width TOYOTA SEQUOIA 2001 Service User Guide

A21016
No.1
No.2
Code Mark 2R
A23370
Lower
Side
Rail
Front
Mark
(1 Cavity)
Upper Side Rail
No. 1 CompressionExpander LH PistonNo. 2 Compression
Lower
Side
Rail
Front
Mark
(2 Cavities)
Upper Side RailNo. 1 Compression No. 2 Compression RH Piston
Expander
45° 45° 45° 45°
60°
60°
60°
60°
EM6484
A04846
Upper
Lower
22.5 mm19.5 mm No.1 and No.5 Others
EM±120
± ENGINE MECHANICALCYLINDER BLOCK
2699 Author: Date:
2005 SEQUOIA (RM1146U)
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings.
Code mark:
No.1None
No.22R
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the ring ends
.
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
4. INSTALL MAIN BEARINGS
HINT:

Main bearings are of 19.5 mm (0.768 in.) and 22.5 mm
(0.886 in.) in width. Install the 22.5 mm (0.886 in.) bear-
ings in the No.1 and No.5 cylinder block journal positions
with the main bearing cap. Install the 19.5 mm (0.768 in.)
bearings in the other positions.

Upper bearings have an oil groove and oil holes, but lower
bearings do not.

A04848
Seal Width
3 ± 4 mm A
BA
B
A04855
New O±Ring
P12477
Seal Packing EM±124
± ENGINE MECHANICALCYLINDER BLOCK
2703 Author: Date:
2005 SEQUOIA (RM1146U)
14. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contacting surfaces of the oil
seal retainer and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) materials from the gasket
surfaces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent

Install a nozzle that has been cut to a 3 ± 4 mm (0.12
± 0.16 in.) opening.

Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install a new O±ring to the cylinder block.
(d) Install the oil seal retainer with the 7 bolts.
Torque: 8.0 N´m (80 kgf´cm, 71 in.´lbf)
15. INSTALL ENGINE COOLANT DRAIN UNIONS
(a) Apply seal packing to 2 or 3 threads.
Seal packing: Part No. 08826±00100 or equivalent

CO0IT±06
B04463
Connect
New O±Ring
B03030
Seal Width
2 ± 3 mm
New O±Ring
CO±8
± COOLINGWATER PUMP
2824 Author: Date:
2005 SEQUOIA (RM1146U)
INSTALLATION
1. INSTALL WATER PUMP
(a) Install a new O±ring to the water bypass pipe end.
(b) Apply soapy water to the O±ring.
(c) Connect the water pump to the water bypass pipe end.
(d) Install the water pump and a new gasket with the 5 bolts,
2 stud bolts and nut. Uniformly tighten the bolts, stud bolts
and nut in several passes.
Torque:
Bolt: 21 N´m (215 kgf´cm, 15 ft´lbf)
Stud bolt and nut: 18 N´m (185 kgf´cm, 13 ft´lbf)
2. INSTALL WATER INLET AND INLET HOUSING AS-
SEMBLY
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water in-
let housing and water pump.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.

Thoroughly clean all components to remove all the
loose material.

Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the sealing groove of water inlet
housing as shown in the illustration.
Seal packing: Part No. 08826±00100 or equivalent

Install a nozzle that has been cut to a 2 ± 3 mm (0.08
± 0.12 in.) opening.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install a new O±ring to the water inlet housing.
(d) Apply soapy water on the O±ring.
(e) Attach the water inlet housing end to the front water by-
pass joint hole.

LU0GY-06
B13060
Seal Width
2 - 3 mmA
B
A
B
P21388
New O-Ring
Engage
B00950
A
B C
DE
AAA
- LUBRICATIONOIL PUMP
LU-15
2849 Author
: Date
:
2005 SEQUOIA (RM1146U)
INSTALLATION
1. INSTALL OIL PUMP
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil pump
and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil pump as shown in the illustra-
tion.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Avoid applying an excessive amount to the surface. Be par-
ticularly careful near oil passage.

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install a new O-ring to the cylinder block.
(d) Engage the spline teeth of the oil pump drive gear with the
large teeth of the crankshaft, and slide the oil pump on the
crankshaft.
(e) Install the oil pump with the 8 bolts. Uniformly tighten the
bolts in several passes.
Torque:
30.5 N´m (310 kgf´cm, 22 ft´lbf) for 14 mm head
15.5 N´m (160 kgf´cm, 11 ft´lbf) for others

B05842
B13061
A
B
Seal Width
2 - 3 mm A
B LU-16
- LUBRICATIONOIL PUMP
2850 Author
: Date
:
2005 SEQUOIA (RM1146U)
HINT:

Use a 6 mm hexagon wrench for the hexagon head bolt.

