Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Sienna 2004-2007 Approved SRM 09 203ee w040001
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14-157
ENGINE MECHANICAL - CYLINDER HEAD ASSY
1405K-08
OVERHAUL
1. REMOVE W/HEAD STRAIGHT SCREW PLUG NO.1 (RH CYLINDER)
(a) Using a 14 mm straight hexagon wrench, remove the 2 screw plugs.
2. REMOVE W/HEAD STRAIGHT SCREW PLUG NO.2 (LH CYLINDER)
(a) Using a 14 mm straight hexagon wrench, remove the 2 screw plugs.
3. REMOVE VALVE LIFTER
HINT:
Store the lifters in correct order so that they can be returned to the original locations when re-assembling.
4. REMOVE INTAKE VALVE
(a) Using SST, compress the valve spring and remove the 2
keepers, retainer, spring and valve.
SST 09202-70020 (09202-00010)
HINT:
Store the valves, valve springs, spring seats and spring retain-
ers in correct order so that they can be returned to the original
SST locations when re-assembling.
A78770
5. REMOVE EXHAUST VALVE
(a) Using SST, compress the valve spring and remove the 2
keepers, retainer, spring and valve.
SST 09202-70020 (09202-00010)
HINT:
Store the valves, valve springs, spring seats and spring retain-
ers in correct order so that they can be returned to the original
SST locations when re-assembling.
A78772
6. REMOVE VALVE STEM OIL O SEAL OR RING
(a) Using needle-nose pliers, remove the oil seal.
7. REMOVE VALVE SPRING SEAT
8. REMOVE SEMICIRCULAR PLUG
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2456
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ENGINE MECHANICAL - CYLINDER HEAD ASSY
9. INSPECT CYLINDER HEAD FOR FLATNESS
(a) Using a precision straight edge and a feeler gauge, mea-
sure the surface contacting the cylinder block and the
manifolds for warpage.
Maximum warpage:
Cylinder block surface 0.05 mm (0.0020 in.)
Intake manifold surface 0.10 mm (0.0039 in.)
Exhaust manifold surface 0.10 mm (0.0039 in.)
Cylinder Block Surface
If warpage is greater than maximum, replace the cylinder head.
Intake Manifold Surface
Exhaust Manifold Surface
A78773
10. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrate, check the combustion chamber,
intake ports, exhaust ports and cylinder block surface for
cracks.
If cracked, replace the cylinder head.
A05227
11. INSPECT INTAKE VALVE
(a) Check the valve overall length.
Standard overall length: 95.45 mm (3.7579 in.)
Minimum overall length: 94.95 mm (3.7382 in.)
Overall Length
EM2534
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
5.470 to 5.485 mm (0.2154 to 0.2159 in.)
Z00052
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2457
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ENGINE MECHANICAL - CYLINDER HEAD ASSY
(c) Check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.5 mm (0.020 in.)
Margin
Thickness
A78774
12. INSPECT EXHAUST VALVE
(a) Check the valve overall length.
Standard overall length: 95.40 mm (3.7559 in.)
Minimum overall length: 94.90 mm (3.7362 in.)
Overall Length
EM2534
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
5.465 to 5.480 mm (0.2152 to 0.2157 in.)
Z00052
(c) Check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.5 mm (0.020 in.)
Margin
Thickness
A78774
13. INSPECT INNER COMPRESSION SPRING
(a) Using vernier calipers, measure the free length of the
valve spring.
Free length: 45.50 mm (1.7913 in.)
EM0801
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Author : Date : 2458
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ENGINE MECHANICAL - CYLINDER HEAD ASSY
(b) Using a steel square, measure the deviation of the valve
Deviation
spring.
Maximum deviation: 2.0 mm (0.079 in.)
A78775
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
186 to 206 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf)
at 33.8 mm (1.331 in.)
If the installed tension is not as specified, replace the valve
spring.
EM0281
14. INSPECT VALVE GUIDE BUSHING OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
guide bushing.
Bushing inside diameter:
5.510 to 5.530 mm (0.2169 to 0.2177 in.)
(b) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Standard oil clearance:
P12754 Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.)
Exhaust 0.030 to 0.065 mm (0.0012 to 0.0026 in.)
Maximum oil clearance:
Intake 0.08 mm (0.0031 in.)
Exhaust 0.10 mm (0.0039 in.)
15. REMOVE VALVE GUIDE BUSHING
(a) Heat the cylinder head to 80 to 100 _C (176 to 212 _F).
A05234
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Author : Date : 2459
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ENGINE MECHANICAL - CYLINDER HEAD ASSY
(b) Using SST and a hammer, tap out the guide bushing.
SST SST 09201-10000, 09201-01055, 09950-70010
(09951-07100)
A78776
16. INSTALL VALVE GUIDE BUSHING
(a) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
Diameter: 10.295 to 10.313 mm (0.4053 to 0.4060 in.)
