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Home >> Toyota >> 2016 >> Highlander LE Plus, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2GR-FE) (Service Information) (Except Hybrid) (2 Of 2) >> Engine Unit >> Reassembly [12/2013 - 08/2014] >> Procedure

Reassembly [12/2013 - 08/2014]: Procedure

  1. INSTALL REAR ENGINE OIL SEAL 
    1. Place the rear engine oil seal retainer on wooden blocks.
    2. Using SST, tap in a new rear engine oil seal until its surface is flush with the rear engine oil seal retainer edge.
      GTY446444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth
      • SST: 09223-15030 
      • SST: 09950-70010 
        1. 09951-07100
      NOTE:
      • Keep the lip free from foreign matter.
      • Do not tap in the engine rear oil seal at an angle.
  2. INSTALL REAR ENGINE OIL SEAL RETAINER 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY442521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing

      Seal Packing

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

      Seal Packing Diameter

      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the rear engine oil seal retainer within 3 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
    2. Install the rear engine oil seal retainer with the 6 bolts.
      GTY434065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      NOTE:

      Be sure to apply adhesive to the bolts (A) before installing them.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

  3. INSTALL WATER INLET PIPE 
    1. Install the water inlet pipe with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      GTY430430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A w/o Oil Cooler
      *B w/ Oil Cooler
    2. Connect the No. 1 water by-pass hose to the water inlet pipe and slide the clip to secure it.
  4. INSTALL CYLINDER HEAD GASKET RH 

    Refer to PROCEDURE - Step 1

  5. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 2

  6. INSTALL CYLINDER HEAD GASKET LH 

    Refer to PROCEDURE - Step 3

  7. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 4

  8. INSTALL VALVE STEM CAP 

    Refer to PROCEDURE - Step 6

  9. INSTALL VALVE LASH ADJUSTER ASSEMBLY 

    Refer to PROCEDURE - Step 7

  10. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  11. INSTALL NO. 3 CAMSHAFT 

    Refer to PROCEDURE - Step 1

  12. INSTALL NO. 4 CAMSHAFT 

    Refer to PROCEDURE - Step 2

  13. INSTALL CAMSHAFT BEARING CAP (for Bank 2) 

    Refer to PROCEDURE - Step 3

  14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 4

  15. INSTALL CAMSHAFT 

    Refer to PROCEDURE - Step 5

  16. INSTALL NO. 2 CAMSHAFT 

    Refer to PROCEDURE - Step 6

  17. INSTALL CAMSHAFT BEARING CAP (for Bank 1) 

    Refer to PROCEDURE - Step 7

  18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 8

  19. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 9

  20. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2) 

    Refer to PROCEDURE - Step 10

  21. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 11

  22. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1) 

    Refer to PROCEDURE - Step 12

  23. INSTALL NO. 1 CHAIN VIBRATION DAMPER 
    1. Install the No. 1 chain vibration damper with the 2 bolts.

      Torque: 22.5 N*m (229 kgf*cm, 17 ft.*lbf) 

      GTY124072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
    1. Install the 2 No. 2 chain vibration dampers.
  25. INSTALL CRANKSHAFT TIMING SPROCKET 
    1. Install the 2 pulley set keys and crankshaft timing sprocket as shown in the illustration.
      GTY191932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL IDLE SPROCKET ASSEMBLY 
    1. Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
      GTY443492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin
      Light coat of engine oil
    2. Temporarily install the No. 1 idle gear shaft and idle sprocket assembly with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the pin hole of the cylinder block sub-assembly.
      NOTE:

      Be careful of the No. 1 idle gear shaft installation position.

      HINT: 

      Check that no foreign matter is on the No. 1 idle gear shaft or No. 2 idle gear shaft.

    3. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.

      Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

      HINT: 

      After installing the idle sprocket assembly, check that the idle sprocket assembly turns smoothly.

