Toyota FJ GSJ15 Technical Manual
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Toyota FJ GSJ15 Technical Manual

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To assist you in your service activities, this manual explains the main characteristics of the new FJ Cruiser
in particular providing a technical explanation of the construction and operation of new mechanism and new
technology used.
This manual is divided into 3 sections.
1. New Model Outline - Explanation of the product to give a general understanding of its features.
2. Technical Description -Technical explanation of the construction and operation of each new system and
3. Appendix - Major technical specifications of the vehicle.
CAUTION, NOTICE, REFERENCE and NOTE are used in the following ways:
A potentially hazardous situation which could result in injury if instructions are
CAUTION
ignored.
NOTICE
Damage to the vehicle or components may occur if instructions are ignored.
REFERENCE
Explains the theory behind mechanisms and techniques.
NOTE
Notes or comments not included under the above 3 titles.
For detailed service specifications and repair procedures, refer to the following Repair Manuals:
2007 FJ Cruiser Repair Manual
2007 FJ Cruiser Electrical Wiring Diagram
All information contained herein is the most up-to-date at the time of publication. We reserve the right to
make changes without prior notice.
2005 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: Dec. 22, 2005 01-051222-00
FOREWORD
Applicable models: GSJ10, GSJ15 series
component.
Manual Name
Pub. No.
RM0240U
EM0240U

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  • Page 1 2005 TOYOTA MOTOR CORPORATION All rights reserved. This book may not be repro- duced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. First Printing: Dec. 22, 2005 01-051222-00...

  • Page 2: Exterior Appearance

    EG-2 NEW MODEL OUTLINE EXTERIOR APPEARANCE 0240MO01Z 0240MO02Z...

  • Page 3: Model Code

    NEW MODEL OUTLINE MODEL CODE GSJ15 L - G K F S K A BASIC MODEL CODE GEAR SHIFT TYPE CODE ENGINE DRIVE TYPE F : 6-Speed Manual, Floor A : 5-Speed Automatic, Floor GSJ10 1GR FE 1GR-FE GSJ15 GRADE STEERING WHEEL POSITION S : SR L : Left-Hand Drive...

  • Page 4: Front View

    EG-4 NEW MODEL OUTLINE EXTERIOR Front View " The headlights and radiator grille evoke an image of the original Land Cruiser FJ-40 series. " The high cabin and rounded design create a modern image. 0240MO03Z Rear View " The quarter windows that extend partway around the rear of the vehicle and the placement of the license plate evoke an image of the original Land Cruiser FJ-40 series.

  • Page 5: Side View

    NEW MODEL OUTLINE Side View " The quarter pillar and over fenders express a sense of individuality and create a dynamic image. " The black rocker panel area creates a three-dimensional appearance. " The rear access doors create a stylish profile. 0240MO05Z...

  • Page 6: Exterior Color

    EG-6 NEW MODEL OUTLINE Exterior Color 0240MO06Z 0240MO07Z Parts Color No. Color Name Parts Color No. Color Name Roof White Bumper 11CR07 Silver Metallic Silver Metallic 11CR07 Silver Metallic Mirror Mirror Black Mica 11BK10 Black Over Bordeaux Mica 11BK10 Black Fender Body Yellow...
  • Page 7 NEW MODEL OUTLINE Tire & Disc Wheel Tire Size P265/70R17 Size 7 1/2J Disc Wheel Disc Wheel Material Steel Aluminum P. C. D.* mm (in.) 139.7 (5.5) 139.7 (5.5) Off Set mm (in.) 15 (0.6) Wheel Design 0240MO08C 0240MO09C Equipment Standard Option *: P.C.D.
  • Page 8 EG-8 NEW MODEL OUTLINE INTERIOR The flexible cabin space and functional design give a modern rugged image to the interior. " The instrument panel has a distinct design that creates an image of two pipes. " The door trim panel has a straight arm rest and pipe-shaped door grip, providing both a dynamic image and usability.

