Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Sienna 2004-2007 Approved SRM 09 20qem w040001
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14-44
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
141AN-02
OVERHAUL
1. REMOVE SPARK PLUG
2. REMOVE OIL FILLER CAP SUB-ASSY
3. REMOVE OIL FILLER CAP GASKET
4. REMOVE CYLINDER HEAD COVER SUB-ASSY LH
5. REMOVE CYLINDER HEAD COVER GASKET NO.2
6. REMOVE CYLINDER HEAD COVER SUB-ASSY
7. REMOVE CYLINDER HEAD COVER GASKET
8. REMOVE VENTILATION VALVE SUB-ASSY
9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Remove both camshaft oil control valves.
(b) Remove the O-ring from each camshaft oil control valve.
10. REMOVE VVT SENSOR
11. REMOVE OIL LEVEL GAGE SUB-ASSY
12. REMOVE OIL LEVEL GAGE GUIDE
13. REMOVE CRANKSHAFT PULLEY
(a) Using SST, loosen the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
SST
A78700
(b) Using SST and the pulley bolt, remove the pulley.
SST 09950- 50013 (09951- 05010, 09952- 05010,
09953-05020, 09954-05031)
SST
NOTICE:
Before using SST, apply lubricating oil on the threads and
tip of the center bolt 150.
A78701
14. REMOVE TIMING BELT NO.1 COVER
15. REMOVE TIMING BELT NO.2 COVER
16. REMOVE ENGINE MOUNTING BRACKET RH
17. REMOVE TIMING BELT GUIDE NO.2
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2343
14-45
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
18. REMOVE TIMING BELT
(a) Set No. 1 cylinder to TDC/compression.
(1) Temporarily install the crankshaft pulley bolt and the
washer to the crankshaft.
(2) Turn the crankshaft clockwise, and align the timing
marks of the crankshaft timing pulley and the oil
pump body.
Turn
A78326
(3) Check that timing marks of the camshaft timing pul-
leys and No. 3 timing belt cover are aligned.
If not, turn the crankshaft 1 revolution (360_).
(4) Remove the crankshaft pulley bolt.
A05052
(b) If re-using the timing belt, check that there are 3 installa-
tion marks on the timing belt as shown in the illustration.
(1) If the installation marks have disappeared, put new
installation marks on the timing belt before remov-
ing.
A52840
(c) Set No. 1 cylinder to approx. 60_BTDC/ compression.
(1) Turn the crankshaft counterclockwise by approx.
Approx. 60_ 60_.
NOTICE:
If the timing belt is disengaged, having the crankshaft
Turn
pulley at the wrong angle can cause the piston head and
valve head to come into contact with each other when you
remove the camshaft timing pulley and camshaft, causing
A78327 damage. So always set the crankshaft pulley at the correct
angle.
(d) Remove the timing belt tensioner.
NOTICE:
Do not install the tensioner as it removed.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2344
14-46
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
(e) Remove the timing belt in this order.
(3)
1st No. 1 idler pulley
2nd RH camshaft timing pulley
3rd No. 2 idler pulley
(5) 4th LH camshaft timing pulley
(2) (4) 5th Water pump pulley
(1) 6th Crankshaft timing pulley
(6)
A78702
19. REMOVE TIMING BELT IDLER SUB-ASSY NO.1
(a) Using a 10 mm socket hexagon wrench, remove the pivot bolt, the timing belt idler No. 1 and the plate
washer.
20. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
21. REMOVE CRANKSHAFT POSITION SENSOR
22. REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the bolt and the RH timing pulley.
SST 09960-10010 (09962-01000, 09963-01000)
SST
A78703
(b) Using SST, remove the bolt and the LH timing pulley.
SST 09960-10010 (09962-01000, 09963-01000)
HINT:
Arrange the camshaft timing pulleys (RH and LH sides) so that
SST they can be returned to the original locations when re-assem-
bling.
