engine TOYOTA RAV4 2006 Service Repair Manual

2AZ-FE ENGINE MECHANICAL – TIMING CHAINEM–29
EM
33. REMOVE NO. 2 CHAIN SUB-ASSEMBLY
(a) Turn the crankshaft by 90
counterclockwise to align
the adjusting hole of the oil pump drive shaft
sprocket with the groove of the oil pump.
(b) Insert a 4 mm diameter bar into the adjusting hole of
the oil pump drive shaft sprocket to lock the gear in
position, and then remove the nut.
(c) Remove the bolt, chain tensioner plate and spring.
(d) Remove the oil pump drive sprocket, oil pump drive
shaft sprocket and No. 2 chain.
INSPECTION
1. INSPECT NO. 1 CHAIN TENSIONER
(a) Check that the plunger moves smoothly when the
ratchet pawl is raised with your finger.
(b) Release the ratchet pawl, then check that the
plunger is locked in place by the ratchet pawl and
does not move when pushed with your finger.
A098351E01
A098352E01
B011415E03
A098357E01

EM–302AZ-FE ENGINE MECHANICAL – TIMING CHAIN
EM
2. INSPECT CHAIN SUB-ASSEMBLY
(a) Using a vernier caliper, measure the length of the 16
links with the chain fully stretched.
Maximum chain elongation:
122.6 mm (4.827 in.)
If the chain elongation is greater than the maximum,
replace the chain sub-assembly.
HINT:
Take the measurements at 3 or more places
selected at random.
3. INSPECT NO. 2 CHAIN SUB-ASSEMBLY
(a) Using a vernier caliper, measure the length of the 8
links with the chain fully stretched.
Maximum chain elongation:
52.4 mm (2.063 in.)
If the chain elongation is greater than the maximum,
replace the No. 2 chain sub-assembly.
HINT:
Take the measurements at 3 or more places
selected at random.
4. INSPECT CHAIN TENSIONER SLIPPER
(a) Using a vernier caliper, measure the tensioner
slipper wear.
Maximum wear:
1.0 mm (0.039 in.)
If the wear is greater than the maximum, replace the
chain tensioner slipper.
5. INSPECT NO. 1 CHAIN VIBRATION DAMPER
(a) Using a vernier caliper, measure the vibration
damper wear.
Maximum wear:
1.0 mm (0.039 in.)
If the wear is greater than the maximum, replace the
No. 1 chain vibration damper.
6. INSPECT CRANKSHAFT TIMING SPROCKET
(a) Wrap the chain around the timing sprocket.
(b) Using a vernier caliper, measure the timing gear
diameter with the chain.
Minimum gear diameter (with chain):
51.6 mm (2.031 in.)
NOTICE:
The vernier caliper must be in contact with the
chain rollers when measuring.
F050593E01
A126891E01
A033838E01
A036686E01
A053035E01

2AZ-FE ENGINE MECHANICAL – TIMING CHAINEM–31
EM
If the gear diameter is less than the minimum,
replace the chain sub-assembly and crankshaft
timing sprocket.
7. INSPECT OIL PUMP DRIVE SPROCKET
(a) Wrap the chain around the drive sprocket.
(b) Using a vernier caliper, measure the drive gear
diameter with the chain.
Minimum gear diameter (with chain):
48.2 mm (1.898 in.)
NOTICE:
The vernier caliper must be in contact with the
chain rollers when measuring.
If the gear diameter is less than the minimum,
replace the No. 2 chain sub-assembly and oil pump
drive sprocket.
8. INSPECT OIL PUMP DRIVE SHAFT SPROCKET
(a) Wrap the chain around the drive shaft sprocket.
(b) Using a vernier caliper, measure the drive shaft gear
diameter with the chain.
Minimum gear diameter (with chain):
48.2 mm (1.898 in.)
NOTICE:
The vernier caliper must be in contact with the
chain rollers when measuring.
If the gear diameter is less than the minimum,
replace the No. 2 chain sub-assembly and oil pump
drive shaft sprocket.
REPLACEMENT
1. REPLACE TIMING CHAIN COVER OIL SEAL
(a) Using a screwdriver and hammer, tap out the oil
seal.
(b) Place the oil seal retainer on wooden blocks.
(c) Apply multi-purpose grease to the lip of a new oil
seal.
NOTICE:
Keep the lip free of foreign objects.
(d) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the timing gear case edge.
SST 09223-22010
NOTICE:
Do not tap the oil seal at an angle.
A053035E01
A053036E01
A032626E01
A094547E01

