TOYOTA SIENNA 2007 Service Repair Manual

2GR-FE EXHAUST – EXHAUST PIPE (for 4WD)EX–11
EX
INSTALLATION
1. INSTALL HEATED OXYGEN SENSOR (for Bank 2
Sensor 2) (See page EC-39)
2. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Install a new gasket to the front exhaust pipe
assembly.
(b) Install the front exhaust pipe assembly with the 2
nuts.
Torque: 62 N*m (632 kgf*cm, 46 ft.*lbf)
3. INSTALL CENTER EXHAUST PIPE ASSEMBLY
(a) Install 2 new gaskets to the center exhaust pipe
assembly.
(b) Connect the 2 exhaust pipe supports, and install the
center exhaust pipe assembly.
(c) Install 2 new bolts and 2 nuts.
Torque: Bolt
43 N*m (438 kgf*cm, 32 ft.*lbf)
Nut
62 N*m (632 kgf*cm, 46 ft.*lbf)
A162667

EX–122GR-FE EXHAUST – EXHAUST PIPE (for 4WD)
EX4. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET
(a) Install the No. 1 exhaust pipe support bracket to oil
pan sub-assembly with 2 new nuts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(b) Loosen the No. 1 exhaust pipe support bracket
bolts.
(c) Install the clamp to No. 1 exhaust pipe support
bracket.
(d) Retighten the No. 1 exhaust pipe support bracket
bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(e) Install the clamp with a new bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(f) Connect the heated oxygen sensor (for bank 2
sensor 2) connector.
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2GR-FE EXHAUST – EXHAUST PIPE (for 4WD)EX–13
EX
5. INSTALL TAIL EXHAUST PIPE ASSEMBLY
(a) Install a new gasket to the center exhaust pipe
assembly.
(b) Connect the 4 exhaust pipe supports, and install the
tail exhaust pipe assembly.
(c) Install 2 new bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
6. INSTALL HEATED OXYGEN SENSOR (for Bank 1
Sensor 2) (See page EC-41)
7. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
8. INSPECT FOR EXHAUST GAS LEAK
If exhaust gas is leaking, repair the leak. Replace
damaged parts as necessary.
A162161

