Complete engine disassembly to remove, inspect, and replace all four pistons and rings, requiring cylinder head removal and lower engine teardown.

Warnings

Tools required

Parts

• Piston and ring set (4 pistons) × 1 — Use OEM specification
• Connecting rod bearing set × 1 — Use OEM specification
• Main bearing set × 1 — Use OEM specification
• Cylinder head gasket × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Oil pump gasket × 1 — Use OEM specification
• Connecting rod bolts (TTY) × 8 — Use OEM specification
• Cylinder head bolts (TTY) × 1 — Use OEM specification
• Main bearing cap bolts (TTY) × 1 — Use OEM specification
• Oil filter × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine coolant seals and O-rings × 1 — Use OEM specification
• RTV silicone sealant (Toyota Genuine) × 1 — Use OEM specification
• Engine assembly lube × 1 — Use OEM specification

Fluids

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

Preparation

1. Position vehicle on level ground and engage parking brake. Place wheel chocks at rear wheels
2. Disconnect negative battery cable and secure away from battery terminal
3. Remove engine cover and plastic undercovers from underneath vehicle
4. Drain engine oil completely and remove oil filter
5. Drain engine coolant from radiator drain and engine block drain plugs into appropriate container
6. Remove air intake system, battery, and battery tray
7. Disconnect all electrical connectors from engine (label for reference)
8. Disconnect fuel lines (relieve fuel pressure first), coolant hoses, and vacuum lines
9. Remove radiator, cooling fans, and A/C condenser (recover refrigerant first if needed)
10. Disconnect exhaust system from manifold
11. Support transmission with jack and disconnect from engine bellhousing
12. Attach engine hoist to lifting points and remove engine mount bolts
13. Carefully lift engine from vehicle and mount securely on engine stand
14. Remove all external accessories: alternator, starter, manifolds, fuel rail, ignition coils, and wiring harness

Procedure

1. 1

   Remove valve cover and timing components
   Remove valve cover by loosening cover bolts in reverse of tightening sequence. Remove timing chain cover, crankshaft pulley using holding tool, and timing chain guides. Mark timing chain orientation to camshaft and crankshaft sprockets before removal. Remove camshafts carefully, noting position and orientation of bearing caps.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
2. 2

   Remove cylinder head
   Loosen cylinder head bolts in reverse of tightening sequence (outside to inside pattern). Remove cylinder head bolts completely and lift cylinder head straight up off engine block. Place cylinder head on clean work surface. Inspect head gasket for failure patterns and save for reference.
   ⚠Cylinder head is heavy (approximately 40 lbs). Use proper lifting technique or have assistant help
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
3. 3

   Remove oil pan and oil pump
   Remove oil pan bolts in crisscross pattern and carefully separate oil pan from engine block. Remove oil pump pickup tube bolts and extract pickup tube. Remove oil pump mounting bolts and extract oil pump assembly from front of engine block.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Pickup Tube12 Nm (9 lb-ft)

   Mounting Bolts47 Nm (35 lb-ft)
4. 4

   Remove ridge from cylinder bores
   Use ridge reamer to carefully remove ridge at top of each cylinder bore where piston ring travel ends. Follow ridge reamer instructions carefully to avoid cutting into cylinder wall. Clean all debris from cylinder bores using shop vacuum and clean lint-free cloth. This prevents piston ring breakage during removal.
   ⚠Do not cut deeper than ridge depth. Excessive material removal will damage cylinder bore
5. 5

   Mark and remove connecting rod caps
   Rotate crankshaft to position pistons at mid-stroke for easy access. Using permanent marker or stamping tool, mark each connecting rod and cap with cylinder number (1-4) and orientation (front/rear). Remove connecting rod cap bolts and carefully remove caps. Keep caps organized with their respective rods.
   ℹ️Connecting rods and caps are matched sets and must not be mixed between cylinders
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
6. 6

   Remove pistons and connecting rods
   Push each piston and connecting rod assembly up and out through top of cylinder bore. Protect crankshaft journals by placing rubber hose or protective caps over connecting rod bolts during removal. Place each piston assembly in labeled container matching cylinder number.
   ⚠Do not allow connecting rod bolts to strike crankshaft journals as this will cause damage
7. 7

   Remove and inspect crankshaft (optional but recommended)
   If replacing main bearings or inspecting crankshaft, mark main bearing cap orientation and position. Loosen main bearing cap bolts in sequence from outside to center. Remove main bearing caps and carefully lift crankshaft from engine block. Inspect all journals for scoring, discoloration, or damage.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
8. 8

   Measure cylinder bores and inspect block
   Use cylinder bore gauge or telescoping gauge with micrometer to measure each cylinder bore at three depths (top, middle, bottom) and in two directions (parallel and perpendicular to crankshaft). Record all measurements. Check for taper (top to bottom) and out-of-round. Maximum taper: 0.05mm (0.002in). Maximum out-of-round: 0.05mm (0.002in). Inspect cylinder walls for scoring or damage.
   ⚠If cylinder measurements exceed specifications, block must be bored and honed by machine shop, or replaced
9. 9

   Clean and prepare engine block
   Thoroughly clean engine block, crankshaft, and all mating surfaces using appropriate solvent and brushes. Remove all old gasket material using plastic gasket scraper. Clean all oil passages with rifle brush and compressed air. Ensure cylinder head deck surface is perfectly clean and flat. Wipe all surfaces with lint-free cloth dampened with brake cleaner.
   ℹ️Absolute cleanliness is critical. Any debris left in engine will cause immediate failure upon startup
10. 10

