1999 toyota avalon service repair manual

1998 Toyota Avalon XLS 1997-98 ENGINES 3.0L V6

1997-98 ENGINES 3.0L V6

ENGINE IDENTIFICATION NOTE:

For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION.

NOTE:

When servicing engine, reference to right and left refers to engine sides as viewed from rear of engine (drive plate end).

Engine serial number is stamped on rear of cylinder block. See Fig. 1 .

ENGINE IDENTIFICATION CODE Engine 3.0L V6

Code 1MZ-FE

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Fig. 1: Locating Engine Serial Number Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT NOTE:

Adjust valve clearance with engine cold.

WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle.

1. Disconnect negative battery cable. Drain cooling system. On Sienna, remove outer cowl top panel assembly, including wiper arms and ventilator louver. See Fig. 2 . Remove right fender apron seal.

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Fig. 2: Removing Outer Cowl Top Panel Assembly (Sienna) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. On all models, disconnect control cables from throttle body (if necessary). Disconnect upper radiator hose at coolant outlet housing. Remove air cleaner cap and airflow meter with air intake hose. Remove nuts and intake manifold cover located above intake manifold.

3. Disconnect necessary electrical connections and vacuum hoses from vacuum switching valve assembly located above intake manifold. Remove nuts and vacuum switching valve assembly.

NOTE:

Vacuum switching valve assembly may be referred to as emission control valve set.

4. Disconnect necessary electrical connections, coolant hoses and vacuum hoses for removal of air intake chamber located above valve cover. Remove No. 1 engine hanger, air intake chamber support, and EGR pipe as necessary.

5. Remove bolts/nuts, air intake chamber and gasket. Disconnect electrical connectors for removal of wiring assemblies located above valve covers. Remove bolts and wiring assemblies.

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6. Remove bolts and ignition coil assemblies. Mark ignition coil installation location for reassembly reference. Remove spark plugs. Remove bolts, valve covers and gaskets. Rotate crankshaft clockwise (viewed from front of engine) so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder on right side when viewed from rear of engine. See Fig. 3 .

7. Ensure timing mark on crankshaft pulley aligns with "0" mark on timing belt cover. Ensure intake and exhaust valve lifters on cylinder No. 1 are loose. If conditions are not as described, rotate crankshaft clockwise one complete revolution.

8. Using feeler gauge, measure and record valve clearance between valve lifter and camshaft on intake valves of cylinders No. 1 and 6 and exhaust valves on cylinders No. 2 and 3. Perform STEP 1. See Fig. 3.

Fig. 3: Identifying Valve & Cylinder Arrangement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. Rotate crankshaft clockwise an additional 2/3 turn (240 degrees). Measure and record valve clearance between valve lifter and camshaft on intake valves of cylinders No. 2 and 3 and exhaust valves on cylinders No. 4 and 5. Perform STEP 2. See Fig. 3 .

10. Rotate crankshaft clockwise an additional 2/3 turn (240 degrees). Measure and record valve clearance between valve lifter and camshaft on intake valves of cylinders No. 4 and 5 and exhaust valves on cylinders No. 1 and 6. Perform STEP 3. See Fig. 3 . Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS .

VALVE CLEARANCE SPECIFICATIONS (1) Application Exhaust Valve Intake Valve (1) Adjust valve clearance with engine cold.

In. (mm) .010-.014 (.25-.35) .006-.010 (.15-.25)

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11. If valve clearance requires adjustment, rotate camshaft so lobe on valve to be adjusted is facing upward, away from valve lifter. Position notch on valve lifter perpendicular to the camshaft. Ensure notch is not aligned with the camshaft.

12. Valve Clearance Adjuster (SST 09248-55040) is used to remove adjusting shim. Using SST "A" of valve clearance adjuster, push downward on valve lifter. See Fig. 4 . Place SST "B" between camshaft and valve lifter with the side marked with a "7" or "9" in the right location, depending on cylinder application.

Side marked with "7" should be used on front valves on No. 1 and 2 cylinders only. Remove SST "A".

13. Using small screwdriver and magnet, remove adjusting shim. Measure and record thickness of removed adjusting shim. Using measured clearance and adjusting shim thickness, select proper replacement adjusting shim. See Fig. 5 and Fig. 6 .

14. Install replacement adjusting shim with imprinted number on adjusting shim facing the valve lifter.

Recheck valve clearance. Before installing valve cover and gasket, apply sealant at front and rear areas of cylinder head. See Fig. 7 .

15. Using NEW gasket, install valve cover. Install and tighten valve cover bolts to specification in several steps. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure. Use NEW gaskets. Tighten all fasteners to specification. Fill cooling system and adjust control cables (if necessary).

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Fig. 4: Adjusting Valve Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 5: Exhaust Valve Adjusting Shim Selection Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 6: Intake Valve Adjusting Shim Selection Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 7: Identifying Cylinder Head Sealant Application Areas Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL & INSTALLATION CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle.

NOTE:

For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

FUEL PRESSURE RELEASE With ignition off, disconnect negative battery cable. Place an approved gasoline container under fuel line. Cover fuel line connection with shop towel. Slowly loosen fuel line connection to release fuel pressure. Once fuel pressure is released, fuel system components may be serviced.

ENGINE WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle.

NOTE:

Remove engine and transaxle as an assembly.

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Removal (Avalon & Camry)

1. Release fuel pressure. See FUEL PRESSURE RELEASE . Drain cooling system and engine oil.

Remove hood, battery and battery tray. Disconnect control cables from throttle body (if necessary).

