FJ CRUISER – NEW FEATURES 5

NEW FEATURES
1GR-FE ENGINE

1. General
 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.
 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.
 For detailed comparisons to the ’09 FJ Cruiser, see Major Difference (See page 8).

147EG01TE

147EG02TE
6 FJ CRUISER – NEW FEATURES

 Engine Specification 

Model ’10 FJ Cruiser ’09 FJ Cruiser

No. of Cyls. & Arrangement 6-cylinder, V Type 

24-valve DOHC, Chain 24-valve DOHC, Chain

Valve Mechanism
Drive (with Dual VVT-i) Drive (with VVT-i)
Combustion Chamber Pentroof Type 

Flow of Intake and Exhaust Gasses Cross-flow 

Fuel System SFI 

Ignition System DIS 

Displacement cm3 (cu. in.) 3956 (241.4) 

Bore × Stroke mm (in.) 94.0 × 95.0 (3.70 × 3.74) 

Compression Ratio 10.4 : 1 10.0 : 1

194 kW @ 5600 rpm 178 kW @ 5200 rpm
Max. Output (SAE-NET)*1
(260 HP @ 5600 rpm) (239 HP @ 5200 rpm)
367 N⋅m @ 4400 rpm 377 N⋅m @ 3800 rpm
Max. Torque (SAE-NET)*1
(271 ft⋅lbf @ 4400 rpm) (278 ft⋅lbf @ 3800 rpm)
Open (BTDC) –11 to 29 –8 to 42
Intake
Valve Close (ABDC) 71 to 31 60 to 10
Timing Open (BBDC) 60 to 25 54
Exhaust
Close (ATDC) 4 to 39 2
Firing Order 1–2–3–4–5–6 

ILSAC Multigrade
Oil Grade 
Engine Oil
Fuel Gasoline or Alcohol Fuel*3 Gasoline
Octane Rating 87 or higher 91 or higher
Research Octane Number (RON) 91 or higher 95 or higher
CARB*4 EPA*5 CARB*4 EPA*5
LEVII-LEV, Tier2-Bin5, LEVII-LEV, Tier2-Bin5,
Emission Tailpipe
SFTP SFTP SFTP SFTP
Regulation
LEVII, Tier2, LEVII, Tier2,
Evaporative
ORVR ORVR ORVR ORVR
Engine Service Mass*2
197 (435) 166 (366)
(Reference) kg (lb)
*1: Maximum output and torque rating are determined using the revised SAE J1349 standard.
*2: The figure shown is the weight of the part including the coolant and oil.
*3: Mixed fuel from 0% ethanol (E0) to 20% ethanol (E20) is available.
*4: California Air Resources Board (CARB)
*5: Environmental Protection Agency (EPA)
 FJ CRUISER – NEW FEATURES 7

 Valve Timing 

: Intake Valve Opening Angle

Intake VVT-i Exhaust VVT-i : Exhaust Valve Opening Angle
Operation Range Operation Range
Intake VVT-i
TDC TDC
Operation Range
4 11 2 8
29
39 42 232
240

244 236

71
60 60
54
Intake VVT-i
Intake VVT-i 31 Operation Range
25
Operation Range 10
BDC Exhaust VVT-i BDC
’10 FJ Cruiser Operation Range ’09 FJ Cruiser 147EG03S

 Performance Curve 

(HP) kW
280
200
260
N⋅m (ft⋅lbf) 240 180

400 300 220 160

300 200 200
140
Torque 200 180
100
100 160 120 Output
0 0 140 100
120
80
100
80 60

60
40
40
20
20
0 0

1000 2000 3000 4000 5000 6000

Engine Speed (rpm) 147EG04S
8 FJ CRUISER – NEW FEATURES

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:

System Outline
 Oil delivery pipes are used for the cylinder head cover.
 The cylinder head structure has been changed; the camshaft housing is
now separate from the cylinder head.
 The shapes of the cylinder head intake ports and the locations of the fuel
Engine Proper injectors have been optimized.
 The surface treatment of the cylinder block liner has been changed.
 A cylinder block water jacket spacer has been added.
 The shape of the piston has been changed.
 A 5 balance weight crankshaft is used.
 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.
Valve Mechanism  A roller rocker arm is used.
 A hydraulic lash adjuster is used.
 Cam lobes with indented R profiles are used.
 Oil passages for the VVT-i controller (exhaust) and the hydraulic lash
Lubrication System adjuster have been added.
 An oil filter with a replaceable element is used.
 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.
Intake and Exhaust System  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.
 The material of the tail exhaust pipe has been changed.
Fuel System The fuel system is made compatible with E20 fuel.
Ignition System Iridium-tipped spark plugs are used.
Charging System A generator pulley with a one-way clutch is used.
Starting System The starter has been changed to one with a 1.4 kW rating output.
 A Dual VVT-i system is used.
 A fuel pump control that can regulate the fuel pump speed to one of
Engine Control System
Low, Middle or High is used.
 A power steering oil pressure sensor is used.
 FJ CRUISER – NEW FEATURES 9

