Toyota 4Runner 2001-06

Cylinder Head 1

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Removal & Installation



1gr-FE Engine
  1. Remove the negative battery cable.
  2.  
  3. Relieve the fuel system pressure. For additional information, please refer to the following topic(s): -Fuel System,- -Relieving Fuel System Pressure-.
  4.  
  5. Remove the timing chain. For additional information, please refer to the following topic: -Timing Chain and Sprockets, Removal & Installation-.
  6.  
  7. Remove the cold air inlet with the air intake assembly.
  8.  
  9. Remove the transmission oil dipstick tube.
  10.  
  11. Remove the front exhaust pipe.
  12.  
  13. Remove the exhaust manifold. For additional information, please refer to the following topic: -Exhaust Manifold, Removal & Installation-.
  14.  
  15. Disconnect the fuel supply and return hoses.
  16.  
  17. Remove the intake manifold.
  18.  
  19. Remove the right rear water bypass joint and gaskets. Remove the O-ring from the coolant outlet pipe.
  20.  
  21. While raising up the right-hand bank secondary timing chain tensioner, insert a pin into the hole to secure the tensioner.
  22.  
  23. Hold the hexagonal portion of the camshaft with a wrench and remove the camshaft sprockets and secondary timing chain.
    WARNING
    Be careful not to damage the cylinder head and valve lifter with the wrench

  24.  
  25. Remove the secondary timing chain tensioner.
  26.  
  27. Remove the camshafts. For additional information, please refer to the following topic: -Camshaft and Valve Lifters, Removal & Installation-.
  28.  
  29. Remove the front camshaft bearing from the cylinder head.
  30.  
  31. Remove the ground cables attached to the cylinder head.
  32.  
  33. Uniformly loosen the eight cylinder head bolts in several steps, using the sequence shown.
    WARNING
    Cylinder head warping or cracking could result from removing the bolts in an incorrect order.



    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-4.0L (1GR-FE) Engine

  34.  
  35. Remove the cylinder head bolts with the plate washers.
  36.  
  37. Lift the cylinder head from the dowels on the cylinder block.
    NOTE
    If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a suitable pry device. Be careful not to damage the contact surfaces of the cylinder head and block.

  38.  
  39. Remove the cylinder head gasket.
  40.  

To install:

  1. Inspect each cylinder head mounting bolt using a dial caliper or equivalent. Each bolt must have a minimum thread outside diameter of 0.421 inches (10.7 mm). If any portion the bolt does not meet this specification, or is cracked, the bolt must be replaced.
  2.  
  3. Remove any old sealer material from the contact surfaces of the cylinder head and cylinder block. Use care to not drop an oil on the contact surfaces.
  4.  
  5. Apply a continuous bead of sealer (0.098-0.118 inches in diameter) to a new cylinder head gasket as shown.

    Click image to see an enlarged view

    Fig. Apply a continuous 3mm diameter bead of gasket material 08826-00080, or equivalent, to the gasket as shown-4.0L (1GR-FE) Engine

  6.  
  7. Place the cylinder head gasket on the cylinder block with the Lot Number stamp upward.

    Click image to see an enlarged view

    Fig. The cylinder head gasket should be installed with the Lot Number facing upward-4.0L (1GR-FE) Engine

  8.  
  9. Place the cylinder head on the cylinder head gasket.
    NOTE
    Place the cylinder head down carefully in order not to damage the cylinder head gasket.

  10.  
  11. Install the cylinder head bolts as follows:
    1. Apply a light coat of clean engine oil to the threads of the cylinder head bolts.
    2.  
    3. Install a plate washer to each bolt.
      WARNING
      When installing the cylinder head bolts, do not allow the plate washers to drop down onto the cylinder head.

    4.  
    5. Using several steps, tighten each bolt in sequence to 27 ft. lbs. (36 Nm).
      NOTE
      If any bolt cannot meet the torque specification, replace the bolt.

    6.  
    7. Mark the front side of each bolt head with paint.
    8.  
    9. Retighten each cylinder head bolts in sequence an additional 180°.
    10.  
    11. Check to ensure the painted marks of the bolts are now 180° to the engine front.