  • Page 9: Interior Color

    NEW MODEL OUTLINE Interior Color 0240MO12Z Color No. Color Name Color No. Color Name 21SV31 Silver Metallic Bordeaux Mica Silver Metallic Yellow Black Mica Blue...

  • Page 10: Combination Meter

    EG-10 NEW MODEL OUTLINE Combination Meter The tachometer and the three (engine coolant, fuel, voltage) gauges are arranged to create a sense of individuality. 4WD models with Automatic Transmission for U.S.A. 0240MO13Z 4WD models with Manual Transmission for Canada 0240MO14Z Accessory Meter The accessory meter with three additional gauges creates a rugged image.

  • Page 11: Audio System

    NEW MODEL OUTLINE EQUIPMENT Audio System The ceiling speaker with exciter creates a space which encompasses the passenger’s body with a shower of sound. " Three types of audio systems are available: Audio Head Unit Design Audio System Equipment " AM/FM Tuner "...

  • Page 12: Speaker Layout

    EG-12 NEW MODEL OUTLINE Speaker Layout Head Unit Box Woofer 0240MO19C Speaker Specification Specification Speaker Speaker Eq ipment Equipment (Maker) Caliber Impedance Input Rating 23 cm 4 Ω Full Range (PANASONIC) 20 W Standard 9 in.) 8 Ω Tweeter (FUJITSU TEN) 6.5 cm (2.6 in.) Standard 8 Ω...
  • Page 13 NEW MODEL OUTLINE Ceiling Speaker with Exciter The ceiling speaker with exciter utilizes the roof headlining as a diaphragm. This speaker has the following features: " The exciter is mounted on the roof headlining. This helps create a better soundscape which otherwise cannot be provided only by the door speakers mounted in lower positions.
  • Page 14 EG-14 NEW MODEL OUTLINE Power Outlet Socket In order to meet multi-purpose outdoor needs, an AC 115 V 400 W power outlet socket is available in the right-hand deck. " In order to protect the vehicle, the output of the power outlet socket is limited to 100 W while the vehicle is running.
  • Page 15 NEW MODEL OUTLINE Glass Front Door Windshield Quarter Back Window Access Door 0240MO22Z Ultraviolet Visible Light Glass Portion Color Glass Type Equipment Reduction Rate Penetration Rate Windshield Green Laminated 100 % 75 % Standard Front Door Green Tempered & UV Cut 90 % 70 % Standard...

  • Page 16: Power Train

    EG-16 NEW MODEL OUTLINE PERFORMANCE Power Train 1GR-FE Engine 0240MO24Z 0240MO25Z No. of Cyls. & Arrangement 6-Cylinder, V-Type Valve Mechanism 24-Valve DOHC with VVT-i Fuel System Displacement 3956 cm (241.4 cu. in.) 178 kW @ 5200 rpm Max. Output* (239 HP @ 5200 rpm) 377 N m @ 3700 rpm Max.
  • Page 17 NEW MODEL OUTLINE Transmission Manual Automatic Type RA61F A750E A750F Combination with Engine 1GR-FE (4WD) 1GR-FE (2WD) 1GR-FE (4WD) Combination with Transfer VF4B (Full-time) VF2A (Part-time) 4.171 3.520 3.520 2.190 2.042 2.042 1.488 1.400 1.400 1.193 1.000 1.000 Gear Ratio 1.000 0.716 0.716...
  • Page 18 EG-18 NEW MODEL OUTLINE Transfer (4WD Models) Type VF2A (Part-time) VF4B (Full-time) Combination with Transmission A750F AT RA61F MT H2/H and H4/HL 1.000 1.000 Gear Ratio Gear Ratio L4/LL 2.566 2.566 Center Differential Type TORSEN* A.D.D.* With : TORSEN is JTEKT CORPORATION’s registered trademark. : Automatic Disconnecting Differential 0240MO35C 0240MO26C...
  • Page 19 NEW MODEL OUTLINE Chassis Suspension Front Suspension Type Double Wishbone Type Independent Suspension Rear Suspension Type 4-link Coil Spring with Lateral Rod Type Suspension 0240MO27Z Steering Type Hydraulic Power Steering Brake Model 4WD (MT) 4WD (AT) Type Ventilated Disc Ventilated Disc Ventilated Disc Front Front...