  27. INSTALL CHAIN SUB-ASSEMBLY 
    1. Align the mark plates and timing marks as shown in the illustration and install the chain sub-assembly.
      GTY446819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark Plate
      *b Timing Mark

      HINT: 

      The camshaft mark plates are orange.

    2. Temporarily place the chain sub-assembly on the crankshaft as shown in the illustration.
      GTY301808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain sub-assembly between the banks.
      GTY426880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark Plate
      *b Turn
      *c When the idle sprocket assembly is reused
      *d Mark
      *e Align
      NOTE:

      When the idle sprocket assembly is reused, align the mark plate with the mark where the mark plate had been in order to tighten the chain sub-assembly between the banks.

    4. Align the mark plate and timing marks as shown in the illustration and install the chain sub-assembly around the crankshaft timing sprocket.
      GTY424193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark Plate
      *b Timing Mark

      HINT: 

      The crankshaft mark plate is yellow.

    5. Temporarily tighten the crankshaft pulley bolt.
    6. Turn the crankshaft clockwise to set it to the center of the block bore (Bank 1) (TDC/compression).
      GTY452166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Center Line
      *b Timing Mark
      *c Sensor Plate
  28. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper.
  29. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Turn the stopper plate clockwise to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.
      GTY425630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Stopper Plate
      *b Plunger
    2. Turn the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
    3. Install the No. 1 chain tensioner assembly with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    4. Remove the hexagon wrench from the No. 1 chain tensioner assembly.
  30. INSPECT VALVE TIMING 
    1. Check the camshaft timing marks.
      NOTE:
      • Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear assembly and each camshaft timing exhaust gear assembly.
      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.
    2. Check that each camshaft timing mark is positioned as shown in the illustration.
      GTY448699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark *b Viewpoint

      HINT: 

      For the camshaft or No. 3 camshaft:

      Be sure to check the mark (A) at the point when the marks (B), (C), and (D) are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

      GTY443331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. If the valve timing is misaligned, reinstall the chain sub-assembly.
    4. Remove the crankshaft pulley bolt.
  31. INSTALL TIMING CHAIN CASE OIL SEAL 

    Refer to PROCEDURE - Step 1

  32. INSTALL ENGINE WATER PUMP ASSEMBLY 
    1. Install a new water pump gasket and the water pump assembly with the 8 bolts.
      GTY451610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

      NOTE:

      Be sure to replace the bolts (A) with new ones or reuse them after applying adhesive 1344.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

  33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line to the engine unit as shown in the following illustration.
      GTY439763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing Diameter: 3.0 mm (0.118 in.) or more Seal Packing

      Seal Packing

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

      Seal Packing Diameter

      3.0 mm (0.118 in.)

      NOTE:
      • Be sure to clean the contact surfaces, especially the surfaces (B) shown in the illustration.
      • If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.
      • Install the timing chain cover sub-assembly within 3 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
    2. Apply seal packing in a continuous line to the timing chain cover sub-assembly as shown in the following illustration.
      GTY443112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Dashed line area
      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)      		 *b Continuous line area
      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
      *c Alternate long and short dashed line area
      (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent)      		 *d Diagonal line area
      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
      Be sure to apply seal packing - -

      Seal Packing

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

      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      NOTE:
      • If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.
      • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
      SEAL PACKING APPLICATION CHART

      Area Seal Packing Diameter Application Position from Inside Seal Line
      Dashed Line Area 3.5 mm (0.138 in.) or more 3.0 to 4.0 mm (0.118 to 0.157 in.)
      Continuous Line Area 4.5 mm (0.177 in.) or more 1.0 to 2.0 mm (0.0394 to 0.0787 in.)
      Alternate Long and Short Dashed Line Area 3.5 mm (0.138 in.) or more 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Diagonal Line Area 6.0 mm (0.236 in.) or more 5.0 mm (0.197 in.)
    3. Install a new gasket.
      GTY307825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the drive rotor spline and the crankshaft as shown in the illustration. Install the drive rotor spline and timing chain cover sub-assembly to the crankshaft.
      GTY433698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft
      *a Drive Rotor Spline
    5. Type X:
      1. Temporarily tighten the timing chain cover sub-assembly with the 23 bolts and 2 nuts.

