engine TOYOTA SIENNA 2007 Service Repair Manual

2GR-FE FUEL – FUEL SYSTEMFU–3
FU
(6) Do not damage the disconnected pipe or
connector. Prevent entry of foreign objects by
covering the connectors with plastic bags.
(e) Observe the following precautions when connecting
the fuel tube connectors (Quick Type A):
(1) Check if there is any damage or foreign objects
on the connecting parts of the pipes.
(2) Line up the 2 parts of the pipes to be connected,
and push them together until the connector
makes a "click" sound. If the pipe is difficult to
push into the connector, apply a small amount of
clean engine oil to the tip of the pipe and reinsert
it.
(3) After connecting the pipes, check that the pipe
and connector are securely connected by pulling
on them.
(4) Check for fuel leaks.
(f) Observe the following precautions when
disconnecting the fuel tube connector (Quick type
B):
(1) Before disconnecting the connector, clean off
any dirt that may be present.
(2) Pinch the tabs of the fuel tube retainer to
disengage the 2 claws. Push the retainer down
as shown in the illustration.
HINT:
Be sure to disconnect the connector by hand.
(3) If the connector and pipe are stuck, hold the fuel
pipe by hand, push, and pull on the connector.
Pull the 2 pipes apart to separate the connector.
(4) Check if there is any dirt or any other foreign
objects on the sealing surfaces of the
disconnected pipes. Clean the sealing surfaces
if necessary.
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FU–42GR-FE FUEL – FUEL SYSTEM
FU
(5) Do not damage the disconnected pipe or
connector. Prevent entry of foreign objects by
covering the connectors with plastic bags.
(g) Observe the following precautions when connecting
the fuel tube connector (Quick Type B):
(1) Line up the 2 parts of the pipes to be connected,
and fully push the fuel tube connector and pipe
together until they are fully seated. Next, push
the retainer into the connector until its claws
lock. If the pipe is difficult to push in to the
connector, apply a small amount of clean engine
oil to the tip of the pipe and reinsert it.
(2) After connecting the pipes, check that the pipe
and connector are securely connected by pulling
on them.
(3) Check for fuel leaks.
(h) Observe the following precautions when handling a
nylon tube:
CAUTION:
• Do not twist the connector part of the nylon
tube or the quick connector when connecting
them.
• Do not bend or twist the nylon tube.
• Do not remove the EPDM protector on the
outside of the nylon tube.
• Do not pinch or kink the nylon tubes to
prevent fuel leakage.
4. INSPECT FOR FUEL LEAK
(a) Check that there are no fuel leaks from the fuel
system after doing any maintenance or repairs (See
page FU-7).
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2GR-FE FUEL – FUEL SYSTEMFU–7
FU
ON-VEHICLE INSPECTION
1. INSPECT FOR FUEL PUMP OPERATION AND FUEL
LEAK
(a) Check fuel pump operation.
(1) Connect the intelligent tester to the DLC3.
(2) Turn the engine switch on (IG) and push the
intelligent tester main switch on.
NOTICE:
Do not start the engine.
(3) Select the following menu items: DIAGNOSIS /
ENHANCED OBD II / ACTIVE TEST / FUEL
PUMP / SPD.
(4) Check for pressure in the fuel inlet tube from
the fuel line. Check that sound of fuel flowing in
the fuel tank can be heard. If no sound can be
heard, check the integration relay, fuel pump,
ECM and wiring connector.
(b) Check for fuel leaks (*1).
(1) Check that there are no fuel leaks anywhere on
the system after performing maintenance. If
there is a fuel leak, repair or replace parts as
necessary.
(c) Turn the engine switch off.
(d) Disconnect the intelligent tester from the DLC3.
2. CHECK FUEL PRESSURE
(a) Discharge the fuel system pressure (See page FU-
1).
(b) Using a voltmeter, measure the battery voltage.
Standard voltage:
11 to 14 V
(c) Disconnect the cable from the negative (-) battery
terminal.
(d) Disconnect the fuel hose from the fuel main tube
(See page FU-1).

FU–82GR-FE FUEL – FUEL SYSTEM
FU
(e) Install SST (pressure gauge) using SST and a fuel
tube connector as shown in the illustration.
SST 09268-31011 (09268-41500, 90467-13001,
95336-08070), 09268-45014 (09268-41200,
09268-41220, 09268-41250)
(f) Wipe up any gasoline.
(g) Connect the cable to the negative (-) battery
terminal.
(h) Connect the intelligent tester to the DLC3.
(i) Select the following menu items: DIAGNOSIS /
ENHANCED OBD II / ACTIVE TEST / FUEL PUMP
/ SPD.
