sensor TOYOTA RAV4 2006 Service Repair Manual

2AZ-FE ENGINE MECHANICAL – TIMING CHAINEM–35
EM
7. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR
PLATE
(a) Install the sensor plate with the "F" mark facing
forward.
8. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) Remove any old packing material and be careful not
to drop any oil on the contact surfaces of the timing
chain cover, cylinder head and cylinder block.
(b) Apply seal packing (Diameter 4.0 to 4.5 mm (0.157
to 0.177 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.
• Install the chain cover within 3 minutes of
applying seal packing.
• Do not add engine oil for at least 2 hours after
installing the chain cover.
(c) Apply a continuous bead of seal packing 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.
• Install the chain cover within 3 minutes of
applying seal packing.
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EM–402AZ-FE ENGINE MECHANICAL – TIMING CHAIN
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(d) Uniformly tighten the 12 bolts and 2 nuts in the
sequence shown in the illustration.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(e) Place a transmission jack underneath the engine,
then put a wooden block on the jack.
(f) Remove the chain block and sling device.
(g) Remove the No. 1 and No. 2 engine hangers.
14. INSTALL CRANKSHAFT POSITION SENSOR (See
page ES-402)
15. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove any old packing material from the contact
surface.
(b) Apply seal packing to the 2 locations shown in the
illustration.
Seal packing:
Toyota Genuine Seal Packing Block, Three
Bond 1207B or Equivalent
NOTICE:
• Remove any oil from the contact surface.
• Install the oil pan within 3 minutes of applying
seal packing.
• Do not add engine oil for at least 2 hours after
installing the oil pan.
(c) Install the cylinder head cover with the 8 bolts and 2
nuts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) for bolt A
14 N*m (143 kgf*cm, 10 ft.*lbf) for bolt B
11 N*m (112 kgf*cm, 8 ft.*lbf) for nut
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EM–582AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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19. REMOVE NO. 2 MANIFOLD STAY
(a) Remove the bolt, nut and stay.
20. REMOVE NO. 1 EXHAUST MANIFOLD HEAT
INSULATOR
(a) Remove the 4 bolts and heat insulator.
21. REMOVE EXHAUST MANIFOLD CONVERTER SUB-
ASSEMBLY
(a) Disconnect the air-fuel ratio sensor connector.
(b) Remove the 5 nuts, manifold converter and gasket.
22. DISCONNECT NO. 1 RADIATOR HOSE
(a) Disconnect the No. 1 radiator hose.
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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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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–61
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37. REMOVE CAMSHAFT
(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.
(c) Remove the camshaft and camshaft timing gear
while holding the timing chain by hand.
(d) Tie the timing chain with a string as shown in the
illustration.
NOTICE:
Be careful not to drop anything inside the timing
chain cover.
38. REMOVE CRANKSHAFT PULLEY (See page EM-25)
39. REMOVE ENGINE MOUNTING BRACKET RH (See
page EM-26)
40. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
(See page EM-26)
41. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR
PLATE
42. REMOVE TIMING CHAIN GUIDE (See page EM-28)
43. REMOVE CHAIN TENSIONER SLIPPER (See page
EM-28)
44. REMOVE NO. 1 CHAIN VIBRATION DAMPER (See
page EM-28)
45. REMOVE CHAIN SUB-ASSEMBLY
46. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
ASSEMBLY (See page ES-395)
47. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
(a) Clamp the camshaft in a vise, and make sure that
the camshaft timing gear does not rotate.
(b) Cover all the oil ports with vinyl tape except the
advance side port shown in the illustration.
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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–63
EM
49. REMOVE CYLINDER HEAD GASKET
DISASSEMBLY
1. REMOVE RADIO SETTING CONDENSER
(a) Remove the bolt and condenser.
2. REMOVE OIL PRESSURE SWITCH
(a) Using a 24 mm deep socket wrench, remove the
sensor.
3. REMOVE ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using SST, remove the sensor and gasket.
SST 09817-33190
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EM–642AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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4. REMOVE CAMSHAFT POSITION SENSOR
(a) Remove the bolt and sensor.
5. REMOVE NO. 2 CAMSHAFT BEARING
(a) Remove the No. 2 camshaft bearing.
6. REMOVE NO. 1 CAMSHAFT BEARING
(a) Remove the No. 1 camshaft bearing.
7. REMOVE VALVE LIFTER
HINT:
Arrange the valve lifters in the correct order.
8. REMOVE INTAKE VALVE
(a) Place the cylinder head on wooden blocks.
(b) Using SST, compress the spring, then remove the 2
retainer locks.
SST 09202-70020 (09202-00010)
(c) Remove the retainer, spring and valve from the
cylinder head.
HINT:
Arrange the removed parts in the correct order.
9. REMOVE EXHAUST VALVE
(a) Place the cylinder head on wooden blocks.
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EM–822AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
EM
(b) Align the bearing claw with the claw groove of No. 1
and No. 2 bearing cap, and push in the No. 1
camshaft bearing.
6. INSTALL NO. 2 CAMSHAFT BEARING
(a) Clean the contact surface of the bearing and the
bearing cap.
NOTICE:
Do not apply engine oil to the contact surfaces
of the camshaft bearing and cylinder block.
(b) Install the No. 2 camshaft bearing onto the cylinder
head.
7. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the camshaft position sensor with the bolt.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
8. INSTALL ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using SST, install a new gasket and the ECT
sensor.
SST 09817-33190
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–85
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(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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EM–862AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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22. INSTALL ENGINE MOUNTING INSULATOR RH (See
page EM-41)
23. INSTALL RADIATOR RESERVOIR (See page EM-112)
24. INSTALL GENERATOR ASSEMBLY (See page CH-15)
25. INSTALL FAN AND GENERATOR V BELT (See page
EM-7)
26. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-7)
27. CONNECT ENGINE WIRE
(a) Connect the ground cable with the bolt.
Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
(b) Connect the camshaft position sensor connector.
(c) Connect the engine coolant temperature sensor
connector.
(d) Connect the engine oil pressure switch connector.
(e) Connect the radio setting condenser connector.
(f) Connect the heater water inlet hose.
28. CONNECT NO. 1 RADIATOR HOSE
(a) Connect the hose to the cylinder head.
29. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
ASSEMBLY (See page ES-396)
30. INSTALL EXHAUST MANIFOLD CONVERTER SUB-
ASSEMBLY
(a) Install a new gasket onto the cylinder head.
(b) Temporarily tighten the exhaust manifold converter
with the 5 nuts.
(c) Tighten the 5 nuts in the sequence shown in the
illustration.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
(d) Connect the air-fuel ratio sensor connector.
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