Friday, March 30, 2012

Toyota Sienna Cylinder Head Removal?

Procedure to Replace Toyota Sienna Cylinder head.
The how to replace cylinder head details for 3.0L engine and 3.3L engine models.

The procedure with complete step by step diagrams is as follows:---

3.0L And 3.3L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Remove or disconnect the following:

    Wiper and blade assembly
    Top cowl seal and panel
    Window washer hoses from the ventilator louvers
    Left and right ventilator louvers
    Heater air duct
  3. Relieve the fuel pressure.
  4. Remove or disconnect the following:

    Turn the ignition key to theOFF
    Negative battery cable

NOTE
Wait at least 90 seconds from the time the negative battery was disconnected to start work.

  1. Drain the cooling system.
  2. Remove or disconnect the following:

    Accelerator and throttle cables, if equipped with an automatic transaxle
    Air cleaner cover, air flow meter and the air duct
    Cruise control actuator and bracket, if equipped
    2 engine ground straps
    Right engine mounting support
    Radiator hoses
    2 heater hoses
    Fuel feed and return lines from the fuel rail assembly
    Pressure hose from the hydraulic motor
    V-bank cover
  3. Disconnect the following vacuum hoses:

    Fuel pressure control Vacuum Switching Valve (VSV)
    Fuel pressure regulator
    Cylinder head rear plate
    Intake air control valve VSV
    Exhaust Gas Recirculation (EGR) vacuum modulator
    EGR valve
  4. Disconnect the following wiring and hoses:

    Intake air control valve
    Fuel pressure regulator
    EGR VSV
  5. Remove the 2 nuts and the emission control valve set.
  6. Disconnect the following hoses;

    Brake booster vacuum hose
    PCV hose
    Intake air control valve vacuum hose
  7. Remove or disconnect the following:

    Data Link Connector (DLC) from the mounting bracket
    2 ground straps from the intake chamber
    Hydraulic motor pressure hose from the intake chamber
    Right Oxygen (O2) sensor connector from the power steering pressure tube
    2 nuts and the power steering pressure tube from the intake chamber
    Both power steering air hoses
    Engine hanger and the intake chamber support
    EGR pipe and gaskets
  8. Disconnect the following wiring:

    Throttle Position (TP) sensor connector
    Idle Air Control (IAC) valve connector
    EGR gas temperature connector
    Air conditioning idle up connector
  9. Disconnect the following vacuum hoses:

    2 vacuum hoses from the Thermal Vacuum Valve (TVV)
    Vacuum hose from the cylinder head rear plate
    Vacuum hose from the charcoal canister
  10. Remove or disconnect the following:

    Air assist hose and the 2 water bypass hoses
    Air intake chamber
    Left engine wiring harness and move it aside
    Wiring harness from the rear of the engine
    Right engine wiring harness and move it aside
    Ignition coils and move them aside
    Timing belt
    Camshaft pulleys and the timing belt rear cover
    Cylinder head rear plate
    Water inlet pipe
    Air assist hose and vacuum hose
    Intake manifold and fuel rail assembly
    Water outlet
    EGR pipe from the right exhaust manifold
    Front exhaust pipe and exhaust manifolds
    Dipstick assembly and the power steering pump bracket
    Valve covers and the Camshaft Position (CMP) sensor
    Camshafts
  11. Be sure the engine is at/or near ambient temperature and remove the 2 (1 on each head) 8mm recessed hex bolts. Loosen and remove the 8 head bolts evenly, in 3 passes, in the reverse order of the installation sequence. Carefully lift the head from the engine; if necessary to pry the head loose, take great care not to damage the mating surfaces. Place the head on wood blocks in a clean work area.

NOTE
If the cylinder head bolts are loosened out of sequence, warpage or cracking could result.



image
Fig. Cylinder head bolt loosening sequence
  1. Remove the cylinder head gasket. With a gasket scraper, carefully remove all the old gasket material from the cylinder head and engine block surfaces.
To install:


image
Fig. Cylinder head bolt tightening sequence-3.0L and 3.3L engines engine
  1. Place the new cylinder head gasket onto the cylinder block.
  2. Install the cylinder head, in sequence, using several steps, as follows:

    Cylinder head onto the gasket
    Cylinder head bolts lubricated with clean engine oil
    Tighten the bolts in sequence in 3 steps to 40 ft. lbs. (54 Nm).

