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

Warnings

Tools required

Parts

• Crankshaft (if replacement required) × 1 — Use OEM specification
• Main bearing set (upper and lower) × 1 — Use OEM specification - measure clearances
• Connecting rod bearing set × 1 — Use OEM specification - measure clearances
• Thrust bearing set × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Timing chain kit (chain, guides, tensioner) × 1 — Use OEM specification
• Oil pump O-rings and gaskets × 1 — Use OEM specification
• Cylinder head gasket × 1 — Use OEM specification
• Engine oil and filter × 1 — Toyota 0W-20
• Engine coolant × 1 — Toyota Super Long Life Coolant - Pink
• Oil drain plug crush washer × 1 — Use OEM specification
• RTV silicone sealant (Toyota FIPG) × 1 — Use OEM specification
• Connecting rod bolts (TTY) × 4 — Use OEM specification - replace always
• Main bearing cap bolts (TTY) × 10 — Use OEM specification - replace always
• Cylinder head bolts (TTY) × 1 — Use OEM specification - replace always
• Harmonic balancer bolt (TTY) × 1 — Use OEM specification - replace if TTY

Fluids

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

Preparation

1. Park vehicle on level surface, engage parking brake, and place wheel chocks
2. Disconnect negative battery cable and wait 90 seconds for airbag system discharge
3. Drain engine oil completely and drain coolant from radiator and engine block
4. Remove engine cover and air intake assembly
5. Remove front wheels and splash shields for access to lower components
6. Relieve fuel system pressure by removing fuel pump fuse and cranking engine
7. Label and photograph all electrical connectors, vacuum lines, and coolant hoses before disconnection
8. Support transmission with jack if separating from engine
9. Attach engine hoist with proper sling points - verify load rating
10. Clear adequate workspace around vehicle for engine removal and stand mounting

Procedure

1. 1

   Remove engine from vehicle
   Disconnect all electrical connectors, fuel lines, coolant hoses, and vacuum lines from engine. Remove exhaust manifold and downpipe connections. Remove axle shafts from transaxle. Unbolt engine mounts and transmission-to-engine bolts. Using engine hoist with load leveler, carefully lift engine and transmission assembly from vehicle. Tilt engine as needed to clear body structure. Once clear, lower assembly onto suitable work surface.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)

   Mounting Bolts47 Nm (35 lb-ft)
2. 2

   Separate transmission and mount engine to stand
   If not already separated, remove transmission-to-engine bolts and carefully separate transmission from engine block. Remove flexplate (automatic) exposing rear of crankshaft. Mount engine securely to engine stand using bellhousing bolt holes. Ensure engine is balanced and stand is on stable surface. Rotate engine to convenient working position with oil pan facing up.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)

   Flexplate Bolts85 Nm (63 lb-ft)
3. 3

   Remove accessory drive and timing components
   Remove serpentine belt and all accessory brackets. Using crankshaft pulley holder tool, remove harmonic balancer bolt (may require impact wrench). Use harmonic balancer puller to remove pulley from crankshaft snout - do not pry or hammer. Remove timing cover bolts in reverse of tightening sequence, noting different bolt sizes. Carefully remove timing cover - may need light prying. Set timing chain tensioner into locked position using pin or wire. Mark timing chain orientation to camshaft and crankshaft sprockets with paint. Remove timing chain tensioner, guides, and chain as assembly. Remove crankshaft timing sprocket.
   Torque spec

   Harmonic Balancer Bolt180 Nm (133 lb-ft)

   Cover Bolts16 Nm (12 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Timing Chain Guide Bolts12 Nm (9 lb-ft)
4. 4

   Remove cylinder head assembly
   Remove valve cover, camshafts, and all associated components. Remove cylinder head bolts in reverse of tightening sequence (start from outside, work inward in multiple passes). Carefully lift cylinder head from block - may need light tapping with rubber mallet. Do not pry between mating surfaces. Place cylinder head on clean padded surface. Remove and discard cylinder head gasket. Clean all gasket material from deck surface using plastic scrapers only - do not gouge aluminum.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
5. 5

