TOYOTA SIENNA 2007 Service Repair Manual

EM–1342GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(c) Using a piston ring compressor, push the correctly
numbered piston and connecting rod assembly into
the cylinder with the front mark of the piston facing
forward.
NOTICE:
Match the numbered connecting rod cap with
the connecting rod.
(d) Check that the front mark of the connecting rod cap
is facing forward.
(e) Apply a light coat of engine oil to the threads and
under the heads of the connecting rod cap bolts.
(f) Install the connecting cap bolts.
HINT:
The connecting cap bolts are tightened in 2
progressive steps.
(g) Step 1
(1) Install and alternately tighten the bolts of the
connecting rod cap in several steps.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
(h) Step 2
(1) Mark the front side of each connecting cap bolt
with paint.
(2) Retighten the cap bolts 90
as shown in the
illustration.
(3) Check the painted mark is now at a 90
angle
to the front.
(i) Check that the crankshaft turns smoothly.
(j) Check the connecting rod thrust clearance (See
page EM-116 ).
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–135
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11. INSTALL INTAKE VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the intake valve
guide bush bore diameter of the cylinder head.
Cylinder bore diameter:
10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Select a new guide bush (STD or O/S 0.05)
If the bush bore diameter of the cylinder head is
greater than 10.306 mm (0.4057 in.), machine the
bush bore to the dimension of 10.335 to 10.356 mm
(0.4069 to 0.4077 in.) to install an O/S 0.05 valve
guide bush.
If the bush bore diameter of the cylinder head is
greater than 10.356 mm (0.4077 in.), replace the
cylinder head.
(b) Heat the cylinder head to 80 to 100
C (176 to
212
F).
(c) Place the cylinder head on wooden blocks.
(d) Using SST, tap in new intake valve guide bushes to
the specified protrusion height.
SST 09201-10000 (09201-01050), 09950-70010
(09951-07100)
Protrusion height:
9.30 to 9.70 mm (0.3661 to 0.3819 in.)
(e) Using a sharp 5.5 mm reamer, ream the valve guide
bushings to obtain the specified clearance.
Standard oil clearance:
0.025 to 0.060 mm (0.0010 to 0.0023 in.)
12. INSTALL EXHAUST VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the exhaust valve
guide bush bore diameter of the cylinder head.
Cylinder bore diameter:
10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Select a new guide bush (STD or O/S 0.05)
A109626
Bush size Bush bore diameter
STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
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A131839
A109628
Bush size Bush bore diameter
STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)

EM–1362GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
If the bush bore diameter of the cylinder head is
greater than 10.306 mm (0.4057 in.), machine the
bush bore to the dimension of 10.335 to 10.356 mm
(0.4069 to 0.4077 in.) to install an O/S 0.05 valve
guide bush.
If the bush bore diameter of the cylinder head is
greater than 10.356 mm (0.4077 in.), replace the
cylinder head.
(b) Heat the cylinder head to 80 to 100
C (176 to
212
F).
(c) Place the cylinder head on wooden blocks.
(d) Using SST, tap in new exhaust valve guide bushes
to the specified protrusion height.
SST 09201-10000 (09201-01050), 09950-70010
(09951-07100)
Protrusion height:
9.30 to 9.70 mm (0.3661 to 0.3819 in.)
(e) Using a sharp 5.5 mm reamer, ream the valve guide
bushings to obtain the specified clearance.
Standard oil clearance:
0.030 to 0.065 mm (0.0012 to 0.0026 in.)
13. INSTALL RING PIN
(a) Using a plastic hammer, tap in new ring pins to the
specified protrusion height.
Specified protrusion height:
2.5 to 3.5 mm (0.098 to 0.138 in.)
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–137
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14. INSTALL NO. 1 STRAIGHT SCREW PLUG
(a) Using a 10 mm hexagon wrench, install 4 new
gaskets and the 4 No. 1 straight screw plugs.
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
15. INSTALL NO. 2 STRAIGHT SCREW PLUG
(a) Using a 14 mm hexagon wrench, install 2 new
gaskets and the 2 No. 2 straight screw plugs.
Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf)
16. INSTALL STUD BOLT
NOTICE:
If the stud bolt is deformed or the threads are
damaged, replace it.
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EM–1382GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(a) Using E6 and E8 "TORX" sockets, install the stud
bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts A
and B
4.0 N*m (41 kgf*cm, 35 in.*lbf) for bolt C
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–139
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17. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, tap in new straight pins as
shown in the illustration.
Protrusion height:
17.5 to 19.5 mm (0.689 to 0.768 in.)
18. INSTALL VALVE SPRING SEAT
(a) Install the valve spring seats to the cylinder head.
19. INSTALL VALVE STEM OIL SEAL
(a) Apply a light coat of engine oil to new valve stem oil
seals.
NOTICE:
Pay attention when installing the intake and
exhaust valve stem oil seals. For example,
installing the intake valve stem oil seal into the
exhaust side or installing the exhaust valve
stem oil seal to the intake side can cause
installation problems later.
