Complete removal and replacement of the crankshaft, requiring engine removal from vehicle, full disassembly of rotating assembly, inspection of all bearing surfaces, and precise reassembly with torque-to-yield fasteners.

Warnings

Tools required

Parts

• Crankshaft (new or reconditioned) × 1 — Use OEM specification
• Main bearing set (upper and lower) × 1 — Use OEM specification - check clearances
• Rod bearing set × 1 — Use OEM specification - check clearances
• Piston ring sets × 4 — Use OEM specification - 4 sets required
• Front crankshaft seal × 1 — Use OEM specification
• Rear crankshaft seal × 1 — Use OEM specification
• Connecting rod bolts (TTY) × 8 — Use OEM specification - replace all
• Main bearing cap bolts (TTY) × 10 — Use OEM specification - replace all
• Cylinder head bolts (TTY) × 10 — Use OEM specification - replace all
• Crankshaft pulley bolt (TTY) × 1 — Use OEM specification
• Timing chain kit (chain, guides, tensioner) × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Cylinder head gasket × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Oil pump O-rings and gaskets × 1 — Use OEM specification
• Water pump × 1 — Use OEM specification - recommended replacement
• Thermostat and gasket × 1 — Use OEM specification
• Oil filter × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine coolant × 1 — Toyota Super Long Life Coolant Pink
• Engine oil × 5 — Toyota Genuine 0W-20
• RTV silicone sealant (Toyota FIPG) × 1 — Use OEM specification - black RTV
• Thread locking compound × 1 — Use per service manual
• Assembly lubricant (engine oil supplement) × 1 — Use OEM specification

Fluids

• Toyota Genuine 0W-20 — 4.5 qt
• Toyota Super Long Life Coolant (Pink) — 7.5 qt

Preparation

1. Ensure vehicle is on level ground with adequate overhead clearance for engine removal
2. Disconnect negative battery terminal and wait 10 minutes for airbag system to discharge
3. Drain engine oil completely and remove oil filter
4. Drain cooling system completely from radiator and engine block drain plugs
5. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls
6. Remove engine cover and air intake assembly
7. Remove hood (mark hinge positions for reinstallation)
8. Remove front wheels and lower splash shields
9. Support vehicle on jack stands at proper lift points
10. Have clean workspace prepared for engine disassembly with engine stand ready
11. Organize containers and labels for fasteners and components

Procedure

1. 1

   Remove Engine from Vehicle
   Disconnect all electrical connectors, vacuum lines, coolant hoses, and fuel lines from engine. Remove radiator and condenser assembly. Disconnect exhaust system at manifold. Remove drive belts and accessory components (alternator, A/C compressor - support aside without disconnecting lines, power steering pump). Disconnect transmission cooler lines if equipped. Support transmission with transmission jack. Remove transmission-to-engine bolts. Attach engine hoist with chains to factory lift points. Remove engine mount bolts - left mount, right mount, and rear mount. Carefully lift engine forward and upward, separating from transmission. Guide engine out of bay, watching for any remaining connections.
   ⚠️Engine weight is approximately 300 lbs. Ensure hoist is properly rated and chains are securely attached to factory lift points.
   ⚠Do not allow engine to hang unsupported by transmission input shaft. Damage to transmission will occur.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
2. 2

   Mount Engine and Remove External Components
   Mount engine securely to engine stand using transmission bell housing bolt holes. Rotate engine to convenient working position. Remove remaining external components: valve cover, exhaust manifold, intake manifold, fuel rail and injectors, water outlet housing, thermostat housing, alternator bracket, A/C compressor bracket, power steering pump bracket, and all remaining sensors. Remove spark plugs. Mark and photograph all component positions and connections.
3. 3

   Remove Timing Cover and Components
   Remove crankshaft pulley using harmonic balancer puller (do not use jaw-type puller on outer ring). Remove timing cover bolts in reverse of tightening sequence. Remove timing cover - may require gentle prying with plastic tools. Inspect timing chain for wear. Rotate crankshaft to TDC on cylinder #1 (timing marks aligned). Use timing chain tensioner pin or bent paperclip to compress and lock tensioner. Remove tensioner bolt, then remove tensioner. Remove timing chain guides. Remove timing chain from crankshaft and camshaft sprockets. Remove crankshaft timing sprocket.
   ⚠Impact wrench is typically required for crankshaft pulley bolt removal. Use proper socket to avoid rounding.
   Torque spec

