Gen 2 engine rebuild thread.

Preliminary cylinder head separation pics.
The socket, which was over $60 with shipping from Snap On. Not only do they overcharge on tools, they overcharge on shipping. It was $22.95 UPS Ground 1 state away, when the actual cost was about $12.



Valves.


One of the cylinder bores. You can see the dark stains from blow by.




Also keep in mind how gunked up everything is? I ran 4 tanks with fuel injector cleaner in it, Techron to be exact.

 

No pitting as far as I can tell.

 

From what I'm reading and I'll have to check, your not even suppose to hone the cylinders due to some kind of silicon coating on the bore. Machine shop said this kind of block can't be bored over because the connecting rods run at a slight angle and boring over will change that angle.

Luckily I had a new one on the way, but I might of ruined the VVT solenoid, I put just the tip in my ultrasonic cleaner which turned it into an electromagnet, and the ohm reading isn't with spec.

Here is the stuff I use to clean bolts and stuff, this will strip all grease right off.




I might get new main and rod bearings, they aren't much aftermarket. Like $60.

I've been smart and bagging/labeling the bolts.

 

Forgot to mention, the engine mostly sounds the SAME when you start it with the injectors and spark plugs disconnected.

The hardest part about doing this rebuilding will be adjusting the lifters. There's not much room for play, and if one is out of adjustment, you have to order a different one, from 35, yes 35 different sizes through Toyota.

The exhaust manifold bolts/nuts on both engines were in poor shape, luckily the intake manifold bolts/nuts are the same ones. Going to try and keep as many bolts as possible since they are nearly $2 EACH from Toyota.

 

Also, why does Toyota sell the oil pump with the timing chain cover as one piece, when it looks like it can come apart?

 

Donor engine right after removing the timing cover.


The oil pump bolts seem sealed somehow. Used an impact and started striping the heads, so I stopped.
After cleaning. The degreaser dulls aluminum a bit.


Seal removed.



Got the head off, the tops of the pistons seem to have less carbon than mine did. So hopefully the block has less wear.

 

Can anyone find the part number for the clips that hold the crankshaft position sensor wiring to the timing cover?

 

Anyone?

 

No luck. Problem is Toyota groups things weird. Tried looking in engine, sensors, wiring, wiring harness, etc.

I noticed a revision, the 06 intake has a blocked off vacuum port, the 08 doesn't. I'm not sure if the 04-05's had a vacuum system the later one's didn't need?



This coolant pipe is a bit rusty, surely a new one can't be expensive, right? It's just a metal tube..



$62?!? Nevermind...

Also, here is the best diagram of the myriad of coolant hoses I've ever seen.

 

Some of the parts are insane.

This input dampener? A new one is $636. Just...why?

 

Monday both the donor engine bock and the block from my car are going to the shop to see which cylinder walls have more wear.
Got the crankshaft main bearing caps, connecting rod bolts and main bearing cap bolts cleaned up.


The donor engine has some rust on the walls, which I'm hoping can be fixed.

 

The main bearing caps are numbered 1-5 with a bulge on the cast pointing to the front of the engine. The connecting rod caps and rods themselves have a letter "U" stamped at different angles so matching them up is as simple as making the letter U legible.

I also am going to have to order a new oil pan, because the stuff they use is extremely strong to seal it, and there was no flanges to slightly tap it off. It's called FPIG and it has 300 PSI of holding strength.

I also can't find any real info online if they coated the cylinders on this engine or not. For some odd reason Toyota doesn't seem to list it. But you also can't easily get oversized pistons for it.

 

That sounds about right. Lined cylinders are a $$@#$@ nightmare because either they can't be honed AT ALL or you have to use some expensive diamond hone.