Toyota FJ Cruiser (GSJ 10, 15 series). Instruction — part 184
1GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM–167
EM
Pin B:
10.5 to 11.5 mm (0.413 to 0.453 in.)
Pin C:
8.5 to 9.5 mm (0.335 to 0.374 in.)
Pin D:
5.5 to 6.5 mm (0.217 to 0.256 in.)
4.
INSTALL TIGHT PLUG
(a) Apply adhesive around new tight plugs.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond
1324 or the equivalent
(b) Using SST, install the tight plugs as shown in the
illustration.
SST
09550-60010 (09951-00350), 09950-70010
(09951-07150)
10 mm
10 mm
8mm
36mm
22 mm
18mm
12 mm
12 mm
12 mm
Protrusion Height: 22.5 to 23.5 mm
Protrusion Height: 5.5 to 6.5 mm
Protrusion Height: 5.5 to 6.5 mm
Protrusion Height: 5.5 to 6.5 mm
Protrusion Height: 10.5 to 11.5 mm
Protrusion Height:
8.5 to 9.5 mm
D
D
D
4 mm
4 mm
4 mm
C
C
C
C
B
B
A
Front Side
Rear Side
Upper Side
Front Side
Rear Side
Lower Side
D
D
A076062E04
EM–168
1GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
Standard depth:
0.2 to 1.2 mm (0.008 to 0.047 in.)
5.
INSTALL OIL JET
(a) Using a screw driver and hammer, tap in the oil jet.
6.
INSTALL NO. 1 SUB-ASSEMBLY OIL NOZZLE
(a) Using a 5 mm socket hexagon wrench, install the 3
oil nozzles.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
7.
INSTALL HOLE SNAP RING
(a) Using a small screwdriver, install a new snap ring
onto the side of the piston pin hole.
HINT:
Check that the end gap of the snap ring does not
overlap with the pin hole cutout portion of the piston.
Right Side
Left Side
0.2 to 1.2 mm
(0.008 to 0.47 in.)
A076064E05
26 to 27°
A076392E04
A076051E01
A032958E01
1GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM–169
EM
8.
INSTALL WITH PIN PISTON SUB-ASSEMBLY
(a) Gradually heat the piston to about 80
°C (176°F).
(b) Coat the piston pin with engine oil.
(c) Align the front marks of the piston and connecting
rod, and push in the piston pin with a thumb.
9.
INSTALL HOLE SNAP RING
(a) Using a small screwdriver, install a new snap ring
onto the other side of the piston pin hole.
HINT:
Make sure that the gap in the snap ring does not
overlap with the pin hole cutout portion of the piston.
10. INSTALL PISTON RING SET
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2
compression rings.
NOTICE:
Install compression ring No. 2 with the painted
mark facing upward.
(c) Position the piston rings so that the ring ends are as
shown.
80°C (176°F)
P012417E10
Front Mark
Front
Mark
A075846E02
A032958E01
Upward
Painted Mark
A076073E01
No. 2
Compression
No. 1
Compression
Front Mark
Oil Ring
Lower Side Rail
Upper Side Rail
Expander
A076074E04
EM–170
1GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
11. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the
connecting rod or connecting cap.
NOTICE:
Clean the back side of the bearing and the
bearing surface of the connecting rod and keep
them free of oil.
12. INSTALL CRANKSHAFT BEARING
HINT:
There are 2 types of main bearings with different widths
(19.0 mm (0.748 in.) and 22.4 mm (0.882 in.)) for use in
the inspection. Install the 22.4mm (0.882 in.) bearings in
the No. 1 and No. 4 cylinder block journal positions with
the main bearing cap. Install the 19.0 mm (0.748 in.)
bearings in the No. 2 and No. 3 positions.
(a) Clean each main journal and bearing.
(b) Install the 4 upper bearings.
(1) Install the upper bearings near the center of the
cylinder block.
NOTICE:
•
The widths of the No. 1 and No. 4 journal
bearings are different from those of the
No. 2 and No. 3 journal bearings.
Therefore, confirm the identity of each
journal bearing prior to installation.
•
Do not apply engine oil to the bearing
installation surfaces of the cylinder block
and the back side of the bearings.
•
Check that the oil groove on the cylinder
block can be seen through the oil supply
holes of the upper bearing.
(c) Install the 4 lower bearings.
(1) Install the lower bearings near the center of the
cylinder block.
NOTICE:
Do not apply engine oil to the bearing or its
contact surface.
HINT:
The number marked on each main bearing cap
indicates the installation position.
P012402E01
No. 1 and No. 4
22.4 mm
19.0 mm
No. 2 and No. 3
Upper
Lower
A076063E05
A094746E02
Mark
1, 2, 3, or 4
A076065E01
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