Remove air cleaner cap and airflow meter with air cleaner hose. Remove air filter and air cleaner case.

2. Remove cruise control actuator and bracket. Remove radiator and coolant reservoir tank. Remove relay box from left front corner of engine compartment and disconnect electrical connectors. Disconnect electrical connections at ignitor and noise filter near left strut tower.

3. Disconnect necessary coolant hoses, electrical connections, fuel lines and vacuum hoses. To disassemble quick disconnect fuel fittings, remove fuel line-to-intake manifold clamp bolt at rear of intake manifold.

Remove fuel pipe clamp from No. 1 fuel pipe at fuel filter. Perform STEP 1. See Fig. 8 . Ensure area around No. 1 fuel pipe and fuel filter is clean. Depress both sides of retainer and pull No. 1 fuel pipe with disconnect fitting from fuel filter. Perform STEP 2. See Fig. 8 .

CAUTION: Use care when disconnecting No. 1 fuel pipe from fuel filter, as some residual fuel pressure may still exist in the fuel system.

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Fig. 8: Disconnecting No. 1 Fuel Pipe From Fuel Filter (Avalon & Camry) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Remove lower panel on passenger's side of instrument panel. Remove glove box. Disconnect necessary electrical connections so engine wiring can be pulled out through firewall. Remove nuts and pull engine wiring through firewall.

5. Remove A/C compressor and power steering pump with hoses attached and secure aside. Raise and support vehicle. Remove lower engine cover. Remove front exhaust pipe that fits between exhaust Helpmelearn November-03-08 10:08:23 AM

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6.

7.

8.

9.

10.

11.

12.

manifolds and catalytic converter.

Disconnect electrical connections, control cables and oil cooler lines from transaxle. Using Wrench (SST 09631-22020), disconnect pressure hose from hydraulic cooling fan pump. Remove fender apron from inside fenderwell for axle shaft removal.

Remove front wheels. Remove cotter pin and retainer from end of axle shaft. Apply brakes and remove axle shaft nut. Drain transaxle fluid. Remove nut and separate tie rod from steering knuckle.

Remove nut and separate stabilizer bar link from lower control arm. Remove ball joint-to-lower control arm bolts/nuts. Separate lower control arm from ball joint.

Cover axle shaft boot with shop towel. Using soft-faced hammer, tap axle shaft from hub assembly. Push hub assembly outward and separate axle shaft from hub assembly.

To remove left (driver's side) axle shaft, pry axle shaft from transaxle and remove. See Fig. 9 . To remove right (passenger's side) axle shaft, remove axle shaft bearing retainer bolt. Remove snap ring and axle shaft. See Fig. 9 .

Support engine with hoist. Remove engine mount-to-transaxle bolts. Remove engine mount bolts/nuts.

Remove bolts and engine mount absorber, located on front of engine, near exhaust manifold.

Remove engine stabilizer rod, engine mounting bracket and right engine mount brace, located near timing belt cover. Lift engine and transaxle from vehicle.

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Fig. 9: Removing Axle Shafts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Installation

1. To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .

2. When installing axle shafts, install NEW snap ring on end of axle shaft. Coat axle shaft splines and sliding surfaces with gear oil. Install axle shafts in transaxle with opening of snap ring facing downward.

3. Ensure left (driver's side) axle shaft will move inward and outward about .079-.118" (2.00-3.00 mm) after being installed. Ensure axle shaft cannot be pulled from transaxle.

4. When installing right (passenger's side) axle shaft, install NEW snap ring and NEW axle shaft bearing retainer bolt. Tighten axle shaft bearing retainer bolt to specification. See TORQUE SPECIFICATIONS .

5. To install remaining components, reverse removal procedure. Adjust fluid levels and control cables (if Helpmelearn November-03-08 10:08:23 AM

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necessary).

Removal (Sienna)

1. Release fuel pressure. See FUEL PRESSURE RELEASE . Drain cooling system and engine oil.

Remove hood, battery and battery tray. Remove cowl top panel assembly. See Fig. 2 . Remove heater air duct. Remove air cleaner cap and airflow meter with air cleaner hose. Remove air filter and air cleaner case.

2. Remove cruise control actuator and bracket. Remove radiator and coolant reservoir tank. Disconnect A/T oil cooler pipe. Disconnect necessary A/C lines, coolant hoses, electrical connections, fuel lines and vacuum hoses. Disconnect shift control cable from transaxle. Remove front exhaust pipe.

3. Remove fender apron seals. Raise and support vehicle. Remove axle shafts. Disconnect stabilizer bar links and intermediate shaft assembly. Disconnect power steering hose from power steering reservoir and reservoir pipe. Remove cover under engine. Attach Engine Hangers (SST 12282-20020). Attach sling device to hangers.

4. Remove right engine mount. Remove engine mount control rod and No. 2 right engine mount bracket.

Remove 4 lower braces from underneath vehicle. Lower engine, transaxle, and front suspension assembly from vehicle.

Installation

To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .

CYLINDER HEAD & MANIFOLDS WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle.

Removal (Avalon & Camry)

1. Release fuel pressure. See FUEL PRESSURE RELEASE . Disconnect negative battery cable. Drain cooling system.

2. Disconnect control cables from throttle body (if necessary). Remove battery and battery tray (if necessary). Drain cooling system.

3. Remove air cleaner cap and airflow meter with air cleaner hose. Remove cruise control actuator and bracket. Disconnect necessary electrical connections, ground straps, coolant hoses, fuel lines and vacuum hoses for removal of air intake chamber and cylinder head.

