check engine TOYOTA RAV4 2006 Service Manual PDF

2AZ-FE ENGINE MECHANICAL – TIMING CHAINEM–25
EM
(c) Remove the 12 bolts and 2 nuts.
(d) Insert the blade of SST between the crankcase,
chain cover and oil pan, then cut off the applied
sealer and remove the oil pan.
SST 09032-00100
NOTICE:
Be careful not to damage the contact surface of
the crankcase, chain cover and oil pan.
20. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley until its groove and the
timing mark "0" of the timing chain cover are
aligned.
(b) Check that each timing mark of the camshaft timing
gear and sprocket is aligned with each timing mark
located on the No. 1 and No. 2 bearing caps as
shown in the illustration.
If not, turn the crankshaft by 1 revolution (360
) to
align the timing marks as above.
21. REMOVE CRANKSHAFT PULLEY
(a) Using SST, fix the pulley in place and loosen the
pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
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2AZ-FE ENGINE MECHANICAL – TIMING CHAINEM–29
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33. REMOVE NO. 2 CHAIN SUB-ASSEMBLY
(a) Turn the crankshaft by 90
counterclockwise to align
the adjusting hole of the oil pump drive shaft
sprocket with the groove of the oil pump.
(b) Insert a 4 mm diameter bar into the adjusting hole of
the oil pump drive shaft sprocket to lock the gear in
position, and then remove the nut.
(c) Remove the bolt, chain tensioner plate and spring.
(d) Remove the oil pump drive sprocket, oil pump drive
shaft sprocket and No. 2 chain.
INSPECTION
1. INSPECT NO. 1 CHAIN TENSIONER
(a) Check that the plunger moves smoothly when the
ratchet pawl is raised with your finger.
(b) Release the ratchet pawl, then check that the
plunger is locked in place by the ratchet pawl and
does not move when pushed with your finger.
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2AZ-FE ENGINE MECHANICAL – TIMING CHAINEM–39
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(b) Turn the crankshaft counterclockwise, then
disconnect the plunger knock pin from the hook.
(c) Turn the crankshaft clockwise, then check that the
plunger is extended.
13. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material and be careful not
to drop any oil on the contact surfaces of the
cylinder block and oil pan.
(b) Apply a continuous bead of seal packing (Diameter
3.0 to 4.0 mm (0.118 to 0.157 in.)) as shown in the
illustration.
Seal packing:
Toyota Genuine Seal Packing Block, Three
Bond 1207B or Equivalent
NOTICE:
• Remove any oil from the contact surface.
• Instal l the oil pan wit hin 3 mi nut es of app lyi ng
seal packing.
• Do not add engine oil for at least 2 hours after
installing the oil pan.
(c) Install the oil pan to the cylinder block.
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EM–422AZ-FE ENGINE MECHANICAL – TIMING CHAIN
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(b) Connect the 2 clamps of the engine wire.
(c) Install the wire harness protector with the bolt.
20. INSTALL ENGINE MOUNTING INSULATOR FR
(a) Install the engine mounting insulator FR with the 2
bolts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
(b) Install the through bolt and nut.
Torque: 145 N*m (1,479 kgf*cm, 107 ft.*lbf)
HINT:
Install the bolt which is used to secure the front
engine mounting bracket FR.
21. INSTALL RADIATOR RESERVOIR
(a) Install the radiator reservoir with the 2 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
22. INSTALL GENERATOR ASSEMBLY (See page CH-15)
23. INSTALL FAN AND GENERATOR V BELT (See page
EM-7)
24. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-7)
25. INSTALL FRONT EXHAUST PIPE (See page EX-4)
26. ADD ENGINE OIL (See page LU-4)
27. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
28. CHECK FOR ENGINE OIL LEAKS
29. CHECK FOR EXHAUST GAS LEAKS
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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–59
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23. DISCONNECT ENGINE WIRE
(a) Disconnect the radio setting condenser connector.
(b) Disconnect the engine oil pressure switch
connector.
(c) Disconnect the engine coolant temperature sensor
connector.
