TOYOTA SIENNA 2007 Service Repair Manual

EM–862GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
28. REMOVE TIMING CHAIN CASE OIL SEAL
(a) Using a screwdriver, pry out the timing chain case
oil seal.
HINT:
Tape the screwdriver tip before use.
29. SET NO. 1 CYLINDER TO TDC / COMPRESSION
(a) Temporarily tighten the pulley set bolt.
(b) Set the timing mark on the crank angle sensor plate
to the RH block bore center line (TDC /
compression).
(c) Check that the timing marks of the camshaft timing
gears are aligned with those of the bearing cap as
shown in the illustration.
If not, turn the crankshaft 1 revolution (360
) and
align the timing marks as above.
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30. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Move the stopper plate upward to release the lock,
and push the plunger deep into the tensioner.
(b) Move the stopper plate downward to set the lock,
and insert a pin of
1.27 mm (0.05 in.) into the
stopper plate's hole.
(c) Remove the 2 bolts and No. 1 chain tensioner
assembly.
31. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the chain tensioner slipper.
32. REMOVE CHAIN SUB-ASSEMBLY
(a) Turn the crankshaft counterclockwise 10
to loosen
the chain sub-assembly of the crankshaft timing
sprocket.
(b) Remove the pulley set bolt.
(c) Remove the chain sub-assembly from the
crankshaft timing sprocket and place it on the
crankshaft.
(d) Turn the camshaft timing gear assembly on the
bank 1 clockwise (approximately 60
) and set it as
shown in the illustration. Be sure to loosen the chain
between the banks.
(e) Remove the chain.
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EM–882GR-FE ENGINE MECHANICAL – ENGINE UNIT
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33. REMOVE IDLE SPROCKET ASSEMBLY
(a) Using a 10 mm hexagon wrench, remove the No. 2
idle gear shaft, idle sprocket assembly and No. 1
idle gear shaft.
34. REMOVE NO. 1 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts and No. 1 chain vibration
damper.
35. REMOVE NO. 2 CHAIN VIBRATION DAMPER
(a) Remove the 2 No. 2 chain vibration dampers.
36. REMOVE CRANKSHAFT TIMING SPROCKET
(a) Remove the crankshaft timing sprocket from the
crankshaft.
(b) Remove the 2 keys from the crankshaft.
37. REMOVE CAMSHAFT TIMING GEARS AND NO. 2
CHAIN (for Bank 1)
(a) While raising the No. 2 chain tensioner assembly,
insert a pin of
1.0 mm (0.039 in.) into the hole to fix
the No. 2 chain tensioner.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–89
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(b) Hold the hexagonal portion of the camshaft with a
wrench, and remove the 2 bolts and 2 camshaft
timing gear assemblies.
NOTICE:
• Be careful not to damage the cylinder head
with the wrench.
• Do not disassemble the camshaft timing gear
assemblies.
(c) Remove the No. 2 chain assembly.
38. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Remove the bolt and No. 2 chain tensioner
assembly.
39. REMOVE CAMSHAFT BEARING CAP (for Bank 1)
(a) Check that the camshafts are positioned as shown
in the illustration.
(b) Uniformly loosen and remove the 8 bearing cap
bolts in the sequence shown in the illustration.
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EM–902GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(c) Uniformly loosen and remove the 12 bearing cap
bolts in the sequence shown in the illustration.
NOTICE:
Uniformly loosen the bolts while keeping the
camshaft level.
(d) Remove the 5 bearing caps.
40. REMOVE CAMSHAFT
(a) Remove the camshaft.
41. REMOVE NO. 2 CAMSHAFT
(a) Remove the No. 2 camshaft.
42. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH
(a) Remove the camshaft housing sub-assembly RH by
prying between the cylinder head and camshaft
housing sub-assembly RH with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of
the cylinder head and camshaft housing.
HINT:
Tape the screwdriver tip before use.
43. REMOVE CAMSHAFT TIMING GEARS AND NO. 2
CHAIN (for Bank 2)
(a) While pushing down the No. 3 chain tensioner
assembly, insert a pin of
1.0 mm (0.039 in.) into the
hole to fix the No. 3 chain tensioner assembly.
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(b) Hold the hexagonal portion of the camshaft with a
wrench, and remove the 2 bolts and 2 camshaft
timing gear assemblies.
NOTICE:
• Be careful not to damage the cylinder head
with the wrench.
• Do not disassemble the camshaft timing gear
assemblies.
(c) Remove the No. 2 chain sub-assembly.
44. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Remove the bolt and No. 3 chain tensioner
assembly.
45. REMOVE CAMSHAFT BEARING CAP (for Bank 2)
(a) Check that the camshafts are positioned as shown
in the illustration.