3. Features of 1GR-FE Engine

The 1GR-FE engine has the following performance features as a result of the use of the items listed below:

(1) High performance and reliability

(2) Low noise and vibration
(3) Lightweight and compact design
(4) Good serviceability
(5) Clean emission and fuel economy

’10 FJ ’09 FJ
Item (1) (2) (3) (4) (5)
Cruiser Cruiser
Upright intake ports are used.    
A taper squish shape is used for the combustion
   
chamber.
A steel laminate type cylinder head gasket is used.   
Engine
A cylinder block made of aluminum alloy is used.   
Proper
Cylinder block water jacket spacers are used.   —
The skirt portion of the piston has a resin coating
    
applied to reduce friction.
A No. 1 oil pan made of aluminum alloy is used.    
A Dual Variable Valve Timing-intelligent (Dual
   —
VVT-i) system is used.
A VVT-i system is used.   — 
Valve
Hydraulic lash adjusters are used.      —
Mechanism
Roller rocker arms are used.    —
Shim-less type valve lifters are used.   — 
Timing chains and chain tensioners are used.     
Lubrication
An oil filter with a replaceable element is used.   —
System
Cooling Toyota genuine Super Long Life Coolant (SLLC)
  
System is used.

Intake and A link-less type throttle body is used.    

Exhaust An intake air chamber made of plastic is used.   
System Stainless steel exhaust manifolds are used.   
12-hole type fuel injectors are used to improve the
   
Fuel System atomization of fuel.
A fuel delivery pipe that is made of plastic is used.   
Ignition The Direct Ignition System (DIS) makes ignition
    
System timing adjustment unnecessary.
Charging A segment conductor type generator is used.    
System A generator pulley with a clutch is used.   —
Serpentine
Belt Drive A serpentine belt drive system is used.    
System

(Continued)
10 FJ CRUISER – NEW FEATURES

’10 FJ ’09 FJ
Item (1) (2) (3) (4) (5)
Cruiser Cruiser
Magnetic Resistance Element (MRE) type VVT
  
sensors are used.

Engine The Electronic Throttle Control System-intelligent

   
Control (ETCS-i) is used.
System An Acoustic Control Induction System (ACIS) is
  — 
used.
An evaporative emission control system is used.   
 FJ CRUISER – NEW FEATURES 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

Cylinder Head Cover (RH)

Cylinder Head Cover (LH)

147EG05TE

Cylinder Head

 The cylinder head structure has been simplified by separating the camshaft housing (cam journal portion)
from the cylinder head.
 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 FJ CRUISER – NEW FEATURES

Cylinder Block

1) Liner

The shape of the cross-hatching of the liner surface has been optimized to improve oil retention
performance, resulting in reduced friction.

Liner
Cylinder Block

Enlarged View of
Cross-hatching

147EG07TE

2) Cylinder Block Water Jacket Spacer

 Cylinder block water jacket spacers have been added to the water jacket.
 The cylinder block water jacket spacer prevents water flow in the middle and below the water jacket
and draws coolant above the cylinder bore, to ensure uniform temperature distribution. As a result,
the viscosity of the engine oil that acts as a lubricant between the bore walls and the pistons can be
lowered, thus reducing friction.

Cylinder Block
Water Jacket Spacer
Water Jacket

A Cylinder Block
A
Water Jacket
Spacer

A – A Cross Section 147EG08TE

 FJ CRUISER – NEW FEATURES 13

Piston

 The piston shape has been optimized for high-compression ratio.

 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.
 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
147EG09TE
’10 FJ Cruiser ’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 FJ CRUISER – NEW FEATURES

5. Valve Mechanism

General

 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.
 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.
 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 (Intake)

VVT-i Controller
(Exhaust)

Roller Rocker Arm

Valve Lifter
Hydraulic Lash
Adjuster

’10 FJ Cruiser ’09 FJ Cruiser 147EG11TE

 FJ CRUISER – NEW FEATURES 15

Camshaft

 A VVT-i controller has been added at the front end of the exhaust camshafts to vary the timing of the
exhaust valves.
 Oil passages are provided on the intake and exhaust camshafts in order to supply engine oil to the VVT-i
system.
 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.

