TOYOTA SIENNA 2007 Service Repair Manual

CO–462GR-FE COOLING – RADIATOR
CO
24. INSTALL BATTERY (See page EM-59)
25. INSTALL NO. 2 AIR CLEANER INLET (See page EM-
60)
26. ADD ENGINE COOLANT (See page CO-7)
27. INSPECT FOR COOLANT LEAK (See page CO-1)
28. ADD AUTOMATIC TRANSAXLE FLUID
29. CHECK AUTOMATIC TRANSAXLE FLUID (See page
AX-123)
30. INSTALL NO. 1 ENGINE UNDER COVER (See page
EM-63)
31. INSTALL V-BANK COVER SUB-ASSEMBLY (See
page EM-63)
32. VEHICLE PREPARATION FOR HEADLIGHT AIM
ADJUSTMENT (See page LI-71)
33. PREPARATION FOR HEADLIGHT AIMING (Using a
tester) (See page LI-71)
34. PREPARATION FOR HEADLIGHT AIMING (Using a
screen) (See page LI-72)
35. HEADLIGHT AIMING INSPECTION (See page LI-74)
36. HEADLIGHT AIMING ADJUSTMENT (See page LI-75)
37. VEHICLE PREPARATION FOR FOG LIGHT AIM
ADJUSTMENT (w/ Fog Light) (See page LI-82)
38. PREPARATION FOR FOG LIGHT AIMING (Using a
screen) (w/ Fog Light) (See page LI-83)
39. FOG LIGHT AIMING INSPECTION (w/ Fog Light) (See
page LI-84)
40. FOG LIGHT AIMING ADJUSTMENT (w/ Fog Light)
(See page LI-85)

2GR-FE LUBRICATION – OIL PUMPLU–13
LU
2. REMOVE OIL PUMP COVER
(a) Remove the 8 bolts, oil pump cover and oil pump
rotor set.
INSPECTION
1. INSPECT OIL PUMP RELIEF VALVE
(a) Coat the relief valve with engine oil and check that it
falls smoothly into the valve hole under its own
weight.
If the valve does not fall smoothly, replace the relief
valve. If necessary, replace the oil pump assembly.
2. INSPECT OIL PUMP ROTOR SET
(a) Install the rotors to the timing chain cover with the
rotors' marks facing outward. Check that the rotors
rotate smoothly.
(b) Check the tip clearance.
(1) Using a feeler gauge, measure the clearance
between the drive and driven rotors, as shown
in the illustration.
Tip clearance
If the clearance is greater than the maximum,
replace the drive and driven rotors.
(c) Check the side clearance.
(1) Using a feeler gauge and precision
straightedge, measure the clearance between
the rotors and precision straightedge, as shown
in the illustration.
Side clearance
If the side clearance is greater than the
maximum, replace the timing chain cover.
A128009
A094628
A128010E01
A128011
Standard Maximum
0.060 to 0.160 mm (0.0024 to 0.0063 in.) 0.160 mm (0.0063 in.)
A128012
Standard Maximum
0.030 to 0.090 mm (0.0012 to 0.0035 in.) 0.090 mm (0.0035 in.)

