Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - 1GR-FE ENGINE MECHANICAL
CYLINDER HEAD GASKET - REMOVAL
| 1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY |
()
| 2. SET NO. 1 CYLINDER TO TDC/COMPRESSION |
Temporarily install the pulley set bolt.
Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the RH block bore center line (TDC/compression).
| *1 | Center Line |
| *2 | Timing Mark |
| *3 | Sensor Plate |
Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration.
If not, turn the crankshaft clockwise 1 revolution (360°) and align the timing marks as above.
| *1 | Timing Mark |
| 3. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY |
Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
| *1 | Plunger |
| *2 | Stopper Plate |
| *3 | Pin |
Move the stopper plate downward to set the lock, and insert a pin with a diameter of 1.27 mm (0.0500 in.) into the stopper plate hole.
Remove the 2 bolts and No. 1 chain tensioner assembly.
| 4. REMOVE CHAIN TENSIONER SLIPPER |
Remove the chain tensioner slipper.
| 5. REMOVE CHAIN SUB-ASSEMBLY |
Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket.
| *1 | Center Line |
| *2 | Timing Mark |
| *3 | Sensor Plate |
Remove the pulley set bolt.
Remove the chain sub-assembly from the crankshaft timing sprocket and place it on the crankshaft.
Turn the camshaft timing gear assembly on bank 1 clockwise approximately 60° so that it is as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks.
Remove the chain sub-assembly.
| *A | for Bank 1 |
| 6. REMOVE NO. 1 IDLE GEAR SHAFT |
Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, No. 1 idle gear and No. 1 idle gear shaft.
| 7. REMOVE NO. 1 CHAIN VIBRATION DAMPER |
Remove the 2 bolts and No. 1 chain vibration damper.
| 8. REMOVE NO. 2 CHAIN VIBRATION DAMPER |
Remove the 2 No. 2 chain vibration dampers.
| 9. REMOVE CRANKSHAFT TIMING SPROCKET |
Remove the crankshaft timing sprocket.
| 10. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) |
While raising the No. 2 chain tensioner assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to hold the No. 2 chain tensioner assembly.
| *1 | Pin |
| *2 | Plunger |
| *a | Push |
Using SST to hold the hexagonal portion of each camshaft, loosen the bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.
- SST
- 09922-10010
| *a | Turn |
| *b | Hold |
- NOTICE:
- Do not loosen the other 4 bolts. If any of the 4 bolts is loosened, replace the camshaft timing gear assembly and/or camshaft timing exhaust gear assembly with a new one.
Remove the 2 bolts and camshaft timing gear assembly together with the No. 2 chain.
| 11. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY |
Remove the bolt and No. 2 chain tensioner assembly.
| 12. REMOVE CAMSHAFT BEARING CAP (for Bank 1) |
Check that the camshafts are positioned as shown in the illustration.
| *1 | Knock Pin |
| *a | Front View |
Uniformly loosen and remove the 8 bearing cap bolts in several steps in the sequence shown in the illustration.
Uniformly loosen and remove the 12 bearing cap bolts in several steps in the sequence shown in the illustration.
- NOTICE:
- Uniformly loosen the bolts while keeping the camshaft level.
Remove the 5 camshaft bearing caps.
Remove the camshaft and No. 2 camshaft.
| 13. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH |
Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a screwdriver.
| *1 | Protective Tape |
- NOTICE:
- Be careful not to damage the contact surfaces of the cylinder head and camshaft housing sub-assembly RH.
- HINT:
- Tape the screwdriver tip before use.
| 14. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) |
While pushing down the No. 3 chain tensioner assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to hold the No. 3 chain tensioner assembly.
| *1 | Pin |
| *2 | Plunger |
| *a | Push |
Using SST to hold the hexagonal portion of each camshaft, loosen the bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.
- SST
- 09922-10010
| *a | Turn |
| *b | Hold |
- NOTICE:
- Do not loosen the other 4 bolts. If any of the 4 bolts is loosened, replace the camshaft timing gear assembly and/or camshaft timing exhaust gear assembly with a new one.
Remove the 2 bolts and camshaft timing gear together with the No. 2 chain.
| 15. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY |
Remove the bolt and No. 3 chain tensioner assembly.
| 16. REMOVE CAMSHAFT BEARING CAP (for Bank 2) |
Check that the camshafts are positioned as shown in the illustration.
| *1 | Knock Pin |
| *a | Front View |
Uniformly loosen and remove the 8 bearing cap bolts in several steps in the sequence shown in the illustration.
Uniformly loosen and remove the 13 bearing cap bolts in several steps in the sequence shown in the illustration.
- NOTICE:
- Uniformly loosen the bolts while keeping the camshaft level.
Remove the 5 camshaft bearing caps.
Remove the No. 3 camshaft and No. 4 camshaft.
| 17. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH |
Remove the camshaft housing sub-assembly LH by prying between the cylinder head and camshaft housing sub-assembly LH with a screwdriver.
| *1 | Protective Tape |
- NOTICE:
- Be careful not to damage the contact surfaces of the cylinder head and camshaft housing sub-assembly LH.
- HINT:
- Tape the screwdriver tip before use.
| 18. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY |
Remove the 24 valve rocker arms from the cylinder head.
- HINT:
- Arrange the removed parts in the correct order.
| 19. REMOVE VALVE LASH ADJUSTER ASSEMBLY |
Remove the 24 valve lash adjusters from the cylinder head.
- HINT:
- Arrange the removed parts in the correct order.
| 20. REMOVE VALVE STEM CAP |
Remove the 24 valve stem caps from the cylinder head.
- HINT:
- Arrange the removed parts in the correct order.
| 21. REMOVE REAR WATER BY-PASS JOINT |
Remove the 2 bolts, 4 nuts, rear water by-pass joint and 2 gaskets.
Remove the O-ring from the No. 1 water outlet pipe.
| 22. REMOVE CYLINDER HEAD SUB-ASSEMBLY |
Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
- NOTICE:
- HINT:
- Arrange the removed parts in the correct order.
Remove the cylinder head sub-assembly.
| 23. REMOVE CYLINDER HEAD LH |
Uniformly loosen and remove the 2 bolts in several steps in the sequence shown in the illustration.
Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
- NOTICE:
- HINT:
- Be sure to keep the removed parts for each installation position separate.
Remove the cylinder head LH.
| 24. REMOVE CYLINDER HEAD GASKET |
| 25. REMOVE NO. 2 CYLINDER HEAD GASKET |