check engine TOYOTA RAV4 2006 Service Manual PDF

2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–85
EM
(c) Examine the front marks and numbers, and check
that the order is as shown in the illustration. Then
install the bearing caps onto the cylinder head.
(d) Apply a light coat of engine oil to the threads and
under the heads of the bearing cap bolts.
(e) Using several steps, uniformly tighten the 20
bearing cap bolts in the sequence shown in the
illustration.
Torque: 29.5 N*m (301 kgf*cm, 22 ft.*lbf) for No.
1 and No. 2 bearing cap
9.0 N*m (92 kgf*cm, 80 in.*lbf) for No. 3
bearing cap
NOTICE:
Install the camshaft with the timing mark of the
camshaft timing gear on top.
6. INSTALL NO. 1 CHAIN VIBRATION DAMPER (See
page EM-33)
7. INSTALL CHAIN SUB-ASSEMBLY (See page EM-33)
8. INSTALL CHAIN TENSIONER SLIPPER (See page
EM-34)
9. INSTALL TIMING CHAIN GUIDE (See page EM-34)
10. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR
PLATE (See page EM-35)
11. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(See page EM-35)
12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (See
page EM-37)
13. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(See page EM-38)
14. INSTALL ENGINE MOUNTING BRACKET RH (See
page EM-38)
15. INSTALL CRANKSHAFT PULLEY (See page EM-38)
16. INSTALL OIL PAN SUB-ASSEMBLY (See page EM-39)
17. INSTALL CRANKSHAFT POSITION SENSOR (See
page ES-402)
18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(See page EM-40)
19. INSTALL SPARK PLUG (See page EM-16)
20. INSTALL IGNITION COIL ASSEMBLY (See page IG-9)
21. INSTALL IDLER PULLEY (See page EM-41)
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31. INSTALL NO. 1 EXHAUST MANIFOLD HEAT
INSULATOR
(a) Install the exhaust manifold heat insulator with the 4
bolts.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
32. INSTALL NO. 2 MANIFOLD STAY
(a) Install the stay with the bolt and nut.
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
33. INSTALL MANIFOLD STAY
(a) Install the stay with the bolt and nut.
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
34. INSTALL FRONT EXHAUST PIPE (See page EX-4)
35. INSTALL OIL DIPSTICK GUIDE
(a) Apply a light coat of engine oil to a new O-ring and
install it onto the guide.
(b) Install the guide with the bolt.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
36. INSTALL OIL DIPSTICK
37. INSTALL INTAKE MANIFOLD INSULATOR (See page
ES-421)
38. INSTALL INTAKE MANIFOLD (See page ES-421)
39. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
(See page FU-13)
40. INSTALL THROTTLE BODY (See page ES-413)
41. INSTALL AIR CLEANER CAP (See page ES-413)
42. ADD ENGINE OIL (See page LU-4)
43. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
44. CHECK FOR FUEL LEAKS
45. ADD ENGINE COOLANT (See page CO-6)
46. CHECK FOR ENGINE COOLANT LEAKS
(a) Check for engine coolant leaks (see page CO-1).
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EM–882AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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47. CHECK FOR ENGINE OIL LEAKS
48. CHECK FOR EXHAUST GAS LEAKS
49. INSPECT IGNITION TIMING (See page EM-1)
50. INSPECT ENGINE IDLING SPEED (See page EM-2)
51. INSPECT COMPRESSION (See page EM-3)
52. INSPECT CO/HC (See page EM-4)
53. INSTALL NO. 1 ENGINE COVER (See page EM-43)
54. INSTALL FRONT FENDER APRON RH
55. INSTALL NO. 1 ENGINE UNDER COVER
56. INSTALL FRONT WHEEL RH
57. INSTALL RADIATOR SUPPORT OPENING COVER
REPAIR
1. REPAIR VALVE SEATS
(a) If the seating is too high on the valve face, use 30

and 45
cutters to correct the seat.
(b) If the seating is too low on the valve face, use 75

and 45
cutters to correct the seat.
Standard width
(c) Lap the valve and valve seat by hand with an
abrasive compound.