4. Remove right engine mount brace, located near timing belt cover. Remove nuts and "V" bank cover, located above intake manifold. See Fig. 10 . Disconnect necessary electrical connectors and vacuum hoses from vacuum switching valve assembly located above intake manifold. Remove vacuum switching valve assembly.

5. Disconnect brackets and hoses from air intake chamber. Remove No. 1 engine hanger and air intake chamber support. See Fig. 10 . Remove EGR pipe and gaskets (if necessary).

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6. Remove bolts/nuts, air intake chamber and gasket. Disconnect electrical connectors for removal of engine wiring located above valve covers. Remove nuts and engine wiring.

7. Remove ignition coils and spark plugs. Mark ignition coil installation location for reassembly reference.

Raise and support vehicle. Remove front exhaust pipe that fits between exhaust manifolds and catalytic converter.

8. Remove timing belt, camshaft sprockets and No. 2 idler pulley. See TIMING BELT . Remove No. 3 timing belt cover from front of cylinder heads. See Fig. 17 .

9. Remove cylinder head rear plate, coolant inlet pipe and air assist hose. See Fig. 10 . Remove intake manifold bolts/nuts, washers and intake manifold along with delivery pipes and injectors.

10. If removing delivery pipe and injectors from intake manifold, remove No. 2 fuel pipe from delivery pipe.

See Fig. 10 . Remove pressure regulator and pulsation damper (if necessary).

CAUTION: DO NOT allow injectors to fall from delivery pipe when removing from intake manifold.

11. To disassemble quick disconnect fuel fittings, remove fuel line-to-intake manifold clamp bolt at rear of intake manifold. Remove fuel pipe clamp from No. 1 fuel pipe at fuel filter. Perform STEP 1. See Fig. 8 .

Ensure area around No. 1 fuel pipe and fuel filter is clean. Depress both sides of retainer and pull No. 1 fuel pipe with disconnect fitting from fuel filter. Perform STEP 2. See Fig. 8 .

CAUTION: Use care when disconnecting No. 1 fuel pipe from fuel filter, as some residual fuel pressure may still exist in the fuel system.

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Fig. 10: Exploded View Of Intake Manifold & Components (Avalon & Camry Shown; Sienna Is Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Helpmelearn November-03-08 10:08:24 AM

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12. Remove coolant outlet housing from front of cylinder heads. See Fig. 10 . Remove exhaust manifold support brackets and exhaust manifolds and gaskets from cylinder heads.

13. Remove power steering pump bracket from front of cylinder head (if necessary). Remove oil dipstick, dipstick tube and "O" ring. Remove bolts, valve covers and gaskets.

14. Remove bolts, camshaft position sensor and gasket from cylinder head. See Fig. 11 . Remove camshafts.

See CAMSHAFTS .

CAUTION: Cylinder head bolts must be loosened in proper sequence to prevent cylinder head warpage.

15. Using an 8-mm hexagon wrench, remove recessed cylinder head bolts. Loosen 12-point cylinder head bolts in sequence using several steps. See Fig. 12 . Remove 12-point cylinder head bolts, cylinder head and cylinder head gasket.

16. Note location of adjusting shims and valve lifters for reassembly reference. Components must be installed in original location. Remove adjusting shims and valve lifters (if necessary).

Removal (Sienna)

1. Remove cowl top panel assembly. See Fig. 3 . Remove right fender apron seal. Release fuel pressure. See FUEL PRESSURE RELEASE . Disconnect negative battery cable. Drain cooling system.

2. Drain cooling system. Remove air cleaner cap and airflow meter with air cleaner hose. Remove front exhaust pipe. Remove right engine mount. Remove engine cover. Disconnect necessary electrical connections, ground straps, coolant hoses, fuel lines and vacuum hoses for removal of air intake chamber and cylinder head. Remove intake manifold, fuel rails and injectors.

CAUTION: DO NOT allow injectors to fall from delivery pipe when removing from intake manifold.

3. Remove coolant outlet. Remove generator drive belt and power steering pump. Remove ignition coils and spark plugs. Mark ignition coil installation location for reassembly reference. Remove timing belt, camshaft sprockets and No. 2 idler pulley. See TIMING BELT. Remove No. 3 timing belt cover from front of cylinder heads. See Fig. 16 .

4. Remove cylinder head rear plate. See Fig. 10 . Remove coolant inlet pipe from left cylinder head and coolant inlet. Remove right exhaust manifold. Remove power steering pump bracket. Remove left exhaust manifold. Remove camshaft position sensor. Remove oil dipstick, dipstick tube and "O" ring.

Remove bolts, valve covers and gaskets. Remove camshafts. See CAMSHAFTS .

CAUTION: Cylinder head bolts must be loosened in proper sequence to prevent cylinder head warpage.

5. Using an 8-mm hexagon wrench, remove recessed cylinder head bolts. Loosen 12-point cylinder head bolts in sequence using several steps. See Fig. 12 . Remove 12-point cylinder head bolts, cylinder head and cylinder head gasket.

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6. Note location of adjusting shims and valve lifters for reassembly reference. Components must be installed in original location. Remove adjusting shims and valve lifters (if necessary).

Fig. 11: Exploded View Of Cylinder Head & Components Helpmelearn November-03-08 10:08:24 AM

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Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 12: Cylinder Head Bolt Removal & Installation Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Inspection

1. Inspect cylinder head warpage at cylinder block and manifold areas. Replace cylinder head if warpage exceeds specification. See CYLINDER HEAD under ENGINE SPECIFICATIONS. 2. Inspect air intake chamber-to-intake manifold surface and exhaust manifold for warpage. Inspect intake manifold-to-cylinder head and air intake chamber surfaces for warpage. Replace components if warpage exceeds specification. See WARPAGE SPECIFICATIONS .

