TOYOTA SIENNA 2007 Service Repair Manual

2GR-FE ENGINE MECHANICAL – ENGINEEM–1
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ENGINE
ON-VEHICLE INSPECTION
1. INSPECT ENGINE COOLANT
(a) Inspect the engine coolant (See page CO-1).
2. INSPECT ENGINE OIL
(a) Inspect the engine oil (See page LU-1).
3. INSPECT BATTERY
(a) Inspect the battery (See page CH-5).
4. INSPECT AIR CLEANER FILTER ELEMENT SUB-
ASSEMBLY
(a) Remove the air cleaner filter element sub-assembly.
(b) Visually check that there is no dirt, blockage, and/or
damage to the air cleaner filter element.
HINT:
• If there is any dirt or a blockage in the air cleaner
filter element, clean it with compressed air.
• If any dirt or a blockage remains even after
cleaning the air cleaner filter element with
compressed air, replace it.
5. INSPECT SPARK PLUG
(a) Inspect the spark plugs (See page IG-5).
6. INSPECT VALVE LASH ADJUSTER NOISE
(a) Rev up the engine several times. Check that the
engine does not emit unusual noises.
If unusual noises occur, warm up the engine and
idle it for over 30 minutes. Then repeat this
procedure.
HINT:
If any defects or problems are found during the
inspection above, perform lash adjuster inspection
(See page EM-100).
7. INSPECT IGNITION TIMING
(a) Warm up the engine.
(b) When using the intelligent tester:
Check the ignition timing.
(1) Connect the intelligent tester to the DLC3.
(2) Enter DATA LIST mode with the intelligent
tester.
Ignition timing:
8 to 12
BTDC at idle
HINT:
Refer to the intelligent tester operator's manual
for help when selecting the DATA LIST.
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(c) When not using the intelligent tester:
Check the ignition timing.
(1) Using SST, connect terminals 13 (TC) and 4
(CG) of the DLC3.
SST 09843-18040
NOTICE:
• Confirm the terminal numbers before
connecting them. Connection with a
wrong terminal can damage the engine.
• Turn off all electrical systems before
connecting the terminals.
• Perform this inspection after the cooling
fan motor is turned off.
(2) Remove the V-bank cover.
(3) Pull out the red lead wire harness.
(4) Connect the tester terminal of the timing light to
the red lead wire as shown in the illustration.
NOTICE:
Use a timing light which can detect the first
signal.
(5) Check the ignition timing at idle.
Ignition timing:
8 to 12
BTDC at idle
NOTICE:
When checking the ignition timing, the
transmission should be in neutral.
HINT:
Run the engine at 1000 to 1300 rpm for 5
seconds, and then check that the engine rpm
returns to idle speed.
(6) Disconnect terminals 13 (TC) and 4 (CG) of the
DLC3.
(7) Check the ignition timing at idle.
Ignition timing:
7 to 24
BTDC at idle
(8) Confirm that the ignition timing moves to the
advanced angle side when the engine rpm is
increased.
(9) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up the engine.
(b) When using the intelligent tester:
Check the idle speed.
(1) Connect the intelligent tester to the DLC3.
(2) Enter DATA LIST mode with the intelligent
tester.
Idle speed:
600 to 700 rpm
NOTICE:
• When checking the idle speed, the
transmission should be in neutral.
• Check the idle speed with the cooling fan
off.
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• Switch off all accessories and air
conditioning before connecting the
intelligent tester.
HINT:
Refer to the intelligent tester operator's manual
for further details.
(c) When not using the intelligent tester:
Check the idle speed.
(1) Using SST, connect the tachometer test probe
to terminal 9 (TAC) of the DLC3.
SST 09843-18030
(2) Check the idle speed.
Idle speed:
600 to 700 rpm
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the intake air surge tank (See page ES-
521).
(d) Remove the 6 ignition coils.
(e) Remove the 6 spark plugs.
(f) Check the cylinder compression pressure.
(1) Insert a compression gauge into the spark plug
hole.
(2) While cranking the engine, measure the
compression pressure.
Compression pressure:
1.3 MPa (13 kgf/cm
2, 189 psi)
Minimum pressure:
0.98 MPa (10 kgf/cm
2, 142 psi)
Difference between each cylinder:
0.1 MPa (1.0 kgf/cm
2, 15 psi)
NOTICE:
• Always use a fully charged battery to
obtain an engine speed of 250 rpm or
more.
• Check the other cylinders' compression
pressure in the same way.
• This measurement must be done as
quickly as possible.
(3) If the cylinder compression is low, pour a small
amount of engine oil into the cylinder through
the spark plug hole and inspect again.
HINT:
• If adding oil increases the compression, the
piston rings and/or cylinder bore may be
worn or damaged.
• If pressure stays low, a valve may be stuck
or seated improperly, or there may be
leakage in the gasket.
(g) Install the 6 spark plugs.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
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(h) Install the 6 ignition coils.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(i) Install the intake air surge tank (See page ES-522).
10. INSPECT CO/HC
(a) Start the engine.
(b) Run the engine at 2500 rpm for approximately 180
seconds.
(c) Insert the CO/HC meter testing probe at least 40 cm
(1.3 ft.) into the tailpipe during idling.
(d) Check CO/HC concentration at idle and/or 2500
rpm.
HINT:
Check regulations and restrictions in your area
when performing 2 mode CO/HC concentration
testing (engine check at both idle speed and at 2500
rpm).
If the CO/HC concentration does not comply with
regulations, perform troubleshooting in the order
given below.
(1) Check air fuel ratio sensor and heated oxygen
sensor operation.
(2) See the table below for possible causes, and
then inspect and repair.
CO HC Problems Causes
Normal High Rough idle1. Faulty ignitions:
– Incorrect timing
– Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaks in intake and exhaust valves
4. Leaks in cylinders
Low HighRough idle
(fluctuating HC reading)1. Vacuum leaks:
– PCV hoses
– Intake manifold
– Throttle body
– Brake booster line
2. Lean mixture causing misfire
High HighRough idle
(black smoke from exhaust)1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI system:
– Faulty fuel pressure regulator
– Defective ECT sensor
– Defective MAF meter
–Faulty ECM
– Faulty injectors
– Faulty throttle position sensor