NOTE
If any bolt does not meet the torque, replace it.



Mark the forward edge of each bolt with paint, then tighten each bolt, in proper sequence, an additional 90 degrees.
Check that each painted mark is now at a 90 degrees angle to the front


NOTE
The paint mark applied to the bolt in the 9 o-clock position and should now be in the 12 o-clock position.



Remaining 8mm bolts, lubricated with engine oil. Tighten both bolts to 13 ft. lbs. (18 Nm).

  1. Install the camshafts.
  2. Check and adjust the valves.
  3. Apply sealant to the cylinder heads where the camshaft supports meet the cylinder heads.
  4. Install or connect the following:

    Cylinder head covers, using new gaskets
    Dipstick and power steering pump bracket
    Exhaust manifolds. Tighten the nuts to 36 ft. lbs. (49 Nm).
    EGR pipe to the right exhaust manifold
    Water outlet
    Intake manifold and the fuel rail assembly. Tighten the intake manifold nuts/bolts to 11 ft. lbs. (15 Nm).
    Air assist hose and the 2 water bypass hoses
    Water inlet pipe and cylinder head rear plate
    Timing belt rear cover and camshaft pulleys
    Timing belt
    Spark plugs and ignition coils
    Right engine wiring harness
    Wiring harness to the rear of the engine
    Left engine wiring harness
    Air intake chamber
    EGR pipe, using new gaskets
  5. Connect the following vacuum hoses:

    The 2 TVV vacuum hoses
    The vacuum hose to the rear cylinder head plate
    Charcoal canister vacuum hose
  6. Connect the following electrical wiring:

    TP sensor connector
    IAC valve connector
    EGR gas temperature connector
    Air conditioning idle up connector
  7. Install or connect the following:

    Engine hanger and the intake chamber support
    Both power steering air hoses
    Power steering pressure tube to the intake chamber
    O2 sensor connector to the pressure tube.
    Both ground straps, to the intake chamber
    DLC to the bracket
  8. Connect the following hoses:

    Power brake booster vacuum hose
    PCV hose
    IAC valve vacuum hose
  9. Install or connect the following:

    Emission control valve set and related vacuum hoses and connectors
    V-bank cover
    Pressure hose to the hydraulic motor
    Fuel lines to the fuel rail assembly
    Heater and radiator hoses
    Right engine mounting support
    both engine ground straps
    Upper front suspension brace, if removed. Tighten the nuts to 59 ft. lbs. (80 Nm).
    Cruise control actuator and bracket
    Air cleaner, air flow meter and air duct assembly
    Accelerator and throttle cables, if equipped with an automatic transaxle
  10. Fill the cooling system.
  11. Install or connect the following:

    Negative battery cable
    Heater air duct
    Left and right ventilator louvers
    Window washer hoses from the ventilator louvers
    Top cowl seal and panel
    Wiper and blade assembly
  12. Start the engine and check for leaks.
  13. Bleed the air from the cooling system.
  14. Road test the vehicle and check for unusual noise, shock, slippage, correct shift points and smooth operation.
  15. Recheck the coolant and engine oil levels.


