check engine TOYOTA SIENNA 2007 Service Repair Manual

EM–1042GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(h) Check for smooth rotation.
(1) Turn the camshaft timing gear assembly within
its movable range (21
) 2 or 3 times, but do not
turn it to the most retarded position. Make sure
that the gear turns smoothly.
NOTICE:
Do not use air pressure to perform the
smooth operation check.
(i) Check the lock in the most retarded position.
(1) Confirm that the camshaft timing gear
assembly is locked at the most retarded
position.
(j) Remove the flange bolt and camshaft timing gear
assembly.
NOTICE:
• Do not remove the other 3 bolts.
• If planning to reuse the gear, be sure to
release the straight pin lock before installing
the gear.
5. INSPECT CAMSHAFT TIMING EXHAUST GEAR
ASSEMBLY
(a) Clamp the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft in the
vise.
(b) Put the camshaft timing exhaust gear assembly and
camshaft together by aligning the key groove and
straight pin.
(c) Lightly press the camshaft timing gear against the
camshaft, and turn the camshaft timing gear
assembly. Push further at the position where the pin
enters the groove.
NOTICE:
Be sure not to turn the camshaft timing exhaust
gear in the retard direction (the right angle).
(d) Check that there is no clearance between the gear's
flange and the camshaft.
(e) Tighten the flange bolt with the camshaft timing
exhaust gear assembly fixed.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
(f) Check the camshaft timing exhaust gear lock.
(1) Make sure that the camshaft timing exhaust
gear assembly is locked.
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EM–1062GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(h) Check for smooth rotation.
(1) Turn the camshaft timing exhaust gear within
its movable range (18.5
) 2 or 3 times, but do
not turn it to the most advanced position. Make
sure that the gear turns smoothly.
NOTICE:
When the air pressure is released from the
advance side path and then from the retard
side path, the gear automatically returns to
the most advanced position due to the
advance assist spring operation and locks.
Gradually release the air pressure from the
retard side path before performing the
smooth rotation check.
(i) Check the lock at the most advanced position.
(1) Make sure that the camshaft timing exhaust
gear is locked at the most advanced position.
(j) Remove the flange bolt and camshaft timing
exhaust gear.
NOTICE:
• Be sure not to remove the other 4 bolts.
• If planning to reuse the gear, be sure to
release the straight pin lock before installing
the gear.
6. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the minimum
diameter of the elongated thread at the measuring
point.
Standard outside diameter:
10.85 to 11.00 mm (0.4272 to 0.4331 in.)
Minimum outside diameter:
10.70 mm (0.4213 in.)
Measuring Point:
103 mm (4.06 in.)
HINT:
If a visual check reveals no excessively thin areas,
check the center of the bolt and find the area that
has the lowest diameter.
If the diameter is less than the minimum, replace the
cylinder head bolt.
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EM–1082GR-FE ENGINE MECHANICAL – ENGINE UNIT
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11. INSPECT IDLE GEAR SHAFT OIL CLEARANCE
(a) Using a micrometer, measure the idle gear shaft
diameter.
Idle gear shaft diameter:
22.987 to 23.000 mm (0.9050 to 0.9055 in.)
(b) Using a caliper gauge, measure the inside diameter
of the idle sprocket.
Idle gear inside diameter:
23.020 to 23.030 mm (0.9063 to 0.9067 in.)
(c) Subtract the idle gear shaft diameter measurement
from the idle sprocket inside diameter
measurement.
Standard oil clearance:
0.020 to 0.043 mm (0.0008 to 0.0017 in.)
Maximum oil clearance:
0.093 mm (0.0037 in.)
If the thrust oil clearance is greater than the
maximum, replace the idle gear shaft and idle
sprocket.
12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Move the stopper plate upward to release the lock.
Push the plunger and check that it moves smoothly.
If necessary, replace the No. 1 chain tensioner
assembly.
13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Check that the plunger moves smoothly.
(b) Measure the worn depth of the No. 2 chain
tensioner.
Maximum depth:
0.9 mm (0.035 in.)
If the depth is greater than the maximum, replace
the No. 2 chain tensioner assembly.
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14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Check that the plunger moves smoothly.
(b) Measure the worn depth of the No. 3 chain
tensioner.
Maximum depth:
0.9 mm (0.035 in.)
If the depth is greater than the maximum, replace
the No. 3 chain tensioner assembly.
15. INSPECT CHAIN TENSIONER SLIPPER
(a) Measure the worn depth of the chain tensioner
slipper.
