engine TOYOTA SIENNA 2007 Service Repair Manual

AX–168U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY
AX
INSTALLATION
1. INSTALL TORQUE CONVERTER CLUTCH
ASSEMBLY
(a) Install the torque converter clutch to the automatic
transaxle.
(b) Using vernier calipers and a straight edge, measure
the dimension "A" between the transaxle fitting part
of the engine and the converter fitting part of the
drive plate (*1).
(c) Using vernier calipers and a straight edge, measure
the dimension "B" shown in the illustration and
check that "B" is greater than "A" (measured in step
(*1)).
Standard:
A + 1 mm (0.03937 in.) or more
NOTICE:
Remember to minus the thickness of the
straight edge.
2. INSTALL TRANSFER ASSEMBLY
HINT:
(See page TF-9)
3. INSTALL AUTOMATIC TRANSAXLE W/TRANSFER
(a) Install the automatic transaxle w/transfer with the 10
bolts to the engine.
To r q u e : B o l t A
64 N*m (650 kgf*cm, 47 ft.*lbf)
Bolt B
46 N*m (470 kgf*cm, 34 ft.*lbf)
Bolt C
43 N*m (439 kgf*cm, 32 ft.*lbf)
(b) Apply a few drops of adhesive to each of 2 threads
on the tip of the 6 torque converter clutch mounting
bolts.
Adhesive:
Part No. 08833-00070, THREE BOND 1324
or equivalent
D031087E01
C065911E01
C163047E01

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLYAX–169
AX
(c) Install the 6 torque converter clutch mounting bolts.
Torque: 41 N*m (413 kgf*cm, 30 ft.*lbf)
NOTICE:
First install the black colored bolt, and then the
remaining 5 bolts.
(d) Install the flywheel housing under cover to the
automatic transaxle with the 2 bolt.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
4. INSTALL TRANSFER STIFFENER PLATE RH
(a) Install the transfer stiffener plate RH with 5 bolts to
the transfer and engine mounting bracket RR.
Torque: 34 N*m (350 kgf*cm, 25 ft.*lbf)
5. INSTALL ENGINE MOUNTING BRACKET FRONT
(a) Install the engine mounting bracket front to the
automatic transaxle with the 3 bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
6. INSTALL TRANSMISSION OIL FILLER TUBE SUB-
ASSEMBLY
(a) Coat a new O-ring with ATF, and install it to the
transmission oil filler tube sub-assembly.
(b) Install the transmission oil filler tube sub-assembly
and bolt to the automatic transaxle.
Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
(c) Connect the 2 clamps to the oil filler tube.
(d) Install the ATF level gauge.
7. INSTALL OIL COOLER INLET TUBE NO.1
(a) Temporarily install the oil cooler outlet tube No.1.
(b) Temporarily install the oil cooler inlet tube No.1.
D030472
D030471
D030512
D030470
D030700

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLYAX–171
AX
11. INSTALL STARTER ASSEMBLY
(a) Install the starter assembly with the 2 bolts (1).
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
(b) Connect the connector (2).
(c) Connect the starter wire with the nut (3).
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
12. CONNECT WIRE HARNESS
(a) Connect the wire harness with the bolt.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
13. INSTALL WIRE HARNESS CLAMP
(a) Install the 2 clamps and 3 bolts.
Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
(b) Connect the wire harnesses to the clamps.
14. INSTALL TRANSMISSION CONTROL CABLE CLAMP
(a) Install the transmission control cable clamp with the
bolt.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
15. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
HINT:
(See page DS-17)
16. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
HINT:
(See page DS-17)
17. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
HINT:
(See page EM-44)
18. RESET MEMORY
HINT:
(See page AX-16)
D030464E03
G025456
D030465
C083203

TF–8TRANSFER – TRANSFER ASSEMBLY
TF
REMOVAL
1. REMOVE ENGINE AND TRANSAXLE
HINT:
(See page EM-26)
2. REMOVE AUTOMATIC TRANSMISSION WITH
TRANSFER
HINT:
(See page AX-164)
3. REMOVE NO. 1 TRANSFER CASE PLUG
(a) Remove the No. 1 transfer case plug.
(b) Remove the No. 1 gasket from the transfer case No.
1 plug.
4. REMOVE NO. 2 TRANSFER CASE PLUG
(a) Remove the No. 2 transfer case plug.
(b) Remove the No. 2 gasket from the No. 2 transfer
case plug.
5. REMOVE TRANSFER DRAIN PLUG
(a) Remove the transfer drain plug and bleed the oil.
(b) Remove the drain gasket from the transfer drain
plug.
6. REMOVE TRANSFER ASSEMBLY
(a) Remove the 2 bolts and 6 bolts.
(b) Using a plastic hammer, remove the transfer
assembly from the transaxle assembly.
NOTICE:
• Remove the transfer assembly from the
transaxle assembly without tilting it.
• When removing the transfer assembly, do not
hold onto the oil seal parts on both sides of
the assembly.
C082977E01
C082785E01