Timing Rotor for VVT

Sensor (Exhaust) No. 2 Camshaft
(Exhaust)

No. 1 Camshaft
VVT-i Controller (Intake)
(Exhaust)
Indented R Portion
of Cam (Profile)
Cam with Indented R

No. 3 Camshaft
(Intake)

No. 4 Camshaft
VVT-i Controller (Exhaust)
(Intake)
Timing Rotor for VVT
Sensor (Exhaust)
VVT-i Controller
147EG20TE
(Exhaust)
16 FJ CRUISER – NEW FEATURES

Hydraulic Lash Adjuster

 The hydraulic lash adjuster, which is located at the fulcrum of the roller rocker arm, consists primarily
of a plunger, plunger spring, check ball and check ball spring.
 The engine oil that is supplied by the cylinder head and the built-in spring actuate the hydraulic lash
adjuster. The oil pressure and the spring force that act on the plunger push the roller rocker arm against
the cam, in order to adjust the valve clearance that is created during the opening and closing of the valve.
As a result, engine noise is reduced.

Cam
Plunger
Roller Rocker
Arm
Oil
Oil Passage Passage

Check Ball

Check Ball Spring Hydraulic Lash

Adjuster
147EG12TE
Plunger Spring

Service Tip

Valve clearance adjustment is not necessary because hydraulic lash adjusters are used.
 FJ CRUISER – NEW FEATURES 17

6. Lubrication System

General

 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.
 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.
 An oil filter with a replaceable element is used.

Camshaft Timing Oil

Control Valve (Exhaust) Oil Delivery Pipe
Roller Rocker Arm

Hydraulic
Lash
Adjuster
Oil
Pump
Oil Filter
VVT-i Controller
(Exhaust)
Oil Filter
’10 FJ Cruiser ’09 FJ Cruiser
147EG13TE
18 FJ CRUISER – NEW FEATURES

 Oil Circuit 

Main Oil Hole

Cylinder Cylinder Head (for Right Bank)

Cylinder Head (for Left Bank) Block

Oil
Camshaft Cylinder Camshaft Cylinder
Filter Timing Head Timing Head
Oil Cover Crankshaft Oil Cover
Relief Control Oil Journals Control Oil
Valve Valve Delivery Valve Delivery
(Intake) Pipe (Intake) Pipe

Camshaft Camshaft
Timing Timing
Oil Crankshaft Primary Oil
Control Pins Chain Control
Valve Tensioner Valve
(Exhaust) (Exhaust)

Oil VVT-i Exhaust VVT-i Exhaust

Pump Camshaft Oil Controller Camshaft
Controller
(Intake) Journals Jets (Intake) Journals
Relief
Valve

Secondary VVT-i Secondary VVT-i

Chain Controller Lash Controller Lash
Adjusters Chain Adjusters
Tensioner (Exhaust) Tensioner (Exhaust)

Oil Intake Intake

Strainer Camshaft Connecting Camshaft
Rods
Journals Journals

Oil Pan

147EG14S

 Specification 

Model ’10 FJ Cruiser ’09 FJ Cruiser

Dry Fill 6.9 (7.3, 6.1) 6.0 (6.3, 5.3)
Drain and Refill with
Oil Capacity 6.1 (6.4, 5.4) 5.2 (5.5, 4.6)
Oil Filter Change
[liters (US qts, Imp. qts)]
Drain and Refill without
5.7 (6.0, 5.0) 4.9 (5.2, 4.3)
Oil Filter Change
 FJ CRUISER – NEW FEATURES 19

Oil Filter

 The oil filter element uses a high-performance filter paper to improve filtration performance. It is also
combustible for environmental protection.
 A plastic oil filter cap assembly is used for weight reduction.
 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

Oil Filter Element

O-ring

Drain Pipe

When draining oil

O-ring
Oil Filter
Oil Filter Cap Assembly Drain Plug

Oil Filter Drain Plug 147EG16TE

Service Tip

 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).
 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 FJ CRUISER – NEW FEATURES

7. Cooling System
The cooling system of the ’10 FJ Cruiser is basically the same as in the ’09 FJ Cruiser.

 Engine Coolant Specification 

Model ’10 FJ Cruiser ’09 FJ Cruiser

TOYOTA Genuine Super
Engine Coolant Type Long Life Coolant (SLLC) 

[liters or the equivalent*

(US qts, Imp. qts)] M/ T 9.4 (9.9, 8.3) 
Capacity
A/ T 9.8 (10.4, 8.6) 

*: 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).
 FJ CRUISER – NEW FEATURES 21

8. Intake and Exhaust System

General

 The shape and installation location of the air cleaner have been changed to improve the output power.
 The throttle valve diameter has been increased from 65 mm (2.6 in.) to 70 mm (2.8 in.) to improve the
output power.
 The shape of the intake air chamber has been optimized to reduce pressure loss.
 The Acoustic Control Induction System (ACIS) has been discontinued to make the intake system more
simple and light-weighted.
 The shapes of the exhaust manifolds have been changed to optimize the exhaust gas flow and reduce
pressure loss.
 The volume and cell density of the three-way catalytic converter which is located at the front exhaust
pipe have been optimized.
 The material of the tail exhaust pipe has been changed to improve the rust resistance.

