Toyota FJ Cruiser (GSJ 10, 15 series). Manual - part 186

1GR-FE ENGINE MECHANICAL – ENGINE UNIT

EM–175

(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. After installation,
cylinder head bolts must be tightened within 15
minutes. Otherwise, the seal packing must be
removed and reapplied.

surface with the Lot No. stamp upward.
NOTICE:
•

Install the cylinder head gasket in the correct
direction.

•

Place the cylinder head carefully in order not
to damage the gasket with the bottom part of
the head.

19. INSTALL CYLINDER HEAD SUB-ASSEMBLY

(a) Place the cylinder head RH 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), (*2) and (*3)).

•

If any cylinder head bolts are broken or
deformed, replace them.

(1) Apply a light coat of engine oil to the threads

and under the heads of the cylinder head bolts.

(2) Using several steps, uniformly install and

tighten the 10 cylinder head bolts and plate
washers with a bi-hexagon wrench 10 mm in
the sequence shown in the illustration.
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

1.25 to 1.5 mm

Seal Packing

Gasket

Ǿ 2.5 to 3 mm

A076271E02

Lot No.

A076272E03

A076273E02

EM–176

1GR-FE ENGINE MECHANICAL – ENGINE UNIT

(3) Mark the front of the cylinder head bolt with

paint. (*1)

(4) Retighten the cylinder head bolts by 180

° as

shown. (*2)

(5) Check that the painted marks are now at 180

from the engine front. (*3)

20. INSTALL NO. 2 CYLINDER HEAD GASKET

(a) Remove any old packing material and oil from the

contact surfaces of the cylinder head and cylinder
block.

(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

surface with the Lot No. stamp upward.
NOTICE:
•

Be careful of the installation direction.

•

Place the cylinder head carefully in order not
to damage the gasket with the bottom part of
the head.

21. INSTALL CYLINDER HEAD LH

(a) Place the cylinder head LH on the cylinder head

gasket.

(b) Install the 8 cylinder head bolts.

HINT:
•

The cylinder head bolts are tightened in 2
successive steps (steps (*4), (*5) and (*6)).

•

If any cylinder head bolts are broken or
deformed, replace them.

(1) Apply a light coat of engine oil to the threads

and under the heads of the cylinder head bolts.

180°

Engine
Front

Paint Mark

A076274E02

10 to 15 mm

Seal Packing

1.25 to 1.5 mm

Gasket

Ǿ 2.5 to 3 mm

A076275E02

Lot No.

A076276E02

1GR-FE ENGINE MECHANICAL – ENGINE UNIT

EM–177

(2) Using several steps, uniformly install and

tighten the 8 cylinder head bolts and plate
washers with a bi-hexagon wrench 10 mm in
the sequence shown in the illustration.
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.

(3) Mark the front of the cylinder head bolt with

paint. (*4)

(4) Retighten the cylinder head bolts by 180

° as

shown. (*5)

(5) Check that the painted marks are now at 180

from the engine front. (*6)

(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 10 cylinder head bolts and plate
washers with a bi-hexagon wrench 10 mm in
the sequence shown in the illustration.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

22. INSTALL NO. 1 CAMSHAFT BEARING

(a) Align the bearing claw with the claw groove of the

bearing cap, and push in the camshaft bearing.
NOTICE:
•

Install the bearing while aligning it with the oil
hole in the bearing cap.

•

Clean the back side of the bearing and the
surface of the bearing cap and keep them free
of oil.

23. INSTALL NO. 2 CAMSHAFT BEARING

(a) Install the No. 2 camshaft bearing onto the cylinder

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

A076277E01

180°

Engine
Front

Paint Mark

A076274E02

A072969E05

Claw

A126364E01

A076279E01

EM–178

1GR-FE ENGINE MECHANICAL – ENGINE UNIT

24. INSTALL 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) 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 as indicated.
NOTICE:
Setting the crankshaft at the wrong angle
could cause the piston head and valve head
to come into contact with each other when
the camshaft is installed. This could cause
damage, so always set the camshaft at the
correct angle.

(b) Apply new engine oil to the thrust portion and

journal of the camshafts.

(1) Place the 2 camshafts on the cylinder head RH

with the No. 1 cam lobes facing as shown the
illustration.

(2) Install the 8 bearing caps in their correct

locations.

(3) Apply a light coat of engine oil to the threads of

the bearing cap bolts.

90°

Set Key

Turn

A076280E02

Bank 1:

A076281E05

Bank 1:

A076282E05

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