Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 166

1GR-FE ENGINE MECHANICAL  –  CYLINDER HEAD

EM–97

EM

(c) Install and tighten the 10 bolts uniformly in several 

steps.
Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)

(d) Connect the 6 fuel injector connectors.

15. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY (See 

page 

FU-19

)

16. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY (See 

page 

FU-17

)

17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Set a new gasket to the bank 2 cylinder head with 

the oval shape facing forward.
NOTICE:
Orient the new gasket correctly.

(b) Install the exhaust manifold with the 6 nuts.

Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

(c) Connect the air fuel ratio sensor connector.

18. INSTALL NO. 2 MANIFOLD STAY

(a) Install the No. 2 manifold stay with the 3 bolts.

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

19. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Set a new gasket to the bank 1 cylinder head with 

the oval shape facing forward.
NOTICE:
Orient the new gasket correctly.

3

9

8

6

2

4

10

1

7

5

A076533E02

Forward

Oval shape

A076439E02

A126448

A126445

Oval Shape

Forward

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EM–98

1GR-FE ENGINE MECHANICAL  –  CYLINDER HEAD

EM

(b) Install the exhaust manifold with the 6 nuts.

Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

(c) Connect the air fuel ratio sensor connector.

20. INSTALL MANIFOLD STAY

(a) Install the manifold stay with the 3 bolts.

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

21. INSTALL FRONT EXHAUST PIPE ASSEMBLY

(a) Check the free length.

(1) Using vernier calipers, measure the free length 

of the compression spring.
Minimum:

40.5mm (1.594 in.)

If the free length is less that the minimum, 
replace the compression spring.

(b) Install a new gasket onto the exhaust manifold RH.

(c) Install a new gasket onto the exhaust front pipe.

(1) Using a wooden block and plastic-faced 

hammer, tap in the new gasket until it is flush 
with the exhaust front pipe.
NOTICE:
•

Make sure that the gasket is in the 
correct direction when installing.

•

Do not reuse the removed gasket.

(d) Install the exhaust front pipe with new 2 nuts.

Torque: 54 N*m (554 kgf*cm, 40 ft.*lbf)

A126447

A126446

A128853

Plastic-faced Hammer

Wooden Block

Gasket

A128852E01

1GR-FE ENGINE MECHANICAL  –  CYLINDER HEAD

EM–99

EM

(e) Install the exhaust center pipe onto the front 

exhaust pipe with the 2 bolts and 2 springs.

Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

(f)

Connect the oxygen sensor connector.

22. INSTALL NO. 2 FRONT EXHAUST PIPE ASSEMBLY

(a) Install a new gasket onto the exhaust manifold LH.
(b) Install a new gasket onto the No. 2 front exhaust 

pipe.

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A126437

EM–100

1GR-FE ENGINE MECHANICAL  –  CYLINDER HEAD

EM

(c) Install the No. 2 front exhaust pipe with the 2 new 

nuts and 2 bolts.
Torque: Nut

54 N*m (554 kgf*cm, 40 ft.*lbf)
Bolt
48 N*m (489 kgf*cm, 35 ft.*lbf)

(d) Connect the oxygen sensor connector.

23. INSTALL EXHAUST PIPE STOPPER BRACKET (for 

4WD)
(a) Install the exhaust pipe stopper bracket with the 2 

bolts.
Torque: 19 N*m (193 kgf*cm, 14 ft.*lbf)

24. INSTALL NO. 1 COOL AIR INLET

(a) Install the cool air inlet with the 2 bolts.

Torque: 12 N*m (122 kgf*cm, 9.0 ft.*lbf)

25. INSTALL CHAIN SUB-ASSEMBLY

Refer to the procedures up to "INSTALL CHAIN 
TENSIONER SLIPPER" (See page 

EM-27

).

26. CHECK FOR FUEL LEAKAGE

27. CHECK FOR EXHAUST GAS LEAKAGE

28. INSPECT IGNITION TIMING (See page 

EM-1

)

29. INSPECT ENGINE IDLING SPEED (See page 

EM-2

)

30. REMOVE COMPRESSION (See page 

EM-3

)

31. INSPECT CO/HC (See page 

EM-3

)

32. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

(See page 

SP-2

)

REPAIR

1.

REPAIR VALVE SEAT
NOTICE:
Use a cutter to gradually smooth the intake valve 
seat.
(a) If the seating is too high on the valve face, use 30

° 

and 45

° cutters to correct the seat.

(b) Intake side:

If the seating is too low on the valve face, use 60

° 

and 45

° cutters to correct the seat.

A129939

1.0 to 1.4 mm 

45 °

30 °

A062787E04

1.0 to 1.4 mm 

45 °

60 °

Intake Side:

A075613E03