Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - 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