check engine light TOYOTA RAV4 2006 Service User Guide

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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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–87
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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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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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(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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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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EM–742GR-FE ENGINE MECHANICAL – ENGINE UNIT
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60. REMOVE PISTON WITH PIN SUB-ASSEMBLY
(a) Check the fitting condition between the piston and
piston pin.
(1) Try to move the piston back and forth on the
piston pin.
HINT:
If any movement is felt, replace the piston and
pin as a set.
(b) Disconnect the connecting rod from the piston.
(1) Using a screwdriver, pry off the snap rings from
the piston.
(2) Gradually heat the piston to approximately
80
C (176F).
(3) Using a brass bar and plastic-faced hammer,
lightly tap out the piston pin and remove the
connecting rod.
HINT:
• The piston and pin are a matched set.
• Arrange the pistons, pins, rings, connecting
rods and bearings in the correct order.
(c) Clean piston.
(1) Using a gasket scraper, remove the carbon
from the piston top.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–77
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(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height
Maximum cam lobe height
If the cam lobe height is less than the minimum,
replace the camshaft.
(c) Using a micrometer, measure the journal diameter.
Standard journal diameter
If the journal diameter is not as specified, check the
oil clearance.
3. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Clamp the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft in the
vise.
(b) Put the camshaft timing gear and camshaft together
by aligning the key groove and straight pin.
(c) Lightly press the gear against the camshaft, and
turn the gear. Push further at the position where the
pin enters the groove.
NOTICE:
Be sure not to turn the camshaft timing gear in
the retard direction (the right angle).
(d) Check that there is no clearance between the gear's
fringe and the camshaft.
(e) Tighten the flange bolt with the camshaft timing gear
fixed in place.
Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
(f) 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.
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Item Specified Condition
Intake 44.316 to 44.416 mm (1.7447 to 1.7487 in.)
Exhaust 44.262 to 44.362 mm (1.7426 to 1.7465 in.)
Item Specified Condition
Intake 44.166 mm (1.7388 in.)
Exhaust 44.112 mm (1.7367 in.)
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Item Specified Condition
No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journal 25.959 to 25.975 mm (1.0220 to 1.0226 in.)
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–79
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(h) Check for smooth rotation.
(1) Turn the camshaft timing gear within its
movable range (21
) 2 or 3 times, but do not
turn it to the most retarded position. Make sure
that the gear turns smoothly.
NOTICE:
Do not use air pressure to perform the
smooth rotation check.
(i) Check the lock in the most retarded position.
(1) Confirm that the camshaft timing gear is locked
at the most retarded position.
(j) Remove the flange bolt and camshaft timing gear.
NOTICE:
• Be sure not to remove the other 3 bolts.
• If planning to reuse the gear, be sure to
release the straight pin lock before installing
the gear.
4. INSPECT CAMSHAFT TIMING EXHAUST GEAR
ASSEMBLY
(a) Clamp the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft in the
vise.
(b) Put the camshaft timing exhaust gear and camshaft
together by aligning the key groove and straight pin.
(c) Lightly press the gear against the camshaft, and
turn the gear. Push further at the position where the
pin enters the groove.
CAUTION:
Be sure not to turn the camshaft timing exhaust
gear in the retard direction (the right angle).
(d) Check that there is no clearance between the gear's
fringe and the camshaft.
(e) Tighten the flange bolt with the camshaft timing
exhaust gear fixed in place.
Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
(f) Check the camshaft timing exhaust gear lock.
(1) Make sure that the camshaft timing exhaust
gear is locked.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–87
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20. INSPECT INTAKE VALVE SEAT
(a) Apply a light coat of Prussian blue to the valve face.
(b) Lightly press the valve face against the valve seat.
(c) Check the valve face and valve seat by using the
following procedure.
(1) If Prussian blue appears around the entire
valve face, the valve face is concentric. If not,
replace the valve.
(2) If Prussian blue appears around the entire
valve seat, the guide and valve face are
concentric. If not, resurface the valve seat.
(3) Check that the valve seat contacts in the
middle of the valve face with the width between
1.1 and 1.5 mm (0.043 and 0.059 in.).
21. INSPECT EXHAUST VALVE SEAT
(a) Apply a light coat of Prussian blue to the valve face.
(b) Lightly press the valve face against the valve seat.
(c) Check the valve face and valve seat by using the
following procedure.
(1) If Prussian blue appears around the entire
valve face, the valve face is concentric. If not,
replace the valve.
(2) If Prussian blue appears around the entire
valve seat, the guide and valve face are
concentric. If not, resurface the valve seat.
(3) Check that the valve seat contacts in the
middle of the valve face with the width between
1.2 and 1.6 mm (0.047 and 0.063 in.).
22. INSPECT INNER COMPRESSION SPRING
(a) Using a vernier caliper, measure the free length of
the inner compression spring.
Standard free length:
45.46 mm (1.7898 in.)
If the free length is not as specified, replace the
spring.
(b) Using a steel square, measure the deviation of the
inner compression spring.
Maximum deviation:
1.0 mm (0.039 in.)
Maximum angle (reference):
2
If the deviation is greater than the maximum,
replace the spring.
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