   Harmonic Balancer Bolt180 Nm (133 lb-ft)

   Cover Bolts15 Nm (11 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

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

   Remove Cylinder Head
   Remove cylinder head bolts in reverse of tightening sequence (typically from outside toward center). Lift cylinder head straight up to avoid damaging gasket surface. Place head on clean surface with combustion chambers facing up. Inspect head gasket and deck surface for damage or warping. Cover open cylinders with clean shop towels to prevent debris entry.
   ⚠Cylinder head bolts are torque-to-yield and must be replaced. Do not reuse.
   Torque spec

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

   Remove Oil Pan and Pickup
   Remove oil pan bolts in crisscross pattern. Carefully separate oil pan from block - may require gentle tapping with soft mallet. Remove oil pan gasket. Remove oil pump pickup tube bolts and extract pickup assembly. Inspect pickup screen for debris.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

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

   Remove Oil Pump and Front Seal Housing
   Remove oil pump mounting bolts and extract oil pump assembly from front of block. Remove front main seal housing bolts and carefully remove housing. Extract front crankshaft seal from housing. Inspect oil pump gears for wear - replacement recommended.
   ℹ️Mark oil pump orientation before removal for proper reinstallation.
   Torque spec

   Oil Pump Bolts12 Nm (9 lb-ft)

   Front Main Seal Housing12 Nm (9 lb-ft)
7. 7

   Remove Flexplate/Flywheel and Rear Seal Housing
   Use flywheel holder tool to prevent rotation. Remove flexplate bolts (automatic transmission) in star pattern. Remove flexplate and inspect for cracks. Remove rear main seal housing bolts and carefully pry housing from block. Extract rear crankshaft seal from housing.
   ⚠Flexplate bolts may be torque-to-yield depending on production date. Recommend replacement.
   Torque spec

   Flexplate Bolts85 Nm (63 lb-ft)

   Rear Main Seal Housing12 Nm (9 lb-ft)
8. 8

   Remove Pistons and Connecting Rods
   Rotate crankshaft to position each piston at bottom dead center. Check connecting rods and caps for cylinder position markings - if not present, mark with permanent marker or stamps (1-4 from timing chain end). Remove connecting rod bolts. Carefully tap rod caps to separate. Remove rod caps and keep matched with rods. Push piston and rod assembly upward and out through top of cylinder bore. Keep pistons organized by cylinder number. Inspect cylinder walls for scoring or wear.
   ⚠️Connecting rod bolts are torque-to-yield and must be replaced. Never reuse.
   ⚠Protect crankshaft journals by covering rod bolts with rubber hose or cap to prevent damage during removal.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
9. 9

   Remove Main Bearing Caps and Crankshaft
   Check main bearing caps for position markings and orientation arrows - mark if not present. Main caps are typically numbered 1-5 from timing chain end with arrows pointing toward front. Remove main bearing cap bolts in reverse order (from ends toward center, multiple passes). Carefully tap main caps with soft mallet to break free. Remove main caps and keep in order. Carefully lift crankshaft straight up from block. Remove upper main bearing shells from block and keep matched with lower shells by position. Inspect all crankshaft journals for scoring, heat discoloration, or wear.
   ⚠️Main bearing cap bolts are torque-to-yield and must be replaced. Never reuse.
   ⚠Main bearing caps must be installed in exact original positions and orientations. Direction arrows must point toward timing chain end.
   ℹ️Crankshaft is heavy (approximately 50 lbs). Use proper lifting technique or get assistance.
   Torque spec

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

    Inspect and Measure Crankshaft and Block
    Thoroughly clean crankshaft with solvent and inspect all journal surfaces. Measure all main and rod journals with micrometer at multiple points to check for taper and out-of-round conditions. Compare measurements to factory specifications (typically 0.0002 inch tolerance). Inspect crankshaft for cracks using magnetic particle or dye penetrant inspection if available. Measure main bearing bore diameter in block with dial bore gauge. Check for scoring or damage. If crankshaft journals are worn beyond specification, crankshaft must be reground and undersize bearings used, or crankshaft replaced.
    ⚠Out-of-spec measurements require professional machine shop services. Do not attempt to assemble with worn components.
11. 11

    Prepare Block and Install New Bearings
    Thoroughly clean engine block, all bearing saddles, and main caps with solvent. Blow out all oil passages with compressed air. Inspect block deck surface for warping with straight edge. Install new upper main bearing shells into block saddles - ensure bearing tabs engage notches and bearings are fully seated. Do not oil bearings yet - Plastigage test requires dry surfaces. Install lower bearing shells into main caps ensuring proper seating.
    ⚠Bearings are precision components. Handle only by edges, never touch bearing surfaces with bare hands.
12. 12

