TOYOTA SEQUOIA 2001 Service Repair Manual

A04852
Ridge
Reamer
A05096
A05095
1
2
4
8
6
3
5
97
10 EM±104
± ENGINE MECHANICALCYLINDER BLOCK
2683 Author: Date:
2005 SEQUOIA (RM1146U)
Reference
Connecting rod big end inside diameter:
Mark º1º55.000 to 55.006 mm (2.1654 to 2.1656 in.)
Mark º2º55.006 to 55.012 mm (2.1656 to 2.1658 in.)
Mark º3º55.012 to 55.018 mm (2.1658 to 2.1661 in.)
Mark º4º55.018 to 55.024 mm (2.1661 to 2.1663 in.)
Crankshaft crank pin diameter:
Mark º1º51.994 to 52.000 mm (2.0470 to 2.0472 in.)
Mark º2º51.988 to 51.994 mm (2.0468 to 2.0470 in.)
Mark º3º51.982 to 51.988 mm (2.0465 to 2.0468 in.)
Standard sized bearing center wall thickness:
Mark º2º1.487 to 1.490 mm (0.0585 to 0.0587 in.)
Mark º3º1.490 to 1.493 mm (0.0587 to 0.0588 in.)
Mark º4º1.493 to 1.496 mm (0.0588 to 0.0589 in.)
Mark º5º1.496 to 1.499 mm (0.0589 to 0.0590 in.)
Mark º6º1.499 to 1.502 mm (0.0590 to 0.0591 in.)
Mark º7º1.502 to 1.505 mm (0.0591 to 0.0593 in.)
(j) Completely remove the Plastigage.
21. REMOVE PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:

Keep the bearings, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in cor-
rect order.
22. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020 to 0.220 mm (0.0008 to 0.0087 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:
2.440 to 2.490 mm (0.0961 to 0.0980 in.)
23. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the 10 main bearing cap
bolts in several passes, in the sequence shown.

A05093
A05097
Plastigage
A05095
A05098
± ENGINE MECHANICALCYLINDER BLOCK
EM±105
2684 Author: Date:
2005 SEQUOIA (RM1146U)
(b) Using 2 screwdrivers, pry out the main bearing cap, and
remove the 5 main bearing caps, 5 lower bearings and 2
lower thrust washers (No.3 main bearing cap only).
NOTICE:
Be careful not to damage the cylinder block.
HINT:

Keep the lower bearing and main bearing cap together.

Arrange the main bearing caps and lower thrust washers
in correct order.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearings and upper thrust washers together
with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for peelings and
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing caps. (See page EM±119)
NOTICE:
Do not turn the crankshaft.
(i) Remove the main bearing caps.
(See procedure (a) and (b) above)
(j) Measure the Plastigage at its widest point.
Standard clearance:
No.1, No.5
0.028 to 0.046 mm (0.0011 to 0.0018 in.)
Others
0.040 to 0.058 mm (0.0016 to 0.0023 in.)
Maximum clearance: 0.065 mm (0.0026 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, replace the crankshaft.

A05089A05088A05090A05176
Number Mark
Number
Mark
Number
Mark No.1No.2 No.3No.4 No.5
No.1No.2
No.3
No.4No.5
Cylinder block (A)
Crankshaft (B)Use bearing
+
24 to 28 18 to 23 12 to 176 to 11 0 to 5 No.1, No.5
EXAMPLE:
Cylinder block º08º + Crankshaft º06º
= Total number 14 (Use bearing º5º)3
4
5
6
7 Mark
Cylinder block (A)
Crankshaft (B)Use bearing
+
24 to 28 18 to 23 12 to 176 to 11 0 to 5
EXAMPLE:
Cylinder block º08º + Crankshaft º06º
= Total number 14 (Use bearing º3º)3
4
5 1
2 Others
Mark EM±106
± ENGINE MECHANICALCYLINDER BLOCK
2685 Author: Date:
2005 SEQUOIA (RM1146U)
HINT:
If using a standard bearing, replace it with one having the same
number. If the number of the bearing cannot be determined, se-
lect the correct bearing by adding together the numbers im-
printed on the cylinder block and crankshaft, then refer to the
table below for the appropriate bearing number. There are 5
sizes of the standard bearings. For No.1 and No.5 position
bearings, use bearings marked º3º, º4º, º5º, º6º and º7º. For oth-
ers position bearings, use bearings marked º1º, º2º, º3º, º4º and
º5º.
Reference
Cylinder block main journal bore diameter (A):
Mark º00º72.000 mm (2.8346 in.)
Mark º01º72.001 mm (2.8347 in.)
Mark º02º72.002 mm (2.8347 in.)
Mark º03º72.003 mm (2.8348 in.)
Mark º04º72.004 mm (2.8348 in.)
Mark º05º72.005 mm (2.8348 in.)
Mark º06º72.006 mm (2.8349 in.)
Mark º07º72.007 mm (2.8349 in.)
Mark º08º72.008 mm (2.8350 in.)
Mark º09º72.009 mm (2.8350 in.)
Mark º10º72.010 mm (2.8350 in.)
Mark º11º72.011 mm (2.8351 in.)
Mark º12º72.012 mm (2.8351 in.)
Mark º13º72.013 mm (2.8352 in.)
Mark º14º72.014 mm (2.8352 in.)

