engine TOYOTA RAV4 2006 Service Repair Manual

2AZ-FE ENGINE MECHANICAL – TIMING CHAINEM–39
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(b) Turn the crankshaft counterclockwise, then
disconnect the plunger knock pin from the hook.
(c) Turn the crankshaft clockwise, then check that the
plunger is extended.
13. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material and be careful not
to drop any oil on the contact surfaces of the
cylinder block and oil pan.
(b) Apply a continuous bead of seal packing (Diameter
3.0 to 4.0 mm (0.118 to 0.157 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.
• Instal l the oil pan wit hin 3 mi nut es of app lyi ng
seal packing.
• Do not add engine oil for at least 2 hours after
installing the oil pan.
(c) Install the oil pan to the cylinder block.
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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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2AZ-FE ENGINE MECHANICAL – TIMING CHAINEM–41
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(d) Install the 2 engine wires with the 2 bolts.
Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
(e) Connect the 2 ventilation hoses to the cylinder head
cover.
16. INSTALL SPARK PLUG (See page EM-16)
17. INSTALL IGNITION COIL ASSEMBLY (See page IG-9)
18. INSTALL IDLER PULLEY
(a) Install the idler pulley with the 2 bolts.
Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
19. INSTALL ENGINE MOUNTING INSULATOR RH
(a) Install the engine mounting insulator RH with the 4
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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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 – TIMING CHAINEM–43
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30. INSTALL NO. 1 ENGINE COVER
(a) Install the engine cover with the 2 nuts.
Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
31. INSTALL FRONT FENDER APRON RH
32. INSTALL NO. 1 ENGINE UNDER COVER
33. INSTALL FRONT WHEEL RH
34. INSTALL RADIATOR SUPPORT OPENING COVER
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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–57
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REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE (See page
FU-9)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
3. REMOVE RADIATOR SUPPORT OPENING COVER
4. REMOVE FRONT WHEEL RH
5. REMOVE NO. 1 ENGINE UNDER COVER
6. REMOVE FRONT FENDER APRON RH
7. REMOVE NO. 1 ENGINE COVER (See page EM-22)
8. DRAIN ENGINE COOLANT (See page CO-6)
9. DRAIN ENGINE OIL (See page LU-4)
10. REMOVE AIR CLEANER CAP (See page ES-411)
11. REMOVE THROTTLE BODY (See page ES-412)
12. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
(See page FU-10)
13. REMOVE INTAKE MANIFOLD (See page ES-419)
14. REMOVE INTAKE MANIFOLD INSULATOR (See page
ES-420)
15. REMOVE FRONT EXHAUST PIPE (See page EX-3)
16. REMOVE OIL DIPSTICK
17. REMOVE OIL DIPSTICK GUIDE
(a) Remove the bolt and guide.
(b) Remove the O-ring from the guide.
18. REMOVE MANIFOLD STAY
(a) Remove the bolt, nut and stay.
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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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EM–602AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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36. REMOVE NO. 2 CAMSHAFT
(a) Place paint marks on the chain in alignment with the
timing marks on the camshaft timing gear and
camshaft timing sprocket.
(b) Remove the 2 nuts, tensioner and gasket.
(c) While holding the camshaft with a wrench, loosen
the camshaft timing set bolt.
(d) Using several steps, uniformly loosen and remove
the 10 bearing cap bolts in the sequence shown in
the illustration.
(e) Remove the 5 bearing caps.
(f) While holding the No. 2 camshaft by hand, remove
the camshaft timing sprocket set bolt.
(g) Remove the camshaft timing sprocket from the No.
2 camshaft with the timing chain wrapped on the
sprocket.
(h) Remove the camshaft timing sprocket from the
timing chain.
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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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