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-4.0L (1GR-FE) Engine

    12.  

  12.  
  13. Install the ground cables to the cylinder head. Tighten the bolts to 71 inch lbs. (8 Nm).
  14.  
  15. Install the front camshaft bearing to the cylinder head.
  16.  
  17. Install the camshafts and sprockets.
  18.  
  19. When installing the secondary timing chain tensioner and tighten the mounting bolts to 14 ft. lbs. (19 Nm).
  20.  
  21. Install the a new O-ring to the water outlet pipe. Apply soapy water to the O-ring to aid in the installation of the water bypass joint. Install two new gaskets with the water bypass joint. Tighten the mounting bolts and nuts to 80 inch lbs. (9 Nm). Connect the heater hose and ECT sensor.
  22.  
  23. Install the intake manifold with new gaskets. Tighten the mounting uniformly in several steps to 21 ft. lbs. (28 Nm).
  24.  
  25. Connect the fuel injector connectors, fuel supply and fuel return hoses.
  26.  
  27. Install the exhaust manifolds. For additional information, refer to the following topic: -Exhaust Manifold, Removal & Installation-.
  28.  
  29. Install the exhaust manifold support brace and tighten the three bolts to 30 ft. lbs. (40 Nm).
  30.  
  31. Install the front exhaust pipe using a new gasket. Tighten the nuts to 46 ft. lbs. (62 Nm).
  32.  
  33. Remove the old O-ring from the transmission oil dipstick tube. Coat a new O-ring with automatic transmission fluid, then place it on the tube. Push the dipstick tube into the transmission pan lower tube. Tighten the dipstick tube mounting bolts to 9 ft. lbs. (12 Nm).
  34.  
  35. Install the cold air inlet and tighten to 9 ft. lbs. (12 Nm).
  36.  
  37. Install the timing chain.
  38.  
  39. Refill the cooling system to the correct level.
  40.  
  41. Refill the engine with oil to the correct level.
  42.  
  43. Start the engine and check for leaks.
  44.  

Left Side


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Fig. For left cylinder head removal, remove these parts-Part 1



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Fig. For left cylinder head removal, remove these parts-Part 2



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Fig. For left cylinder head removal, remove these parts-Part 3



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Fig. For left cylinder head removal, remove these parts-Part 4



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Fig. For left cylinder head removal, remove these parts-Part 5



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Fig. For left cylinder head removal, remove these parts-Part 6



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Fig. For left cylinder head removal, remove these parts-Part 7



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Fig. For left cylinder head removal, remove these parts-Part 8

  1. Remove the timing chain.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Remove the front exhaust pipe.
  6.  
  7. Remove the exhaust manifold.
  8.  
  9. Remove the fuel pipes.
  10.  
  11. Remove the intake manifold.
  12.  
  13. Remove the water by-pass joint.
  14.  
  15. Remove the chain vibration damper.
  16.  
  17. Remove the left camshaft timing gears and chain. Insert a 1mm diameter pin into the tensioner hole to retain it.
  18.  
  19. Remove the tensioner.
  20.  
  21. Loosen the bolts in several steps, in the sequence shown and remove the camshafts. Keep the caps in order.
  22.  
  23. Remove the ground cable.
  24.  
  25. Loosen the 2 head bolts in several steps, in the sequence shown.
  26.  
  27. Loosen the remaining 8 head bolts in several steps, in the sequence shown.
  28.  
  29. Lift the head from the block. Discard the gasket.
  30.  
  31. Clean the mating surfaces thoroughly, without scratching.
  32.  


    Click image to see an enlarged view

    Fig. Camshaft bearing cap loosening sequence-4.0L engine, left side



    Click image to see an enlarged view

    Fig. Loosen these 2 head bolts in several steps, in the sequence shown-4.0L engine, left side



    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-4.0L engine, left side


To install:

  1. Inspect each head bolt. Using a caliper, measure the thread outside diameter. Standard diameter is 0.4272-0.4331 inch (10.85-11.00mm). Minimum diameter is 0.421 inch (10.7mm).
  2.  
  3. Carefully remove any old silicone gasket material.
  4.  
  5. Apply a continuous 3mm diameter bead of gasket material 08826-00080, or equivalent, to the gasket as shown.
  6.  