A04862
± ENGINE MECHANICALCYLINDER BLOCK
EM±107
2686 Author: Date:
2005 SEQUOIA (RM1146U)Mark º15º
72.015 mm (2.8352 in.)
Mark º16º72.016 mm (2.8353 in.)
Crankshaft main journal diameter (B):
Mark º00º67.000 mm (2.6378 in.)
Mark º01º66.999 mm (2.6378 in.)
Mark º02º66.998 mm (2.6377 in.)
Mark º03º66.997 mm (2.6377 in.)
Mark º04º66.996 mm (2.6376 in.)
Mark º05º66.995 mm (2.6376 in.)
Mark º06º66.994 mm (2.6376 in.)
Mark º07º66.993 mm (2.6375 in.)
Mark º08º66.992 mm (2.6375 in.)
Mark º09º66.991 mm (2.6374 in.)
Mark º10º66.990 mm (2.6374 in.)
Mark º11º66.989 mm (2.6374 in.)
Mark º12º66.988 mm (2.6373 in.)
Standard bearing center wall thickness:
No.1 and No.5
Mark º3º2.487 to 2.490 mm (0.0979 ± 0.0980 in.)
Mark º4º2.490 to 2.493 mm (0.0980 ± 0.0981 in.)
Mark º5º2.493 to 2.496 mm (0.0981 ± 0.0983 in.)
Mark º6º2.496 to 2.499 mm (0.0983 ± 0.0984 in.)
Mark º7º2.499 to 2.502 mm (0.0984 ± 0.0985 in.)
Others
Mark º1º2.481 to 2.484 mm (0.0977 ± 0.0978 in.)
Mark º2º2.484 to 2.487 mm (0.0978 ± 0.0979 in.)
Mark º3º2.487 to 2.490 mm (0.0979 ± 0.0980 in.)
Mark º4º2.490 to 2.493 mm (0.0980 ± 0.0981 in.)
Mark º5º2.493 to 2.496 mm (0.0981 ± 0.0983 in.)
(k) Completely remove the Plastigage.
24. REMOVE CRANKSHAFT
(a) Lift up the crankshaft.
(b) Remove the 5 upper main bearings and 2 upper thrust
washers from the cylinder block.
HINT:
Arrange the main bearing caps, bearings and thrust washers in
correct order.
25. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.

A04873
A04860
A04887
A04888
EM±108
± ENGINE MECHANICALCYLINDER BLOCK
2687 Author: Date:
2005 SEQUOIA (RM1146U)
26. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
HINT:
Arrange the piston rings in correct order only.
27. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to approx. 60°C (140°F).
(c) Using a plastic±faced hammer and brass bar, lightly tap
out the piston pin and pin and remove the connecting rod.
HINT:

The piston and pin are a matched set.

Arrange the pistons, pins, rings, connecting rods and
bearings in correct order.

EM0EB±17
A04849
A04850A04210A04212A05178
Cylinder Block Side
Main Bearing Cap Side
A04853
± ENGINE MECHANICALCYLINDER BLOCK
EM±109
2688 Author: Date:
2005 SEQUOIA (RM1146U)
INSPECTION
1. CLEAN CYLINDER BLOCK
(a) Using a gasket scraper, remove all the gasket material
from the top surface of the cylinder block.
(b) Using a soft brush and solvent, thoroughly clean the cylin-
der block.
2. INSPECT CYLINDER BLOCK
(a) Inspect for flatness.
Using a precision straight edge and feeler gauge, mea-
sure the surfaces contacting the cylinder head and main
bearing cap for warpage.
Maximum warpage: 0.07 mm (0.0028 in.)
If warpage is greater than maximum, replace the cylinder block.
(b) Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 8 cylinders and re-
place all the 8 pistons. (See page EM±116) If necessary, re-
place the cylinder block.

A04211Mark 1, 2 or 3 Front
No.2 No.4 No.6 No.8
No.1 No.3 No.5 No.7
:
A04262A04851A05181
1
2
B
C
AThrust
Direction
Axial
Direction
10 mm
(0.39 in.)
10 mm
(0.39 in.) Front
1
2
1
A04852
Ridge
Reamer
A0513850 ± 64 mm (1.97 ± 2.52 in.) EM±110
± ENGINE MECHANICALCYLINDER BLOCK
2689 Author: Date:
2005 SEQUOIA (RM1146U)
(c) Inspect the cylinder bore diameter.
HINT:
There are 3 sizes of the standard cylinder bore diameter,
marked º1º, º2º and º3º accordingly. The mark is stamped on the
top of the cylinder block.
Using a cylinder gauge, measure the cylinder bore diame-
ter at positions A, B and C in the thrust and axial direc-
tions.
Standard diameter:
STD Mark º1º94.002 to 94.010 mm (3.7009 to 3.7012 in.)STD Mark 1
Mark º2º
94.002 to 94.010 mm (3.7009 to 3.7012 in.)
94.010 to 94.023 mm (3.7012 to 3.7017 in.)Mark 2
Mark º3º
94.010 to 94.023 mm (3.7012 to 3.7017 in.)
94.023 to 94.031 mm (3.7017 to 3.7020 in.)
Maximum diameter:
STD94.231 mm (3.7099 in.)
O/S 0.5094.731 mm (3.7296 in.)
If the diameter is greater than maximum, rebore all the 8 cylin-
ders and replace all the 8 pistons. (See page EM±116) If neces-
sary, replace the cylinder block.
(d) Remove the cylinder ridge.
If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,
grind the top of the cylinder.
(e) Using vernier calipers, measure the thread outside diam-
eter of the main bearing cap bolt.
Standard diameter:
10.760 to 10.970 mm (0.4236 to 0.4319 in.)
Minimum diameter: 10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the cap bolt.