A78704
23. REMOVE TIMING BELT NO.3 COVER
24. REMOVE TIMING BELT IDLER BRACKET
25. REMOVE CRANKSHAFT TIMING PULLEY
(a) Remove the bolt and the timing belt plate.
(b) Install the pulley bolt to the crankshaft.
(c) Using SST, remove the crankshaft timing pulley.
SST
SST 09950- 50013 (09951- 05010, 09952- 05010,
09953-05020, 09954-05011)
NOTICE:
S Do not scratch the sensor part of the crankshaft tim-
ing pulley.
S Before using SST, apply lubricating oil on the threads
A78705 and tip of the center bolt 150.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2345
14-47
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
26. REMOVE WATER PUMP ASSY
(a) Remove the 3 bolts, the 3 nuts, the water pump and the
gasket.
27. REMOVE CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being removed. If the
camshaft is not kept level, damage to the cylinder head or
A78535 to the camshaft may result. To avoid this, the following
steps should be carried out.
(a) Align the timing marks (2 dot marks) of the camshaft drive
and the driven gears by turning the camshaft with a
wrench.
Align
A78706
Main Gear (b) Secure the exhaust camshaft sub-gear to the main gear
Sub-Gear with a service bolt.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
Recommended service bolt
Thread diameter 6 mm
Thread pitch 1.0 mm
Service Bolt Bolt length 16 to 20 mm
HINT:
A78707 When removing the camshaft, make certain that the torsional
spring force of the sub-gear has been eliminated by installation
of the service bolt.
2 (c) Using several steps, loosen and remove the 10 bearing
6
1
cap bolts uniformly in the sequence shown in the illustra-
10 tion. Remove the 5 bearing caps and the camshaft.
5 NOTICE:
8
9 S Do not pry out the camshaft.
S Be careful not to damage the portion of the cylinder
4 7
head receiving the shaft thrust.
3
A78708
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2346
14-48
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
28. REMOVE NO.2 CAMSHAFT
1
(a) Using several steps, loosen and remove the 10 bearing
5
9 cap bolts uniformly in the sequence shown in the illustra-
2
6 tion. Remove the 5 bearing caps and the No. 2 camshaft.
7
NOTICE:
3 10
S Do not pry out the camshaft.
8
4 S Be careful not to damage the portion of the cylinder
head receiving the shaft thrust.
A78709 (b) Remove the oil seal from the No.2 camshaft.
29. REMOVE NO.3 CAMSHAFT SUB-ASSY
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being removed. If the
camshaft is not kept level, damage to the cylinder head or
to the camshaft may result. To avoid this, the following
steps should be carried out.
(a) Align the timing marks (1 dot marks) of the camshaft drive
and the driven gears by turning the camshaft with a
wrench.
Align A78710
(b) Secure the exhaust camshaft sub-gear to the main gear
Service Bolt
with a service bolt.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
Recommended service bolt
Thread diameter 6 mm
Thread pitch 1.0 mm
Bolt length 16 to 20 mm
HINT:
Main Gear Sub-Gear A78711 When removing the camshaft, make certain that the torsional
spring force of the sub-gear has been eliminated by installation
of the service bolt.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2347
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ENGINE MECHANICAL - PARTIAL ENGINE ASSY
1 2
(c) Using several steps loosen and remove the 10 bearing
5
9 cap bolts uniformly in the sequence shown in the illustra-
6 tion. Remove the 5 bearing caps and the No. 3 camshaft.
7
10 NOTICE:
S Do not pry out the camshaft.
3 8
S Be careful not to damage the portion of the cylinder
4
head receiving the shaft thrust.
A78712
30. REMOVE NO.4 CAMSHAFT SUB-ASSY
2
(a) Using several steps, loosen and remove the 10 bearing
6 1
cap bolts uniformly in the sequence shown in the illustra-
10 tion. Remove the 5 bearing caps and the No. 4 camshaft.
5
8 NOTICE:
9
S Do not pry out the camshaft.
