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EM-70
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD
EM1XR-01
INSPECTION
1. INSPECT CYLINDER HEAD
(a) Inspect flatness.
Using a precision straight edge and feeler gauge, mea-
sure the flatness of the contact surfaces of the cylinder
block and manifolds.
Maximum warpage: 0.10 mm (0.0039 in.)
Cylinder Block Side:
If warpage is greater than the maximum, replace the cylinder
head.
Intake Manifold Side:
Exhaust Manifold Side:
A22932
(b) Inspect cranks.
Using a dye penetrant, check the combustion chamber,
intake ports, exhaust ports and cylinder block surface for
cracks.
If cracked, replace the cylinder head.
A22933
EM-71
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD
2. INSPECT INTAKE MANIFOLD FOR FLATNESS
Intake Air Surge Tank Side Using a precision straight edge and feeler gauge, mea-
sure the flatness of the contact surfaces of the cylinder
head and intake air surge tank.
Maximum warpage:
Intake air surge tank side: 0.8 mm (0.031 in.)
Cylinder head side: 0.2 mm (0.008 in.)
If warpage is greater than the maximum, replace the intake
manifold.
Cylinder Head Side
A22967
3. INSPECT EXHAUST MANIFOLD FOR FLATNESS
Using a precision straight edge and feeler gauge, measure the
flatness of the contact surface the cylinder head.
Maximum warpage: 0.7 mm (0.028 in.)
If warpage is greater than the maximum, replace the exhaust
manifold.
HINT:
Maximum warpage of each installation surface:
A22968 0.3 mm (0.012 in.)
4. INSPECT VALVE
(a) Inspect valve stem diameter.
Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
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.)
Z00052
(b) Inspect valve face angle.
(1) Grind the valve enough to remove pits and carbon.
(2) Check that the valve is ground to the correct valve
face angle.
Valve face angle: 44.5_
44.5_
Z00054
EM-72
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD
(c) Inspect valve head margin thickness.
Using vernier calipers, check the valve head margin thick-
ness.
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.
EM0181
(d) Inspect overall length.
Using vernier calipers, check the overall length.
Standard overall length:
Intake 106.95 mm (4.2106 in.)
Overall
Length Exhaust 105.80 mm (4.1654 in.)
Minimum overall length:
Intake 106.40 mm (4.1890 in.)
Exhaust 105.30 mm (4.1457 in.)
EM2534
If the overall length is less than the minimum, replace the valve.
(e) Inspect valve stem tip.
Check the surface of the valve stem tip for wear.
NOTICE:
Do not grind off more than the minimum length.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
EM0255
5. CLEAN VALVE SEAT
(a) Using a 45_ carbide cutter, resurface the valve seats.
(b) Clean the valve seats.
A22934
6. INSPECT VALVE SEAT
(a) Apply a light coat of prussian blue (or white lead) to the
valve face.
(b) Lightly press the valve against the valve seat.
NOTICE:
Width
Do not rotate the valve.
(c) Check the valve face and seat according to the following
procedure.
P12729 (1) If prussian blue (or white lead) appears around the
entire face, the valve is centered.
EM-73
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD
If not, replace the valve.
(2) If the prussian blue (or white lead) appears around
the entire valve seat, the guide and face are cen-
tered.
If not, resurface the valve seat.
(3) Check that the seat contacts the middle of the valve
face with the width below.
Standard width: 1.0 to 1.4 mm (0.039 to 0.055 in.)
7. REPAIR VALVE SEAT
NOTICE:
45_ Take off a cutter gradually to make the intake valve seat
30_ smooth.
(a) If the seating is too high to the valve face, use 30_ and 45_
cutters to correct the seat.
1.0 to 1.4 mm
A01476
Intake Side: (b) Intake side:
If the seating is too low to the valve face, use 60_ and 45_
60_
cutters to correct the seat.
45_
1.0 to 1.4 mm
A23191
Exhaust Side: (c) Exhaust side:
If the seating is too low to the valve face, use 75_ and 45_
75_ cutters to correct the seat.
45_
1.0 to 1.4 mm
A01477
(d) Handrub the valve and valve seat with an abrasive com-
pound.
