Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Sienna 2004-2007 Approved SRM 09 20qem x040001
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14-33
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
141AM-02
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER NO.1
4. REMOVE FRONT FENDER LINER LH
5. REMOVE FRONT FENDER LINER RH
6. REMOVE FRONT FENDER APRON SEAL LH
7. REMOVE FRONT FENDER APRON SEAL RH
8. DRAIN COOLANT (See page 16-8 )
9. DRAIN ENGINE OIL (See page 17-23 )
10. DRAIN AUTOMATIC TRANSAXLE FLUID (See page 40-22 )
11. DRAIN TRANSFER OIL (4WD DRIVE TYPE)
12. REMOVE FRONT WIPER ARM HEAD CAP
13. REMOVE FR WIPER ARM RH (See page 66-8 )
14. REMOVE FR WIPER ARM LH (See page 66-8 )
15. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-8 )
16. REMOVE WIPER LINK ASSY (See page 66-8 )
17. REMOVE COWL TOP TO COWL BRACE INNER NO.1 (See page 11-13 )
18. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT (See page 11-13 )
19. REMOVE V-BANK COVER SUB-ASSY (See page 14-7 )
20. REMOVE BATTERY
21. REMOVE AIR CLEANER CAP SUB-ASSY (See page 19-5 )
22. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSY
23. REMOVE AIR CLEANER INLET NO.2 (See page 19-5 )
24. REMOVE AIR CLEANER CASE (See page 19-5 )
25. REMOVE AIR CLEANER BRACKET (See page 19-5 )
26. REMOVE AIR CLEANER INLET NO.1 (See page 19-5 )
27. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
28. REMOVE GENERATOR ASSY (See page 19-19 )
29. REMOVE ENGINE MOVING CONTROL ROD (See page 14-84 )
30. REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-84 )
31. REMOVE GENERATOR BRACKET NO.2 (See page 14-84 )
32. REMOVE GENERATOR BELT ADJUSTING BAR (See page 17-1 1)
33. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (See page 17-1 1)
34. SEPARATE TRANSMISSION CONTROL CABLE ASSY (See page 40-47 )
35. DISCONNECT UNION TO CHECK VALVE HOSE
36. DISCONNECT FUEL VAPOR FEED HOSE NO.1
37. DISCONNECT FUEL PIPE SUB-ASSY NO.1 (See page 11-1 )
38. DISCONNECT HEATER WATER INLET HOSE B
39. DISCONNECT HEATER WATER OUTLET HOSE B
40. DISCONNECT RADIATOR HOSE INLET
41. DISCONNECT RADIATOR HOSE OUTLET
42. DISCONNECT OIL COOLER INLET HOSE NO.1
43. DISCONNECT OIL COOLER OUTLET HOSE NO.1
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2332
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ENGINE MECHANICAL - PARTIAL ENGINE ASSY
44. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1
A78339
45. DISCONNECT STEERING GEAR OUTLET RETURN
TUBE
A78340
46. REMOVE GLOVE COMPARTMENT DOOR ASSY
47. SEPARATE ENGINE WIRE
(a) Disconnect the engine wire harness from the ECM and
the junction block.
(b) Disconnect the engine wire harness from the engine room
junction block.
(1) Remove the nut and separate the wire harness.
(2) Using a screwdriver, release the engine room junc-
tion block. Separate the engine wire by pulling it up-
ward.
(c) Pull out the engine wire harness.
(d) Remove the body ground.
A78341
48. REMOVE PROPELLER SHAFT (4WD DRIVE TYPE) (See page 30-6 )
SST 09325-20010
49. REMOVE EXHAUST PIPE ASSY CENTER (4WD DRIVE TYPE) (See page 15-6 )
50. REMOVE EXHAUST PIPE ASSY FRONT (2WD DRIVE TYPE) (See page 15-2 )
51. REMOVE EXHAUST PIPE ASSY FRONT (4WD DRIVE TYPE) (See page 15-6 )
52. SEPARATE FRONT STABILIZER LINK ASSY LH (See page 30-18 )
53. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
54. REMOVE FRONT AXLE HUB LH NUT (See page 30-18 )
SST 09930-00010
55. REMOVE FRONT AXLE HUB RH NUT
SST 09930-00010
HINT:
Perform the same procedure as above on the opposite side.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2333
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ENGINE MECHANICAL - PARTIAL ENGINE ASSY
56. SEPARATE SPEED SENSOR FRONT LH (See page 30-18 )
57. SEPARATE SPEED SENSOR FRONT RH
HINT:
Perform the same procedure as above on the opposite side.
58. SEPARATE TIE ROD ASSY LH (See page 30-18 )
SST 09628-6201 1
59. SEPARATE TIE ROD ASSY RH
SST 09628-6201 1
HINT:
Perform the same procedure as above on the opposite side.
60. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (See page 30-18 )
61. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
62. SEPARATE FRONT AXLE ASSY LH (See page 30-18 )
63. SEPARATE FRONT AXLE ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
64. SEPARATE STEERING INTERMEDIATE SHAFT ASSY (See page 51-19 )
65. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine lifter.
(b) Remove the 6 bolts, the 2 nuts, the frame side rail plate
RH and LH.
A78345
(c) Remove the 6 bolts, the 2 nuts, the front suspension
member brace rear RH and LH.
(d) Carefully remove the engine assembly from the vehicle.
A78346
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2334
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ENGINE MECHANICAL - PARTIAL ENGINE ASSY
(e) Install the No. 2 engine hanger in correct direction (shown
in the illustration).
Part No.:
No. 2 engine hanger 12282-20020
Bolt 90080-11331
Torque: 20 Nm (199 kgfcm, 14 ftlbf)
(f) Attach the engine sling and hang the engine assembly
with the chain block.
A36439
66. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
67. REMOVE MANIFOLD STAY
68. REMOVE EXHAUST MANIFOLD SUB-ASSY RH (2WD DRIVE TYPE) (See page 14-129 )
69. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY (4WD DRIVE TYPE)
(See page 14-129 )
70. REMOVE VANE PUMP V BELT (See page 14-5 )
71. REMOVE VANE PUMP ASSY
(a) Remove the 2 nuts and disconnect the PS pressure tube.
A78347
(b) Remove the 2 bolts and the vane pump.
A52890
72. REMOVE STABILIZER BAR FRONT (4WD DRIVE TYPE)
73. REMOVE RACK & PINION POWER STEERING GEAR ASSY (4WD DRIVE TYPE)
74. REMOVE FRONT FRAME ASSY
RH LH (a) Remove the 2 nuts and separate engine mounting insula-
tor RH and LH.
A78403
2005 SIENNA REPAIR MANUAL (RM1163U)
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ENGINE MECHANICAL - PARTIAL ENGINE ASSY
(b) Remove the nut and separate the engine mounting insu-
lator FR.
A78348
(c) 4WD:
4WD
Remove the 2 bolts and separate the engine mounting in-
sulator RR.
A52340
75. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30-18 )
SST 09520-01010, 09520-24010 (09520-32040)
76. REMOVE FRONT DRIVE SHAFT ASSY RH (2WD DRIVE TYPE) (See page 30-18 )
77. REMOVE FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE) (See page 30-18 )
78. REMOVE STARTER ASSY (See page 19-5 )
79. REMOVE ENGINE MOUNTING BRACKET FR (See page 40-9 )
80. REMOVE AUTOMATIC TRANSAXLE ASSY (2WD DRIVE TYPE) (See page 40-9 )
81. REMOVE TRANSFER STIFFENER PLATE RH (4WD DRIVE TYPE) (See page 40-9 )
82. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (4WD DRIVE TYPE) (See page 40-9 )
83. REMOVE DRIVE SHAFT BEARING BRACKET (2WD DRIVE TYPE)
84. REMOVE ENGINE MOUNTING BRACKET RR (4WD DRIVE TYPE)
85. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (See page 14-154 )
SST 09213-54015 (91651-60855), 09330-00021
86. INSTALL ENGINE STAND
87. REMOVE ENGINE HANGER NO.2
88. REMOVE EMISSION CONTROL VALVE SET (See page 14-7 )
89. REMOVE INTAKE AIR SURGE TANK (See page 14-7 )
90. REMOVE INTAKE MANIFOLD (See page 14-129 )
91. REMOVE WATER OUTLET (See page 14-129 )
92. REMOVE IGNITION COIL ASSY
93. REMOVE MANIFOLD CONVERTER INSULATOR NO.3
94. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2
95. REMOVE MANIFOLD STAY NO.2
96. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2 (See page 14-146 )
97. REMOVE ENGINE MOUNTING BRACKET RH
98. REMOVE PUMP BRACKET
99. REMOVE GENERATOR BRACKET NO.1
100. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 (See page 17-1 1)
101. REMOVE WATER INLET
102. REMOVE THERMOSTAT
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2336
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ENGINE MECHANICAL - PARTIAL ENGINE ASSY
103. REMOVE ENGINE OIL PRESSURE SWITCH ASSY
Oil Pressure Switch (a) Using a 27 mm deep socket wrench, remove the oil pres-
sure switch.
A80061
104. REMOVE KNOCK SENSOR (See page 10-13 )
105. REPLACE PARTIAL ENGINE ASSY
106. INSTALL KNOCK SENSOR (See page 10-13 )
107. INSTALL ENGINE OIL PRESSURE SWITCH ASSY
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080 THREE BOND 1344,
LOCTITE 242 or equivalent.
(b) Using a 27 mm deep socket wrench, install the oil pressure switch.