(d) Recheck the valve seating position.
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Item Standard Condition
Intake 1.0 to 1.4 mm (0.0394 to 0.0551 in.)
Exhaust 1.2 to 1.6 mm (0.0427 to 0.0630 in.)

2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–113
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(b) Install the air cleaner case with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
38. INSTALL AIR CLEANER FILTER ELEMENT SUB-
ASSEMBLY
39. INSTALL AIR CLEANER CAP (See page ES-413)
40. INSTALL PURGE VSV (See page EC-16)
41. INSTALL RADIATOR RESERVOIR
(a) Install the reservoir with the 2 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
42. INSTALL RADIATOR ASSEMBLY
(a) Install the radiator (see page CO-32).
43. INSTALL BATTERY TRAY
44. INSTALL BATTERY
(a) Install the battery.
(b) Install the battery clamp with the bolt and nut.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) for bolt
5.0 N*m (51 kgf*cm, 44 in.*lbf) for nut
45. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
46. ADD AUTOMATIC TRANSAXLE FLUID
(a) Add automatic transaxle fluid for U241E (2WD) (see
page AX-151).
(b) Add automatic transaxle fluid for U140F (4WD) (see
page AX-152).
47. CHECK FOR FUEL LEAKS (See page FU-14)
48. ADD ENGINE COOLANT (See page CO-6)
49. CHECK FOR ENGINE COOLANT LEAKS
(a) Check for engine coolant leaks (see page CO-1).
50. CHECK FOR AUTOMATIC TRANSAXLE FLUID
LEAKS
51. ADJUST SHIFT LEVER POSITION
(a) Adjust the shift lever position for U241E (2WD) (see
page AX-138).
(b) Adjust the shift lever position for U140F (4WD) (see
page AX-138).
52. INSTALL NO. 1 ENGINE COVER (See page EM-43)
53. INSTALL FRONT FENDER APRON RH
54. INSTALL NO. 2 ENGINE UNDER COVER
55. INSTALL NO. 1 ENGINE UNDER COVER
56. INSTALL FRONT WHEEL
57. INSTALL RADIATOR SUPPORT OPENING COVER
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2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–127
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52. INSPECT BALANCE SHAFT OIL CLEARANCE
(a) Using several steps, uniformly loosen and remove
the 8 bolts in the sequence shown in the illustration.
(b) Remove the balance shaft housing from the
crankcase.
HINT:
Keep the lower bearing and balance shaft housing
together.
(c) Lift out the No. 1 and No. 2 balance shafts.
HINT:
Keep the upper bearing with the crankcase.
(d) Clean each bearing and journal.
(e) Check each bearing and journal for pitting and
scratches.
If a bearing or journal is damaged, replace the
bearings. If necessary, replace the balance shaft.
(f) Inspect the balance shaft housing bolt.
(1) Using a vernier caliper, measure the length of
the bolts from the seat to the end.
Standard bolt length:
58.3 to 59.7 mm (2.295 to 2.350 in.)
Maximum bolt length:
60.3 mm (2.374 in.)
If the bolt length is greater than the maximum,
replace the balance shaft bolt.
(g) Place the No. 1 and No. 2 balance shafts onto the
crankcase.
(h) Lay a strip of Plastigage across each journal.
(i) Install the balance shaft housing.
(j) Apply a light coat of engine oil on the threads and
under the heads of the bolts.
(k) Using several steps, uniformly install and tighten the
8 bolts in the sequence shown in the illustration.
Torque: 21.6 N*m (220 kgf*cm, 16 ft.*lbf)
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EM–1282AZ-FE ENGINE MECHANICAL – ENGINE UNIT
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(l) Mark the front of the bolts with paint.
(m) Retighten the bolts 90
as shown in the illustration.
(n) Check that the paint mark is now at a 90
angle to
the front.
(o) Remove the balance shaft housing from the
crankcase.
(p) Measure the Plastigage at its widest point.
Standard oil clearance:
0.004 to 0.049 mm (0.0002 to 0.0019 in.)
Maximum oil clearance:
0.049 mm (0.0019 in.)
