engine TOYOTA RAV4 2006 Service Repair Manual

EM–622AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
EM
(c) Apply air pressure of 100 kPa (1.0 kgf/cm2, 14 psi)
to the oil path, then turn the camshaft timing gear to
the advance direction (counterclockwise) by hand.
CAUTION:
Cover the paths with a shop rag to avoid oil
splashes.
HINT:
Depending on the air pressure, the camshaft timing
gear will turn to the advance angle side without
applying force by hand. Also, under the condition
that the pressure is difficult to apply because of air
leakage from the port, there may be the case that
the lock pin is difficult to release.
(d) Remove the flange bolt of the camshaft timing gear.
NOTICE:
• Be sure not to remove the other 4 bolts.
• When reusing the camshaft timing gear,
release the straight pin lock first, then install
the gear.
48. REMOVE CYLINDER HEAD SUB-ASSEMBLY
(a) Using several steps, uniformly loosen and remove
the 10 cylinder head bolts and 10 plate washers
with a 10 mm bi-hexagon wrench in the sequence
shown in the illustration.
NOTICE:
Head warpage or cracking could result from
removing the bolts in the wrong order.
(b) Using a screwdriver with its tip wrapped with tape,
pry between the cylinder head and cylinder block,
and remove the cylinder head.
NOTICE:
Be careful not to damage the contact surfaces of
the cylinder head and cylinder block.
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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–63
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49. REMOVE CYLINDER HEAD GASKET
DISASSEMBLY
1. REMOVE RADIO SETTING CONDENSER
(a) Remove the bolt and condenser.
2. REMOVE OIL PRESSURE SWITCH
(a) Using a 24 mm deep socket wrench, remove the
sensor.
3. REMOVE ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using SST, remove the sensor and gasket.
SST 09817-33190
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EM–642AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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4. REMOVE CAMSHAFT POSITION SENSOR
(a) Remove the bolt and sensor.
5. REMOVE NO. 2 CAMSHAFT BEARING
(a) Remove the No. 2 camshaft bearing.
6. REMOVE NO. 1 CAMSHAFT BEARING
(a) Remove the No. 1 camshaft bearing.
7. REMOVE VALVE LIFTER
HINT:
Arrange the valve lifters in the correct order.
8. REMOVE INTAKE VALVE
(a) Place the cylinder head on wooden blocks.
(b) Using SST, compress the spring, then remove the 2
retainer locks.
SST 09202-70020 (09202-00010)
(c) Remove the retainer, spring and valve from the
cylinder head.
HINT:
Arrange the removed parts in the correct order.
9. REMOVE EXHAUST VALVE
(a) Place the cylinder head on wooden blocks.
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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–65
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(b) Using SST, compress the spring, then remove the 2
retainer locks.
SST 09202-70020 (09202-00010)
(c) Remove the retainer, spring and valve from the
cylinder head.
HINT:
Arrange the removed parts in the correct order.
10. REMOVE VALVE SPRING SEAT
(a) Using compressed air and a magnetic finger,
remove the spring seat by blowing air.
HINT:
Arrange the valves, valve springs, spring seats and
spring retainers in the correct order.
11. REMOVE VALVE STEM OIL SEAL
(a) Using needle-nose pliers, remove the 16 oil seals.
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EM–662AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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INSPECTION
1. INSPECT CYLINDER HEAD FOR WARPAGE
(a) Using a precision straightedge and feeler gauge,
measure the warpage of the contact surfaces of the
cylinder block and manifolds.
Maximum warpage:
0.08 mm (0.0032 in.)
If the warpage is greater than the maximum, replace
the cylinder head sub-assembly.
2. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrant, inspect the combustion
chamber, intake ports, exhaust ports and cylinder
block surface for cracks.
If cracked, replace the cylinder head.
3. INSPECT VALVE SEAT
(a) Apply a light coat of Prussian blue to the valve face.
(b) Lightly press the valve against the seat.
NOTICE:
Do not turn the valve.
(c) Check the valve face and seat in accordance with
the following procedure.
(1) If blue appears 360
around the face, the valve
is concentric. If not, replace the valve.
(2) If blue appears 360
around the valve seat, the
guide and face are concentric. If not, resurface
the valve seat (see page EM-87).
(3) Check that the seat contact is in the middle of
the valve face with a width.
Standard width
A098134E01
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Item Standard Condition
Intake 1.0 to 1.4 mm (0.0039 to 0.0551 in.)
Exhaust 1.2 to 1.6 mm (0.0472 to 0.0630 in.)

