compression TOYOTA RAV4 2006 Service User Guide

2AZ-FE ENGINE MECHANICAL – TIMING CHAINEM–25
EM
(c) Remove the 12 bolts and 2 nuts.
(d) Insert the blade of SST between the crankcase,
chain cover and oil pan, then cut off the applied
sealer and remove the oil pan.
SST 09032-00100
NOTICE:
Be careful not to damage the contact surface of
the crankcase, chain cover and oil pan.
20. 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.
21. REMOVE CRANKSHAFT PULLEY
(a) Using SST, fix the pulley in place and loosen the
pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
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2AZ-FE ENGINE MECHANICAL – TIMING CHAINEM–33
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2. INSTALL CRANKSHAFT TIMING SPROCKET
3. INSTALL NO. 1 CHAIN VIBRATION DAMPER
(a) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
4. INSTALL CHAIN SUB-ASSEMBLY
(a) Set the No. 1 cylinder to TDC/compression.
(1) Turn the camshafts with a wrench (using the
hexagonal lobe) to align the timing marks of the
camshaft timing gear with each timing mark
located on the No. 1 and No. 2 bearing caps as
shown in the illustration.
(2) Using the crankshaft pulley bolt, turn the
crankshaft to position the key on the crankshaft
upward.
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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–71
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9. INSPECT VALVE LIFTER
(a) Using a micrometer, measure the lifter diameter.
Standard lifter diameter:
30.966 to 30.976 mm (1.2191 to 1.2195 in.)
If the diameter is not as specified, replace the valve
lifter.
10. INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using a caliper gauge, measure the valve lifter bore
diameter of the cylinder head.
Standard lifter bore diameter:
31.009 to 31.025 mm (1.2208 to 1.2215 in.)
If the diameter is not as specified, replace the
cylinder head sub-assembly.
(b) Subtract the valve lifter diameter measurement from
the valve lifter bore diameter measurement.
Standard oil clearance:
0.033 to 0.059 mm (0.0013 to 0.0023 in.)
Maximum oil clearance:
0.079 mm (0.0031 in.)
If the oil clearance is greater than the maximum,
replace the valve lifter. If necessary, replace the
cylinder head sub-assembly.
11. INSPECT INNER COMPRESSION SPRING
(a) Using a vernier caliper, measure the free length of
the valve spring.
Standard free length:
47.43 mm (1.8673 in.)
If the length is not as specified, replace the inner
compression spring.
(b) Using a steel square, measure the deviation of the
inner compression spring.
Maximum deviation:
1.6 mm (0.063 in.)
Maximum angle (Reference):
2
If the deviation is greater than the maximum,
replace the inner compression spring.
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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 UNITEM–133
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61. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2
compression rings.
(b) Remove the oil ring and expander by hand.
62. REMOVE PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, pry out the 2 snap rings.
63. REMOVE PISTON
(a) Gradually heat the piston up to 80 to 90
C (176 to
194
F).
(b) Using a plastic-faced hammer and brass bar, lightly
tap out the piston pin, then remove the connecting
rod.
HINT:
• The piston and pin are a matched set.
• Arrange the piston, pin, ring, connecting rod and
bearings in the correct order.
64. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance
while prying the crankshaft back and forth with a
screwdriver.
Standard thrust clearance:
0.04 to 0.24 mm (0.0016 to 0.0095 in.)
Maximum thrust clearance:
0.30 mm (0.012 in.)
If the thrust clearance is greater than the maximum,
replace the thrust washers as a set.
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EM–542GR-FE ENGINE MECHANICAL – ENGINE UNIT
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18. REMOVE CRANKSHAFT PULLEY
(a) Using SST, loosen the crankshaft pulley set bolt.
SST 09213-70011 (09213-70020), 09330-00021
(b) Using the pulley set bolt and SST, remove the
crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05021)
19. REMOVE WATER PUMP ASSEMBLY (See page CO-
13)
20. REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Using a screwdriver, pry out the oil seal retainer.
HINT:
Tape the screwdriver tip before use.
21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
(w/ Oil Pump) (See page LU-14)
22. SET NO. 1 CYLINDER TO TDC / COMPRESSION
(a) Temporarily tighten the pulley set bolt.
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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–622GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(b) Remove the 2 bolts and water outlet pipe.
(c) Disconnect the water by-pass hose.
43. REMOVE VALVE STEM CAP
(a) Remove the valve stem caps from the cylinder
head.
HINT:
Arrange the removed parts in the correct order.
44. REMOVE INTAKE VALVE
(a) Using SST and wooden blocks, compress the
compression spring and remove the valve retainer
lock.
SST 09202-70020 (09202-00010)
(b) Remove the retainer, compression spring and valve.
HINT:
Arrange the removed parts in the correct order.
45. REMOVE EXHAUST VALVE
(a) Using SST and wooden blocks, compress the
compression spring and remove the valve retainer
lock.
SST 09202-70020 (09202-00010)
(b) Remove the retainer, compression spring and valve.
HINT:
Arrange the removed parts in the correct order.
46. REMOVE VALVE STEM OIL SEAL
(a) Using needle-nose pliers, remove the oil seals.
47. REMOVE VALVE SPRING SEAT
(a) Using compressed air and a magnetic finger,
remove the valve spring seat by blowing air onto it.
48. REMOVE NO. 1 STRAIGHT SCREW PLUG
NOTICE:
If water leaks from the No. 1 screw plug or the plug is
corroded, replace it.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–73
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(v) Remove the upper bearings and upper thrust
washers from the cylinder block.
HINT:
Arrange the bearings and thrust washers in the
correct order.
57. REMOVE CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSEMBLY
(a) Remove the 2 water drain cocks from the cylinder
block.
(b) Remove the water drain cock plugs from the water
drain cocks.
58. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, remove the 3 oil
nozzles.
(b) Check the oil nozzles for damage or clogging.
If necessary, replace the oil nozzle.
59. REMOVE PISTON RING SET
HINT:
Arrange the piston rings in the correct order.
(a) Using a piston ring expander, remove the 2
compression rings.
(b) Using a piston ring expander, remove the 2 side
rails.
(c) Remove the oil ring expander by hand.
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