Toyota Sienna Service Manual: Disassembly

1. Remove oil filler cap sub-assembly

(A) remove the oil filler cap sub-assembly and oil filler gasket.

2. REMOVE SPARK PLUG

(a) Remove the spark plugs.

3. REMOVE OIL PAN DRAIN PLUG

(a) Remove the oil pan drain plug and oil pan drain plug gasket.

4. REMOVE VENTILATION VALVE SUB-ASSEMBLY

(a) Remove the ventilation valve sub-assembly.

5. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the 4 bolts and 4 camshaft position sensors.

6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Remove the 4 bolts and 4 camshaft oil control valves.

7. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the bolt and crankshaft position sensor.

8. REMOVE NO. 1 OIL PIPE

(a) Remove the 2 oil pipe unions, gaskets and oil pipe.

(b) Remove the oil control valve filter LH and gaskets.

9. REMOVE OIL PIPE

(a) Remove the bolt.

(b) Remove the 2 oil pipe unions and oil pipe.

(c) Remove the oil control valve filter RH and gaskets.

10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Remove the cylinder block water drain cocks from the cylinder block.

(b) Remove the cylinder block water drain cock plugs from the water drain cocks.

11. REMOVE OIL FILTER ELEMENT

(a) Remove the drain plug.

NOTICE: Do not remove the O-ring from the oil filter cap.

(b) Connect the hose to the pipe.

(c) Insert the pipe with the hose into the oil filter cap.

(d) Make sure that the oil is completely drained and remove the pipe and O-ring.

(e) Using SST, remove the oil filter cap sub-assembly.

SST 09228-06501

(f) Remove the oil filter element and O-ring from the oil filter cap sub-assembly.

NOTICE: Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.

12. REMOVE CRANKSHAFT PULLEY

(a) Using SST, loosen the crankshaft pulley bolt.

SST 09213-70011 (09213-70020), 09330-00021

(b) Using SST, remove the crankshaft pulley bolt and crankshaft pulley.

SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)

13. REMOVE OIL COOLER ASSEMBLY

(a) Remove the bolt, 2 clamps, and 4 clips and disconnect the 2 water by-pass hoses.

(b) Remove the union bolt, oil cooler assembly, and Oring.

14. REMOVE NO. 1 OIL COOLER BRACKET

(a) Remove the 3 bolts, 3 nuts, and oil cooler pipe with No. 1 oil cooler bracket.

(b) Remove the bolt, 2 nuts, No. 1 oil cooler bracket, and gasket.

(c) Using a "TORX" socket wrench E8, remove the 2 stud bolts.

15. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH

(a) Remove the 6 bolts and No. 1 front engine mounting bracket LH.

(b) Using a "TORX" socket wrench E8, remove the 2 stud bolts.

16. REMOVE WATER INLET HOUSING

(a) Remove the 2 nuts, water inlet and thermostat.

(b) Remove the gasket.

(c) Remove the drain cock plug.

(d) Remove the drain cock assembly.

(e) Remove the 2 stud bolts.

(f) Separate the No. 1 water by-pass hose.

(g) Remove the 2 bolts, nut, and water inlet housing.

(h) Remove the 2 O-rings.

17. REMOVE WATER OUTLET

(a) Remove the 2 bolts, 4 nuts and water outlet.

(b) Remove the 2 gaskets and O-ring.

18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)

(a) Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.

(b) Remove the 3 gaskets.

19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)

(a) Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.

NOTICE: The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the head cover.

(b) Remove the 3 gaskets.

20. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 16 bolts and 2 nuts.

(b) Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.

SST 09032-00100

NOTICE: Be careful not to damage the contact surfaces of the oil pans.

(c) Using a "TORX" socket wrench E6, remove the 2 stud bolts.

21. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.

(b) Using a "TORX" socket wrench E6, remove the 2 stud bolts.

22. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 16 bolts and 2 nuts.

HINT: Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.