Maximum depth:
1.0 mm (0.039 in.)
If the depth is greater than the maximum, replace
the chain tensioner slipper.
16. INSPECT NO. 1 CHAIN VIBRATION DAMPER
(a) Measure the worn depth of the No. 1 chain vibration
damper.
Maximum depth:
1.0 mm (0.039 in.)
If the depth is greater than the maximum, replace
the No. 1 chain vibration damper.
17. INSPECT NO. 2 CHAIN VIBRATION DAMPER
(a) Measure the worn depth of the No. 2 chain vibration
damper.
Maximum depth:
1.0 mm (0.039 in.)
If the depth is greater than the maximum, replace
the No. 2 chain vibration damper.
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EM–1102GR-FE ENGINE MECHANICAL – ENGINE UNIT
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18. INSPECT CYLINDER HEAD SUB-ASSEMBLY
(a) Using a precision straight edge and feeler gauge,
measure the warpage of the contact surface of the
cylinder block and manifolds.
Standard warpage
Maximum warpage
If the warpage is greater than the maximum, replace
the cylinder head assembly.
(b) Using a dye penetrant, check the intake ports,
exhaust ports and cylinder surface for cracks.
If cracked, replace the cylinder head assembly.
19. INSPECT INTAKE VALVE
(a) Using a micrometer, measure the diameter of the
valve stem.
Valve stem diameter:
5.470 to 5.485 mm (0.2154 to 0.2159 in.)
If the valve stem is not as specified, check the oil
clearance.
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Item Warpage
Cylinder head lower 0.05 mm (0.0020 in.)
Intake 0.08 mm (0.0031 in.)
Exhaust 0.08 mm (0.0031 in.)
Item Warpage
Cylinder head lower 0.10 mm (0.0039 in.)
Intake 0.10 mm (0.0039 in.)
Exhaust 0.10 mm (0.0039 in.)
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(b) Using vernier calipers, measure the valve head
margin thickness.
Standard margin thickness:
1.0 mm (0.039 in.)
Minimum margin thickness:
0.5 mm (0.0197 in.)
If the margin thickness is less than the minimum,
replace the intake valve.
(c) Using vernier calipers, measure the valve's overall
length.
Standard overall length:
105.85 mm (4.1673 in.)
Minimum overall length:
105.35 mm (4.1476 in.)
If the overall length is less than the minimum,
replace the intake valve.
20. INSPECT EXHAUST VALVE
(a) Using a micrometer, measure the diameter of the
valve stem.
Valve stem diameter:
5.465 to 5.480 mm (0.2151 to 0.2157 in.)
If the valve stem is not as specified, check the oil
clearance.
(b) Using vernier calipers, measure the valve head
margin thickness.
Standard margin thickness:
1.0 mm (0.039 in.)
Minimum margin thickness:
0.5 mm (0.0197 in.)
If the margin thickness is less than the minimum,
replace the exhaust valve.
(c) Using vernier calipers, measure the valve's overall
length.
Standard overall length:
110.40 mm (4.3464 in.)
Minimum overall length:
109.90 mm (4.3268 in.)
If the overall length is less than the minimum,
replace the exhaust valve.
21. INSPECT INTAKE VALVE SEAT
(a) Apply a light coat of Prussian blue to the valve face.
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EM–1122GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(b) Lightly press the valve face against the valve seat.
(c) Check the valve face and valve spring seat by using
the following procedure:
(1) If Prussian blue appears around the entire
valve face, the valve face is concentric. If not,
replace the valve.
(2) If Prussian blue appears around the entire
valve seat, the guide and valve face are
concentric. If not, resurface the valve spring
seat.
(3) Check that the valve spring seat contacts in the
middle of the valve face with the width between
1.1 and 1.5 mm (0.043 and 0.059 in.).
22. INSPECT EXHAUST VALVE SEAT
(a) Apply a light coat of Prussian blue to the valve face.
(b) Lightly press the valve face against the valve spring
seat.
(c) Check the valve face and valve spring seat by using
the following procedure:
(1) If Prussian blue appears around the entire
valve face, the valve face is concentric. If not,
replace the valve.
(2) If Prussian blue appears around the entire
valve seat, the guide and valve face are
concentric. If not, resurface the valve spring
seat.
(3) Check that the valve spring seat contacts in the
middle of the valve face with the width between
1.1 and 1.5 mm (0.043 and 0.059 in.).
23. REPAIR INTAKE VALVE SEAT
NOTICE:
• Repair the seat while checking the seating
position.
