Complete removal and replacement of the crankshaft, requiring engine removal from vehicle and full disassembly of rotating assembly including pistons, connecting rods, and bearings.

Warnings

Tools required

Parts

• Crankshaft (new or reground) × 1 — Use OEM specification
• Main bearing set (standard or oversized) × 1 — Match to crankshaft journal size
• Thrust bearing set × 1 — Use OEM specification
• Connecting rod bearing set × 1 — Match to crankshaft journal size
• Front crankshaft seal × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Oil pump assembly × 1 — Inspect and replace if worn
• Timing chain kit (chain, guides, tensioner) × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Cylinder head gasket × 1 — Use OEM specification
• Connecting rod bolts (TTY) × 8 — Use OEM specification - replace mandatory
• Main bearing cap bolts (TTY) × 10 — Use OEM specification - replace mandatory
• Cylinder head bolts (TTY) × 1 — Use OEM specification - replace mandatory
• Oil pump pickup tube O-ring × 1 — Use OEM specification
• Engine coolant × 1 — Toyota Super Long Life Coolant (Pink)
• Engine oil and filter × 1 — 0W-20 synthetic
• Oil drain plug crush washer × 1 — Use OEM specification
• RTV silicone sealant × 1 — Toyota Genuine FIPG or equivalent

Fluids

• Toyota Genuine 0W-20 — 5 qt
• Toyota Super Long Life Coolant (Pink) — 10 qt

Preparation

1. Disconnect negative battery cable and wait 90 seconds for airbag system to discharge
2. Drain engine oil completely and remove oil filter
3. Drain engine coolant from radiator and engine block drain plugs
4. Remove engine cover and air intake assembly
5. Relieve fuel system pressure by removing fuel pump relay and cranking engine
6. Disconnect all electrical connectors, marking locations with tape and labels
7. Disconnect fuel lines, heater hoses, radiator hoses, and vacuum lines
8. Remove exhaust manifold and catalytic converter assembly
9. Remove drive belts, alternator, A/C compressor (set aside without disconnecting refrigerant lines), and power steering pump
10. Support transmission with transmission jack and remove transmission-to-engine bolts
11. Remove engine mounts and attach engine hoist with load leveler to factory lifting points
12. Carefully lift engine from vehicle and mount securely on engine stand
13. Position engine stand for easy access to all sides of the engine

Procedure

1. 1

   Remove valve train components and cylinder head
   Remove valve cover and gasket. Mark timing chain position relative to camshaft and crankshaft sprockets using paint or scribe marks. Remove timing chain tensioner, guides, and timing chain. Remove cylinder head bolts in reverse of tightening sequence (start from outside, work toward center). Lift cylinder head off engine block and place on clean padded surface with valves facing up. Inspect head gasket surface for damage.
2. 2

   Remove timing cover and front accessories
   Using impact wrench, remove harmonic balancer bolt (crankshaft pulley bolt). Use harmonic balancer puller to remove balancer from crankshaft - never use a jaw puller that grips the outer ring. Remove timing cover bolts (10mm and 8mm) in sequence. Carefully pry timing cover off using plastic pry tools at designated pry points. Remove front crankshaft seal from timing cover housing.
   Torque spec

   Harmonic Balancer Bolt180 Nm (133 lb-ft)
3. 3

   Remove oil pan and oil pump
   Remove oil pan bolts in reverse order of tightening sequence. Use gasket scraper to carefully separate oil pan from engine block. Remove oil pump pickup tube bolts and remove pickup tube. Remove oil pump mounting bolts and extract oil pump assembly from front of engine block. Inspect oil pump drive chain and gears for wear.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Pickup Tube12 Nm (9 lb-ft)

   Oil Pump Bolts12 Nm (9 lb-ft)
4. 4

   Mark and remove connecting rod caps
   Rotate crankshaft to position piston #1 at bottom dead center. Using permanent marker or number stamps, mark each connecting rod cap and rod with cylinder number (1-4) and orientation (ensure marks face same direction). Remove connecting rod cap bolts. Carefully remove connecting rod caps, keeping bearings with their respective caps. Push pistons up into cylinders slightly to clear crankshaft journals.
5. 5