        Bolt Length

        Item Length
        Bolt (A) 40 mm (1.57 in.)
        Bolt (B) 55 mm (2.17 in.)
        Bolt (C) 25 mm (0.984 in.)
        NOTE:

        Make sure that there is no oil on the threads of the bolts (B) and (C).

        GTY439894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Nut
    6. Type Y:
      1. Temporarily tighten the timing chain cover sub-assembly with the 23 bolts and 2 nuts.

        Bolt Length

        Item Length
        Bolt (A) 40 mm (1.57 in.)
        Bolt (B) 55 mm (2.17 in.)
        Bolt (C) 28 mm (1.102 in.)
        NOTE:

        Make sure that there is no oil on the threads of the bolts (B) and (C).

        GTY439894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Nut
    7. Fully tighten the bolts in this order: Area 1 and Area 2.
      GTY450061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Area 1
      *b Area 2
      *c Area 3
      *d Area 4

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

    8. Fully tighten the bolts and nuts in Area 3.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      HINT: 

      Tighten the bolts and nuts from top to bottom as shown in the illustration.

    9. Fully tighten the bolts in Area 4.

      Bolt (A) 

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      except Bolt (A) 

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      HINT: 

      Tighten the bolts from bottom to top as shown in the illustration.

    10. Install a new timing chain cover plate gasket and the timing chain cover plate with the 4 bolts.

      Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf) 

  34. INSTALL WATER INLET HOUSING 
    1. Install 2 new O-rings.
      GTY443427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Apply a small amount of water or soapy water to the O-ring (A) shown in the illustration before installation.

    2. Install the 2 stud bolts.
      GTY442360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

    3. Install the water inlet housing with the 2 bolts and nut.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      NOTE:

      Be careful that the O-ring does not get caught between the parts.

    4. Connect the No. 1 water by-pass hose.
    5. Apply adhesive around the drain cock assembly.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    6. Install the drain cock assembly to the water inlet housing.

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

    7. Install the drain cock plug to the drain cock assembly.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

    8. Install a new gasket to the thermostat.
    9. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat into the water inlet housing.
      GTY424288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      The jiggle valve may be set within 10° of either side of the prescribed position.

    10. Install the water inlet with the 2 nuts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  35. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH 
    1. Using an E8 "TORX" socket wrench, install the 2 stud bolts.
      GTY441997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Stud Bolt

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    2. Install the No. 1 front engine mounting bracket LH with the 6 bolts.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

      NOTE:
      • Install the water inlet and No. 1 front engine mounting bracket LH within 15 minutes of installing the timing chain cover sub-assembly.
      • Do not start the engine for at least 2 hours after installation.
  36. INSTALL NO. 1 OIL PAN BAFFLE PLATE 
    1. Install the No. 1 oil pan baffle plate with the 7 bolts.
      GTY453312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      HINT: 

      Temporarily tighten the 7 bolts. Fully tighten the 2 bolts (A) shown in the illustration before tightening the other bolts.

  37. INSTALL OIL PAN SUB-ASSEMBLY 
    1. w/o Oil Cooler:
      1. Using an E8 "TORX" socket wrench, install the 2 stud bolts.
        GTY440124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *A Timing Chain Cover Sub-assembly Side *B Cylinder Block Bottom Side

        Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    2. w/ Oil Cooler:
      1. Using an E8 "TORX" socket wrench, install the 4 stud bolts.
        GTY432201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *A Cylinder Block Bottom Side *B Timing Chain Cover Sub-assembly Side
        *C Oil Pan Sub-assembly LH Side - -

        Stud Bolt (A) 

        Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

        Stud Bolt (B) 

        Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

    3. Install the oil pan sub-assembly.

      Refer to PROCEDURE - Step 20

  38. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
      GTY434233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Timing Chain Cover Sub-assembly Side

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

    2. Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  39. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
      GTY435326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY451611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing

      Seal Packing

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

      Seal Packing Diameter

      3.0 to 4.0 mm (0.118 to 0.157 in.)