    Install new main bearings and crankshaft
    Install new upper main bearing shells into engine block saddles (without lubrication yet). Install new lower bearing shells into main caps. Lubricate all bearing surfaces and crankshaft journals with engine assembly lube. Carefully lower crankshaft into position. Install main bearing caps in correct position and orientation. Install new main bearing cap bolts and torque in sequence from center outward to 75 Nm (55 lb-ft), then rotate an additional 90 degrees. Verify crankshaft rotates smoothly.
    ⚠Main bearing cap bolts are TTY and must be replaced. Torque sequence and angle are critical
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
11. 11

    Prepare new pistons and rings
    Remove old pistons from connecting rods if reusing rods (typically pistons are replaced as piston/rod assemblies). Install new piston rings onto each piston using ring expander tool. Install oil control ring first (bottom), then second compression ring with marking facing up, then top compression ring with marking facing up. Using feeler gauges, check ring end gaps by placing each ring in cylinder bore and measuring gap. Top ring gap: 0.20-0.40mm, second ring gap: 0.35-0.55mm. Stagger ring end gaps 120 degrees apart.
    ⚠Do not expand rings more than necessary. Excessive expansion will permanently weaken rings
12. 12

    Install pistons and connecting rods
    Lubricate cylinder walls, piston skirts, and piston rings with clean engine oil. Verify ring gaps are properly staggered. Compress piston rings using ring compressor and ensure compressor is tight and square to piston. Insert piston/rod assembly into correct cylinder bore with directional marking facing front of engine. Gently tap piston into cylinder using wooden hammer handle until piston crown is flush with block deck. Guide connecting rod onto crankshaft journal and install bearing shells.
    ⚠Ensure piston orientation is correct. Arrow or mark on piston crown must face front of engine
13. 13

    Install connecting rod caps and torque
    Lubricate connecting rod bearing shells and crankshaft rod journals with assembly lube. Install connecting rod caps in correct orientation matching marks made during disassembly. Install new connecting rod bolts and hand tighten. Torque connecting rod bolts to 45 Nm (33 lb-ft), then rotate an additional 90 degrees. Verify crankshaft rotates smoothly after each rod cap installation. Check connecting rod side clearance with feeler gauge: specification 0.15-0.35mm.
    ⚠Connecting rod bolts are TTY and must be replaced. Do not reuse old bolts
    Torque spec

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

    Install oil pump and oil pan
    Install new oil pump gasket and mount oil pump to engine block. Torque oil pump mounting bolts to specification. Install oil pump pickup tube with new O-ring and torque pickup tube bolts to 12 Nm (9 lb-ft). Apply continuous bead of RTV sealant to oil pan mating surface and install oil pan within 10 minutes of sealant application. Torque oil pan bolts in crisscross pattern to 12 Nm (9 lb-ft).
    ℹ️Allow RTV sealant to cure for minimum 2 hours before adding oil
    Torque spec

    Mounting Bolts47 Nm (35 lb-ft)

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
15. 15

    Install cylinder head and timing components
    Place new cylinder head gasket on block deck with markings facing up. Carefully lower cylinder head into position. Install new cylinder head bolts and torque in sequence (center outward) to 65 Nm (48 lb-ft), then rotate an additional 90 degrees. Install camshafts in correct position with timing marks aligned. Install timing chain with marks aligned to camshaft and crankshaft sprockets. Install timing chain guides and tensioner. Install timing cover with new gasket and torque cover bolts to 16 Nm (12 lb-ft). Install valve cover with new gasket.
    ⚠Cylinder head bolts are TTY and must be replaced. Timing marks must be precisely aligned or severe engine damage will occur
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)

    Cover Bolts16 Nm (12 lb-ft)

Reassembly

1. Install all external engine accessories: alternator, starter, manifolds, fuel rail, ignition coils, and sensors
2. Verify all electrical connectors and sensors are reconnected correctly
3. Carefully lower engine into vehicle using engine hoist and align with transmission
4. Install engine mount bolts and torque mounting bolts to specifications
5. Reconnect transmission to engine bellhousing
6. Reconnect exhaust system to manifold
7. Install radiator, cooling fans, and A/C condenser
8. Reconnect all fuel lines, coolant hoses, vacuum lines, and electrical connections
9. Install air intake system, battery tray, and battery
10. Install new oil filter and fill engine with 5 quarts Toyota Genuine 0W-20 engine oil
11. Fill cooling system with 10 quarts Toyota Super Long Life Coolant (Pink)
12. Install oil drain plug with new crush washer and torque to 35 Nm (26 lb-ft)
13. Install plastic undercovers and engine cover
14. Reconnect negative battery cable

Verification

• Perform final visual inspection of all connections, hoses, and fasteners
• Verify oil level on dipstick is at full mark
• Remove ignition coils and disable fuel pump. Crank engine for 10 seconds to build oil pressure (oil pressure light should extinguish)
• Reinstall ignition coils and start engine. Monitor for unusual noises, vibrations, or leaks
• Allow engine to reach operating temperature and verify cooling system operation
• Check for oil and coolant leaks around all gasket surfaces
• Perform test drive and monitor engine performance under load
• Re-check all fluid levels after test drive and top off as needed
• Monitor oil consumption and engine performance for first 500 miles of break-in period
• Change engine oil and filter at 500 miles to remove break-in debris

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