Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 168

EM–104

1GR-FE ENGINE MECHANICAL  –  ENGINE ASSEMBLY

EM

EXHAUST 
MANIFOLD 
SUB-ASSEMBLY 
RH

NO. 2 VENTILATION 
HOSE

ENGINE MOUNTING 
BRACKET FRONT 
NO. 1 RH

ENGINE MOUNTING BRACKET 
FRONT NO. 1 LH

EXHAUST MANIFOLD 
SUB-ASSEMBLY LH

VENTILATION 
HOSE

HEATER WATER 
OUTLET HOSE

HEATER WATER 
INLET HOSE

N*m (kgf*cm, ft*lbf)  : Specified torque

Non-reusable part

43 (435, 31)

GASKET

x2

38 (387, 28)

43 (435, 31)

38 (387, 28)

30 (306, 22)

x6

GASKET

30 (306, 22)

38 (387, 28)

43 (435, 31)

x4

38 (387, 28)

x6

A126455E01

1GR-FE ENGINE MECHANICAL  –  ENGINE ASSEMBLY

EM–105

EM

;

OIL LEVEL GAUGE 
SUB-ASSEMBLY

INTAKE 
MANIFOLD

26 (265, 19)

x10

9.0 (92, 80 in.*lbf)

GASKET

GASKET

10 (102, 7.4)

IGNITION COIL 
ASSEMBLY

x3

10 (102, 7.4)

x3

IGNITION COIL 
ASSEMBLY

OIL FILLER CAP 
SUB-ASSEMBLY

9.0 (92, 80 in.*lbf)

OIL FILLER 
CAP 
HOUSING

GASKET

36 (367, 27)

36 (367, 27)

V-RIBBED BELT TENSIONER 
ASSEMBLY

NO. 1 IDLER PULLEY 
SUB-ASSEMBLY

NO. 2 IDLER PULLEY 
SUB-ASSEMBLY

39 (398, 29)

54 (551, 40)

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part

A126507E01

EM–106

1GR-FE ENGINE MECHANICAL  –  ENGINE ASSEMBLY

EM

REMOVAL

1.

DISCHARGE FUEL SYSTEM PRESSURE
(See page 

FU-1

)

2.

REMOVE BATTERY

3.

DRAIN ENGINE COOLANT (See page 

CO-3

)

4.

DRAIN ENGINE OIL (See page 

LU-4

)

5.

REMOVE HOOD SUPPORT (See page 

ED-5

)

6.

REMOVE HOOD SUB-ASSEMBLY
(a) Disconnect the windshield washer hose.
(b) Remove the 4 bolts, then remove the hood.

7.

REMOVE RADIATOR ASSEMBLY
Refer to the procedures up to " REMOVE RADIATOR 
ASSEMBLY" (See page 

CO-22

).

8.

REMOVE MANUAL TRANSMISSION UNIT 
ASSEMBLY (for Manual Transmission)
Refer to the procedures up to " REMOVE MANUAL 
TRANSMISSION UNIT ASSEMBLY" (See page 

MT-8

).

9.

REMOVE AUTOMATIC TRANSMISSION ASSEMBLY 
(for Automatic Transmission)
Refer to the procedures up to " REMOVE AUTOMATIC 
TRANSMISSION ASSEMBLY" (See page 

AT-172

 or 

AT-

178

).

10. REMOVE CLUTCH DISC ASSEMBLY (for Manual 

Transmission)
Refer to the procedures up to " REMOVE CLUTCH DISC 
ASSEMBLY" (See page 

CL-21

).

11. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual 

Transmission)
(a) Using SST, hold the crankshaft.

SST

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

(b) Remove the 8 bolts, then remove the flywheel and 2 

spacers.

A126452

SST

A076326E02

G036171

1GR-FE ENGINE MECHANICAL  –  ENGINE ASSEMBLY

EM–107

EM

12. REMOVE DRIVE PLATE AND RING GEAR SUB-

ASSEMBLY (for Automatic Transmission)
(a) Using SST, hold the crankshaft.

SST

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

(b) Remove the 8 bolts, then remove the drive plate 

and 2 spacers.

13. REMOVE THROTTLE BODY BRACKET (See page 

FU-11

)

14. REMOVE OIL BAFFLE PLATE (See page 

FU-11

)

15. REMOVE NO. 1 SURGE TANK STAY (See page 

FU-11

)

16. REMOVE NO. 2 SURGE TANK STAY (See page 

FU-12

)

17. REMOVE INTAKE AIR SURGE TANK (See page 

FU-

12

)

18. REMOVE GENERATOR ASSEMBLY (See page 

CH-10

)

19. SEPARATE COOLER COMPRESSOR ASSEMBLY 

(See page 

ES-420

)

20. REMOVE VANE PUMP ASSEMBLY (See page 

PS-8

)

21. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Remove the No. 2 fuel pipe clamp.
(b) Pinch the retainer as illustrated, then pull the fuel 

tube connector out of the pipe.
NOTICE:
•

Remove any dirt and foreign matter from the 
fuel tube connector before performing this 
work.

•

Do not allow any scratches or foreign matter 
onto the parts when disconnecting, as the 
fuel tube connector has the O-rings that seals 
the pipe.

•

Perform this work by hand. Do not use any 
tools.

•

Do not forcibly bend, twist or turn the nylon 
tube.

•

Protect the disconnected part by covering it 
with a vinyl bag after disconnecting the fuel 
tube.

•

If the fuel tube connector and pipe are stuck, 
push and pull to release them.

SST

A076326E02

A076327

A126401