(j) Measure the fuel pressure.
Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf*cm
2, 44.1 to 49.7
psi)
• If the fuel pressure is greater than the standard
value, replace the fuel pressure regulator.
• If the fuel pressure is less than the standard
value, check the fuel hoses and connections, fuel
pump, fuel filter and fuel pressure regulator.
(k) Disconnect the intelligent tester from the DLC3.
(l) Start the engine.
(m) Measure the fuel pressure at idle.
Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf*cm
2, 44.1 to 49.7
psi)
(n) Stop the engine.
(o) Check that the fuel pressure remains as specified
for 5 minutes after the engine stops.
Fuel pressure:
147 kPa (1.5 kgf*cm
2, 21 psi) or more
If the fuel pressure is not as specified, check the fuel
pump, pressure regulator and/or fuel injectors.
(p) After checking the fuel pressure, disconnect the
cable from the negative (-) battery terminal and
carefully remove the SST to prevent gasoline from
splashing.
(q) Reconnect the fuel tube to the main fuel tube (fuel
tube connector).
(r) Install the No. 1 fuel pipe clamp to the fuel tube
connector.
(s) Check for fuel leaks (*1).
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FU–202GR-FE FUEL – FUEL INJECTOR
FU
(e) Connect the union to check valve hose. (*1)
(f) Connect the No. 1 ventilation hose. (*2)
(g) Install the clamp and connect the throttle with motor
body assembly connector. (*3)
(h) Connect the vapor feed hose assembly. (*4)
(i) Connect the 2 water by-pass hoses to the throttle
with motor body assembly. (*5)
4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
(a) Install the 2 bolts and air cleaner cap sub-assembly.
(b) Connect the No. 2 ventilation hose and air cleaner
hose band.
(c) Connect the vacuum hose (EVAP) to the air cleaner
hose.
(d) Connect the 3 vacuum hoses.
5. ADD ENGINE COOLANT (See page CO-7)
6. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
7. INSPECT FOR ENGINE COOLANT LEAK (See page
CO-1)
8. INSTALL NO. 1 ENGINE UNDER COVER
9. INSPECT FOR FUEL LEAK (See page FU-7)
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2GR-FE FUEL – FUEL INJECTORFU–13
FU
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
HINT:
See page FU-1.
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. REMOVE NO. 1 ENGINE UNDER COVER
4. DRAIN ENGINE COOLANT (See page CO-6)
5. REMOVE FRONT WIPER ARM HEAD CAP (See page
WW-4)
6. REMOVE FRONT WIPER ARM RH (See page WW-4)
7. REMOVE FRONT WIPER ARM LH (See page WW-4)
8. REMOVE COWL TOP VENTILATOR LOUVER SUB-
ASSEMBLY (See page WW-4)
9. REMOVE WINDSHIELD WIPER MOTOR AND LINK
ASSEMBLY (See page WW-4)
10. REMOVE NO. 1 COWL TOP TO COWL BRACE INNER
(a) Remove the 2 bolts and the No. 1 cowl top to cowl
brace inner.
11. REMOVE COWL TOP PANEL SUB-ASSEMBLY
OUTER FRONT
(a) Remove the wire harness clamp.
(b) Disconnect the fuel pump resistor connector.
(c) Remove the 7 bolts and the cowl top panel outer
front.
12. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page EM-28)
13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
(a) Disconnect the 3 vacuum hoses.
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FU–202GR-FE FUEL – FUEL INJECTOR
FU
(e) Connect the union to check valve hose. (*1)
(f) Connect the No. 1 ventilation hose. (*2)
(g) Install the clamp and connect the throttle with motor
body assembly connector. (*3)
(h) Connect the vapor feed hose assembly. (*4)
(i) Connect the 2 water by-pass hoses to the throttle
with motor body assembly. (*5)
4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
(a) Install the 2 bolts and air cleaner cap sub-assembly.
(b) Connect the No. 2 ventilation hose and air cleaner
hose band.
(c) Connect the vacuum hose (EVAP) to the air cleaner
hose.
(d) Connect the 3 vacuum hoses.
5. ADD ENGINE COOLANT (See page CO-7)
6. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
7. INSPECT FOR ENGINE COOLANT LEAK (See page
CO-1)
8. INSTALL NO. 1 ENGINE UNDER COVER
9. INSPECT FOR FUEL LEAK (See page FU-7)
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2GR-FE FUEL – FUEL PRESSURE PULSATION DAMPERFU–25
FU
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
HINT:
See page FU-1.
