TOYOTA SIENNA 2007 Service Repair Manual

2GR-FE FUEL – FUEL INJECTORFU–19
FU
(i) Connect the 6 fuel injector connectors.
2. CONNECT FUEL TUBE SUB-ASSEMBLY
(a) Push in the tube connector onto the pipe until the
tube connector makes a "click" sound.
NOTICE:
• Before connecting the tube, make sure that it
is not damaged. Make sure that there is no
dirt present on the connecting surfaces.
• After connecting, check that the fuel tube
connector and the pipe are securely
connected by pulling on them.
(b) Install the No. 2 fuel pipe clamp.
3. 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
assembly.
(b) Using a 5 mm hexagon socket wrench, install the 4
bolts. (*1)
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
(c) Install the intake air surge tank assembly with the 2
nuts and 2 bolts. (*2)
Torque: Nut
16 N*m (163 kgf*cm, 12 ft.*lbf)
Bolt
21 N*m (214 kgf*cm, 15 ft.*lbf)
(d) Connect the connector.
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Tightening Parts
Surge Tank and Intake Manifold
No. 1 Surge Tank Stay and Surge Tank
Throttle Body Bracket and Surge Tank
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FU–202GR-FE FUEL – FUEL INJECTOR
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(e) Connect the union to check valve hose. (*1)
(f) Connect the No. 1 ventilation hose. (*2)
(g) Install the clamp and connect the throttle with motor
body assembly connector. (*3)
(h) Connect the vapor feed hose assembly. (*4)
(i) Connect the 2 water by-pass hoses to the throttle
with motor body assembly. (*5)
4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
(a) Install the 2 bolts and air cleaner cap sub-assembly.
(b) Connect the No. 2 ventilation hose and air cleaner
hose band.
(c) Connect the vacuum hose (EVAP) to the air cleaner
hose.
(d) Connect the 3 vacuum hoses.
5. ADD ENGINE COOLANT (See page CO-7)
6. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
7. INSPECT FOR ENGINE COOLANT LEAK (See page
CO-1)
8. INSTALL NO. 1 ENGINE UNDER COVER
9. INSPECT FOR FUEL LEAK (See page FU-7)
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2GR-FE FUEL – FUEL INJECTORFU–21
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10. INSTALL V-BANK COVER SUB-ASSEMBLY (See
page EM-63)
11. INSTALL COWL TOP PANEL SUB-ASSEMBLY
OUTER FRONT
(a) Install the 7 bolts and the cowl top panel sub-
assembly outer front.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(b) Connect the fuel pump resistor connector.
(c) Connect the wire harness clamp.
12. INSTALL NO. 1 COWL TOP TO COWL BRACE INNER
(a) Install the 2 bolts and the No.1 cowl top to cowl
brace inner.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
13. INSTALL WINDSHIELD WIPER MOTOR AND LINK
ASSEMBLY (See page WW-6)
14. INSTALL FRONT WIPER ARM LH (See page WW-6)
15. INSTALL FRONT WIPER ARM RH (See page WW-7)
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2GR-FE FUEL – FUEL INJECTORFU–13
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REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
HINT:
See page FU-1.
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. REMOVE NO. 1 ENGINE UNDER COVER
4. DRAIN ENGINE COOLANT (See page CO-6)
5. REMOVE FRONT WIPER ARM HEAD CAP (See page
WW-4)
6. REMOVE FRONT WIPER ARM RH (See page WW-4)
7. REMOVE FRONT WIPER ARM LH (See page WW-4)
8. REMOVE COWL TOP VENTILATOR LOUVER SUB-
ASSEMBLY (See page WW-4)
9. REMOVE WINDSHIELD WIPER MOTOR AND LINK
ASSEMBLY (See page WW-4)
10. REMOVE NO. 1 COWL TOP TO COWL BRACE INNER
(a) Remove the 2 bolts and the No. 1 cowl top to cowl
brace inner.
11. REMOVE COWL TOP PANEL SUB-ASSEMBLY
OUTER FRONT
(a) Remove the wire harness clamp.
(b) Disconnect the fuel pump resistor connector.
(c) Remove the 7 bolts and the cowl top panel outer
front.
12. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page EM-28)
13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
(a) Disconnect the 3 vacuum hoses.
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FU–142GR-FE FUEL – FUEL INJECTOR
FU
(b) Remove the No. 2 ventilation hose and air cleaner
hose band.
(c) Disconnect the vacuum hose (EVAP) from the air
cleaner hose.
(d) Remove the 2 bolts and air cleaner cap sub-
assembly.
14. REMOVE INTAKE AIR SURGE TANK ASSEMBLY
(a) Disconnect the 2 water by-pass hoses from the
throttle with motor body assembly. (*1)
(b) Disconnect the fuel vapor feed hose assembly.(*2)
(c) Disconnect the throttle with motor body assembly
connector and clamp. (*3)
(d) Disconnect the No. 1 ventilation hose. (*4)
(e) Disconnect the union to check valve hose. (*5)
(f) Disconnect the connector.
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2GR-FE FUEL – FUEL INJECTORFU–15
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(g) Using a 5 mm socket hexagon wrench, remove the
4 bolts. (*1)
(h) Remove the 2 nuts, 2 bolts, and intake air surge
tank. (*2)
(i) Remove the gasket from the intake air surge tank.
15. DISCONNECT FUEL TUBE SUB-ASSEMBLY
(a) Remove the No. 2 fuel pipe clamp.
(b) Pinch the tube connector and pull out the fuel pipe.
NOTICE:
• Check that there is no dirt or other foreign
objects around the connector before
disconnecting it. Clean the connector as
necessary.
• It is necessary to prevent mud or dirt from
entering the quick connector. If mud or dirt
gets in the connector, the O-rings may not
seal properly.
• Only disconnect the quick connector by
hand.
• Do not bend, kink or twist the nylon tubes.
Protect the connector by covering it with a
plastic bag.
• If the pipe and the connector are stuck,
carefully try wiggling or pushing and pulling
on the connector to release it. Pull the
connector off the pipe carefully.
16. REMOVE FUEL INJECTOR ASSEMBLY
(a) Disconnect the 6 fuel injector connectors.
(b) Remove the 5 bolts and fuel delivery pipe sub-
assembly together with the 6 fuel injectors.
NOTICE:
Be careful not to drop the fuel injectors when
removing the fuel delivery pipe sub-assembly.
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FU–162GR-FE FUEL – FUEL INJECTOR
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(c) Remove the 6 injector vibration insulators from the
intake manifold.
(d) Pull out the fuel injectors from the fuel delivery pipe
sub-assembly.
(e) Remove the 6 O-rings from the fuel injectors.
INSPECTION
1. INSPECT FUEL INJECTOR ASSEMBLY
(a) Inspect the injector resistance.
(1) Using an ohmmeter, measure the resistance
between the terminals.
Standard resistance
If the resistance is not as specified, replace the
injector.
(b) Inspect the injection volume.
CAUTION:
This test involves high-pressure fuel and
electricity. Take every precaution regarding the
safe handling of both fuel and electricity.
Perform this test in a safe area, and avoid any
sparks or flames. Do not smoke.
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Tester Connection Condition Specified Condition
1-2 always11.6 to 12.4