   Remove oil pan and oil pump
   Remove oil pan bolts in crisscross pattern. Carefully separate oil pan from block using RTV cutter or thin blade - do not pry excessively. Remove oil pickup tube from oil pump and block. Remove oil pump mounting bolts and withdraw oil pump assembly from front of block. Inspect oil pump drive mechanism and crankshaft drive gear for wear.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Bolts12 Nm (9 lb-ft)

   Oil Pump Pickup Tube12 Nm (9 lb-ft)
6. 6

   Mark and measure connecting rod positions
   Rotate crankshaft to position cylinder 1 piston at bottom dead center. Using permanent marker or stamping tool, mark each connecting rod cap and rod body with cylinder number (1-4) and orientation mark (toward front of engine). Take photographs of markings. Before removing rod caps, rotate crankshaft to check for proper rod-to-crankshaft journal alignment. Measure connecting rod side clearance with feeler gauge and record measurements.
   ⚠Failure to properly mark connecting rod positions will result in incorrect reassembly and immediate engine damage.
7. 7

   Remove pistons and connecting rods
   Remove connecting rod cap bolts from rod #1. Carefully remove rod cap and lower bearing shell, keeping them together and organized. Push piston and rod assembly upward out of cylinder bore from below. Place clean shop towel in bore to prevent debris entry. Install rod cap back onto rod to prevent damage and keep bearings with their respective rods. Repeat for cylinders 2, 3, and 4. Store piston assemblies in order on clean surface. Inspect rod bearings for unusual wear patterns indicating crankshaft damage.
   ⚠Do not allow connecting rods to contact crankshaft journals during removal - can cause scoring.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
8. 8

   Mark and measure main bearing caps
   Main bearing caps are numbered from factory, but verify markings are visible. Caps should be numbered 1-5 from front to back with directional arrow pointing to front of engine. Using Plastigage, check main bearing clearances before removal: place Plastigage strip on each journal, install cap at specified torque, remove cap and measure crushed Plastigage width. Record all clearances - should be 0.0008-0.0019 inches. Check crankshaft endplay using dial indicator on front of crankshaft while prying shaft forward and backward - should be 0.0016-0.0095 inches.
   ℹ️Do not rotate crankshaft with Plastigage installed - will give false readings.
9. 9

   Remove main bearing caps and crankshaft
   Remove main bearing cap bolts in reverse order of tightening sequence (start from outer caps working toward center). Remove caps #1, #2, #4, and #5 first, keeping lower bearing shells with their caps. Cap #3 (center) contains thrust bearing - note orientation of thrust washers. Carefully lift crankshaft straight up from block, avoiding contact with bearing surfaces. Place crankshaft on padded surface or V-blocks. Remove upper bearing shells from block, keeping them organized by position. Remove front and rear main seals from block and seal housings.
   ⚠Crankshaft weighs approximately 40-50 lbs. Use proper lifting technique or assistance.
   Torque spec

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

    Inspect crankshaft and measure journals
    Thoroughly clean crankshaft with solvent and blow dry with compressed air, ensuring all oil passages are clear. Inspect all journal surfaces for scoring, discoloration, or unusual wear. Using outside micrometer, measure all main and rod journals at multiple points to check for out-of-round and taper. Main journal specification: 2.0461-2.0472 inches. Rod journal specification: 1.7707-1.7717 inches. Out-of-round and taper must not exceed 0.0008 inches. If journals are beyond specification, crankshaft must be machined or replaced. Check oil passage holes for debris or blockage.
    ⚠Crankshaft machining requires undersized bearings. Consult machine shop for availability before proceeding.
11. 11

    Prepare engine block and install new bearings
    Clean all bearing saddles in block thoroughly with solvent and lint-free cloth. Inspect bearing bores for damage or scoring. Clean all oil passages with rifle brush and compressed air. Install new upper main bearing shells into block - bearings should snap into place with oil holes aligned. Do not file or modify bearings. Install new lower bearing shells into main caps with tangs properly seated in notches. Verify thrust bearing halves are installed in correct orientation on center main cap #3.
    ⚠Never mix bearing shells from different sets or positions. Bearings are matched sets and position-specific.
12. 12