4 7 S Be careful not to damage the portion of the cylinder
head receiving the shaft thrust.
3
A78713 (b) Remove the oil seal from the No. 4 camshaft.
31. INSPECT CAMSHAFT TIMING GEAR ASSY
(a) Clamp the camshaft in a vise on the hexagonal lobe.
(b) Check that VVT-i will not turn.
A05739
(c) Cover all the oil ports except the port on the advance
angle side (nearest to the convex portion) shown in the il-
lustration with vinyl tape.
(d) Using the air gun, apply about 100 kPa (1 kgf/cm2, 14 psi)
of air pressure to the port on the advance side shown in
the illustration.
NOTICE:
Some oil spraying will occur. Be prepared to catch the
Convex Portion
A78714 spray with a shop rag.
HINT:
Perform this in order to release the lock pin for the maximum
delay angle lock.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2348
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ENGINE MECHANICAL - PARTIAL ENGINE ASSY
(e) Under the condition above, turn VVT-i to the advance
angle side (the white arrow marked direction in the il-
lustration) by hand.
Standard: Must turn
HINT:
Depending on the air pressure, VVT-i will turn to the advance
angle side without applying force by hand. Also, if the pressure
can be hardly applied because of the air leakage from the port,
it might be difficult to get the lock-pin to release.
(f) Check that the VVT-i moves freely within about 30_
range. Avoid moving the VVT-i unit to the maximum delay
angle position as the lock-pin will re-engage.
Standard: Smooth movable range is about 30_
(g) Turn VVT-i by hand and lock it at the maximum delay
angle position.
32. REMOVE CAMSHAFT TIMING GEAR ASSY
NOTICE:
Do not remove or install the camshaft timing gear (VVT-i)
unless you are changing the VVT-i or the camshaft.
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
A05739
(b) Using a 46 mm socket wrench, remove the lock nut by
turning it clockwise.
NOTICE:
S Remove it with the lock-pin engaged and locked at
the maximum delay angle position.
S The lock nut has LH threads.
S Never use any tool other than the socket wrench. Oth-
er tools will deform the cam angle rotor.
A05740 (c) Remove the camshaft VVT-i.
NOTICE:
Never remove the 3 bolts on the gear.
If it is difficult to remove VVT-i, tap it lightly using a plastic-faced
hammer and then remove it.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2349
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ENGINE MECHANICAL - PARTIAL ENGINE ASSY
33. REMOVE CAMSHAFT SUB GEAR
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
P12596
(b) Using SST, turn the sub-gear counterclockwise, and re-
SST move the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
A78715
(c) Using snap ring pliers, remove the snap ring.
(d) Remove the wave washer, the camshaft sub-gear and
the camshaft gear bolt washer.
HINT:
Arrange the camshaft sub-gears and gear bolt washers (RH
and LH sides) so that they can be returned to the original loca-
tion when re-assembling.
A52353
34. REMOVE ENGINE HANGER NO.2
35. REMOVE CYLINDER HEAD COVER REAR
36. REMOVE OIL CONTROL VALVE FILTER
(a) Remove the plug, the gasket and the valve filter.
A05275
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2350
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ENGINE MECHANICAL - PARTIAL ENGINE ASSY
37. REMOVE CYLINDER HEAD SUB-ASSY
(a) Using an 8 mm hexagon wrench, remove the hexagon
Front
bolt.
A78716
(b) Using several steps, loosen the 8 cylinder head bolts uni-
formly in the sequence shown in the illustration. Remove
Front
the 8 cylinder head bolts and the plate washers.
2 7 5 3 NOTICE:
S Be careful not to drop washers into the cylinder head.
S Head warpage or cracking could result from remov-
4 6 8 1 ing bolts in an incorrect order.
A78717
38. REMOVE CYLINDER HEAD GASKET
39. REMOVE CYLINDER HEAD LH
(a) Using an 8 mm hexagon wrench, remove the hexagon
Front
bolt.