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the No. 2 oil pan sub-assembly within 3 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
    3. Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  40. INSTALL OIL PAN DRAIN PLUG 
    1. Install a new oil pan drain plug gasket and the oil pan drain plug.

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

      GTY232260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Apply seal packing as shown in the illustration.
      GTY426594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Seal Packing

      Seal Packing

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

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the cylinder head cover sub-assembly within 3 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
    2. Install 3 new gaskets as shown in the illustration.
      GTY439216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
    4. Install the cylinder head cover sub-assembly with the 12 bolts and a new seal washer in the order shown in the illustration.
      Fig 1: Tightening Sequence Of Cylinder Head Cover Sub-Assembly
      GTY451964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Washer

      Bolt (A) 

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      except Bolt (A) 

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      HINT: 

      After tightening all bolts, check the tightening torque of the bolts (1) and (11). Retighten the bolt if necessary.

  42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    1. Apply seal packing as shown in the illustration.
      GTY439159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Seal Packing

      Seal Packing

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

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the cylinder head cover sub-assembly LH within 3 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
    2. Install 3 new gaskets as shown in the illustration.
      GTY439262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new No. 2 cylinder head cover gasket to the cylinder head cover sub-assembly LH.
    4. Install the cylinder head cover sub-assembly LH with the 12 bolts and a new seal washer in the order shown in the illustration.
      Fig 2: Tightening Sequence Of Cylinder Head Cover Sub-Assembly LH
      GTY439449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Washer

      Bolt (A) 

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      except Bolt (A) 

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      HINT: 

      After tightening all bolts, check the tightening torque of the bolts (1) and (11). Retighten the bolt if necessary.

  43. INSTALL WATER OUTLET 
    1. Install 2 new gaskets and a new O-ring.

      HINT: 

      Apply soapy water to the O-ring.

      GTY295919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the water outlet with the 2 bolts and 4 nuts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      NOTE:

      Be careful that the O-ring does not get caught between the parts.

      GTY441951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
      *b Bolt
  44. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Apply a light coat of engine oil to a new O-ring and install it to the engine oil level dipstick guide.
      GTY452297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. w/o Oil Cooler:
      1. Install the engine oil level dipstick guide with the bolt.

        Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

        GTY446805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. w/ Oil Cooler:
      1. Install the engine oil level dipstick guide.
        GTY299596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) 
    1. Using an E8 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
      GTY438655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    2. Install a new gasket to the No. 1 oil cooler bracket.
    3. Install the oil cooler pipe with the bolt and 2 nuts.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

    4. Using an E7 "TORX" socket wrench, install the stud bolt as shown in the illustration.
      GTY427797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Stud Bolt
      *b Nut
    5. Install a new gasket to the oil pan sub-assembly.
    6. Install the No. 1 oil cooler bracket with oil cooler pipe with the 3 bolts and 3 nuts.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  46. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler) 

    Refer to PROCEDURE - Step 1

  47. INSTALL CRANKSHAFT PULLEY 

    Refer to PROCEDURE - Step 2

  48. INSTALL OIL FILTER CAP ASSEMBLY 

    Refer to PROCEDURE - Step 3

  49. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    1. for Bank 1:
      1. Apply adhesive to the cylinder block water drain cock sub-assembly.
        GTY444682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Adhesive

        Adhesive

        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      2. Install the cylinder block water drain cock sub-assembly as shown in the illustration.
        GTY454209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *A for Bank 1

        Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

        NOTE:

        Do not rotate the cylinder block water drain cock sub-assembly more than 1 revolution (360°) after tightening it to the specified torque.