    Install crankshaft and verify clearances
    Lubricate all upper bearing shells with clean engine oil. Carefully lower crankshaft into block, aligning all journals with bearings. Place Plastigage strips on all main journals. Lubricate lower bearing shells. Install main bearing caps in correct positions with arrows pointing toward front of engine. Install new main bearing cap bolts finger-tight. Torque main cap bolts to 75 Nm (55 lb-ft) in sequence from center outward, then apply additional angle per specification. Remove caps one at a time and measure Plastigage - clearance should be within 0.0008-0.0019 inches. If clearances are correct, remove caps, remove Plastigage residue, and prepare for final assembly.
    ⚠Do not rotate crankshaft with Plastigage installed. Remove all Plastigage residue before final assembly.
    ⚠Bearing clearances outside specification will cause immediate engine failure. Verify measurements carefully.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
13. 13

    Final crankshaft installation
    Remove all main caps. Thoroughly lubricate all upper and lower bearing shells with assembly lube or clean engine oil. Ensure crankshaft journals are clean and oil passages are clear. Install main bearing caps in correct order with new TTY bolts. Torque main cap bolts to 75 Nm (55 lb-ft) in proper sequence (center cap first, then alternating outward). Follow with additional angle torque per Toyota specification (typically 90 degrees additional). Verify crankshaft rotates freely by hand with no binding. Recheck endplay - should be 0.0016-0.0095 inches. Install front and rear main seal housings with new seals using seal driver.
    ⚠TTY bolts must not be reused. Always install new main bearing cap bolts.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)

    Front Main Seal Housing12 Nm (9 lb-ft)

    Rear Main Seal Housing12 Nm (9 lb-ft)
14. 14

    Install pistons and connecting rods
    Install new connecting rod bearings into rods and caps. Stagger piston ring end gaps per specification (typically 120 degrees apart). Lubricate rings, pistons, and cylinder bores with engine oil. Using piston ring compressor, compress rings fully. Orient piston with mark toward front of engine. Insert connecting rod into cylinder from top, guiding rod carefully to avoid journal contact. Align rod with crankshaft journal and pull piston down into bore. Rotate crankshaft to bottom dead center. Lubricate rod bearings and install rod cap in correct orientation. Install new TTY connecting rod bolts and torque to 45 Nm (33 lb-ft) plus additional angle per specification. Repeat for all cylinders. Verify crankshaft rotates freely after each rod installation.
    ⚠Guide connecting rods carefully to prevent scoring crankshaft journals. Use rod bolt protectors if available.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
15. 15

    Install oil pump and oil pan
    Install oil pump drive mechanism onto crankshaft. Apply thin coat of RTV sealant to oil pump mating surface per Toyota procedure. Install oil pump and torque bolts to 12 Nm (9 lb-ft). Install oil pump pickup tube with new O-ring and torque to 12 Nm (9 lb-ft). Clean oil pan and block mating surfaces thoroughly. Install new oil pan gasket or apply RTV sealant per specification. Install oil pan and torque bolts in sequence from center outward to 12 Nm (9 lb-ft). Allow RTV to cure per manufacturer specification before adding oil.
    Torque spec

    Oil Pump Bolts12 Nm (9 lb-ft)

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
16. 16

    Install cylinder head and timing components
    Place new cylinder head gasket on block - verify correct orientation and alignment dowels. Carefully lower cylinder head onto block. Install new TTY cylinder head bolts with light oil on threads. Torque head bolts to 65 Nm (48 lb-ft) in proper sequence (center outward in spiral pattern), then apply additional angle torque per specification. Install camshafts and valve train components per specification. Install crankshaft timing sprocket. Install timing chain with marks aligned on cam and crank sprockets. Install timing chain guides and torque to 12 Nm (9 lb-ft). Install timing chain tensioner with pin installed, torque to 25 Nm (18 lb-ft), then release tensioner pin. Verify timing marks alignment. Clean timing cover mating surface and install new gasket. Install timing cover with bolts torqued in sequence: 10mm bolts to 45 Nm (33 lb-ft), 8mm bolts to 25 Nm (18 lb-ft).
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

