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FJ Cruiser PDF
FJ Cruiser PDF
NEW FEATURES
J1GR-FE ENGINE
1. General
D The 1GR-FE engine is a 4.0-liter, 24-valve DOHC V6 engine. In this engine, a Dual Variable Valve
Timing-intelligent (Dual VVT-i) system, in which the VVT-i system has also been added to the exhaust
side, and the roller rocker arm are used to minimize friction, offering excellent engine performance, fuel
economy and clean emissions.
D The 1GR-FE engine is compatible with gasoline/ethanol mixed fuel which contains up to 20% ethanol
(E20). Unleaded gasoline with an octane rating of 87 (research octane number 91) or higher can be used
on this engine.
D For detailed comparisons to the 09 FJ Cruiser, see Major Difference (See page 8).
147EG01TE
147EG02TE
Engine Specification A
Model
10 FJ Cruiser
09 FJ Cruiser
6-cylinder, V Type
Pentroof Type
Cross-flow
Fuel System
SFI
Ignition System
DIS
3956 (241.4)
10.4 : 1
10.0 : 1
Open (BTDC)
11_ to 29_
8_ to 42_
Close (ABDC)
71_ to 31_
60_ to 10_
Open (BBDC)
60_ to 25_
54_
Close (ATDC)
4_ to 39_
2_
Firing Order
123456
Oil Grade
ILSAC Multigrade
Engine Oil
Gasoline
Octane Rating
87 or higher
91 or higher
91 or higher
95 or higher
Displacement
Bore Stroke
mm (in.)
Compression Ratio
Valve
Timing
Intake
Exhaust
Fuel
Emission
Regulation
Tailpipe
Evaporative
kg (lb)
CARB*4
EPA*5
CARB*4
EPA*5
LEVII-LEV,
SFTP
Tier2-Bin5,
SFTP
LEVII-LEV,
SFTP
Tier2-Bin5,
SFTP
LEVII,
ORVR
Tier2,
ORVR
LEVII,
ORVR
Tier2,
ORVR
197 (435)
166 (366)
Maximum output and torque rating are determined using the revised SAE J1349 standard.
The figure shown is the weight of the part including the coolant and oil.
Mixed fuel from 0% ethanol (E0) to 20% ethanol (E20) is available.
California Air Resources Board (CARB)
Environmental Protection Agency (EPA)
Valve Timing A
: Intake Valve Opening Angle
Intake VVT-i
Operation Range
Exhaust VVT-i
Operation Range
Intake VVT-i
Operation Range TDC
2_ 8_
TDC
4_ 11_
29_
39_
232_
42_
240_
244_
236_
71_
60_
Intake VVT-i
31_
Operation Range
25_
BDC
10 FJ Cruiser
"
60_
54_
Intake VVT-i
Operation Range
Exhaust VVT-i
Operation Range
10_
BDC
09 FJ Cruiser
147EG03S
Performance Curve A
(HP) kW
280
260
Torque
200
Nm (ftlbf)
240
180
400
300
220
160
300
200
200
200
100
0
180
100
0
160
120
140
100
120
100
60
60
40
20
0
2000 3000 4000 5000
Engine Speed (rpm)
Output
80
80
40
1000
140
20
0
6000
147EG04S
2. Major Difference
The 1GR-FE engine on the 10 FJ Cruiser and the 1GR-FE engine on the 09 FJ Cruiser have the following
major differences:
Outline
System
Engine Proper
D Oil delivery pipes are used for the cylinder head cover.
D The cylinder head structure has been changed; the camshaft housing is
now separate from the cylinder head.
D The shapes of the cylinder head intake ports and the locations of the fuel
injectors have been optimized.
D The surface treatment of the cylinder block liner has been changed.
D A cylinder block water jacket spacer has been added.
D The shape of the piston has been changed.
D A 5 balance weight crankshaft is used.
Valve Mechanism
Lubrication System
D Oil passages for the VVT-i controller (exhaust) and the hydraulic lash
adjuster have been added.
D An oil filter with a replaceable element is used.
D
D
D
D
D
D
D
The shape and installation location of the air cleaner have been changed.
A filter paper type air cleaner element is used.