   Mark and remove main bearing caps
   Using permanent marker or stamps, mark each main bearing cap with position (front to rear: 1, 2, 3, 4, 5) and orientation arrow pointing toward front of engine. The thrust bearing is located at position #3 (center). Remove main bearing cap bolts in sequence, starting from outer caps working toward center. Use main bearing cap puller if caps are tight - never pry or hammer on caps. Keep main bearings with their respective caps for inspection.
6. 6

   Remove crankshaft from engine block
   Carefully lift crankshaft straight up out of engine block using proper lifting technique or crankshaft lifting tool. Place crankshaft on padded clean surface or V-blocks. Remove upper main bearings from engine block, keeping them in order. Remove thrust bearing washers from #3 main journal location. Remove rear main seal housing bolts and remove housing with seal.
7. 7

   Inspect and measure crankshaft and block
   Clean all oil passages in crankshaft with solvent and compressed air. Inspect all journal surfaces for scoring, heat discoloration, or damage. Using micrometer, measure all main and rod journal diameters in multiple locations. Standard main journal diameter: 2.1648-2.1654 inches (54.986-54.999mm). Standard rod journal diameter: 1.8893-1.8898 inches (47.988-48.000mm). Measure taper and out-of-round (must be within 0.0004 inch). If beyond specification, crankshaft must be reground to next undersize or replaced. Use dial bore gauge to measure main bearing bores in block for roundness and proper diameter.
8. 8

   Install new main bearings and check clearances
   Clean all bearing surfaces in block and caps thoroughly with lint-free cloth and brake cleaner. Install upper main bearing shells into engine block, ensuring oil holes align with block passages. Place strip of Plastigage on each crankshaft main journal (parallel to crankshaft axis). Carefully lower crankshaft into position. Install lower bearing shells into main caps (no oil yet). Install main caps in correct position and orientation. Install NEW main bearing cap bolts finger-tight, then torque in sequence from center outward to 75 Nm (55 lb-ft). Then tighten additional 90 degrees using angle gauge. DO NOT rotate crankshaft. Remove caps one at a time and measure Plastigage width. Clearance should be 0.0008-0.0020 inches (0.02-0.05mm). If clearance is incorrect, verify bearing size and crankshaft measurements.
   ⚠Do not rotate crankshaft with Plastigage installed or measurements will be invalid.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
9. 9

   Final main bearing installation
   Remove main bearing caps and remove all Plastigage residue with solvent. Apply thin coat of assembly lube or clean engine oil to all bearing surfaces (both upper and lower shells). Install thrust bearing washers at #3 main position with oil grooves facing outward. Carefully lower crankshaft into position. Install main caps with lubricated bearings in correct position and orientation. Install NEW main bearing cap bolts and torque in sequence from center (#3) outward to 75 Nm (55 lb-ft), then additional 90 degrees. Check crankshaft endplay using dial indicator - should be 0.0016-0.0094 inches (0.04-0.24mm). Verify crankshaft rotates freely by hand.
   ⚠Excessive crankshaft endplay indicates incorrect thrust bearing installation or worn components.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
10. 10

    Install connecting rod bearings and pistons
    Clean connecting rod and cap bearing surfaces thoroughly. Install new rod bearing shells into connecting rods and caps. Apply Plastigage to rod journals and install rod caps with NEW connecting rod bolts to check clearances (torque to 45 Nm then 90 degrees additional). Verify clearance is 0.0008-0.0020 inches. Remove caps, clean Plastigage, and apply assembly lube to bearings. Install piston rings if removed (use ring compressor). Stagger ring gaps 120 degrees apart. Apply engine oil to cylinder walls. Using ring compressor, install piston/rod assemblies into cylinders from top, ensuring rod cap markings face correct direction. Guide rod over crankshaft journal and install rod cap with lubricated bearing. Install NEW rod bolts and torque to 45 Nm (33 lb-ft) plus 90 degrees additional rotation.
    ⚠Connecting rods must be installed with markings facing the same direction as originally marked. Reversed rods will cause immediate engine failure.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
11. 11

    Install rear main seal and housing
    Clean rear main seal housing and engine block mating surface. Install new rear main seal into housing using seal installation tool - ensure seal is square and seated fully. Apply thin bead of RTV sealant to housing mating surface as per factory specifications. Install housing onto engine block and torque bolts evenly to 12 Nm (9 lb-ft). Allow RTV to cure for 1 hour before adding oil.
    Torque spec

