Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Sienna 1998-2003 Approved FSM 06 cylhea remo
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EM-33
ENGINE MECHANICAL - CYLINDER HEAD
EM0B8-05
REMOVAL
NOTICE:
Do not remove or install the camshaft timing gear (VVT-i)
beside changing VVT-i or the camshaft.
1. REMOVE OUTER FR COWL TOP PANEL ASSEMBLY
(See page BO-35 )
2. DRAIN ENGINE COOLANT
3. REMOVE RH FENDER APRON SEAL
4. REMOVE GENERATOR DRIVE BELT
(See page CH-7 )
5. REMOVE PS PUMP (See page SR-24 )
6. REMOVE FRONT EXHAUST PIPE (See page EM-76 )
7. REMOVE RH ENGINE MOUNTING STAY
8. REMOVE V-BANK COVER
(a) Using a 5 mm hexagon wrench, remove the 3 cap nuts.
(b) Loosen the V-bank cover fastener counterclockwise.
(c) Remove the V-bank cover.
9. REMOVE AIR CLEANER HOSE WITH RESONATOR
10. REMOVE AIR INTAKE CHAMBER ASSEMBLY
5 mm (a) Disconnect the accelerator cable.
Hexagon (b) Disconnect the throttle position sensor connector.
Wrench A10518 (c) Disconnect the IAC valve connector.
(d) Disconnect the No.1 VSV connector for the ACIS.
(e) Disconnect the No.2 VSV connector for the ACIS.
(f) Disconnect the VSV connector for the EVAP.
(g) Remove the 2 nuts, and disconnect the PS pressure tube
from the No.1 engine hanger.
(h) Disconnect the PCV hose from the PCV valve on the RH
cylinder head.
(i) Disconnect the ground strap and cable from the intake air
control valve for the ACIS.
(h)
(j) Disconnect the ground cable from the air intake chamber.
(k) Disconnect the brake booster vacuum hose from the air
intake chamber.
(j)
(i) A06658
2001 SIENNA (RM787U)
Author : Date : 976
EM-34
ENGINE MECHANICAL - CYLINDER HEAD
(l) Disconnect the 2 water bypass hoses from the throttle
body.
(m) Disconnect the air assist hose from the throttle body.
(l) (n) Disconnect the purge hose from the pipe on the emission
(n)
(l)
control valve set.
(p) (m) (o) Disconnect the 2 vacuum hoses from the vacuum tank for
the ACIS.
(p) Disconnect the engine wire clamp from the emission con-
(o) trol valve set.
A15357
(q) Remove the 2 bolts and No.1 engine hanger.
(r) Remove the 2 bolts and throttle body bracket.
Engine
Hanger
Throttle Body
Bracket
A09695
8 mm Hexagon Wrench (s) Using an 8 mm hexagon wrench, remove the 2 bolts, 2
nuts, the air intake chamber assembly and gasket.
A05073
11. REMOVE INTAKE MANIFOLD ASSEMBLY
(a) Disconnect the 6 injector connectors.
(b) Disconnect the fuel inlet hose from the fuel filter.
CAUTION:
Perform connecting operations of the fuel tube connector
(quick type) after observing the precautions.
(See page SF-1 )
(c) Disconnect the heater hose from the intake manifold.
(c) (b) A05074
(d) Remove the 9 bolts, 2 nuts, 2 plate washers, the intake
manifold, delivery pipes and injectors assembly.
NOTICE:
S Be careful not to drop the injectors when removing
the delivery pipes.
S Pay attention to put any hung load on the injector to
and from the side direction.
12. REMOVE WATER OUTLET
A07428 (a) Disconnect the ECT sender gauge connector.
(b) Disconnect the ECT sensor connector.
2001 SIENNA (RM787U)
Author : Date : 977
EM-35
ENGINE MECHANICAL - CYLINDER HEAD
(c) Disconnect the ground strap connector.
(d) Disconnect the upper radiator hose.