The throttle valve diameter has been increased.
The shape of the intake air chamber has been optimized.
The Acoustic Control Induction System (ACIS) has been discontinued.
The shape of the exhaust manifold has been changed.
The volume and cell density of the three-way catalytic converter have
been optimized.
D The material of the tail exhaust pipe has been changed.
Fuel System
Ignition System
Charging System
Starting System
The starter has been changed to one with a 1.4 kW rating output.
Engine
Proper
(1)
(3)
(4)
(5)
f
f
f
f
Valve
Mechanism
(2)
f
f
10 FJ
Cruiser
09 FJ
Cruiser
Lubrication
System
Cooling
System
Intake and
Exhaust
System
Fuel System
f
f
Charging
System
Serpentine
Belt Drive
System
f
f
(Continued)
10
Item
Engine
Control
System
(1)
(2)
(3)
(4)
(5)
10 FJ
Cruiser
09 FJ
Cruiser
11
4. Engine Proper
Cylinder Head Cover
An oil delivery pipe is installed inside each cylinder head cover. This ensures lubrication to the sliding parts
of the roller rocker arm, proving reliability.
Oil Delivery Pipe
147EG05TE
Cylinder Head
D The cylinder head structure has been simplified by separating the camshaft housing (cam journal portion)
from the cylinder head.
D By fitting the fuel injector so that its nozzle end juts into the intake port, the intake port cross sectional
area has become smooth, enhancing the efficiency of air intake. Furthermore, the distance between the
injector nozzle end and intake valve has been shortened and as a result, the amount of fuel that adheres
to the intake port will be reduced, increasing the fuel economy as well as reducing the exhaust emissions.
Camshaft Housing
Fuel Injector
Cylinder Head
10 FJ Cruiser
09 FJ Cruiser
147EG06TE
238EG07
12
Enlarged View of
Cross-hatching
147EG07TE
Cylinder Block
Water Jacket
Spacer
A A Cross Section
147EG08TE
13
D In order to reduce weight, cast holes have been provided on the bottom of the piston head near the pin
bosses as shown in the illustration below.
D The outer surface of the No. 2 compression ring has been plated with chrome in order to be compatible
with gasoline/ethanol mixed fuel.
Weight Reduction
10 FJ Cruiser
147EG09TE
09 FJ Cruiser
Crankshaft
The 5 balance weight crankshaft is used for weight reduction, and the installation location of the balance
weight has been optimized to reduce vibration and noise.
Front
5 Balance Weights
10 FJ Cruiser
Front
9 Balance Weights
09 FJ Cruiser
147EG10TE
14
5. Valve Mechanism
General
D A Dual Variable Valve Timing-intelligent (Dual VVT-i) system, in which the VVT-i system has also been
added to the exhaust side, is used. As a result, the valve timing has been optimized, achieving lower fuel
consumption, higher engine performance and lower exhaust emissions.
D The 10 FJ Cruiser 1GR-FE engine uses the roller rocker arms with built-in needle bearings. This reduces
the friction that occurs between the cams and the roller rocker arms that push the valves down, thus
improving fuel economy.
D Hydraulic lash adjusters, which maintain a constant zero valve clearance through the use of oil pressure
and spring force, are used.
VVT-i Controller (Exhaust)
VVT-i Controller (Intake)
VVT-i Controller
(Exhaust)
Roller Rocker Arm
Valve Lifter
Hydraulic Lash
Adjuster
10 FJ Cruiser
09 FJ Cruiser
147EG11TE
15
D A VVT-i controller has been added at the front end of the exhaust camshafts to vary the timing of the
exhaust valves.
D Oil passages are provided on the intake and exhaust camshafts in order to supply engine oil to the VVT-i
system.
D Together with the use of the roller rocker arms, the cam profile has been modified. This results in
increased valve lift when the valve begins to open and as it finishes closing, helping to achieve enhanced
output performance.
