TOYOTA SIENNA 2007 Service Repair Manual

EM–1422GR-FE ENGINE MECHANICAL – ENGINE UNIT
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25. INSTALL WATER INLET PIPE
(a) Install the water inlet pipe with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(b) Install the No. 1 water by-pass hose.
26. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH
(a) Place the cylinder head gasket on the cylinder block
surface with the Lot No. stamp upward.
NOTICE:
• Be careful of the installation direction.
• Gently place the cylinder head in order not to
damage the gasket with the bottom part of the
head.
(b) Place the cylinder head on the cylinder block.
NOTICE:
Be careful not to allow oil to adhere to the
bottom part of the cylinder head.
HINT:
The cylinder head bolts are tightened in 3
progressive steps.
(c) Apply a light coat of engine oil to the threads and
under the heads of the cylinder head bolts.
(d) Step 1
(1) Using a 10 mm bi-hexagon wrench, install and
uniformly tighten the 8 cylinder head bolts with
the plate washers in several steps and in the
sequence shown in the illustration.
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
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(e) Step 2
(1) Mark the cylinder head bolt head with paint as
shown in the illustration.
(2) Tighten the cylinder head bolts another 90
.
(f) Step 3
(1) Tighten the cylinder head bolts an additional
90
.
(2) Check that the painted mark is now facing
rearward.
27. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
(a) Place the cylinder head gasket on the cylinder block
surface with the Lot No. stamp upward.
NOTICE:
• Be careful of the installation direction.
• Gently place the cylinder head in order not to
damage the gasket with the bottom part of the
head.
(b) Place the cylinder head on the cylinder block.
NOTICE:
Be careful not to allow oil to adhere to the
bottom part of the cylinder head.
HINT:
The cylinder head bolts are tightened in 3
progressive steps.
(c) Apply a light coat of engine oil to the threads and
under the heads of the cylinder head bolts.
(d) Step 1
(1) Using a 10 mm bi-hexagon wrench, install and
uniformly tighten the 8 cylinder head bolts with
the plate washers in several steps in the
sequence shown in the illustration.
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
(e) Step 2
(1) Mark the cylinder head bolt head with paint as
shown in the illustration.
(2) Tighten the cylinder head bolts another 90
.
(f) Step 3
(1) Tighten the cylinder head bolts an additional
90
.
(2) Check that the painted mark is now facing
rearward.
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EM–1442GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(g) Tighten the 2 bolts in the order shown in the
illustration.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
28. INSTALL VALVE LASH ADJUSTER ASSEMBLY
NOTICE:
• Keep the lash adjuster free of dirt and foreign
objects.
• Only use clean engine oil.
(a) Place the lash adjuster into a container filled with
engine oil.
(b) Insert SST's tip into the lash adjuster's plunger and
use the tip to press down on the check ball inside
the plunger.
SST 09276-75010
(c) Squeeze SST and lash adjuster together to move
the plunger up and down 5 to 6 times.
(d) Check the movement of the plunger and bleed the
air.
OK:
Plunger moves up and down.
NOTICE:
When bleeding air from the high-pressure
chamber, make sure that the tip of SST is
actually pressing the check ball as shown in the
illustration. If the check ball is not pressed, air
will not bleed.
(e) After bleeding the air, remove SST. Then, try to
press the plunger quickly and firmly with a finger.
OK:
Plunger is very difficult to move.
If the result is not as specified, replace the lash
adjuster.
(f) Install the lash adjusters.
NOTICE:
Install the lash adjuster to the same place where
it was removed from.
29. INSTALL NO. 1 VALVE ROCKER ARM SUB-
ASSEMBLY
(a) Apply engine oil to the lash adjuster tip and valve
stem cap end.
(b) Make sure that the 24 No. 1 valve rocker arms are
installed as shown in the illustration.
30. INSTALL CAMSHAFT BEARING CAP (for Bank 1)
(a) Apply engine oil to the camshaft journals, camshaft
housing sub-assembly RH and camshaft bearing
caps.
(b) Install the camshaft and No. 2 camshaft to the
camshaft housing sub-assembly RH.
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(c) Make sure of the marks and numbers on the
camshaft bearing caps and place them in each
proper position and direction.
(d) Temporarily tighten the 8 bolts in the order shown in
the illustration.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
31. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH
(a) Make sure that the valve rocker arm is installed as
shown in the illustration.
(b) Apply seal packing in a continuous line as shown in
the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three
Bond 1207B or equivalent
Seal diameter:
3.5 to 4.5 mm (0.138 to 0.177 in.)
NOTICE:
• Remove any oil from the contact surface.
• Install the camshaft housing sub-assembly
RH within 3 minutes.
• Do not start the engine for at least 2 hours
after installing.
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EM–1462GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(c) Install the camshaft housing sub-assembly RH and
tighten the 12 bolts in the order shown in the
illustration.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
NOTICE:
• When installing the camshaft housing RH, it
is necessary to correctly position the
camshafts as shown in the illustration.
Failure to correctly position these parts may
result in damage due to contact between the
pistons and valves. If a camshaft is rotated
with a piston at TDC, valve contact will occur.
• If any of the bolts are loosened during
installation, remove the camshaft housing,
clean the installation surfaces, and reapply
seal packing.
• If the camshaft housing is removed because
any of the bolts are loosened during
installation, make sure that the previously
applied seal packing does not enter any oil
passages.