  • Page 20: Srs Airbag System

    EG-20 NEW MODEL OUTLINE SAFETY SRS Airbag System The SRS (Supplemental Restraint System) driver and front passenger airbags are used to help reduce shocks to the head and chest of the driver in the event of frontal impact collision and as supplements to the seat belts. "...
  • Page 21 NEW MODEL OUTLINE ENVIRONMENT Recycling TSOP (TOYOTA Super Olefin Polymer), which can easily be recycled, is used for many parts. Exterior : TSOP 0240MO28Z...
  • Page 22 EG-22 NEW MODEL OUTLINE Interior : TSOP 0240MO29C Rear Rear Outside Outside 0240MO30C...
  • Page 23 NEW MODEL OUTLINE DIMENSIONS 870 (34.3) mm (in.) 1810 (71.3)* 1830 (72.0)* 865 (34.1) 2690 (105.9) 1115 (43.9) 4670 (183.9) : 2WD Models : 4WD Models 1605 (63.2) 1905 (75.0) 0240MO31C...

  • Page 24: Equipment List

    EG-24 NEW MODEL OUTLINE EQUIPMENT LIST ": Standard f: Option CHASSIS " " Tire P265/70R17 " " 7 1/2J Steel Disc Wheel Disc Wheel 7 1/2J Aluminum " ABS with EBD, Brake Assist, TRAC, AUTO LSD, VSC " ABS with EBD, Brake Assist, TRAC, VSC Brake Control ABS with EBD, Brake Assist, TRAC, A-TRAC, VSC Rear Diff.
  • Page 25 EG-2 ENGINE — 1GR-FE ENGINE ENGINE 1GR-FE ENGINE JDESCRIPTION The 1GR-FE engine is a 4.0-liter, 24-valve DOHC V6 engine. This engine uses the VVT-i (Variable Valve Timing-intelligent) system, DIS (Direct Ignition System), ACIS (Acoustic Control Induction System), and ETCS-i (Electronic Throttle Control System-intelligent). These control functions achieve improved engine performance, fuel economy, and clean emissions.
  • Page 26 5.2 liters (5.5 US qts, 4.6 Imp. qts) Oil Capacity Without Oil Filter 4.9 liters (5.2 US qts, 4.3 Imp. qts) Oil Grade ILSAC TOYOTA Genuine Super Long Life Type Coolant or the following* Engine Coolant 9.4 liters (9.9 US qts, 8.3 Imp. qts) Capacity Capacity 9.8 liters (10.4 US qts, 8.6 Imp.
  • Page 27 EG-4 ENGINE — 1GR-FE ENGINE " Valve Timing f : Intake Valve Opening Angle : Exhaust Valve Opening Angle VVT-i Operation Range Open -8_ to 42_ BTDC Intake Intake Close 60_ to 10_ ABDC Open 54_ BBDC Exhaust Exhaust Close 2_ ATDC VVT-i Operation...
  • Page 28 Shim-less type valve lifters are used. Valve Mechanism A timing chain and chain tensioner are used. The engine coolant that is used is the TOYOTA genuine SLLC Cooling System (Super Long Life Coolant). A cable-less type throttle body is used.
  • Page 29 EG-6 ENGINE — 1GR-FE ENGINE fENGINE PROPER 1. Cylinder Head Cover " Lightweight yet high-strength aluminum cylinder head covers are used. " An oil filler extension housing is provided on the left bank cylinder head cover for use when filling the engine oil to improve serviceability.