NOTE
The cylinder head must be installed within 3 minutes and the bolts tightened with 15 minutes. Otherwise, the silicone material must be removed and re-applied.



Click image to see an enlarged view

Fig. Apply a continuous 3mm diameter bead of gasket material 08826-00080, or equivalent, to the gasket as shown-4.0L engine

  1. Position a new gasket on the block with the lot number facing up.
  2.  
  3. Install the head. Lightly oil each head bolt with clean engine oil. Tighten the bolts, in several even passes, to 27 ft. lbs. (36 Nm).
  4.  
  5. Using a torque angle gauge, tighten each bolt, in sequence, an additional 180 degrees. If an angle gauge is not available, make a paint mark on each bolt head and the cylinder head, and tighten each bolt 180 degrees.
  6.  
  7. Apply a light coat of clean engine oil to the threads and install the 2 front head bolts. Tighten the bolts in the sequence shown to 22 ft. lbs. (30 Nm).
  8.  
  9. Install the camshafts.
  10.  


    Click image to see an enlarged view

    Fig. Cylinder head gasket placement-4.0L engine, left side



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-4.0L engine



    Click image to see an enlarged view

    Fig. Front head bolt torque sequence-4.0L engine, left side



NOTE
The camshaft thrust clearance is very small. The camshaft must be kept level during installation. If the camshaft is not kept level, the portion of the head which receives the thrust may crack or be damaged causing the camshaft to seize or break. To avoid this, the following steps must be taken:

  1. Turn the crankshaft so that the crankshaft key is at the 9:00 o-clock position.
  2.  


    Click image to see an enlarged view

    Fig. Turn the crankshaft so that the crankshaft key is at the 9:00 o-clock position-4.0L engine, left side

  3. Place the camshafts on the head as shown.
  4.  



Click image to see an enlarged view

Fig. Place the camshafts on the head as shown-4.0L engine, left side

  1. Install the bearing caps.
    1. Tighten the cap bolts, in several even passes, in the sequence shown, to 80 inch lbs (9 Nm) for 10mm bolts; 18 ft. lbs. (24 Nm) for 12mm bolts.
    2.  


      Click image to see an enlarged view

      Fig. Tighten the cap bolts, in several even passes, in the sequence shown-4.0L engine, left side

    3. Turn the camshafts clockwise until the knock pin is in a position 90 degrees to the head.
    4.  



    Click image to see an enlarged view

    Fig. Install the bearing caps-4.0L engine, left side

  2.  
  3. Install the tensioner. Torque to 14 ft. lbs. (19 Nm).
  4.  
  5. Install the chain aligning the yellow links with the timing marks on the gears.
  6.  
  7. Align the timing marks on the timing gears with the marks on the bearing caps, and install the gear/chain assembly. Torque the bolts to 74 ft. lbs. (100 Nm).
  8.  
  9. Install the water bypass joint. Apply soapy water to the new O-ring and using 2 new gaskets. Torque the 2 bolts and 4 nuts to 80 inch lbs. (9 Nm).
  10.  
  11. Install the intake manifold, using new gaskets. Torque the 10 bolts, in several even passes, to 19 ft. lbs. (26 Nm).
  12.  
  13. Connect the fuel lines.
  14.  
  15. Install the exhaust manifold. Torque to 22 ft. lbs. (30 Nm). Torque the manifold stay to 30 ft. lbs. (40 Nm).
  16.  
  17. The remainder of installation is the reverse of removal.
  18.  


    Click image to see an enlarged view

    Fig. Turn the camshafts clockwise until the knock pin is in a position 90 degrees to the head



    Click image to see an enlarged view

    Fig. Install the chain aligning the yellow links with the timing marks on the gears



    Click image to see an enlarged view

    Fig. Align the timing marks on the timing gears with the marks on the bearing caps


 
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