TRANSFER – TRANSFER ASSEMBLYTF–9
TF
INSTALLATION
1. INSTALL TRANSFER ASSEMBLY
(a) Apply sealant 1281 to the transaxle assembly and
transfer assembly in continuous beaded from of 1.2
mm diameter as shown in the illustration.
NOTICE:
• Wipe any grease off from the attaching
surfaces.
• Install it within 10 minutes after applying the
sealant.
• Sealant stuck on the gasket, case oil seal and
driving plug may cause oil leakage and
seizure due to oil shortage. Care must be
taken.
(b) Install the transfer assembly to the transaxle
assembly with the 2 bolts and 6 nuts.
Torque: 69 N*m (700 kgf*cm, 51 ft.*lbf)
NOTICE:
• Check that the gasket is installed to the
transfer assembly before installing them to
the transaxle assembly.
• Install the transfer assembly to the transaxle
assembly without tilting.
• When moving the transfer assembly, do not
hold the oil seal on the both sides.
2. INSTALL AUTOMATIC TRANSMISSION WITH
TRANSFER
HINT:
(See page AX-167)
3. INSTALL ENGINE AND TRANSAXLE
HINT:
(See page EM-44)
4. INSTALL TRANSFER DRAIN PLUG
(a) Install the transfer drain plug with a new drain
gasket.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
5. INSTALL NO. 2 TRANSFER CASE PLUG
(a) Install the No. 2 transfer case plug with a new No. 2
gasket.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
C083714E01
C082785
C082977E01

PP–52PREPARATION – SUSPENSION
PP
EQUIPMENT
To r q u e w r e n c h
Dial indicator with magnetic base
Wheel balancer
Tire pressure gauge
Alignment tester
Camber-caster-kingpin gauge
Toe-in gauge
Angle gauge
Drill
Plastic hammer
Engine Sling Device
Universal Engine Lifter
Chain Block
Slide calipers
Wooden block

AXLE – FRONT AXLE HUBAH–9
AH
4. INSTALL FRONT AXLE HUB LH HOLE SNAP RING
(a) Using snap ring pliers, install a new front axle hub
LH hole snap ring.
5. INSTALL FRONT WHEEL BEARING DUST
DEFLECTOR NO.1 LH
(a) Using SST(s) and a hammer, install the bearing dust
deflector No. 1 LH.
SST 09316-60011 (09316-00011, 09316-00031),
09608-32010
HINT:
Align the hole for the speed sensor in the bearing
dust deflector No. 1 LH with the steering knuckle.
6. INSTALL LOWER BALL JOINT ASSEMBLY FRONT
LH
(a) Install the lower ball joint assembly front LH and
tighten the nut.
Torque: 123 N*m (1,250 kgf*cm, 91 ft.*lbf)
(b) Install a new cotter pin.
NOTICE:
If the holes for the cotter pin are not aligned,
tighten the nut up to 60
further.
INSTALLATION
1. INSTALL FRONT AXLE ASSEMBLY LH
(a) Install the 2 bolts, nuts and front axle assembly LH
with the 2 bolts and nuts to the shock absorber
assembly front LH.
Torque: 230 N*m (2,350 kgf*cm, 170 ft.*lbf)
NOTICE:
• Only when reusing the bolts and nuts, apply
the small amount of engine oil to the screw
part of the nuts.
• Do not excessively push out the front axle
assembly LH.
• Be careful not to damage the outboard joint
boot.
• Be careful not to damage the speed sensor
rotor.
2. INSTALL FRONT SUSPENSION ARM SUB-
ASSEMBLY LOWER NO.1 LH (See page DS-18)
3. INSTALL TIE ROD END SUB-ASSEMBLY LH (See
page DS-18)
4. INSTALL FRONT DISC
F045465
F045054E03
C083023

SUSPENSION – FRONT LOWER SUSPENSION ARMSP–21
SP
INSTALLATION
1. INSTALL FRONT SUSPENSION ARM SUB-
ASSEMBLY LOWER NO.1 LH
(a) Install the front lower arm bush stopper to the front
suspension arm sub-assembly lower No.1 LH.
(b) Install the bolt and nut to the rear side of the front
suspension arm sub-assembly lower No.1 LH.
Torque: 206 N*m (2,100 kgf*cm, 152 ft.*lbf)
(c) Install the 2 bolts on the front side of the front
suspension arm sub-assembly lower No.1 LH.
Torque: 200 N*m (2,040 kgf*cm, 148 ft.*lbf)
2. INSTALL TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Install the transverse engine engine mounting
insulator with the 3 nuts.
Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf)
3. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
HINT:
(See page EM-52)
F044965
F044964
C083387

