engine TOYOTA SIENNA 2007 Service Service Manual

INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMSIN–39
IN
• In the DTC check, it is very important to determine
whether the problem indicated by the DTC either: 1)
still occurs, or 2) occurred in the past but has returned
to normal. In addition, the DTC should be compared
to the problem symptom to see if they are related. For
this reason, DTCs should be checked before and after
confirmation of symptoms (i.e., whether or not
problem symptoms exist) to determine current system
conditions, as shown in the flowchart below.
• Never skip the DTC check. Failing to check DTCs
may, depending on the case, result in unnecessary
troubleshooting for systems operating normally or
lead to repairs not related to the problem. Follow the
procedures listed in the flowchart in the correct order.
Theft Deterrent System XXXXX
Engine Immobiliser System
XX
Cruise Control SystemXXX
Dynamic Laser Cruise Control System
XXX
Lighting System
XX
Wiper and Washer SystemXXXXX
Power Door Lock Control System X X X
Wireless Door Lock Control SystemXX
Key Reminder Warning System X X XX
Meter / Gauge System X X X
Audio and Visual SystemXXXX
Rear Seat Entertainment System XXXXX
Navigation System
XXXX
Clearance Sonar SystemXXXXX
Rear View Monitor System XXXXX
Power Window Control System (with Jam
Protection Function)XXX
Power Window Control System (without Jam
Protection Function)XXXXX
Power Mirror Control System (with Memory) X X X
Power Mirror Control System (without Memory)XXXXX
Front Power Seat Control System X X X
Rear No. 2 Seat Assembly (with Power Stowing
Function)XXXXX
Window Deogger SystemXXXXX
Power Slide Door System
XX
Slide Door Closer System X X X
Back Door Closer SystemXX
Power Back Door SystemXX
Sliding Roof System XXXXX
Multiplex Communication System XXXXX
CAN Communication System XXXXXSystemSYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
DTC Check
(Normal Mode)DTC Check
(Check Mode)Sensor Check/
Test Mode
(Input Signal
Check)Data List Active Test

INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMSIN–41
IN
If a DTC was displayed in the initial DTC check, the
problem may have occurred in a wire harness or
connector in that circuit in the past. Check the wire
harness and connectors.
B
A
The problem still occurs in a place other than the diagnostic
circuit (the DTC displayed first is either for a past problem or
a secondary problem).
4. SYMPTOM SIMULATION
HINT:
The most difficult case in troubleshooting is when no
problem symptoms occur. In such a case, a thorough
problem analysis must be carried out. A simulation of the
same or similar conditions and environment in which the
problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a
technician has, troubleshooting without confirming the
problem symptoms will lead to important repairs being
overlooked and mistakes or delays.
For example:
With a problem that only occurs when the engine is
cold or as a result of vibration caused by the road
during driving, the problem can never be
determined if the symptoms are being checked on
a stationary vehicle or a vehicle with a warmed-up
engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom
simulation tests below are effective substitutes for
the conditions and can be applied on a stationary
vehicle. Important points in the symptom
simulation test:
In the symptom simulation test, the problem
symptoms as well as the problem area or parts
must be confirmed. First, narrow down the
possible problem circuits according to the
symptoms. Then, connect the tester and carry out
the symptom simulation test, judging whether the
circuit being tested is defective or normal. Also,
confirm the problem symptoms at the same time.
Refer to the problem symptoms table for each
system to narrow down the possible causes.SYSTEM NORMAL
TROUBLESHOOTING OF EACH PROBLEM SYMPTOM