(d) Disconnect the camshaft position sensor connector.
(e) Remove the bolt and ground cable.
24. REMOVE FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-6)
25. REMOVE FAN AND GENERATOR V BELT (See page
EM-6)
26. REMOVE GENERATOR ASSEMBLY (See page CH-9)
27. REMOVE ENGINE MOUNTING INSULATOR RH (See
page EM-22)
28. REMOVE IDLER PULLEY (See page EM-23)
29. REMOVE IGNITION COIL ASSEMBLY (See page IG-9)
30. REMOVE SPARK PLUG (See page EM-8)
31. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(See page EM-24)
32. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(See page EM-26)
33. REMOVE CRANKSHAFT POSITION SENSOR (See
page ES-402)
34. REMOVE OIL PAN SUB-ASSEMBLY (See page EM-
24)
35. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley until its groove and the
timing mark "0" of the timing chain cover are
aligned.
(b) Check that each timing mark of the camshaft timing
gear and sprocket is aligned with each timing mark
located on the No. 1 and No. 2 bearing caps as
shown in the illustration.
If not, turn the crankshaft by 1 revolution (360
) to
align the timing marks as above.
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EM–662AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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INSPECTION
1. INSPECT CYLINDER HEAD FOR WARPAGE
(a) Using a precision straightedge and feeler gauge,
measure the warpage of the contact surfaces of the
cylinder block and manifolds.
Maximum warpage:
0.08 mm (0.0032 in.)
If the warpage is greater than the maximum, replace
the cylinder head sub-assembly.
2. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrant, inspect the combustion
chamber, intake ports, exhaust ports and cylinder
block surface for cracks.
If cracked, replace the cylinder head.
3. INSPECT VALVE SEAT
(a) Apply a light coat of Prussian blue to the valve face.
(b) Lightly press the valve against the seat.
NOTICE:
Do not turn the valve.
(c) Check the valve face and seat in accordance with
the following procedure.
(1) If blue appears 360
around the face, the valve
is concentric. If not, replace the valve.
(2) If blue appears 360
around the valve seat, the
guide and face are concentric. If not, resurface
the valve seat (see page EM-87).
(3) Check that the seat contact is in the middle of
the valve face with a width.
Standard width
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Item Standard Condition
Intake 1.0 to 1.4 mm (0.0039 to 0.0551 in.)
Exhaust 1.2 to 1.6 mm (0.0472 to 0.0630 in.)

2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–67
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4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Check the lock of the camshaft timing gear.
(1) Clamp the camshaft in a vise, and confirm that
the camshaft timing gear is locked.
NOTICE:
Be careful not to damage the camshaft.
(b) Release the lock pin.
(1) Cover the 4 oil paths of the cam journal with
vinyl tape as shown in the illustration.
HINT:
The 2 advance side paths are provided in the
groove of the camshaft. Plug one of the paths
with a rubber piece.
(2) Break through the tape of the advance side
path and the retard side path on the opposite
side of the groove.
(3) Apply approximately 200 kPa (2.0 kgf/cm
2, 28
psi) of air pressure to the paths whose tape
was broken in the procedure above.
CAUTION:
Some oil spraying will occur. Contain the
spray with a shop rag.
(4) Check that the camshaft timing gear revolves in
the advance direction when weakening the air
pressure of the retard side path.
OK:
Gear rotates in advance direction.
HINT:
This operation releases the lock pin for the
extreme retard position.
(5) When the camshaft timing gear reaches the
extreme advance position, remove the air gun
from the retard side path and advance side
path, in that order.
NOTICE:
Do not remove the air gun from the advance
side path first. The gear may abruptly shift
in the retard direction and break the lock
pin.
(c) Check for smooth rotation.
(1) Rotate the camshaft timing gear within its
movable range several times, but do not turn it
to the extreme retard position. Check that the
gear rotates smoothly.
OK:
Gear rotates smoothly.
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EM–682AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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NOTICE:
Do not use an air gun to perform the
smooth operation check.
(d) Check the lock in the extreme retard position.