(e) After handrubbing, clean the valve and valve seat.
A22935
EM-74
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD
8. INSPECT INNER COMPRESSION SPRING
Deviation
(a) Inspect squareness.
Using a steel square, measure the squareness of the in-
ner compression spring.
Maximum deviation: 2.0 mm (0.079 in.)
If the deviation is greater than the maximum, replace the inner
compression spring.
EM0988
(b) Inspect free length.
Using vernier calipers, measure the free length of the in-
ner compression spring.
Free length: 47.80 mm (1.8819 in.)
If the free length is not as specified, replace the inner compres-
sion spring.
EM0801
(c) Inspect tension.
Using a spring tester, measure the tension of the inner
compression spring at the specified installed length.
Installed tension:
186.2 to 205.8 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf) at
33.3 mm (1.311 in.)
If the installed tension is not as specified, replace the inner com-
pression spring.
EM0281
9. INSPECT VALVE GUIDE BUSH OIL CLEARANCE
(a) Using a caliper gauge, measure the inside 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 (Step 8)
from the valve guide bush inside diameter measurement.
Standard oil clearance:
A22936 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.)
Maximum oil clearance:
Intake 0.08 mm (0.0031 in.)
Exhaust 0.10 mm (0.0039 in..)
If the oil clearance is greater than the maximum, replace the
valve and valve guide bush.
EM-75
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD
10. INSPECT VALVE LIFTER
Using a micrometer, measure the valve lifter diameter.
Valve lifter diameter:
30.966 to 30.976 mm (1.2191 to 1.2195 in.)
P16860
11. INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using a caliper gauge, measure the lifter bore diameter
Diameter of the cylinder head.
Lifter bore diameter:
31.009 to 31.025 mm (1.2208 to 1.2215 in.)
(b) Subtract the valve lifter diameter measurement (Step 10)
from the lifter bore diameter measurement.
Standard oil clearance:
A22942 0.033 to 0.059 mm (0.0013 to 0.0023 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
If the oil clearance is greater than the maximum, replace the
valve lifter.
If necessary, replace the cylinder head.
12. INSPECT CAMSHAFT OIL CLEARANCE
Plastigage (a) Clean the camshaft bearing caps, camshaft bearings and
camshaft journals.
(b) Install the camshaft bearing (See page EM-89).
(c) Place the camshaft on the cylinder head.
(d) Lay a strip of Plastigage across each of the camshaft jour-
nals.
(e) Install the camshaft bearing caps (See page EM-89).
A22943 NOTICE:
Do not turn the camshafts.
(f) Remove the camshaft bearing caps (See page EM-62).
EM-76
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD
(g) Measure the Plastigage at its widest point.
Standard oil clearance (Cylinder head RH):
No. 1
0.008 to 0.038 mm (0.0003 to 0.0015 in.)
(Intake)
No. 1
0.040 to 0.079 mm (0.0016 to 0.0031 in.)
(Exhaust)
Others 0.025 to 0.062 mm (0.0010 to 0.0024 in.)
Standard oil clearance (Cylinder head LH):
A22944
No. 1 0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Others 0.025 to 0.062 mm (0.0010 to 0.0024 in.)
Maximum oil clearance (Cylinder head RH):
No. 1
0.07 mm (0.0028 in.)
(Intake)
Others 0.10 mm (0.0039 in.)
Maximum oil clearance (Cylinder head LH):
0.10 mm (0.0039 in.)
If the oil clearance is greater than the maximum, replace the
camshaft bearings and/or camshaft.
If necessary, replace the camshaft bearing caps and cylinder
head together.
Reference:
Cylinder head journal
40.009 to 40.017 mm (1.5752 to 1.5755 in.)
bore diameter
Camshaft bearing
center wall thickness 2.004 to 2.008 mm (0.0789 to 0.0791 in.)
(Mark "2")
Camshaft journal di-
35.971 to 35.985 mm (1.4165 to 1.4167 in.)
ameter
(h) Remove the Plastigage completely.
(i) Remove the camshafts.
(j) Remove the camshaft bearing.
13. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshafts (See page EM-89).
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.04 to 0.09 mm (0.0016 to 0.0035 in.)
Maximum thrust clearance: 0.11 mm (0.0043 in.)
If the thrust clearance is greater than the maximum, replace the
A22945 camshafts.
EM-77
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD
If necessary, replace the camshaft bearing caps and cylinder
head as a set.
14. INSPECT CAMSHAFT
(a) Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the runout at the
center journal.
Maximum runout: 0.06 mm (0.0024 in.)
If the runout is greater than the maximum, replace the camshaft
.
A22983
(b) Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake: 44.168 to 44.268 mm (1.7389 to 1.7428 in.)
Exhaust: 44.580 to 44.680 mm (1.7551 to 1.7591 in.)
Minimum cam lobe height:
Intake: 44.018 mm (1.7330 in.)
Exhaust: 44.430 mm (1.7492 in.)
EM2011 If the cam lobe height is less than the minimum, replace the
camshaft.
(c) Inspect the camshaft journals.
Using a micrometer, measure the journal diameter.
No. 1 journal diameter:
35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Other journal diameter:
22.959 to 22.975 mm (0.9039 to 0.9045 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
15. INSPECT CAMSHAFT TIMING GEAR
(a) Fix the intake camshaft with a vise.
NOTICE:
Be careful not to damage the camshaft.
A22984
EM-78
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD
(b) Align the knock pin hole in the camshaft timing gear as-
Knock Pin sembly with the knock pin of the camshaft, and install the
camshaft timing gear assembly with the bolt.
Torque: 100 Nm (1,020 kgfcm, 74 ftlbf)
(c) Confirm that the camshaft timing gear assembly is locked.
A22985
(d) Release the lock pin.
(1) Cover the 4 oil paths of the cam journal with mask-
Retard Side ing tape as shown in the illustration.
Paths
HINT:
One of the 2 grooves on the cam journal is for retards (upper)
and the other is for advances (lower). Each groove has 2 oil
Advance paths. Plug one of the oil paths for each groove with rubber
Side Paths pieces before wrapping the cam journal with tape.
(2) Prick a hole in the tape placed on the advance side
path. Prick a hole in the retard side path, on the op-
posite side to that of the advance side path, as
shown in the illustration.
Open Close
Close Open
Rubber
Piece Masking Tape
A22986
(3) Apply about 200 kPa (2.0 kgf/cm2) of air pressure
Advance to the two broken paths (the advance side path and
Retard
Side Path Side Path the retard side path).
NOTICE:
Cover the paths with a shop rag to avoid oil splashing.
A22987
(4) Confirm that the camshaft timing gear assembly ro-
Advance Retard tates in the advance direction when reducing the air
Side Path Side Path
pressure applied to the retard path.
HINT:
When the lock pin is released, the camshaft timing gear rotates
in the advance direction.
(5) When the camshaft timing gear comes to the most
advanced position, release the air pressure from
Hold Pressure Decompress
A22988 the retard side path, and then release the air pres-
sure from the advance side path.
EM-79
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD
NOTICE:
The camshaft timing assembly gear occasionally shifts to
the retard side abruptly if the air pressure of the advanced
side path is released first. This often results in breakage of
the lock pin.
(e) Check for smooth revolution.
Allow the camshaft timing gear assembly to turn back and
forth at any position, except where the lock pin meets at
the most retarded angle. Check the movable range and
that there is no disturbance.
Standard: Moves smoothly in a range of about 31 _
NOTICE:
Be sure to perform this check by hand, instead of air pres-
sure.
(f) Check the lock in the most retarded position.
Confirm that the camshaft timing gear assembly is locked
at the most retarded position.
(g) Remove the set bolt and camshaft timing gear assembly.
NOTICE:
Be sure not to remove the other 3 bolts.
Set Bolt
A22989
16. INSPECT CYLINDER HEAD SET BOLT
Using a vernier caliper, measure the outside thread diameter of
the bolt.
Standard outside diameter:
10.85 to 11.00 mm (0.4272 to 0.4331 in.)
Minimum outside diameter:
10.7 mm (0.421 in.)
A22890
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