Three-way Catalytic Converter

(for Front Exhaust Pipe)

Intake Air Chamber

Air Cleaner

Throttle Body
Tail Exhaust Pipe
Center Exhaust Pipe
Exhaust Manifold
147EG17TE
22 FJ CRUISER – NEW FEATURES

Air Cleaner

 The shape and installation location of the air cleaner have been changed to make the intake passage
shorter and straight, thus reducing pressure loss and improving the output power.
 The air cleaner element has been changed from the full-fabric type for the ’09 FJ Cruiser to a filter paper
type to reduce pressure loss.

Air Cleaner
Air Cleaner

Front Front

Intake Air Chamber Intake Air Chamber

’10 FJ Cruiser ’09 FJ Cruiser

147EG18TE
 FJ CRUISER – NEW FEATURES 23

9. Fuel System
 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.
 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 Fuel Pump Assembly

147EG21TE
24 FJ CRUISER – NEW FEATURES

10. Ignition System

 The spark plug has been changed from conventional type spark plug to iridium-tipped spark plug.
 Iridium-tipped spark plugs are used to achieve a 200000 km (120000 miles) maintenance interval. By
adopting an iridium center electrode, ignition performance that is superior to that of platinum-tipped spark
plugs is achieved and durability is increased.

Iridium Tip

Platinum Tip

147EG22S

 Specification 

Model ’10 FJ Cruiser ’09 FJ Cruiser

DENSO SK20HR11 (Iridium) K20HR-U11 (Nickel)
Type
NGK — LFR6C11 (Nickel)
Plug Gap [mm (in.)] 1.0 to 1.1 (0.0394 to 0.0433) 

11. Charging System

 A one-way clutch is set to the generator pulley.
 Operation of the one-way clutch cancels generator pulley inertia and helps to prevent slipping of the
V-ribbed belt. This realizes a low tension V-ribbed belt that achieves reduced friction.

Coil Spring Pulley

Generator Pulley
Shaft One-way Clutch 147EG23TE
 FJ CRUISER – NEW FEATURES 25

12. Starting System

The starter has been changed to a more compact and light-weight RA1.4 type.

 Specification 

Model ’10 FJ Cruiser ’09 FJ Cruiser

Type 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)
Rotating Direction* Clockwise 

*: Viewed from pinion end

Length Length

147EG24TE

’10 FJ Cruiser ’09 FJ Cruiser

26 FJ CRUISER – NEW FEATURES

13. Engine Control System

General

The ’10 and ’09 FJ Cruiser 1GR-FE engine control systems have the following differences:

’10 FJ ’09 FJ
System Outline
Cruiser Cruiser
SFI
An L-type SFI system detects the intake air volume with a
(Sequential Multiport  
hot-wire type mass air flow meter.
Fuel Injection)
 This ECM determines the optimal ignition timing in
ESA accordance with the signals received from the sensors
(Electronic Spark and sends (IGT) ignition signal to the igniter.  
Advance)  The ECM corrects ignition timing in response to engine
knocking.
ETCS-i
Optimally controls the opening angle of the throttle valve
(Electronic Throttle
in accordance with the accelerator pedal input and the  
Control
engine and vehicle conditions.
System-intelligent)
Dual VVT-i
Controls the intake and exhaust camshafts to optimal valve
(Variable Valve  —
timing in accordance with the engine operating conditions.
Timing-intelligent)
Controls the intake camshaft to optimal valve timing in
VVT-i — 
accordance with the engine operating conditions.
ACIS The intake air passages are switched based on engine speed
(Acoustic Control and throttle valve opening angle to provide high — 
Induction System) performance in all engine speed ranges.
Based on signals from the ECM, the fuel pump control
 —
ECU controls the fuel pump to 3 stages.
The ECM controls fuel pump speed by switching the circuit
Fuel Pump Control — 
to the fuel pump resistor.
The fuel pump is stopped when the SRS airbag is deployed
 
in a frontal, side, or rear side collision.
Air Fuel Ratio Sensor Maintains the temperature of the air fuel ratio sensors or
and Oxygen Sensor heated oxygen sensors at an appropriate level to increase the  
Heater Control detection accuracy of the exhaust gas oxygen concentration.
 The ECM controls the purge flow of evaporative
emission (HC) in the canister in accordance with engine
conditions.
Evaporative
 Approximately 5 hours after the ignition switch has been
Emission  
turned off, the ECM operates the pump module to detect
Control
any evaporative emission leakage occurring between the
fuel tank and the charcoal canister. The ECM can detect
leaks by monitoring for changes in the fuel tank pressure.
By turning the air conditioning compressor on or off in
Air Conditioning
accordance with the engine condition, driveability is  
Cut-off Control
maintained.
When the ECM detects a malfunction, the ECM records the
Diagnosis  
malfunction and memorizes information related to the fault.
When the ECM detects a malfunction, the ECM stops or
Fail-safe controls the engine according to the data already stored in  
the memory.
 FJ CRUISER – NEW FEATURES 27

Construction

The configuration of the engine control system is as shown in the following chart.

