Complete removal and replacement of main bearing shells, requiring engine removal from vehicle and extensive disassembly to access crankshaft bearing surfaces.

Warnings

Tools required

Parts

• Main bearing set (standard or appropriate undersize) × 1 — Use OEM specification
• Thrust bearing washers (upper and lower) × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Oil pump gasket × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• RTV sealant (Toyota Genuine) × 1 — Use OEM specification
• Engine coolant × 1 — Toyota Super Long Life Coolant (Pink)
• New main cap bolts (recommended) × 10 — Use OEM specification

Fluids

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

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery terminal and isolate cable
3. Drain engine oil completely and remove oil filter
4. Drain engine coolant from radiator and engine block drain plugs
5. Remove engine cover and air intake assembly
6. Remove front wheels and engine under covers
7. Support transmission with transmission jack or sturdy support
8. Clearly label all electrical connectors, vacuum lines, and hoses before disconnection
9. Position engine hoist in front of vehicle with adequate clearance
10. Have clean workspace prepared for engine stand mounting

Procedure

1. 1

   Remove engine from vehicle
   Disconnect all electrical connectors, fuel lines, coolant hoses, and exhaust connections from engine. Remove engine mounting bolts, transmission bell housing bolts (if removing with transmission), and radiator. Attach engine hoist chains to factory lifting points. Slowly lift engine while checking for any remaining connections. Tilt engine as needed to clear body and lift out of engine bay.
2. 2

   Mount engine to stand and remove accessories
   Mount engine securely to engine stand using bell housing bolt holes. Remove alternator, A/C compressor, power steering pump, starter, and all remaining accessories. Remove valve cover, timing chain cover, timing chain, and cylinder head. Keep all bolts organized by location.
3. 3

   Remove oil pan and oil pump
   Remove all oil pan bolts and carefully separate oil pan from engine block using plastic scraper if needed. Remove oil pump pickup tube. Remove oil pump assembly from front of block. Clean all gasket surfaces thoroughly.
4. 4

   Mark and inspect main bearing caps
   Using permanent marker or punch marks, clearly mark each main bearing cap with its cylinder number (1-5 from front) and orientation arrow pointing to front of engine. Inspect cap markings - they should already have factory numbers. Photograph cap positions before removal for reference.
   ⚠Improper cap orientation or position will cause immediate engine failure. Triple-check markings.
5. 5

   Remove main bearing cap bolts
   Working from outer caps toward center (caps 1, 5, 2, 4, then 3), loosen main cap bolts gradually in cross pattern. Remove bolts completely and store with corresponding cap. Inspect bolts for any stretching or damage - replacement is strongly recommended.
   ℹ️Loosen in stages to prevent crankshaft distortion. Do not loosen all at once.
6. 6

   Remove main bearing caps and crankshaft
   Carefully remove main bearing caps, keeping them in exact order with lower bearing shells in place. Gently lift crankshaft straight up out of block. Place on clean padded surface. Remove upper bearing shells from block, keeping them with corresponding cap and lower shell. Note position of thrust washers (typically on center main bearing).
7. 7

   Inspect crankshaft journals
   Using micrometer, measure all five main bearing journal diameters in multiple locations to check for taper and out-of-round condition. Standard journal diameter is approximately 2.1648-2.1654 inches. Any taper over 0.0004 inch or out-of-round over 0.0004 inch requires crankshaft machining. Inspect journals for scoring, discoloration, or damage.
   ⚠Damaged journals must be machined and undersize bearings fitted. Do not attempt to reuse with damaged surfaces.
8. 8

   Clean and inspect block bearing saddles
   Thoroughly clean all main bearing saddles in block using lint-free rags and solvent. Inspect saddles for cracks, scoring, or damage. Ensure all oil passages are clear using compressed air (wear eye protection). Check block deck surface for warpage if head gasket failure was suspected.
9. 9

   Install new upper bearing shells
   Wipe new upper bearing shells with clean engine oil. Install upper bearing shells into block saddles, ensuring tang engages notch in block. Shells should snap into place firmly. Verify correct positioning - oil holes in shell must align with oil passages in block. Install thrust washers in correct position (check service manual for specific bearing number).
   ℹ️Never file or sand bearings. They must fit exactly as manufactured.
10. 10