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. REMOVE NO. 1 ENGINE UNDER COVER
4. DRAIN ENGINE COOLANT (See page CO-6)
5. REMOVE FRONT WIPER ARM HEAD CAP (See page
WW-4)
6. REMOVE FRONT WIPER ARM RH (See page WW-4)
7. REMOVE FRONT WIPER ARM LH (See page WW-4)
8. REMOVE COWL TOP VENTILATOR LOUVER SUB-
ASSEMBLY (See page WW-4)
9. REMOVE WINDSHIELD WIPER MOTOR AND LINK
ASSEMBLY (See page WW-4)
10. REMOVE NO. 1 COWL TOP TO COWL BRACE INNER
(See page FU-13)
11. REMOVE COWL TOP PANEL SUB-ASSEMBLY
OUTER FRONT (See page FU-13)
12. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page EM-28)
13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See
page FU-13)
14. REMOVE INTAKE AIR SURGE TANK ASSEMBLY
(See page FU-14)
15. REMOVE FUEL PRESSURE PULSATION DAMPER
ASSEMBLY
(a) Remove the clip.
(b) Pull out the fuel pressure pulsation damper from the
fuel delivery pipe.
(c) Remove the O-ring from the fuel pressure pulsation
damper.
INSTALLATION
1. INSTALL FUEL PRESSURE PULSATION DAMPER
ASSEMBLY
(a) Apply a light coat of spindle oil or gasoline to a new
O-ring and install it to the fuel pressure pulsation
damper.
(b) Install the fuel pressure pulsation damper to the fuel
delivery pipe.
(c) Install the clip.
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FU–262GR-FE FUEL – FUEL PRESSURE PULSATION DAMPER
FU
2. INSTALL INTAKE AIR SURGE TANK ASSEMBLY (See
page FU-19)
3. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See
page FU-20)
4. ADD ENGINE COOLANT (See page CO-7)
5. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
6. INSPECT FOR ENGINE COOLANT LEAK (See page
CO-1)
7. INSTALL NO. 1 ENGINE UNDER COVER
8. INSPECT FOR FUEL LEAK (See page FU-7)
9. INSTALL V-BANK COVER SUB-ASSEMBLY (See
page EM-63)
10. INSTALL COWL TOP PANEL SUB-ASSEMBLY
OUTER FRONT (See page FU-21)
11. INSTALL NO. 1 COWL TOP TO COWL BRACE INNER
(See page FU-21)
12. INSTALL WINDSHIELD WIPER MOTOR AND LINK
ASSEMBLY (See page WW-6)
13. INSTALL FRONT WIPER ARM LH (See page WW-6)
14. INSTALL FRONT WIPER ARM RH (See page WW-7)

2GR-FE EMISSION CONTROL – EMISSION CONTROL SYSTEMEC–5
EC
ON-VEHICLE INSPECTION
1. INSPECT FUEL CUT RPM
(a) Increase the engine speed to at least 3500 rpm.
(b) Use a sound scope to check for injector operating
sounds.
(c) Check that when the throttle lever is released,
injector operating sounds stop momentarily (at 2500
rpm) and then resume (at 1400 rpm).
Standard
2. CHECK AIR TIGHTNESS IN FUEL TANK AND FILLER
PIPE
(a) Disconnect the vent line hose from the fuel tank.
(b) Connect the pressure gauge to the fuel tank.
(c) Apply pressure to the fuel tank to create an internal
pressure of 4 kPa (41 gf/cm
2, 0.58 psi).
(d) Check that the internal pressure of the fuel tank is
maintained for 1 minute.
(e) Check the connected portions of each hose and
pipe.
(f) Check the installed parts on the fuel tank.
If any malfunctions, damage or other problems are
found, replace the fuel tank and filler pipe.
(g) Reconnect the vent line hose to the fuel tank.
3. INSPECT FUEL CUT OFF VALVE AND FUEL CHECK
VA LV E
(a) Disconnect the vent line hose from the fuel tank.
(b) Connect the pressure gauge to the fuel tank.
(c) Fill the fuel tank with fuel.
(d) Apply pressure of 4 kPa (41 gf/cm
2, 0.58 psi) to the
vent port of the fuel tank.
HINT:
Check the amount of fuel in the fuel tank. When the
fuel tank is full, the float valve of the fill check valve
is closed and no air can pass through.
(e) Remove the fuel tank cap, and check that the
pressure drops.
If the pressure does not drop, replace the fuel tank
assembly.
(f) Reconnect the vent line hose to the fuel tank.
Item Specified Condition
Fuel cut off rpm 2500 rpm
Fuel return rpm 1400 rpm
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