Engine Mechanical: Overhaul Toyota Sequoia I

REASSEMBLY

Note. Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace all gaskets and oil seals with new ones.

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1. Install spark plug tubes: Apply adhesive to the end of the spark plug tube. (Scheme 27) Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent. NOTE: Avoid tapping a new spark plug tube too far for measuring the amount of the protrusion while tapping. Using a wooden block and hammer, tap in a new spark tube until there is 40.9 - 42.1 mm (1.610 - 1.658 in.) protruding from the camshaft bearing cap installation surface of the cylinder head. (Scheme 28)
2. Install valves: Using SST, push in a new oil seal. (Scheme 29) SST 09201-41020. NOTE: Numbers correspond to callouts in illustration. Install the valve (1), spring seat (2), valve spring (3) and spring retainer (4). (Scheme 30) Using SST, compress the valve spring and place the 2 keepers around the valve stem. (Scheme 31) SST 09202-70020 (09202-00010). CAUTION: Be careful not to damage the valve stem tip. Using a plastic-faced hammer and the valve stem (not in use) tip wound with vinyl tape, lightly tap the valve stem tip to assure proper fit. (Scheme 32)
3. Install shims and valve lifters: Install the shim and valve lifter. Check that the valve lifter rotates smoothly by hand.

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1. Install RH exhaust manifold to cylinder head: NOTE: Be careful of the installation direction. Place a new gasket on the cylinder head with the white painted marks facing the manifold side. (Scheme 33) Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes. see scheme 76 Torque: 44 N.m (450 kgf.cm, 32 ft.lbf). Install the heat insulator with the 4 bolts. Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf).
2. Install LH exhaust manifold to cylinder head: NOTE: Be careful of the installation direction. Place a new gasket on the cylinder head with the white painted marks facing the manifold side. (Scheme 34) Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes. see scheme 77 Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) Install the heat insulator with the 4 bolts. Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf).
3. Place cylinder heads on cylinder block: NOTE: On the rear side of the cylinder head gasket are marks to distinguish the LH and RH banks, a "2UR" mark for the RH bank and a "2UL" mark for the LH bank. (Scheme 35) Be careful of the installation direction. Place 2 new cylinder head gaskets in position on the cylinder block. Place the 2 cylinder heads in position on the cylinder head gaskets.
4. Install cylinder head bolts: Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. Install the plate washer to the cylinder head bolt. NOTE: Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan. see scheme 74 Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes in the sequence shown, then do the other side as shown. (Scheme 36) Torque: 32 N.m (325 kgf.cm, 24 ft.lbf) If any of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. Mark the front of the cylinder head bolt with paint. (Scheme 37) Retighten the cylinder head bolts by 180 degrees in the numerical order shown. (Scheme 36) Check that the painted mark is now at a 180 degree angle to front.
5. Install spark plugs.
6. Assemble exhaust camshaft: NOTE: Attach the pins on the gears to the gear spring ends. (Scheme 38) Install the camshaft gear spring, camshaft sub-gear and wave washer. Using snap ring pliers, install the snap ring. (Scheme 39) CAUTION: Be careful not to damage the camshaft. Mount the hexagon wrench head portion of the camshaft in a vise. see scheme 69 Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt. SST 09960-10010 (09962-01000, 09963-00500). Align the gear teeth of the main gear and sub-gear, and tighten the service bolt. (Scheme 40)
7. Install camshaft housing plugs: Remove any old packing (FIPG) material. Apply seal packing to the camshaft housing plug grooves. (Scheme 41) Seal packing: Part No. 08826-00080 or equivalent. Install the 2 camshaft housing plugs to the cylinder heads. (Scheme 42)
