Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 170

EM–112

1GR-FE ENGINE MECHANICAL  –  ENGINE ASSEMBLY

EM

INSPECTION

1.

INSPECT INTAKE MANIFOLD FOR WARPAGE
(a) Using a precision straight edge and feeler gauge, 

measure the warpage of the contact surfaces of the 
cylinder head and intake air surge tank.
Maximum warpage:

Intake air surge tank side:

0.8 mm (0.031 in.)

Cylinder head side:

0.2 mm (0.008 in.) 

If the warpage is greater than the maximum, replace 
the intake manifold.

Intake Air Surge Tank Side

Cylinder Head Side

A076807E02

1GR-FE ENGINE MECHANICAL  –  ENGINE ASSEMBLY

EM–113

EM

INSTALLATION

1.

INSTALL ENGINE WIRE
(a) Connect the connectors to the engine.
(b) Engage the clamps to the engine.
(c) Connect the connector to the knock sensor sub 

wire.

(d) Install the ground wire onto the bank 2 cylinder head 

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

(e) Install the ground wire onto the bank 1 cylinder head 

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

2.

INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY

3.

INSTALL OIL FILLER CAP HOUSING
(a) Install a new gasket.
(b) Install the oil filler cap housing with the 2 nuts.

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

4.

INSTALL OIL FILLER CAP SUB-ASSEMBLY

5.

INSTALL IGNITION COIL ASSEMBLY (See page 

IG-8

)

6.

INSTALL INTAKE MANIFOLD (See page 

EM-96

)

7.

INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY (See 
page 

EM-32

)

8.

INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY (See 
page 

EM-33

)

9.

INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
(See page 

EM-33

)

10. INSTALL FRONT NO. 1 ENGINE MOUNTING 

BRACKET LH
(a) Install the engine mounting bracket with engine 

mounting insulator with the 3 bolts.
Torque: 43 N*m (435 kgf*cm, 31 ft.*lbf)

11. INSTALL FRONT NO. 1 ENGINE MOUNTING 

BRACKET RH
(a) Install the engine mounting bracket with engine 

mounting insulator with the 4 bolts.
Torque: 43 N*m (435 kgf*cm, 31 ft.*lbf)

12. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH 

(See page 

EM-96

)

13. INSTALL NO. 2 MANIFOLD STAY (See page 

EM-96

)

14. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH 

(See page 

EM-97

)

15. INSTALL MANIFOLD STAY (See page 

EM-97

)

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G036197E01

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1GR-FE ENGINE MECHANICAL  –  ENGINE ASSEMBLY

EM

16. INSTALL NO. 2 VENTILATION HOSE

17. INSTALL VENTILATION HOSE

18. INSTALL HEATER OUTLET WATER HOSE

19. INSTALL HEATER INLET WATER HOSE

G036199E01

G036200E01

G036202E01

G036201E01

1GR-FE ENGINE MECHANICAL  –  ENGINE ASSEMBLY

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EM

20. INSTALL ENGINE ASSEMBLY

(a) Attach the engine sling device and hang the engine 

with a chain block.

(b) Lower the engine into the engine compartment 

carefully.

(c) Attach the engine mounting brackets to the frame 

brackets.

(d) Install the engine mounting brackets onto the frame 

brackets with the 4 bolts and 4 nuts.
Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf)

(e) Remove the 4 bolts and 2 engine hangers.

21. INSTALL ENGINE WIRE

(a) Connect the front differential connector (for 

Automatic Transmission 4WD).

(b) Install the ground wire with the bolt and engage the 

clamp.
Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf)

(c) Connect the 2 connectors to the A/C unit.
(d) Connect the 3 connectors to the ECM.
(e) Connect the connector to the four wheel drive ECU 

(for Automatic Transmission 4WD).

(f)

Install the glove compartment door (see page 

IP-

28

).

22. INSTALL NO. 2 ENGINE WIRE

(a) Install the engine wire onto the engine room relay 

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

A126458

No. 1

No. 2

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A126440

A126451