VVT-i Controller
(Exhaust)
No. 2 Camshaft
(Exhaust)
No. 1 Camshaft
(Intake)
Indented R Portion
of Cam (Profile)
Cam with Indented R
No. 3 Camshaft
(Intake)
No. 4 Camshaft
(Exhaust)
VVT-i Controller
(Intake)
VVT-i Controller
(Exhaust)
16
Oil
Passage
Check Ball
Check Ball Spring
Hydraulic Lash
Adjuster
Plunger Spring
Service Tip
Valve clearance adjustment is not necessary because hydraulic lash adjusters are used.
147EG12TE
17
6. Lubrication System
General
D Oil passages for the camshaft timing oil control valve (exhaust) and the VVT-i controller (exhaust) have
been added with the use of the VVT-i system on the exhaust side.
D With the use of the hydraulic lash adjuster and the roller rocker arm, oil passages have been added and
an oil delivery pipe is used.
D An oil filter with a replaceable element is used.
Camshaft Timing Oil
Control Valve (Exhaust)
Hydraulic
Lash
Adjuster
Oil
Pump
Oil Filter
10 FJ Cruiser
Oil Filter
VVT-i Controller
(Exhaust)
09 FJ Cruiser
147EG13TE
18
Oil Circuit A
Main Oil Hole
Cylinder
Block
Camshaft
Timing
Oil
Control
Valve
(Intake)
Cylinder
Head
Cover
Oil
Delivery
Pipe
Oil
Jets
Cylinder
Head
Cover
Oil
Delivery
Pipe
Camshaft
Timing
Oil
Control
Valve
(Exhaust)
Primary
Chain
Tensioner
Crankshaft
Pins
Exhaust
Camshaft
Journals
VVT-i
Controller
(Intake)
Camshaft
Timing
Oil
Control
Valve
(Intake)
Crankshaft
Journals
Camshaft
Timing
Oil
Control
Valve
(Exhaust)
Oil
Pump
Exhaust
Camshaft
Journals
VVT-i
Controller
(Intake)
Relief
Valve
Secondary
Chain
Tensioner
VVT-i
Controller
(Exhaust)
Oil
Strainer
Secondary
Chain
Tensioner
Lash
Adjusters
Intake
Camshaft
Journals
VVT-i
Controller
(Exhaust)
Lash
Adjusters
Intake
Camshaft
Journals
Connecting
Rods
Oil Pan
147EG14S
"
Specification A
Model
Oil Capacity
[liters (US qts, Imp. qts)]
10 FJ Cruiser
09 FJ Cruiser
Dry Fill
19
D The oil filter element uses a high-performance filter paper to improve filtration performance. It is also
combustible for environmental protection.
D A plastic oil filter cap assembly is used for weight reduction.
D This oil filter has a structure which can allow the draining of the oil remaining in the oil filter. This
prevents oil from spattering when replacing the oil filter element and allows the technician to work
without touching hot oil.
Oil Filter Bracket
O-ring
Drain Pipe
O-ring
Oil Filter Cap Assembly
Oil Filter
Drain Plug
147EG16TE
Service Tip
D The oil in the oil filter can be drained by removing the oil filter drain plug and inserting the drain
pipe supplied with the oil filter element into the oil filter. For details, refer to the 2010 FJ
CRUISER Repair Manual (Pub. No. RM1470U).
D The engine oil maintenance interval for a model that has an oil filter with a replaceable oil filter
element is the same as that for a conventional model.
20
7. Cooling System
The cooling system of the 10 FJ Cruiser is basically the same as in the 09 FJ Cruiser.
"
Model
Engine Coolant
[liters
(US qts, Imp. qts)]
10 FJ Cruiser
09 FJ Cruiser
M/T
A/T
Type
Capacity
*: Similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite and non-borate coolant
with long-life hybrid organic acid technology (Coolant with long-life hybrid organic acid technology is
a combination of low phosphates and organic acids).
21
Throttle Body
Tail Exhaust Pipe
Center Exhaust Pipe
Exhaust Manifold
147EG17TE
22
Air Cleaner
Air Cleaner
Front
Front
Intake Air Chamber
10 FJ Cruiser
23
9. Fuel System
D The fuel pressure has been increased from 284 kPa (2.9 kgf/cm2, 41 psi) to 324 kPa (3.3 kgf/cm2, 47 psi)
to be compatible with alcohol fuel.