NOTICE:
Remove the Plastigage completely after the
measurement.
If the oil clearance is greater than the maximum,
replace the bearing. If necessary, replace the
balance shaft.
HINT:
If replacing a bearing, select a new one with the
same number.
Standard balance shaft housing journal bore
diameter
Standard balance shaft journal diameter:
22.985 to 23.000 mm (0.9049 to 0.9055 in.)
Standard bearing center wall thickness
53. REMOVE BALANCE SHAFT
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Item Specified Condition
Mark 1 26.000 to 26.006 mm (1.0236 to
1.0239 in.)
Mark 2 26.007 to 26.012 mm (1.0239 to
1.0214 in.)
Mark 3 26.013 to 26.018 mm (1.0241 to
1.0243 in.)
Item Specified Condition
Mark 1 1.486 to 1.489 mm (0.05850 to
0.05862 in.)
Mark 2 1.490 to 1.492 mm (0.05866 to
0.05874 in.)
Mark 3 1.493 to 1.495 mm (0.0585 to 0.0586
in.)
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2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–129
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54. REMOVE NO. 1 BALANCE SHAFT BEARING
55. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the lip of the oil seal.
(b) Using a screwdriver with its tip wrapped with tape,
pry out the oil seal.
NOTICE:
After removing, check the crankshaft for
damage. If damaged, smooth the surface with
400-grit sandpaper.
56. REMOVE STIFFENING CRANKCASE ASSEMBLY
(a) Using several steps, uniformly loosen and remove
the 11 bolts in the sequence shown in the
illustration.
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2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–131
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(a) Using marking paint, write the matched cylinder
number on each connecting rod and cap.
HINT:
The matchmarks in the connecting rods and caps
are for ensuring correct reassembly.
(b) Using a 12 mm socket wrench, remove the 2 bolts
and connecting rod cap.
(c) Clean the crank pin and bearing.
(d) Check the crank pin and bearing for pitting and
scratches.
(e) Lay a strip of Plastigage on the crank pin.
(f) Check that the front mark of the connecting rod cap
is facing in the correct direction.
(g) Apply a light coat of engine oil to the threads and
under the heads of the connecting rod bolts.
(h) Using a 12 mm socket wrench, tighten the bolts in
several passes to the specified torque.
Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)
(i) Mark the front of the connecting rod bolts with paint.
(j) Retighten the cap bolts 90
as shown in the
illustration.
(k) Check that the crankshaft turns smoothly.
(l) Using a 12 mm socket wrench, remove the 2 bolts
and connecting rod cap.
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EM–1342AZ-FE ENGINE MECHANICAL – ENGINE UNIT
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HINT:
The thrust washer thickness is 1.93 to 1.98 mm
(0.0760 to 0.0780 in.).
65. INSPECT CRANKSHAFT OIL CLEARANCE
NOTICE:
Do not turn the crankshaft during the measurement.
(a) Using several steps, uniformly loosen and remove
the 10 bearing cap bolts in the sequence shown in
the illustration.
(b) Remove the 5 bearing caps from the cylinder block.
HINT:
• Keep the No. 2 crankshaft bearings and
crankshaft bearing caps together.
• Arrange the bearing caps in correct order.
(c) Remove the crankshaft.
HINT:
Keep the crankshaft bearings and crankshaft thrust
washer uppers together with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
• If the journal or bearing is damaged, replace the
bearings.
• If necessary, replace the crankshaft.
(f) Place the crankshaft onto the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Examine the front marks and numbers, and install
the bearing caps onto the cylinder block in the order
shown in the illustration.
(i) Apply a light coat of engine oil to the threads and
under the heads of the crankshaft bearing cap set
bolts.
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2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–135
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(j) Using several steps, uniformly install and tighten the
10 bearing cap bolts in the sequence shown in the
illustration.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
(k) Mark the front of the bearing cap bolts with paint.
(l) Retighten the 10 bearing cap bolts by 90
.
(m) Check that the paint marks are at a 90
angle to the
front.
(n) Remove the crankshaft bearing caps.
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