IN–42INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
IN
(a) VIBRATION METHOD: When a malfunction seems
to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of
the sensor suspected to be the cause of the
problem, and check whether or not the
malfunction occurs.
NOTICE:
Applying strong vibration to relays may open
relays.
(2) CONNECTORS
Slightly shake the connector vertically and
horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and
horizontally.
HINT:
The connector joint and fulcrum of the vibration
are the major areas that should be checked
thoroughly.
(b) HEAT METHOD: When a malfunction seems to
occur when the area in question is heated.
(1) Heat the component that is the possible cause of
the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE:
• Do not heat to more than 60
C (140F).
Exceeding this temperature may damage
the components.
• Do not apply heat directly to the parts in
the ECU.
(c) WATER SPRINKLING METHOD: When a
malfunction seems to occur on a rainy day or in
high-humidity.
(1) Sprinkle water onto the vehicle and check if the
malfunction occurs.
NOTICE:
• Never sprinkle water directly into the
engine compartment. Indirectly change
the temperature and humidity by spraying
water onto the front of the radiator.
• Never apply water directly onto the
electronic components.
HINT:
If the vehicle has or had a water leakage
problem, the leakage may have damaged the
ECU or connections. Look for evidence of
corrosion or short circuits. Proceed with caution
during water tests.B071602E03
D025085E02

2GR-FE COOLING – COOLING FAN SYSTEMCO–5
CO
ON-VEHICLE INSPECTION
1. INSPECT COOLING FAN SYSTEM
(a) Put the vehicle in the following conditions:
(1) The engine switch is off.
(2) The coolant temperature is less than 95
C
(203
F).
(3) The battery voltage is between 9 and 14 V.
(4) The A/C switch is OFF.
(b) Clamp the 400 A probe of an ammeter over the M+
wire of each cooling fan motor.
(c) Turn the ignition switch to the ON position and wait
for approximately 10 seconds. Check that the fan
stops.
(d) Start the engine. Check that the fan stops with the
engine idling.
HINT:
• Make sure that the radiator engine coolant
temperature is less than 95
C (203F).
• Turn the A/C switch OFF.
(e) Check that the fan operates when the A/C switch is
turned ON (MAX COOL and the magnetic clutch is
operating).
Standard current
HINT:
The coolant temperature is less than 95
C (203F).
(f) Check that the fan operates when the engine
coolant temperature sensor connector is
disconnected.
Standard current
Item Specified Condition
No. 1 cooling fan motor 5 to 14 A
No. 2 cooling fan motor 4 to 12 A
Item Specified Condition
No. 1 cooling fan motor 5 to 19 A
No. 2 cooling fan motor 4 to 16 A

CO–62GR-FE COOLING – COOLING FAN SYSTEM
CO
(g) After the engine is warmed up, check that the fan
operates as shown in the illustration.
HINT:
• The coolant temperature at which the fan starts
operating is approximately 95
C (203F).
• This system can also be checked using the
intelligent tester.
• Select the following menu items: Powertrain /
Engine / Data List / Initial Engine Coolant Temp.
A139339E05

2GR-FE LUBRICATION – OIL PUMPLU–11
LU
REMOVAL
1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
HINT:
See page EM-26
2. REMOVE OIL LEVEL GAUGE GUIDE SUB-
ASSEMBLY (See page EM-39)
3. REMOVE NO. 1 OIL PIPE (See page EM-77)
4. REMOVE OIL PIPE (See page EM-77)
5. REMOVE CRANKSHAFT PULLEY (See page EM-79)
6. SEPARATE OIL COOLER PIPE
(a) Remove the bolt and 2 nuts, and disconnect the oil
cooler pipe from the oil pan sub-assembly.
(b) Remove the gasket from the oil pan sub-assembly.
7. REMOVE WATER INLET HOUSING (See page CO-12)
8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 1) (See page EM-82)
9. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 2) (See page EM-82)
10. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY (See page
EM-82)
11. REMOVE OIL STRAINER SUB-ASSEMBLY (See page
EM-83)
12. REMOVE OIL PAN SUB-ASSEMBLY (See page EM-
83)
13. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
(a) Remove the 23 bolts and 2 nuts as shown in the
illustration.
A141494
A128004

