mounting TOYOTA RAV4 2006 Service Owner's Manual

EM–422AZ-FE ENGINE MECHANICAL – TIMING CHAIN
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(b) Connect the 2 clamps of the engine wire.
(c) Install the wire harness protector with the bolt.
20. INSTALL ENGINE MOUNTING INSULATOR FR
(a) Install the engine mounting insulator FR with the 2
bolts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
(b) Install the through bolt and nut.
Torque: 145 N*m (1,479 kgf*cm, 107 ft.*lbf)
HINT:
Install the bolt which is used to secure the front
engine mounting bracket FR.
21. INSTALL RADIATOR RESERVOIR
(a) Install the radiator reservoir with the 2 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
22. INSTALL GENERATOR ASSEMBLY (See page CH-15)
23. INSTALL FAN AND GENERATOR V BELT (See page
EM-7)
24. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-7)
25. INSTALL FRONT EXHAUST PIPE (See page EX-4)
26. ADD ENGINE OIL (See page LU-4)
27. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
28. CHECK FOR ENGINE OIL LEAKS
29. CHECK FOR EXHAUST GAS LEAKS
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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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(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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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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EM–1022AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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(b) Remove the front drive shaft (for 4WD) (see page
DS-40).
42. REMOVE PROPELLER SHAFT ASSEMBLY (for 4WD)
(See page PR-3)
43. REMOVE ENGINE MOUNTING INSULATOR FR
(a) Remove the through bolt and nut.
(b) Remove the 2 bolts and engine mounting insulator
FR.
44. REMOVE ENGINE MOUNTING INSULATOR RR
(a) Remove the through bolt.
(b) Remove the 2 nuts, 2 bolts and engine mounting
insulator RR.
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2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–103
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45. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the No. 1 and No. 2 engine hangers with the
bolts as shown in the illustration.
Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf)
Part No.
(b) Attach the sling device to the engine hangers and
chain block.
(c) Carefully remove the engine with transaxle from the
vehicle.
46. REMOVE ENGINE MOUNTING INSULATOR RH
(a) Remove the 2 nuts, 4 bolts and engine mounting
insulator RH.
47. REMOVE ENGINE MOUNTING INSULATOR LH
(a) Remove the through bolt and nut.
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Item Part No.
No. 1 engine hanger 12281-28010
No. 2 engine hanger 12282-28010
Bolt 91512-61020
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EM–1042AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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(b) Remove the 4 bolts and engine mounting insulator
LH.
48. REMOVE DRIVE SHAFT BEARING BRACKET (for
2WD)
(a) Remove the 3 bolts and bracket.
49. REMOVE DRIVE SHAFT BEARING BRACKET (for
4WD)
(a) Remove the 3 bolts and bracket.
50. REMOVE TRANSFER ASSEMBLY (for 4WD) (See
page TF-59)
51. REMOVE STARTER ASSEMBLY (See page ST-7)
52. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY
(a) Remove the automatic transaxle for U241E (2WD)
(see page AX-147).
(b) Remove the automatic transaxle for U140F (4WD)
(see page AX-148).
53. REMOVE TORQUE CONVERTER CLUTCH
ASSEMBLY
(a) Remove the torque converter clutch for U241E
(2WD) (see page AX-148).
(b) Remove the torque converter clutch for U140F
(4WD) (see page AX-149).
54. REMOVE DRIVE PLATE SUB-ASSEMBLY
(a) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
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(b) Attach the sling device and the engine with the
chain block.
9. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Lift the engine assembly (with transaxle) with the
chain block.
(b) Lower the engine out of the vehicle slowly and
carefully.
NOTICE:
Make sure the engine is clear of all wiring, hoses
and cables.
10. INSTALL ENGINE MOUNTING INSULATOR LH
(a) Install the engine mounting insulator LH with the 4
bolts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
(b) Install the engine mounting insulator LH with the
through bolt and nut.
HINT:
Install the through bolt by tightening the nut.
Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf)
11. INSTALL ENGINE MOUNTING INSULATOR RH
(a) Install the engine mounting insulator RH with the 2
bolts and 2 nuts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) for bolt
95 N*m (969 kgf*cm, 70 ft.*lbf) for nut A
52 N*m (530 kgf*cm, 38 ft.*lbf) for nut B
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2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–109
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12. REMOVE ENGINE HANGER
(a) Remove the No. 1 and No. 2 engine hangers.
13. INSTALL ENGINE MOUNTING INSULATOR RR
(a) Install the engine mounting insulator RR with the 2
nuts and 2 bolts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
(b) Install the through bolt which is used to secure the
rear engine mounting insulator, into the rear engine
mounting bracket.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
14. INSTALL ENGINE MOUNTING INSULATOR FR
(a) Install the engine mounting insulator FR with the 2
bolts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
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