HINT:
The intake valve oil seals are gray and the exhaust
valve oil seals are black.
(b) Using SST, push in the oil seals.
SST 09201-41020
NOTICE:
Failure to use SST will cause the seal to be
damaged or improperly seated.
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EM–1402GR-FE ENGINE MECHANICAL – ENGINE UNIT
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20. INSTALL EXHAUST VALVE
(a) Apply a sufficient coat of engine oil to the tip area of
the exhaust valve shown in the illustration.
(b) Install the exhaust valve, inner compression spring
and valve spring retainer to the cylinder head.
NOTICE:
Install the same parts in the same combination
to the original locations.
(c) Using SST, compress the inner compression spring
and install the 2 valve spring retainer locks.
SST 09202-70020 (09202-00010)
(d) Using a plastic hammer, lightly tap the valve stem
tip to ensure a proper fit.
NOTICE:
Be careful not to damage the retainer.
21. INSTALL INTAKE VALVE
(a) Apply a sufficient coat of engine oil to the tip area of
the intake valve shown in the illustration.
(b) Install the intake valve, inner compression spring
and valve spring retainer to the cylinder head.
NOTICE:
Install the same parts in the same combination
to the original locations.
(c) Using SST, compress the inner compression spring
and install the 2 valve spring retainer locks.
SST 09202-70020 (09202-00010)
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–141
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(d) Using a plastic hammer, lightly tap the valve stem
tip to ensure a proper fit.
NOTICE:
Be careful not to damage the retainer.
22. INSTALL VALVE STEM CAP
(a) Apply a light coat of engine oil to the valve stem
caps.
(b) Install the valve stem caps on the valves.
23. INSTALL ENGINE REAR OIL SEAL
(a) Place the oil seal retainer on wooden blocks.
(b) Using SST, tap in a new engine rear oil seal until its
surface is flush with the engine rear oil seal retainer
edge.
SST 09223-15030, 09950-70010 (09951-07100)
NOTICE:
• Keep the lip free of foreign matter.
• Do not tap on the oil seal at an angle.
24. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Apply seal packing in a continuous line as shown in
the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three
Bond 1207B or equivalent
Seal Diameter:
2.0 to 3.0 mm (0.079 to 0.118 in.)
NOTICE:
• Remove any oil from the contact surface.
• Install the oil seal retainer within 3 minutes
after applying seal packing.
• Do not start the engine for at least 2 hours
after installation.
(b) Install the engine rear oil seal retainer with the 6
bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
NOTICE:
Be sure to apply adhesive 1324 to the bolts in
the places indicated by A before installing them.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond
1324 or equivalent
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EM–1422GR-FE ENGINE MECHANICAL – ENGINE UNIT
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25. INSTALL WATER INLET PIPE
(a) Install the water inlet pipe with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(b) Install the No. 1 water by-pass hose.
26. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH
(a) Place the cylinder head gasket on the cylinder block
surface with the Lot No. stamp upward.
NOTICE:
• Be careful of the installation direction.
• Gently place the cylinder head in order not to
damage the gasket with the bottom part of the
head.
(b) Place the cylinder head on the cylinder block.
NOTICE:
Be careful not to allow oil to adhere to the
bottom part of the cylinder head.
HINT:
The cylinder head bolts are tightened in 3
progressive steps.
(c) Apply a light coat of engine oil to the threads and
under the heads of the cylinder head bolts.
(d) Step 1
(1) Using a 10 mm bi-hexagon wrench, install and
uniformly tighten the 8 cylinder head bolts with
the plate washers in several steps and in the
sequence shown in the illustration.
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–143
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(e) Step 2
(1) Mark the cylinder head bolt head with paint as
shown in the illustration.
(2) Tighten the cylinder head bolts another 90
.
(f) Step 3
(1) Tighten the cylinder head bolts an additional
90
.
(2) Check that the painted mark is now facing
rearward.
27. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
(a) Place the cylinder head gasket on the cylinder block
surface with the Lot No. stamp upward.
NOTICE:
• Be careful of the installation direction.
• Gently place the cylinder head in order not to
damage the gasket with the bottom part of the
head.
(b) Place the cylinder head on the cylinder block.
NOTICE:
Be careful not to allow oil to adhere to the
bottom part of the cylinder head.
HINT:
The cylinder head bolts are tightened in 3
progressive steps.
(c) Apply a light coat of engine oil to the threads and
under the heads of the cylinder head bolts.
(d) Step 1
(1) Using a 10 mm bi-hexagon wrench, install and
uniformly tighten the 8 cylinder head bolts with
the plate washers in several steps in the
sequence shown in the illustration.
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
(e) Step 2
(1) Mark the cylinder head bolt head with paint as
shown in the illustration.
(2) Tighten the cylinder head bolts another 90
.
(f) Step 3
(1) Tighten the cylinder head bolts an additional
90
.
(2) Check that the painted mark is now facing
rearward.
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