SP–20SUSPENSION – FRONT LOWER SUSPENSION ARM
SP
REMOVAL
1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
HINT:
(See page EM-34)
2. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the 3 nuts and transverse engine engine
mounting insulator.
3. REMOVE FRONT SUSPENSION ARM SUB-
ASSEMBLY LOWER NO.1 LH
(a) Remove the 2 bolts on the front side of the front
suspension arm sub-assembly lower No.1 LH.
(b) Remove the bolt and nut on the rear side of the front
suspension arm sub-assembly lower No.1 LH.
(c) Remove the front suspension arm sub-assembly
lower No.1 LH.
(d) Remove the front lower arm bush stopper from the
front suspension arm sub-assembly lower No.1 LH.
C083387
F044964
F044965

TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEMTW–39
TW
HINT:
*1: Displayed only when the ID No. is not registered.
*2: It may take about 5 to 6 minutes until the values
are displayed. If the values are not displayed after a
few minutes, perform troubleshooting according to
the inspection procedure for DTCs C2121/21 to
C2124/24 (See page TW-42).
METER:
2. ACTIVE TEST
Using the intelligent tester to perform ACTIVE TEST
allows the meters, indicators and other items to be
operated without removing any parts. Performing
ACTIVE TEST early in troubleshooting is one way to
save diagnostic time. It is possible to display the DATA
LIST on the intelligent tester during ACTIVE TEST.
(a) Make sure that the ignition switch is off.
(b) Connect the intelligent tester to the DLC3.
(c) Turn the ignition switch to the ON position.
(d) Enter the following menus: DIAGNOSIS / OBD/
MOBD / METER / ACTIVE TEST.
METER:
TIRE TEMP1ID1 temperature in tire/min.: -50C (-58F),
max.: 205
C (401F)Actual tire temperatureIf -50
C (-58F) is displayed,
data has not been received.
TIRE TEMP2ID2 temperature in tire/min.: -50
C (-58F),
max.: 205
C (401F)Actual tire temperatureIf -50
C (-58F) is displayed,
data has not been received.
TIRE TEMP3ID3 temperature in tire/min.: -50
C (-58F),
max.: 205
C (401F)Actual tire temperatureIf -50
C (-58F) is displayed,
data has not been received.
TIRE TEMP4ID4 temperature in tire/min.: -50
C (-58F),
max.: 205
C (401F)Actual tire temperatureIf -50
C (-58F) is displayed,
data has not been received.
BATT VOLT1 ID1 battery voltage/OVER or LESS OVER -
BATT VOLT2 ID2 battery voltage/OVER or LESS OVER -
BATT VOLT3 ID3 battery voltage/OVER or LESS OVER -
BATT VOLT4 ID4 battery voltage/OVER or LESS OVER -
INITIAL SW INFOTire pressure warning reset switch setting
information/WITH or WITHOUTWITH or WITHOUT -
INIT THRESHOLD1ID1 initial threshold of low-pressure/min.: 0 kPa
(0 kgf/cm
2, 0 psi), max.: 637.5 kPa (6.4 kgf/cm2,
93 psi)Tire pressure after initialization -
INIT THRESHOLD2ID2 initial threshold of low-pressure/min.: 0 kPa
(0 kgf/cm
2, 0 psi), max.: 637.5 kPa (6.4 kgf/cm2,
93 psi)Tire pressure after initialization -
INIT THRESHOLD3ID3 initial threshold of low-pressure/min.: 0 kPa
(0 kgf/cm
2, 0 psi), max.: 637.5 kPa (6.4 kgf/cm2,
93 psi)Tire pressure after initialization -
INIT THRESHOLD4ID4 initial threshold of low-pressure/min.: 0 kPa
(0 kgf/cm
2, 0 psi), max.: 637.5 kPa (6.4 kgf/cm2,
93 psi)Tire pressure after initialization -
# CODES Number of DTCs recorded/min.: 0, max.: 255 Min.: 0, Max.: - - Tester Display Measurement Item/Range Normal Condition Diagnostic Note
Tester Display Measurement Item/Range Normal Condition Diagnostic Note
SPEED METERVehicle speed/Min.: 0 km/h (0 mph), Max.: 255
km/h (158 mph)Almost same as actual vehicle speed
(When driving)-
Tester Display Test Part Control Range Diagnostic Note
TIRE PRESS WARN Tire Pressure Warning LightTire Pressure Warning Light is
OFF/ONConfirm that the vehicle is
stopped with the engine idling