8. Install camshafts: Install the RH camshafts. Apply MP grease to the thrust portion of the intake and exhaust camshafts. Place the intake and exhaust camshafts. Set the timing mark (1 dot mark) of the camshaft main gear at approx. 10 degree angle. see scheme 63 Remove any old packing (FIPG) material from front bearing cap. NOTE: Do not apply seal packing to the front bearing cap grooves. Apply seal packing to the front bearing cap as shown in the illustration. (Scheme 43) Seal packing: Part No. 08826-00080 or equivalent. - Install a nozzle that has been cut to a 1.5 mm (0.06 in.) opening. - Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. - Immediately remove nozzle from the tube and reinstall cap. NOTE: Installing the front bearing cap will determine the thrust portion of the camshaft. Install the front bearing cap. NOTE: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap. Install the other bearing caps in the sequence shown with the arrow mark facing forward. (Scheme 44) Push in the camshaft oil seal. (Scheme 45) NOTE: Each bolts length and position corresponds to an identification letter indicated in the illustration. (Scheme 46) Bolt Lengths: - Bolt "A" 25 mm (0.98 in.). - Bolt "B" 38 mm (1.50 in.). - Bolt "C" 52 mm (2.05 in.). - Bolt "D" 72 mm (2.83 in.). - Bolt "E" 94 mm (3.70 in.). Torque: Bolt A: 7.5 N.m (80 kgf.cm, 69 in..lbf). Others: 16 N.m (160 kgf.cm, 12 ft.lbf). Apply a light coat of engine oil on the threads and under the heads (D and E) of the bearing cap bolts. (Scheme 46) Do not apply engine oil under the heads of the bearing cap bolt (A), (B) and (C). Install the oil feed pipe the 22 bearing cap bolts as shown. (Scheme 46) Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown. See Note in step 9 and (Scheme 46). Boring the service bolt installed in the driven subgear upward by turning the hexagon wrench head portion of the camshaft with a wrench. see scheme 61 Remove the service bolt. Install the LH camshafts. Apply MP grease to the thrust portion of the intake and exhaust camshafts. Place the intake and exhaust camshafts. Engage the intake gear to the exhaust gear by meeting the timing marks (2 dot marks) on each gear. (Scheme 48) Remove any old packing (FIPG) material. NOTE: Do not apply seal packing to the front bearing cap grooves. Apply seal packing to the front bearing cap. Seal packing: Part No. 08826-00080 or equivalent. - Install a nozzle that has been cut to a 1.5 mm (0.06 in.) opening. - Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. - Immediately remove nozzle from the tube and reinstall cap. NOTE: Installing the front bearing cap will determine the thrust portion of the camshaft. Install the front bearing cap. see scheme 159 NOTE: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap. Install the other bearing caps in the sequence shown with the arrow mark facing forward. Push in the camshaft oil seal. see scheme 160 NOTE: Each bolts length and position corresponds to an identification letter indicated in the illustration. see scheme 161 Bolt Lengths: - Bolt "A" 25 mm (0.98 in.). - Bolt "B" 38 mm (1.50 in.). - Bolt "C" 52 mm (2.05 in.). - Bolt "D" 72 mm (2.83 in.). - Bolt "E" 94 mm (3.70 in.). Torque: Bolt A: 7.5 N.m (80 kgf.cm, 69 in..lbf). Others: 16 N.m (160 kgf.cm, 12 ft.lbf). Apply a light coat of engine oil on the threads and under the heads (D and E) of the bearing cap bolts. see scheme 161 Do not apply engine oil under the heads of the bearing cap bolt (A), (B) and (C). Install the oil feed pipe the 22 bearing cap bolts as shown. see scheme 161 Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown. See Note in step 9 and see scheme 162. Boring the service bolt installed in the driven subgear upward by turning the hexagon wrench head portion of the camshaft with a wrench. see scheme 65 Remove the service bolt.
9. Check and adjust valve clearance. Turn the camshaft and position the cam lobe upward, and check and adjust the valve clearance.
10. Install semi-circular plugs: Remove any old packing (FIPG) material. Apply seal packing to the semi-circular plug grooves. see scheme 164 Seal packing: Part No. 08826-00080 or equivalent Install the 4 semi-circular plugs to the cylinder heads. see scheme 165
11. Install cylinder head covers: Remove any old packing (FIPG) material. Apply seal packing to the cylinder heads as shown in the illustration. see scheme 166 Seal packing: Part No. 08826-00080 or equivalent Install the gasket to the cylinder head cover. Install the seal washer to the bolt. Install the cylinder head cover with the 18 bolts. Uniformly tighten the bolts in several passes. Install the 2 cylinder head covers. Torque: 6.0 N.m (60 kgf.cm, 53 in.lbf).
12. Install engine hangers. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf).
13. Install oil dipstick and guide for engine.
14. Install rear water bypass joint: Install 2 new gaskets to the cylinder head. Install the 4 nuts holding the water bypass joint to the cylinder heads. Alternately tighten the nuts. see scheme 167 Torque: 18 N.m (185 kgf.cm, 13 ft.lbf).