    Rear Main Seal Housing12 Nm (9 lb-ft)
12. 12

    Install oil pump and pickup tube
    Install new or inspected oil pump assembly onto front of engine block, aligning drive chain with crankshaft sprocket. Torque oil pump bolts to 12 Nm (9 lb-ft). Install new O-ring on oil pump pickup tube. Install pickup tube into oil pump and torque bolts to 12 Nm (9 lb-ft). Verify pickup tube-to-oil pan clearance will be 0.24-0.47 inches when pan is installed.
    Torque spec

    Oil Pump Bolts12 Nm (9 lb-ft)

    Oil Pump Pickup Tube12 Nm (9 lb-ft)
13. 13

    Install oil pan
    Clean oil pan and engine block mating surfaces thoroughly. Apply continuous bead of RTV sealant to oil pan groove (approximately 3-4mm diameter bead). Install oil pan within 3 minutes of applying RTV. Install oil pan bolts and torque in sequence from center outward to 12 Nm (9 lb-ft). Allow RTV to cure 1 hour before filling with oil.
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)
14. 14

    Install timing cover and front seal
    Install new front crankshaft seal into timing cover using seal installation tool - ensure seal is flush and square. Clean timing cover and engine block mating surfaces. Apply RTV sealant to specific areas as shown in service manual. Install new timing cover gasket. Position timing cover onto engine block, being careful not to damage front seal on crankshaft snout. Install timing cover bolts - torque 8mm bolts to 25 Nm (18 lb-ft) and 10mm bolts to 45 Nm (33 lb-ft) in specified sequence.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    Front Main Seal Housing12 Nm (9 lb-ft)
15. 15

    Install timing chain and cylinder head
    Rotate crankshaft to TDC for cylinder #1. Install new timing chain guides and torque bolts to 12 Nm (9 lb-ft). Compress new timing chain tensioner and install retaining pin. Install tensioner and torque bolt to 25 Nm (18 lb-ft). Install timing chain onto crankshaft sprocket first, then route over camshaft sprockets, aligning timing marks. Remove tensioner pin. Clean cylinder head and block surfaces. Install new head gasket with TOP mark facing up. Install cylinder head and NEW head bolts. Torque cylinder head bolts in sequence to 65 Nm (48 lb-ft), then tighten additional 90 degrees, then final 90 degrees (total 180 degrees additional). Install camshaft caps and torque in sequence. Verify valve timing marks are correctly aligned.
    ⚠Incorrect valve timing will cause engine damage. Triple-check all timing marks before proceeding.
    Torque spec

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

    Cylinder Head Bolts65 Nm (48 lb-ft)
16. 16

    Install harmonic balancer and complete engine reassembly
    Apply thin coat of clean engine oil to front crankshaft seal lip. Install harmonic balancer onto crankshaft, ensuring it is fully seated. Install NEW crankshaft pulley bolt (if TTY type). Torque harmonic balancer bolt to 180 Nm (133 lb-ft) using impact wrench. Install valve cover with new gasket. Rotate engine by hand two complete revolutions and verify timing marks realign and there is no binding. Install all remaining external components (exhaust manifold, alternator, A/C compressor, power steering pump, etc.) with specified torques.
    Torque spec

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)

Reassembly

1. Install engine into vehicle by reversing removal procedure, ensuring all mounts align properly
2. Reconnect transmission using new transmission-to-engine bolts torqued to 55 Nm (41 lb-ft)
3. Reconnect all electrical connectors, fuel lines, coolant hoses, and vacuum lines per labels created during disassembly
4. Install new oil filter and fill engine with 5.0 quarts Toyota Genuine 0W-20 oil
5. Fill cooling system with 10 quarts Toyota Super Long Life Coolant (Pink) and bleed air from system
6. Double-check all fasteners, connections, and fluid levels before starting engine

Verification

• Reconnect battery and perform initial startup - monitor for unusual noises, vibrations, or oil pressure warnings
• Engine should start immediately and idle smoothly - oil pressure should reach normal range within 5 seconds
• Allow engine to reach operating temperature while monitoring for leaks around oil pan, timing cover, and rear main seal
• Check for coolant leaks around cylinder head gasket and timing cover
• Perform test drive and verify normal operation under load - no knocking, excessive vibration, or oil consumption
• After 500 miles, recheck all fluid levels and inspect for any leaks
• Monitor oil consumption and condition for first 1000 miles during break-in period

More procedures for this vehicle