VG
MASS AIR FLOW METER SFI
THA #10
INTAKE AIR TEMP. SENSOR NO. 1 INJECTOR
#20
NO. 2 INJECTOR
#30
NO. 3 INJECTOR
CRANKSHAFT POSITION NE #40
NO. 4 INJECTOR
SENSOR #50
NO. 5 INJECTOR
#60
NO. 6 INJECTOR
ENGINE COOLANT THW
TEMP. SENSOR
ESA
IGT1 to
IGT6
VPA IGNITION COIL
ACCELERATOR PEDAL
WITH IGNITER
POSITION SENSOR VPA2 IGF1

SPARK PLUGS
VTA1
THROTTLE POSITION SENSOR
VTA2
ETCS-i
KNK1
KNOCK SENSORS M THROTTLE CONTROL
KNK2 MOTOR

VV1
VVT SENSORS (INTAKE) ECM
VV2 VVT-i (INTAKE)

EV1 OC1 CAMSHAFT TIMING OIL

VVT SENSORS (EXHAUST) CONTROL VALVE (Bank 1)
EV2

STP OC2 CAMSHAFT TIMING OIL

STOP LIGHT SWITCH CONTROL VALVE (Bank 2)

L4
L4 POSITION SWITCH*1 VVT-i (EXHAUST)

4WD
OE1 CAMSHAFT TIMING OIL
A.D.D. DETECTION SWITCH*1 CONTROL VALVE (Bank 1)

OE2 CAMSHAFT TIMING OIL

CENTER DIFF. LOCK 4WD CONTROL VALVE (Bank 2)
DETECTION SWITCH*2

FUEL PUMP CONTROL

COMBINATION METER SPD
FC
CIRCUIT OPENING RELAY
 Vehicle Speed Signal
FPC
FUEL PUMP
F/PS CONTROL ECU
AIRBAG SENSOR ASSEMBLY DI

(Continued)
147EG25S
28 FJ CRUISER – NEW FEATURES

IGNITION SWITCH IGSW AIR FUEL RATIO SENSOR

AND OXYGEN SENSOR
 Ignition Signal HEATER CONTROL
AIR FUEL RATIO
PARK/NEUTRAL POSITION SENSOR HEATER
SWITCH*3 NSW HA1A
(Bank 1, Sensor 1)
 Neutral Start Signal R, D, 3, 2 HA2A
(Bank 2, Sensor 1)
 Shift Lever Position Signal
OXYGEN SENSOR HEATER
HT1B
SHIFT LOCK CONTROL ECU*3 (Bank 1, Sensor 2)
HT2B
(Bank 2, Sensor 2)
TRANSMISSION 4, L
CONTROL SWITCH

EVAPORATIVE
AIR FUEL RATIO SENSOR
EMISSION CONTROL
A1A
(Bank 1, Sensor 1)
A2A CANISTER PUMP
(Bank 2, Sensor 1)
MODULE
MPMP LEAK DETECTION
HEATED OXYGEN SENSOR
PUMP
OX1B VPMP
(Bank 1, Sensor 2) VENT VALVE
OX2B
(Bank 2, Sensor 2)
PRG
PURGE VSV
CANISTER PUMP MODULE ECM

CANISTER PRESSURE PPMP

THWO
SENSOR COMBINATION METER
STA W
STARTER RELAY MIL
ELS1 PI CRUISE MAIN
TAILLIGHT RELAY INDICATOR LIGHT
ELS2
AC INVERTER*4

POWER STEERING OIL PSP MREL

PRESSURE SENSOR +B, +B2 EFI MAIN RELAY
AC1
AIR CONDITIONING
ACT
AMPLIFIER IMI
BATT IMO
BATTERY TRANSPONDER KEY ECU
+BM
ALT
GENERATOR
TC
CRUISE CONTROL CCS
MAIN SWITCH TACH
DLC3
TRANSFER NEUTRAL TFN CANH
SWITCH*3
CANL
CAN 147EG26S
*1: 4WD Models with A/ T
*2: 4WD Models with M/ T
*3: Models with A/T
*4: Models with power outlet socket (AC 115 V, 400 W)
 FJ CRUISER – NEW FEATURES 29

