Saturday, August 26, 2023

How to fix a 2005 Toyota Sienna coolant leak

If your Sienna is overheating, but only while idle, you might have a coolant leak from the "valley".  It's a lot of work to reseal the coolant valley gasket, but it's mostly just a lot of bolts, with some other steps.

This is the go-to video to watch: https://www.youtube.com/watch?v=I6QC0p7x1cw  Watch the whole thing (multiple times).

He skips some basic steps, so watch this video for step-by-step instructions for the initial steps: https://www.youtube.com/watch?v=2R_v3vn0rNo

Here's another video with some more step-by-step instructions for the middle steps, especially for removing the 3 bolts behind the intake manifold: https://www.youtube.com/watch?v=QLx8wArDpnQ

This video might have additional hints for locations of bolts: https://www.youtube.com/watch?v=yv71aCmJaE8

Here's some torque specs: https://www.tsienna.net/knock_sensor-2306.html

More torque specs:

May be a graphic of map, blueprint, floor plan and text that says '14-32 ENGINE MECHANICAL PARTIAL ENGINE Search မ Cylinder Block Sub-assy Water Inlet Housing 199, Engine Rear Oil Seal Retainer Oil Pump Assy (439, 32) Engine Rear Oil Seal O-ring 30 (306, 22) (82, 1i lbf) 8.0 (82, 71ir ((((© lbf) Oil Pump Seal Oil Filter Sub-assy Oil Pan Baffle Plate' 

This picture will help  you find all the bolts:

May be a doodle of map, floor plan, blueprint and text that says '18. Remove the nut and ground cabie. 19. Disconnect the fuel injector connectors. 20. Remove the intake manifold nuts and bolts in the sequence shown using several passes. 21. Remove the intake manifold. ENLARGE Fig. Remove the intake manifold nuts and bolts in the sequence shown-3.3L engine inot' 

This will help you find bolts too: 

May be a doodle of floor plan, blueprint and text that says 'camma aooe Diny Moogle wise Loncea Mpsas Shopping Cart 22271-20040 Toyota Parts... 1. Install the intake manifold. Tighten the retainers using several passes to 11 ft. lbs. (15 Nm). 2. Install the remaining components in the reverse order of removal. cyg ma Mail Ram. ENLARGE Fig. Tighten the intake manifold nuts and bolts in the sequence shown-3.3 engine >Back to Top' 

This is the intake valley plate that has the leaky gasket.  It will be helpful in finding the locations of the 10 bolts.

No photo description available.

Finally, here's some details which worked for me. I used Toyota FIPG, which I bought on Amazon.  The directions say wait 15 minutes, but I waited 16 hours.  However, when I added coolant it leaked a whole bunch.  When I drove it, it leaked more.  I didn't do anything at all the next 3-5 days, and didn't drive it.  After 3-5 days, I topped off the coolant, and it didn't leak at all. Not one drop.  The coolant level stayed the same.  I drove it about 150 miles, and no leaks, and no overheating at all.  The temperature is right below the mid-point, which is perfect.  I think it just took 3-5 days for the FIPG to fully cure.  Maybe I used too much?

One of the hardest parts was getting the 3 bolts out behind the intake manifold gasket.  The two on the drivers-side were 12 mm, and they weren't too bad.  I was able to squeeze a 1/4" breaker bar with a socket, or a 1/4" socket wrench and it came right out.  The 14mm bolt on the passenger side was much harder.  Feel around just to the right (closer to the driver) of the 14mm bolt, and there is a 10mm bolt.  Loosen that 10mm bolt with a 1/4" socket wrench, which will move some of the hoses out of the way, which will give you more room to get the 14mm bolt out.  (Don't remove the 10mm bolt - just loosen it).  Then this 14mm wrench will be super helpful in getting the 14mm bolt out: https://www.amazon.com/dp/B082M8Z6G9  With those tricks and tools, it's really not that hard to get those 3 bolts out.  Some people complained about putting back in the 3 bolts, but I didn't have any major troubles, especially if the 10mm bolt is loosened.  (Don't forget to tighten back that 10mm bolt).

There is some risk in dropping your tools or bolts, so you can tie medium-gauge fishing line (8-10 lb?) around your tools or bolts, which helps if you drop something.  I did drop a few bolts, but I got lucky and was able to recover them - one time because it fell on the ground.

The 14mm flexible head ratcheting wrench - one of my favorite tools in my toolbox.  Although I have no idea if I'll use it again.  It was fun to use.

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