    Cover Bolts16 Nm (12 lb-ft)
17. 17

    Install harmonic balancer and external components
    Install new front crankshaft seal if not already done. Lubricate seal lip and harmonic balancer hub. Install harmonic balancer onto crankshaft, ensuring proper seating. Install new harmonic balancer bolt (if TTY type) and torque to 180 Nm (133 lb-ft) - may require impact wrench. Use pulley holder to prevent crankshaft rotation. Install all accessory brackets and components. Install flexplate or flywheel to crankshaft flange with new bolts if TTY. Torque flexplate bolts to 85 Nm (63 lb-ft) in star pattern. Install all sensors with new O-rings where applicable.
    Torque spec

    Harmonic Balancer Bolt180 Nm (133 lb-ft)

    Flexplate Bolts85 Nm (63 lb-ft)

    Mounting Bolts47 Nm (35 lb-ft)
18. 18

    Reinstall engine into vehicle
    Remove engine from stand. Align engine with transmission and mate components together. Install transmission-to-engine bolts and torque to 55 Nm (41 lb-ft). Using engine hoist, carefully lower engine assembly into engine bay, tilting as needed to clear body structure. Align engine mounts and install mount bolts torqued to 47 Nm (35 lb-ft). Reconnect axle shafts to transaxle. Reconnect all electrical connectors, vacuum lines, coolant hoses, and fuel lines per labels and photographs. Install exhaust system connections. Reinstall air intake assembly and engine cover.
    Torque spec

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)

    Mounting Bolts47 Nm (35 lb-ft)
19. 19

    Fill fluids and perform initial start
    Install oil drain plug with new crush washer and torque to 35 Nm (26 lb-ft). Fill engine with 5 quarts Toyota Genuine 0W-20 oil. Install new oil filter. Fill cooling system with 10 quarts Toyota Super Long Life Coolant (pink). Bleed cooling system per procedure. Reconnect battery negative cable. Prime fuel system by cycling ignition on/off several times without cranking. Perform initial engine start and monitor for leaks, unusual noises, or warning lights. Allow engine to reach operating temperature while monitoring coolant level and oil pressure.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Torque-to-yield (TTY) fasteners include main bearing cap bolts, connecting rod bolts, cylinder head bolts, and harmonic balancer bolt - all must be replaced with new components
2. All bearing clearances must be verified with Plastigage or micrometers before final assembly - out-of-spec clearances will cause catastrophic failure
3. Timing chain alignment marks must be precisely positioned - incorrect timing will cause valve-to-piston contact and engine damage
4. RTV sealant cure times must be observed before filling with fluids - premature filling will cause leaks
5. Follow all torque sequences exactly as specified - improper tightening patterns will cause gasket failure or component damage

Verification

• Verify engine oil pressure reaches normal operating range (20-80 PSI depending on RPM and temperature) within 5 seconds of starting
• Check for oil leaks at main seal areas, oil pan, timing cover, and all gasket surfaces with engine running
• Verify no coolant leaks at cylinder head gasket or external connections
• Listen for unusual noises including knocking, ticking, or rattling that could indicate bearing problems or timing issues
• Confirm Check Engine Light (CEL) is off and no diagnostic trouble codes are present
• Verify smooth engine operation at idle and under load with no misfires or hesitation
• Road test vehicle to verify normal performance, oil pressure under load, and operating temperature stability
• Recheck all fluid levels after test drive and inspect for any new leaks
• After 500 miles, re-torque cylinder head bolts if required by Toyota specification (consult service manual)
• Change engine oil and filter after initial 500-1000 mile break-in period to remove assembly residue and metal particles

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