Torque: 15 Nm (153 kgfcm, 11 ftlbf)
108. INSTALL THERMOSTAT (See page 16-16 )
109. INSTALL WATER INLET (See page 16-16 )
110. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 (See page 17-1 1)
111. INSTALL GENERATOR BRACKET NO.1
Torque: 58 Nm (591 kgfcm, 43 ftlbf)
112. INSTALL PUMP BRACKET
Torque: 32 Nm (326 kgfcm, 24 ftlbf)
113. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 54 Nm (551 kgfcm, 40 ftlbf)
114. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2 (See page 14-146 )
115. INSTALL MANIFOLD STAY NO.2
Torque: 49 Nm (500 kgfcm, 36 ftlbf)
116. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 14-146 )
117. INSTALL MANIFOLD CONVERTER INSULATOR NO.3 (See page 14-146 )
118. INSTALL IGNITION COIL ASSY (See page 14-7 )
119. INSTALL WATER OUTLET (See page 14-129 )
120. INSTALL INTAKE MANIFOLD (See page 14-129 )
121. INSTALL INTAKE AIR SURGE TANK (See page 14-7 )
122. INSTALL EMISSION CONTROL VALVE SET (See page 14-7 )
123. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (See page 14-154 )
SST 09213-54015 (91651-60855), 09330-00021
124. INSTALL DRIVE SHAFT BEARING BRACKET (2WD DRIVE TYPE)
Torque: 64 Nm (650 kgfcm, 47 in.lbf)
125. INSTALL ENGINE MOUNTING BRACKET RR (4WD DRIVE TYPE)
Torque: 64 Nm (653 kgfcm, 47 in.lbf)
126. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (4WD DRIVE TYPE) (See page 40-8 )
127. INSTALL TRANSFER STIFFENER PLATE RH (4WD DRIVE TYPE) (See page 40-8 )
128. INSTALL AUTOMATIC TRANSAXLE ASSY (2WD DRIVE TYPE) (See page 40-8 )
129. INSTALL ENGINE MOUNTING BRACKET FR (See page 40-8 )
130. INSTALL STARTER ASSY (See page 19-5 )
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2337
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ENGINE MECHANICAL - PARTIAL ENGINE ASSY
131. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30-18 )
132. INSTALL FRONT DRIVE SHAFT ASSY RH (2WD DRIVE TYPE) (See page 30-18 )
133. INSTALL FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE) (See page 30-18 )
134. INSTALL FRONT FRAME ASSY
RH LH (a) Install the engine mounting insulator RH and LH with the
2 nuts.
Torque: 95 Nm (969 kgfcm, 70 ftlbf)
A78403
(b) Install the engine mounting insulator FR with the nut.
Torque: 87 Nm (887 kgfcm, 64 ftlbf)
A78348
(c) 4WD:
4WD
Install the engine mounting insulator RR with the 2 bolts.
Torque: 75 Nm (765 kgfcm, 55 ftlbf)
A52340
135. INSTALL RACK & PINION POWER STEERING GEAR ASSY (4WD DRIVE TYPE)
Torque: 70 Nm (714 kgfcm, 52 ftlbf)
136. INSTALL STABILIZER BAR FRONT (4WD DRIVE TYPE)
Torque: 17 Nm (173 kgfcm, 13 ftlbf)
137. INSTALL VANE PUMP ASSY
(a) Temporarily tighten the bolt.
(b) Install the adjusting strut to the engine mounting bracket
RH with the bolt.
Torque: 44 Nm (449 kgfcm, 32 ftlbf)
A52890
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2338
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ENGINE MECHANICAL - PARTIAL ENGINE ASSY
(c) Connect the PS pressure tube with the 2 nuts.
Torque: 7.8 Nm (80 kgfcm, 69 in.lbf)
A78347
138. INSTALL VANE PUMP V BELT (See page 14-5 )
139. INSTALL EXHAUST MANIFOLD SUB-ASSY RH (2WD DRIVE TYPE) (See page 14-129 )
140. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY (4WD DRIVE TYPE)
(See page 14-129 )
141. INSTALL MANIFOLD STAY (See page 14-129 )
142. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See page 14-129 )
143. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
B C C B (a) Set the engine assembly with transaxle on the engine lift-
B B er.
(b) Install the engine assembly to the vehicle.
(c) Install the frame side rail plate RH and LH with the 6 bolts
and the 2 nuts.
A A Torque:
Bolt A 85 Nm (867 kgfcm, 63 ftlbf)
A78345 Bolt B 32Nm (329 kgfcm, 24 ftlbf)
Nut C 32Nm (329 kgfcm, 24 ftlbf)
(d) Install the front suspension member brace rear RH and
LH with the 6 bolts and the 2 nuts.