WARPAGE SPECIFICATIONS Application Air Intake Chamber Exhaust Manifold Intake Manifold Air Intake Chamber Surface Cylinder Head Surface

In. (mm) .0039 (.100) .0196 (.500) .0059 (.150) .0031 (.080)

3. Using caliper, measure 12-point cylinder head bolt diameter at the small diameter, just below the bolt head. Replace cylinder head bolt if diameter is less than .3445" (8.750 mm).

4. Inspect cylinder block deck surface for warpage. Replace cylinder block if deck surface warpage exceeds specification. See CYLINDER BLOCK under ENGINE SPECIFICATIONS. Inspect camshaft and components. See CAMSHAFTS .

5. Inspect valve lifter for damage. Measure valve lifter diameter and bore diameter. Ensure oil clearance is within specification. Replace components if not within specification. See VALVE LIFTERS under ENGINE SPECIFICATIONS.

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Fig. 13: Installing Cylinder Head Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Installation

1. Install NEW cylinder head gaskets on cylinder block. Ensure identification mark is facing upward at lower corner of cylinder block. See Fig. 13 . Ensure all holes in cylinder head gaskets align with cylinder block.

2. Install cylinder head. Apply engine oil on cylinder head bolt threads and cylinder head bolt-to-cylinder head contact surfaces. Install and tighten 12-point cylinder head bolts to specification in sequence using several passes. See Fig. 12 . See TORQUE SPECIFICATIONS .

3. Install recessed cylinder head bolts and tighten to specification. See TORQUE SPECIFICATIONS .

Install camshafts using proper procedure. See CAMSHAFTS .

4. To install remaining components, reverse removal procedure. See Fig. 14 . If camshaft or cylinder head components are serviced, adjust valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.

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Fig. 14: Intake Manifold Bolt Installation Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. If spark plug tube gasket in valve cover requires replacement, bend gasket retaining tabs upward. Push spark plug tube gasket from valve cover. DO NOT scratch valve cover sealing surface.

6. Using Gasket/Seal Installer (SST 09608-03070), install spark plug tube gasket until it is even with valve cover surface. Bend retaining tabs downward. Coat spark plug tube gasket sealing area with grease.

7. Apply sealant to grooves of semi-circular plugs and install in cylinder head. See Fig. 11 . Using NEW gasket, install camshaft position sensor. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS .

8. Before installing valve cover and gasket, apply sealant at front and rear areas of cylinder head. See Fig. 7 . Using NEW gasket, install valve cover. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

9. If injector was removed from delivery pipe, coat NEW "O" ring with gasoline. Install NEW grommets and NEW "O" rings on injector. Using twisting motion, install injector in delivery pipe. Ensure injectors rotate smoothly after delivery pipe is installed. If injector does not rotate smoothly, check for damaged "O" rings.

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10. If installing pressure regulator in delivery pipe, coat NEW "O" ring with gasoline and install on pressure regulator. Install pressure regulator. Ensure pressure regulator rotates smoothly in delivery pipe. If pressure regulator does not rotate smoothly, check for damaged "O" rings.

11. Before installing coolant inlet pipe, apply soapy water solution on "O" ring and then install. If installing intake air control valve in air intake chamber, apply light coat of engine oil on rubber area of the valve and apply sealant at designated areas. See Fig. 15 .

12. Use NEW gasket when installing intake air control valve. Tighten nuts to specification. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . Adjust fluid levels and control cables.

Fig. 15: Identifying Intake Air Control Valve Sealant & Engine Oil Application Areas Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CRANKSHAFT FRONT SEAL Removal & Installation (Oil Pump Installed)

1. Remove timing belt and crankshaft sprocket. See TIMING BELT. Using a knife, cut seal lip from oil seal. Pry oil seal from oil pump body. DO NOT damage sealing surfaces.

2. To install, apply grease to lip of new oil seal. Using hammer and Oil Seal Installer (SST 09223-00010), install oil seal until oil seal surface is even with oil pump body. To install remaining components, reverse removal procedure.

Removal & Installation (Oil Pump Removed)

Pry oil seal from oil pump body. To install, use hammer and Oil Seal Installer (SST 09223-00010). Install new oil seal until oil seal surface is even with oil pump body. Apply grease to seal lip of oil seal.

TIMING BELT Helpmelearn November-03-08 10:08:24 AM

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WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle.

Removal

1. Disconnect negative battery cable. Remove coolant reservoir. On Sienna, remove cowl top panel assembly. See Fig. 3 . On all models, raise and support vehicle. Remove passenger's side front wheel.

Remove right lower engine cover. Remove accessory drive belts.

2. Remove engine stabilizer rod, engine mounting bracket and right engine mount brace, located near timing belt cover. Remove generator bracket for access to timing belt covers.

3. Using Pulley Holder (SST 09213-54015) and Handle (SST 09330-00021), hold crankshaft pulley.

Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley.

4. Remove No. 1 and 2 timing belt covers and gaskets. See Fig. 16 . Remove engine mounting bracket. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide.

Fig. 16: Exploded View Of Timing Belt & Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 17 .

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6. Ensure timing marks on camshaft sprockets are aligned with timing mark on No. 3 timing belt cover. See Fig. 17 . If timing marks are not aligned, rotate crankshaft clockwise one full revolution (360 degrees).