EM–322AZ-FE ENGINE MECHANICAL – TIMING CHAIN
EM
INSTALLATION
1. INSTALL NO. 2 CHAIN SUB-ASSEMBLY
(a) Set the crankshaft key in the left horizontal position.
(b) Turn the cutout of the drive shaft so that it faces
upward.
(c) Align the yellow mark links with the timing marks of
each gear as shown in the illustration.
(d) Install the sprockets onto the crankshaft and oil
pump shaft with the chain wrapped on the gears.
(e) Temporarily tighten the oil pump drive shaft sprocket
with the nut.
(f) Insert the damper spring into the adjusting hole, and
then install the chain tensioner plate with the bolt.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
(g) Align the adjusting hole of the oil pump drive shaft
sprocket with the groove of the oil pump.
(h) Insert a 4 mm diameter bar into the adjusting hole of
the oil pump drive shaft gear to lock the gear in
position, and then tighten the nut.
Torque: 29.5 N*m (301 kgf*cm, 22 ft.*lbf)
B011424E01
A094198E06
A090851E03
A098352E01

2AZ-FE ENGINE MECHANICAL – TIMING CHAINEM–33
EM
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.
A128186
A132570
A098367E01
A052505E01

EM–342AZ-FE ENGINE MECHANICAL – TIMING CHAIN
EM
(b) Install the chain onto the crankshaft timing sprocket
with the gold or orange mark link aligned with the
timing mark on the crankshaft.
(c) Using SST and a hammer, tap in the crankshaft
timing sprocket.
SST 09309-37010
(d) Align the gold or yellow links with each timing mark
located on the camshaft timing gear and sprocket,
then install the chain.
5. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
6. INSTALL TIMING CHAIN GUIDE
(a) Install the timing chain guide with the bolt.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
A094576E01
A098369E01
A098370E01
A124787E01
A077243E01

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.
A124770
A094577E01

EM–362AZ-FE ENGINE MECHANICAL – TIMING CHAIN
EM
• Do not add engine oil for at least 2 hours after
installing the chain cover.
A132566E02

2AZ-FE ENGINE MECHANICAL – TIMING CHAINEM–37
EM
(d) Install the timing chain cover with the 12 bolts and 2
nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) for bolt A
25 N*m (255 kgf*cm, 18 ft.*lbf) for bolt B
55 N*m (561 kgf*cm, 41 ft.*lbf) for bolt C
11 N*m (112 kgf*cm, 8 ft.*lbf) for nut
HINT:
Bolt length:
(e) Using an E10 "torx" socket, install the stud bolt for
the V-ribbed belt tensioner.
Torque: 21.5 N*m (219 kgf*cm, 16 ft.*lbf)
9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Release the ratchet pawl, then fully push in the
plunger and hook the hook to the pin so that the
plunger is in the position shown in the illustration.
A132568E03
Bolt A 30 mm (1.18 in.) length for 10 mm head
Bolt B 30 mm (1.18 in.) length for 12 mm head
Bolt C 40 mm (1.57 in.) length for 14 mm head
A014253E03
A098376E03

EM–382AZ-FE ENGINE MECHANICAL – TIMING CHAIN
EM
(b) Install a new gasket and the chain tensioner with the
2 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
NOTICE:
When installing the chain tensioner, set the
hook again if the hook releases the plunger.
10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Install the V-ribbed belt tensioner with the bolt and
nut.
Torque: 59.5 N*m (607 kgf*cm, 44 ft.*lbf)
NOTICE:
Do not lift the engine more than necessary.
11. INSTALL ENGINE MOUNTING BRACKET RH
(a) Install the engine mounting bracket RH with the 3
bolts.
Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf)
12. INSTALL CRANKSHAFT PULLEY
(a) Using SST, fix the pulley in place and tighten the
bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 180 N*m (1,835 kgf*cm, 133 ft.*lbf)
A098377E03
A112212
A128165
A098346E01