Complete engine teardown to access, inspect, and replace all pistons and rings, requiring removal of cylinder head, oil pan, and connecting rod caps.

Warnings

Tools required

Parts

• Piston and ring assembly (standard or oversized as measured) × 4 — Use OEM specification
• Connecting rod bearing set (standard or oversized) × 1 — Use OEM specification
• Cylinder head gasket × 1 — Use OEM specification
• Cylinder head bolt set (TTY) × 1 — Use OEM specification
• Connecting rod bolt set (TTY) × 4 — Use OEM specification
• Main bearing cap bolt set (TTY) × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Rear crankshaft seal × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• RTV silicone sealant (Toyota FIPG) × 1 — Use OEM specification

Fluids

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

Preparation

1. Disconnect negative battery cable and wait 90 seconds for airbag system discharge
2. Drain engine oil completely and remove oil filter
3. Drain engine coolant from radiator drain and engine block drain plugs
4. Remove engine cover and air intake system
5. Remove all accessory drive belts
6. Label and disconnect all vacuum lines, electrical connectors, fuel lines, and coolant hoses from engine
7. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls
8. Support engine from above with hoist or support fixture
9. Remove right side engine mount to allow engine tilt for access
10. Place vehicle on jack stands at appropriate lift points with adequate clearance underneath
11. Have clean workspace prepared for organizing removed components by cylinder number

Procedure

1. 1

   Remove exhaust manifold and intake manifold
   Disconnect oxygen sensors and remove exhaust manifold heat shield. Remove exhaust manifold bolts and separate manifold from cylinder head. Remove throttle body and intake manifold assembly with fuel rail attached. Cap all openings to prevent contamination.
2. 2

   Remove valve cover and accessory components
   Remove ignition coils and spark plugs. Unbolt valve cover and remove carefully to avoid damaging gasket sealing surfaces. Remove any remaining accessories that will interfere with cylinder head removal (alternator, A/C compressor - support without disconnecting refrigerant lines).
3. 3

   Remove timing chain and components
   Rotate crankshaft to TDC on cylinder #1 (timing marks aligned). Lock timing chain tensioner and remove timing chain guide. Mark timing chain orientation to camshaft and crankshaft sprockets. Remove camshaft sprockets and timing chain as assembly. Remove timing chain cover bolts and separate cover from block.
   ⚠Do not rotate crankshaft or camshafts once timing chain is removed or valve-to-piston contact may occur.
   Torque spec

   Cover Bolts15 Nm (11 lb-ft)
4. 4

   Remove cylinder head
   Loosen cylinder head bolts in reverse of tightening sequence (spiral pattern from outside to inside). Remove bolts completely and discard (TTY bolts). Carefully lift cylinder head from block using appropriate lift points. Place on clean padded surface. Remove and discard cylinder head gasket.
   ⚠Cylinder head is heavy (approximately 40 lbs). Use proper lifting technique or get assistance to avoid injury or dropping the head.
5. 5

   Remove oil pan and oil pickup tube
   Remove oil pan bolts in cross pattern. Carefully separate oil pan from block using plastic gasket scraper if needed. Remove oil pump pickup tube mounting bolts and remove tube with O-ring. Inspect oil pump screen for debris.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

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

   Inspect and mark connecting rods
   Rotate crankshaft to position each piston at bottom dead center one at a time. Use permanent marker or engraver to mark each connecting rod and cap with cylinder number (1-4) and orientation mark pointing toward front of engine. Verify marks are clear and will not be removed during cleaning.
   ⚠️Failure to properly mark connecting rod orientation will result in reversed installation and immediate bearing failure. Mark both rod and cap on the same side.
7. 7

   Remove cylinder ridge and connecting rod assemblies
   Use ridge reamer to remove any ridge at top of each cylinder bore before removing pistons. Loosen connecting rod bolts and remove caps, keeping each cap with its matching rod. Push piston/rod assembly up and out through top of block. Place each assembly in order with its cap and bolts. Inspect rod bearings for wear patterns.
   ⚠Do not remove pistons without first removing cylinder ridge or piston ring damage will occur.
8. 8

   Measure cylinder bores
   Clean cylinder bores thoroughly with solvent and lint-free cloth. Using cylinder bore gauge or telescoping gauge with micrometer, measure each bore at three depths (top, middle, bottom) and two orientations (parallel and perpendicular to crankshaft). Record all measurements. Calculate taper and out-of-round. Compare to service limits (typically 0.05mm taper max, 0.03mm out-of-round max). Determine if standard or oversized pistons are needed.
   ⚠If any cylinder exceeds wear limits, block must be bored and honed to next oversize. This requires professional machine shop services.
9. 9

   Remove pistons from connecting rods
   Support connecting rod in vise with soft jaws or on padded surface. Use piston pin press or carefully drive out piston pin using appropriate drift. Keep each piston with its original rod if reusing rods. Remove and discard old piston rings using ring expander tool.
10. 10

    Clean and inspect all components
    Thoroughly clean block deck surface, cylinder bores, connecting rods, and all mating surfaces. Inspect connecting rods for cracks, bending, or damage. Check rod big end bore for out-of-round condition. Clean crankshaft journals and inspect for scoring or wear. Measure crankshaft rod journals with micrometer and compare to specifications.
11. 11