    Check bearing clearances with Plastigage
    Place strip of Plastigage across each main journal parallel to crankshaft axis. Carefully lower crankshaft into block. Install main caps in correct positions and orientation. Install main cap bolts and torque to 40 Nm (30 lb-ft) ONLY - do not add 90° angle yet. Do not rotate crankshaft. Remove caps and measure flattened Plastigage width using package scale. Clearance should be 0.0008-0.0020 inches. Record all measurements.
    ⚠Excessive clearance indicates need for undersize bearings or crankshaft machining. Do not proceed if out of specification.
    Torque spec

    Main Cap Bolts75 Nm (55 lb-ft) + 90°
11. 11

    Final bearing installation
    Remove crankshaft again and clean all Plastigage residue from journals and bearings using lint-free cloth. Lubricate all upper bearing shells and thrust washers with clean engine oil. Carefully lower crankshaft into position. Lubricate all lower bearing shells with clean engine oil and install into caps.
12. 12

    Install and torque main bearing caps
    Install main bearing caps in correct positions with orientation arrows pointing to front of engine. Install new main cap bolts (if using). Working from center cap outward (3, 2, 4, 1, 5), torque all bolts in two stages: First stage to 40 Nm (30 lb-ft) in cross pattern for each cap. Second stage, tighten each bolt an additional 90 degrees using angle gauge. Verify crankshaft rotates freely by hand after each cap installation.
    ⚠If crankshaft binds at any point, stop immediately. Remove cap and inspect for foreign material or bearing misalignment.
    Torque spec

    Main Cap Bolts75 Nm (55 lb-ft) + 90°
13. 13

    Check crankshaft endplay
    Using dial indicator against crankshaft snout, pry crankshaft fully forward and zero indicator. Pry crankshaft fully rearward and note reading. Endplay specification is 0.0016-0.0094 inches. If out of specification, verify thrust washer installation and condition.
14. 14

    Reinstall oil pump and oil pan
    Install oil pump with new gasket. Install oil pickup tube. Apply thin bead of RTV sealant to oil pan mating surface where specified in service manual. Install new oil pan gasket and position oil pan. Install and torque oil pan bolts to specification in cross pattern from center outward.
    Torque spec

    Gasket Bolts20 Nm (15 lb-ft)
15. 15

    Complete engine reassembly and installation
    Reinstall cylinder head with new head gasket following proper torque sequence. Reinstall timing chain, timing cover with new gasket, and valve cover. Reinstall all accessories. Remove engine from stand and install back into vehicle, reversing removal procedure. Reconnect all electrical connectors, hoses, fuel lines, and exhaust. Install new oil filter and fill with correct amount of fresh 0W-20 engine oil. Refill cooling system with Toyota pink coolant.
    ℹ️Follow cylinder head torque sequence carefully. Head bolt procedure is separate from this main bearing procedure.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    Mounting Bolts47 Nm (35 lb-ft)

Reassembly

1. Torque all fasteners to specified values in correct sequence
2. Use only new gaskets and seals throughout reassembly
3. Apply thread locker to bolts only where specified by manufacturer
4. Double-check all electrical connector engagements
5. Verify all cooling system hoses are properly clamped
6. Ensure all exhaust connections are secure to prevent leaks

Verification

• Reconnect battery and check for any warning lights before starting
• With spark plugs removed, crank engine several revolutions to prime oil system and verify no mechanical binding
• Reinstall spark plugs and start engine - it should start quickly without unusual noises
• Check for oil leaks at pan gasket, timing cover, and all seal areas
• Verify oil pressure gauge shows normal pressure (varies by temperature, typically 4.3 psi at idle when warm)
• Check for coolant and fuel leaks at all connection points
• Allow engine to reach full operating temperature and verify no overheating or leaks develop
• Monitor engine for first 100 miles for any unusual noises, vibrations, or oil consumption
• Change engine oil and filter after 500 miles of break-in period

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