  • Page 30: Cylinder Head

    ENGINE — 1GR-FE ENGINE 3. Cylinder Head " The cylinder head, which is made of aluminum, contains a pentroof-type combustion chamber. The spark plug is located in the center of the combustion chamber in order to improve the engine’s anti-knocking performance.

  • Page 31: Cylinder Block

    EG-8 ENGINE — 1GR-FE ENGINE " The cylinder head bolts are positioned below the camshaft journal in the front of the right bank, and holes are provided in the camshaft journals to allow installation of the bolts. Thus, the front end of the right bank is shortened, resulting in the overall length of the engine being shorter.
  • Page 32 ENGINE — 1GR-FE ENGINE " A water passage is provided between the cylinder bores. By allowing the engine coolant to flow between the cylinder bores, this construction enables the temperature of the cylinder walls to be kept uniform. Water Passage 238EG12 "...
  • Page 33 EG-10 ENGINE — 1GR-FE ENGINE 5. Piston " The pistons are made of aluminum alloy. " The piston head portion uses a taper squish shape to accomplish fuel combustion efficiency. " The piston skirt is coated with resin to reduce friction losses. "...
  • Page 34 ENGINE — 1GR-FE ENGINE 7. Crankshaft " A crankshaft made of steel, which excels in rigidity and wear resistance, is used. " The crankshaft has 4 main bearing journals and 9 balance weights. " All pin and journal fillets are roll-finished to maintain adequate strength. Roll-finished Balance Weight Front...

  • Page 35: Crankshaft Pulley

    EG-12 ENGINE — 1GR-FE ENGINE 9. Crankshaft Pulley The rigidity of the torsional damper rubber is optimized to reduce noise. Torsional Damper Rubber 238EG18 10. Oil Pan " The oil pan No.1 material is made of aluminum alloy. " The oil pan No.2 material is made of steel. "...
  • Page 36 ENGINE — 1GR-FE ENGINE fVALVE MECHANISM 1. General " The intake camshafts are driven by the crankshaft via the primary timing chain. The intake camshaft of the respective bank drives the exhaust camshafts via the secondary timing chain. " The valves are directly opened and closed by 4 camshafts. "...
  • Page 37 EG-14 ENGINE — 1GR-FE ENGINE 2. Camshaft " The camshafts are made of a cast iron alloy. " An oil passage is provided in the intake camshaft in order to supply engine oil to the VVT-i system. " A timing rotor is provided in front of the VVT-i controller to detect the actual position of the intake camshaft.

  • Page 38: Timing Chain And Chain Tensioner

    ENGINE — 1GR-FE ENGINE 3. Timing Chain and Chain Tensioner " Both the primary and secondary timing chains use roller chains with a pitch of 9.525mm (0.375 in.). " The timing chain is lubricated by an oil jet. " The primary chain uses one timing chain tensioner and each of the secondary chains for the right and left banks uses one timing chain tensioner.

  • Page 39: Lubrication System

    EG-16 ENGINE — 1GR-FE ENGINE _LUBRICATION SYSTEM 1. General J The lubrication circuit is fully pressurized and oil passes through an oil filter. J A cycloid rotor type oil pump is used. This oil pump is integrated with the timing chain cover. This pump is directly driven by the crankshaft.

  • Page 40: Oil Pump

    ENGINE — 1GR-FE ENGINE 2. Oil Pump Ordinarily, the timing chain cover with oil pump construction has only a single position for mounting the oil pump rotor to the crankshaft, when installing the timing chain cover. However, in this engine, the inner shape of the oil pump rotor and the shape of the area of the crankshaft on which the rotor is mounted are designed to provide 4 different assembly patterns.