A78718
(b) Using several steps, loosen the 8 cylinder head bolts uni-
formly in the sequence shown in the illustration. Remove
Front
the 8 cylinder head bolts and the plate washers.
4 6 8 1 NOTICE:
S Be careful not to drop washers into the cylinder head.
S Head warpage or cracking could result from remov-
2 7 5 3
ing bolts in an incorrect order.
A78719
40. REMOVE CYLINDER HEAD GASKET NO.2
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2351
14-53
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
41. REMOVE WATER INLET HOUSING
2
8 (a) Remove the 8 bolts, the 2 nuts and the water inlet hous-
10 ing.
5
3 4
6
9
7
1
A78314
42. REMOVE OIL FILTER SUB-ASSY
SST (a) Using SST, remove the oil filter.
SST 09228-07501
(b) Using a 12 mm socket hexagon wrench, remove the oil fil-
ter union.
A78720
43. REMOVE OIL PAN DRAIN PLUG
44. REMOVE OIL PAN SUB-ASSY NO.2
(a) Remove the 10 bolts and the 2 nuts.
A36750
(b) Insert the blade of SST between oil pan No. 1 and oil pan
SST No. 2, cut off the sealer and remove the oil pan No. 2.
SST 09032-00100
NOTICE:
SST S Be careful not to damage the contact surface of oil
pan No. 1 where oil pan No. 2 is mounting.
S Do not damage flange portion of oil pan No. 2 when re-
moving.
A00019
45. REMOVE OIL STRAINER SUB-ASSY
(a) Remove the bolt, the 2 nuts, the oil strainer and the gasket.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2352
14-54
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
46. REMOVE OIL PAN SUB-ASSY
(a) Loosen and remove the 15 bolts and the 2 nuts uniformly.
B04136
(b) Using a screwdriver, remove the oil pan by prying be-
tween the cylinder block and the oil pan.
NOTICE:
Be careful not to damage the contact surfaces of the oil pan
and cylinder block.
B04137
47. REMOVE OIL PAN BAFFLE PLATE
48. REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying
between the oil seal retainer and the main bearing cap.
P12508
49. REMOVE ENGINE REAR OIL SEAL
(a) Using a screwdriver and a hammer, tap out the oil seal.
P12589
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2353
14-55
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
50. REMOVE OIL PUMP ASSY
(a) Remove the 9 bolts.
(b) Using a screwdriver, remove the oil pump by prying be-
tween the oil pump and the main bearing cap.
(c) Remove the O-ring.
A51990
51. REMOVE OIL PUMP SEAL
(a) Using a screwdriver, pry out the oil seal.
A62375
52. REMOVE SPARK PLUG TUBE GASKET
(a) Bend up the tab on the ventilation baffle plate which pre-
vents the gasket from the slipping out.
NOTICE:
Be careful not to damage the baffle plate of the cylinder
head cover.
(b) Using a screwdriver and a hammer, tap out the gasket.
A05245
(c) Using needle-nose pliers, pry out the gasket.
NOTICE:
Be careful not to damage the cylinder head cover.
A05243
53. INSPECT TIMING BELT
NOTICE:
S Do not bend, twist or turn the timing belt inside out.
S Do not allow the timing belt to come into contact with
oil, water or steam.
S Do not utilize timing belt tension when installing or re
moving the mounting bolt of the camshaft timing
pulley.
EM3336 Check the belt for any defects, as shown in the illustrations.
Also check these points below.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2354
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ENGINE MECHANICAL - PARTIAL ENGINE ASSY
(a) If there is premature parting,
S Check for proper installation.
S Check the timing cover gasket for damage and
proper installation.
(b) If the belt teeth are cracked or damaged, check to see if
either camshaft is locked.
(c) If there is noticeable wear or cracks on the belt face,
check to see if there are nicks on the side of the idler
pulley lock and water pump.