Remove crankshaft pulley bolt from crankshaft.

CAUTION: If reusing timing belt, ensure 3 reference marks and front mark are on timing belt. See Fig. 16 . If reference marks or front mark are not apparent, place reference mark on timing belt at timing mark area on camshaft sprockets or dot area on crankshaft sprocket for reassembly reference. Place front mark on timing belt to indicate direction of timing belt installation.

7. Alternately loosen bolts and remove timing belt tensioner and dust boot. See Fig. 16 . Remove timing belt. Remove idler pulleys (if necessary).

8. If removing camshaft sprocket, use Camshaft Sprocket Holder (SST 09960-10010) to hold camshaft sprocket. On right camshaft sprocket, Adapter (SST 09249-63010) must also be used. Remove bolt and camshaft sprocket.

9. If removing crankshaft sprocket, remove timing belt plate. See Fig. 16 . Using puller, remove crankshaft sprocket.

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Fig. 17: Aligning Timing Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 18: Identifying Timing Belt Reference Marks & Front Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Inspection

1. Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely.

Replace damaged components.

2. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists.

NOTE:

Timing belt tensioner may seep a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner.

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3. Hold timing belt tensioner body with rod facing upward and press rod against solid surface. Replace timing belt tensioner if rod moves.

4. Measure timing belt tensioner rod protrusion from end of rod to edge of timing belt tensioner housing.

See Fig. 19 . Replace timing belt tensioner if distance is not .394-.425" (10.00-10.80 mm).

Fig. 19: Measuring Timing Belt Tensioner Rod Protrusion Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Installation

1. If installing crankshaft sprocket, align crankshaft sprocket with key in crankshaft. Using hammer and Sprocket Installer (SST 09223-46011), install crankshaft sprocket with flange toward cylinder block.

2. Install timing belt plate. Install and tighten bolt to specification. See TORQUE SPECIFICATIONS .

Install No. 1 and 2 idler pulleys (if removed). Install and tighten bolts to specification. See TORQUE SPECIFICATIONS . Ensure idler pulleys are clean and rotate smoothly.

3. If installing camshaft sprockets, ensure camshaft sprockets are installed with flange in correct direction.

Right camshaft sprocket must be installed with flange outward (away from cylinder head), while left camshaft sprocket must be installed with flange inward (against cylinder head). See Fig. 16 .

4. Align hole in camshaft sprocket with pin in camshaft and install sprocket. Install and tighten camshaft sprocket bolt to specification.

5. Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 17 .

6. Using camshaft sprocket holder, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 17 .

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sprocket. Ensure front mark is pointing toward timing belt end of engine.

CAUTION: Ensure reference marks on timing belt align with timing mark on camshaft sprockets and dot on crankshaft sprocket when installing timing belt. Front mark must face toward timing belt end of engine.

8. Install timing belt on crankshaft sprocket, water pump pulley, left camshaft sprocket, No. 2 idler pulley, right camshaft sprocket, and then on No. 1 idler pulley. Using press, apply pressure on rod of timing belt tension until rod is retracted and holes in rod and housing are aligned. See Fig. 20 .

9. Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 20 .

Release press and install dust boot on timing belt tensioner. Install timing belt tensioner. Install and alternately tighten bolts to specification. See TORQUE SPECIFICATIONS .

10. Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 17 .

11. Ensure timing mark on each camshaft sprocket is aligned with timing mark on No. 3 timing belt cover.

See Fig. 17 . If all timing marks are not aligned, remove timing belt and reinstall. Remove crankshaft pulley bolt.

12. Install timing belt guide with cupped side away from crankshaft sprocket and flat side toward timing belt.

Install engine mounting bracket on front of cylinder block. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS .

13. Using NEW gaskets, install No. 1 and 2 timing belt covers. Install and tighten bolts to specification.

14. Align crankshaft key with key groove of crankshaft pulley. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specification.

15. To install remaining components, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .

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Fig. 20: Retracting Timing Belt Tensioner Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VALVE LIFTER Removal

Remove camshaft. See CAMSHAFTS . Note location of adjusting shims and valve lifters for reassembly reference. Remove adjusting shims and valve lifters from cylinder head.

Inspection

Inspect components for damage. Measure valve lifter diameter and bore diameter. Ensure oil clearance is within specification. Replace components if not within specification. See VALVE LIFTERS under ENGINE SPECIFICATIONS. Installation Helpmelearn November-03-08 10:08:24 AM

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To install, reverse removal procedure. Ensure components are installed in original location. If camshaft, adjusting shim or valve lifter are replaced, check valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS. CAMSHAFTS WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle.

NOTE:

When servicing camshafts, reference to right and left components are as viewed from rear of engine.

Removal

1. Disconnect negative battery cable. Drain cooling system. Disconnect control cables from throttle body (if necessary). On Sienna, remove cowl top panel. See Fig. 3 . On all models, disconnect upper radiator hose at coolant outlet housing.

2. Remove air cleaner cap and airflow meter with air cleaner hose. Remove nuts and intake manifold cover located above intake manifold.

3. Disconnect necessary electrical connections and vacuum hoses from vacuum switching valve assembly located above intake manifold. Remove nuts and vacuum switching valve assembly.

NOTE:

Vacuum switching valve assembly may be referred to as emission control valve set.

4. Disconnect necessary electrical connections, coolant hoses and vacuum hoses for removal of air intake chamber located above valve cover. See Fig. 10 .