    Check Main Bearing Clearances with Plastigage
    Place strips of Plastigage across each crankshaft main journal parallel to crankshaft axis. Carefully lower crankshaft into block onto bearings. Install main caps in correct positions with arrows pointing forward. Install new main bearing cap bolts finger tight only. Torque bolts to 75 Nm in sequence (typically center cap first, then alternating outward), then add angle per specification. Carefully remove main caps without rotating crankshaft. Measure compressed Plastigage width using scale on Plastigage envelope. Clearance should be 0.0008-0.0018 inches typical. If clearance is incorrect, determine cause (wrong bearing size, damaged journals, etc.). Remove crankshaft and all Plastigage residue before final assembly.
    ⚠Do not rotate crankshaft with Plastigage installed or measurements will be invalid.
    ⚠These bolts will be discarded after Plastigage check. Use new bolts for final assembly.
    Torque spec

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

    Final Crankshaft Installation
    Remove crankshaft and thoroughly clean all Plastigage residue. Apply assembly lubricant liberally to all upper main bearing surfaces. Carefully lower crankshaft into position. Apply assembly lubricant to lower main bearing surfaces. Install main caps in correct positions with directional arrows pointing toward timing chain end. Install new main bearing cap bolts. Torque bolts in sequence to 75 Nm, then add additional angle per manufacturer specification (typically 90 degrees additional). Verify crankshaft rotates freely by hand with no binding. If binding occurs, disassemble and inspect for debris or misaligned bearings.
    ⚠️Use only new torque-to-yield main bearing cap bolts for final assembly. This is the third set of bolts required.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
14. 14

    Prepare and Install Pistons and Rods
    If reusing pistons, remove old rings and thoroughly clean ring grooves. Install new piston rings using ring installer tool - oil control ring first (expander and rails), then lower compression ring, then upper compression ring. Ensure ring gaps are properly staggered per specification (typically 120 degrees apart). Apply assembly lubricant to piston rings and cylinder walls. Install new rod bearing shells in rods and caps. Apply assembly lubricant to rod bearings. Cover rod bolts with rubber hose. Position piston ring gaps per specification. Compress piston rings using ring compressor. Insert piston into correct cylinder bore with orientation mark toward timing chain end. Tap piston gently into bore until rings enter cylinder. Guide connecting rod onto crankshaft journal. Install rod cap in correct orientation. Install new rod bolts and torque to 45 Nm plus angle per specification. Repeat for all four cylinders.
    ⚠️Use only new torque-to-yield connecting rod bolts. Never reuse.
    ⚠Ensure rod caps are installed in correct orientation. Mismatch will cause immediate bearing failure.
    Torque spec

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

    Install Rear Seal Housing and Flexplate
    Install new rear crankshaft seal into rear seal housing using seal driver tool - seal must be flush with housing face. Apply thin bead of RTV sealant to housing mating surface per service manual. Install housing onto block and torque bolts to 12 Nm in crisscross pattern. Allow RTV to cure per manufacturer specification before adding oil. Position flexplate onto crankshaft with alignment dowel engaged. Install flexplate bolts and torque in star pattern to 85 Nm using flywheel holder tool.
    ⚠Ensure rear seal is fully seated and square in housing before installation.
    Torque spec

    Rear Main Seal Housing12 Nm (9 lb-ft)

    Flexplate Bolts85 Nm (63 lb-ft)
16. 16

    Install Oil Pump and Front Seal Housing
    Install new front crankshaft seal into front seal housing using seal driver - seal must be flush with housing. Pack oil pump with petroleum jelly to ensure priming. Install oil pump onto crankshaft and align with block. Torque oil pump bolts to 12 Nm. Apply thin bead of RTV to front seal housing mating surface. Install housing and torque bolts to 12 Nm in crisscross pattern.
    Torque spec

    Oil Pump Bolts12 Nm (9 lb-ft)

    Front Main Seal Housing12 Nm (9 lb-ft)
17. 17

    Install Oil Pickup and Pan
    Install new O-ring on oil pickup tube. Install pickup tube and torque bolts to 12 Nm. Clean oil pan and block mating surfaces thoroughly. Install new oil pan gasket or apply RTV per service manual specification. Position oil pan and install bolts finger tight. Torque oil pan bolts in sequence from center outward to 12 Nm.
    Torque spec