A A Torque:
Bolt A 85 Nm (867 kgfcm, 63 ftlbf)
Bolt B 32Nm (329 kgfcm, 24 ftlbf)
Nut C 32Nm (329 kgfcm, 24 ftlbf)
B B B B
C C
A78346
144. INSTALL STEERING INTERMEDIATE SHAFT ASSY (See page 51-19 )
145. INSTALL FRONT AXLE ASSY LH (See page 30-18 )
146. INSTALL FRONT AXLE ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
147. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (See page 30-18 )
148. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
2005 SIENNA REPAIR MANUAL (RM1163U)
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ENGINE MECHANICAL - PARTIAL ENGINE ASSY
149. INSTALL TIE ROD ASSY LH (See page 30-18 )
150. INSTALL TIE ROD ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
151. INSTALL SPEED SENSOR FRONT LH (See page 30-18 )
152. INSTALL SPEED SENSOR FRONT RH
HINT:
Perform the same procedure as above on the opposite side.
153. INSTALL FRONT AXLE HUB LH NUT (See page 30-18 )
154. INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
155. INSTALL FRONT STABILIZER LINK ASSY LH (See page 30-18 )
156. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
157. INSTALL EXHAUST PIPE ASSY FRONT (2WD DRIVE TYPE) (See page 15-2 )
158. INSTALL EXHAUST PIPE ASSY FRONT (4WD DRIVE TYPE) (See page 15-6 )
159. INSTALL EXHAUST PIPE ASSY CENTER (4WD DRIVE TYPE) (See page 15-6 )
160. INSTALL PROPELLER SHAFT (4WD DRIVE TYPE) (See page 30-6 )
161. CONNECT FUEL PIPE SUB-ASSY NO.1 (See page 11-1 )
162. INSTALL TRANSMISSION CONTROL CABLE ASSY (See page 40-47 )
163. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (See page 17-1 1)
164. INSTALL GENERATOR BELT ADJUSTING BAR (See page 17-1 1)
165. INSTALL GENERATOR BRACKET NO.2 (See page 14-84 )
166. INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-84 )
167. INSTALL ENGINE MOVING CONTROL ROD (See page 14-84 )
168. INSTALL GENERATOR ASSY (See page 19-19 )
169. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
170. INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE) (See page 14-1 )
171. INSTALL AIR CLEANER INLET NO.1 (See page 19-5 )
172. INSTALL AIR CLEANER BRACKET (See page 19-5 )
173. INSTALL AIR CLEANER CASE (See page 19-5 )
174. INSTALL AIR CLEANER INLET NO.2 (See page 19-5 )
175. INSTALL AIR CLEANER CAP SUB-ASSY (See page 19-5 )
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2340
14-42
ENGINE MECHANICAL - PARTIAL ENGINE ASSY
176. CONNECT VACUUM HOSE
Vacuum Hose Routing Diagram
From Canister
Actuator
VSV for EVAP
Vacuum Surge Tank
Vacuum Surge
Tank
VSV for ACIS
Actuator
VSV
A78349
177. INSTALL V-BANK COVER SUB-ASSY (See page 14-7 )
178. INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT (See page 11-13 )
179. INSTALL COWL TOP TO COWL BRACE INNER NO.1 (See page 11-13 )
180. INSTALL WIPER LINK ASSY (See page 66-8 )
181. INSTALL FR WIPER ARM LH (See page 66-8 )
182. INSTALL FR WIPER ARM RH (See page 66-8 )
183. INSTALL FRONT WHEELS (See page 14-5 )
184. ADD TRANSFER OIL (4WD DRIVE TYPE) (See page 31-4 )
185. INSPECT TRANSFER OIL (4WD DRIVE TYPE) (See page 31-4 )
186. ADD AUTOMATIC TRANSAXLE FLUID
187. ADD ENGINE OIL (See page 17-23 )
188. ADD COOLANT (See page 16-8 )
189. ADD POWER STEERING FLUID
190. BLEED POWER STEERING FLUID
191. INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40-2 )
192. CHECK FOR ENGINE OIL LEAKS
193. CHECK FOR ENGINE COOLANT LEAKS (See page 16-8 )
194. CHECK POWER STEERING FLUID LEAKAGE
195. INSPECT FOR FUEL LEAKS
2005 SIENNA REPAIR MANUAL (RM1163U)
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ENGINE MECHANICAL - PARTIAL ENGINE ASSY
196. CHECK FOR EXHAUST GAS LEAKS
197. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26-7 )
198. INSPECT STEERING WHEEL CENTER POINT
199. INSPECT IGNITION TIMING (See page 14-1 )
SST 09843-18040
200. INSPECT ENGINE IDLE SPEED (See page 14-1 )
SST 09843-18040
201. INSPECT CO/HC (See page 14-1 )
202. CHECK ABS SPEED SENSOR SIGNAL (See page 05-386 )
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2342
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