check engine TOYOTA SIENNA 2007 Service Repair Manual

EM–1182GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
31. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Install the crankshaft bearing cap (See page EM-
126).
(b) Using a dial indicator, measure the thrust clearance
while prying the crankshaft back and forth with a
screwdriver.
Standard thrust clearance:
0.04 to 0.24 mm (0.0016 to 0.0094 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than the maximum,
replace the thrust washers as a set. If necessary,
replace the crankshaft.
Thrust washer thickness:
2.43 to 2.48 mm (0.0957 to 0.0976 in.)
32. INSPECT CYLINDER BLOCK FOR WARPAGE
(a) Using a precision straight edge and feeler gauge,
measure the warpage of the contact surface of the
cylinder head gasket.
Maximum warpage:
0.07 mm (0.0028 in.)
If the warpage is greater than the maximum, replace
the cylinder block.
33. INSPECT CYLINDER BORE
(a) Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 6
cylinders. If necessary, replace the cylinder block.
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EM–1222GR-FE ENGINE MECHANICAL – ENGINE UNIT
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39. INSPECT CONNECTING ROD
(a) Using a rod aligner and feeler gauge, check the
connecting rod alignment.
(1) Check for out-of-alignment.
Maximum out-of-alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If the out-of-alignment is greater than the
maximum, replace the connecting rod
assembly.
(2) Check for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than the maximum,
replace the connecting rod assembly.
40. INSPECT CONNECTING ROD BOLT
(a) Using vernier calipers, measure the tension portion
diameter of the bolt.
Standard diameter:
7.2 to 7.3 mm (0.284 to 0.287 in.)
Minimum diameter:
7.0 mm (0.276 in.)
If the diameter is less than the minimum, replace the
bolt.
41. INSPECT CRANKSHAFT
(a) Inspect for circle runout.
(1) Clean the crank journal.
(2) Place the crankshaft on V-blocks.
(3) Using a dial indicator, measure the circle runout
at the center journal.
Maximum circle runout:
0.06 mm (0.0024 in.)
If the circle runout is greater than the
maximum, replace the crankshaft.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–123
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(b) Inspect the main journals.
(1) Using a micrometer, measure the diameter of
each main journal.
Standard journal diameter:
60.988 to 61.000 mm (2.4011 to 2.4016 in.)
If the diameter is not as specified, check the oil
clearance. If necessary, replace the crankshaft.
(2) Check each main journal for taper and out-of-
round as shown in the illustration.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
If the taper and out-of-round is greater than the
maximum, replace the crankshaft.
(c) Inspect the crank pin.
(1) Using a micrometer, measure the diameter of
each crank pin.
Crankshaft pin diameter:
52.992 to 53.000 mm (2.0863 to 2.0866 in.)
If the diameter is not as specified, check the oil
clearance. If necessary, replace the crankshaft.
(2) Check each crank pin for taper and out-of-
round as shown in the illustration.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
If the taper and out-of-round is greater than the
maximum, replace the crankshaft.
42. INSPECT CRANKSHAFT OIL CLEARANCE
(a) Check the crank journal and bearing for pitting and
scratches.
(b) Install the crankshaft bearing (See page EM-126).
(c) Place the crankshaft on the cylinder block.
(d) Lay a strip of Plastigage across each journal.
(e) Examine the front marks and numbers and install
the bearing caps on the cylinder block.
HINT:
A number is marked on each main bearing cap to
indicate the installation position.
(f) Install the main bearing cap (See page EM-126).
NOTICE:
Do not turn the crankshaft.
(g) Remove the main bearing caps (See page EM-76).
(h) Measure the Plastigage at its widest point.
Standard oil clearance:
0.026 to 0.047 mm (0.0010 to 0.0019 in.)
Maximum oil clearance:
0.050 mm (0.0020 in.)
If the oil clearance is greater than the maximum,
replace the bearings. If necessary, replace the
crankshaft.
NOTICE:
Completely remove the Plastigage after the
measurement.
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2GR-FE ENGINE MECHANICAL – ENGINEEM–1
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ENGINE
ON-VEHICLE INSPECTION
1. INSPECT ENGINE COOLANT
(a) Inspect the engine coolant (See page CO-1).
2. INSPECT ENGINE OIL
(a) Inspect the engine oil (See page LU-1).
