Toyota FJ Cruiser (GSJ 10, 15 series). Manual — part 156

1GR-FE ENGINE MECHANICAL – CAMSHAFT

EM–57

EM

7.

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

tensioner clockwise, push in the plunger of the No. 1
chain tensioner as shown in the illustration.

(b) While turning the stopper plate of the tensioner

counterclockwise, insert a bar of

φ 3.5 mm (0.138

in.) into the holes in the stopper plate and No. 1
chain tensioner to fix the stopper plate.

(c) Install the No. 1 chain tensioner with the 2 bolts.

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

(d) Remove the bar from the No. 1 chain tensioner.
(e) Install a new gasket and the timing chain cover plate

with the 4 bolts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

(f)

Turn the crankshaft pulley 2 complete revolutions
slowly until its groove and the "0" timing mark of the
timing chain cover are aligned.

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

gears are aligned with the timing marks of the
bearing cap as shown in the illustration.

8.

SET CYLINDER TO TDC/COMPRESSION (See page

EM-8

)

9.

INSPECT VALVE CLEARANCE (See page

EM-9

)

10. ADJUST VALVE CLEARANCE (See page

EM-10

)

11. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

LH
(a) Remove any old packing (FIPG) material.

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

Stopper Plate

Stopper Plate

Push

A076294E02

A076530E01

Bank 1:

Timing Marks

Timing Marks

Timing Marks

Bank 2:

G036290E06

EM–58

1GR-FE ENGINE MECHANICAL – CAMSHAFT

EM

(b) Apply a continuous bead of seal packing (diameter

2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and
timing chain cover as shown in the illustration.
Seal packing:

Toyota Genuine Seal Packing Black, Three
Bond 1207B or the equivalent

NOTICE:
Install the cylinder head cover within 3 minutes
of applying the seal packing. Tighten the
cylinder head cover bolts and nuts within 15
minutes of installing the cylinder head cover.
Otherwise, the seal packing must be removed
and reapplied.

(c) Install the seal washers onto the bolts.

(d) Install the cylinder head cover with the 10 bolts and

2 nuts. Tighten the bolts and nuts uniformly in
several steps.
Torque: Bolt A

10 N*m (102 kgf*cm, 7.4 ft.*lbf)
Bolt B
9.0 N*m (92 kgf*cm, 80 in.*lbf)
Nut
9.0 N*m (92 kgf*cm, 80 in.*lbf)

HINT:
Each bolt length is as follows.

12. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove any old packing (FIPG) material.

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

(b) Apply a continuous bead of seal packing (diameter

2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and
timing chain cover as shown in the illustration.
Seal packing:

Toyota Genuine Seal Packing Black, Three
Bond 1207B or the equivalent

NOTICE:
Install the cylinder head cover within 3 minutes
of applying the seal packing. Tighten the
cylinder head cover bolts and nuts within 15
minutes of installing the cylinder head cover.
Otherwise, the seal packing must be removed
and reapplied.

(c) Install the seal washers onto the bolts.

Seal Packing

Seal Width: 2 to 3 mm

A076311E02

A

A

A

A

A

A

A

B

B

B

Nut

Nut

A076503E03

Bolt

Length

A

25 mm (0.98 in.)

B

60 mm (2.36 in.)

Seal Width: 2 to 3 mm

Seal Packing

A076310E02

1GR-FE ENGINE MECHANICAL – CAMSHAFT

EM–59

EM

(d) Install the cylinder head cover with the 10 bolts and

2 nuts. Tighten the bolts and nuts uniformly in
several steps.
Torque: Bolt A

10 N*m (102 kgf*cm, 7.4 ft.*lbf)
Bolt B
9.0 N*m (92 kgf*cm, 80 in.*lbf)
Nut
9.0 N*m (92 kgf*cm, 80 in.*lbf)

HINT:
Each bolt length is as follows.

13. INSTALL IGNITION COIL ASSEMBLY (See page

IG-8

)

14. INSTALL INTAKE AIR SURGE TANK (See page

FU-

17

)

15. INSTALL NO. 2 SURGE TANK STAY (See page

FU-19

)

16. INSTALL NO. 1 SURGE TANK STAY (See page

FU-19

)

17. INSTALL OIL BAFFLE PLATE (See page

FU-19

)

18. INSTALL THROTTLE BODY BRACKET (See page

FU-

19

)

19. INSTALL AIR CLEANER ASSEMBLY (See page

ES-

431

)

20. CONNECT CABLE TO NEGATIVE BATTERY

TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)

21. ADD ENGINE COOLANT (See page

CO-3

)

22. CHECK FOR ENGINE COOLANT LEAKAGE (See

page

CO-4

)

23. CHECK FOR ENGINE OIL LEAKAGE

24. INSPECT IGNITION TIMING (See page

EM-1

)

25. INSTALL V-BANK COVER (See page

ES-431

)

A

A

A

A

A

A

A

B

B

B

Nut

Nut

A072943E03

Bolt

Length

A

25 mm (0.98 in.)

B

60 mm (2.36 in.)

EM–60

1GR-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

ENGINE

1GR-FE ENGINE MECHANICAL

CYLINDER HEAD

COMPONENTS

12 (122, 9.0)

NO. 2 FUEL PIPE CLAMP

N*m (kgf*cm, ft*lbf) : Specified torque

NO. 1 COOL AIR
INLET

NO. 1 FUEL PIPE SUB-ASSEMBLY

NO. 2 FUEL PIPE SUB-ASSEMBLY

NO. 2 FUEL PIPE CLAMP

A126431E01