LU–142GR-FE LUBRICATION – OIL PUMP
LU
(d) Check the body clearance.
(1) Using a feeler gauge, measure the clearance
between the timing chain cover and driven
rotor, as shown in the illustration.
Body clearance
If the body clearance is greater than the
maximum, replace the timing chain cover.
REASSEMBLY
1. INSTALL OIL PUMP COVER
(a) Coat the drive and driven rotors with engine oil and
place them into the timing chain cover with the
marks facing outward (oil pump cover side). Check
that the rotors rotate smoothly.
(b) Install the oil pump cover with the 8 bolts.
Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf)
Bolt length
2. INSTALL OIL PUMP RELIEF VALVE
(a) Coat the oil pump relief valve with engine oil.
(b) Insert the relief valve and relief valve spring into the
oil pump cover hole.
(c) Using a 27 mm socket wrench, install the plug.
Torque: 49 N*m (500 kgf*cm, 37 ft.*lbf)
INSTALLATION
1. INSTALL TIMING CHAIN CASE OIL SEAL
(a) Using SST, tap in a new oil seal until its surface is
flush with the timing chain case edge.
SST 09223-22010, 09506-35010
NOTICE:
• Keep the lip free from foreign matter.
• Do not tap on the oil seal at an angle.
• Make sure that the oil seal edge does not
stick out of the timing chain case.
A128013
Standard Maximum
0.250 to 0.325 mm (0.0098 to 0.0128 in.) 0.325 mm (0.0128 in.)
A128010E02
A094627E02
Item Length
Bolt A 22 mm (0.87 in.)
Bolt B 40 mm (1.58 in.)
A128008
A125109E04

2GR-FE LUBRICATION – OIL PUMPLU–15
LU
2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) Apply seal packing in a continuous line to the
engine unit as shown in the following illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three
Bond 1207B or equivalent
Seal diameter:
3.0 mm (0.118 in.)
NOTICE:
• Be sure to clean and degrease the contact
surfaces, especially the surfaces indicated by
C in the illustration.
• When the contact surfaces are wet, wipe them
with an oil-free cloth before applying seal
packing.
• Install the chain cover within 3 minutes.
• Do not start the engine for at least 2 hours
after installing.
A132228E03

LU–162GR-FE LUBRICATION – OIL PUMP
LU
(b) Apply seal packing in a continuous line to the timing
chain cover as shown in the following illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three
Bond 1207B or equivalent
Toyota Genuine Seal Packing 1282B, Three
Bond 1282B or equivalent
A134901E05

2GR-FE LUBRICATION – OIL PUMPLU–17
LU
NOTICE:
• When the contact surfaces are wet, wipe them
with an oil-free cloth before applying seal
packing.
• Install the chain cover within 3 minutes and
tighten the bolts within 15 minutes after
applying seal packing.
• Do not start the engine for at least 2 hours
after installing it.
Apply seal packing as follows
(c) Install a new gasket.
(d) Align the oil pump's drive rotor spline and the
crankshaft as shown in the illustration. Install the
spline and chain cover to the crankshaft.
(e) Temporarily tighten the timing chain cover with the
23 bolts and 2 nuts.
Area Seal Packing Diameter Application Position from Inside Seal Line
Continuous Line Area 4.5 mm (0.177 in.) or more 3.0 to 4.0 mm (0.118 to 0.158 in.)
Alternate Long and Short Dashed Line
Area3.5 mm (0.138 in.) or more 2.0 to 3.0 mm (0.079 to 0.118 in.)
Dashed Line Area 3.5 mm (0.138 in.) or more 3.0 to 4.0 mm (0.118 to 0.158 in.)
Diagonal Line Area 6.0 mm (0.236 in.) or more 5.0 mm (0.197 in.)
A128017E01
A132229E02
A128019E02

