Toyota FJ Cruiser (GSJ 10, 15 series). Manual — part 185

1GR-FE ENGINE MECHANICAL – ENGINE UNIT

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13. INSTALL CRANKSHAFT

(a) Apply engine oil to the upper bearing and install the

crankshaft onto the cylinder block.

(b) Install the 2 upper thrust washers onto the No. 2

journal position of the cylinder block.
(1) Push the crankshaft toward the front (rear)

side.

(2) Install the 2 upper thrust washers with the oil

grooves facing outward.

(c) Install the 2 lower thrust washers onto the No. 2

bearing cap with the grooves facing outward.

(d) Examine the front marks and numbers, check the

sequence number is as shown in the illustration and
install the bearing caps on the cylinder block.

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

bearing cap bolts.

(f)

Temporarily install the 8 main bearing cap bolts in
the inside positions.

(g) Install the main bearing caps. Tighten the 2 bolts for

each bearing cap until the clearance between the
bearing cap and the cylinder block is under 6 mm
(0.23 in.).

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Less than 6 mm

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(h) Using a plastic-faced hammer, lightly tap the

bearing cap to ensure a proper fit.

(i)

Apply a light coat of engine oil to the threads of the
main bearing cap bolts.

(j)

Install the 16 main bearing cap bolts. Using several
steps, tighten the bolts uniformly in the sequence
shown in the illustration.
Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)

(k) Mark the front side of the bearing cap bolts with

paint.

(l)

Retighten the bearing cap bolts 90

° in the sequence

as shown.

(m) Check that the painted marks are now at a 90

°

angle from the front.

(n) Check that the crankshaft turns smoothly.

(o) Using several steps, tighten the 8 main bearing cap

bolts uniformly in the sequence shown in the
illustration.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)

14. INSTALL PISTON SUB-ASSEMBLY WITH

CONNECTIONG ROD
(a) Apply engine oil to the cylinder walls, pistons, and

surfaces of connecting rod bearings.

(b) Check the position of the piston ring ends.

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7

15

1 2

3 4

6

5

8

9

14

13

10

11

12

16

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Painted Mark

Front

90°

90°

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3

7

1

2

4

5

6

8

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Front Mark

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(c) Using a piston ring compressor, push the correct

number piston and connecting rod into each
cylinder with the front mark of the piston facing
forward.
NOTICE:
•

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

•

Match the numbered connecting rod cap with
the connecting rod.

(d) Check that the protrusion of the connecting rod cap

is facing in the correct direction.

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

connecting rod cap bolts.

(f)

Tighten the bolts alternately to the specified torque.
Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)

(g) Mark the front side of the each connecting cap bolt

with paint.

(h) Retighten the cap bolts 90

° as shown.

(i)

Check that the crankshaft turns smoothly.

15. INSTALL REAR ENGINE OIL SEAL RETAINER

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

contact surfaces of the oil seal retainer and cylinder
block.

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

2 to 3 mm (0.08 to 0.12 in.)) to the oil seal retainer
as shown in the illustration.
Seal packing:

Toyota Genuine Seal Packing Black, Three
Bond 1207B or the equivalent

NOTICE:
Parts must be assembled within 3 minutes of
application. Otherwise, the seal packing must be
removed and reapplied.

Protrusion

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90°

90°

Front

Painted Mark

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Seal Width: 2 to 3 mm

Seal Packing

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(c) Install the oil seal retainer with the 5 bolts and 2

nuts.
Torque: Nut

9.0 N*m (92 kgf*cm, 80 in.*lbf)
Bolt
10 N*m (102 kgf*cm, 7.4 ft.*lbf)

16. INSTALL KNOCK SENSOR

(a) Install the 2 knock sensors with the 2 bolts as shown

in the illustration.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)

(b) Connect the knock sensor connectors.
(c) Install the knock sensor wire.

17. INSTALL NO. 1 WATER OUTLET PIPE

(a) Install the water outlet pipe with the 3 bolts.

Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf)

18. INSTALL CYLINDER HEAD GASKET

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

contact surfaces of the cylinder head and cylinder
block.

LH Bank:

RH Bank:

Upper

Upper

Engine
Rear

Engine
Front

15°

15°

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