5. Remove No. 1 engine hanger and air intake chamber support. See Fig. 10 . Remove EGR pipe (if necessary).

6. Remove bolts/nuts, air intake chamber and gasket. Disconnect electrical connectors for removal of engine wiring located above valve covers. Remove bolts and engine wiring.

7. Remove bolts and ignition coil assemblies. Mark ignition coil installation location for reassembly reference. Remove spark plugs. Remove bolts, valve covers and gaskets.

8. Remove timing belt and camshaft sprockets. See TIMING BELT. Remove No. 3 timing belt cover from front of cylinder heads. See Fig. 16 . If servicing left cylinder head camshafts, remove camshaft position sensor and gasket. See Fig. 11 .

9. To service camshafts in right cylinder head, align timing marks (2 dots) on camshaft gears by rotating exhaust camshaft using hex area of camshaft. To service camshafts in left cylinder head, align timing marks (1 dot) on camshaft gears by rotating exhaust camshaft using hex area of camshaft. See Fig. 21 .

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Fig. 21: Aligning Camshaft Timing Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. On all applications, secure sub-gear on exhaust camshaft to main gear with a 6 x 1.0 x 18-mm service bolt "A". See Fig. 22 . Before removing camshaft bearing cap bolts, ensure torsional spring force of sub-gear is held by service bolt "A".

NOTE:

Camshaft bearing caps are numbered for location on top of camshaft bearing cap. Camshaft bearing cap is also stamped with either an "I" for intake camshaft or an "E" for exhaust camshaft. Arrow on top of camshaft bearing cap must point toward timing belt end of engine. See Fig. 20 .

Camshaft bearing caps must be installed in correct location.

11. Note location of camshaft bearing caps, as camshaft bearing caps are numbered for location on top of camshaft bearing cap. Camshaft bearing cap is also stamped with either an "I" for intake camshaft or an "E" for exhaust camshaft. Arrow on top of camshaft bearing cap must point toward timing belt end of engine. See Fig. 23 .

Fig. 22: Installing Service Bolt To Secure Sub-Gear (Right Cylinder Shown; Left Cylinder Head Is Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 23: Identifying Camshaft Bearing Caps (Right Cylinder Shown; Left Cylinder Head Is Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Camshaft bearing cap bolts must be removed in proper sequence to prevent damage to cylinder head and camshaft thrust surfaces.

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12. Remove intake camshaft bearing cap bolts in sequence using several steps. See Fig. 24 . Remove camshaft bearing caps and intake camshaft.

13. Remove exhaust camshaft bearing cap bolts in sequence using several steps. See Fig. 24 . Remove camshaft bearing caps, exhaust camshaft and oil seal.

14. If disassembling exhaust camshaft, mount hexagonal area of camshaft in soft-jawed vise. Using Spanner Wrench (SST 09960-10010), rotate sub-gear counterclockwise and remove service bolt "A". See Fig. 25 .

Remove snap ring, wave washer, sub-gear and gear spring. See Fig. 11 .

Fig. 24: Camshaft Bearing Cap Bolt Removal Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 25: Disassembling & Reassembling Exhaust Camshaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Inspection

1. Inspect components for damage. Check camshaft journal diameter, lobe height and journal runout.

Replace camshaft if not within specification. See CAMSHAFT under ENGINE SPECIFICATIONS. 2. Install camshaft in cylinder head. Using Plastigage, check camshaft oil clearance. Tighten camshaft bearing cap bolts to specification in sequence when checking oil clearance. See Fig. 27 . See TORQUE SPECIFICATIONS .

3. Replace camshaft and/or cylinder head if oil clearance is not within specification.

4. Check camshaft end play with camshaft bearing cap bolts tightened to specification. Replace camshaft and/or cylinder head if end play is not within specification.

5. Install both camshafts without sub-gear installed on exhaust camshaft. Tighten camshaft bearing cap bolts to specification. Check gear backlash between camshaft gears.

6. Replace camshaft if gear backlash exceeds specification. See CAMSHAFT under ENGINE SPECIFICATIONS. Measure distance between ends of gear spring. Replace gear spring if distance is not .716-.740" (18.20-18.80 mm).

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Installation

1. When assembling exhaust camshaft, install gear spring, sub-gear, wave washer and snap ring. Using spanner wrench, rotate sub-gear counterclockwise until holes in main gear and sub-gear are aligned.

Ensure pins on the gears align with ends of gear spring. Install service bolt "A". See Fig. 25 .

2. Apply grease to thrust surfaces and journals of camshafts. Install exhaust camshaft in cylinder head.

Rotate exhaust camshaft so timing marks (2 dots) on right cylinder head or 1 dot on left cylinder head are positioned at 90-degree angle to cylinder head. See Fig. 26 .

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Fig. 26: Positioning Exhaust Camshafts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Helpmelearn November-03-08 10:08:24 AM

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3. Apply grease to seal lip on NEW oil seal. Install oil seal on exhaust camshaft. Apply sealant on No. 1 exhaust camshaft bearing cap at bearing cap-to-cylinder head surface.

4. Install exhaust camshaft bearing caps in numerical order. Ensure arrow on top of camshaft bearing cap is pointing toward timing belt end of engine. See Fig. 23 .

5. Coat camshaft bearing cap bolt-to-camshaft bearing cap surface and bolt threads with engine oil. Install and tighten exhaust camshaft bearing cap bolts to specification in sequence using several steps. See Fig. 27 . See TORQUE SPECIFICATIONS .

6. Install intake camshaft in cylinder head. Rotate intake camshaft so timing marks (2 dots) on right cylinder head or 1 dot on left cylinder head are aligned with timing mark on exhaust camshaft. See Fig. 21 .