    Install new piston rings
    If cylinder bores are within specification, hone lightly with 320-grit stones to establish proper crosshatch pattern. Clean bores thoroughly with soap and water, then dry and oil lightly. Install piston rings on new pistons using ring expander tool in order: oil control ring (expander and rails), second compression ring, top compression ring. Check ring end gap by inserting each ring square into cylinder bore and measuring with feeler gauge (typically 0.25-0.50mm). File end gap if necessary to achieve specification.
    ⚠Piston rings are directional and fragile. Install with markings facing up. Excessive force during installation will crack rings.
12. 12

    Install pistons on connecting rods
    Install new piston pin on each piston/rod assembly ensuring correct orientation (piston directional mark toward front, rod numbers toward intake side). Secure with new pin clips fully seated in grooves. Verify piston moves freely on pin without binding. Lubricate all components with assembly lube or clean engine oil.
13. 13

    Check bearing clearances
    Install new connecting rod bearings in rods and caps (dry, no oil). Place strip of Plastigage on each crankshaft rod journal. Install connecting rod assemblies and torque caps to specification plus angle. Remove caps carefully without rotating and measure Plastigage width. Clearance should be 0.020-0.045mm. If out of specification, different bearing size is required.
    ⚠Do not rotate crankshaft with Plastigage installed. This procedure uses new TTY bolts that must be discarded after checking clearance.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
14. 14

    Install piston and rod assemblies
    Oil cylinder bores and piston rings liberally. Stagger ring end gaps 120 degrees apart around piston. Install piston ring compressor on piston and compress rings fully. Orient piston with directional mark toward front of engine and rod numbers toward intake side. Insert assembly into correct cylinder bore from top. Tap piston gently through ring compressor into bore using wooden hammer handle. Guide connecting rod onto crankshaft journal.
15. 15

    Install connecting rod caps with final torque
    Lubricate rod bearings and crankshaft journals with assembly lube. Install connecting rod caps matching orientation marks. Install NEW connecting rod bolts and hand tighten. Torque bolts to 45 Nm in two stages, then rotate an additional 90 degrees using angle gauge. Verify crankshaft rotates freely after each rod is installed.
    ⚠️Must use NEW torque-to-yield connecting rod bolts. Initial torque spec is followed by angle rotation per manufacturer specification (typically 90 degrees but verify).
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
16. 16

    Reinstall oil pump pickup tube and oil pan
    Install new O-ring on oil pump pickup tube. Install tube and torque bolts to specification. Clean oil pan and block mating surfaces thoroughly. Apply new gasket or RTV sealant per manufacturer specification. Install oil pan and torque bolts in cross pattern to specification.
    Torque spec

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
17. 17

    Install cylinder head
    Verify block deck and cylinder head mating surfaces are completely clean and dry. Install new cylinder head gasket with alignment dowels, ensuring correct orientation. Carefully lower cylinder head onto block. Install NEW cylinder head bolts with light oil on threads. Hand tighten all bolts. Torque in proper sequence (center outward spiral pattern) to 65 Nm, then rotate each bolt additional 90 degrees, then additional 45 degrees using torque angle gauge.
    ⚠️Cylinder head bolts are TTY and require multi-stage torque plus angle procedure. Must follow exact sequence and torque steps or head gasket failure will occur.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
18. 18

    Reinstall timing components
    Install new front crankshaft seal. Clean timing cover and block surfaces. Apply new gasket or RTV to timing cover and install, torquing cover bolts to specification. Rotate crankshaft to TDC position. Install timing chain on crankshaft sprocket and camshaft sprockets with timing marks aligned per specifications. Install chain guides and tensioner. Verify timing marks alignment before releasing tensioner.
    ⚠️Incorrect timing chain installation will cause valve-to-piston contact and immediate engine destruction. Verify all timing marks multiple times before finalizing.
    Torque spec

    Cover Bolts15 Nm (11 lb-ft)

Reassembly

1. Install valve cover with new gasket, torque bolts evenly to specification
2. Reinstall intake manifold with new gaskets and torque bolts in proper sequence
3. Reinstall exhaust manifold with new gaskets and torque bolts evenly
4. Reconnect all vacuum lines, electrical connectors, fuel lines, and coolant hoses per labels
5. Install new spark plugs and ignition coils
6. Reinstall all accessory components and drive belts
7. Reinstall engine mount and remove engine support fixture
8. Install new oil filter and drain plug with new crush washer, torque drain plug to 35 Nm
9. Fill engine with 4.5 quarts Toyota Genuine 0W-20 oil
10. Fill cooling system with 7.5 quarts Toyota Super Long Life Pink Coolant
11. Reconnect negative battery cable

Verification

• With spark plugs removed, rotate engine by hand several complete revolutions to verify no binding or interference
• Reinstall spark plugs and perform initial start with close monitoring for unusual noises
• Check for oil leaks around oil pan, timing cover, and valve cover during initial run
• Allow engine to reach operating temperature and verify proper cooling system operation
• Check for coolant leaks around cylinder head gasket area
• Perform compression test on all cylinders - should be within 10% of each other and meet specification (typically 175-220 psi)
• Monitor oil pressure gauge during warm-up - should show normal pressure immediately
• Check and top off all fluid levels after test run
• Recheck cylinder head bolt torque after engine reaches operating temperature (follow cold retorque procedure if specified by manufacturer)
• Perform 500-mile oil change after break-in period to remove assembly residue and metal particles

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