IG–62GR-FE IGNITION – IGNITION COIL AND SPARK PLUG
IG
ON-VEHICLE INSPECTION
NOTICE:
In this section, the terms "cold" and "hot" refer to the
temperature of the coils. "Cold" means approximately -
10
C (14F) to 50C (122F). "Hot" means approximately
50
C (122F) to 100C (212F).
1. INSPECT IGNITION COIL ASSEMBLY
(a) Check for DTCs.
NOTICE:
If any DTC is present, perform troubleshooting
in accordance with the procedures for that DTC.
(b) Remove the ignition coil assembly and spark plug.
(See page IG-8).
(c) Check that sparks occur.
(1) Disconnect the 6 fuel injector connectors.
(2) Install the spark plugs to each ignition coil, and
connect the ignition coil connectors.
(3) Ground the spark plugs.
(4) Check if a spark occurs at each spark plug
while the engine is being cranked.
NOTICE:
• Be sure to ground the spark plugs when
checking.
• Replace the ignition coil if it receives an
impact.
• Do not crank the engine for more than 2
seconds.
(d) Perform the spark test according to the flowchart
below.
(1) Check that the ignition coil connector is
securely connected.
Result
(2) Perform a spark test on each ignition coil.
1. Replace the ignition coil with a normal one.
2. Perform the spark test again.
Result
A133895
A133897
Result Proceed to
NG Connect securely
OK Go to next step
Result Proceed to
NG Go to next step
OK Replace ignition coil

2GR-FE IGNITION – IGNITION COIL AND SPARK PLUGIG–7
IG
(3) Check the spark plug (See page EM-1).
Result
(4) Check the power supply to the ignition coil.
1. Turn the ignition switch to the ON position.
2. Check that there is battery voltage at the
ignition coil positive (+) terminal.
Result
(5) Measure the resistance of the crankshaft
position sensor (See page ES-514).
Result
(6) Check the IGT signal from the ECM (See page
ES-233)
Result
(e) Using a 16 mm (0.63 in.) plug wrench, install the
spark plugs.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
(f) Connect the 6 fuel injector connectors.
(g) Install the ignition coil assembly (See page IG-10).
2. INSPECT SPARK PLUG
NOTICE:
• Never use a wire brush for cleaning.
• Never attempt to adjust the electrode gap on a
used spark plug.
(a) Check the electrode.
(1) Using a megohmmeter, measure the insulation
resistance.
Standard insulation resistance:
10 M
or higher
HINT:
• If the result is 10 M
or less, clean the plug
and measure the resistance again.
• If a megohmmeter is not available, perform
the following simple inspection instead.
(b) Alternative inspection method:
(1) Quickly accelerate the engine to 4000 rpm 5
times.
Result Proceed to
NG Replace spark plug
OK Go to next step
Result Proceed to
NGCheck wiring between ignition
switch and ignition coil
OK Go to next step
Result Proceed to
NG Replace crankshaft position sensor
OK Go to next step
Result Proceed to
NG Check ECM
OKRepair wiring between ignition coil
and ECM
I039522E10

IG–82GR-FE IGNITION – IGNITION COIL AND SPARK PLUG
IG
(2) Remove the spark plugs.
(3) Visually check the spark plug.
If the electrode is dry, the spark plug is
functioning properly. If the electrode is damp,
proceed to the next step.
(c) Check the spark plug for any damage to its threads
and insulator. If there is damage, replace the spark
plug.
Recommended spark plug
NOTICE:
Use only the listed spark plug or equivalent to
ensure engine performance and smooth
driveability.
(d) Check the spark plug electrode gap.
Maximum electrode gap for used spark plug:
1.4 mm (0.055 in.)
If the gap is greater than the maximum, replace the
spark plug.
Electrode gap for new spark plug:
1.0 to 1.1 mm (0.039 to 0.043 in.)
(e) Clean the spark plugs.
If the electrode has traces of wet carbon, clean the
electrode with a spark plug cleaner and then dry it.
Standard air pressure:
588 kPa (6 kgf*cm
2, 85 psi)
Standard duration:
20 seconds or less
HINT:
Only use the spark plug cleaner when the electrode
is free of oil. If the electrode has traces of oil, use
gasoline to clean off the oil before using the spark
plug cleaner.
(f) Install the ignition coil assembly and spark plug.
(See page IG-10).
Manufacturer Spark Plug Type
DENSO FK20HR11
A163282E01
B062019

2GR-FE CHARGING – CHARGING SYSTEMCH–5
CH
PROBLEM SYMPTOMS TABLE
Result
Symptom Suspected Area See page
Charge Warning Light Comes ON while DrivingClutch pulley
CH-8
Generator assembly
Noise Occurs from Generator while Engine is RunningV-ribbed belt
CH-9 Clutch pulley
Generator assembly