If the bushing bore diameter of the cylinder head is greater than
10.313 mm (0.4060 in.), machine the bushing bore to the di-
mension of 10.345 to 10.363 mm (0.4073 to 0.4080 in.)
HINT:
P12956 Bushing diameter
STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
O/S 10.383 to 10.394 mm (0.4088 to 0.4092 in.)
Intake Exhaust
Bushing length
Intake 34.5 mm (1.358 in.)
Exhaust 40.5 mm (1.594 in.)
40.5 mm
34.5 mm (b) Heat the cylinder head to 80 to 100 _C (176 to 212 _F)
(1.594 in.)
(1.358 in.)
A78777
(c) Using SST and a hammer, tap in a new guide bushing to
SST the specified protrusion height.
SST 09201-10000, 09201-01055, 09950-70010
(09951-07100)
Protrusion height:
Intake: 11.1 to 11.5 mm (0.437 to 0.453 in.)
Exhaust: 8.9 to 9.3 mm (0.350 to 0.366 in.)
A78778
(d) Using a sharp 5.5 mm reamer, ream the guide bushing to
obtain the standard specified clearance between the
guide bushing and the valve stem.
Standard oil clearance:
Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.)
Exhaust 0.030 to 0.065 mm (0.0012 to 0.0026 in.)
Z09124
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ENGINE MECHANICAL - CYLINDER HEAD ASSY
17. INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the
valve face.
(b) Lightly press the valve against the seat.
NOTICE:
Do not rotate the valve.
(c) Check the valve face and seat according to the following
procedure.
(1) If blue appears 360_ around the face, the valve is
concentric. If not, replace the valve.
(2) If blue appears 360_ around the valve seat, the
Width guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the
A78779 valve face with the width between 1.0 to 1.4 mm
(0.039 to 0.055 in.).
18. REPAIR VALVE SEATS
NOTICE:
45_ Releasing the seat-cutter pressure gradually helps to
make smoother valve seat faces.
30_
(a) If the seating is too high on the valve face, use 30_ and
45_ cutters to correct the seat.
1.0 to 1.4 mm
A78780
(b) If the seating is too low on the valve face, use 60_ and 45_
cutters to correct the seat.
60_ (c) Hand-lap the valve and valve seat with an abrasive com-
pound.
45_
(d) Recheck the valve seating position.
1.0 to 1.4 mm
A78781
19. INSPECT VALVE LIFTER
(a) Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 to 30.976 mm (1.2191 to 1.2195 in.)
EM6368
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ENGINE MECHANICAL - CYLINDER HEAD ASSY
20. INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter bore diameter:
31.009 to 31.025 mm (1.2208 to 1.2215 in.)
(b) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
P12685 0.033 to 0.059 mm (0.0013 to 0.0023 in.)
Maximum oil clearance: 0.07 mm (0.0028 in.)
21. INSPECT CAMSHAFT GEAR BACKLASH
(a) Install camshaft timing gear assembly.
(b) Install the camshafts to the cylinder head.
NOTICE:
S Install without valves and sub-gear.
S Install with its timing mark matched.
(c) Set the dial indicator to the teeth of the intake camshaft
at a right angle (90_).
(d) Measure the backlash of the camshaft timing gear at least
4 positions.
Standard backlash:
0.020 to 0.200 mm (0.0008 to 0.0079 in.)
Maximum backlash: 0.30 mm (0.0118 in.)
22. INSPECT CAMSHAFT THRUST CLEARANCE
A33264 (a) Install the camshafts.
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.040 to 0.090 mm (0.0016 to 0.0035 in.)
Maximum thrust clearance: 0.12 mm (0.0047 in.)
If the thrust clearance is greater than maximum, replace the
camshaft. If necessary, replace the bearing caps and cylinder
head together.
A05238 23. INSPECT CAMSHAFT OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2462
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ENGINE MECHANICAL - CYLINDER HEAD ASSY
(c) Lay a strip of plastigage across each of the camshaft jour-
nal.
(d) Install the bearing caps.
Torque: 16 Nm (163 kgfcm, 12 ftlbf)
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps.
A05239
(f) Measure the plastigage at its widest point.
Standard oil clearance:
Intake #4, #5 journals
0.025 to 0.057 mm (0.0010 to 0.0022 in.)
Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.)
Maximum oil clearance 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder head
A05240 together.
NOTICE:
Completely remove the plastigage.
RH Cylinder 24. INSTALL RING W/HEAD PIN (RH CYLINDER)
10 mm
(a) Using a plastic-faced hammer, tap in a new ring pin to the
8 mm specified protrusion height.
Protrusion height: 3 mm (0.12 in.)
A78782
LH Cylinder
25. INSTALL RING PIN (LH CYLINDER)
10 mm
(a) Using a plastic-faced hammer, tap in a new ring pin to the
8 mm specified protrusion height.
Protrusion height: 3 mm (0.12 in.)