D The pulsation damper and pressure regulator are surface-treated to be compatible with alcohol fuel,
resulting in improving the corrosion resistance.
Canister
Pulsation Damper
Pressure Regulator
Fuel Delivery Pipe
Fuel Tank
Fuel Injector
24
Iridium Tip
Platinum Tip
147EG22S
"
Specification A
Model
Type
Plug Gap
DENSO
10 FJ Cruiser
09 FJ Cruiser
SK20HR11 (Iridium)
K20HR-U11 (Nickel)
LFR6C11 (Nickel)
NGK
[mm (in.)]
Generator Pulley
Shaft
Pulley
One-way Clutch
147EG23TE
25
Specification A
Model
Type
10 FJ Cruiser
09 FJ Cruiser
RA1.4
RA2.0
Rating Output
[kW]
1.4
2.0
Rating Voltage
[V]
12
Length
[mm (in.)]
153.1 (6.0)
185.3 (7.3)
Weight
[g (lb)]
3750 (8.3)
4700 (10.4)
Clockwise
Rotating Direction*
*: Viewed from pinion end
Length
Length
147EG24TE
10 FJ Cruiser
09 FJ Cruiser
26
Outline
10 FJ
Cruiser
09 FJ
Cruiser
SFI
(Sequential Multiport
Fuel Injection)
ESA
(Electronic Spark
Advance)
ETCS-i
(Electronic Throttle
Control
System-intelligent)
Dual VVT-i
(Variable Valve
Timing-intelligent)
VVT-i
ACIS
(Acoustic Control
Induction System)
Evaporative
Emission
Control
Air Conditioning
Cut-off Control
Diagnosis
Fail-safe
27
VG
SFI
THA
#10
#20
#30
CRANKSHAFT POSITION
SENSOR
NE
#40
#50
#60
ENGINE COOLANT
TEMP. SENSOR
THW
IGT1 to
IGT6
ACCELERATOR PEDAL
POSITION SENSOR
KNOCK SENSORS
VVT SENSORS (INTAKE)
VPA
VPA2
IGF1
VTA2
KNK2
VV2
EV1
ECM
OC1
OC2
L4
4WD
4WD
COMBINATION METER
SPD
THROTTLE CONTROL
MOTOR
VVT-i (INTAKE)
EV2
STP
IGNITION COIL
WITH IGNITER
ETCS-i
KNK1
VV1
ESA
SPARK PLUGS
VTA1
VVT-i (EXHAUST)
OE1
OE2
FC
FPC
NO. 1 INJECTOR
NO. 2 INJECTOR
NO. 3 INJECTOR
NO. 4 INJECTOR
NO. 5 INJECTOR
NO. 6 INJECTOR
F / PS
DI
28
IGNITION SWITCH
IGSW
D Ignition Signal
PARK/NEUTRAL POSITION
SWITCH*3
D Neutral Start Signal
D Shift Lever Position Signal
NSW
HA1A
R, D, 3, 2
HA2A
HT1B
HT2B
4, L
EVAPORATIVE
EMISSION CONTROL
A1A
A2A
CANISTER PUMP
MODULE
MPMP
OX1B
STARTER RELAY
TAILLIGHT RELAY
AC INVERTER*4
POWER STEERING OIL
PRESSURE SENSOR
AIR CONDITIONING
AMPLIFIER
BATTERY
GENERATOR
*1:
*2:
*3:
*4:
VPMP
OX2B
PRG
PURGE VSV
ECM
LEAK DETECTION
PUMP
VENT VALVE
PPMP
THWO
STA
ELS1
PI
COMBINATION METER
MIL
CRUISE MAIN
INDICATOR LIGHT
ELS2
PSP
MREL
+B, +B2
AC1
ACT
BATT
IMI
IMO
+BM
ALT
CRUISE CONTROL
MAIN SWITCH
CCS
TRANSFER NEUTRAL
SWITCH*3
TFN
TC
TACH
DLC3
CANH
CANL
CAN
147EG26S
29
Ignition
Switch
Circuit Opening
Relay
Park / Neutral
Position Switch*
Combination Meter
D Vehicle Speed Signal
D MIL
Electronic Controlled
Transmission Solenoid Valve*
Fuel Pump
Control ECU
A/C Amplifier
Battery
CAN
Fuel Pump
ECM
Leak
Detection
Pump
Vent
Valve
Purge VSV
Intake Air