MORE DETAILS FOR CYLINDER REMOVAL GO THROUGH IT:----

3.3L Engines
  1. Before servicing the vehicle, refer to the precautions section.
  2. Properly relieve the fuel system pressure.
  3. Disconnect the negative battery cable.
  4. Drain the engine oil.
  5. Drain and recycle the engine coolant.
  6. Remove the right hand front wheel.
  7. Remove the wiper arms.
  8. Remove the cowl panel.
  9. Remove the wiper link assembly.
  10. Remove the cowl top to inner brace.
  11. Remove the cowl top cover outer sub assembly.
  12. Remove the engine cover.
  13. Remove the air cleaner assembly.
  14. Remove the air surge tank.
  15. Disconnect the fuel pipe sub assembly.
  16. Disconnect the heater hose inlet pipe.
  17. Remove the intake manifold.
  18. Disconnect the radiator inlet hose.
  19. Disconnect the water outlet as follows:
    1. Disconnect the engine coolant temperature sensor.
    2. Remove the clamp, bolts nuts and washers.
    3. Lock the clamp open and remove the water outlet with the by pass hose and remove the gaskets.
  20. Remove the right hand front fender apron seal.
  21. Remove the compressor to crankshaft pulley belt.
  22. Remove the vane pump belt.
  23. Remove the engine moving control rod.
  24. Remove the number 2 engine mounting stay as follows:
    1. Remove the bolt and wire harness bracket.
    2. Remove the bolt, stay and bracket.
  25. Remove the number 2 alternator bracket and the alternator belt adjusting bar.
  26. Remove the crankshaft pulley.
  27. Remove the timing belt covers 1 and 2. Refer to the timing belt removal and installation procedure in this manual.
  28. Remove the right hand engine mount bracket.
  29. Remove the timing belt guide and timing belt. Refer to the timing belt removal and installation procedure in this manual.
  30. Remove the timing belt guide number 2. Refer to the timing belt removal and installation procedure in this manual.
  31. Remove the camshaft pulley and lower timing cover. Refer to the timing belt removal and installation procedure in this manual.
  32. Remove the vane pump.
  33. Remove the propeller shaft on 4 wheel drive models.
  34. Remove the front exhaust pipe on 2 wheel drive models, or center exhaust pipe on 4 wheel drive models.
  35. Remove the number 1 exhaust manifold heat insulator.
  36. Remove the manifold stay.
  37. Disconnect the oxygen sensor and remove the right hand exhaust manifold.
  38. Disconnect the front exhaust pipe assembly.
  39. Remove the number 3 manifold converter and number e exhaust manifold hear insulator.
  40. Disconnect the oxygen sensor and remove the left hand exhaust manifold.
  41. Remove the dipstick tube.
  42. Remove the ignition coil.
  43. Remove the cylinder head covers.
  44. Remove the camshafts and their sub assemblies.
  45. Disconnect the VVT sensor connector.
  46. Disconnect the camshaft timing oil control valve connector and wire harness clamp.
  47. Remove the hexagon bolt on the right hand side head.
  48. On the left hand side, make sure to disconnect the ground cable, wire harness clamp bracket and water inlet. Remove the hexagon bolt.
  49. Be sure the engine is at/or near ambient temperature and remove the 2 (1 on each head) 8mm recessed hex bolts. Loosen and remove the 8 head bolts evenly, in 3 passes, in the reverse order of the installation sequence. Carefully lift the head from the engine; if necessary to pry the head loose, take great care not to damage the mating surfaces. Place the head on wood blocks in a clean work area.
    NOTE
    If the cylinder head bolts are loosened out of sequence, warpage or cracking could result.



    Click image to see an enlarged view
    Fig. Remove the hexagon bolt on the right hand side head-3.3L engine


    Click image to see an enlarged view
    Fig. Remove the hexagon bolt on the left hand side head-3.3L engine
  50. Remove the cylinder head gasket. With a gasket scraper, carefully remove all the old gasket material from the cylinder head and engine block surfaces.
To install:
  1. Place the new cylinder head gasket onto the cylinder block.
  2. Install the cylinder head, in sequence, using several steps, as follows:
    NOTE
    If any bolt does not meet the torque, replace it.


    NOTE
    The paint mark applied to the bolt in the 9 o-clock position and should now be in the 12 o-clock position.



    Cylinder head onto the gasket
    Cylinder head bolts lubricated with clean engine oil
    Tighten the bolts in sequence in 3 steps to 40 ft. lbs. (54 Nm).



    Mark the forward edge of each bolt with paint, then tighten each bolt, in proper sequence, an additional 90 degrees.
    Check that each painted mark is now at a 90 degrees angle to the front



    Tighten the hexagon bolts, lubricated with engine oil. Tighten to 14 ft. lbs. (18 Nm).
  3. Tighten the water outlet bolt to 14 ft. lbs. (18 Nm).
  4. Install the camshafts.
  5. Check and adjust the valves.
  6. Apply sealant to the cylinder heads where the camshaft supports meet the cylinder heads. Install the cylinder head covers, using new gaskets.
  7. Install the remaining components in the reverse order of removal.
  8. Fill the engine with correct grade and amount of oil.
  9. Fill the cooling system.
  10. Start the engine and check for leaks.
  11. Bleed the air from the cooling system.
  12. Road test the vehicle and check for unusual noise, shock, slippage, correct shift points and smooth operation.
  13. Recheck the coolant and engine oil levels.

These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html


max