• Keep the lip free of foreign matter.
(a) Using a 45
cutter, resurface the valve spring seat
so that the valve spring seat width is more than the
specification.
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(b) Using 30 and 60 cutters, correct the valve seat so
that the valve contacts the entire circumference of
the seat. The contact should be in the center of the
valve spring seat, and the valve spring seat width
should be maintained within the specified range
around the entire circumference of the seat.
Width:
1.1 to 1.5 mm (0.043 to 0.059 in.)
(c) Handrub the valve and valve seat with an abrasive
compound.
(d) Check the valve seating position.
24. REPAIR EXHAUST VALVE SEAT
NOTICE:
• Repair the seat while checking the seating
position.
• Keep the lip free of foreign matter.
(a) Using a 45
cutter, resurface the valve spring seat
so that the valve spring seat width is more than the
specification.
(b) Using 30
and 75 cutters, correct the valve seat so
that the valve contacts the entire circumference of
the seat. The contact should be in the center of the
valve seat, and the valve seat width should be
maintained within the specified range around the
entire circumference of the seat.
Width:
1.1 to 1.5 mm (0.043 to 0.059 in.)
(c) Handrub the valve and valve seat with an abrasive
compound.
(d) Check the valve seating position.
25. INSPECT INNER COMPRESSION SPRING
(a) Using vernier calipers, measure the free length of
the inner compression spring.
Free length:
45.46 mm (1.7898 in.)
If the free length is not as specified, replace the
inner compression spring.
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(i) Lay a strip of Plastigage across each of the
camshaft journals.
(j) Install the bearing caps (See page EM-126).
NOTICE:
Do not turn the camshaft.
(k) Remove the bearing caps (See page EM-76).
(l) Measure the Plastigage at its widest point.
Standard oil clearance
Maximum oil clearance
If the oil clearance is greater than the maximum,
replace the camshaft. If necessary, replace the
camshaft housing.
29. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Install the connecting rod cap (See page EM-126).
(b) Using a dial indicator, measure the thrust clearance
while moving the connecting rod back and forth.
Standard thrust clearance:
0.15 to 0.40 mm (0.0059 to 0.0157 in.)
Maximum thrust clearance:
0.50 mm (0.020 in.)
If the thrust clearance is greater than the maximum,
replace the connecting rod assemblies as
necessary. If necessary, replace the crankshaft.
30. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Clean the crank pin and bearing.
(b) Check the crank pin and bearing for pitting and
scratches.
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Item Oil Clearance
No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journals 0.025 to 0.062 mm (0.00098 to 0.0024 in.)
Item Oil Clearance
No. 1 journal 0.10 mm (0.0039 in.)
Other journals 0.09 mm (0.0035 in.)
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(c) Lay a strip of Plastigage on the crank pin.
(d) Check that the front mark of the connecting rod cap
is facing forward.
(e) Install the connecting rod cap (See page EM-126).
NOTICE:
Do not turn the crankshaft.
(f) Remove the 2 bolts and connecting rod cap (See
page EM-76).
(g) Measure the Plastigage at its widest point.
Standard oil clearance:
0.045 to 0.067 mm (0.0018 to 0.0026 in.)
Maximum oil clearance:
0.070 mm (0.0028 in.)
If the oil clearance is greater than the maximum,
replace the connecting rod bearings. If necessary,
inspect the crankshaft.
HINT:
If replacing a bearing, replace it with one that has
the same number as its respective connecting rod
cap. Each bearing's standard thickness is indicated
by a 1, 2, 3 or 4 mark on its surface.
Connecting rod diameter
Connecting rod bearing center wall thickness
Crankshaft pin diameter:
52.992 to 53.000 mm (2.0863 to 2.0866 in.)
NOTICE:
Completely remove the Plastigage after the
measurement.
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Mark Diameter
1 56.000 to 56.006 mm (2.2047 to 2.2050 in.)
2 56.007 to 56.012 mm (2.2050 to 2.2052 in.)
3 56.013 to 56.018 mm (2.2052 to 2.2054 in.)
4 56.019 to 56.024 mm (2.2055 to 2.2057 in.)
Mark Thickness
1 1.481 to 1.484 mm (0.0583 to 0.0584 in.)
2 1.484 to 1.487 mm (0.0584 to 0.0585 in.)
3 1.487 to 1.490 mm (0.0585 to 0.0587 in.)
4 1.490 to 1.493 mm (0.0587 to 0.0588 in.)