check engine TOYOTA RAV4 2006 Service Manual Online

EM–1422AZ-FE ENGINE MECHANICAL – ENGINE UNIT
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(d) Subtract the piston pin diameter measurement from
the piston pin bore diameter measurement.
Standard oil clearance:
0.001 to 0.007 mm (0.00004 to 0.0003 in.)
Maximum oil clearance:
0.013 mm (0.0005 in.)
If the oil clearance is greater than the maximum,
replace the connecting rod. If necessary, replace
the piston and piston pin as a set.
(e) Subtract the piston pin diameter measurement from
the connecting rod small end bore diameter
measurement.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance:
0.017 mm (0.0007 in.)
If the oil clearance is greater than the maximum,
replace the connecting rod. If necessary, replace
the connecting rod and piston pin as a set.
8. INSPECT CONNECTING ROD SUB-ASSEMBLY
(a) Using a connecting rod aligner and feeler gauge,
check the connecting rod alignment.
(1) Check for misalignment.
Maximum misalignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If the misalignment is greater than the
maximum, replace the connecting rod.
(2) Check for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than the maximum,
replace the connecting rod.
9. INSPECT CONNECTING ROD BOLT
(a) Using a vernier caliper, measure the tension portion
diameter of the bolt.
Standard diameter:
7.2 to 7.3 mm (0.283 to 0.287 in.)
Maximum diameter:
7.0 mm (0.276 in.)
If the diameter is less than the minimum, replace the
connecting rod bolt.
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10. INSPECT CRANKSHAFT
(a) Using a dial indicator and V-blocks, measure the
circle runout as shown in the illustration.
Maximum taper and distortion:
0.003 mm (0.0001 in.)
If the taper and distortion are greater than the
maximum, replace the crankshaft.
(b) Using a micrometer, measure the diameter of each
main journal.
Standard diameter:
54.988 to 55.000 mm (2.1830 to 2.1654 in.)
If the diameter is not as specified, check the
crankshaft oil clearance.
(c) Check each main journal for taper and distortion as
shown in the illustration.
Maximum taper and distortion:
0.003 mm (0.0001 in.)
If the taper and distortion are greater than the
maximum, replace the crankshaft.
Standard diameter (Reference)
(d) Using a micrometer, measure the diameter of each
crank pin.
Standard diameter:
47.990 to 48.000 mm (1.8894 to 1.8898 in.)
If the diameter is not as specified, check the
connecting rod oil clearance.
(e) Inspect each crank pin for taper and distortion as
shown in the illustration.
Maximum taper and distortion:
0.003 mm (0.0001 in.)
If the taper and distortion are greater than the
maximum, replace the crankshaft.
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Mark Specified Condition
0 54.999 to 55.000 mm (2.1653 to
2.1654 in.)
1 54.997 to 54.998 mm (2.1652 to
2.1653 in.)
2 54.995 to 54.996 mm (2.1652 to
2.1652 in.)
3 54.993 to 54.994 mm (2.1651 to
2.1651 in.)
4 54.991 to 54.992 mm (2.1650 to
2.1650 in.)
5 54.998 to 54.990 mm (2.1649 to
2.1650 in.)
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REPLACEMENT
1. REPLACE TIMING CHAIN COVER OIL SEAL
HINT:
There are 2 methods to replace the oil seal.
(a) If the timing chain cover is removed from the
cylinder block:
(1) Using a screwdriver and hammer, tap out the
oil seal.
(2) Apply multi-purpose grease to the lip of a new
oil seal.
NOTICE:
Keep the lip free of foreign objects.
(3) Using SST and a hammer, tap in the new oil
seal until its surface is flush with the timing
chain cover edge.
SST 09223-22010
NOTICE:
Do not tap the oil seal at an angle.
(b) If the timing chain cover oil seal is installed to the
cylinder block:
(1) Remove the fan and generator V belt (see page
EM-6).
(2) Remove the crankshaft pulley (see page EM-
25).
(3) Using a knife, cut off the lip of the oil seal.
(4) 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.
(5) Apply multi-purpose grease to the lip of a new
oil seal.
NOTICE:
Keep the lip free of foreign objects.
(6) Using SST and a hammer, tap in the new oil
seal until its surface is flush with the timing
chain cover edge.
SST 09223-22010
NOTICE:
Do not tap the oil seal at an angle.
(7) Install the crankshaft pulley (see page EM-38).
(8) Install the fan and generator V belt (see page
EM-7).
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EM–1462AZ-FE ENGINE MECHANICAL – ENGINE UNIT
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2. REPLACE 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.
(c) Apply multi-purpose grease to the lip of a new oil
seal.
NOTICE:
Keep the lip free of foreign objects.
(d) Using SST and a hammer, tap in the new oil seal
until its surface is flush with the rear oil seal retainer
edge.
SST 09223-15030, 09950-70010 (09951-07100)
NOTICE:
• Wipe any extra grease off the crankshaft.
• Do not tap the oil seal at an angle.
3. REPLACE STUD BOLT (for Cylinder Block)
NOTICE:
If the stud bolt is deformed or the threads are
damaged, replace it.
(a) Remove the 8 stud bolts.
(b) Install the 8 stud bolts into the cylinder block.
To r q u e
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Item Specified Condition
A 5.0 N*m (51 kgf*cm, 44 in.*lbf)
B 21.5 N*m (219 kgf*cm, 16 ft.*lbf)
C 5.0 N*m (51 kgf*cm, 44 in.*lbf)
D 5.0 N*m (51 kgf*cm, 44 in.*lbf)