(d) If there is wear or damage on only one side of the belt,
check the belt guide and the alignment of each pulley.
(e) If there is noticeable wear on the belt teeth,
S Check timing cover for damage.
S Check gasket has been installed correctly.
S Check for foreign object on the pulley teeth.
If there is any doubt about the belt condition, replace the timing
belt.
54. INSPECT CAMSHAFT
(a) Inspect camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the runout at the
center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the runout is greater than maximum, replace the camshaft.
EM1628
(b) Inspect cam lobes.
(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake 43.132 to 43.232 mm (1.6981 to 1.7020 in.)
Exhaust 43.010 to 43.110 mm (1.6933 to 1.6972 in.)
Minimum cam lobe height:
Intake 42.98 mm (1.6921 in.)
Exhaust 42.86 mm (1.6874 in.)
A51428 If the cam lobe height is less than minimum, replace the cam-
shaft.
(c) Inspect camshaft journals.
(1) Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 to 26.975 mm (1.0614 to 1.0620 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
A51429
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2355
14-57
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
55. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
Tension Portion eter of the bolt.
Standard outside diameter:
8.95 to 9.05 mm (0.3524 to 0.3563 in.)
Minimum outside diameter: 8.75 mm (0.3445 in.)
If the diameter is less than minimum, replace the bolt.
A78721
56. INSTALL SPARK PLUG TUBE GASKET
(a) Using SST and a hammer, tap in a new gasket until its sur-
SST face is flush with the upper edge of the cylinder head cov-
er.
SST 09950- 60010 (09951- 00430), 09950- 70010
(09951-07100)
(b) Return the ventilation plate tab to its original position.
(c) Apply a light coat of MP grease to the gasket lip.
A78722
57. INSTALL ENGINE REAR OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)
NOTICE:
SST S Be careful not to tap the oil seal at an angle.
S Keep the lip free of foreign objects.
(b) Apply MP grease to the oil seal lip.
A78723 58. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Remove any old packing material from the contact sur-
face.
Seal Width 2 to 3 mm (b) Apply a continuous bead of seal packing (Diameter 2 to
A
3 mm (0.08 to 0.12 in.)) as shown in the illustration.
A Seal packing: Part No. 08826-00080 or equivalent
B NOTICE:
S Remove any oil from the contact surface.
B S Install the oil seal retainer within 3 minutes after ap-
plying seal packing.
S Do not expose the seal to engine oil within 2 hours af-
A78724 ter installing.
(c) Install the oil seal retainer with the 6 bolts. Tighten the bolt
uniformly in several steps.
Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2356
14-58
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
59. INSTALL OIL PUMP SEAL
SST (a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the oil pump body edge.
SST 09223-00010
NOTICE:
S Be careful not to tap the oil seal at an angle.
S Keep the lip free of foreign objects.
(b) Apply MP grease to the oil seal lip.
A78754 60. INSTALL OIL PUMP ASSY
(a) Remove any old packing material from the contact sur-
face.
(b) Apply a light coat of engine oil to a new O-ring and place
it on the cylinder block.
A36784
(c) Apply a continuous bead of seal packing (Diameter 2 to
3 mm (0.08 to 0.12 in.)) as shown in the illustration.
B
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
A S Remove any oil from contact surface.
S Apply seal packing to the inner side of the bolt holes.
S Install the oil pump within 3 minutes after applying
C seal packing.
S Do not expose the seal to engine oil within 2 hours af-
ter installing.
Seal Packing
A
Seal Width
B
2 to 3 mm
C
A78725
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2357
14-59
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
(d) Align the key of the oil pump drive gear with the keyway
located on the crankshaft, and slide the oil pump into
place.
A36785
(e) Install the oil pump with the 9 bolts. Tighten the bolts uni-
A
B formly in several steps.