A04877
A04878
A04879
A23367
Mark 1, 2 or 3 Mark 1, 2 or 3 LH Piston
RH Piston30.75 mmFront Mark
(1 Cavity)
Front Mark
(2 Cavities)
± ENGINE MECHANICALCYLINDER BLOCK
EM±111
2690 Author: Date:
2005 SEQUOIA (RM1146U)
3. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.
(c) Using solvent and a brush, thoroughly clean the piston.
NOTICE:
Do not use a wire brush.
4. INSPECT PISTON AND CONNECTING ROD
(a) Inspect the piston oil clearance.
HINT:
There are 3 sizes of the standard piston diameter, marked º1º,
º2º and º3º accordingly. The mark is stamped on the piston top.
(1) Using a micrometer, measure the piston diameter at
right angles to the piston pin center line, 30.75 mm
(1.2106 in.) from the piston head.
Piston diameter:
STD Mark º1º93.902 to 93.935 mm (3.6969 to 3.6982 in.)STD Mark 1
Mark º2º
93.902 to 93.935 mm (3.6969 to 3.6982 in.)
93.912 to 93.940 mm (3.6973 to 3.6984 in.)Mark 2
Mark º3º
93.912 to 93.940 mm (3.6973 to 3.6984 in.)
93.920 to 93.950 mm (3.6976 to 3.6988 in.)
O/S 0.5094.402 to 94.450 mm (3.7166 to 3.7185 in.)
(2) Measure the cylinder bore diameter in the thrust
directions (see step 2 above).

A23368
Cylinder Block
Front
No.2 No.4 No.6
No.8
No.1
No.5 No.7
RH Piston
No.3
:
LH PistonMark 1, 2 or 3
Mark 1, 2 or 3 Mark 1, 2 or 3
Front
Mark
(1 Cavity)
Front
Mark
(2 Cavities)
A04880
EM±112
± ENGINE MECHANICALCYLINDER BLOCK
2691 Author: Date:
2005 SEQUOIA (RM1146U)
(3) Subtract the piston diameter measurement from the
cylinder bore diameter measurement.
Standard oil clearance:
0.030 to 0.071 mm (0.0012 to 0.0028 in.)
Maximum oil clearance: 0.13 mm (0.0051 in.)
If the oil clearance is greater than maximum, replace all the 8
pistons and rebore all the 8 cylinders. (See page EM±116) If
necessary, replace the cylinder block.
HINT
Use a new cylinder block:

Use a piston with the same number mark as the cylinder
diameter number marked on the cylinder block.

The shape of the piston differs for the LH and RH banks.
The LH piston is marked with 1 cavity and º2º, the RH pis-
ton with 2 cavities and º2º.
(b) Inspect the piston ring groove clearance.
Using a feeler gauge, measure the clearance between
the new piston ring and the wall of the ring groove.
Ring groove clearance:
No.10.030 to 0.080 mm (0.0012 to 0.0031 in.)
No.20.020 to 0.060 mm (0.0008 to 0.0024 in.)
If the clearance is not as specified, replace the piston.

A04872
105 mm
EM7639
A04048
60°C
Z14454
± ENGINE MECHANICALCYLINDER BLOCK
EM±113
2692 Author: Date:
2005 SEQUOIA (RM1146U)
(c) Inspect the piston ring end gap.
(1) Insert the piston ring into the cylinder bore.
(2) Using a piston, push the piston ring a little to the bot-
tom of the ring travel, 105 mm (4.13 in.) from the top
of the cylinder block.
(3) Using a feeler gauge, measure the end gap.
Standard end gap:
No.10.300 to 0.400 mm (0.0118 to 0.0157 in.)
No.20.400 to 0.550 mm (0.0157 to 0.0217 in.)
Oil (Side rail)0.130 to 0.380 mm (0.0051 to 0.0150 in.)
Maximum end gap:
No.11.10 mm (0.0433 in.)
No.21.30 mm (0.0512 in.)
Oil (Side rail)0.90 mm (0.0354 in.)
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, rebore all the 8 cylinders (See page EM±116) or replace
the cylinder block.
(d) Inspect the piston pin fit.
At 60°C (140°F), you should be able to push the piston
pin into the piston pin hole with your thumb.
(e) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Check for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If bend is greater than maximum, replace the connecting rod as-
sembly.