EM–1262GR-FE ENGINE MECHANICAL – ENGINE UNIT
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REASSEMBLY
1. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, tap in new straight pins to
the cylinder block.
Standard protrusion
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Item Protrusion
Pin A 23 mm (0.906 in.)
Pin B 6 mm (0.236 in.)
Pin C 11 mm (0.433 in.)

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2. INSTALL STUD BOLT
(a) Using E8 and E10 "TORX" sockets, install the stud
bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A
17 N*m (173 kgf*cm, 13 ft.*lbf) for bolt B
3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, install the No. 1 oil
nozzle sub-assembly.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
4. INSTALL PISTON SUB-ASSEMBLY WITH PIN
(a) Using a screwdriver, install a new piston pin hole
snap ring at one end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not
aligned with the pin hole cutout portion of the piston.
Pin D 9 mm (0.354 in.)Item Protrusion
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(b) Gradually heat the piston to approximately 80C
(176
F).
(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting
rod, and push in the piston pin with your thumb.
HINT:
The piston and pin are a matched set.
(e) Check the fitting condition between the piston and
piston pin by trying to move the piston back and
forth on the piston pin.
(f) Using a screwdriver, install a new piston pin hole
snap ring at the other end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not
aligned with the pin hole cutout portion of the piston.
5. INSTALL PISTON RING SET
(a) Install the oil ring expander and 2 side rails by hand.
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(b) Using a piston ring expander, install the
compression ring as shown in the illustration.
(c) Position the piston rings so that the ring ends are as
shown in the illustration.
NOTICE:
Do not align the ring ends.
6. INSTALL CRANKSHAFT BEARING
(a) Clean the main journal and both surfaces of the
bearing.
NOTICE:
Main bearings come in widths between 18.0 mm
(0.709 in.) and 21.0 mm (0.827 in.). Install the
21.0 mm (0.827 in.) bearings in the No. 1 and No.
4 cylinder block journal positions with the main
bearing cap. Install the 18.0 mm (0.709 in.)
bearings in the No. 2 and No. 3 positions.
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(b) Install the upper bearing.
(1) Install the upper crankshaft bearings to the
cylinder block as shown in the illustration.
NOTICE:
• Do not apply engine oil to the bearings
and the contact surfaces.
• Both sides of the oil groove in the
cylinder block should be visible through
the oil feed holes in the bearing. The
amount visible on each side of the holes
should be equal.
(c) Install the lower crankshaft bearing.
(1) Install the lower crankshaft bearings to the
crankshaft bearing caps.
(2) Using vernier calipers, measure the distance
between the crankshaft bearing cap's edge and
the lower crankshaft bearing's edge.
Dimension (A - B):
0.7 mm (0.0276 in.) or less
NOTICE:
Do not apply engine oil to the crankshaft
bearings and the contact surfaces.
7. INSTALL CRANKSHAFT THRUST WASHER SET
(a) Apply engine oil to the crankshaft thrust washer.
(b) Install the 2 upper crankshaft thrust washers under
the No. 2 journal position of the cylinder block sub-
assembly with the oil grooves facing outward.
8. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing, then place the
crankshaft on the cylinder block.
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(b) Confirm the projection and numbers of the main
bearing caps and install the bearing caps on the
cylinder block.
HINT:
A number is marked on each main bearing cap to
indicate the installation position.
(c) Apply a light coat of engine oil to the threads and
under the heads of the crankshaft bearing cap bolts.
(d) Temporarily install the 8 crankshaft bearing cap
bolts to the inside positions.
(e) Insert the crankshaft bearing cap with your hand
until the clearance between the crankshaft bearing
cap and the cylinder block is less than 6 mm (0.23
in.) by marking the 2 internal crankshaft bearing cap
bolts as a guide.
Bolt length:
100 to 102 mm (3.94 to 4.02 in.)
(f) Using a plastic hammer, lightly tap the crankshaft
bearing cap to ensure a proper fit.
(g) Apply a light coat of engine oil to the threads and
under the heads of the 8 crankshaft bearing cap
bolts.
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