Temp. Sensor
Canister
Pressure
Sensor
Canister
Mass Air
Flow Meter
Throttle Position
Sensor
Knock Sensor
Knock Sensor
Injector
Camshaft Timing Oil Control
Valve (Bank 2, Intake)
VVT Sensor (Bank 2, Intake)
Injector
Camshaft Timing Oil Control
Valve (Bank 1, Intake)
VVT Sensor (Bank 1, Intake)
Camshaft Timing
Oil Control Valve
(Bank 1, Exhaust)
VVT Sensor
(Bank 1, Exhaust)
VVT Sensor
(Bank 2, Exhaust)
TWC Sensor
TWC
(Bank 1, Sensor 1)
Crankshaft
Position Sensor
TWC
TWC
147EG27S
30
Throttle Body
D Throttle Position
Sensor
D Throttle Control
Motor
ECM
Fuel Pump
Heated Oxygen Sensor
(Bank 2, Sensor 2)
Knock Sensor 1
Purge VSV
Ignition Coil with
Igniter
Ignition Coil
with Igniter
Injector
Engine Coolant
Temp. Sensor
Power
Steering Oil
Pressure
Sensor
VVT Sensor
(Bank 2, Exhaust)
VVT Sensor
(Bank 1, Intake)
Camshaft Timing
Oil Control Valve
(Bank 2, Exhaust)
VVT Sensor
(Bank 2, Intake)
Crankshaft Position Sensor
Injector
Knock Sensor 2
147EG29TE
31
Outline
Quantity
ECM
32-bit CPU
(Supplier /
DENSO)
Hot-wire Type
Intake Air
Temperature
Sensor
Thermistor
Type
Crankshaft
Position Sensor
Pick-up Coil
Type (Rotor
Teeth/36-2)
VVT Sensors
(Intake)
MRE Type
(Rotor Teeth/3)
VVT Sensors
(Exhaust)
MRE Type
(Rotor Teeth/3)
Accelerator Pedal
Position Sensor
No-contact
Type
Throttle
Position Sensor
No-contact
Type
Knock Sensors
Built-in
Piezoelectric
Type
(Flat Type)
2
(1 Each
Bank)
Heated Oxygen
Sensors
(Bank 1, Sensor 2)
(Bank 2, Sensor 2)
Heated Type
(Cup Type)
2
(1 Each
Bank)
Air Fuel
Ratio Sensors
(Bank 1, Sensor 1)
(Bank 2, Sensor 1)
Heated Type
(Planar Type)
2
(1 Each
Bank)
Engine Coolant
Temperature
Sensor
Thermistor
Type
2
(1 Each
Bank)
2
(1 Each
Bank)
Function
The ECM optimally controls the
SFI, ESA, and ISC to suit the
operating conditions of the engine
in accordance with the signals
provided by the sensors.
This sensor has a built-in hot-wire
to directly detect the intake air
mass and flow rate.
This sensor detects the intake air
temperature by means of an
internal thermistor.
This sensor detects the engine
speed and performs the cylinder
identification.
10 FJ 09 FJ
Cruiser Cruiser
(Continued)
32
Components
Power Steering
Oil Pressure
Sensor
Injectors
Camshaft Timing
Oil Control
Valves
Outline
Piezoresistance
Type
12-hole Type
Electromagnetic
Coil Type
10 FJ 09 FJ
Cruiser Cruiser
Quantity
Function
4
(2 Each
Bank)
33
The Magnetic Resistance Element (MRE) type VVT sensor (exhaust) has been added to each bank on
the exhaust side, the same as on the intake side. The installation location has been set on the cylinder head
cover.