(1) Confirm that the camshaft timing gear is locked
at the extreme retard position.
5. INSPECT CAMSHAFT
(a) Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout
at the center journal.
Maximum circle runout:
0.03 mm (0.0012 in.)
If the circle runout is greater than the
maximum, replace the camshaft.
(b) Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe
height.
Standard cam lobe height:
47.306 to 47.406 mm (1.8624 to 1.8664 in.)
Minimum cam lobe height:
47.196 mm (1.8581 in.)
If the cam lobe height is less than the minimum,
replace the camshaft.
(c) Inspect the camshaft journals.
(1) Using a micrometer, measure the journal
diameter.
Standard journal diameter
If the journal diameter is not as specified, check
the oil clearance.
6. INSPECT NO. 2 CAMSHAFT
(a) Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout
at the center journal.
Maximum circle runout:
0.03 mm (0.0012 in.)
If the circle runout is greater than the
maximum, replace the No. 2 camshaft.
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Journal Position Specified Condition
No. 1 35.971 to 35.985 mm (1.4162 to
1.4167 in.)
Other 22.959 to 22.975 mm (0.9039 to
0.9045 in.)
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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–69
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(b) Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe
height.
Standard cam lobe height:
45.983 to 46.083 mm (1.8104 to 1.8143 in.)
Minimum cam lobe height:
45.873 mm (1.8060 in.)
If the cam lobe height is less than the minimum,
replace the No. 2 camshaft.
(c) Inspect the camshaft journals.
(1) Using a micrometer, measure the journal
diameter.
Standard journal diameter
If the journal diameter is not as specified, check
the oil clearance.
7. INSPECT CAMSHAFT OIL CLEARANCE
(a) Clean the 10 bearing caps and camshaft journals.
(b) Place the 2 camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the
camshaft journals.
(d) Install the 10 bearing caps (see page EM-84).
NOTICE:
Do not turn the camshaft.
(e) Remove the 10 bearing caps for the No. 2 camshaft
(see page EM-60) and camshaft (see page EM-61).
(f) Measure the Plastigage at its widest point.
Standard oil clearance
Maximum oil clearance
NOTICE:
Completely remove the Plastigage after the
measurement.
A036687E01
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Journal Position Specified Condition
No. 1 35.971 to 35.985 mm (1.4162 to
1.4167 in.)
Other 22.959 to 22.975 mm (0.9039 to
0.9045 in.)
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Item Standard Condition
Intake No. 1 journal 0.007 to 0.038 mm (0.0003 to 0.0015
in.)
Exhaust No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031
in.)
Other journal 0.025 to 0.062 mm (0.0010 to 0.0024
in.)
Item Standard Condition
Intake No. 1 journal 0.07 mm (0.0028 in.)
Other journal 0.10 mm (0.0039 in.)

EM–842AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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(c) Mark the front of the cylinder head bolts with paint.
(d) Retighten the cylinder head bolts by 90
as shown
in the illustration.
(e) Check that the paint mark is now at a 90
angle to
the front.
3. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
(a) Put the camshaft timing gear and camshaft together
with the straight pin and key groove misaligned, as
shown in the illustration.
(b) Turn the camshaft timing gear as shown in the
illustration while pushing it gently against the
camshaft. Push further at the position where the pin
fits into the groove.
NOTICE:
Be sure not to turn the camshaft timing gear to
the retard angle side (the right angle).
(c) Check that there is no clearance between the gear
fringe and camshaft.
(d) Tighten the flange bolt with the camshaft timing gear
fixed in place.
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
(e) Check that the camshaft timing gear can move to
the retard angle side (the right direction) and is
locked in the most retarded position.
4. INSTALL NO. 2 CAMSHAFT TIMING SPROCKET
(a) Clamp the camshaft in a vise, then install the
camshaft timing sprocket with the bolt.
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
NOTICE:
Do not damage the camshaft.
5. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil to the journal portion
of the camshaft.
(b) Place the 2 camshafts on the cylinder head with the
No. 1 cam lobes facing the directions shown in the
illustration.
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