  • Page 41: Oil Filter Bracket

    EG-18 ENGINE — 1GR-FE ENGINE 4. Oil Filter Bracket J The oil filter is mounted on an oil filter bracket placed on the left bank. Therefore, the oil filter can be replaced easily. J During an oil filter replacement, the filter is removed from the top. Therefore, the oil filter bracket is designed to catch the oil that leaks from the oil filter.
  • Page 42 " A thermostat with a bypass valve is located in the water inlet housing to maintain suitable temperature distribution in the cooling system. " A viscous coupling type cooling fan is used. " The engine coolant that is used is TOYOTA genuine SLLC (Super Long Life Coolant). To Throttle Body From Heater Core...

  • Page 43: Water Pump

    EG-20 ENGINE — 1GR-FE ENGINE 2. Water Pump The water pump has two volute chambers, and circulates coolant uniformly to the left and right banks of the cylinder block. Timing Chain Cover From Water Inlet Housing Rotor Water Pump Gasket View from Back Side Cross Section Water Pump...
  • Page 44 ENGINE — 1GR-FE ENGINE 4. TOYOTA Genuine SLLC TOYOTA genuine SLLC (Super Long Life Coolant) is used. The maintenance interval is as shown in the table below: Type TOYOTA Genuine SLLC First Time 100000 miles (160000 km) Maintenance Maintenance Intervals...
  • Page 45 EG-22 ENGINE — 1GR-FE ENGINE fINTAKE AND EXHAUST SYSTEM 1. General " A cable-less type throttle body is used and it realizes excellent throttle control. " The ETCS-i (Electronic Throttle Control System-intelligent) is used to ensure excellent throttle control in all operating ranges. For details, see page EG-50. "...

  • Page 46: Air Cleaner

    ENGINE — 1GR-FE ENGINE 2. Air Cleaner " A full-fabric type air cleaner element is used. " A charcoal filter, which adsorbs the HC that accumulates in the intake system when the engine is stopped, is used in the air cleaner case in order to reduce evaporative emissions. This filter is maintenance-free. Air Cleaner Case Air Cleaner Element Air Cleaner Cap...

  • Page 47: Intake Manifold

    EG-24 ENGINE — 1GR-FE ENGINE 4. Intake Air Chamber " The intake air chamber contains an ACIS (Acoustic Control Induction System) actuator. The ACIS actuator actuates the intake air control valve that is used to change the intake pipe length to improve engine performance in all engine speed ranges.

  • Page 48: Exhaust Manifold

    ENGINE — 1GR-FE ENGINE 6. Exhaust Manifold " A stainless steel exhaust manifold with an integrated TWC (Three-Way Catalytic converter) is used for warm-up of the TWC and for weight reduction. " An ultra thin-wall, high-cell density, ceramic type TWC is used. One of this type of TWC is incorporated for each of the right and left banks.
  • Page 49 EG-26 ENGINE — 1GR-FE ENGINE fFUEL SYSTEM 1. General " A fuel return system is used. " A fuel cut control is used to stop the fuel pump when the SRS airbag is deployed in a frontal or side collision. For details, see page EG-60. "...
  • Page 50 ENGINE — 1GR-FE ENGINE Service Tip The fuel drain mark has been provided at the fuel tank. When dismantling (scrapping) the vehicle, drain fuel by making a hole at this mark. Fuel Drain Mark 0240EG22C 2. Fuel Tank The multi-layer plastic fuel tank consists of six layers of four types of materials, and one of those is a recyclable material to address environmental concerns.

  • Page 51: Ignition System

    EG-28 ENGINE — 1GR-FE ENGINE "IGNITION SYSTEM 1. General A DIS (Direct Ignition System) is used. The DIS improves ignition timing accuracy, reduces high-voltage loss, and enhances the overall reliability of the ignition system by eliminating the distributor. The DIS is an independent ignition system which has one ignition coil (with an integrated igniter) for each cylinder.

  • Page 52: Spark Plug

    ENGINE — 1GR-FE ENGINE 3. Spark Plug Long-reach type spark plugs are used. This type of spark plugs allows the area of the cylinder head to receive the spark plugs to be made thick. Thus, the water jacket can be extended near the combustion chamber, contributing to cooling system performance.

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