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