check engine TOYOTA RAV4 2006 Service Repair Manual

EM–1162GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
17. INSTALL WATER INLET PIPE
(a) Install the water inlet pipe with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(b) Install the water by-pass hose.
18. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for
Bank 1)
(a) Check the piston protrusions for each cylinder.
(1) Clean the cylinder block with solvent.
(2) Set the piston of the cylinder to be measured to
slightly before TDC.
(b) Place the cylinder head gasket on the cylinder block
surface with the front face of the Lot No. stamp
upward.
NOTICE:
• Be careful of the installation direction.
• Gently place the cylinder head in order not to
damage the gasket with the bottom part of the
head.
(c) Place the cylinder head on the cylinder block.
NOTICE:
Ensure that no oil is on the mounting surface of
the cylinder head.
HINT:
The cylinder head bolts are tightened in 3
progressive steps.
(d) Apply a light coat of engine oil to the threads and
under the heads of the cylinder head bolts.
(e) Step 1
(1) Using a 10 mm bi-hexagon wrench, install and
uniformly tighten the 8 cylinder head bolts with
the plate washers in several steps, in the
sequence shown in the illustration.
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
(f) Step 2
(1) Mark the cylinder head bolt head with paint as
shown in the illustration.
(2) Tighten the cylinder heads bolts another 90
in
the sequence shown in step 1.
(g) Step 3
(1) Tighten the cylinder head bolts by an additional
90
in the sequence shown in step 1.
(2) Check that the painted mark is now facing
rearward.
19. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for
Bank 2)
(a) Check the piston protrusions for each cylinder.
(1) Clean the cylinder block with solvent.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–117
EM
(2) Set the piston of the cylinder to be measured to
slightly before TDC.
(b) Place the cylinder head gasket on the cylinder block
surface with the front face of the Lot No. stamp
upward.
NOTICE:
• Be careful of the installation direction.
• Gently place the cylinder head in order not to
dama ge the gaske t wi th t he b ottom part of t he
head.
(c) Place the cylinder head on the cylinder block.
NOTICE:
Ensure that no oil is on the mounting surface of
the cylinder head.
HINT:
The cylinder head bolts are tightened in 3
progressive steps.
(d) Apply a light coat of engine oil to the threads and
under the heads of the cylinder head bolts.
(e) Step 1
(1) Using a 10 mm bi-hexagon wrench, install and
uniformly tighten the 8 cylinder head bolts with
the plate washers in several steps, in the
sequence shown in the illustration.
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
(f) Step 2
(1) Mark the cylinder head bolt heads with paint as
shown in the illustration.
(2) Tighten the cylinder head bolts another 90
in
the sequence shown in step 1.
(g) Step 3
(1) Tighten the cylinder head bolts by an additional
90
in the sequence shown in step 1.
(2) Check that the painted mark is now facing
rearward.
(h) Install the 2 bolts in the order shown in the
illustration.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
20. INSTALL VALVE LASH ADJUSTER ASSEMBLY
(a) Be sure to inspect the valve lash adjuster before
installing it (see page EM-75).
(b) Install the lash adjusters.
NOTICE:
Install the lash adjuster at the same place it was
removed from.
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EM–1262GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(d) Remove the lock pin of the chain tensioner. Check
that each timing mark is aligned with the crankshaft
at the TDC / compression.
(e) Remove the pulley set bolt.
37. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (w/
Oil Pump) (See page LU-17)
38. INSTALL WATER PUMP ASSEMBLY (See page CO-
13)
39. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Apply seal packing in a continuous line as shown in
the illustration.
Seal packing:
Toyota Genuine Seal Packing Block, Three
Bond 1207B or Equivalent
Standard seal diameter:
2.0 to 3.0 mm (0.079 to 0.118 in.)
NOTICE:
• Remove any oil from the contact surface.
• Install the crankcase within 3 minutes after
applying seal packing.
• Do not start the engine for at least 2 hours
after the installation.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–131
EM
REPAIR
1. REPAIR INTAKE VALVE SEAT
NOTICE:
Keep the lip free from foreign matter.
(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 60

and 45
cutters to correct the seat.
(c) Hand-lap the valve and valve seat with an abrasive
compound.
(d) Check the valve seating position.