LU–182GR-FE LUBRICATION – OIL PUMP
LU
Bolt length
NOTICE:
Make sure that there is no oil on the bolt
threads.
(f) Fully tighten the bolts in: Area 1 and Area 2.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(g) Fully tighten the bolts and nuts in: Area 3.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
HINT:
Tighten the bolts and nuts from top to bottom as
shown in the illustration.
(h) Fully tighten the bolts in: Area 4.
Torque: Bolt A
43 N*m (438 kgf*cm, 32 ft.*lbf)
Except bolt A
21 N*m (214 kgf*cm, 15 ft.*lbf)
HINT:
Tighten the bolts from bottom to top as shown in the
illustration.
3. INSTALL WATER INLET HOUSING (See page CO-13)
4. INSTALL OIL PAN SUB-ASSEMBLY (See page EM-
160)
5. INSTALL OIL STRAINER SUB-ASSEMBLY (See page
EM-161)
6. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY (See page
EM-162)
7. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 1) (See page EM-163)
8. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 2) (See page EM-163)
9. INSTALL CRANKSHAFT PULLEY (See page EM-166)
10. INSTALL OIL COOLER PIPE
(a) Install a new gasket to the oil pan sub-assembly.
(b) Install the oil cooler pipe with the bolt and 2 nuts.
Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
11. INSTALL NO. 1 OIL PIPE (See page EM-167)
12. INSTALL OIL PIPE (See page EM-168)
13. INSTALL OIL LEVEL GAUGE GUIDE SUB-
ASSEMBLY (See page EM-48)
14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
HINT:
See page EM-44
Item Length
Bolt A 40 mm (1.57 in.)
Bolt B 55 mm (2.17 in.)
Bolt C 25 mm (0.98 in.)
A141494

2GR-FE LUBRICATION – ENGINE OIL COOLERLU–21
LU
INSTALLATION
1. INSTALL ENGINE OIL COOLER
(a) Clean the oil cooler contact surface on the cooler
mounting.
(b) Install a new O-ring to the oil cooler.
(c) Install the oil cooler assembly with the union bolt.
Torque: 68 N*m (693 kgf*cm, 50 ft.*lbf)
Install the 2 water by-pass hoses with the bolt, 2
clamps, and 4 clips.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
(See page EM-47)
3. INSTALL NO. 2 EXHAUST MANIFOLD HEAT
INSULATOR (See page EM-48)
4. INSTALL NO. 2 MANIFOLD STAY (See page EM-48)
5. INSTALL EXHAUST PIPE ASSEMBLY
for 2WD:(See page EX-4)
for 4WD:(See page EX-10)
6. ADD ENGINE OIL (See page LU-6)
7. ADD ENGINE COOLANT (See page CO-7)
8. INSPECT FOR OIL LEAK (See page LU-6)
9. CHECK ENGINE OIL LEVEL
10. INSTALL NO. 1 ENGINE UNDER COVER (See page
EM-63)
A136292
A136291

2GR-FE LUBRICATION – LUBRICATION SYSTEMLU–1
LU
LUBRICATION SYSTEM
ON-VEHICLE INSPECTION
1. CHECK ENGINE OIL LEVEL
(a) Warm up the engine, stop it and wait 5 minutes. The
oil level should be between the dipstick's low level
mark and full level mark.
If the engine oil level is low, check for leakage and
add oil up to the full level mark.
NOTICE:
Do not add engine oil above the full level mark.
2. CHECK ENGINE OIL
(a) Check the engine oil for deterioration, water
contamination, discoloring or thinning.
If the oil is bad, replace the engine oil and engine oil
filter.
3. CHECK OIL PRESSURE
(a) Disconnect the oil pressure switch connector.
(b) Using a 24 mm deep socket wrench, remove the oil
pressure switch.
(c) Install the oil pressure gauge with adapter.
(d) Warm up the engine.
(e) Check the oil pressure.
Standard oil pressure
If the oil pressure is not as specified, check the oil
pump (See page LU-13).
(f) Remove the oil pressure gauge.
(g) Apply adhesive to 2 or 3 threads of the oil pressure
switch.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond
1344 or equivalent
A160879
A160880
Engine Condition Oil Pressure
Idle
80 kPa (0.8 kgf/cm
2, 11.6 psi) or more
3000 rpm380 kPa (3.9 kgf/cm
2, 55.5 psi) or
more
A050082E21

LU–22GR-FE LUBRICATION – LUBRICATION SYSTEM
LU
(h) Using a 24 mm deep socket wrench, install the oil
pressure switch.
Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)
NOTICE:
Do not start the engine within 1 hour after
installation.
(i) Connect the oil pressure switch connector.
(j) Check for engine oil leaks.
A160879