engine TOYOTA SIENNA 2007 Service Repair Manual

LU–42GR-FE LUBRICATION – OIL AND OIL FILTER
LU
REPLACEMENT
CAUTION:
• Prolonged and repeated contact with engine oil will
result in the removal of natural oils from the skin,
leading to dryness, irritation and dermatitis. In
addition, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
• Precautions should be taken when replacing engine
oil to minimize the risk of your skin making contact
with used engine oil. Protective clothing and gloves
that cannot be penetrated by oil should be worn. The
skin should be washed with soap and water, or
waterless hand cleaner, to remove any used engine oil
thoroughly. Do not use gasoline, thinners, or solvents.
• In order to preserve the environment, used oil and
used oil filters must be disposed of at designated
disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug, and drain the oil into a
container.
(c) Clean and install the oil drain plug with a new
gasket.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
2. REMOVE OIL FILTER ELEMENT
(a) Connect the hose with an inside diameter of 15 mm
(0.59 in.) to the pipe.
(b) Remove the oil filter drain plug from the oil filter cap.
A127996E01
A127997

LU–62GR-FE LUBRICATION – OIL AND OIL FILTER
LU
3. INSTALL OIL FILTER ELEMENT
(a) Clean the inside of the oil filter cap, threads, and O-
ring groove.
(b) Apply a light coat of engine oil to a new O-ring and
install it to the oil filter cap.
NOTICE:
Make sure that the O-ring does not get twisted
on the groove.
(c) Install a new oil filter element to the oil filter cap.
(d) Remove all dirt and foreign matter from the
installation surface and the inside of the cap on the
engine side.
(e) Apply a light coat of engine oil to the O-ring again
and install the oil filter cap.
NOTICE:
Make sure that the O-ring does not get caught
between the parts.
(f) Using SST, install the oil filter cap.
SST 09228-06501
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
NOTICE:
Make sure that there is no clearance between
the parts after tightening the oil filter cap.
(g) Apply a light coat of engine oil to a new O-ring and
install it to the oil filter cap.
NOTICE:
Remove all dirt and foreign matter from the
installation surface.
(h) Install the oil filter drain plug to the oil filter cap.
Torque: 13 N*m (127 kgf*cm, 10 ft.*lbf)
NOTICE:
Make sure that the O-ring does not get caught
between the parts.
4. ADD ENGINE OIL
(a) Add clean engine oil and install the oil filler cap.
Engine oil
Capacity:
5. INSPECT FOR OIL LEAK
(a) Start the engine. Check for engine oil leaks from the
connected parts of the oil filter cap and oil filter drain
plug.
A128001E02
A128002E01
A161390E01
Oil Grade Oil Viscosity (SAE)
ILSAC multigrade engine oil 5W-30
Item Standard Condition
Drain and refill with oil filter change 6.1 liters (6.4 US qts, 5.4 lmp. qts)
Drain and refill without oil filter change 5.7 liters (6.0 US qts, 5.0 lmp. qts)
Dry fill 7.1 liters (7.5 US qts, 6.2 lmp. qts)

2GR-FE LUBRICATION – OIL PUMPLU–13
LU
2. REMOVE OIL PUMP COVER
(a) Remove the 8 bolts, oil pump cover and oil pump
rotor set.
INSPECTION
1. INSPECT OIL PUMP RELIEF VALVE
(a) Coat the relief valve with engine oil and check that it
falls smoothly into the valve hole under its own
weight.
If the valve does not fall smoothly, replace the relief
valve. If necessary, replace the oil pump assembly.
2. INSPECT OIL PUMP ROTOR SET
(a) Install the rotors to the timing chain cover with the
rotors' marks facing outward. Check that the rotors
rotate smoothly.
(b) Check the tip clearance.
(1) Using a feeler gauge, measure the clearance
between the drive and driven rotors, as shown
in the illustration.
Tip clearance
If the clearance is greater than the maximum,
replace the drive and driven rotors.
(c) Check the side clearance.
(1) Using a feeler gauge and precision
straightedge, measure the clearance between
the rotors and precision straightedge, as shown
in the illustration.
Side clearance
If the side clearance is greater than the
maximum, replace the timing chain cover.
A128009
A094628
A128010E01
A128011
Standard Maximum
0.060 to 0.160 mm (0.0024 to 0.0063 in.) 0.160 mm (0.0063 in.)
A128012
Standard Maximum
0.030 to 0.090 mm (0.0012 to 0.0035 in.) 0.090 mm (0.0035 in.)

