2007 TOYOTA SIENNA engine

EM–382GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
(b) Remove the engine hangers.
80. REMOVE VENTILATION HOSE
(a) Using pliers, grip the claws of the 2 clips and slide
the 2 clips to remove the ventilation hose.
81. REMOVE INTAKE AIR SURGE TANK ASSEMBLY
(a) Disconnect the 2 water by-pass hoses from the
throttle with motor body assembly (*1).
(b) Disconnect the vapor feed hose (*2).
(c) Disconnect the throttle with motor body assembly
connector and clamp (*3).
(d) Disconnect the No. 1 ventilation hose.
(e) Disconnect the connector.
(f) Remove the 4 bolts, No. 1 surge tank stay and
throttle body bracket.
(g) Using a 5 mm socket hexagon wrench, remove the
4 bolts.
(h) Remove the 2 nuts and intake air surge tank (*4).
(i) Remove the gasket from the intake air surge tank
(*5).
82. REMOVE IGNITION COIL ASSEMBLY
(a) Remove the 6 bolts and 6 ignition coils.
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2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–39
EM
83. REMOVE NO. 2 ENGINE MOUNTING STAY RH
(a) Remove the bolt and No. 2 engine mounting stay
RH.
84. REMOVE INTAKE MANIFOLD
(a) Uniformly loosen and remove the 6 bolts and 4 nuts.
(b) Remove the intake manifold and 2 gaskets.
85. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Disconnect the A/F sensor connector clamp.
(b) Uniformly loosen and remove the 6 nuts.
(c) Remove the manifold and gasket.
86. REMOVE OIL LEVEL GAUGE GUIDE SUB-
ASSEMBLY
(a) Remove the oil level gauge.
(b) Remove the 2 bolts, No. 1 and No. 2 oil level gauge
guides.
(c) Remove the O-rings from the oil level gauge guide.
87. REMOVE NO. 2 MANIFOLD STAY
(a) Remove the bolt, nut and No. 2 manifold stay.
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EM–402GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
88. REMOVE NO. 2 EXHAUST MANIFOLD HEAT
INSULATOR
(a) Remove the 3 bolts and No. 2 insulator.
89. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Uniformly loosen and remove the 6 nuts.
(b) Remove the manifold and gasket.
90. REMOVE ENGINE MOUNTING BRACKET RH
(a) Remove the engine mounting bracket and 3 bolts.
91. REMOVE DRIVE SHAFT BEARING BRACKET (for
2WD)
(a) Remove the 3 bolts and drive shaft bearing bracket.
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2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–41
EM
92. REMOVE ENGINE MOUNTING BRACKET RR (for
4WD)
(a) Remove the 3 bolts and engine mounting bracket
RR.
93. REMOVE GENERATOR ASSEMBLY (See page CH-17)
94. REMOVE COOLER COMPRESSOR ASSEMBLY
95. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Remove the 5 bolts and V-ribbed belt tensioner
assembly.
96. REMOVE NO. 2 TIMING GEAR COVER
(a) Remove the 2 bolts and No. 2 timing gear cover.
97. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the bolt, plate and No. 2 idler pulley sub-
assembly.
98. REMOVE WATER PUMP PULLEY (See page CO-12)
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EM–422GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
99. REMOVE NO. 1 ENGINE FRONT MOUNTING
BRACKET LH
(a) Remove the 6 bolts and No. 1 engine front mounting
bracket LH.
100. REMOVE RADIO SETTING CONDENSER
(a) Remove the 2 bolts and 2 radio setting condensers.
101. REMOVE NO. 1 VACUUM SWITCHING VALVE
ASSEMBLY
(a) Remove the bolt and No. 1 vacuum switching valve.
102. REMOVE ENGINE OIL PRESSURE SWITCH
ASSEMBLY
(a) Using a 24 mm deep socket wrench, remove the
engine oil pressure switch assembly.
103. REMOVE KNOCK CONTROL SENSOR (See page ES-
522)
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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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EC–62GR-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM
EC
4. CHECK AIR INLET LINE
(a) Disconnect the air inlet line hose from the charcoal
canister.
(b) Check that air can flow freely into the air inlet line.
If air cannot flow freely into the air inlet line, repair or
replace it.
(c) Reconnect the air inlet line hose to the charcoal
canister.
5. VISUALLY INSPECT HOSES, CONNECTORS AND
GASKETS
(a) Check for cracks, leaks or damage.
HINT:
Removal or problems with the engine oil dipstick, oil
filler cap, PCV hose and other components may
cause the engine to run improperly. Disconnection,
looseness or cracks in the parts of the air induction
system between the throttle body and cylinder head
will allow air suction and cause the engine to run
improperly.
If necessary, replace any damaged parts.
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IN–36INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
IN
HOW TO PROCEED WITH
TROUBLESHOOTING
1. OPERATION FLOW
HINT:
Perform troubleshooting in accordance with the
procedures below. The following is an outline of basic
troubleshooting procedures. Confirm the troubleshooting
procedures for the circuit you are working on before
beginning troubleshooting.
NEXT
(a) Ask the customer about the conditions and environment
when the problem occurred.
NEXT
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before proceeding.
NEXT
(a) Visually check the wire harnesses, connectors and fuses
for open and short circuits.
(b) Warm up the engine to the normal operating
temperature.
(c) Confirm the problem symptoms and conditions, and
check for DTCs
Result
B
A
1VEHICLE BROUGHT TO WORKSHOP
2CUSTOMER PROBLEM ANALYSIS
3INSPECT BATTERY VOLTAGE
4SYMPTOM CONFIRMATION AND DTC (AND FREEZE FRAME DATA) CHECK
Result Proceed to
DTC is output A
DTC is not output B
Go to step 6