Toyota FJ Cruiser (GSJ 10, 15 series). Manual — part 148

1GR-FE ENGINE MECHANICAL – TIMING CHAIN

EM–25

EM

21. REMOVE OIL BAFFLE PLATE (See page

FU-11

)

22. REMOVE NO. 1 SURGE TANK STAY (See page

FU-11

)

23. REMOVE NO. 2 SURGE TANK STAY (See page

FU-12

)

24. REMOVE INTAKE AIR SURGE TANK (See page

FU-

12

)

25. REMOVE IGNITION COIL ASSEMBLY (See page

IG-8

)

26. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE

ASSEMBLY (See page

ES-414

)

27. REMOVE VVT SENSOR (See page

ES-417

)

28. REMOVE WATER INLET (See page

CO-8

)

29. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(See page

EM-40

)

30. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

LH (See page

EM-40

)

31. REMOVE TIMING CHAIN OR BELT COVER SUB-

ASSEMBLY
(a) Remove the 24 bolts and 2 nuts.

(b) Remove the timing chain cover by prying between

the timing chain cover, cylinder head or cylinder
block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of
the timing chain cover, cylinder block and
cylinder head.

(c) Remove the O-ring from the LH cylinder head.

32. REMOVE TIMING GEAR CASE OR TIMING CHAIN

CASE OIL SEAL (See page

EM-163

)

G036303E01

G036304E01

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1GR-FE ENGINE MECHANICAL – TIMING CHAIN

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33. SET NO. 1 COMPRESSION TO TDC/COMPRESSION

(a) Using the crankshaft pulley set bolt, turn the

crankshaft to align the crankshaft set key with the
timing line of the cylinder block.

(b) Check that the timing marks of the camshaft timing

gears are aligned with the timing marks of the
bearing caps as shown in the illustration.
If not, turn the crankshaft 1 complete revolution
(360

°) and align the timing marks as above.

34. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

NOTICE:
•

Never rotate the crankshaft with the chain
tensioner removed.

•

When rotating the camshaft with the timing chain
removed, rotate the crankshaft counterclockwise
40

° from the TDC first.

(a) While turning the stopper plate of the tensioner

upward, push in the plunger of the chain tensioner
as shown in the illustration.

(b) While turning the stopper plate of the tensioner

downward, insert a bar of

φ 3.5 mm (0.138) into the

holes in the stopper plate and tensioner to fix the
stopper plate.

(c) Remove the 2 bolts, then remove the chain

tensioner.

35. REMOVE CHAIN TENSIONER SLIPPER

36. REMOVE IDLE SPROCKET ASSEMBLY

(a) Using a 10 mm hexagon wrench, remove the No. 2

idle gear shaft, No. 1 idle gear and No. 1 idle gear
shaft.

37. REMOVE NO. 2 CHAIN VIBRATION DAMPER

(a) Remove the 2 No. 2 chain vibration dampers.

38. REMOVE CHAIN SUB-ASSEMBLY

Timing Line

Set Key

A076450E02

Bank 1:

Timing Marks

Timing Marks

Timing Marks

Bank 2:

G036290E06

Stopper Plate

Stopper Plate

Push

A072958E02

A072959E01

1GR-FE ENGINE MECHANICAL – TIMING CHAIN

EM–27

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INSTALLATION

1.

INSTALL CHAIN TENSIONER SLIPPER

2.

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
(a) While turning the stopper plate of the tensioner

clockwise, push in the plunger of the tensioner as
shown in the illustration.

(b) While turning the stopper plate of the tensioner

counterclockwise, insert a bar of

φ 35 mm (0.138 in.)

into the holes in the stopper plate and tensioner to
fix the stopper plate.

(c) Install the chain tensioner with the 2 bolts.

Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf)

3.

INSTALL CHAIN SUB-ASSEMBLY
(a) Set the No. 1 cylinder to TDC/ compression.

(1) Align the timing marks of the camshaft timing

gears and bearing caps.

(2) Using the crankshaft pulley set bolt, turn the

crankshaft to align the crankshaft set key with
the timing line of the cylinder block.

Stopper Plate

Stopper Plate

Push

A076294E02

Bank 1:

Timing Marks

Timing Marks

Timing Marks

Bank 2:

G036290E06

Timing Line

Set Key

A076296E02

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1GR-FE ENGINE MECHANICAL – TIMING CHAIN

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(b) Align the yellow mark link with the timing mark of the

crankshaft timing link.

(c) Align the orange mark links with the timing marks of

the camshaft timing gears, and install the chain.

4.

INSTALL NO. 2 CHAIN VIBRATION DAMPER
(a) Install the 2 No. 2 chain vibration dampers.

5.

INSTALL IDLE SPROCKET ASSEMBLY
(a) Apply a light coat of engine oil to rotating surface of

the No. 1 idle gear shaft.

(b) Temporarily install the No. 1 idle gear shaft together

with the No. 2 idle gear shaft with the knock pin of
the No. 1 idle gear shaft and the knock pin groove of
the cylinder block are aligned.
NOTICE:
Orient the idle gear shafts correctly.

(c) Using a 10 mm hexagon wrench, tighten the No. 2

idle gear shaft.
Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)

(d) Remove the bar from the chain tensioner.

6.

INSTALL TIMING GEAR CASE OR TIMING CHAIN
CASE OIL SEAL (See page

EM-163

)

7.

INSTALL TIMING CHAIN OR BELT COVER SUB-
ASSEMBLY
(a) Remove any old packing (FIPG) material.

HINT:
Do not drop any oil on the contact surfaces of the
timing chain cover, cylinder head and cylinder block.

(b) Install a new O-ring onto the bank 2 cylinder head

as shown in the illustration.

Timing Mark

Mark Link

A076297E03

Mark Links

Timing Marks

G036259E02

Knock Pin

Forward

A076299E02

G036305E01