Toyota Engine 1 GR FE Repair Manual

 Toyota Engine 1 GR FE Repair Manual

The 4.0 L (3,956 cc) variant of the 1GR-FE is intended for longitudinal mounting in pickup applications with RWD and 4WD. Its bore and stroke are 94 mm and 95 mm, respectively (3.70 in and 3.74 in). When tuned for 87 octane, the output is 236 horsepower (176 kW; 239 PS) at 5200 rpm with 266 lb-ft (361 Nm; 37 kgm) of torque at 4000 rpm, and when tuned for 91 octane, the output is 240 hp (179 kW; 243 PS) at 5200 rpm with 278 lb-ft (377 Nm; 38 This engine has a 10.0:1 compression ratio and Toyota's VVT-i variable valve timing system on the intake cam. Service weight is 166 kg when fluids are included (366 lb).

With Dual VVT-i, this engine's output has been increased to 270 hp (201 kW; 274 PS) at 5600 rpm and 278 lb-ft (377 Nm; 38 kgm) at 4400 rpm on 87 octane.  The 1GR combines matched pistons and a "taper-squish" combustion chamber design internally to enhance anti-knocking and engine performance as well as intake and fuel efficiency. Toyota switched to an intake port with a siamese shape, which minimizes the surface area of the port walls and prevents fuel from clinging to them.. 

To increase adhesion between the liner and cylinder block in this engine, unique spiny cast-iron cylinder liners were cast into the block. The entire cylinder block needs to be replaced if the cylinder wall sustains damage (scoring, deep protrusions, etc.). A high temperature plastic insulator/protector, which fills the empty area between the outside portion of the cylinders and block material typical of open deck engines, is also added to the 1GR for greater block rigidity. The 1GR uses water tunnels between the engine bores for improved cooling performance. There are a total of four of these passageways, two on each bank. This lessens hot spots in the cylinder and maintains more consistent combustion chamber temperatures.

A bolt-on TRD supercharger kit was available on the Tacoma and FJ Cruiser but has been discontinued by Toyota.

The single VVT-i engine is slightly modified for the new 2015 Toyota HiLux; the sole modification is the removal of an air intake baffle tank and the replacement of that component with a regular air filter housing to intake pipe to surge tank type. Resonators are now present in the new intake pipe. Power output remains constant.

Toyota's Acoustic Control Induction System is available on first-generation 1GR-FE models with a single VVT-i. The intake manifold is divided into two portions by a bulkhead, and its effective length is controlled by an intake air control valve located inside the bulkhead. An actuator closes the intake air control valve to lengthen the intake manifold's useful length when the engine is running at moderate revs and heavy load. The intake air control valve opens up under other operating circumstances to shorten the intake manifold's effective length.

Applications with VVT-i (calendar years):

2002-2009 Toyota 4Runner / Hilux Surf (GRN210/215)

2007-2011 Toyota Land Cruiser (GRJ200)

2002-2009 Toyota Land Cruiser Prado (GRJ120/121/125)

2004–2015 Toyota Tacoma (GRN225/245/250/265/270)

2005-2015 Toyota Hilux (GGN10/20)

2005-2006 Toyota Tundra (GSK30)

2006-2009 Toyota Tundra (GSK50/51)

2005–2015 Toyota Fortuner (GGN50/60)

2006-2009 Toyota FJ Cruiser (GSJ10/15)

2009–present Toyota Land Cruiser 70

2015–present Toyota Hilux

Applications with Dual VVT-i (calendar years):

2009–present Toyota 4Runner (GRN280/285)

2009–present Toyota FJ Cruiser

2011–2014 Toyota Tundra (GSK50/51)

2012–2021 Toyota Land Cruiser (GRJ200)

2021–present Toyota Land Cruiser (GRJ300)

2012–present Lexus GX 400 (GRJ150)

2015–present Toyota Fortuner

2009–present Toyota Land Cruiser Prado (GRJ150/150R/155)