TOYOTA SIENNA 2007 Service Repair Manual

EM–442GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
4. INSPECT INTAKE MANIFOLD
(a) Cylinder head side:
(1) Using a precision straightedge and feeler
gauge, measure the surface contacting the
cylinder head for warpage.
Maximum warpage:
0.1 mm (0.003 in.)
If the warpage is greater than the
maximum, replace the intake manifold.
(b) Surge tank side:
(1) Using a precision straightedge and feeler
gauge, measure the surface contacting the
surge tank for warpage.
Maximum warpage:
0.1 mm (0.003 in.)
If the warpage is greater than the
maximum, replace the intake manifold.
INSTALLATION
1. INSTALL ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using a 19 mm deep socket wrench, install the
engine coolant temperature sensor and a new
gasket.
Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)
2. INSTALL KNOCK CONTROL SENSOR (See page ES-
522)
3. INSTALL ENGINE OIL PRESSURE SWITCH
ASSEMBLY
(a) Clean the threads of the oil pressure switch. Apply
adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a 24 mm deep socket wrench, install the oil
pressure switch.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
NOTICE:
Do not start the engine within 1 hour after
installation to prevent oil leaks.
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4. INSTALL NO. 1 VACUUM SWITCHING VALVE
ASSEMBLY
(a) Install the bolt and No. 1 vacuum switching valve.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
5. INSTALL RADIO SETTING CONDENSER
(a) Install the 2 bolts and 2 radio setting condensers.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
6. INSTALL NO. 1 ENGINE FRONT MOUNTING
BRACKET LH
(a) Install the No. 1 engine front mounting bracket LH
with the 6 bolts.
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
7. INSTALL WATER PUMP PULLEY (See page CO-13)
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EM–462GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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8. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the No. 2 idler pulley sub-assembly and cover
plate with the bolt.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
9. INSTALL NO. 2 TIMING GEAR COVER
(a) Install the No. 2 timing gear cover with the 2 bolts.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Temporarily install the V-ribbed belt tensioner with
the 5 bolts.
HINT:
Each bolt length is as follows:
A: 70 mm (2.76 in.)
B: 33 mm (1.30 in.)
(b) Install the V-ribbed belt tensioner by tightening the
bolt 1 and bolt 2 in the order shown in the
illustration.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
(c) Tighten the other bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
11. INSTALL GENERATOR ASSEMBLY (See page CH-26)
12. INSTALL COOLER COMPRESSOR ASSEMBLY (See
page AC-231)
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13. INSTALL ENGINE MOUNTING BRACKET RR (for
4WD)
(a) Install the engine mounting bracket RR with the 3
bolts.
Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf)
14. INSTALL DRIVE SHAFT BEARING BRACKET (for
2WD)
(a) Install the drive shaft bearing bracket with the 3
bolts.
Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf)
15. INSTALL ENGINE MOUNTING BRACKET RH
(a) Install the engine mounting bracket RH with the 3
bolts.
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Install a new gasket as shown in the illustration.
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EM–482GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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(b) Install the exhaust manifold sub-assembly LH with
the 6 nuts in the order shown in the illustration.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
17. INSTALL NO. 2 EXHAUST MANIFOLD HEAT
INSULATOR
(a) Install the No. 2 insulator with the 3 bolts.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
18. INSTALL NO. 2 MANIFOLD STAY
(a) Install the No. 2 manifold stay with the bolt and nut
in the order shown in the illustration.
Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf)
19. INSTALL OIL LEVEL GAUGE GUIDE SUB-
ASSEMBLY
(a) Install 2 new O-rings to the oil level gauge guide.
(b) Apply a light coat of engine oil to the O-rings.
(c) Push in the oil level gauge guide end into the guide
hole.
(d) Install the No. 1 oil level gauge guide with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(e) Install the No. 2 oil level gauge guide with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(f) Install the oil level gauge.
20. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Install a new gasket as shown in the illustration.
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(b) Install the exhaust manifold sub-assembly RH with
the 6 nuts in the order shown in the illustration.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
21. INSTALL INTAKE MANIFOLD
NOTICE:
DO NOT apply oil to the bolts listed below:
(a) Set a new gasket on each cylinder head.
NOTICE:
• Align the port holes of the gasket and
cylinder head.
• Make sure that the gasket is installed in the
correct direction.
(b) Set the intake manifold on the cylinder heads.
(c) Install and tighten the 6 bolts and 4 nuts uniformly in
several steps.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
22. INSTALL NO. 2 ENGINE MOUNTING STAY RH
(a) Install the No. 2 mounting stay RH with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
23. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 6 ignition coil assemblies with the 6 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
24. INSTALL INTAKE AIR SURGE TANK ASSEMBLY
NOTICE:
DO NOT apply oil to the bolts listed below:
(a) Install a new gasket to the intake air surge tank.