Each bolt length is indicated in the illustration.
Bolt length:
35 mm (1.38 in.) for A of 12 mm head
50 mm (1.97 in.) for B of 12 mm head
106 mm (4.17 in.) for C of 12 mm head
40 mm (1.57 in.) for D of 14 mm head
30 mm (1.18 in.) for E of 6 mm hexagon head
2. INSTALL OIL STRAINER
Install a new gasket and the oil strainer with the 2 bolts and 2
nuts.
Torque: 7.5 N´m (76 kgf´cm, 66 in.´lbf)
3. INSTALL NO.1 OIL PAN
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the No.1 oil
pan, cylinder block, oil pump and rear oil seal retainer.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the No.1 oil pan as shown in the il-
lustration.
Seal packing: Part No. 08826-00080 or equivalent

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.

B07335
A
B
A
A
A
BBBC
BBBB
C
CC
D
D
B05839
B05845
AB
Seal Width
2 - 3 mm A
B
- LUBRICATIONOIL PUMP
LU-17
2851 Author
: Date
:
2005 SEQUOIA (RM1146U)
(c) Temporarily install the No.1 oil pan with the 18 bolts, stud
bolt and 2 nuts.
HINT:
Each bolt length is indicated in the illustration.
Bolt length:
20 mm (0.79 in.) for A of 10 mm head
25 mm (0.98 in.) for B of 12 mm head
60 mm (2.36 in.) for C of 12 mm head
35 mm (1.38 in.) for D of 10 mm head
(d) Set the No.1 oil pan as shown in the illustration.
NOTICE:
Make sure the clearance between the rear ends of the No.1
oil pan and cylinder block is 0.2 mm (0.008 in.) or less. If the
clearance is more than 0.2 mm (0.008 in.), the No.1 oil pan
will be stretched.
(e) Uniformly tighten the bolts, and nuts in several passes.
Torque:
7.5 N´m (76 kgf´cm, 66 in.´lbf) for 10 mm head
28 N´m (290 kgf´cm, 21 ft´lbf) for 12 mm head
4. INSTALL OIL PAN BAFFLE PLATE
Install the baffle plate with the 7 bolts and 2 nuts.
Torque: 7.5 N´m (76 kgf´cm, 66 in.´lbf)
5. INSTALL NO.2 OIL PAN
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the No.1 and
No.2 oil pans.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.
NOTICE:
Do not use a solvent which will affect the painted surfaces.
(b) Apply seal packing to the No.2 oil pan as shown in the il-
lustration.
Seal packing: Part No. 08826-00080 or equivalent

Install a nozzle that has been cut to a 3 - 4 mm (0.12
- 0.16 in.) opening.

TR0DI±01
F19284
A B C D
F19286
± TRANSFERREAR OUTPUT SHAFT
TR±29
2967 Author: Date:
2005 SEQUOIA (RM1146U)
INSPECTION
1. INSPECT OUTPUT SHAFT REAR
Using a micrometer, measure the outer diameter of the output
shaft rear journal surface.
Standard diameter:
Part A: 27.98 to 27.99 mm (1.1016 to 1.1020 in.)
Part B: 31.98 to 32.00 mm (1.2591 to 1.2598 in.)
Part C: 34.98 to 35.00 mm (1.3772 to 1.3780 in.)
Part D: 36.98 to 37.00 mm (1.4559 to 1.4567 in.)
Minimum diameter:
Part A: 27.98 mm (1.1016 in.)
Part B: 31.98 mm (1.2591 in.)
Part C: 34.98 mm (1.3772 in.)
Part D: 36.98 mm (1.4559 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft rear.
2. INSPECT FRONT DRIVE CLUTCH SLEEVE AND
GEAR SHIFT FORK NO. 1 CLEARANCE
(a) Using vernier calipers, measure the thickness of the gear
shift fork No. 1 claw.
Thickness: 10 mm (0.3937 in.)
(b) Using vernier calipers, measure the width of the groove
of the front drive clutch sleeve.
Width: 10.5 mm (0.4134 in.)
(c) Calculate the clearance between the front drive clutch
sleeve and gear shift fork No. 1.
Standard clearance:
0.26 to 0.84 mm (0.0102 to 0.0331 in.)
Maximum clearance:
0.84 mm (0.0331 in.)
If the clearance exceeds the maximum, replace the front drive
clutch sleeve or gear shift fork No. 1.