(b) Remove the oil pan sub-assembly by prying between the oil pan sub-assembly and cylinder block sub-assembly with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.

HINT: Tape the screwdriver tip before use.

(c) Remove the 2 O-rings.

(d) Using a "TORX" socket wrench E8, remove the 2 stud bolts.

23. REMOVE OIL PAN BAFFLE PLATE

(a) Remove the 7 bolts and oil pan baffle plate.

24. REMOVE ENGINE REAR OIL SEAL RETAINER

(a) Remove the 6 bolts.

(b) Using a screwdriver, pry out the engine rear oil seal retainer.

NOTICE: Be careful not to damage the engine rear oil seal retainer.

HINT: Tape the screwdriver tip before use.

25. REMOVE ENGINE REAR OIL SEAL

(a) Place the oil seal retainer on wooden blocks.

NOTICE: Be careful not to damage the engine rear oil seal retainer.

(b) Using a screwdriver and a hammer, tap out the oil seal.

HINT: Tape the screwdriver tip before use.

26. REMOVE WATER PUMP ASSEMBLY

(a) Remove the 16 bolts, water pump assembly and gasket.

27. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

(a) Remove the 15 bolts and 2 nuts as shown in the illustration.

(b) Remove the timing chain cover sub-assembly by prying between the timing chain cover and cylinder head sub-assembly or cylinder block sub-assembly with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.

HINT: Tape the screwdriver tip before use.

(c) Remove the 4 bolts, chain cover plate and chain cover plate gasket.

(d) Remove the gasket.

28. REMOVE TIMING CHAIN CASE OIL SEAL

(a) Using a screwdriver, pry out the timing chain case oil seal.

HINT: Tape the screwdriver tip before use.

29. SET NO. 1 CYLINDER TO TDC / COMPRESSION

(a) Temporarily tighten the pulley set bolt.

(b) Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC / compression).

(c) Check that the timing marks of the camshaft timing gears are aligned with those of the bearing cap as shown in the illustration.

If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.

30. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

(b) Move the stopper plate downward to set the lock, and insert a pin of φ1.27 mm (0.05 in.) into the stopper plate's hole.

(c) Remove the 2 bolts and No. 1 chain tensioner assembly.

31. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the chain tensioner slipper.

32. REMOVE CHAIN SUB-ASSEMBLY

(a) Turn the crankshaft counterclockwise 10° to loosen the chain sub-assembly of the crankshaft timing sprocket.

(b) Remove the pulley set bolt.

(c) Remove the chain sub-assembly from the crankshaft timing sprocket and place it on the crankshaft.

(d) Turn the camshaft timing gear assembly on the bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain between the banks.

(e) Remove the chain.

33. REMOVE IDLE SPROCKET ASSEMBLY

(a) Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft.

34. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and No. 1 chain vibration damper.

35. REMOVE NO. 2 CHAIN VIBRATION DAMPER

(a) Remove the 2 No. 2 chain vibration dampers.

36. REMOVE CRANKSHAFT TIMING SPROCKET

(a) Remove the crankshaft timing sprocket from the crankshaft.

(b) Remove the 2 keys from the crankshaft.

37. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

(a) While raising the No. 2 chain tensioner assembly, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix the No. 2 chain tensioner.

(b) Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.

NOTICE: Be careful not to damage the cylinder head with the wrench. Do not disassemble the camshaft timing gear assemblies.

(c) Remove the No. 2 chain assembly.

38. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt and No. 2 chain tensioner assembly.

39. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

(a) Check that the camshafts are positioned as shown in the illustration.

(b) Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.

(c) Uniformly loosen and remove the 12 bearing cap bolts in the sequence shown in the illustration.

NOTICE: Uniformly loosen the bolts while keeping the camshaft level.

(d) Remove the 5 bearing caps.

40. REMOVE CAMSHAFT

(a) Remove the camshaft.

41. REMOVE NO. 2 CAMSHAFT

(a) Remove the No. 2 camshaft.

42. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

(a) Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

HINT: Tape the screwdriver tip before use.

43. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

(a) While pushing down the No. 3 chain tensioner assembly, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix the No. 3 chain tensioner assembly.

(b) Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.

NOTICE: Be careful not to damage the cylinder head with the wrench. Do not disassemble the camshaft timing gear assemblies.

(c) Remove the No. 2 chain sub-assembly.

44. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt and No. 3 chain tensioner assembly.

45. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

(a) Check that the camshafts are positioned as shown in the illustration.

(b) Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.

(c) Uniformly loosen and remove the 13 bearing cap bolts in the sequence shown in the illustration.

NOTICE: Uniformly loosen the bolts while keeping the camshaft level.

(d) Remove the 5 bearing caps.

46. REMOVE NO. 3 CAMSHAFT

(a) Remove the No. 3 camshaft.

47. REMOVE NO. 4 CAMSHAFT

(a) Remove the No. 4 camshaft.

48. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

(a) Remove the camshaft housing sub-assembly LH by prying between the cylinder head and camshaft housing sub-assembly LH with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

HINT: Tape the screwdriver tip before use.

49. REMOVE NO. 1 VALVE ROCKER ARM SUBASSEMBLY

(a) Remove the 24 No. 1 valve rocker arm subassemblies.

HINT: Arrange the removed parts in the correct order.

50. REMOVE VALVE LASH ADJUSTER ASSEMBLY

(a) Remove the 24 valve lash adjuster assemblies from the cylinder head.

HINT: Arrange the removed parts in the correct order.

51. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

(a) Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE: Be careful not to drop washers into the cylinder head. Cylinder head warpage or cracking could result from removing bolts in an incorrect order.

HINT:

Be sure to keep separate the removed parts for each installation position.

(b) Remove the cylinder head sub-assembly RH and cylinder head gasket.

52. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

(a) Uniformly loosen and remove the cylinder head set bolts in the sequence shown in the illustration.

(b) Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE: Be careful not to drop washers into the cylinder head. Cylinder head warpage or cracking could result from removing bolts in an incorrect order.

HINT:

Be sure to keep separate the removed parts for each installation position.

(c) Remove the cylinder head sub-assembly LH and No. 2 cylinder head gasket.

53. REMOVE WATER INLET PIPE

(a) Remove 2 clamps and separate the No. 1 water bypass hose.

(b) Remove the 2 bolts and water inlet pipe.

54. REMOVE VALVE STEM CAP

(a) Remove the valve stem caps from the cylinder heads.

HINT: Arrange the removed parts in the correct order.

55. REMOVE INTAKE VALVE

(a) Using SST, compress the inner compression spring and remove the valve spring retainer locks.

SST 09202-70020 (09202-00010) (b) Remove the valve spring retainer, inner compression spring and intake valve.

HINT: Arrange the removed parts in the correct order.

56. REMOVE EXHAUST VALVE

(a) Using SST, compress the inner compression spring and remove the valve spring retainer locks.

SST 09202-70020 (09202-00010) (b) Remove the valve spring retainer, inner compression spring and exhaust valve.

HINT: Arrange the removed parts in the correct order.

57. REMOVE VALVE STEM OIL SEAL

(a) Using needle-nose pliers, remove the valve stem oil seals.

58. REMOVE VALVE SPRING SEAT

(a) Using compressed air and a magnetic finger, remove the valve spring seats by blowing air onto them.

59. REMOVE NO. 1 STRAIGHT SCREW PLUG

(a) Using a 10 mm hexagon wrench, remove the 4 No.

1 straight screw plugs and 4 gaskets.

NOTICE: If water leaks from the straight screw plug or the plug corrodes, replace it.

60. REMOVE NO. 2 STRAIGHT SCREW PLUG

(a) Using a 14 mm hexagon wrench, remove the 2 No.

2 straight screw plugs and 2 gaskets.