(b) Uniformly loosen and remove the 8 bearing cap
bolts in the sequence shown in the illustration.
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EM–922GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(c) Uniformly loosen and remove the 13 bearing cap
bolts in the sequence shown in the illustration.
NOTICE:
Uniformly loosen the bolts while keeping the
camshaft level.
(d) Remove the 5 bearing caps.
46. REMOVE NO. 3 CAMSHAFT
(a) Remove the No. 3 camshaft.
47. REMOVE NO. 4 CAMSHAFT
(a) Remove the No. 4 camshaft.
48. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH
(a) Remove the camshaft housing sub-assembly LH by
prying between the cylinder head and camshaft
housing sub-assembly LH with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of
the cylinder head and camshaft housing.
HINT:
Tape the screwdriver tip before use.
49. REMOVE NO. 1 VALVE ROCKER ARM SUB-
ASSEMBLY
(a) Remove the 24 No. 1 valve rocker arm sub-
assemblies.
HINT:
Arrange the removed parts in the correct order.
50. REMOVE VALVE LASH ADJUSTER ASSEMBLY
(a) Remove the 24 valve lash adjuster assemblies from
the cylinder head.
HINT:
Arrange the removed parts in the correct order.
51. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH
(a) Using a 10 mm bi-hexagon wrench, uniformly
loosen the 8 bolts in the sequence shown in the
illustration. Remove the 8 cylinder head bolts and
plate washers.
NOTICE:
• Be careful not to drop washers into the
cylinder head.
• Cylinder head warpage or cracking could
result from removing bolts in an incorrect
order.
HINT:
Be sure to keep separate the removed parts for
each installation position.
(b) Remove the cylinder head sub-assembly RH and
cylinder head gasket.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–93
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52. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH
(a) Uniformly loosen and remove the cylinder head set
bolts in the sequence shown in the illustration.
(b) Using a 10 mm bi-hexagon wrench, uniformly
loosen the 8 bolts in the sequence shown in the
illustration. Remove the 8 cylinder head bolts and
plate washers.
NOTICE:
• Be careful not to drop washers into the
cylinder head.
• Cylinder head warpage or cracking could
result from removing bolts in an incorrect
order.
HINT:
Be sure to keep separate the removed parts for
each installation position.
(c) Remove the cylinder head sub-assembly LH and
No. 2 cylinder head gasket.
53. REMOVE WATER INLET PIPE
(a) Remove 2 clamps and separate the No. 1 water by-
pass hose.
(b) Remove the 2 bolts and water inlet pipe.
54. REMOVE VALVE STEM CAP
(a) Remove the valve stem caps from the cylinder
heads.
HINT:
Arrange the removed parts in the correct order.
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EM–942GR-FE ENGINE MECHANICAL – ENGINE UNIT
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55. REMOVE INTAKE VALVE
(a) Using SST, compress the inner compression spring
and remove the valve spring retainer locks.
SST 09202-70020 (09202-00010)
(b) Remove the valve spring retainer, inner
compression spring and intake valve.
HINT:
Arrange the removed parts in the correct order.
56. REMOVE EXHAUST VALVE
(a) Using SST, compress the inner compression spring
and remove the valve spring retainer locks.
SST 09202-70020 (09202-00010)
(b) Remove the valve spring retainer, inner
compression spring and exhaust valve.
HINT:
Arrange the removed parts in the correct order.
57. REMOVE VALVE STEM OIL SEAL
(a) Using needle-nose pliers, remove the valve stem oil
seals.
58. REMOVE VALVE SPRING SEAT
(a) Using compressed air and a magnetic finger,
remove the valve spring seats by blowing air onto
them.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–95
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59. REMOVE NO. 1 STRAIGHT SCREW PLUG
(a) Using a 10 mm hexagon wrench, remove the 4 No.
1 straight screw plugs and 4 gaskets.
NOTICE:
If water leaks from the straight screw plug or the
plug corrodes, replace it.
60. REMOVE NO. 2 STRAIGHT SCREW PLUG
(a) Using a 14 mm hexagon wrench, remove the 2 No.
2 straight screw plugs and 2 gaskets.
NOTICE:
If water leaks from the straight screw plug or the
plug corrodes, replace it.
61. REMOVE RING PIN
NOTICE:
It is not necessary to remove the ring pin unless it is
being replaced.
62. REMOVE STUD BOLT
NOTICE:
If the stud bolt is deformed or the threads are
damaged, replace it.
63. REMOVE STRAIGHT PIN
NOTICE:
If the straight pin is deformed or the threads are
damaged, replace it.
64. REMOVE INTAKE VALVE GUIDE BUSH
(a) Heat the cylinder head to 80 to 100
C (176 to
212
F).
(b) Place the cylinder head on wooden blocks.
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