(e) Disconnect the engine coolant reservoir hose.
(f) Remove the 2 bolts, 2 nuts and 2 plate washers.
(g) Disconnect the water bypass hose, and remove the water
outlet.
(h) Remove the 2 gaskets.
13. REMOVE IGNITION COILS
14. REMOVE SPARK PLUGS
15. REMOVE TIMING BELT (See page EM-16 )
16. REMOVE CAMSHAFT TIMING PULLEYS
Gasket P20049 (See page EM-16 )
17. REMOVE NO.2 IDLER PULLEY (See page EM-16 )
18. REMOVE NO.3 TIMING BELT COVER
Clamp
(a) Disconnect the 3 engine wire clamps from the timing belt
Clamp cover.
(b) Remove the 6 bolts and timing belt cover.
19. REMOVE CAMSHAFT POSITION SENSORS
20. REMOVE CAMSHAFT TIMING OIL CONTROL VALVES
Clamp
A05077
21. DISCONNECT ENGINE WIRE PROTECTOR FROM
REAR SIDE
Remove the nut, and disconnect the engine wire protector from
the RH cylinder head.
A10531
22. DISCONNECT ENGINE WIRE AND PROTECTOR
FROM RH SIDE
Remove the 5 nuts, and disconnect the engine wire and protec-
tor from the RH cylinder head cover.
A10519
2001 SIENNA (RM787U)
Author : Date : 978
EM-36
ENGINE MECHANICAL - CYLINDER HEAD
23. DISCONNECT ENGINE WIRE PROTECTOR FROM LH
SIDE
Remove the 2 bolts, and disconnect the engine wire protector
from the LH cylinder head cover.
A05205
Rear 24. DISCONNECT CYLINDER HEAD REAR PLATE FROM
Plate LH CYLINDER HEAD
Remove the 2 bolts, and disconnect the rear plate.
25. DISCONNECT WATER INLET PIPE FROM LH CYL-
INDER HEAD AND WATER INLET
(a) Remove the bolt, and disconnect the inlet pipe from the
water inlet.
(b) Remove the O-ring from the inlet pipe.
Inlet Pipe A07596
26. REMOVE PS PUMP BRACKET
Remove the 3 bolts and pump bracket.
A05189
27. REMOVE RH EXHAUST MANIFOLD
(a) Disconnect the oxygen sensor (bank 1 sensor 1) connec-
tor.
(b) Remove the 3 bolts and heat insulator.
(c) Remove the 6 nuts, exhaust manifold and gasket.
A01813
28. REMOVE LH EXHAUST MANIFOLD
(a) Disconnect the oxygen sensor (bank 2 sensor 1) connec-
tor.
Manifold (b) Remove the bolt, nut and exhaust manifold stay.
Stay (c) Remove the 3 bolts and heat insulator.
(d) Remove the 6 nuts, exhaust manifold and gasket.
A07281
2001 SIENNA (RM787U)
Author : Date : 979
EM-37
ENGINE MECHANICAL - CYLINDER HEAD
29. REMOVE OIL DIPSTICK AND GUIDE
(a) Remove the bolt holding the dipstick guide to the LH cylin-
der head.
(b) Pull out the dipstick guide together with the dipstick from
the No.1 oil pan.
(c) Remove the O-ring from the dipstick guide.
O-Ring
A07283
30. REMOVE CYLINDER HEAD COVERS
Remove the 8 bolts, cylinder head cover and gasket. Remove
the 2 cylinder head covers.
31. REMOVE CAMSHAFTS OF RH CYLINDER HEAD
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be held level while it is being removed. If the
camshaft is not kept level, the portion of the cylinder head
A01816 receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
Intake (a) Remove the intake camshaft.
(1) Align the timing marks (2 dot marks) of the camshaft
drive and driven gears by turning the camshaft with
a wrench.