15. Install front water bypass joint: Install 2 new gaskets and the water bypass joint with the 4 nuts. Alternately tighten the nuts. see scheme 168 Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) Connect the ECT sensor and water sender gauge connectors.
16. Install water inlet and inlet housing assembly.
17. Assemble upper and lower intake manifolds: Install the 2 delivery pipes and 8 injectors. Install new 2 gaskets, fuel pressure regulator and fuel pulsation damper. see scheme 56 Install the fuel return hose to the lower intake manifold with the 3 bolts. Connect the fuel return hose to the fuel pressure regulator. Install the EVAP pipe to the intake manifold with the 2 bolts. see scheme 55 Install new 2 gaskets, union and brake booster tube to the upper intake manifold with the bolt. Install the accelerator cable clamp and VSV for EVAP to the upper intake manifold and connect the EVAP hose. see scheme 54 Install a new gasket and upper intake manifold with the 13 bolts and 3 nuts. Install the throttle body.
18. Install intake manifold assembly: NOTE: Align the port holes of the gasket and cylinder head. Be careful of the installation direction. Place 2 new gaskets on the cylinder heads with white painted mark facing upward. see scheme 169 Place the intake manifold assembly on the cylinder heads. Install and uniformly tighten the 6 bolts and 4 nuts in several passes. see scheme 53 Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) Install the accelerator cable bracket to the intake manifold with the 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf). Install the throttle body cover bracket to the intake manifold. see scheme 52 Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) Install the wire bracket to the intake manifold. Connect the engine wire to the engine hanger and wire bracket. Install the engine wire to the LH No. 1 timing belt rear plate. Connect the wire protector to the rear water bypass joint and RH and LH cylinder heads with the 3 bolts. see scheme 51 Install the 2 ground cables to the RH and LH cylinder heads. Install the guide for the A/T bracket to the LH cylinder head. Connect the No. 1 water bypass hose (from water inlet housing) from the throttle body. see scheme 49 Connect the 2 wire clamps to the throttle body. Connect the 2 wire clamps to the wore clamp bracket on the RH delivery pipe. see scheme 50 Connect the accelerator cable to the throttle body.
19. Connect hoses to intake manifold: NOTE: Letters in illustration correspond to following steps. Connect the vacuum hose to the pipe. see scheme 48 Connect the PCV hose to the PCV valve on the LH the cylinder head. Connect the EVAP hose (from charcoal canister) to the VSV for EVAP. Connect the EVAP hose (from charcoal canister) to the EVAP pipe on the intake manifold. Connect the EVAP hose (from intake air connector) to the EVAP pipe on the intake manifold. Connect the PS air hose to the intake manifold. Connect the brake booster tube.
20. Connect connectors to intake manifold: Connect the throttle position sensor connector. Connect the accelerator pedal position sensor connector. Connect the throttle motor connector. Connect the VSV connector for the EVAP. Connect the 8 injector connectors. Connect the ECT sensor connector. Connect the water sender gauge connector. Connect the 8 ignition coil connectors. Connect the 2 heated oxygen sensor connectors.
21. Connect fuel inlet hose and fuel return hose.
22. Install timing belt rear plates: Install the RH timing belt rear plates. Install the No. 1 timing belt rear plate to the cylinder head with the 3 bolts and stud bolt. Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf). Install the LH timing belt rear plates: Connect the wire clamp to the No. 1 timing belt rear plate. Install the No. 1 timing belt rear plate to the cylinder head with the 3 bolts. Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf).
23. Install throttle body cover.
24. Install ignition coils.
25. Install oil dipstick and guide for A/T.
26. Install front exhaust pipe. see scheme 307
27. Install PS pump from engine.
28. Install camshaft position sensor.
29. Install camshaft timing pulleys. See «INSTALLATION»(ref-170140-S06325738602005010400000).
30. Connect timing belt to camshaft timing pulleys. See «INSTALLATION»(ref-170140-S06325738602005010400000).
31. Check engine oil level.

Note. Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace all gaskets, O-rings and oil seals with new parts.