Engine Control System Diagram

Ignition Park/Neutral
Combination Meter
Switch Position Switch*
 Vehicle Speed Signal
Circuit Opening  MIL
Relay

Electronic Controlled
Transmission Solenoid Valve*
Fuel Pump
Control ECU

A/ C Amplifier
Accelerator Pedal Position Sensor
DLC3
Battery Power Steering Oil Pressure Sensor
Electric Load Switch (Taillight Relay)
CAN
Stop Light Switch

Fuel Pump

ECM

Leak
Detection
Pump
Vent Purge VSV
Valve
Intake Air
Temp. Sensor Throttle Control Motor
Canister
Pressure Canister
Sensor

Mass Air Throttle Position

Flow Meter Sensor

Knock Sensor Knock Sensor

Injector Injector
Camshaft Timing Oil Control Camshaft Timing Oil Control
Valve (Bank 2, Intake) Valve (Bank 1, Intake)
VVT Sensor (Bank 2, Intake) VVT Sensor (Bank 1, Intake)

Ignition Coil with Igniter

Camshaft Timing
Camshaft Timing Oil Control Oil Control Valve
Valve (Bank 2, Exhaust) (Bank 1, Exhaust)

VVT Sensor VVT Sensor

(Bank 2, Exhaust) (Bank 1, Exhaust)

Engine Coolant Temp. Sensor

Air Fuel Ratio Sensor

(Bank 2, Sensor 1) Air Fuel Ratio
TWC TWC Sensor
(Bank 1, Sensor 1)
Crankshaft
Position Sensor
TWC TWC

Heated Oxygen Sensor Heated Oxygen Sensor

(Bank 2, Sensor 2) (Bank 1, Sensor 2)

147EG27S

*: Models with A/ T
30 FJ CRUISER – NEW FEATURES

Layout of Main Components

Accelerator Pedal Position Sensor Fuel Pump Control ECU

Mass Air Flow Meter
 Intake Air Temp. Sensor
Throttle Body
 Throttle Position
Sensor ECM
 Throttle Control
Motor

Fuel Pump Canister Pump Module

 Leak Detection Pump
Air Fuel Ratio Sensor Heated Oxygen Sensor  Canister Pressure
(Bank 1, Sensor 1) (Bank 2, Sensor 2) Sensor
 Vent Valve
Heated Oxygen Sensor Air Fuel Ratio Sensor
(Bank 1, Sensor 2) (Bank 2, Sensor 1) 147EG28TE

VVT Sensor (Bank 1, Exhaust)

Camshaft Timing Oil Control
Valve (Bank 1, Intake) Camshaft Timing Oil Control Ignition Coil
Valve (Bank 2, Intake) Knock Sensor 1 with Igniter
Camshaft Timing Oil
Control Valve (Bank 1, Purge VSV
Exhaust) Ignition Coil with Injector
Igniter

Engine Coolant
Power
Temp. Sensor
Steering Oil
Pressure
Sensor

VVT Sensor
(Bank 2, Exhaust)
VVT Sensor Camshaft Timing
(Bank 1, Intake) Oil Control Valve
(Bank 2, Exhaust)
VVT Sensor
(Bank 2, Intake)
Injector
Crankshaft Position Sensor Knock Sensor 2
147EG29TE
 FJ CRUISER – NEW FEATURES 31

Main Components of Engine Control System

1) General

The 1GR-FE engine control system has the following main components:

’10 FJ ’09 FJ
Components Outline Quantity Function
Cruiser Cruiser
The ECM optimally controls the
32-bit CPU SFI, ESA, and ISC to suit the
ECM (Supplier/ 1 operating conditions of the engine  
DENSO) in accordance with the signals
provided by the sensors.
This sensor has a built-in hot-wire
Mass Air Flow
Hot-wire Type 1 to directly detect the intake air  
Meter
mass and flow rate.
Intake Air This sensor detects the intake air
Thermistor
Temperature 1 temperature by means of an  
Type
Sensor internal thermistor.
Pick-up Coil This sensor detects the engine
Crankshaft
Type (Rotor 1 speed and performs the cylinder  
Position Sensor
Teeth/36-2) identification.
2
VVT Sensors MRE Type This sensor performs the cylinder
(1 Each  
(Intake) (Rotor Teeth/3) identification.
Bank)
2
VVT Sensors MRE Type This sensor performs the cylinder
(1 Each  —
(Exhaust) (Rotor Teeth/3) identification.
Bank)
This sensor detects the amount of
Accelerator Pedal No-contact
1 pedal effort applied to the  
Position Sensor Type
accelerator pedal.
Throttle No-contact This sensor detects the throttle
1  
Position Sensor Type valve opening angle.
This sensor detects an occurrence
Built-in
2 of the engine knocking indirectly
Piezoelectric
Knock Sensors (1 Each from the vibration of the cylinder  
Type
Bank) block caused by the occurrence of
(Flat Type)
engine knocking.
This sensor detects the oxygen
Heated Oxygen
2 concentration in the exhaust
Sensors Heated Type
(1 Each emission by measuring the  
(Bank 1, Sensor 2) (Cup Type)
Bank) electromotive force which is
(Bank 2, Sensor 2)
generated in the sensor itself.
As with the oxygen sensor, this
Air Fuel sensor detects the oxygen
2
Ratio Sensors Heated Type concentration in the exhaust
(1 Each  
(Bank 1, Sensor 1) (Planar Type) emission. However, it detects the
Bank)
(Bank 2, Sensor 1) oxygen concentration in the
exhaust emission linearly.
Engine Coolant This sensor detects the engine
Thermistor
Temperature 1 coolant temperature by means of  
Type
Sensor an internal thermistor.
(Continued)
32 FJ CRUISER – NEW FEATURES

