Toyota FJ Cruiser (GSJ 10, 15 series). Instruction — part 177

1GR-FE ENGINE MECHANICAL – ENGINE UNIT

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EM

27. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 4 stud bolts from the oil pan.

(b) Remove the 17 bolts and 2 nuts.

(c) Using a screwdriver, remove the oil pan by prying

between the oil pan and cylinder block in the
sequence shown.
NOTICE:
Be careful not to damage the contact surfaces of
the cylinder block and oil pan.

(d) Remove the O-ring from the oil pump.

28. REMOVE WATER PUMP ASSEMBLY

(a) Remove the 17 bolts, then remove the water pump

and gasket.

29. REMOVE TIMING CHAIN OR BELT COVER SUB-

ASSEMBLY
(a) Remove the 15 bolts and 2 nuts.

Y

A126353

A126352

Pry

G036806E01

A072954E01

G036855E03

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1GR-FE ENGINE MECHANICAL – ENGINE UNIT

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(b) Remove the timing chain cover by prying between

the timing chain cover, cylinder head and 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 4 bolts and timing chain cover plate.
(d) Remove the O-ring from the cylinder head LH.

30. 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 in.) into

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

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

tensioner.

31. REMOVE CHAIN TENSIONER SLIPPER

32. 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.

33. REMOVE NO. 2 CHAIN VIBRATION DAMPER

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

34. REMOVE CHAIN SUB-ASSEMBLY

35. REMOVE CRANKSHAFT TIMING GEAR OR

SPROCKET

G036859E01

Stopper Plate

Stopper Plate

Push

A072958E02

G036860E01

G036844E01

1GR-FE ENGINE MECHANICAL – ENGINE UNIT

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36. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts, then remove the No. 1 chain

vibration damper.

37. REMOVE CAMSHAFT TIMING GEARS AND NO. 2

CHAIN (for Bank 1)
(a) While raising chain tensioner No. 2 upward, insert a

pin of

φ 1.0 mm (0.039 in.) into the hole to fix it.

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

wrench, and remove the 2 bolts, camshaft timing
gear, camshaft timing gear assembly and No. 2
timing chain.
NOTICE:
•

Be careful not to damage the cylinder head
and valve lifter with the wrench.

•

Do not disassemble the camshaft timing gear
assembly.

38. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt, then remove the No. 2 chain

tensioner.

39. REMOVE CAMSHAFT TIMING GEARS AND NO. 2

CHAIN (for Bank 2)
(a) While pushing down the No. 3 chain tensioner,

insert a pin of

φ 1.0 mm (0.039 in.) into the hole to fix

it.

G036808E01

Raise

G036850E01

Hold

Loosen

G036834E01

A072962E01

Push

G036835E01

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

wrench, and remove the 2 bolts, camshaft timing
gear, camshaft timing gear assembly and No. 2
timing chain.
NOTICE:
•

Be careful not to damage the cylinder head
and valve lifter with the wrench.

•

Do not disassemble the camshaft timing gear
assembly.

40. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt, then remove the No. 3 chain

tensioner.

41. INSPECT CAMSHAFT THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance

while moving the camshaft back and forth.
Standard thrust clearance:

0.04 to 0.09 mm (0.016 to 0.035 in.)

Maximum thrust clearance:

0.11 mm (0.0043 in.)

If the thrust clearance is greater than the maximum,
replace the camshafts.
If necessary, replace the camshaft bearing caps and
cylinder head as a set.

42. REMOVE CAMSHAFTS

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) Remove the camshafts of bank 1.

(1) Rotate the camshafts counterclockwise using a

wrench so that cam lobes of No. 1 cylinder face
in the directions as shown in the illustration.

Loosen

Hold

G036836E01

A072965E01

A075624E01

Bank 1:

A072966E05