check engine TOYOTA SIENNA 2007 Service Repair Manual

EM–1282GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(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.)

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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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EM–1342GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(c) Using a piston ring compressor, push the correctly
numbered piston and connecting rod assembly into
the cylinder with the front mark of the piston facing
forward.
NOTICE:
Match the numbered connecting rod cap with
the connecting rod.
(d) Check that the front mark of the connecting rod cap
is facing forward.
(e) Apply a light coat of engine oil to the threads and
under the heads of the connecting rod cap bolts.
(f) Install the connecting cap bolts.
HINT:
The connecting cap bolts are tightened in 2
progressive steps.
(g) Step 1
(1) Install and alternately tighten the bolts of the
connecting rod cap in several steps.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
(h) Step 2
(1) Mark the front side of each connecting cap bolt
with paint.
(2) Retighten the cap bolts 90
as shown in the
illustration.
(3) Check the painted mark is now at a 90
angle
to the front.
(i) Check that the crankshaft turns smoothly.
(j) Check the connecting rod thrust clearance (See
page EM-116 ).
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(e) Step 2
(1) Mark the cylinder head bolt head with paint as
shown in the illustration.
(2) Tighten the cylinder head bolts another 90
.
(f) Step 3
(1) Tighten the cylinder head bolts an additional
90
.
(2) Check that the painted mark is now facing
rearward.
27. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
(a) Place the cylinder head gasket on the cylinder block
surface with the Lot No. stamp upward.
NOTICE:
• Be careful of the installation direction.
• Gently place the cylinder head in order not to
damage the gasket with the bottom part of the
head.
(b) Place the cylinder head on the cylinder block.
NOTICE:
Be careful not to allow oil to adhere to the
bottom part of the cylinder head.
HINT:
The cylinder head bolts are tightened in 3
progressive steps.
(c) Apply a light coat of engine oil to the threads and
under the heads of the cylinder head bolts.
(d) Step 1
(1) Using a 10 mm bi-hexagon wrench, install and
uniformly tighten the 8 cylinder head bolts with
the plate washers in several steps in the
sequence shown in the illustration.
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
(e) Step 2
(1) Mark the cylinder head bolt head with paint as
shown in the illustration.
(2) Tighten the cylinder head bolts another 90
.
(f) Step 3
(1) Tighten the cylinder head bolts an additional
90
.
(2) Check that the painted mark is now facing
rearward.
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EM–1442GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(g) Tighten the 2 bolts in the order shown in the
illustration.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
28. INSTALL VALVE LASH ADJUSTER ASSEMBLY
NOTICE:
• Keep the lash adjuster free of dirt and foreign
objects.
• Only use clean engine oil.
(a) Place the lash adjuster into a container filled with
engine oil.
(b) Insert SST's tip into the lash adjuster's plunger and
use the tip to press down on the check ball inside
the plunger.
SST 09276-75010
(c) Squeeze SST and lash adjuster together to move
the plunger up and down 5 to 6 times.
(d) Check the movement of the plunger and bleed the
air.
OK:
Plunger moves up and down.
NOTICE:
When bleeding air from the high-pressure
chamber, make sure that the tip of SST is
actually pressing the check ball as shown in the
illustration. If the check ball is not pressed, air
will not bleed.
(e) After bleeding the air, remove SST. Then, try to
press the plunger quickly and firmly with a finger.
OK:
Plunger is very difficult to move.
If the result is not as specified, replace the lash
adjuster.
(f) Install the lash adjusters.
NOTICE:
Install the lash adjuster to the same place where
it was removed from.
29. INSTALL NO. 1 VALVE ROCKER ARM SUB-
ASSEMBLY
(a) Apply engine oil to the lash adjuster tip and valve
stem cap end.
(b) Make sure that the 24 No. 1 valve rocker arms are
installed as shown in the illustration.
30. INSTALL CAMSHAFT BEARING CAP (for Bank 1)
(a) Apply engine oil to the camshaft journals, camshaft
housing sub-assembly RH and camshaft bearing
caps.
(b) Install the camshaft and No. 2 camshaft to the
camshaft housing sub-assembly RH.
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EM–1502GR-FE ENGINE MECHANICAL – ENGINE UNIT
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40. INSTALL CRANKSHAFT TIMING SPROCKET
(a) Install the 2 keys and crankshaft timing sprocket as
shown in the illustration.
41. INSTALL IDLE SPROCKET ASSEMBLY
(a) Apply a light coat of engine oil to the rotating surface
of the No. 1 idle gear shaft.
(b) Temporarily install the No. 1 idle gear shaft and idle
sprocket with the No. 2 idle gear shaft while aligning
the knock pin of the No. 1 idle gear with the knock
pin groove of the cylinder block.
NOTICE:
Be careful of the idle gear direction.
HINT:
Check that no foreign objects are on the No. 1 and
No. 2 idle gear shafts.
(c) Using a 10 mm hexagon wrench, tighten the No. 2
idle gear shaft.
Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
HINT:
After installing the idle sprocket assembly, check
that the idle sprocket turns smoothly.
42. INSTALL CHAIN SUB-ASSEMBLY
(a) Align the mark plate and timing marks as shown in
the illustration and install the chain.
HINT:
The camshaft mark plate is orange.
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(d) Remove the hexagon wrench of the chain tensioner.
Check that each timing mark is aligned with the
crankshaft at the TDC / compression.
(e) Remove the pulley set bolt.
45. INSTALL TIMING CHAIN CASE OIL SEAL
(a) Using SST, tap in a new oil seal until its surface is
flush with the timing gear case edge.
SST 09223-22010, 09506-35010
NOTICE:
• Keep the lip free of 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.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–163
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55. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 1)
(a) Apply seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three
Bond 1207B or equivalent
NOTICE:
• Remove any oil from the contact surface.
• Install the head cover within 3 minutes after
applying seal packing.
• Do not start the engine for at least 2 hours
after installing.
(b) Install 3 new gaskets as shown in the illustration.
(c) Install a new gasket to the head cover.
(d) Install a head cover with the 12 bolts and a new
washer.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A
10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts
except A
HINT:
After tightening all bolts, check the tightening torque
of 1 and 11. Retighten the bolt if necessary.
56. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 2)
(a) Apply seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three
Bond 1207B or equivalent
NOTICE:
• Remove any oil from the contact surface.
• Install the head cover within 3 minutes after
applying seal packing.
• Do not start the engine for at least 2 hours
after installing.
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EM–1642GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(b) Install 3 new gaskets as shown in the illustration.
(c) Install a new cylinder head cover gasket to the
cylinder head cover sub-assembly.
(d) Install the cylinder head cover with the 12 bolts and
a new washer.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A
10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts
except A
HINT:
After tightening all bolts, check the tightening torque
of 1 and 10. Retighten the bolt if necessary.
57. INSTALL WATER OUTLET
(a) Install 2 new gaskets and a new O-ring.
HINT:
Apply soapy water to the O-ring.
(b) Install the water outlet with the 2 bolts and 4 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts
10 N*m (103 kgf*cm, 7 ft.*lbf) for nuts
NOTICE:
Be careful that the O-ring does not get caught
between the parts.
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