Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 159

1GR-FE ENGINE MECHANICAL  –  CYLINDER HEAD

EM–69

EM

10. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Disconnect the air fuel ratio sensor connector.

(b) Remove the 6 nuts and the exhaust manifold.
(c) Remove the gasket.

11. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY 

(See page 

FU-13

)

12. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY 

(See page 

FU-14

)

13. REMOVE INTAKE MANIFOLD

(a) Disconnect the 6 fuel injector connectors.

(b) Remove the 10 bolts, then remove the intake 

manifold and gasket.

14. REMOVE WATER BY-PASS JOINT RR

(a) Disconnect the engine coolant temperature sensor 

connector.

(b) Disconnect the heater hose.

(c) Remove the 2 bolts and 4 nuts, then remove the 

water by-pass joint RR and 2 gaskets.

(d) Remove the O-ring from the water outlet hose.

15. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 

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

of 

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

A126445

A126448

A076533E01

A076534E01

Raise

G036251E01

EM–70

1GR-FE ENGINE MECHANICAL  –  CYLINDER HEAD

EM

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

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

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

timing gear, camshaft timing gear assembly and No. 
2 timing chain.
NOTICE:
Do not disassemble the camshaft timing gear 
assembly.

16. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

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

tensioner.

17. REMOVE CAMSHAFTS (for Bank 1)

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) Rotate the camshafts counterclockwise using a 

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

(b) Using several steps, loosen and remove the 16 

bearing cap bolts uniformly in the sequence shown 
in the illustration.

(c) Remove the 8 bearing caps and 2 camshafts.

18. REMOVE NO. 2 CAMSHAFT BEARING

19. REMOVE CYLINDER HEAD SUB-ASSEMBLY

(a) Remove the bolt and separate the ground cable.

G036252E01

A072962E01

A072966E03

1

2

3

4

6

7

8

5

9

10

11

12

14

15

13

16

A072967E05

1GR-FE ENGINE MECHANICAL  –  CYLINDER HEAD

EM–71

EM

(b) Using several steps, loosen the 8 cylinder head 

bolts on the cylinder head uniformly with a 10 mm 
bi-hexagon wrench in the sequence shown in the 
illustration. Remove the 8 cylinder head bolts and 8 
plate washers.
NOTICE:
•

Be careful not to drop the plate washers into 
the cylinder head.

•

Cylinder head warpage or cracking could 
result from removing the bolts in the wrong 
order.

(c) Lift the cylinder head from the dowels on the 

cylinder block, and place the cylinder head on 
wooden blocks on a bench.
NOTICE:
Be careful not to drop the plate washers into the 
cylinder head.
If the cylinder head is difficult to lift off, pry between 
the cylinder head and cylinder block with a 
screwdriver.

20. REMOVE CYLINDER HEAD GASKET

21. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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

vibration damper.

22. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 

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

insert a pin of 

φ 10 mm (0.039 in.) into the hole to fix 

it.

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

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

8

2

1

3

4

5

6

7

A076273E03

A076805E01

A076292E01

Push

G036254E02

G036255E01

EM–72

1GR-FE ENGINE MECHANICAL  –  CYLINDER HEAD

EM

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

timing gear, camshaft timing gear assembly and No. 
2 timing chain.
NOTICE:
Do not disassemble the camshaft timing gear 
assembly.

23. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

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

tensioner.

24. REMOVE 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) Using several steps, loosen and remove the 16 

bearing cap bolts uniformly in the sequence shown 
in the illustration.

(b) Remove the 8 bearing caps and 2 camshafts.

25. REMOVE CYLINDER HEAD LH

(a) Remove the bolt, then separate the ground cable.
(b) Remove the bolt, then separate the air fuel ratio 

connector bracket.

(c) Using several steps, remove the 2 cylinder head 

bolts from the cylinder head in the sequence shown 
in the illustration.

(d) Using several steps, uniformly loosen the 8 cylinder 

head bolts on the cylinder head with a 10 mm bi-
hexagon wrench in the sequence shown in the 
illustration. Remove the 8 cylinder head bolts and 8 
plate washers.
NOTICE:
•

Be careful not to drop the plate washers into 
the cylinder head.

•

Cylinder head warpage or cracking could 
result form removing the bolts in the wrong 
order.

A072965E01

3

6

4

7

9

8

5

2

1

10

11

12

13

14

15

16

A072968E05

2

1

A072969E03

8

4

3

5

2

1

6

7

A076277E02