(b) Using a 5 mm hexagon socket wrench, install the 4
bolts and 2 nuts.
Torque: Bolt
18 N*m (184 kgf*cm, 13 ft.*lbf)
Nut
16 N*m (163 kgf*cm, 12 ft.*lbf)
(c) Install the throttle body bracket, No. 1 surge tank
stay and 4 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
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Tightening Parts
Intake Manifold and Cylinder Head Sub-assembly RH
Intake Manifold and Cylinder Head Sub-assembly LH
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Tightening Parts
Surge Tank and Intake Manifold
No. 1 Surge Tank Stay and Cylinder Head Cover
No. 1 Surge Tank Stay and Surge Tank
Throttle Body Bracket and Cylinder Head Cover
Throttle Body Bracket and Surge Tank
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EM–502GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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(d) Connect the connector.
(e) Connect the No. 1 ventilation hose.
(f) Install the clamp and connect the throttle with motor
body assembly connector.
(g) Connect the vapor feed hose.
(h) Connect the 2 water by-pass hoses to the throttle
with motor body assembly.
25. INSTALL VENTILATION HOSE
(a) Using pliers, grip the claws of the 2 clips and slide
the 2 clips to the intake air surge tank assembly and
ventilation valve.
26. INSTALL ENGINE HANGERS
(a) Install the 4 bolts, and 2 engine hangers.
27. REMOVE ENGINE STAND
28. INSTALL DRIVE PLATE AND RING GEAR SUB-
ASSEMBLY (See page EM-13)
29. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for
2WD)
HINT:
See page AX-166.
30. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for
4WD)
HINT:
(See page AX-167).
31. INSTALL TRANSFER STIFFENER PLATE RH (See
page AX-168)
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2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–51
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32. INSTALL MANIFOLD STAY
(a) Install the bolt, nut, and manifold stay.
Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf)
33. INSTALL ENGINE FRONT MOUNTING BRACKET
(See page AX-167)
34. INSTALL STARTER ASSEMBLY (See page ST-13)
35. INSTALL ENGINE WIRE
36. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See
page DS-17)
37. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for
2WD) (See page DS-17)
38. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for
4WD) (See page DS-17)
39. INSTALL FRONT FRAME ASSEMBLY
(a) Install the engine mounting insulators RH and LH
with the 2 nuts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
(b) Install the engine mounting insulator FR with the
bolt.
Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf)
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(c) Install the engine mounting insulator RR with the 2
bolts.
Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf)
(d) Connect the connector and clamp.
40. INSTALL POWER STEERING LINK (See page PS-39)
41. INSTALL FRONT STABILIZER BAR
HINT:
(See page SP-36).
42. REMOVE ENGINE HANGERS
(a) Remove the 4 bolts and 2 engine hangers.
43. INSTALL VANE PUMP ASSEMBLY
(a) Install the vane pump with the 2 bolts and nut.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
(b) Install the 2 pressure feed tube clamp nuts.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
(c) Connect the power steering oil pressure switch
connector.
44. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine assembly with transaxle on the
engine lifter.
(b) Install the engine assembly to the vehicle.
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2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–53
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(c) Install the frame side rail plates RH and LH with the
6 bolts and 2 nuts.
Torque: A
85 N*m (867 kgf*cm, 63 ft.*lbf)
B
32 N*m (329 kgf*cm, 24 ft.*lbf)
(d) Install the front suspension member brace rear RH
and LH with the 6 bolts and 2 nuts.
Torque: A
85 N*m (867 kgf*cm, 63 ft.*lbf)
B
32 N*m (329 kgf*cm, 24 ft.*lbf)
45. RECONNECT SUCTION HOSE SUB-ASSEMBLY (See
page AC-231)
46. RECONNECT DISCHARGE HOSE SUB-ASSEMBLY
(See page AC-232)
47. INSTALL STEERING INTERMEDIATE SHAFT SUB-
ASSEMBLY (See page SR-10)
48. INSTALL FRONT AXLE ASSEMBLY LH (See page DS-
18)
49. INSTALL FRONT AXLE ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
50. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM
LH (See page DS-18)
51. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM
RH
HINT:
Use the same procedures described for the LH side.
52. INSTALL TIE ROD ASSEMBLY LH (See page DS-18)
53. INSTALL TIE ROD ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
54. INSTALL FRONT SPEED SENSOR LH (See page DS-
18)
55. INSTALL FRONT SPEED SENSOR RH
HINT:
Use the same procedures described for the LH side.
56. INSTALL FRONT AXLE HUB NUT LH (See page DS-
19)
57. INSTALL FRONT AXLE HUB NUT RH
HINT:
Use the same procedures described for the LH side.
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