Toyota FJ Cruiser (GSJ 10, 15 series). Instruction — part 189

1GR-FE ENGINE MECHANICAL – ENGINE UNIT

EM–187

EM

(e) Install the oil pan with the 17 bolts and 2 nuts.

Tighten the bolts and nuts uniformly in several
steps.
Torque: 10 mm (0.39 in.) head

10 N*m (102 kgf*cm, 7 ft.*lbf)
12 mm (0.47 in.) head
21 N*m (214 kgf*cm, 16 ft.*lbf)

HINT:
Each bolt length is as follows:

39. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Install a new gasket, then install the oil strainer with

the 2 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

40. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove any old packing material and be careful not

to drop any oil on the No. 2 contact surfaces of the
oil pan and oil pan.

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

3 to 4 mm (0.12 to 0.16 in.)) as shown in the
illustration.
Seal packing:

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

NOTICE:
Install the No. 2 oil pan within 3 minutes of
applying the seal packing. After installation, the
No. 2 oil pan bolts and nuts must be tightened
within 15 minutes. Otherwise, the seal packing
must be removed and reapplied.

(c) Install the No. 2 oil pan with the 10 bolts and 2 nuts.

Tighten the bolts and nuts uniformly in several
steps.
Torque: Bolt

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

41. INSTALL OIL PAN DRAIN PLUG

(a) Install the drain plug with a new gasket.

Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)

A
A

B

B

B B

B

B

B A

Nut

Nut

B

A

A

C

C

B

A

A126352E01

Bolt

length

A

25 mm (0.98 in.)

B

45 mm (1.77 in.)

C

14 mm (0.55 in.)

A072951E03

Seal Packing

Seal Width: 3 to 4 mm

A076308E02

A126351

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1GR-FE ENGINE MECHANICAL – ENGINE UNIT

EM

42. INSTALL CRANKSHAFT PULLEY

(a) Using SST, fix the pulley and tighten the bolt.

SST

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

Torque: 250 N*m (2,549 kgf*cm, 185 ft.*lbf)

43. SET NO. 1 CYLINDER TO TDC/COMPRESSION

44. INSPECT VALVE CLEARANCE

45. ADJUST VALVE CLEARANCE

46. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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

contact surfaces of the cylinder head, timing chain
cover and cylinder head cover.

(b) Install the gasket onto the cylinder head cover.

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

2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and
timing chain cover as shown in the illustration.
Seal packing:

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

NOTICE:
Install the cylinder head cover within 3 minutes
of applying the seal packing. After installation,
the cylinder head cover bolts and nuts must be
tightened within 15 minutes. Otherwise the seal
packing must be removed and reapplied.

(d) Install the seal washers onto the bolts.

(e) Install the cylinder head cover with the 10 bolts and

2 nuts. Tighten the bolts and nuts uniformly in
several steps.
Torque: Bolt A

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

HINT:
Each bolt length is as follows:

47. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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

contact surfaces of the cylinder head, timing chain
cover and cylinder head cover.

(b) Apply adhesive to the threads of the ventilation

valve.
Adhesive:

Part No. 08833-00070, THREE BOND 1324 or
the equivalent

SST

A076309E02

Seal Width: 2 to 3 mm

Seal Packing

A076310E02

A

A

A

A

A

A

A

B

B

B

Nut

Nut

A072943E02

Bolt

length

A

25 mm (0.98 in.)

B

60 mm (2.36 in.)

1GR-FE ENGINE MECHANICAL – ENGINE UNIT

EM–189

EM

(c) Install the ventilation valve onto the cylinder head

cover.
Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)

(d) Install the gasket onto the cylinder head cover.

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

2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and
timing chain cover as shown in the illustration.
Seal packing:

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

NOTICE:
Install the cylinder head cover of 3 minutes of
applying the seal packing. After installation, the
cylinder head cover bolts and nuts must be
tightened within 15 minutes. Otherwise, the seal
packing must be removed and reapplied.

(f)

Install the seal washers onto the bolts.

(g) Install the cylinder head cover with the 10 bolts and

2 nuts. Tighten the bolts and nuts uniformly in
several steps.
Torque: Bolt A

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

HINT:
Each bolt length is as follows:

48. INSTALL OIL CONTROL VALVE FILTER

(a) Check that no foreign objects on the mesh part of

the 2 filters.

(b) Install a new gasket onto each new plug.
(c) Insert the filters into the plugs.
(d) Apply adhesive to 2 or 3 threads of the plugs.

Adhesive:

Part No. 08833-00080, THREE BOND 1344
LOCTITE 242 or the equivalent

(e) Install the plugs onto each cylinder head.

Torque: 62 N*m (632 kgf*cm, 46 ft.*lbf)

49. INSTALL CRANKSHAFT POSITION SENSOR

(a) Install the crankshaft position sensor with the bolt.

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

Seal Packing

Seal Width: 2 to 3 mm

A076311E02

A

A

A

A

A

A

A

B

B

B

Nut

Nut

A072944E02

Bolt

length

A

25 mm (0.98 in.)

B

60 mm (2.36 in.)

Mesh Part

Apply
Adhesive

A076312E02

G036795E01

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1GR-FE ENGINE MECHANICAL – ENGINE UNIT

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50. INSTALL VVT SENSOR

(a) Apply a light coat of engine oil to the O-ring of each

VVT sensor.

(b) Install the 2 VVT sensors with the 2 bolts.

Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

51. INSTALL CYLINDER BLOCK WATER DRAIN COCK

SUB-ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the drain cock

ends.
Adhesive:

Part No. 08833-00070, THREE BOND 1324 or
the equivalent

(b) Tighten the drain cocks to the specified torque, and

rotate them clockwise as shown in the illustration.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
NOTICE:
•

Do not rotate the drain cocks more than 1
complete revolution (360

°) after tightening

the drain cocks to the specified torque.

•

Do not loosen the drain cocks after setting
them correctly.

52. INSTALL OIL LEVEL GAUGE GUIDE

(a) Install a new O-ring onto the oil level gauge guide.
(b) Apply a light coat of engine oil to the O-ring.
(c) Push the oil level gauge guide end into the guide

hole of the oil pan.

(d) Install the oil level gauge guide with the bolt.

Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

53. INSTALL SPARK PLUG

(a) Using a spark plug wrench, install the 6 spark plugs.

Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)

54. INSTALL WATER INLET

(a) Install a new gasket onto the timing chain cover.
(b) Install a new O-ring onto the water by-pass outlet

pipe.

Bank 1:

Bank 2:

G036794E02

Adhesive

A076531E03

45 q

45 q

45 q

15 q

A076313E01

O-Ring

Push

A076314E02

A121044