Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 185

1GR-FE ENGINE MECHANICAL  –  ENGINE UNIT

EM–171

EM

13. INSTALL CRANKSHAFT

(a) Apply engine oil to the upper bearing and install the 

crankshaft onto the cylinder block.

(b) Install the 2 upper thrust washers onto the No. 2 

journal position of the cylinder block.
(1) Push the crankshaft toward the front (rear) 

side.

(2) Install the 2 upper thrust washers with the oil 

grooves facing outward.

(c) Install the 2 lower thrust washers onto the No. 2 

bearing cap with the grooves facing outward.

(d) Examine the front marks and numbers, check the 

sequence number is as shown in the illustration and 
install the bearing caps on the cylinder block.

(e) Apply a light coat of engine oil to the threads of the 

bearing cap bolts.

(f)

Temporarily install the 8 main bearing cap bolts in 
the inside positions.

(g) Install the main bearing caps. Tighten the 2 bolts for 

each bearing cap until the clearance between the 
bearing cap and the cylinder block is under 6 mm 
(0.23 in.).

A076393E01

A076075E01

A076067E01

Less than 6 mm

A076069E02

EM–172

1GR-FE ENGINE MECHANICAL  –  ENGINE UNIT

EM

(h) Using a plastic-faced hammer, lightly tap the 

bearing cap to ensure a proper fit.

(i)

Apply a light coat of engine oil to the threads of the 
main bearing cap bolts.

(j)

Install the 16 main bearing cap bolts. Using several 
steps, tighten the bolts uniformly in the sequence 
shown in the illustration.
Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)

(k) Mark the front side of the bearing cap bolts with 

paint.

(l)

Retighten the bearing cap bolts 90

° in the sequence 

as shown.

(m) Check that the painted marks are now at a 90

° 

angle from the front.

(n) Check that the crankshaft turns smoothly.

(o) Using several steps, tighten the 8 main bearing cap 

bolts uniformly in the sequence shown in the 
illustration.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)

14. INSTALL PISTON SUB-ASSEMBLY WITH 

CONNECTIONG ROD
(a) Apply engine oil to the cylinder walls, pistons, and 

surfaces of connecting rod bearings.

(b) Check the position of the piston ring ends.

A076070E01

7

15

1 2

3 4

6

5

8

9

14

13

10

11

12

16

A076071E04

Painted Mark

Front

90°

90°

A076072E03

3

7

1

2

4

5

6

8

A075843E03

Front Mark

A076385E02

1GR-FE ENGINE MECHANICAL  –  ENGINE UNIT

EM–173

EM

(c) Using a piston ring compressor, push the correct 

number piston and connecting rod into each 
cylinder with the front mark of the piston facing 
forward.
NOTICE:
•

Clean the back side of the bearing and the 
bearing surface of the connecting rod cap 
and keep them free of oil.

•

Match the numbered connecting rod cap with 
the connecting rod.

(d) Check that the protrusion of the connecting rod cap 

is facing in the correct direction.

(e) Apply a light coat of engine oil to the threads of the 

connecting rod cap bolts.

(f)

Tighten the bolts alternately to the specified torque.
Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)

(g) Mark the front side of the each connecting cap bolt 

with paint.

(h) Retighten the cap bolts 90

° as shown.

(i)

Check that the crankshaft turns smoothly.

15. INSTALL REAR ENGINE OIL SEAL RETAINER

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

contact surfaces of the oil seal retainer and cylinder 
block.

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

2 to 3 mm (0.08 to 0.12 in.)) to the oil seal retainer 
as shown in the illustration.
Seal packing:

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

NOTICE:
Parts must be assembled within 3 minutes of 
application. Otherwise, the seal packing must be 
removed and reapplied.

Protrusion

A075149E02

A075150E03

90°

90°

Front

Painted Mark

A075151E03

Seal Width: 2 to 3 mm

Seal Packing

A076269E03

EM–174

1GR-FE ENGINE MECHANICAL  –  ENGINE UNIT

EM

(c) Install the oil seal retainer with the 5 bolts and 2 

nuts.
Torque: Nut

9.0 N*m (92 kgf*cm, 80 in.*lbf)
Bolt
10 N*m (102 kgf*cm, 7.4 ft.*lbf)

16. INSTALL KNOCK SENSOR

(a) Install the 2 knock sensors with the 2 bolts as shown 

in the illustration.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)

(b) Connect the knock sensor connectors.
(c) Install the knock sensor wire.

17. INSTALL NO. 1 WATER OUTLET PIPE

(a) Install the water outlet pipe with the 3 bolts.

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

18. INSTALL CYLINDER HEAD GASKET

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

contact surfaces of the cylinder head and cylinder 
block.

LH Bank:

RH Bank:

Upper

Upper

Engine 
Rear

Engine 
Front

15°

15°

A078438E04

G036807E01