2. REPAIR EXHAUST VALVE SEAT
NOTICE:
Keep the lip free from foreign matter.
(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 45

and 75
cutters to correct the seat.
(c) Hand-lap the valve and valve seat with an abrasive
compound.
(d) Check the valve seating position.
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2AZ-FE FUEL – FUEL INJECTORFU–9
FU
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
• DISCHARGE FUEL SYSTEM PRESSURE
procedures must be performed before
disconnecting any part of the fuel system.
• After performing the DISCHARGE FUEL SYSTEM
PRESSURE procedures, pressure will remain in
the fuel line. When disconnecting the fuel line,
place a cloth or equivalent over fittings to reduce
the risk of fuel spray.
(a) Remove the console box (see page IR-83).
(b) Disconnect the connector.
(c) Start the engine. After the engine has stopped, turn
the ignition switch off.
HINT:
DTC P0171 (system too lean) may be set.
(d) Check that the engine does not start.
(e) Remove the fuel tank cap, and let the air out of the
fuel tank.
(f) Connect the connector.
(g) Install the console box (see page IR-90).
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
3. REMOVE NO. 1 ENGINE COVER (See page ES-410)
4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-411)
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FU–142AZ-FE FUEL – FUEL INJECTOR
FU
(f) Connect the 4 fuel injector connectors.
(g) Install the 2 wire harness clamps.
3. CONNECT NO. 2 VENTILATION HOSE
(a) Connect the ventilation hose to the ventilation valve.
NOTICE:
Make sure that the paint mark and hose clamp
are at the correct angle when installing the hose.
4. CONNECT FUEL MAIN TUBE
(a) Connect the fuel main tube.
(b) Push the fuel tube connector until it makes a "click"
sound.
(c) Install the fuel pipe clamp.
(d) Install the fuel tube to the fuel hose clamp.
5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-413)
6. INSTALL NO. 1 ENGINE COVER (See page ES-414)
7. CONNECT CABLE TO BATTERY NEGATIVE
TERMINAL
8. CHECK FOR FUEL LEAKAGE
(a) Make sure that there are no fuel leaks after
performing maintenance on the fuel system.
(1) Connect the intelligent tester to the DLC3.
(2) Turn the ignition switch ON, and push the
intelligent tester main switch ON.
NOTICE:
Do not start the engine.
(3) Select the Active Test mode on the intelligent
tester.
HINT:
Refer to the intelligent tester operator's manual
for further details.
(4) Check that there are no leaks from the fuel
system.
(5) Turn the ignition switch OFF.
(6) Disconnect the intelligent tester from the DLC3.
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2AZ-FE FUEL – FUEL PRESSURE PULSATION DAMPERFU–27
FU
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE (See page
FU-9)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. REMOVE NO. 1 ENGINE COVER (See page ES-410)
4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-411)
5. DISCONNECT FUEL MAIN TUBE (See page FU-10)
6. REMOVE FUEL PRESSURE PULSATION DAMPER
ASSEMBLY
(a) Remove the 2 bolts and fuel pressure pulsation
damper.
INSTALLATION
1. INSTALL FUEL PRESSURE PULSATION DAMPER
ASSEMBLY
(a) Apply a light coat of gasoline or spindle oil to the O-
ring of the fuel pressure pulsation damper.
(b) Install the fuel pressure pulsation damper with the 2
bolts.
Torque: 9.0 N*m (90 kgf*cm, 80 in.*lbf)
NOTICE:
Make sure that the O-ring is not cracked or
jammed when installing.
2. INSTALL FUEL MAIN TUBE (See page FU-14)
3. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-413)
4. INSTALL NO. 1 ENGINE COVER (See page ES-414)
5. CONNECT CABLE TO BATTERY NEGATIVE
TERMINAL
6. CHECK FOR FUEL LEAKS (See page FU-14)
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2GR-FE FUEL – FUEL SYSTEMFU–9
FU
ON-VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION
(a) Connect the intelligent tester to the DLC3.
(b) Turn the ignition switch ON.
NOTICE:
Do not start the engine.
(c) Select the following tester menus: DIAGNOSIS,
ENHANCED OBD II, ACTIVE TEST and FUEL
PUMP/SPD. Operate the fuel pump.