C A Torque:
A
Bolt A 8.0 Nm (82 kgfcm, 71 in.lbf)
Bolt B 20 Nm (199 kgfcm, 14 ftlbf)
B Bolt C 43 Nm (439 kgfcm, 32 ftlbf)
A
A A
A51990
61. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 Nm (80 kgfcm, 71 in.lbf)
62. INSTALL OIL PAN BAFFLE PLATE
Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
63. INSTALL OIL PAN SUB-ASSY
(a) Remove any old seal packing from the contact surface.
(b) Apply a continuous bead of seal packing (Diameter 3 to
4 mm (0.12 to 0.16 in.)) as shown in the illustration.
Region "X" Region "Y" Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
S Remove any oil from the contact surface.
S Apply seal packing to the outer side of the bolt holes
in the region "X".
S Apply seal packing to the inner side of the bolt holes
in the region "Y".
S Install the oil pan within 3 minutes after applying seal
packing.
A B
S Do not expose the seal to engine oil within 2 hours af-
Seal Packing ter installing.
A B (c) Install the oil pan No. 1 with the 15 bolts and the 2 nuts.
Tighten the bolts uniformly in several steps.
Torque:
10 mm head 8.0 Nm (82 kgfcm, 71 in.lbf)
Seal Width 12 mm head 20 Nm (199 kgfcm, 14 ftlbf)
3 to 4 mm
A78726
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2358
14-60
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
64. INSTALL OIL STRAINER SUB-ASSY
(a) Install a new gasket and the oil strainer with the bolt and the 2 nuts.
Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
65. INSTALL OIL PAN SUB-ASSY NO.2
(a) Remove any old seal packing from the contact surface.
(b) Apply a continuous bead of seal packing (Diameter 4 to
Seal Packing 5 mm (0.16 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
S Remove any oil from the contact surface.
S Apply seal packing to the inner side of the bolt holes.
S Install the oil pan within 3 minutes after applying seal
packing.
S Do not expose the seal to engine oil within 2 hours af-
ter installing.
(c) Install the oil pan No. 2 with the 10 bolts and the 2 nuts.
Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
A B
A
Seal Width
4 to 5 mm
B
A78727
66. INSTALL OIL PAN DRAIN PLUG
(a) Install the drain plug with a new gasket.
Torque: 45 Nm (459 kgfcm, 33 ftlbf)
67. INSTALL WATER INLET HOUSING
(a) Remove any old packing material from the contact sur-
face.
(b) Apply a continuous bead of seal packing (Diameter 3 to
5 mm (0.12 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent
Seal Width 3 to 5 mm NOTICE:
S Remove any oil from the contact surface.
S Install the water inlet housing within 3 minutes after
applying seal packing.
Seal Packing S Do not expose the seal to coolant within 2 hours after
A78728 installing.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2359
14-61
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
(c) Install the water inlet housing with the 8 bolts and the 2
9
3 nuts. Using several steps, tighten the bolts and the nuts
uniformly in the sequence shown in the illustration.
1 Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
6
8 7
5
2
4
10
A78314
68. INSTALL CYLINDER HEAD GASKET
Front
(a) Place a new cylinder head gasket on the cylinder block
with the R mark upward.
NOTICE:
S Remove any oil from the contact surface.
S Be careful of the installing orientation.
S Place the cylinder head on the gasket carefully in or-
der not to damage the gasket at the bottom part of the
A78324 head.
69. INSTALL CYLINDER HEAD SUB-ASSY
NOTICE:
The cylinder head bolts are tightened in 2 successive
steps.
(a) Apply a light coat of engine oil on the threads of the cylin-
der head bolts.
(b) Install the plate washers to the cylinder head bolts.
(c) Using several steps, install and tighten the 8 cylinder
head bolts uniformly in the sequence shown in the illustra-
Front
tion.
7 2 4 6 Torque: 54 Nm (550 kgfcm, 40 ftlbf)
5 3 1 8
A78717
(d) Mark the front side of each cylinder head bolt head with
paint as shown in the illustration.