7. Install intake camshaft bearing caps in numerical order. Ensure arrow on top of camshaft bearing cap is pointing toward timing belt end of engine. See Fig. 23 .

8. Coat camshaft bearing cap bolt-to-camshaft bearing cap surface and bolt threads with engine oil. Install and tighten intake camshaft bearing cap bolts to specification in sequence using several steps. See Fig. 27 . See TORQUE SPECIFICATIONS .

CAUTION: Ensure service bolt "A" is removed from sub-gear on exhaust camshafts.

9. On all cylinder head applications, remove service bolt "A" from exhaust camshaft. Check and adjust valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS. 10. Apply sealant to grooves of semi-circular plugs and install in cylinder head (if removed). See Fig. 11 .

Before installing valve cover and gasket, apply sealant at front and rear areas of cylinder head. See Fig. 7.

11. Using NEW gasket, install valve cover. Install and tighten valve cover bolts to specification in several steps. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure. Tighten all fasteners to specification. Fill cooling system and adjust control cables.

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Fig. 27: Camshaft Bearing Cap Bolt Installation Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CRANKSHAFT REAR OIL SEAL Removal

Remove transaxle and drive plate. Using a knife, cut off oil seal lip. Pry oil seal from crankshaft rear oil seal housing. Use care not to damage sealing surfaces.

Installation

1. Ensure all sealing surfaces are clean. Apply grease to seal lip of oil seal. Using Oil Seal Installer (SST 09223-15030), install oil seal in crankshaft rear oil seal housing until oil seal is even with housing surface.

2. Apply Loctite to drive plate bolts. Install and tighten bolts to specification in a crisscross pattern. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure.

WATER PUMP WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle.

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Removal

1. Disconnect negative battery cable. Drain cooling system. Remove timing belt, camshaft sprockets and No. 2 idler pulley. See TIMING BELT .

2. Remove No. 3 timing belt cover. See Fig. 16 . Remove bolts/nuts, water pump and gasket.

Installation

To install, reverse removal procedure. Use NEW gaskets. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Ensure proper procedure is followed when installing timing belt. Fill cooling system.

THERMOSTAT CAUTION: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat.

Removal

1.

2.

3.

4.

Drain engine coolant.

Remove air cleaner cap assembly and air filter.

Disconnect ECT switch connectors.

Disconnect engine wire protector from water inlet and RH cylinder head. z Remove the 2 nuts, and disconnect the engine wire protector from the water inlet and cylinder head.

5. Disconnect water inlet pipe from water inlet and LH cylinder head. z Remove the bolt, and disconnect the inlet pipe from the water inlet. z Remove the O-ring from the inlet pipe.

6. Remove water inlet and thermostat. z Remove the 3 nuts, water inlet and thermostat. z Remove the gasket from the thermostat.

Inspection

NOTE:

The thermostat is numbered with the valve opening temperature.

1. Immerse the thermostat in water and gradually heat the water.

2. Check the valve opening temperature: 80-84°C (176-183°F). If valve opening temperature is not as specified, replace the thermostat.

3. Check the valve lift. 10.0mm (0.394 in.) or more at 95°C (203°F). If the valve lift is not as specified, replace the thermostat.

4. Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)). If not closed, replace the thermostat.

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Installation

1. Install new gasket on to the thermostat.

2. Align the thermostat jiggle valve with the upper stud bolt and insert the thermostat in the water inlet housing.

NOTE:

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

The jiggle valve may be set within 15° of either side of the prescribed position.

Install the water inlet with the 3 nuts.

Install a new O-ring to the water inlet pipe.

Apply soapy water to the O-ring.

Connect the water inlet pipe to the water inlet.

Install the bolt holding the water inlet pipe to the cylinder head.

Install engine wire protector.

Connect ECT switch connectors.

Reinstall air filter and air cleaner cap assembly.

Fill with engine coolant.

Start engine and check for leaks.

Recheck engine coolant level.

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Fig. 28: Thermostat Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OIL PAN WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle.

Removal

1. Disconnect negative battery cable. Raise and support vehicle. Drain engine oil. Remove front exhaust pipe that fits between exhaust manifolds and catalytic converter.

2. Remove dipstick. Remove No. 2 oil pan bolts/nuts. See Fig. 29 . Install Seal Cutter (SST 09032-00100) between No. 1 and 2 oil pans. Carefully tap seal cutter around No. 2 oil pan to loosen seal. DO NOT damage sealing surfaces. Remove No. 2 oil pan.

3. Remove pick-up tube and gasket. See Fig. 29 . Remove drive plate cover, located at rear of No. 1 oil pan.

Remove No. 1 oil pan-to-transaxle bolts. Note location of remaining No. 1 oil pan-to-cylinder block bolts.

Remove bolts and No. 1 oil pan. Remove cover plate, gasket and baffle plate from No. 1 oil pan (if Helpmelearn November-03-08 10:08:24 AM

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necessary).

Installation

1. Install cover plate with NEW gasket and baffle plate on No. 1 oil pan (if necessary). Install and tighten bolts to specification. See TORQUE SPECIFICATIONS .

2. Ensure sealing surfaces are clean. Apply a .16-.20" (4.0-5.0 mm) diameter bead of sealant on No. 1 oil pan. See Fig. 30 . Install No. 1 oil pan. Install and tighten No. 1 oil pan-to-cylinder block bolts to specification.