Align A05280
Intake Main Gear (2) Secure the exhaust camshaft sub-gear to the main
Sub-Gear
gear with a service bolt.
Recommended service bolt:
Thread diameter 6 mm
Thread pitch 1.0 mm
Bolt length 16 - 20 mm
HINT:
Service Bolt When removing the camshaft, mark certain that the torsional
A05195 spring force of the sub-gear has been eliminated by the above
operation.
2001 SIENNA (RM787U)
Author : Date : 980
EM-38
ENGINE MECHANICAL - CYLINDER HEAD
Intake (3) Uniformly loosen and remove the 10 bearing cap
2 bolts, in several passes, in the sequence shown.
6 (4) Remove the 5 bearing caps and intake camshaft.
10 1
5
9
8
4 7
3
A05207
Exhaust 1 (b) Remove the exhaust camshaft.
2 (1) Uniformly loosen and remove the 10 bearing cap
5
bolts, in several passes, in the sequence shown.
9 6
(2) Remove the 5 bearing caps, oil seal and exhaust
7 10 camshaft.
3
8 32. REMOVE CAMSHAFTS OF LH CYLINDER HEAD
4 NOTICE:
Since the thrust clearance of the camshaft is small, the
A05197 camshaft must be held level while it is being removed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
Intake (a) Remove the intake camshaft.
(1) Align the timing marks (1 dot mark) of the camshaft
drive and driven gears by turning the camshaft with
a wrench.
Align A05284
Intake (2) Secure the exhaust camshaft sub-gear to the main
Service Bolt gear with a service bolt.
Recommended service bolt:
Thread diameter 6 mm
Thread pitch 1.0 mm
Bolt length 16 - 20 mm
HINT:
When removing the camshaft, make sure that the torsional
Main Gear Sub-Gear A05198 spring force of the sub-gear has been eliminated by the above
operation.
2001 SIENNA (RM787U)
Author : Date : 981
EM-39
ENGINE MECHANICAL - CYLINDER HEAD
Intake 1 (b) Uniformly loosen and remove the 10 bearing cap bolts, in
5 2
6 several passes, in the sequence shown.
9
(c) Remove the 5 bearing caps and intake camshaft.
7 10
8
3
4
A05199
Exhaust 2 (d) Remove the exhaust camshaft
(1) Uniformly loosen and remove the 10 bearing cap
6
1 bolts, in several passes, in the sequence shown.
10 (2) Remove the 5 bearing caps, oil seal and exhaust
5 camshaft.
7
9 HINT:
4 8 S Arrange the camshafts in the correct order.
S Arrange the bearing caps in the correct order.
3 A05200
33. DISASSEMBLE EXHAUST CAMSHAFTS
(a) Mount the hexagonal wrench head portion of the cam-
shaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
P12596
(b) Using SST, turn the sub-gear counterclockwise, and re-
move the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
SST
P12797
(c) Using snap ring pliers, remove the snap ring.
(d) Remove the wave washer.
(e) Remove the camshaft sub-gear.
(f) Remove the camshaft gear spring.
HINT:
Arrange the camshaft sub-gears and gear springs (RH and LH
side).
P12590
2001 SIENNA (RM787U)
Author : Date : 982
EM-40
ENGINE MECHANICAL - CYLINDER HEAD
Recessed Heat Bolt
34. REMOVE CYLINDER HEADS
(a) Using an 8 mm hexagon wrench, remove the cylinder
head (recessed head) bolt on each cylinder head, then re-
peat for the other side, as shown.
8 mm Hexagon Wrench
Front
A05222
(b) Uniformly loosen and remove the 8 cylinder head (12
12 Pointed Head Bolt
pointed head) bolts on each cylinder head, in several
passes, in the sequence shown, then repeat for the other
side, as shown. Remove the 16 cylinder head bolts and
plate washers.
NOTICE:
Head warpage or cracking could result from removing
bolts in an incorrect order.
2 7 5 3
4 6 8 1
Front
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