2GR-FE COOLING – WATER PUMPCO–11
CO
REMOVAL
1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
HINT:
See page EM-26
2. SECURE ENGINE (See page EM-37)
3. REMOVE GENERATOR ASSEMBLY (See page CH-17)
4. REMOVE COMPRESSOR AND MAGNETIC CLUTCH
(See page AC-227)
5. REMOVE NO. 1 ENGINE FRONT MOUNTING
BRACKET LH (See page EM-42)
6. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the 2 bolts, 2 idler pulley cover plates and 2
idler pulley sub-assemblies.
7. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Remove the 5 bolts and V-ribbed belt tensioner
assembly.
A129645E01
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CO–122GR-FE COOLING – WATER PUMP
CO
8. REMOVE WATER PUMP PULLEY
(a) Using SST, hold the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)
(b) Remove the 4 bolts and water pump pulley.
9. REMOVE WATER INLET HOUSING
(a) Disconnect the water hose.
(b) Remove the 2 bolts, nut and water inlet housing.
(c) Remove the water inlet housing gasket and water
outlet pipe O-ring.
10. REMOVE WATER PUMP ASSEMBLY
(a) Remove the 16 bolts, water pump assembly and
water pump gasket.
INSPECTION
1. INSPECT WATER PUMP ASSEMBLY
(a) Visually check the drain hole and air hole for coolant
leakage.
(b) Turn the pulley, and check that the water pump
bearing moves smoothly and noiselessly.
If the bearing does not move smoothly and
noiselessly, replace the water pump.
A128112E03
A133375E04
A128120
A094889
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2GR-FE COOLING – WATER PUMPCO–13
CO
INSTALLATION
1. INSTALL WATER PUMP ASSEMBLY
(a) Install a new water pump gasket and the water
pump assembly with the 16 bolts.
Torque: Bolt A
21 N*m (214 kgf*cm, 15 ft.*lbf)
Bolts B and C
9.1 N*m (93 kgf*cm, 81 in.*lbf)
NOTICE:
• Make sure that there is no oil on the threads
of bolts A.
• Be sure to replace 2 bolts C with new ones or
reuse them after applying adhesive 1344.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond
1344 or equivalent
2. INSTALL WATER INLET HOUSING
(a) Install a new water inlet housing No. 1 gasket and
water outlet pipe O-ring.
(b) Install the water inlet housing with the 2 bolts and
nut.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
NOTICE:
Be careful not to allow the O-ring to get caught
between the parts.
(c) Connect the water hose.
3. INSTALL WATER PUMP PULLEY
(a) Temporarily install the water pump pulley with the 4
bolts.
(b) Using SST, hold the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)
(c) Tighten the 4 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
A128115E01
A128122
A133375E04
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CO–142GR-FE COOLING – WATER PUMP
CO
4. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Install the V-ribbed belt tensioner assembly with the
5 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
5. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the 2 idler pulley cover plates and idler pulley
sub-assemblies with the 2 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
6. INSTALL NO. 1 ENGINE FRONT MOUNTING
BRACKET LH (See page EM-45)
7. INSTALL GENERATOR ASSEMBLY (See page CH-26)
8. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
(See page AC-231)
9. INSTALL ENGINE HANGERS (See page EM-50)
10. REMOVE ENGINE STAND
11. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
HINT:
See page EM-44
12. ADD ENGINE COOLANT (See page CO-7)
13. INSPECT FOR COOLANT LEAK (See page CO-1)
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2GR-FE COOLING – COOLING SYSTEMCO–1
CO
COOLING SYSTEM
ON-VEHICLE INSPECTION
1. INSPECT FOR COOLANT LEAK
CAUTION:
Do not remove the radiator cap while the engine and
radiator are still hot. Pressurized, hot engine coolant
and steam may be released and cause serious
burns.
NOTICE:
Before performing each inspection, turn the A/C
switch OFF.
(a) Fill the radiator with coolant and attach a radiator
cap tester.
(b) Warm up the engine.
(c) Using a radiator cap tester, increase the pressure
inside the radiator to 118 kPa (1.2 kgf/cm
2, 17 psi),
and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and
water pump for leaks. If no external leaks are found,
check the heater core, cylinder block and cylinder
head.
2. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR
(a) Check that the engine coolant level is between the
LOW and FULL lines when the engine is cold.
If the engine coolant level is low, check for leaks and
add "TOYOTA Super Long Life Coolant" or similar
high quality ethylene glycol based non-silicate, non-
amine, non-nitrite and non-borate coolant with long-
life hybrid organic acid technology to the FULL line.
NOTICE:
Do not substitute plain water for engine coolant.
3. INSPECT ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
Do not remove the radiator cap while the engine
and radiator are still hot. Pressurized, hot
engine coolant and steam may be released and
cause serious burns.
(b) Check if there are any excessive deposits of rust or
scales around the radiator cap and radiator filler
hole. Also, the coolant should be free of oil.
If excessively dirty, clean the coolant passage and
replace the coolant.
(c) Install the radiator cap.
A161453

2GR-FE COOLING – THERMOSTATCO–17
CO
INSPECTION
1. INSPECT THERMOSTAT
(a) Inspect the thermostat.
HINT:
The valve opening temperature is inscribed on the
thermostat.
(b) Immerse the thermostat in water and gradually heat
the water.
(c) Check the valve opening temperature.
Valve opening temperature:
80 to 84
C (176 to 183F)
If the valve opening temperature is not as specified,
replace the thermostat.
(d) Check the valve lift.
Valve lift:
7.7 mm (0.303 in.) or more at 95
C (203F)
If the valve lift is not as specified, replace the
thermostat.
(e) Check that the valve is fully closed when the
thermostat is at low temperatures (below 40
C
(104
F)).
If it is not fully closed, replace the thermostat.
INSTALLATION
1. INSTALL THERMOSTAT
(a) Install a new gasket to the thermostat.
(b) Install the thermostat with the jiggle valve facing up.
HINT:
The jiggle valve may be set within 10
on either side
of the prescribed position.
2. INSTALL WATER INLET
(a) Install the water inlet with the 2 nuts .
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
P013560
P000436
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A132392E01
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CO–182GR-FE COOLING – THERMOSTAT
CO
3. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler pulley cover plate and idler pulley
sub-assembly with the bolt.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
4. CONNECT NO. 2 RADIATOR HOSE
(a) Connect the No. 2 radiator hose to the engine.
5. INSTALL V-RIBBED BELT (See page EM-7)
6. INSTALL FRONT FENDER APRON SEAL RH
7. INSTALL FRONT WHEEL RH
8. ADD ENGINE COOLANT (See page CO-7)
9. INSTALL NO. 1 ENGINE UNDER COVER (See page
EM-63)
10. INSPECT FOR COOLANT LEAK (See page CO-1)
11. INSTALL V-BANK COVER SUB-ASSEMBLY (See
page EM-63)
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