F19285
F19288
F19287
TR±30
± TRANSFERREAR OUTPUT SHAFT
2968 Author: Date:
2005 SEQUOIA (RM1146U)
3. INSPECT HIGH AND LOW CLUTCH SLEEVE AND
GEAR SHIFT FORK NO. 2 CLEARANCE
(a) Using vernier calipers, measure the thickness of the gear
shift fork No. 2 claw.
Thickness: 10 mm (0.3937 in.)
(b) Using vernier calipers, measure the width of the groove
of the high and low clutch sleeve.
Width: 10.5 mm (0.4134 in.)
(c) Calculate the clearance between the high and low clutch
sleeve and gear shift fork No. 1.
Standard clearance:
0.26 to 0.84 mm (0.0102 to 0.0331 in.)
Maximum clearance:
0.84 mm (0.0331 in.)
If the clearance exceeds the maximum, replace the high and
low clutch sleeve or gear shift fork No. 2.
4. INSPECT CENTER DIFFERENTIAL CASE AND FRONT
DRIVE CLUTCH SLEEVE
(a) Check that the tip of the spline gear of the front drive
clutch sleeve is not worn.
(b) Install the front drive clutch sleeve to the center differen-
tial case and check that the front drive clutch sleeve
moves smoothly.
5. INSPECT CENTER DIFFERENTIAL CASE AND HIGH
AND LOW CLUTCH SLEEVE
(a) Check that the tip of the spline gear of the front drive
clutch sleeve is not worn.
(b) Install the front drive clutch sleeve to the center differen-
tial case and check that the front drive clutch sleeve
moves smoothly.

F19908
Color
Bearing
CapDrill MarkYoke
Z00735
PR0027
SST
PR0028
± PROPELLER SHAFTSPIDER BEARING
PR±11
2994 Author: Date:
2005 SEQUOIA (RM1146U)
4. 4WD, REAR PROPELLER SHAFT:
SELECT SPIDER BEARING
Select an appropriate bearing according to the drill mark on the
yoke.
YokeBearing
With drill markWith color mark (White)
No drill markNo color mark
5. INSTALL SPIDER BEARING
(a) Apply MP grease to a new spider and bearings.
HINT:
Be careful not to apply too much grease.
(b) Align the matchmarks on the yoke and shaft.
(c) Fit the spider into the yoke.
(d) Using SST, install the bearing on the spider.
SST 09332±25010
(e) Using SST, adjust both bearings so that the snap ring
grooves are at maximum and equal in width.

R13763
10 m (33 ft) or more SSTBattery
H00401Weight
X Y
Y
H23914
Inner Diam.
Tires
(3 or More)Width RS±28
± SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
3311 Author: Date:
2005 SEQUOIA (RM1146U)
(2) Move the SST at least 10 m (33 ft) away from the
steering wheel pad tied down to the disc wheel.
(e) Cover the steering wheel pad with a cardboard box or
tires.
Covering method using cardboard box:
Cover the steering wheel pad with the cardboard box and
place the weights on the cardboard box in 4 places total-
ling at least 190 N (19 kg, 43 lb).
Cardboard box size:
Must exceed the following dimensions:
X = 460 mm (18.11 in.)
Y = 650 mm (25.59 in.)
NOTICE:

When dimension Y of the cardboard box exceeds the
diameter of the disc wheel with tire which the steering
wheel pad is tied to, X should be the following size.
X = 460 mm (18.11 in.) + width of tire

If a cardboard box smaller than the specified size is
used, the cardboard box will be broken by the shock
from the airbag deployment.

Covering method using tires:
Place at least 3 tires without disc wheels on the tire
with disc wheel which the steering wheel pad is tied
to. Place the tire with disc wheel on them.
Tire size: Must exceed the following dimensions:
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:
Do not use tires with disc wheels except on the top and bot-
tom.
NOTICE:

The tires may be marked by the airbag deployment,
so use the redundant tires.

Do not place the SST connector under the tire be-
cause it could be damaged.