engine TOYOTA SIENNA 2007 Service Repair Manual

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEMES–49
ES
FC IDL Idle fuel cutON: when throttle valve fully closed and
engine speed over 1500 rpm
FC TAU FC TAUFuel cut initiated under light load to prevent
incomplete combustion
IGNITION Ignition -
CYL #1 Cylinder #1 misfire rate Displayed only during idling
CYL #2 Cylinder #2 misfire rate Displayed only during idling
CYL #3 Cylinder #3 misfire rate Displayed only during idling
CYL #4 Cylinder #4 misfire rate Displayed only during idling
CYL #5 Cylinder #5 misfire rate Displayed only during idling
CYL #6 Cylinder #6 misfire rate Displayed only during idling
CYL ALL All cylinder misfire rate Displayed only during idling
MISFIRE RPM Misfire RPM -
MISFIRE LOAD Misfire load -
MISFIRE MARGIN Misfire monitoring -
ENG RUN TIME Accumulated engine running time -
TIME DTC CLEAR Cumulative time after DTC cleared -
DIST DTC CLEAR Accumulated distance after DTC cleared -
WU CYC DTC CLEAR Warm-up cycle after DTC cleared -LABEL
(Intelligent Tester Display)Measurement Item Diagnostic Note

2GR-FE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSORES–515
ES
ENGINE
2GR-FE ENGINE CONTROL SYSTEM
ENGINE COOLANT TEMPERATURE SENSOR
COMPONENTS
A162205E03

ES–5162GR-FE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR
ES
REMOVAL
1. DRAIN ENGINE COOLANT (See page CO-6)
2. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page EM-28)
3. REMOVE NO. 2 AIR CLEANER INLET (See page EM-
28)
4. REMOVE NO. 1 AIR CLEANER INLET (See page EM-
28)
5. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-493)
6. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See
page EM-28)
7. REMOVE ENGINE COOLANT TEMPERATURE
SENSOR
(a) Remove the engine coolant temperature sensor
connector.
(b) Remove the engine coolant temperature sensor.
INSPECTION
1. INSPECT ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using an ohmmeter, measure the resistance
between the terminals.
Standard resistance
• If the result is as specified, do not replace the
engine coolant temperature sensor.
• If the result is not as specified, replace the
engine coolant temperature sensor.
NOTICE:
In case of checking the engine coolant
temperature sensor in water, do not allow water
to go into the terminals. After checking, dry the
engine coolant temperature sensor.
A162197
A164436E01
Condition Specified Condition
20
C (68F) 2.32 to 2.59 k
80C (176F) 0.310 to 0.326 k

2GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSORES–521
ES
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
(See page FU-13)
2. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page EM-28)
3. DRAIN ENGINE COOLANT (See page CO-6)
4. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY
HINT:
(See page WW-4)
5. REMOVE FRONT OUTER COWL TOP PANEL SUB-
ASSEMBLY (See page EM-27)
6. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-493)
7. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See
page EM-28)
8. REMOVE INTAKE AIR SURGE TANK ASSEMBLY
(a) Disconnect the 2 water by-pass hoses from the
throttle body [A].
(b) Disconnect the vapor feed hose [B].
(c) Disconnect the throttle body connector and clamp
[C].
(d) Disconnect the ventilation hose [D].
(e) Disconnect the union to check valve hose [E].
(f) Disconnect the connector [F].
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ES–5222GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR
ES
(g) Using a 5 mm socket hexagon wrench, remove the
4 bolts [G].
(h) Remove the 2 nuts, 2 bolts and intake air surge tank
[H].
(i) Remove the gasket from the intake air surge tank [I].
9. REMOVE FUEL MAIN TUBE SUB-ASSEMBLY (See
page EM-30)
10. REMOVE INTAKE MANIFOLD (See page EM-39)
11. REMOVE KNOCK CONTROL SENSOR
(a) Disconnect the 2 knock sensor connectors.
(b) Remove the 2 bolts and then remove the 2 knock
control sensors.
INSPECTION
1. KNOCK CONTROL SENSOR
(a) Using an ohmmeter, measure the resistance
between the terminals.
Resistance:
120 to 280 k
at 20C (68F)
If the resistance is not specified, replace the knock
control sensor.
INSTALLATION
1. INSTALL KNOCK CONTROL SENSOR
(a) Install the 2 knock control sensors with the 2 bolts
as shown in the illustration.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
(b) Connect the 2 knock control sensor connectors.
2. INSTALL INTAKE MANIFOLD (See page EM-49)
3. INSTALL FUEL MAIN TUBE SUB-ASSEMBLY (See
page EM-56)
4. INSTALL INTAKE AIR SURGE TANK
NOTICE:
DO NOT apply oil to the bolts listed below.
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A129615
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Tightening PartsTo r q u e
N*m (kgf*cm, ft.*lbf)QTY
Surge Tank and Intake Manifold 18 (184, 13) 4
No. 1 Surge Tank Stay and Surge Tank 21 (214, 15) 1
Throttle Body Bracket and Surge Tank 21 (214, 15) 1

2GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSORES–523
ES
(a) Install a new gasket to the intake air surge tank [A].
(b) Using a 5 mm hexagon socket wrench, install the 4
bolts [B].
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
(c) Install the intake air surge tank with the 2 nuts and 2
bolts [C].
Torque: Nut
16 N*m (163 kgf*cm, 12 ft.*lbf)
Bolt
21 N*m (214 kgf*cm, 15 ft.*lbf)
(d) Connect the connector [D].
(e) Connect the union to check valve hose [E].
(f) Connect the ventilation hose No. 2 [F].
(g) Install the clamp and connect the throttle with motor
body assembly connector [G].
(h) Connect the vapor feed hose [H].
(i) Connect the 2 water by-pass hoses to the throttle
with motor body assembly [I].
5. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See
page EM-59)
6. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-496)
7. ADD ENGINE COOLANT (See page CO-7)
8. INSPECT FOR ENGINE COOLANT LEAK (See page
CO-1)
9. INSPECT FOR FUEL LEAK (See page FU-7)
10. INSTALL FRONT OUTER COWL TOP PANEL SUB-
ASSEMBLY (See page EM-61)
11. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY
HINT:
(See page WW-5)
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A129467
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ES–5242GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR
ES
12. INSTALL V-BANK COVER SUB-ASSEMBLY (See
page EM-63)

EXTERIOR – FRONT BUMPERET–3
ET
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE FRONT BUMPER ASSEMBLY
(a) Remove the 4 screws and separate the fender liner
from the front bumper assembly.
(b) Remove the 8 screws and separate the engine
under cover from the front bumper assembly.
B125278
B125279

2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–43
EM
104. REMOVE ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using a 19 mm deep socket wrench, remove the
EFI engine coolant temperature sensor and gasket.
INSPECTION
1. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Using a precision straightedge and feeler gauge,
measure the warpage on the contact surface of the
cylinder head.
Maximum warpage:
0.7 mm (0.028 in.)
HINT:
The maximum allowable warpage of each
installation surface is 0.3 mm (0.012 in.).
If the warpage is greater than the maximum, replace
the manifold.
2. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Using a precision straightedge and feeler gauge,
measure the warpage on the contact surface of the
cylinder head.
Maximum warpage:
0.7 mm (0.028 in.)
HINT:
The maximum allowable warpage of each
installation surface is 0.3 mm (0.012 in.).
If the warpage is greater than the maximum, replace
the manifold.
3. INSPECT INTAKE AIR SURGE TANK ASSEMBLY
(a) Using a precision straightedge and feeler gauge,
measure the warpage on the contact surface of the
intake manifold.
Maximum warpage:
2.5 mm (0.098 in.)
If the warpage is greater than the maximum,
replace the surge tank.
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A139214
A139215
A134935

EM–442GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
4. INSPECT INTAKE MANIFOLD
(a) Cylinder head side:
(1) Using a precision straightedge and feeler
gauge, measure the surface contacting the
cylinder head for warpage.
Maximum warpage:
0.1 mm (0.003 in.)
If the warpage is greater than the
maximum, replace the intake manifold.
(b) Surge tank side:
(1) Using a precision straightedge and feeler
gauge, measure the surface contacting the
surge tank for warpage.
Maximum warpage:
0.1 mm (0.003 in.)
If the warpage is greater than the
maximum, replace the intake manifold.
INSTALLATION
1. INSTALL ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using a 19 mm deep socket wrench, install the
engine coolant temperature sensor and a new
gasket.
Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)
2. INSTALL KNOCK CONTROL SENSOR (See page ES-
522)
3. INSTALL ENGINE OIL PRESSURE SWITCH
ASSEMBLY
(a) Clean the threads of the oil pressure switch. Apply
adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a 24 mm deep socket wrench, install the oil
pressure switch.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
NOTICE:
Do not start the engine within 1 hour after
installation to prevent oil leaks.
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A129648
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A139194