(d) Tighten the 8 bolts in the order shown in the
illustration.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
32. INSTALL CAMSHAFT BEARING CAP (for Bank 2)
(a) Apply engine oil to the camshaft journals, camshaft
housing sub-assembly LH and camshaft bearing
caps.
(b) Install the No. 3 camshaft and No. 4 camshaft to the
camshaft housing LH.
(c) Make sure of the marks and numbers on the
camshaft bearing caps and place them in each
proper position and direction.
(d) Temporarily tighten the 8 bolts in the order shown in
the illustration.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
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33. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
(a) Make sure that the valve rocker arm is installed as
shown in the illustration.
(b) Apply seal packing in a continuous line as shown in
the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three
Bond 1207B or equivalent
Seal diameter:
3.5 to 4.5 mm (0.138 to 0.177 in.)
NOTICE:
• Remove any oil from the contact surface.
• Install the camshaft housing sub-assembly
LH within 3 minutes.
• Do not start the engine for at least 2 hours
after installing.
(c) Install the camshaft housing sub-assembly LH and
tighten the 13 bolts in the order shown in the
illustration.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
NOTICE:
• When installing the camshaft housing LH, it is
necessary to correctly position the camshafts
as shown in the illustration. Failure to
correctly position these parts may result in
damage due to contact between the pistons
and valves. If a camshaft is rotated with a
piston at TDC, valve contact will occur.
• If any of the bolts are loosened during
installation, remove the camshaft housing,
clean the installation surfaces, and reapply
seal packing.
• If the camshaft housing is removed because
any of the bolts are loosened during
installation, make sure that the previously
applied seal packing does not enter any oil
passages.
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EM–1482GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(d) Tighten the 8 bolts in the order shown in the
illustration.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
34. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Install the No. 2 chain tensioner assembly with the
bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(b) While pushing in the tensioner, insert a pin of
1.0
mm (0.039 in.) into the hole to fix it.
35. INSTALL CAMSHAFT TIMING GEARS AND NO. 2
CHAIN (for Bank 1)
(a) Align the mark plate (yellow) with the timing marks
(1-dot mark) of the camshaft timing gears as shown
in the illustration.
(b) Apply a light coat of engine oil to the bolt threads
and bolt-seating surface.
(c) Align the knock pin of the camshaft with the pin hole
of the camshaft timing gear. Install the camshaft
timing gear and camshaft timing exhaust gear RH
with the No. 2 chain sub-assembly installed.
(d) Hold the hexagonal portion of the camshaft with a
wrench, and tighten the 2 bolts and camshaft timing
gear assemblies.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
(e) Remove the pin from the No. 2 chain tensioner
assembly.
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36. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Install the No. 3 chain tensioner assembly with the
bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(b) While pushing in the tensioner, insert a pin of
1.0
mm (0.039 in.) into the hole to hold it.
37. INSTALL CAMSHAFT TIMING GEARS AND NO. 2
CHAIN (for Bank 2)
(a) Align the mark plate (yellow) with the timing marks
(2-dot mark) of the camshaft timing gears as shown
in the illustration.
(b) Apply a light coat of engine oil to the bolt threads
and bolt-seating surface.
(c) Align the knock pin of the camshaft with the pin hole
of the camshaft timing gear. Install the camshaft
timing gear and camshaft timing exhaust gear LH
with the No. 2 chain sub-assembly installed.
(d) Hold the hexagonal portion of the camshaft with a
wrench, and tighten the 2 bolts.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
(e) Remove the pin from the No. 3 chain tensioner
assembly.
38. INSTALL NO. 1 CHAIN VIBRATION DAMPER
(a) Install the No. 1 chain vibration damper with the 2
bolts.
Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf)
39. INSTALL NO. 2 CHAIN VIBRATION DAMPER
(a) Install the 2 No. 2 chain vibration dampers.
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EM–1502GR-FE ENGINE MECHANICAL – ENGINE UNIT
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40. INSTALL CRANKSHAFT TIMING SPROCKET
(a) Install the 2 keys and crankshaft timing sprocket as
shown in the illustration.
41. INSTALL IDLE SPROCKET ASSEMBLY
(a) Apply a light coat of engine oil to the rotating surface
of the No. 1 idle gear shaft.
(b) Temporarily install the No. 1 idle gear shaft and idle
sprocket with the No. 2 idle gear shaft while aligning
the knock pin of the No. 1 idle gear with the knock
pin groove of the cylinder block.
NOTICE:
Be careful of the idle gear direction.
HINT:
Check that no foreign objects are on the No. 1 and
No. 2 idle gear shafts.
(c) Using a 10 mm hexagon wrench, tighten the No. 2
idle gear shaft.
Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
HINT:
After installing the idle sprocket assembly, check
that the idle sprocket turns smoothly.
42. INSTALL CHAIN SUB-ASSEMBLY
(a) Align the mark plate and timing marks as shown in
the illustration and install the chain.
HINT:
The camshaft mark plate is orange.
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(b) Do not pass the chain over the crankshaft, just put it
on it.
(c) Turn the camshaft timing gear assembly on the
bank 1 counterclockwise to tighten the chain
between the banks.
NOTICE:
When the idle sprocket is reused, align the chain
plate with the mark where the plate had been in
order to tighten the chain between the banks.
(d) Align the mark plate and timing marks as shown in
the illustration and install the chain onto the
crankshaft timing sprocket.
HINT:
The crankshaft mark plate is yellow.
(e) Temporarily tighten the pulley set bolt.
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