3. Using NEW gasket, install pick-up tube. Install and tighten bolt/nuts to specification.

4. Apply a .16-.20" (4.0-5.0 mm) diameter bead of sealant on No. 2 oil pan. See Fig. 30 . Install No. 2 oil pan. Install and tighten bolts/nuts to specification.

5. Install and tighten No. 1 oil pan-to-transaxle bolts to specification. See TORQUE SPECIFICATIONS .

Install drive plate cover. Install and tighten bolts to specification. To install remaining components, reverse removal procedure.

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Fig. 29: Exploded View Of Oil Pan & Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 30: Identifying Oil Pan Sealant Application Areas Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

OVERHAUL Helpmelearn November-03-08 10:08:24 AM

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CYLINDER HEAD Cylinder Head

1. Inspect cylinder head warpage at cylinder block and manifold surfaces. Replace cylinder head if warpage exceeds specification. See CYLINDER HEAD under ENGINE SPECIFICATIONS. 2. To check camshaft oil clearance using Plastigage, install camshaft in cylinder head using proper procedure. See CAMSHAFT under REMOVAL & INSTALLATION. Replace camshaft and/or cylinder head if oil clearance is not within specification.

3. Check camshaft end play with camshaft bearing cap bolts tightened to specification. Replace camshaft and/or cylinder head if end play is not within specification.

4. Ensure valve lifter bore diameter is within specification. See VALVE LIFTERS under ENGINE SPECIFICATIONS. 5. If installing spark plug tubes in NEW cylinder head, apply sealant on cylinder head end of spark plug tube. Using press, install spark plug tube until distance between top surface of spark plug tube and camshaft bearing cap surface of cylinder head is 1.669-1.709" (42.40-43.40 mm).

6. If installing PCV pipe in NEW cylinder head, use hammer and wooden block to install PCV pipe. The PCV pipes are installed between exhaust camshaft and outer edge of cylinder head. See Fig. 11 . Install PCV pipe until top of PCV pipe is even with valve cover gasket surface on cylinder head.

Valve Springs

Ensure valve spring free length, pressure and out-of-square are within specification. See VALVES & VALVE SPRINGS under ENGINE SPECIFICATIONS. CAUTION: Intake valve stem oil seal is Light Brown, and exhaust valve stem oil seal is Gray. Ensure proper valve stem oil seal is installed.

Valve Stem Oil Seals

Lubricate valve stem oil seal with engine oil. Install valve stem oil seal using Oil Seal Installer (SST 0920141020).

Valve Guides

1. Ensure valve guide inside diameter is within specification. See CYLINDER HEAD under ENGINE SPECIFICATIONS. Replace valve guide if inside diameter exceeds specification.

2. To replace valve guide, heat cylinder head to 176-212°F (80-100°C). Using hammer and Valve Guide Remover/Installer (SST 09201-01055), drive valve guide from camshaft side of cylinder head.

3. Measure cylinder head valve guide bore inside diameter. If bore inside diameter is .4053-.4060" (10.29510.313 mm), use standard valve guide. If bore inside diameter is .4073-.4080" (10.345-10.363 mm), use oversize valve guide.

4. If bore inside diameter exceeds .4060" (10.313 mm), machine valve guide bore to .4073-.4080" (10.34510.363 mm) for oversize valve guide. If bore I.D. exceeds .4080" (10.363 mm), replace cylinder head.

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CAUTION: Exhaust valve guide is 1.594" (40.50 mm) long, and intake valve guide is 1.358" (34.50 mm) long. Ensure proper length valve guide is installed.

5. To install valve guide, heat cylinder head to 176-212°F (80-100°C). Using hammer and valve guide remover/installer, drive valve guide in from camshaft side of cylinder head until valve guide installed height is within specification. See CYLINDER HEAD under ENGINE SPECIFICATIONS. Valve guide installed height is measured from top of valve guide to cylinder head surface, right next to the valve guide.

6. Using .216" (5.50 mm) reamer, ream valve guide to obtain specified valve stem-to-guide oil clearance.

See CYLINDER HEAD under ENGINE SPECIFICATIONS. Valve Seat

Ensure valve seat angle and seat width are within specification. See CYLINDER HEAD under ENGINE SPECIFICATIONS. Valve seat replacement information is not available from manufacturer.

Valves

Ensure minimum refinish length, stem diameter and valve margin are within specification. See VALVES & VALVE SPRINGS under ENGINE SPECIFICATIONS. Replace valve if not within specification.

Valve Seat Correction Angles

Use 30-degree and 45-degree stones to lower valve seat contact area. Use 75-degree and 45-degree stones to raise valve seat contact area.

VALVE TRAIN Valve Lifters

Ensure valve lifter diameter, bore diameter and oil clearance are within specification. See VALVE LIFTERS under ENGINE SPECIFICATIONS. Replace components if not within specification.

CYLINDER BLOCK ASSEMBLY Piston & Rod Assembly

1. Ensure connecting rod and connecting rod cap are marked with matching cylinder number for reassembly reference. Piston and connecting rod must be installed in cylinder block with front mark facing timing belt end of engine. See Fig. 31 .

2. Before disassembling piston and connecting rod, try to move piston back and forth on piston pin. Replace piston and piston pin if any movement is felt.

3. When removing piston from connecting rod, remove snap rings from piston. Heat piston to 140°F (60°C) in water. Remove piston pin. Separate piston from connecting rod. Ensure piston pin diameter is within specification. See PISTONS, PINS & RINGS under ENGINE SPECIFICATIONS. Helpmelearn November-03-08 10:08:25 AM

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