LU–142GR-FE LUBRICATION – OIL PUMP
LU
(d) Check the body clearance.
(1) Using a feeler gauge, measure the clearance
between the timing chain cover and driven
rotor, as shown in the illustration.
Body clearance
If the body clearance is greater than the
maximum, replace the timing chain cover.
REASSEMBLY
1. INSTALL OIL PUMP COVER
(a) Coat the drive and driven rotors with engine oil and
place them into the timing chain cover with the
marks facing outward (oil pump cover side). Check
that the rotors rotate smoothly.
(b) Install the oil pump cover with the 8 bolts.
Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf)
Bolt length
2. INSTALL OIL PUMP RELIEF VALVE
(a) Coat the oil pump relief valve with engine oil.
(b) Insert the relief valve and relief valve spring into the
oil pump cover hole.
(c) Using a 27 mm socket wrench, install the plug.
Torque: 49 N*m (500 kgf*cm, 37 ft.*lbf)
INSTALLATION
1. INSTALL TIMING CHAIN CASE OIL SEAL
(a) Using SST, tap in a new oil seal until its surface is
flush with the timing chain case edge.
SST 09223-22010, 09506-35010
NOTICE:
• Keep the lip free from 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.
A128013
Standard Maximum
0.250 to 0.325 mm (0.0098 to 0.0128 in.) 0.325 mm (0.0128 in.)
A128010E02
A094627E02
Item Length
Bolt A 22 mm (0.87 in.)
Bolt B 40 mm (1.58 in.)
A128008
A125109E04

2GR-FE LUBRICATION – OIL PUMPLU–15
LU
2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) Apply seal packing in a continuous line to the
engine unit as shown in the following illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three
Bond 1207B or equivalent
Seal diameter:
3.0 mm (0.118 in.)
NOTICE:
• Be sure to clean and degrease the contact
surfaces, especially the surfaces indicated by
C in the illustration.
• When the contact surfaces are wet, wipe them
with an oil-free cloth before applying seal
packing.
• Install the chain cover within 3 minutes.
• Do not start the engine for at least 2 hours
after installing.
A132228E03

2GR-FE LUBRICATION – OIL PUMPLU–17
LU
NOTICE:
• When the contact surfaces are wet, wipe them
with an oil-free cloth before applying seal
packing.
• Install the chain cover within 3 minutes and
tighten the bolts within 15 minutes after
applying seal packing.
• Do not start the engine for at least 2 hours
after installing it.
Apply seal packing as follows
(c) Install a new gasket.
(d) Align the oil pump's drive rotor spline and the
crankshaft as shown in the illustration. Install the
spline and chain cover to the crankshaft.
(e) Temporarily tighten the timing chain cover with the
23 bolts and 2 nuts.
Area Seal Packing Diameter Application Position from Inside Seal Line
Continuous Line Area 4.5 mm (0.177 in.) or more 3.0 to 4.0 mm (0.118 to 0.158 in.)
Alternate Long and Short Dashed Line
Area3.5 mm (0.138 in.) or more 2.0 to 3.0 mm (0.079 to 0.118 in.)
Dashed Line Area 3.5 mm (0.138 in.) or more 3.0 to 4.0 mm (0.118 to 0.158 in.)
Diagonal Line Area 6.0 mm (0.236 in.) or more 5.0 mm (0.197 in.)
A128017E01
A132229E02
A128019E02

