Toyota 4Runner 2001-06

Valve Covers

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Removal & Installation



1GR-FE Engine


Click image to see an enlarged view

Fig. Exploded view of some components that must be removed or disconnected to access the valve cover

  1. Remove the engine appearance cover.
  2.  
  3. Remove the air intake assembly.
  4.  
  5. Remove the upper intake manifold (air surge tank).
  6.  
  7. Remove the ignition coils for each spark plug.
  8.  
  9. Remove the valve cover mounting bolts, nuts and seal washers.
  10.  
  11. Remove the valve cover.

    Click image to see an enlarged view

    Fig. Location of the valve cover mounting bolts, nuts and seal washers-4.0L (1GR-FE) Engine

  12.  

To install:

  1. Remove any old gasket material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and valve cover.
  2.  
  3. Apply a continuous bead of the seal packing 0.08-0.12 in. (2-3 mm) in diameter across the cylinder head and timing chain cover as shown in the illustration, then install the valve cover.
    NOTE
    Install the valve cover within 3 minutes after applying sealant. After installing it, the valve cover bolts and nuts must be tightened within 15 minutes. Otherwise the sealant must be removed and reapplied.



    Click image to see an enlarged view

    Fig. Apply sealant to the cylinder head and timing chain cover as shown-4.0L (1GR-FE) and 4.7L (2UZ-FE) Engine

  4.  
  5. Install the seal washers to the bolts and tighten the bolts to 80 inch lbs. 9 Nm). The bolts must tighten uniformly in several steps.
  6.  
  7. Install the ignition coils for each spark plug.
  8.  
  9. Install the upper intake manifold.
  10.  
  11. Install the air intake assembly.
  12.  
  13. Install the engine appearance cover.
  14.  
  15. Start the engine and check for leaks.
  16.  

2uz-FE Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the four bolts retaining the ignition coils to the cylinder head cover and the spark plugs. Tag for identification, and then remove the coil assemblies.
  4.  
  5. On the left side (driver-s side):
    1. The engine oil dipstick may interfere with cylinder head cover removal, so pull the dipstick out and set it aside.
    2.  
    3. Reposition the fuel lines and EVAP hoses as necessary. It shouldn-t be necessary to disconnect them, just unclip from their retainers and reposition.
    4.  
    5. Disconnect the breather hose.
    6.  

  6.  
  7. On the right side (passenger-s side):
    1. Disconnect the L-Shaped PCV breather hose.
    2.  
    3. Unclip the power steering vacuum switch hose that runs to the intake manifold plenum and reposition.
    4.  
    5. Remove the nine cylinder head cover bolts and carefully remove the cylinder head cover. Use care. The cover is aluminum. Light alloy parts can be easily damaged.
    6.  

  8.  

To install:

  1. Clean all parts well. In addition to the cylinder head cover gaskets, Toyota uses small amounts of Formed-In-Place-Gasket® (FIPG) sealer in two spots at the camshaft drive end of the cylinder head next to the timing belt covers. Note the position of this sealer before cleaning it off since new sealer must be installed in the same locations. All of this old sealer must be removed. Use care not to gouge the aluminum sealing surfaces on either the head or the cylinder head cover.
  2.  
  3. Installation is the reverse of the removal procedure. Apply fresh FIPG material (sealer, Toyota #08826-00080, or equivalent) at the places indicated.
  4.  
  5. Install a new gasket to the cylinder head cover. The bolts also use seal washers and they must be in good condition and properly installed. Install the cylinder head cover and the bolts.
  6.  
  7. Torque the cylinder head cover bolts evenly in several passes to 80 inch lbs. (9 Nm).
  8.  

5vz-FE Engine
  1. Disconnect the accelerator cable from the throttle linkage.
  2.  
  3. Remove the air intake assembly
  4.  
  5. Remove the high-tension cords (spark plug wires) from each ignition coil, and remove the ignition coils.
  6.  
  7. Remove the upper intake manifold (air surge tank).
  8.  
  9. Remove the air intake connector assembly as follows:
    1. Remove the bolt and disconnect the engine wire.
    2.  
    3. Disconnect the fuel return hose.
    4.  
    5. Disconnect the vacuum sensing hose form the fuel pressure regulator.
    6.  
    7. Remove the bolt and disconnect the ground strap from the intake air connector.
    8.  
    9. Disconnect the DLC1 from the bracket.
    10.  
    11. Remove the intake air connector assembly and gasket.

      Click image to see an enlarged view

      Fig. Location of the mounting bolts and nuts for the air intake connector assembly-3.4L (5VZ-FE) Engine

    12.  

  10.  
  11. Disconnect any remaining hoses, sensor connectors and wiring clamps needed for clearance.
  12.  
  13. Loosen and remove the valve cover bolts.
  14.  
  15. Remove the valve covers, work on one at a time to avoid confusion.

    Click image to see an enlarged view

    Fig. The cylinder head covers are secured to the heads by the bolts shown on 3.4L (5VZ-FE) Engines



    Click image to see an enlarged view

    Fig. Use a ratchet, an extension, and a socket to remove the valve cover bolts



    Click image to see an enlarged view

    Fig. Lift off the valve cover



    Click image to see an enlarged view

    Fig. Valve cover bolt locations



    Click image to see an enlarged view

    Fig. Remove the gasket from the groove in the valve cover

  16.  

To install:

  1. Clean the mating areas on the cover and cylinder head of any remaining sealant material.
  2.  
  3. Apply a proper sealant (08826-00080 or equivalent) to the valve as shown. Install a new gasket to the cylinder head cover. Attach the cover with the mounting bolts and tighten to 53 inch lbs. (6 Nm).

    Click image to see an enlarged view

    Fig. Apply the proper sealant to the location indicated on the cylinder head.

  4.  
  5. The remainder of the installation is reverse order of removal. Note the following torques:

    Air intake connector: 13 ft. lbs. (18 Nm).
     
    Upper intake manifold (air surge tank): 13 ft. lbs. (18 Nm).
     
    Upper intake manifold support: 13 ft. lbs. (18 Nm) for top bolt, 30 ft. lbs. (40 Nm) for bottom bolt.
     
    Start the engine and check for leaks.
     

  6.  

 
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