Hello everyone.

I recently and knowingly bought a 4th Gen (248k miles) with engine knock, and with the intent of rebuilding it. I have always wanted to rebuild and engine.

Out of curiosity, I had a Toyota dealership look at it.
"Engine knocking #4 cylinder has 0 compression due to internal engine failure. Recommend replacing engine with used engine."

I was quoted 7K for a used engine with 173k miles. I literally asked the service agent what he was smoking so he said he will call me back with another option. He came back with an 80k mile engine for 9K. When I asked what it would cost if they rebuild the engine, he said that the cost savings will be about $100. Even if that is true, I believe that doing the job myself will be a more rewarding experience.

So, my plan is to pull the engine out by the weekend and take it apart. Does anyone know where I can *cough* dl a 2005 service manual? I currently have '03, '04 and I think '06.
The heads and block will go to the machine shop to be hot tanked, resurfaced, etc. Could someone recommend a good machine shop in the Aurora/Denver area?

Any advice/tips in general.. on marking/labeling parts so they go back in the original spot? I have most of the tools needed for the job and a co-worker is going lend me his hoist and stand for the engine. I might need a crow's foot tool set and a magnetic spark plug socket.

I want to keep this vehicle in the family for the foreseeable future so I am willing to put in work.


Looking forward to reading your posts.

bz

I don't have any advice but please do share the process with us.

I think the 03/04 service manual should be the same as the 05

Have you called any dismantlers on what used engine would cost you? You will NEVER rebuild it back to original toyota specs. These engines are precisely built in clean rooms by experts. It may sound like fun until it grenades on you. Just sayin

Disagree on not being able to build it back to "original toyota specs" and the engines being "built in clean rooms."

Toyota published specs so the engine could be rebuilt to "original toyota specs," which is completely obvious. These are not complex engines and none of the specs require capabilities outside the realm of a competent machinist and mechanic. There might be special tools for some aspects, like maybe the valve timing assembly, but even so, you can get the tools and build it to spec. The tolerances on these engines are not hard to achieve if you use good practices.

As for clean rooms, do you have evidence of this? A positive pressure clean room is a huge expense. Toyota produced a reliable engine for mass production, not a low production cutting edge technological trophy piece. Its a light truck engine put in a $30k chassis in the mid 2000s.

There is a good reason why these engines can go 1 million miles. And its not because they were built in a home garage. Have at it if you have the time. For me, Id trust a used engine over anything I could rebuild. And save money in the end.

I agree with everything @triethylborane said

I worked for a large diesel engine manufacturer known for making quality engines in pickups, medium and heavy duty trucks, etc. No clean rooms were used, and everything is put together on an assembly line without fancy tools. Now a rebuild would of course need a little bit of machining, but you're not doing anything crazy like milling the head from a solid chunk.

I'd say go for it OP, especially if you aren't depending on it for a daily driver and can let it sit for a bit while working through the project. Definitely take a lot of pictures and post them up for us all to see

I have rebuilt many engines in my life and all had a very long life after the rebuilds and I wouldn't hesitate to rebuilt any engine, all you need to have is a reasonably clean environment/garage/work area for the final stages to do a rebuild, it's very easy to clean and or keep clean any internal parts until you seal everything up.

Alright folks. I think I am ready to start. Just realized that I need to create a tapatalk account to upload photos from my mobile device.
Will upload some photos later.

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Here are some general photos.Attachment 1

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Smdh....

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Let's begin..

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Whoops.....

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FYI OP, I just did a quick search of your area for used engines and found one for $2500.

IMO, I don't have the skills to rebuild an engine, but I sure as hell would re/re one fast if I had to for much cheaper.

This is where I found the engines: Search Results

Also, if you are looking for V6 engines....go for one that has no head gasket issues. So that would be 06-09' that you're looking for.

Looking forward to see what you find. Good job getting those exhaust manifold bolts off but maybe easier in CO.