LU–182GR-FE LUBRICATION – OIL PUMP
LU
Bolt length
NOTICE:
Make sure that there is no oil on the bolt
threads.
(f) Fully tighten the bolts in: Area 1 and Area 2.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(g) Fully tighten the bolts and nuts in: Area 3.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
HINT:
Tighten the bolts and nuts from top to bottom as
shown in the illustration.
(h) Fully tighten the bolts in: Area 4.
Torque: Bolt A
43 N*m (438 kgf*cm, 32 ft.*lbf)
Except bolt A
21 N*m (214 kgf*cm, 15 ft.*lbf)
HINT:
Tighten the bolts from bottom to top as shown in the
illustration.
3. INSTALL WATER INLET HOUSING (See page CO-13)
4. INSTALL OIL PAN SUB-ASSEMBLY (See page EM-
160)
5. INSTALL OIL STRAINER SUB-ASSEMBLY (See page
EM-161)
6. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY (See page
EM-162)
7. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 1) (See page EM-163)
8. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 2) (See page EM-163)
9. INSTALL CRANKSHAFT PULLEY (See page EM-166)
10. INSTALL OIL COOLER PIPE
(a) Install a new gasket to the oil pan sub-assembly.
(b) Install the oil cooler pipe with the bolt and 2 nuts.
Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
11. INSTALL NO. 1 OIL PIPE (See page EM-167)
12. INSTALL OIL PIPE (See page EM-168)
13. INSTALL OIL LEVEL GAUGE GUIDE SUB-
ASSEMBLY (See page EM-48)
14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
HINT:
See page EM-44
Item Length
Bolt A 40 mm (1.57 in.)
Bolt B 55 mm (2.17 in.)
Bolt C 25 mm (0.98 in.)
A141494

2GR-FE IGNITION – IGNITION COIL AND SPARK PLUGIG–9
IG
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. DRAIN ENGINE COOLANT
3. REMOVE FRONT WIPER ARM HEAD CAP (See page
WW-4)
4. REMOVE FRONT WIPER ARM RH (See page WW-4)
5. REMOVE FRONT WIPER ARM LH (See page WW-4)
6. REMOVE COWL TOP VENTILATOR LOUVER SUB-
ASSEMBLY (See page WW-4)
7. REMOVE WINDSHIELD WIPER MOTOR AND LINK
ASSEMBLY (See page WW-4)
8. REMOVE NO. 1 COWL TOP TO COWL BRACE INNER
(See page FU-13)
9. REMOVE COWL TOP PANEL SUB-ASSEMBLY
OUTER FRONT (See page FU-13)
10. REMOVE NO. 1 ENGINE UNDER COVER
11. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page EM-28)
12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See
page FU-13)
13. REMOVE INTAKE AIR SURGE TANK ASSEMBLY
(See page FU-14)
14. REMOVE NO. 1 SURGE TANK STAY
(a) Remove the 2 bolts and nut and disconnect the 2
harness clamps.
(b) Remove the bolt and No. 1 surge tank stay.
A161840
A134967

2GR-FE IGNITION – IGNITION COIL AND SPARK PLUGIG–11
IG
2. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 6 ignition coils with the 6 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(b) Connect the 6 ignition coil connectors.
3. INSTALL NO. 1 SURGE TANK STAY
NOTICE:
DO NOT apply oil to the bolt listed below:
(a) Install the No. 1 surge tank stay with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(b) Install the 2 bolts, 2 clamps, and nut.
Torque: 8.3 N*m (84 kgf*cm, 73 in.*lbf)
4. INSTALL INTAKE AIR SURGE TANK ASSEMBLY (See
page FU-19)
5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See
page FU-20)
6. ADD ENGINE COOLANT (See page CO-7)
7. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
8. INSPECT FOR ENGINE COOLANT LEAK (See page
CO-1)
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)
A134966E01
Tightening Parts
No. 1 surge tank stay and cylinder head cover
A134967
A161840

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