147EG30TE
Timing Rotor
Piezoresistance
Voltage
Ratio
Oil Pressure
Cross Section
Pressure (MPa)
Output Characteristic
147EG31S
34
ECM
147EG32TE
Duty-cycl
e
Control
Feedback
Correction
VVT Sensors
Camshaft
Timing Oil
Control
Valves
35
Objective
Earliest Timing
(EX)
During Idling
TDC
EX
Latest Timing
(IN)
IN
BDC
to Advance
Side (EX)
At Light Load
EX
Effect
Eliminating overlap
to reduce blow back
to the intake side.
D Stabilized
idling rpm
D Better fuel
economy
Eliminating overlap
to reduce blow back
to the intake side.
Ensured engine
stability
Increasing overlap
increases internal
EGR, reducing
pumping loss.
D Better fuel
economy
D Improved
emission
control
Advancing the
intake valve close
timing for volumetric
efficiency
improvement.
Improved
torque
in low to
medium
speed range
Improved
output
Eliminating overlap
to reduce blow back
to the intake side.
D Stabilized
fast idle rpm
D Better fuel
economy
Eliminating overlap
to minimize blow
back to the intake
side.
Improved
startability
147EG34S
to Retard
Side (IN)
IN
147EG35S
to Advance
Side (IN)
At Medium Load
EX
to Retard
Side (EX)
IN
147EG36S
In Low to Medium
Speed Range with
Heavy Load
EX
to Retard
Side (EX)
IN
to Advance
Side (IN)
147EG37S
In High Speed
Range with Heavy
Load
EX
to Retard
Side (IN)
IN
to Advance
Side (EX)
147EG38S
Earliest Timing
(EX)
At Low
Temperatures
EX
Latest Timing
(IN)
IN
147EG34S
D Upon Starting
D Stopping the
Engine
Earliest Timing
(EX)
EX
Latest Timing
(IN)
IN
147EG34S
36
Intake Side A
Timing Chain Sprocket
Vane Sub-assembly
Outer Housing
Intake Camshaft
Timing Rotor
Oil Pressure
In Operation
At a Stop
Lock Pin
"
147EG41TE
Exhaust Side A
Timing Chain Sprocket
Lock Pin
Outer Housing
Exhaust Camshaft
Vane Sub-assembly
147EG42TE
37
This camshaft timing oil control valve controls the spool valve using duty-cycle control from the ECM.
This allows hydraulic pressure to be applied to the VVT-i controller advance or retard side. When the
engine is stopped, the camshaft timing oil control valve (intake) will move to the retard position, and
the camshaft timing oil control valve (exhaust) will move to the advance position.
"
Exhaust Side A
To VVT-i Controller
(Advance Side)*
To VVT-i Controller
(Retard Side)*
Sleeve
Spring
Drain
Drain
Oil Pressure
Spool Valve
147EG40S
*: The advance and retard sides of the intake side oil control valve are reverse of the exhaust side.
38
Intake Side A
Vane Sub-assembly
ECM
Oil Pressure
Rotation Direction
IN Drain
147EG43TE
"
Exhaust Side A
Rotation Direction
Oil Pressure
Drain IN
Vane Sub-assembly
147EG44TE
39
When the camshaft timing oil control valve is positioned as illustrated below by the retard signals from
the ECM, the resultant oil pressure is applied to the timing retard side vane chamber to rotate the
camshaft in the timing retard direction.
"
Intake Side A
Rotation Direction
ECM
Oil Pressure
Vane Sub-assembly
Drain IN
147EG45TE
"
Exhaust Side A
Rotation Direction
Camshaft Timing Oil
Control Valve (Exhaust)
ECM
Oil Pressure
Vane Sub-assembly
IN
Drain
147EG46TE
c. Hold
After reaching the target timing, the engine valve timing is maintained by keeping the camshaft timing
oil control valve in the neutral position unless the engine operating conditions change. This maintains
the engine valve timing at the desired target position by preventing the engine oil from running out of
the oil control valve.
40
System Diagram A
Fuel Pump
Operation Request
FPC
FPC
Fuel Pump
Duty Signal
Fuel Pump
Control ECU
ECM
Diagnosis Signal
DI
DI
04E0EG24C
"
+B
High
GND
04E0EG25C
12.3 ms
8.2 ms
Middle
+B
GND
04E0EG26C
4.1 ms
+B
GND
Low
04E0EG27C
GND
Stop
04E0EG28C