(d) Touch the fuel hose in the engine compartment to
check the fuel flow, and you will be able to hear the
sound of the fuel pump.
(e) Stop the fuel pump. If there is no fuel flow, the fuel
pump may not be operating. Check the fuel pump
circuit.
2. CHECK FUEL PRESSURE
(a) Check that the battery positive voltage is above 12
V.
(b) Perform the "DISCHARGE FUEL SYSTEM
PRESSURE" procedures (see page FU-1).
(c) Disconnect the cable from the negative (-) battery
terminal.
(d) Disconnect the fuel main tube (see page FU-22).
(e) Install SST (pressure gauge) using SST and a fuel
tube connector as shown in the illustration.
SST 09268-41048 (90467-13001, 95336-08070,
09268-41500), 09268-45014 (09268-41200,
09268-41220, 09268-41250)
(f) Wipe up any gasoline.
(g) Reconnect the cable to the negative (-) battery
terminal.
(h) Start the engine.
(i) Measure the fuel pressure at idle.
Standard fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2,44.1 to 49.7
psi)
• If the fuel pressure is greater than the standard
value, replace the fuel pump.
• If the fuel pressure is less than the standard
value, check the connection of the fuel hose and
the fuel pump.
(j) Stop the engine.
(k) Check that the fuel pressure remains as specified
for 5 minutes after the engine stops.
Standard fuel pressure:
147 kPa (1.5 kgf/cm
2, 21 psi) or more
If the fuel pressure is not as specified, check the fuel
pump or fuel injector.
(l) After checking the fuel pressure, carefully
disconnect the negative (-) battery cable, and
remove SST and fuel tube connector to prevent
gasoline from splashing.
(m) Reconnect the fuel main tube (see page FU-29).
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2GR-FE FUEL – FUEL INJECTORFU–13
FU
REMOVAL
CAUTION:
Do not allow fuel to spray when removing the pipe
between the high pressure side fuel pump and the fuel
injector. The fuel in the pipe is highly pressurized.
1. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
• The "DISCHARGE FUEL SYSTEM PRESSURE"
procedures must be performed before
disconnecting any part of the fuel system.
• After performing the "DISCHARGE FUEL SYSTEM
PRESSURE" procedures, pressure will remain in
the fuel line. When disconnecting the fuel line,
place a cloth or equivalent over fittings to reduce
the risk of fuel spray.
(a) Remove the console box (see page IP-16).
(b) Start the engine. After the engine has stopped, turn
the ignition switch OFF.
HINT:
DTC P0171/P0172 (system too lean) may be set.
(c) Check that the engine does not start.
(d) Remove the fuel tank cap, and let the air out of the
fuel tank.
(e) Connect the connector.
(f) Install the console box (see page IP-23).
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
3. REMOVE ENGINE ASSEMBLY
(a) Remove the engine (see page EM-21).
4. REMOVE INTAKE AIR SURGE TANK ASSEMBLY
(See page EM-27)
5. DISCONNECT FUEL MAIN TUBE
(a) Remove the No. 2 fuel pipe clamp.
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FU–182GR-FE FUEL – FUEL INJECTOR
FU
(g) Temporarily install the 5 bolts which are used to hold
the fuel delivery pipe to the intake manifold.
NOTICE:
After installing the fuel injector, check that it
turns smoothly. If it does not, reinstall it with a
new O-ring.
(h) Tighten the 5 bolts which are used to hold the fuel
delivery pipe to the intake manifold.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(i) Connect the 6 fuel injector connectors.
2. CONNECT FUEL MAIN TUBE
(a) Push in the tube connector to the pipe until the tube
connector makes a "click" sound.
NOTICE:
• Check that there is no damage or foreign
objects on the connected part of the fuel pipe.
• After connecting, check if the fuel tube
connector and the pipe are securely
connected by pulling on them.
(b) Install the No. 2 fuel pipe clamp.
3. INSTALL INTAKE AIR SURGE TANK ASSEMBLY (See
page EM-34)
4. INSTALL ENGINE ASSEMBLY
(a) Install the engine (see page EM-31).
5. ADD ENGINE COOLANT (See page CO-8)
6. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
7. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
8. CHECK FOR FUEL LEAKS
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