’10 FJ ’09 FJ
Components Outline Quantity Function
Cruiser Cruiser
Power Steering
Piezoresistance This sensor detects the oil
Oil Pressure 1  —
Type pressure of the power steering.
Sensor
This fuel injector contains an
electro-magnetically operated
Injectors 12-hole Type 6  
nozzle to inject fuel into the intake
port.
The camshaft timing oil control
valve changes the valve timing by
Camshaft Timing Electro- 4
switching the oil passage that acts
Oil Control magnetic (2 Each  
on the VVT-i controller in
Valves Coil Type Bank)
accordance with the signals
received from the ECM.
 FJ CRUISER – NEW FEATURES 33

2) VVT Sensor (Exhaust)

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.

VVT Sensor (Bank 2, Exhaust)

147EG30TE
Timing Rotor

3) Power Steering Oil Pressure Sensor

 The power steering oil pressure sensor fitted on the power steering vane pump monitors the oil
pressure when the power steering is operated, and transmits oil pressure signals to the ECM.
 In accordance with the oil pressure signals, the ECM regulates the engine speed appropriate to the load
that changes during the power steering operation, helping improve fuel efficiency.

Piezoresistance

Voltage
Ratio

Oil Pressure
Pressure (MPa)

Cross Section Output Characteristic

147EG31S
34 FJ CRUISER – NEW FEATURES

Dual VVT-i (Variable Valve Timing-intelligent) System

1) General

 The Dual VVT-i system is designed to control the intake and exhaust camshafts within a range of 40
and 35 respectively (of Crankshaft Angle) to provide valve timing that is optimally suited to the
engine condition. This improves torque in all the speed ranges as well as increasing fuel economy, and
reducing exhaust emissions.

Camshaft Timing OCV* (Bank 1, Exhaust)

Camshaft Timing OCV* (Bank 1, Intake)
VVT Sensor (Bank 1, Exhaust)
Engine Coolant Temp. Sensor
Camshaft Timing OCV*
(Bank 2, Intake)
VVT Sensor
(Bank 2, Exhaust)

Camshaft Timing OCV*

(Bank 2, Exhaust)
ECM
VVT Sensor
(Bank 2, Intake)

Crankshaft Position Sensor  Mass Air Flow Meter

 Throttle Position Sensor
 Vehicle Speed Signal
VVT Sensor (Bank 1, Intake)

147EG32TE

*: Oil Control Valve

 By using the engine speed, intake air volume, throttle position and engine coolant temperature, the
ECM calculates optimal valve timing for each driving condition and controls the camshaft timing oil
control valve. In addition, the ECM uses signals from the intake and exhaust VVT sensors for each
bank and the crankshaft position sensor to detect the actual valve timing, thus providing feedback
control to achieve the target valve timing.

ECM
Crankshaft Position Sensor

Mass Air Flow Meter Target Valve Timing Camshaft

Duty-cycl Timing Oil
e Control
Throttle Position Sensor Valves
Control
Feedback
Engine Coolant Temp. Sensor Correction

VVT Sensors Actual Valve Timing

Vehicle Speed Signal

147EG33S
 FJ CRUISER – NEW FEATURES 35

2) Effectiveness of the Dual VVT-i System

Operation State Objective Effect

TDC Latest Timing
Earliest Timing
(EX) (IN)
 Stabilized
Eliminating overlap
idling rpm
During Idling EX IN to reduce blow back
 Better fuel
to the intake side.
economy

BDC 147EG34S

to Advance to Retard
Side (EX) Side (IN)
Eliminating overlap
Ensured engine
At Light Load EX IN to reduce blow back
stability
to the intake side.