3. INSPECT BATTERY
(a) Inspect the battery (See page CH-5).
4. INSPECT AIR CLEANER FILTER ELEMENT SUB-
ASSEMBLY
(a) Remove the air cleaner filter element sub-assembly.
(b) Visually check that there is no dirt, blockage, and/or
damage to the air cleaner filter element.
HINT:
• If there is any dirt or a blockage in the air cleaner
filter element, clean it with compressed air.
• If any dirt or a blockage remains even after
cleaning the air cleaner filter element with
compressed air, replace it.
5. INSPECT SPARK PLUG
(a) Inspect the spark plugs (See page IG-5).
6. INSPECT VALVE LASH ADJUSTER NOISE
(a) Rev up the engine several times. Check that the
engine does not emit unusual noises.
If unusual noises occur, warm up the engine and
idle it for over 30 minutes. Then repeat this
procedure.
HINT:
If any defects or problems are found during the
inspection above, perform lash adjuster inspection
(See page EM-100).
7. INSPECT IGNITION TIMING
(a) Warm up the engine.
(b) When using the intelligent tester:
Check the ignition timing.
(1) Connect the intelligent tester to the DLC3.
(2) Enter DATA LIST mode with the intelligent
tester.
Ignition timing:
8 to 12
BTDC at idle
HINT:
Refer to the intelligent tester operator's manual
for help when selecting the DATA LIST.
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EM–22GR-FE ENGINE MECHANICAL – ENGINE
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(c) When not using the intelligent tester:
Check the ignition timing.
(1) Using SST, connect terminals 13 (TC) and 4
(CG) of the DLC3.
SST 09843-18040
NOTICE:
• Confirm the terminal numbers before
connecting them. Connection with a
wrong terminal can damage the engine.
• Turn off all electrical systems before
connecting the terminals.
• Perform this inspection after the cooling
fan motor is turned off.
(2) Remove the V-bank cover.
(3) Pull out the red lead wire harness.
(4) Connect the tester terminal of the timing light to
the red lead wire as shown in the illustration.
NOTICE:
Use a timing light which can detect the first
signal.
(5) Check the ignition timing at idle.
Ignition timing:
8 to 12
BTDC at idle
NOTICE:
When checking the ignition timing, the
transmission should be in neutral.
HINT:
Run the engine at 1000 to 1300 rpm for 5
seconds, and then check that the engine rpm
returns to idle speed.
(6) Disconnect terminals 13 (TC) and 4 (CG) of the
DLC3.
(7) Check the ignition timing at idle.
Ignition timing:
7 to 24
BTDC at idle
(8) Confirm that the ignition timing moves to the
advanced angle side when the engine rpm is
increased.
(9) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up the engine.
(b) When using the intelligent tester:
Check the idle speed.
(1) Connect the intelligent tester to the DLC3.
(2) Enter DATA LIST mode with the intelligent
tester.
Idle speed:
600 to 700 rpm
NOTICE:
• When checking the idle speed, the
transmission should be in neutral.
• Check the idle speed with the cooling fan
off.
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2GR-FE ENGINE MECHANICAL – ENGINEEM–3
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• Switch off all accessories and air
conditioning before connecting the
intelligent tester.
HINT:
Refer to the intelligent tester operator's manual
for further details.
(c) When not using the intelligent tester:
Check the idle speed.
(1) Using SST, connect the tachometer test probe
to terminal 9 (TAC) of the DLC3.
SST 09843-18030
(2) Check the idle speed.
Idle speed:
600 to 700 rpm
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the intake air surge tank (See page ES-
521).
(d) Remove the 6 ignition coils.
(e) Remove the 6 spark plugs.
(f) Check the cylinder compression pressure.
(1) Insert a compression gauge into the spark plug
hole.
(2) While cranking the engine, measure the
compression pressure.
Compression pressure:
1.3 MPa (13 kgf/cm
2, 189 psi)
Minimum pressure:
0.98 MPa (10 kgf/cm
2, 142 psi)
Difference between each cylinder:
0.1 MPa (1.0 kgf/cm
2, 15 psi)
NOTICE:
• Always use a fully charged battery to
obtain an engine speed of 250 rpm or
more.
• Check the other cylinders' compression
pressure in the same way.
• This measurement must be done as
quickly as possible.