2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–35
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(f) Connect the union to check valve hose.
(g) Connect the No. 2 ventilation hose.
(h) Install the clamp and connect the throttle body
connector.
(i) Connect the vapor feed hose.
(j) Connect the 2 water by-pass hoses to the throttle
body.
23. REMOVE ENGINE FROM ENGINE STAND
(a) Install a sling device and chain block to the engine.
(b) Remove the engine from the engine stand.
24. INSTALL DRIVE PLATE AND RING GEAR SUB-
ASSEMBLY
(a) Clean the bolt and its hole.
(b) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond
1324 or Equivalent
(c) Using SST, hold the crankshaft.
SST 09213-70011, 09330-00021
(d) Install the flywheel, drive plate and drive plate
spacer on the crankshaft.
(e) Uniformly install and tighten the 8 bolts in the
sequence shown in the illustration.
Torque: 178 N*m (1,815 kgf*cm, 132 ft.*lbf)
NOTICE:
Do not start the engine for at least 1 hour after
the installation.
25. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
(a) 2WD:
Install the automatic transaxle (see page AX-174).
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2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–41
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62. ADD AUTOMATIC TRANSAXLE FLUID
(a) 2WD:
Add automatic transmission fluid (see page AX-
177).
(b) 4WD:
Add automatic transmission fluid (see page AX-
178).
63. ADD TRANSFER OIL (for 4WD) (See page TF-45)
64. ADD ENGINE OIL (See page LU-6)
65. ADD ENGINE COOLANT (See page CO-8)
66. CHARGE REFRIGERANT (See page AC-172)
67. CHECK FOR LEAKAGE OF REFRIGERANT (See
page AC-173)
68. CHECK FOR ENGINE OIL LEAKS (See page LU-6)
69. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
70. CHECK FOR FUEL LEAKS
71. INSPECT EXHAUST GAS LEAKS
72. INSPECT SHIFT LEVER POSITION
(a) 2WD:
Inspect the shift lever position (see page AX-159).
(b) 4WD:
Inspect the shift lever position (see page AX-158).
73. ADJUST TRANSMISSION CONTROL CABLE
(a) 2WD:
Adjust the shift lever position (see page AX-159).
(b) 4WD:
Adjust the shift lever position (see page AX-159).
74. INSTALL FRONT FLOOR COVER (See page FU-39)
75. INSTALL NO. 2 ENGINE UNDER COVER
(a) Install the under cover with the 2 clips.
76. INSTALL REAR ENGINE UNDER COVER LH
(a) Install the under cover with the 2 clips.
77. INSTALL REAR ENGINE UNDER COVER RH
(a) Install the under cover with the 2 clips.
78. INSTALL NO. 1 ENGINE UNDER COVER
(a) Install the under cover with the 4 bolts and 12 clips.

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–55
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(b) Set the timing mark on the crank angle sensor plate
to the RH block bore center line (TDC /
compression).
(c) Check that the timing marks of the camshaft timing
gears are aligned with the timing marks of the
bearing cap as shown in the illustration. If not, turn
the crankshaft 1 revolution (360
) and align the
timing marks as above.
23. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Move the stopper plate upward to release the lock,
and push the plunger deep into the tensioner.
(b) Move the stopper plate downward to set the lock,
and insert a hexagon wrench into the stopper plate
hole.
(c) Remove the 2 bolts and chain tensioner.
24. REMOVE CHAIN TENSIONER SLIPPER
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EM–642GR-FE ENGINE MECHANICAL – ENGINE UNIT
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51. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance
while moving the connecting rod back and forth.
Standard thrust clearance:
0.15 to 0.40 mm (0.0059 to 0.0157 in.)
Maximum thrust clearance:
0.50 mm (0.0197 in.)
If the thrust clearance is greater than the maximum,
replace one or more connecting rods as necessary.
If necessary, replace the crankshaft.
52. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check that the front mark on the connecting rod and
cap are aligned to ensure the correct reassembly.
NOTICE:
The front mark on the connecting rods and caps
are for ensuring the correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(c) Using the 2 removed connecting rod cap bolts,
remove the connecting rod cap and lower bearing
by wiggling the connecting rod cap right and left.
HINT:
Keep the lower bearing inserted to the connecting
rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and
scratches.
(f) Lay a strip of Plastigage on the crank pin.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–65
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(g) Check that the front mark of the connecting rod cap
is facing forward.
(h) Install and alternately tighten the bolts of the
connecting rod cap in several steps.
NOTICE:
Do not turn the crankshaft.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
(i) Mark the front side of each connecting cap bolt with
paint.
(j) Retighten the cap bolts by 90
as shown.
(k) Check that the painted mark is now at a 90
angle to
the front.
NOTICE:
Do not turn the crankshaft.
(l) Remove the 2 connecting rod cap bolts.
(m) Using the 2 removed connecting rod cap bolts,
remove the connecting rod cap and lower bearing
by wiggling the connecting rod cap right and left.
HINT:
Keep the lower bearing inserted to the connecting
rod cap.
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EM–682GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(c) Using a screwdriver, pry out the main bearing caps.
Remove the 4 main bearing caps and lower
bearings.
NOTICE:
• Pry up the main cap little by little to the right
and left in turns.
• Be careful not to damage the joint surface of
the cylinder block and main bearing caps.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
HINT:
If the journal or bearing is damaged, replace the
bearing.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Examine the front marks and numbers and install
the bearing caps on the cylinder block.
HINT:
A number is marked on each main bearing cap to
indicate the installation position.
(i) Apply a light coat of engine oil on the threads and
under the heads of the bearing cap bolts.
(j) Place the crankshaft bearing cap on the cylinder
block.
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