Toyota FJ Cruiser (GSJ 10, 15 series). Instruction — part 171

EM–116

1GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

EM

(b) Connect the connector to the engine room relay

block.

(c) Install the ground wire onto the frame with the bolt.

Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf)

(d) Install the ground wire onto the body with the bolt.

Torque: 8.4 N*m (85 kgf*cm, 7.4 in.*lbf)

23. CONNECT HEATER WATER OUTLET HOSE A (FROM

HEATER UNIT)

24. CONNECT HEATER INLET WATER HOSE

A126450

A126441

A126442

A126444

A126443

1GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

EM–117

EM

25. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY

(a) Connect the No. 2 fuel tube connector and fuel pipe,

and install the No. 2 fuel pipe clamp.
NOTICE:
Align the fuel tube connector with the pipe, then
push the fuel tube connector in until the retainer
makes a click sound. If the connection is tight,
apply a small amount of engine oil to the tip of
the pipe. After connecting, pull the pipe and
connector to make sure that they are securely
connected.

26. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Connect the No. 1 fuel tube connector and fuel pipe,

and install the No. 2 fuel pipe clamp.
NOTICE:
Align the fuel tube connector with the pipe, then
push the fuel tube connector in until the retainer
makes a click sound. If the connection is tight,
apply a small amount of engine oil to the tip of
the pipe. After connecting, pull the pipe and
connector to make sure that they are securely
connected.

27. INSTALL VANE PUMP ASSEMBLY (See page

PS-14

)

28. INSTALL COOLER COMPRESSOR ASSEMBLY (See

page

ES-421

)

29. INSTALL GENERATOR ASSEMBLY (See page

CH-17

)

30. INSTALL INTAKE AIR SURGE TANK (See page

FU-

17

)

31. INSTALL NO. 2 SURGE TANK STAY (See page

FU-19

)

32. INSTALL NO. 1 SURGE TANK STAY (See page

FU-19

)

33. INSTALL OIL BAFFLE PLATE (See page

FU-19

)

34. INSTALL THROTTLE BODY BRACKET (See page

FU-

19

)

35. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual

Transmission)
(a) Using SST, hold the crankshaft.

SST

09213-54015 (91651-60855), 09330-00021

A126503

A126502

A076326

EM–118

1GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

EM

(b) Apply adhesive to the 2 or 3 end threads of the

bolts.
Adhesive:

Toyota Genuine Adhesive 1324, Three Bond
1324 or the equivalent.

(c) Install the flywheel and 2 spacers onto the

crankshaft.

(d) Install the flywheel with the 6 bolts in the order

shown in the illustration.
Torque: 83 N*m (846 kgf*cm, 61 ft.*lbf)

36. INSTALL DRIVE PLATE AND RING GEAR SUB-

ASSEMBLY (for Automatic Transmission)
(a) Using SST, hold the crankshaft.

SST

09213-54015 (91651-60855), 09330-00021

(b) Apply adhesive to the 2 or 3 end threads of the

bolts.
Adhesive:

Toyota Genuine Adhesive 1324, Three Bond
1324 or the equivalent.

(c) Install the drive plate and 2 spacers onto the

crankshaft.

(d) Install the drive plate with the 6 bolts in the order

shown in the illustration.
Torque: 83 N*m (846 kgf*cm, 61 ft.*lbf)

37. INSTALL CLUTCH DISC ASSEMBLY (for Manual

Transmission)
Refer to the procedures up to "INSTALL CLUTCH DISC
ASSEMBLY" (See page

CL-23

).

A057108

1

2

3

4

5

6

7

8

G036171E01

A076326

A057108

1

2

3

4

5

6

7

8

A076327E02

1GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

EM–119

EM

38. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY

(for Manual Transmission)
Refer to the procedures up to "INSTALL MANUAL
TRANSMISSION" (See page

MT-11

).

39. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

(for Automatic Transmission)
Refer to the procedures up to "INSTALL AUTOMATIC
TRANSMISSION" (See page

AT-175

or

AT-181

).

40. INSTALL RADIATOR ASSEMBLY

Refer to the procedures up to "INSTALL RADIATOR
ASSEMBLY" (See page

CO-28

).

41. INSTALL HOOD SUB-ASSEMBLY

(a) Install the hood with the 4 bolts.
(b) Connect the windshield washer hose.

42. INSTALL HOOD SUPPORT (See page

ED-5

)

43. INSTALL BATTERY

44. ADD ENGINE COOLANT (See page

CO-3

)

45. ADD ENGINE OIL (See page

LU-5

)

46. PERFORM INITIALIZATION (for Automatic

Transmission)
(See page

AT-19

or

AT-19

47. CHECK FOR ENGINE COOLANT LEAKAGE (See

page

CO-4

)

48. CHECK FOR ENGINE OIL LEAKAGE

49. CHECK FOR FUEL LEAKAGE

50. CHECK FOR EXHAUST GAS LEAKAGE

51. INSPECT IGNITION TIMING (See page

EM-1

)

52. INSPECT ENGINE IDLING SPEED (See page

EM-2

)

53. INSPECT COMPRESSION (See page

EM-3

)

54. INSPECT CO/HC (See page

EM-3

)

55. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Refer to the procedures up to "INSPECT AND ADJUST
FRONT WHEEL ALIGNMENT" (See page

SP-2

).

A126452