(3) If the cylinder compression is low, pour a small
amount of engine oil into the cylinder through
the spark plug hole and inspect again.
HINT:
• If adding oil increases the compression, the
piston rings and/or cylinder bore may be
worn or damaged.
• If pressure stays low, a valve may be stuck
or seated improperly, or there may be
leakage in the gasket.
(g) Install the 6 spark plugs.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
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EM–42GR-FE ENGINE MECHANICAL – ENGINE
EM
(h) Install the 6 ignition coils.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(i) Install the intake air surge tank (See page ES-522).
10. INSPECT CO/HC
(a) Start the engine.
(b) Run the engine at 2500 rpm for approximately 180
seconds.
(c) Insert the CO/HC meter testing probe at least 40 cm
(1.3 ft.) into the tailpipe during idling.
(d) Check CO/HC concentration at idle and/or 2500
rpm.
HINT:
Check regulations and restrictions in your area
when performing 2 mode CO/HC concentration
testing (engine check at both idle speed and at 2500
rpm).
If the CO/HC concentration does not comply with
regulations, perform troubleshooting in the order
given below.
(1) Check air fuel ratio sensor and heated oxygen
sensor operation.
(2) See the table below for possible causes, and
then inspect and repair.
CO HC Problems Causes
Normal High Rough idle1. Faulty ignitions:
– Incorrect timing
– Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaks in intake and exhaust valves
4. Leaks in cylinders
Low HighRough idle
(fluctuating HC reading)1. Vacuum leaks:
– PCV hoses
– Intake manifold
– Throttle body
– Brake booster line
2. Lean mixture causing misfire
High HighRough idle
(black smoke from exhaust)1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI system:
– Faulty fuel pressure regulator
– Defective ECT sensor
– Defective MAF meter
–Faulty ECM
– Faulty injectors
– Faulty throttle position sensor

EM–1282GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(b) Gradually heat the piston to approximately 80C
(176
F).
(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting
rod, and push in the piston pin with your thumb.
HINT:
The piston and pin are a matched set.
(e) Check the fitting condition between the piston and
piston pin by trying to move the piston back and
forth on the piston pin.
(f) Using a screwdriver, install a new piston pin hole
snap ring at the other end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not
aligned with the pin hole cutout portion of the piston.
5. INSTALL PISTON RING SET
(a) Install the oil ring expander and 2 side rails by hand.
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EM–1322GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(h) Install the 8 crankshaft bearing cap bolts to the
outside positions.
(i) Install the crankshaft bearing cap bolts.
HINT:
The crankshaft bearing cap bolts are tightened in 2
progressive steps.
(j) Step 1
(1) Install and uniformly tighten the 16 crankshaft
bearing cap bolts in the sequence shown in the
illustration.
Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)
If any of the crankshaft bearing cap bolts does
not meet the torque specified, replace it.
(k) Step 2
(1) Mark the front of the bearing cap bolts with
paint.
(2) Retighten the bearing cap bolts 90
in the order
above.
(3) Check that the painted mark is now at a 90

angle to the front.
(l) Install 8 new seal washers and uniformly tighten the
8 crankshaft bearing cap bolts in several steps and
in the sequence shown in the illustration.
Torque: 52 N*m (525 kgf*cm, 38 ft.*lbf)
Bolt length
(m) Check that the crankshaft turns smoothly.
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Item Length
Bolt A 45 mm (1.77 in.)
Except bolt A 30 mm (1.18 in.)

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–133
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(n) Check the crankshaft thrust clearance (See page
EM-118).
9. INSTALL CONNECTING ROD BEARING
(a) Install the connecting rod bearing to the connecting
rod and connecting rod cap.
(b) Using vernier calipers, measure the distance
between the connecting rod's and bearing cap's
edges and the connecting rod bearing's edge.
Dimension (A - B):
0.7 mm (0.0276 in.) or less
NOTICE:
Do not apply engine oil to the bearings and the
contact surfaces.
10. INSTALL PISTON SUB-ASSEMBLY WITH
CONNECTING ROD
(a) Apply engine oil to the cylinder walls, the pistons,
and the surfaces of the connecting rod bearings.
(b) Position the piston rings so that the ring ends are as
shown in the illustration.
NOTICE:
Do not align the ring ends.
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