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1. Assemble piston and connecting rod: Using a small screwdriver, install a new snap ring on one side of the piston pin hole. (Scheme 63) Gradually heat the piston to about 60°C (140°F). see scheme 236 Coat the piston pin with engine oil. NOTE: The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with "LH" and "2L", the RH piston with "RH" and "2R". (Scheme 64) Position the piston front mark with respect to the outside mark on the connecting rod as shown in the illustration. Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb. Using a small screwdriver, install a new snap ring on the other side of the piston pin hole. (Scheme 63)
2. Install piston rings: Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings with the code mark facing upward. (Scheme 65) For Code marks (Scheme 66) NOTE: Do not align the ring ends. Position the piston rings so that the ring ends are as shown.
3. Install bearings: Align the bearing claw with the groove of the connecting rod or connecting cap. (Scheme 68) Install the bearings in the connecting rod and connecting rod cap.
4. Install main bearings: Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings. (Scheme 70) NOTE: A number is marked on each main bearing cap to indicate the installation position. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings. (Scheme 71)
5. Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward. see scheme 282
6. Place crankshaft on cylinder block.
7. Place main bearing caps and lower thrust washers on cylinder block: Install the 2 thrust washers on the No. 3 bearing cap with the grooves facing outward. see scheme 283 Install the 5 main bearing caps in their proper locations. see scheme 284
8. Install main bearing cap bolts: Apply a light coat of engine oil on the threads and under the main bearing cap bolts. Install and uniformly tighten the 10 main bearing cap bolts in several passes, in the sequence shown. see scheme 285 Torque: 27 N.m (275 kgf.cm, 20 ft.lbf). If any one of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt. Mark the front of the main bearing cap bolt with paint. see scheme 286 Retighten the main bearing cap bolts by 90 degrees in the numerical order shown. Check that the painted mark is now at a 90 degree angle to the front. Check that the crankshaft turns smoothly.
9. Check crankshaft thrust clearance, see step 21 under DISASSEMBLY.
10. Install piston and connecting rod assembles: Using a piston ring compressor, push correctly the numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. see scheme 287
11. Place connecting rod cap on connecting rod: Match the numbered connecting rod cap with the connecting rod. see scheme 288 Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap. Check that the outside mark of the connecting rod cap is facing in correct direction. see scheme 289
12. Install connecting rod cap bolts. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. see scheme 212 Install and alternately tighten the 2 connecting rod cap bolts in several passes. Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts. Mark the front of the connecting cap bolt with paint. see scheme 290 Retighten the cap bolts by 90 degrees as shown. Check that the painted mark is now at a 90 degree angle to the front. Check that the crankshaft turns smoothly.
13. Check connecting rod thrust clearance. See 18 under DISASSEMBLY.
14. Install rear oil seal retainer: 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. Apply seal packing to the oil seal retainer as shown in the illustration. see scheme 291 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 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Install a new O-ring to the cylinder block. see scheme 292 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: Apply seal packing to 2 or 3 threads. see scheme 293 Seal packing: Part No. 08826-00100 or equivalent. NOTE: After applying the specified torque, rotate the drain union clockwise until its drain port is facing forward. see scheme 294 Install the 2 drain unions. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
16. Install oil pump.
17. Install oil strainer.
18. Install No. 1 oil pan.
19. Install oil pan baffle plate.
20. Install No. 2 oil pan.
21. Install water pump.
22. Install the mounting bracket with the 4 bolts. Install the 2 mounting brackets. Torque: 36 N.m (370 kgf.cm, 27 ft.lbf)
23. Install engine wire to LH side of cylinder block: Install the brackets on the engine wire with the 2 bolts. see scheme 295 Install the engine wire cover with the 2 bolts.
24. Install oil cooler pipe bracket for A/T with the bolt.
25. Install knock sensors.
26. Install starter.
27. Install water bypass pipe Install a new O-ring to the water bypass pipe. Apply soapy water to the O-ring. Push in the water bypass pipe end into the pipe hole of the water pump. Install the water bypass pipe with the bolt. see scheme 296 Torque: 18 N.m (185 kgf.cm, 13 ft.lbf). Install the wire clamp to the bracket of the water bypass pipe.
28. Install cylinder heads. See «Installation»(ref-170140-S13010331002005010400000).
29. Install Timing Belt And Pulleys. see scheme 307
30. Disconnect engine from engine stand.