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