90_ (e) Retighten the cylinder head bolts by 90_in the same se-
quence as step (c).
Front (f) Check that the painted mark is now at a 90_ angle to the
front.
Painted mark
A78730
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2360
14-62
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
(g) Using an 8 mm socket hexagon wrench, install the hexa-
gon bolt.
Front
Torque: 19 Nm (189 kgfcm, 14 ftlbf)
A78716
Front
70. INSTALL CYLINDER HEAD GASKET NO.2
(a) Place a new cylinder head gasket on the cylinder block
with the L mark upward.
NOTICE:
S Remove any oil from the contact surface.
S Be careful of the installing orientation.
S Place the cylinder head on the gasket carefully in or-
der not to damage the gasket at the bottom part of the
A78325 head.
71. INSTALL CYLINDER HEAD LH
NOTICE:
The cylinder head bolts are tightened in 2 successive
steps.
(a) Apply a light coat of engine oil on the threads of the cylin-
der head bolts.
(b) Install the plate washers to the cylinder head bolts.
(c) Using several steps, install and tighten the 8 cylinder
head bolts uniformly in the sequence shown in the illustra-
Front
tion.
5 3 1 8 Torque: 54 Nm (550 kgfcm, 40 ftlbf)
7 2 4 6
A78719
(d) Mark the front side of each cylinder head bolt head with
paint as shown in the illustration.
90_ (e) Retighten the cylinder head bolts by 90_in the same se-
quence as step (c).
Front (f) Check that the painted mark is now at a 90_ angle to the
front.
Painted mark
A78730
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2361
14-63
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
(g) Using an 8 mm socket hexagon wrench, install the hexa-
gon bolt.
Front
Torque: 19 Nm (189 kgfcm, 14 ftlbf)
A78718
72. INSTALL OIL CONTROL VALVE FILTER
(a) Check that no foreign object is on the mesh part of the fil-
ter.
(b) Assemble the valve filter and the plug.
(c) Install the plug with a new gasket.
Torque: 45 Nm (459 kgfcm, 33 ftlbf)
A05418
73. INSTALL CYLINDER HEAD COVER REAR
(a) Install the rear cover and a new gasket.
Torque: 10 Nm (102 kgfcm, 7 ftlbf)
74. INSTALL CAMSHAFT SUB GEAR
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
P12595
(b) Install the camshaft gear bolt washer and the camshaft
Wave Washer
sub-gear .
Camshaft
HINT:
Sub-Gear
Attach the pins on the gears to the gear bolt washer ends.
(c) Install the wave washer.
Camshaft Gear
Bolt Washer
A78732
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2362
14-64
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
(d) Using snap ring pliers, install the snap ring.
A52353
(e) Using SST, align the holes of the camshaft main gear and
sub-gear by turning camshaft sub-gear counterclock-
SST wise, and temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(f) Align the gear teeth of the main gear and sub-gear and
tighten the service bolt.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
NOTICE:
A78733 Be careful not to damage the camshaft journals.
HINT:
When installing the camshaft, make certain that the torsional
spring force of the sub-gear has been eliminated by installation
of the service bolt.
75. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Align the alignment pin with the alignment pin groove and
install VVT-i on the camshaft.
NOTICE:
Install it with the lock-pin engaged and locked at the maxi-
mum delay angle position.
(b) Apply engine oil on the nut, the mounting surface of VVT-i
Align and the screw threads.
A78734 NOTICE:
S Be sure to apply the oil, otherwise the specified
torque cannot be obtained.
S New nuts must be used when replacing VVT-i unit.
(c) Using a 46 mm socket wrench, install and tighten a lock
nut by turning it counterclockwise.
Torque: 150 Nm (1,530 kgfcm, 111 ftlbf)
NOTICE:
S The lock nut has LH threads.
S Never use any tool other than the socket wrench. Oth-
er tools will deform the cam angle rotor.
A05738
2005 SIENNA REPAIR MANUAL (RM1163U)
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