Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 165

1GR-FE ENGINE MECHANICAL  –  CYLINDER HEAD

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

2.5 to 3 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.

8.

INSTALL CYLINDER HEAD SUB-ASSEMBLY
(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, tighten each bolt uniformly 

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

1.25 to 1.5 mm

Seal Packing

Gasket

Ǿ 2.5 to 3 mm

A076271E02

Lot No.

A076272E03

1

7

8

6

5

4

3

2

A076273E02

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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 ground cable with the bolt.

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

9.

INSTALL NO. 2 CAMSHAFT BEARING
(a) Install the No. 2 camshaft bearing onto the cylinder 

head.
NOTICE:
Clean the installation planes of the back side of 
the bearing and cylinder head and keep them 
free of oil.

10. INSTALL 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) 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.

(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.

180°

Engine 
Front

Paint Mark

A076274E02

A076279E01

90°

Set Key

Turn

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1GR-FE ENGINE MECHANICAL  –  CYLINDER HEAD

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(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 heads 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)

(g) Turn the camshafts clockwise until the knock pin 

comes to a position 90

° to the cylinder head.

11. INSTALL NO. 2 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)

A076282E03

1

2

3

4

6

7

8

5

9

10

11

12

14

15

13

16

A072967E06

Turn

Turn

90 °

90 °

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Push

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1GR-FE ENGINE MECHANICAL  –  CYLINDER HEAD

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12. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 

CHAIN (for Bank 1)
(a) Align the yellow mark links with the timing marks (1 

dot mark) 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 RH 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 No. 2 pin from the tensioner.

13. INSTALL WATER BY-PASS JOINT RR

(a) Install a new O-ring onto the water outlet pipe.
(b) Apply soapy water to the O-ring.
(c) Install 2 new gaskets and water by-pass joint rear 

with the 2 bolts and 4 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

(d) Connect the heater hose.
(e) Connect the engine coolant temperature sensor 

connector.

14. INSTALL INTAKE MANIFOLD

(a) Set a new gasket on each cylinder head.

NOTICE:
•

Align the port holes of the gasket and 
cylinder head.

•

Orient the gasket correctly.

(b) Set the intake manifold on the cylinder heads.

Mark Links

Timing Marks

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Timing Marks

Timing Marks

G036257E01

G036252E01

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A076536E01