Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 188

1GR-FE ENGINE MECHANICAL  –  ENGINE UNIT

EM–183

EM

(2) Using the crankshaft pulley set bolt, turn the 

crankshaft to align the crankshaft set key with 
the timing line of the cylinder block.

(b) Align the yellow mark link with the timing mark of the 

crankshaft timing gear.

(c) Align the orange mark links with the timing marks of 

the camshaft timing gears, and install the chain.

34. INSTALL NO. 2 CHAIN VIBRATION DAMPER

(a) Instal the 2 No. 2 chain vibration dampers.

35. INSTALL IDLE SPROCKET ASSEMBLY

(a) Apply a light coat of engine oil to the rotating surface 

of idle gear shaft No. 1.

Timing Line

Set Key

A076296E02

Timing Mark

Mark Link

A076297E03

Mark Links

Timing Marks

G036259E02

G036844E01

EM–184

1GR-FE ENGINE MECHANICAL  –  ENGINE UNIT

EM

(b) Temporarily install idle gear shaft No. 1 together 

with idle gear shaft No. 2 while aligning the knock 
pin of idle gear shaft No. 1 with the knock pin groove 
of the cylinder block.
NOTICE:
Install the idle gear in the correct direction.

(c) Using a 10 mm hexagon wrench, tighten idle gear 

shaft No. 2.
Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)

(d) Remove the bar from the chain tensioner.

36. INSTALL TIMING CHAIN OR BELT COVER SUB-

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

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

(b) Install a new O-ring onto the cylinder head LH as 

shown in the illustration.

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

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

Water pump part:

Toyota Genuine Seal Packing 1282B, Three 
Bond 1282B or the equivalent

Other parts:

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

NOTICE:
•

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

•

Do not apply seal packing to A as shown in 
the illustration.

Knock Pin

Forward

A076299E02

G036845E01

Seal Packing

Seal Packing

Water Pump 
Part

Water Pump Part

Seal Width 3 to 4 mm

3 to 4 mm

3 to 4 mm

16.7 mm

3 to 4 mm

B - B’

B

B

A

Seal 
Packing

A076303E08

1GR-FE ENGINE MECHANICAL  –  ENGINE UNIT

EM–185

EM

(d) Keep the seal surface between the cylinder block 

and the cylinder head shown in the illustration free 
of oil before installing the chain cover.

(e) Align the key way of the oil pump drive rotor with the 

rectangular portion of the crankshaft timing gear, 
and slide the timing chain cover into place.

(f)

Install the timing chain cover with the 15 bolts and 2 
nuts. Tighten the bolts and nuts uniformly in several 
steps.
Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf)
NOTICE:
•

Do not wrap the chain and slipper beyond the 
timing chain cover seal line.

•

After installing the timing chain cover, install 
the water pump within 15 minutes.

HINT:
Each bolt length is as follows:

(g) Install the timing chain cover plate with the 4 bolts.

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

37. INSTALL WATER PUMP ASSEMBLY

(a) Install a new gasket and the water pump with the 17 

bolts.
Torque: Bolt A

9.0 N*m (92 kgf*cm, 80 in.*lbf)
Bolt B
23 N*m (235 kgf*cm, 17 ft.*lbf)

38. INSTALL OIL PAN SUB-ASSEMBLY

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

contact surfaces of the cylinder block, rear oil seal 
retainer and oil pan.

A126368

15 q

A076304E01

A

A

A

A

A

B

B

B

B

B

B

A

A

A

A

Nut

Nut

G036855E02

Bolt

length

A

25 mm (0.98 in.)

B

55 mm (2.17 in.)

B

B

B

B

B

B

B

B

B

A

A

A

A

A

A

A

A

A072954E05

EM–186

1GR-FE ENGINE MECHANICAL  –  ENGINE UNIT

EM

(b) Install the 4 stud bolts.

Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)

(c) Install a new O-ring onto the oil pump.

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

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

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

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

A

B

14

9.0

A

24

16.5

9.0

27.5

B

[mm]

A126369E01

A076306E01

Seal 
Packing

Seal Width: 3 to 4 mm

G036851E02