147EG35S

to Advance to Retard
Side (IN) Side (EX)  Better fuel
Increasing overlap
economy
increases internal
At Medium Load EX IN  Improved
EGR, reducing
emission
pumping loss.
control
147EG36S

Advancing the Improved

In Low to Medium intake valve close torque
EX IN
Speed Range with timing for volumetric in low to
Heavy Load efficiency medium
to Retard to Advance
Side (EX) improvement. speed range
Side (IN)
147EG37S

Retarding the intake

In High Speed valve close timing
EX IN Improved
Range with Heavy for volumetric
output
Load to Retard to Advance efficiency
Side (IN) Side (EX) improvement.
147EG38S

Earliest Timing Latest Timing

(EX) (IN)  Stabilized
Eliminating overlap
At Low fast idle rpm
EX IN to reduce blow back
Temperatures  Better fuel
to the intake side.
economy
147EG34S

Earliest Timing Latest Timing

(EX) (IN)
Eliminating overlap
 Upon Starting
to minimize blow Improved
 Stopping the EX IN
back to the intake startability
Engine side.
147EG34S
36 FJ CRUISER – NEW FEATURES

3) Construction

a. VVT-i Controller
 The VVT-i controller consists of an outer housing that is driven by the timing chain sprocket, and
a vane sub-assembly that is coupled to each camshaft.
 The intake side uses a VVT-i controller with 3 vanes, and the exhaust side has used one with 4 vanes.
 When the engine stops, the VVT-i controller (intake) is locked at the most retarded angle by its lock
pin, and the VVT-i controller (exhaust) is locked at the most advanced angle. This ensures excellent
engine startability.
 The oil pressure sent from the advance or retard side passages of the intake and exhaust camshafts
causes rotation of the VVT-i controller vane sub-assembly relative to the timing chain sprocket, to
vary the valve timing continuously.
 An advance assist spring is provided on the VVT-i controller (exhaust). This helps to apply torque
in the advanced angle direction so that the vane lock pin securely engages with the housing when
the engine stops.

 Intake Side 

Timing Chain Sprocket

Vane Sub-assembly

Outer Housing

Intake Camshaft

Timing Rotor Oil Pressure

In Operation At a Stop
Lock Pin 147EG41TE

 Exhaust Side 

Timing Chain Sprocket

Lock Pin
Outer Housing

Exhaust Camshaft

Vane Sub-assembly
Advance Assist Spring 147EG42TE
 FJ CRUISER – NEW FEATURES 37

b. Camshaft Timing Oil Control Valve

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 

To VVT-i Controller To VVT-i Controller

(Advance Side)* (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 FJ CRUISER – NEW FEATURES

4) Operation

a. Advance

When the camshaft timing oil control valve is positioned as illustrated below by the advance signals
from the ECM, the resultant oil pressure is applied to the timing advance side vane chamber to rotate
the camshaft in the timing advance direction.

 Intake Side 

Camshaft Timing Oil

Vane Sub-assembly
Control Valve (Intake)

ECM

Oil Pressure
Rotation Direction IN Drain

147EG43TE

 Exhaust Side 

Camshaft Timing Oil

Control Valve (Exhaust)

ECM

Rotation Direction Oil Pressure

Drain IN
Vane Sub-assembly
147EG44TE
 FJ CRUISER – NEW FEATURES 39

b. Retard

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 

Camshaft Timing Oil

Rotation Direction Control Valve (Intake)

ECM

Oil Pressure
Vane Sub-assembly Drain IN

147EG45TE

 Exhaust Side 

Rotation Direction

Camshaft Timing Oil

Control Valve (Exhaust)

ECM

Oil Pressure
IN Drain
Vane Sub-assembly
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 FJ CRUISER – NEW FEATURES

Fuel Pump Control

 The ECM transmits a fuel pump operation request signal to the fuel pump control ECU that corresponds
to the engine operating conditions. The fuel pump control ECU receives this request signal and controls
the speed of the fuel pump in 3 stages. As a result, under light engine loads, fuel pump speed is kept low
to reduce electric power loss.
 The fuel pump control ECU controls fuel pump speed by receiving a duty cycle signal (FPC terminal
input) from the ECM, control is performed to 3 stages (High, Middle, Low).
 The fuel pump control ECU also detects failures in the input and output circuits at the fuel pump control
ECU and transmits the failure status to the ECM.

 System Diagram 

Fuel Pump
Operation Request
FPC FPC
Fuel Pump
Duty Signal

ECM Fuel Pump

Control ECU

Diagnosis Signal
DI DI

04E0EG24C

 FPC Terminal Input 

FPC Input Signal (Duty Signal) Fuel Pump Speed

+B
High
GND 04E0EG25C

12.3 ms
8.2 ms
Middle
+B
GND 04E0EG26C

4.1 ms

+B Low
GND
04E0EG27C

GND Stop
04E0EG28C