Answer
Yes, changing out the spark plugs on Toyota's tranverse mount V6 engines is tough. I have a 2002 Sienna which is similar to all models 2003 and prior. The front 3 plugs are easy. But the back 3 are really tough to reach.
2001 and prior Siennas only need the Denso platinum plugs PK20TR11 which I think are dual head plugs. But older Siennas can probably still benefit from pricier iridium plugs because they fire more consistently at lower voltage and can take higher temperatures than platinum. I did some research on the web, and folks are raving about Denso Iridium Power IK20s. They are a bit more than the NGKs, but on eBay, I found a set of 4 for just $33-buy-it-now in CA. So I bought 3 sets (12 plugs total).
Tools you'll need - a common 3/8 inch square rachet socket driver. The overall length must not exceed 8 inches inches long and mine is a cheap one from any store. But I would recommend that the rachet have a push button socket release and a fine tooth rachet that clicks every 15 degrees. Next, you need a med-long extension. The spark plug is deep in the tube and you'll need ideally, 5 3/4 inches and no more than 6 1/2 inches max. Of course you need a standard spark plug socket. Additionally, you'll need a 5mm allen wrench. and lastly, a 10 mm closed-end crescent wrench. Length should be no longer than 7 inches.
Installation: pop the hood, and remove the plastic engine cover. I assume you know how to remove the front plugs. So I'll only focus on the rear plugs.
Start on the right side. Unclip some of the vacuum hoses and spread them out to the sides of the opening. You should see a hole that extends back underneath the air intake and next to the exhaust manifold. Reach back there with your arm. feel for a 1 inch square block and securing hex bolt. Using feel only, use the 10mm closed-end box wrench and loosen the securing nut. A hard counterclockwise tweak should break it loose, and about a half dozen more small loosening motions should loosen the bolt so you can switch out and use your fingers. Remove the bolt and place it away from the engine in a safe place. Lift the boot assembly out. Watch to make sure the rubber grommet doesn't slide off and fall in the oblivion never to be found.
WithOUT the rachet driver, get the socket and extension and slide down tube, then reach in with rachet and unscrew the spark plug. Remove the rachet, and lift extension and spark plug out. If your socket doesn't grip the spark plug, take it out, wrap the lip with a little masking tape). Installation is the reverse of removal.
Get a new spark plug. Slide it inside the spark plug socket and make sure it grips but not too tightly. The plugs are pre-gapped at the factory and have a plastic sleeve to protect the head. You must NOT allow the plug to drop down the tube because the impact could bend the tip and affect the gap or damage the plug.
There are two metal compression washers on the spark plug. There's no room for a torque wrench back there, so tighten the plugs down until the compression washers just begin to feel like bottoming out. Then twist another 30 deg. Do NOT slide the boot/coil assembly back over the spark plug yet. The first boot must remain out from its tube to allow the second boot room for removal.
The middle boot assembly is a bit harder. It's just like the first, but you need to disconnect the wire harness clip to each boot/ignition coil.. With a single hand, rock the boot assembly a little until it lifts up and off the plug about 1 inch. Then turn the boot assembly clockwise a little and use the technique you practiced to unclip the wiring harness from the boot assembly. There is only room for one hand in there. Be persistent and follow technique and practice. Eventually, you should be able to get the wire clip off.
Now the boot/coil should lift out easily. Then use the spark plug socket and reach back in there and slide the socket down the tube and then attach the rachet driver and remove the spark plug. Installation the reverse of removal. Again, be careful about dropping any parts down into the engine.
The 3rd boot is like the 2nd, because you need to disconnect the wiring clip, but it's different in that instead of reaching in from the right side, most of the extraction uses the opening from the left side.
My dealer claims this can take 2 hours of labour. I used simple tools and did all six myself in 1 hour 15 minutes making lots of little mistakes. If you follow these directions and have simple tools and do not exceed my dimension recommendations, you should be able to get in there and do this in under 45 minutes. Good luck.
For more information on this and related procedures please visit: http://www.siennaclub.org/forum/index.php?showtopic=12402
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