2152 to 0.2158 in.)

45.5 °

A075611E03

Margin 
Thickness

EM00181E02

1GR-FE ENGINE MECHANICAL  –  CYLINDER HEAD

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(d) Inspect the overall length.

(1) Using vernier calipers, check the overall length.

Standard overall length

Minimum overall length

If the overall length is less than the minimum, 
replace the valve.

(e) Inspect the valve stem tip.

(1) Check the surface of the valve stem tip for 

wear.
NOTICE:
Do not grind to less than the minimum 
length.
If the valve stem tip is worn, resurface the tip 
with a grinder or replace the valve.

6.

CLEAN VALVE SEAT
(a) Using a 45

° carbide cutter, resurface the valve 

seats.

(b) Clean the valve seats.

7.

INSPECT VALVE SEAT
(a) Apply a light coat of prussian blue to the valve face.
(b) Lightly press the valve against the valve seat.

NOTICE:
Do not rotate the valve.

(c) Check the valve face and seat according to the 

following procedure.
(1) If blue appears 360

° around the face, the valve 

is concentric.
If not, replace the valve.

(2) If the blue appears 360

° around the valve seat, 

the guide and face are concentric.
If not, resurface the valve seat.

(3) Check that the seat is in contact with the middle 

of the valve face with the following width.
Standard width:

1.0 to 1.4 mm (0.039 to 0.055 in.)

Overall 
Length

EM02534E08

Valve

Specification

Intake

106.95 mm (4.2106 in.)

Exhaust

105.80 mm (4.1654 in.)

Valve

Specification

Intake

106.70 mm (4.2008 in.)

Exhaust

105.55 mm (4.1555 in.)

EM00255E01

A075612E01

Width

P012729E01

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1GR-FE ENGINE MECHANICAL  –  CYLINDER HEAD

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8.

INSPECT INNER COMPRESSION SPRING
(a) Inspect the deviation.

(1) Using steel squares, measure the deviation of 

the inner compression spring.
Maximum deviation:

2.0 mm (0.079 in.)

If the deviation is greater than the maximum, 
replace the inner compression spring.

(b) Inspect the free length.

(1) Using vernier calipers, measure the free length 

of the inner compression spring.
Free length:

47.80 mm (1.8819 in.)

If the free length is not as specified, replace the 
inner compression spring.

(c) Inspect the tension.

(1) Using a spring tester, measure the tension of 

the inner compression spring at the specified 
installed length.
Installed tension

If the installed tension is not as specified, 
replace the inner compression spring.

9.

INSPECT VALVE GUIDE BUSH OIL CLEARANCE
(a) Using a caliper gauge, measure the internal 

diameter of the valve guide bush.
Inside diameter:

5.51 to 5.53 mm (0.2169 to 0.2177 in.)

(b) Subtract the valve stem diameter measurement 

from the valve guide bush internal diameter 
measurement.
Standard oil clearance

Maximum oil clearance

If the oil clearance is greater than the maximum, 
replace the valve and valve guide bush.

EM00988E03

EM00801E01

EM00281E01

Installed Length

Specification

33.3 mm (1.311 in.)

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

lbf)

A075615E02

Valve Guide Bush

Specification

Intake

0.025 to 0.060 mm (0.0010 to 0.0024 in.)

Exhaust

0.030 to 0.065 mm (0.0012 to 0.0026 in.)

Valve Guide Bush

Specification

Intake

0.08 mm (0.0031 in.)

Exhaust

0.10 mm (0.0039 in..)