NOTICE: If water leaks from the straight screw plug or the plug corrodes, replace it.

61. REMOVE RING PIN

NOTICE: It is not necessary to remove the ring pin unless it is being replaced.

62. REMOVE STUD BOLT

NOTICE: If the stud bolt is deformed or the threads are damaged, replace it.

63. REMOVE STRAIGHT PIN

NOTICE: If the straight pin is deformed or the threads are damaged, replace it.

64. REMOVE INTAKE VALVE GUIDE BUSH

(a) Heat the cylinder head to 80 to 100°C (176 to 212°F).

(b) Place the cylinder head on wooden blocks.

(c) Using SST and a hammer, tap out the intake valve guide bushes.

SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)

65. REMOVE EXHAUST VALVE GUIDE BUSH

(a) Heat the cylinder head to 80 to 100°C (176 to 212°F).

(b) Place the cylinder head on wooden blocks.

(c) Using SST and a hammer, tap out the exhaust valve guide bushes.

SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)

66. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD

(a) Check that the matchmarks on the connecting rod sub-assembly and connecting rod cap are aligned.

HINT: The matchmarks on the connecting rod subassembly and connecting rod cap are for ensuring the correct reassembly.

(b) Remove the 2 connecting rod cap bolts.

(c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

HINT: Keep the lower bearing inserted to the connecting rod cap.

(d) Using a ridge reamer, remove all the carbon from the top of the cylinder.

(e) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

HINT:

• Keep the bearing, connecting rod and cap together.
• Arrange the piston and connecting rod assemblies in the correct order.

67. REMOVE CONNECTING ROD BEARING

HINT: Arrange the removed parts in the correct order.

68. REMOVE CRANKSHAFT

(a) Uniformly loosen and remove the 8 crankshaft bearing cap bolts and seal washers in several steps and in the sequence shown in the illustration.

(b) Uniformly loosen the 16 crankshaft bearing cap bolts, in several steps and in the sequence shown in the illustration

(c) Using a screwdriver, pry out the main bearing caps.

Remove the 4 crankshaft bearing caps and lower crankshaft bearings.

NOTICE: Push up on the cap little by little, from the right and left side alternately so that the cap can be removed Be careful not to damage the joint surface of the cylinder block and the main bearing cap.

(d) Remove the crankshaft.

69. REMOVE CRANKSHAFT BEARING

(a) Remove the upper crankshaft bearing and lower crankshaft bearing.

HINT: Arrange the removed parts in the correct order.

70. REMOVE CRANKSHAFT THRUST WASHER SET

(a) Remove the upper crankshaft bearings and upper crankshaft thrust washers from the cylinder block sub-assembly.

71. REMOVE PISTON RING SET

(a) Using a piston ring expander, remove the 2 compression rings.

(b) Remove the oil ring expander and 2 side rails by hand.

HINT: Arrange the removed parts in the correct order.

72. REMOVE PISTON SUB-ASSEMBLY WITH PIN

(a) Check the fitting condition between the piston and piston pin.

(1) Try to move the piston back and forth on the piston pin.

If any movement is felt, replace the piston and pin as a set.

(b) Disconnect the connecting rod from the piston.

(1) Using a screwdriver, pry off the piston pin hole snap rings from the piston.

(2) Gradually heat the piston to approximately 80°C (176°F).

(3) Using a brass bar and plastic hammer, lightly tap out the piston pin and remove the connecting rod.

HINT:

• The piston and pin are a matched set.
• Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

(c) Using a gasket scraper, remove the carbon from the piston top.

(d) Using a groove cleaning tool or broken ring, clean the piston ring grooves.

(e) Using solvent and a brush, thoroughly clean the piston.

NOTICE: Do not use a wire brush.

73. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, remove the bolts and No. 1 oil nozzle sub-assembly.

(b) Check the 3 oil nozzles for damage or clogging.

If necessary, replace the No. 1 oil nozzle subassembly.

74. CLEAN CYLINDER BLOCK