A78783
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ENGINE MECHANICAL - CYLINDER HEAD ASSY
Protrusion Height 26. INSTALL SPARK PLUG TUBE
(a) Using paint, mark the standard position from the edge.
Standard protrusion height:
42.4 to 43.4 mm (1.669 to 1.709 in.)
HINT:
Use either end of the spark plug tube.
(b) Apply adhesive to the spark plug tube where it will be
pressed into the cylinder head.
Mark A78784 Adhesive: Part No. 08833-00070 THREE BOND 1324
or equivalent
NOTICE:
S Install the spark plug tube within 3 minutes after ap-
plying adhesive.
S Do not deform the spark plug tube.
S Do not expose the seal to coolant within an hour after
installing.
(c) Using a press and wooden block, install the spark plug
Press
Wooden tube to the required protrusion height.
Block NOTICE:
Protrusion Be careful not to drip the adhesive.
Height
A78785
Wooden 27. INSTALL PCV PIPE (RH CYLINDER)
Block (a) Using a wooden block and hammer, tap in 2 new PCV
pipes until its top edge is flush with the cylinder head
edge.
NOTICE:
Be careful not to damage the cylinder head edge.
Flush
A78786
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ENGINE MECHANICAL - CYLINDER HEAD ASSY
RH Cylinder 28. INSTALL STUD BOLT
(a) Install the stud bolts on the intake side.
Torque: 7.5 Nm (76 kgfcm, 66 in.lbf)
49 mm
M8
A78787
LH Cylinder
49 mm
M8
A78788
29. INSTALL STUD BOLT
(a) Install the stud bolts on the exhaust side.
Torque: 15 Nm (153 kgfcm, 11 ftlbf)
30. INSTALL VALVE STEM OIL O SEAL OR RING
(a) Apply a light coat of engine oil on the valve stem.
Intake Exhaust
NOTICE:
Light Brown Pay much attention assembling the oil seal for intake and
exhaust. Assembling the wrong one may cause a failure.
Gray
HINT:
The intake valve oil seal is light brown and the exhaust valve oil
seal is gray.
A78789
(b) Using SST, push in a new oil seal.
SST SST 09201-41020
NOTICE:
Failure to use SST will cause the seal to be damaged or im-
properly seated.
A78790
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ENGINE MECHANICAL - CYLINDER HEAD ASSY
31. INSTALL INTAKE VALVE
(a) Install the valve, spring seat, valve spring, and spring re-
tainer.
NOTICE:
Install the same part in the same combination to the origi-
nal locations.
P12668
(b) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202-70020 (09202-00010)
SST
A78770
(c) Using a plastic-faced hammer and a discarded valve (the
tip is wrapped with tape), lightly tap the installed valve to
fitting into place.
NOTICE:
Be careful not to damage the installed valve stem tip.
A05246
32. INSTALL EXHAUST VALVE
(a) Install the valve, spring seat, valve spring, and spring re-
tainer.
NOTICE:
Install the same parts in the same combination to the origi-
nal locations.
A52900
(b) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202-70020 (09202-00010)
SST
A78772
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Author : Date : 2466
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ENGINE MECHANICAL - CYLINDER HEAD ASSY
(c) Using a plastic-faced hammer and a discarded valve (the
tip is wrapped with tape), lightly tap the installed valve to
fitting into place.
NOTICE:
Be careful not to damage the installed valve stem tip.
A05246
33. INSTALL VALVE LIFTER
(a) Apply a light coat of engine oil on the valve lifter.
NOTICE:
Install the same part in the same combination to the original locations.
(b) Install the valve lifter.
(c) Check that the valve lifter rotates smoothly by hand.
34. INSTALL SEMICIRCULAR PLUG
(a) Remove any old seal packing (FIPG) material.
(b) Apply seal packing to the semi-circular plug grooves.
Seal packing: Part No. 08826-00080 or equivalent
Seal Packing A78791
(c) Install the 2 semi-circular plugs to the cylinder heads.
NOTICE:
: Semi-circular Plug S Install the plugs flush with the top of the cylinder
head.
RH Cylinder S Install the semi-circular plugs within 3 minutes after
applying seal packing.
S Do not expose the seal to engine oil within 2 hours af-
ter installing.
Front
LH Cylinder
A78792
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ENGINE MECHANICAL - CYLINDER HEAD ASSY
35. INSTALL W/HEAD STRAIGHT SCREW PLUG NO.1 (RH CYLINDER)
(a) Using a 10mm socket hexagon wrench, install 2 new gaskets and the 2 screw plugs.
Torque: 44 Nm (449 kgfcm, 32 ftlbf)
36. INSTALL W/HEAD STRAIGHT SCREW PLUG NO.2 (LH CYLINDER)
(a) Using a 10mm socket hexagon wrench, install 2 new gaskets and the 2 screw plugs.
Torque: 44 Nm (449 kgfcm, 32 ftlbf)
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2468
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