      3. Install the cylinder block water drain cock plug to the cylinder block water drain cock sub-assembly.

        Torque: 12.7 N*m (130 kgf*cm, 9 ft.*lbf) 

    2. for Bank 2:

      HINT: 

      Perform this operation only when a cylinder block water drain cock sub-assembly is installed.

      1. Apply adhesive to the cylinder block water drain cock sub-assembly.
        GTY444682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Adhesive

        Adhesive

        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      2. Install the cylinder block water drain cock sub-assembly as shown in the illustration.
        GTY453570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *A for Bank 2

        Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

        NOTE:

        Do not rotate the cylinder block water drain cock sub-assembly more than 1 revolution (360°) after tightening it to the specified torque.

      3. Install the cylinder block water drain cock plug to the cylinder block water drain cock sub-assembly.

        Torque: 12.7 N*m (130 kgf*cm, 9 ft.*lbf) 

  50. INSTALL TAPER SCREW PLUG 

    HINT: 

    Perform this operation only when a taper screw plug is installed.

    1. Apply adhesive to the taper screw plug.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the taper screw plug to the cylinder block sub-assembly.

      Torque: 12.7 N*m (130 kgf*cm, 9 ft.*lbf) 

      GTY451306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL NO. 1 OIL PIPE 
    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
      NOTE:

      Do not touch the mesh when installing the oil control valve filter LH.

    2. Install the oil control valve filter LH to the oil pipe union. Install 2 new gaskets and temporarily install the No. 1 oil pipe (on the cylinder head cover sub-assembly side) with the union.
      GTY435443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil Pipe Union
    3. Install a new gasket and temporarily install the No. 1 oil pipe (on the cylinder head sub-assembly side) with the oil pipe union.
    4. Tighten the oil pipe union (on the cylinder head cover sub-assembly side).

      Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) 

    5. Tighten the oil pipe union (on the cylinder head sub-assembly side).

      Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) 

      NOTE:

      If the link that connects the gaskets is broken, remove the link by using side cutters or a similar tool.

  52. INSTALL OIL PIPE 
    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
      NOTE:

      Do not touch the mesh when installing the oil control valve filter RH.

    2. Install the oil control valve filter RH to the oil pipe union. Install 2 new gaskets and temporarily install the oil pipe (on the cylinder head cover sub-assembly side) with the oil pipe union.
      GTY450146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil Pipe Union
    3. Install a new gasket and temporarily install the oil pipe (on the cylinder head sub-assembly side) with the oil pipe union.
    4. Install the bolt (A) to the cylinder head sub-assembly.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    5. Tighten the oil pipe union (on the cylinder head cover sub-assembly side).

      Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) 

    6. Tighten the oil pipe union (on the cylinder head sub-assembly side).

      Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) 

      NOTE:

      If the link that connects the gaskets is broken, remove the link by using side cutters or a similar tool.

  53. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  54. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2) 

    Refer to PROCEDURE - Step 1

  55. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2) 

    Refer to PROCEDURE - Step 2

  56. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1) 

    Refer to PROCEDURE - Step 3

  57. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1) 

    Refer to PROCEDURE - Step 4

  58. INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side of Bank 2) 

    Refer to PROCEDURE - Step 1

  59. INSTALL CAMSHAFT POSITION SENSOR (for Intake Side of Bank 2) 

    Refer to PROCEDURE - Step 2

  60. INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side of Bank 1) 

    Refer to PROCEDURE - Step 3

  61. INSTALL CAMSHAFT POSITION SENSOR (for Intake Side of Bank 1) 

    Refer to PROCEDURE - Step 4

  62. INSTALL VENTILATION VALVE SUB-ASSEMBLY 
    1. Apply adhesive to the ventilation valve sub-assembly.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Using a 19 mm deep socket wrench, install the ventilation valve sub-assembly.

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

      GTY439178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

  64. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install a new oil filler cap gasket.
    2. Install the oil filler cap sub-assembly.
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