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
18. 18

    Install Cylinder Head
    Clean cylinder head and block deck surfaces thoroughly. Inspect surfaces for warping or damage. Install new cylinder head gasket with orientation marks UP and toward timing chain end. Carefully lower cylinder head onto block ensuring dowel pins engage. Install new cylinder head bolts and torque in proper sequence: first pass to 65 Nm, then add angle per specification (typically 90 degrees additional in multiple steps). Refer to service manual for exact sequence.
    ⚠️Cylinder head bolts are torque-to-yield and must be replaced with new bolts.
    ⚠Follow exact torque sequence and angle specifications. Improper sequence causes head gasket failure.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
19. 19

    Install Timing Components
    Install crankshaft timing sprocket onto crankshaft. Rotate crankshaft to TDC position for cylinder #1. Rotate camshafts to TDC position with timing marks aligned. Install new timing chain onto crankshaft sprocket then route around camshaft sprockets with colored links aligned with timing marks. Install timing chain guides and torque bolts to 12 Nm. Compress new timing chain tensioner and lock with pin or paperclip. Install tensioner and torque bolt to 25 Nm. Remove tensioner pin to apply tension. Verify all timing marks align correctly. Rotate crankshaft two complete revolutions and recheck timing mark alignment. Clean timing cover and block mating surfaces. Install new timing cover gasket. Install timing cover and torque 8mm bolts to 25 Nm and 10mm bolts to 45 Nm in proper sequence. Install new crankshaft pulley bolt and torque to 180 Nm using impact wrench or holding tool.
    ⚠️Incorrect timing chain installation will cause catastrophic engine damage. Triple-check all timing marks before proceeding.
    ⚠Crankshaft pulley bolt is typically TTY. Use new bolt per service manual.
    Torque spec

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

    Cover Bolts15 Nm (11 lb-ft)

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)
20. 20

    Reinstall External Components and Engine
    Reinstall all external engine components in reverse order of removal: thermostat and housing, water outlet, fuel rail and injectors, intake manifold, exhaust manifold, valve cover with new gasket, all brackets and accessories, all sensors and electrical connectors. Install new spark plugs. Remove engine from stand. Position engine for installation into vehicle using hoist. Guide engine into position aligning with transmission. Install transmission-to-engine bolts and torque to 55 Nm. Install engine mounts and torque mounting bolts to specified values. Reconnect all hoses, lines, electrical connectors, and exhaust system. Reinstall radiator and condenser. Install accessory drive belt. Install hood, wheels, and splash shields.
    Torque spec

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

    Mounting Bolts26 Nm (19 lb-ft)

Reassembly

1. All torque-to-yield fasteners (main bearing cap bolts, rod bolts, cylinder head bolts, crankshaft pulley bolt) must be replaced with new components
2. Bearing clearances must be verified before final assembly - out-of-spec clearances require correction
3. Timing chain alignment is critical - verify timing marks align at TDC after installation and after two complete crankshaft rotations
4. Apply assembly lubricant to all bearing surfaces during installation
5. Follow exact torque sequences for main caps, rod caps, cylinder head, and timing cover
6. RTV sealant cure time must be observed before adding fluids or starting engine
7. Use new gaskets for all components - oil pan, timing cover, valve cover, cylinder head, and all seals

Verification

• Install new oil filter and fill engine with Toyota Genuine 0W-20 oil to proper level (4.5 quarts)
• Fill cooling system with Toyota Super Long Life Coolant (Pink) - 7.5 quarts total capacity
• Reconnect battery negative terminal
• Before starting, rotate crankshaft by hand using breaker bar on crankshaft pulley bolt - ensure smooth rotation with no binding or unusual resistance
• Prime oil system if possible using oil pump priming tool through oil pressure sender port
• Start engine and verify immediate oil pressure on gauge - if no pressure within 10 seconds, shut down immediately
• Check for oil leaks at pan, timing cover, and seal areas while engine runs
• Check for coolant leaks at all connections
• Allow engine to reach operating temperature and verify proper thermostat operation
• Monitor engine for unusual noises - any knocking, ticking, or grinding requires immediate shutdown and inspection
• After initial warm-up and cool-down, recheck oil and coolant levels
• Check for diagnostic trouble codes
• Road test vehicle under light load initially, gradually increasing load
• Perform oil and filter change after 500 miles of break-in period
• Inspect for leaks after break-in period

More procedures for this vehicle