Toyota FJ Cruiser (GSJ 10, 15 series). Instruction — part 164

1GR-FE ENGINE MECHANICAL – CYLINDER HEAD

EM–89

EM

INSTALLATION

1.

INSTALL NO. 2 CYLINDER HEAD GASKET
(a) Remove any old packing (FIPG) material.

HINT:
Do not drop any oil on the contact surface of the
cylinder head and cylinder block.

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

2.5 to 3.0 mm (0.098 to 0.118 in.)) to a new cylinder
head gasket as shown in the illustration.
Seal packing:

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

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

(c) Place the cylinder head gasket on the cylinder block

surface with the Lot No. stamp facing upward.
NOTICE:
•

Orient the cylinder head gasket correctly.

•

Place the cylinder head carefully in order not
to damage the gasket with the bottom part of
the head.

2.

INSTALL CYLINDER HEAD LH
(a) Place the cylinder head on the cylinder head gasket.
(b) Install the 8 cylinder head bolts.

HINT:
•

The cylinder head bolts are tightened in 2
successive steps (steps (*1) and (*2)).

•

If any cylinder head bolts are broken or
deformed, replace them.

(1) Apply a light coat of engine oil to the threads of

the cylinder head bolts.

(2) Install the plate washer onto the cylinder head

bolt.

(3) Using several steps, uniformly tighten each bolt

with a 10 mm bi-hexagon wrench in the
sequence shown in the illustration. (*1)
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
If any cylinder head bolts do not meet the
torque specification, replace them.
NOTICE:
Do not drop the washers into the cylinder
head.

10 to 15 mm

10 to 15 mm

Seal Packing

1.25 to 1.5 mm

Gasket

Ǿ 2.5 to 3 mm

A076275E02

Lot No.

A076276E02

1

5

6

4

7

8

3

2

A076277E01

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1GR-FE ENGINE MECHANICAL – CYLINDER HEAD

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(4) Mark the front side of each cylinder head bolt

with paint.

(5) Retighten the cylinder head bolts 180

° as

shown. (*2)

(6) Check that the painted marks are now at 180

°

from the engine front.

(c) Install the 2 cylinder head bolts.

(1) Apply a light coat of engine oil to the threads of

the cylinder head bolts.

(2) Using several steps, uniformly install and

tighten the 2 cylinder head bolts in the
sequence shown in the illustration.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

(d) Install the ground cable with the bolt.

Torque: 8.0 N*m (82 kgf*cm, 71 ft.*lbf)

(e) Install the air fuel ratio sensor connector bracket

with bolt.
Torque: 19 N*m (189 kgf*cm, 14 ft.*lbf)

3.

INSTALL CAMSHAFTS (for Bank 2)
NOTICE:
Keep the camshaft level while it is being removed.
The camshaft thrust clearance is very small and
failing to keep it level could crack or damage the
cylinder head journal surface, which receives the
thrust force. This could subsequently lead the
camshaft to seize or break. Perform the following
steps to avoid such problems.

(a) Set the crankshaft position.

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

crankshaft, and set the crankshaft set key in
the left horizontal position.
NOTICE:
Installing the crankshaft at the wrong angle
could cause the piston head and valve head
to come into contact with each other when
installing the camshaft. This could cause
damage, so always set the crankshaft at the
correct angle.

(b) Apply new engine oil to the thrust portion and

journal of the camshafts.

180 q

Engine
Front

Paint Mark

A076274E01

1

2

A072969E05

90 q

Set Key

Turn

A076280E01

1GR-FE ENGINE MECHANICAL – CYLINDER HEAD

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(c) Place the 2 camshafts onto the cylinder head with

the cam lobes of No. 1 cylinder facing in the
directions shown in the illustration.

(d) Install the 8 bearing caps in the proper locations as

shown.

(e) Apply a light coat of engine oil to the threads and

under the leads of the bearing cap bolts.

(f)

Using several steps, uniformly install and tighten the
16 bearing cap bolts in the sequence shown in the
illustration.
Torque: 10 mm (0.39 in.) head

9.0 N*m (92 kgf*cm, 80 in.*lbf)
12 mm (0.47 in.) head
24 N*m (245 kgf*cm, 18 ft.*lbf)

4.

INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
(a) While pushing in the tensioner, insert a pin of

φ 1.0

mm (0.039 in.) into the hole to fix it.

(b) Install the No. 2 chain tensioner with the bolt.

Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)

A076284E04

A076285E03

3

6

4

7

9

8

5

2

1

10

11

12

13

14

15

16

A072968E08

Push

A076289E01

A072965E01

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1GR-FE ENGINE MECHANICAL – CYLINDER HEAD

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5.

INSTALL CAMSHAFT TIMING GEARS AND NO. 2
CHAIN (for Bank 2)
(a) Align the yellow mark links with the timing marks (1

dot mark and 2 dot marks) of the camshaft timing
gears as shown in the illustration.

(b) Align the timing marks on the camshaft timing gears

with the timing marks on the bearing caps, and
install the camshaft timing gears with the chain onto
the LH camshafts.

(c) Temporarily install the 2 camshaft timing gear bolts.

NOTICE:
Do not push the camshaft timing gear assembly
against the camshaft forcibly when installing it.

(d) Hold the hexagonal portion of the camshaft with a

wrench, and tighten the 2 bolts.
Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)

(e) Remove the pin from tensioner No. 2.

6.

INSTALL NO. 1 CHAIN VIBRATION DAMPER
(a) Install the chain vibration damper with the 2 bolts.

Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)

7.

INSTALL CYLINDER HEAD GASKET
(a) Remove any old packing (FIPG) material.

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

Mark Links

Timing Marks

A076290E03

Timing Marks

Timing Marks

G036258E02

G036255E01

A076292E01