Toyota Sequoia (2005). Manual - part 675

A04211

Mark 1, 2 or 3

Front

No.2

No.4

No.6

No.8

No.1

No.3

No.5

No.7

:

A04262

A04851

A05181

1

2

B

C

A

Thrust 
Direction

Axial
Direction

10 mm
(0.39 in.)

10 mm
(0.39 in.)

Front

1

2

1

A04852

Ridge
Reamer

A05138

50 – 64 mm (1.97 – 2.52 in.)

EM–110

–

ENGINE MECHANICAL

CYLINDER BLOCK

2689

(c)

Inspect the cylinder bore diameter.

HINT:
There are 3 sizes of the standard cylinder bore diameter,
marked ”1”, ”2” and ”3” 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  ”1”

94.002 to 94.010 mm (3.7009 to 3.7012 in.)

STD

Mark   1

Mark  ”2”

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  ”3”

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:

STD

94.231 mm (3.7099 in.)

O/S 0.50

94.731 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 Piston

30.75 mm

Front Mark
(1 Cavity)

Front Mark
(2 Cavities)

–

ENGINE MECHANICAL

CYLINDER BLOCK

EM–111

2690

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 ”1”,
”2” and ”3” 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 ”1”

93.902 to 93.935 mm (3.6969 to 3.6982 in.)

STD

Mark  1

Mark ”2”

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 ”3”

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 0.50

94.402 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 Piston

Mark 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 MECHANICAL

CYLINDER BLOCK

2691

(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 ”2”, the RH pis-
ton with 2 cavities and ”2”.

(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.1

0.030 to 0.080 mm (0.0012 to 0.0031 in.)

No.2

0.020 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 MECHANICAL

CYLINDER BLOCK

EM–113

2692

(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.1

0.300 to 0.400 mm (0.0118 to 0.0157 in.)

No.2

0.400 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.1

1.10 mm (0.0433 in.)

No.2

1.30 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.