at 20C (68F)

2GR-FE FUEL – FUEL INJECTORFU–17
FU
(1) Install the fuel tube connector to SST (hose),
then connect the tube connector to the fuel
pipe (vehicle side).
SST 09268-31011 (09268-41500, 90467-
13001, 95336-08070)
(2) Install the O-ring to the fuel injector sub-
assembly.
(3) Connect SST (adaptor and hose) to the
injector, and hold the injector and union with
SST (clamp).
SST 09268-31011 (90467-13001, 95336-
08070), 09268-41140, 09268-41400
(4) Put the injector into the graduated cylinder.
CAUTION:
Install a suitable vinyl tube onto the injector
to contain gasoline spray.
(5) Operate the fuel pump (See page FU-7).
(6) Connect SST (wire) to the injector and the
battery for 15 seconds, and measure the
injection volume with the graduated cylinder.
Test each injector 2 or 3 times.
SST 09842-30080
Vo l u m e :
84 to 100 cm
3 (5.1 to 6.0 cu in.) in 15
seconds
Difference between each injector:
16 cm
3 (0.98 cu in.) or less
If the injection volume is not as specified,
replace the injector.
(c) Check for leakage.
(1) In the condition above, disconnect the tester
probes of SST (wire) from the battery and
check for fuel leakage from the injector.
Fuel drop:
1 drop or less in 16 minutes
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FU–182GR-FE FUEL – FUEL INJECTOR
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INSTALLATION
1. INSTALL FUEL INJECTOR ASSEMBLY
(a) Apply a light coat of spindle oil or gasoline to new O-
rings, and install them to each injector.
(b) Apply a light coat of spindle oil or gasoline where
the fuel delivery pipe contacts the O-ring.
(c) Push the fuel injector while turning it to install the
injector in the fuel delivery pipe.
(d) Position the fuel injector connector outward.
NOTICE:
• Be careful not to twist the O-ring.
• After installing the fuel injector, check that it
turns smoothly. If not, reinstall it with a new
O-ring.
(e) Install 6 new insulators to the intake manifold.
(f) Place the fuel delivery pipe which has the 6 fuel
injectors installed to it in position on the intake
manifold.
NOTICE:
Be careful not to drop the fuel injectors when
installing the fuel delivery pipe.
(g) Temporarily install the 5 bolts which are used to hold
the fuel delivery pipe to the intake manifold.
NOTICE:
After installing the fuel injectors, check that they
turn smoothly. If not, reinstall the injectors with
new O-rings.
(h) Tighten the 5 bolts which are used to hold the fuel
delivery pipe to the intake manifold.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
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2GR-FE FUEL – FUEL INJECTORFU–19
FU
(i) Connect the 6 fuel injector connectors.
2. CONNECT FUEL TUBE SUB-ASSEMBLY
(a) Push in the tube connector onto the pipe until the
tube connector makes a "click" sound.
NOTICE:
• Before connecting the tube, make sure that it
is not damaged. Make sure that there is no
dirt present on the connecting surfaces.
• After connecting, check that the fuel tube
connector and the pipe are securely
connected by pulling on them.
(b) Install the No. 2 fuel pipe clamp.
3. 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
assembly.
(b) Using a 5 mm hexagon socket wrench, install the 4
bolts. (*1)
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
(c) Install the intake air surge tank assembly with the 2
nuts and 2 bolts. (*2)
Torque: Nut
16 N*m (163 kgf*cm, 12 ft.*lbf)
Bolt
21 N*m (214 kgf*cm, 15 ft.*lbf)
(d) Connect the connector.
A137341
A129477E02
Tightening Parts
Surge Tank and Intake Manifold
No. 1 Surge Tank Stay and Surge Tank
Throttle Body Bracket and Surge Tank
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