2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–67
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4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) 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.
(b) Release the lock pin.
(1) Cover the 4 oil paths of the cam journal with
vinyl tape as shown in the illustration.
HINT:
The 2 advance side paths are provided in the
groove of the camshaft. Plug one of the paths
with a rubber piece.
(2) Break through the tape of the advance side
path and the retard side path on the opposite
side of the groove.
(3) Apply approximately 200 kPa (2.0 kgf/cm
2, 28
psi) of air pressure to the paths whose tape
was broken in the procedure above.
CAUTION:
Some oil spraying will occur. Contain the
spray with a shop rag.
(4) Check that the camshaft timing gear revolves in
the advance direction when weakening the air
pressure of the retard side path.
OK:
Gear rotates in advance direction.
HINT:
This operation releases the lock pin for the
extreme retard position.
(5) When the camshaft timing gear reaches the
extreme advance position, remove the air gun
from the retard side path and advance side
path, in that order.
NOTICE:
Do not remove the air gun from the advance
side path first. The gear may abruptly shift
in the retard direction and break the lock
pin.
(c) Check for smooth rotation.
(1) Rotate the camshaft timing gear within its
movable range several times, but do not turn it
to the extreme retard position. Check that the
gear rotates smoothly.
OK:
Gear rotates smoothly.
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EM–682AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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NOTICE:
Do not use an air gun to perform the
smooth operation check.
(d) Check the lock in the extreme retard position.
(1) Confirm that the camshaft timing gear is locked
at the extreme retard position.
5. INSPECT CAMSHAFT
(a) Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout
at the center journal.
Maximum circle runout:
0.03 mm (0.0012 in.)
If the circle runout is greater than the
maximum, replace the camshaft.
(b) Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe
height.
Standard cam lobe height:
47.306 to 47.406 mm (1.8624 to 1.8664 in.)
Minimum cam lobe height:
47.196 mm (1.8581 in.)
If the cam lobe height is less than the minimum,
replace the camshaft.
(c) Inspect the camshaft journals.
(1) Using a micrometer, measure the journal
diameter.
Standard journal diameter
If the journal diameter is not as specified, check
the oil clearance.
6. INSPECT NO. 2 CAMSHAFT
(a) Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout
at the center journal.
Maximum circle runout:
0.03 mm (0.0012 in.)
If the circle runout is greater than the
maximum, replace the No. 2 camshaft.
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Journal Position Specified Condition
No. 1 35.971 to 35.985 mm (1.4162 to
1.4167 in.)
Other 22.959 to 22.975 mm (0.9039 to
0.9045 in.)
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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–69
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(b) Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe
height.
Standard cam lobe height:
45.983 to 46.083 mm (1.8104 to 1.8143 in.)
Minimum cam lobe height:
45.873 mm (1.8060 in.)
If the cam lobe height is less than the minimum,
replace the No. 2 camshaft.
(c) Inspect the camshaft journals.
(1) Using a micrometer, measure the journal
diameter.
Standard journal diameter
If the journal diameter is not as specified, check
the oil clearance.
7. INSPECT CAMSHAFT OIL CLEARANCE
(a) Clean the 10 bearing caps and camshaft journals.
(b) Place the 2 camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the
camshaft journals.
(d) Install the 10 bearing caps (see page EM-84).
NOTICE:
Do not turn the camshaft.
(e) Remove the 10 bearing caps for the No. 2 camshaft
(see page EM-60) and camshaft (see page EM-61).
(f) Measure the Plastigage at its widest point.
Standard oil clearance
Maximum oil clearance
NOTICE:
Completely remove the Plastigage after the
measurement.
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Journal Position Specified Condition
No. 1 35.971 to 35.985 mm (1.4162 to
1.4167 in.)
Other 22.959 to 22.975 mm (0.9039 to
0.9045 in.)
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Item Standard Condition
Intake No. 1 journal 0.007 to 0.038 mm (0.0003 to 0.0015
in.)
Exhaust No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031
in.)
Other journal 0.025 to 0.062 mm (0.0010 to 0.0024
in.)
Item Standard Condition
Intake No. 1 journal 0.07 mm (0.0028 in.)
Other journal 0.10 mm (0.0039 in.)

EM–702AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
EM
If the oil clearance on the No. 1 journal is greater
than the maximum, choose a new bearing and
install it.
If the oil clearance on the other journals is greater
than the maximum, replace the cylinder head sub-
assembly or the camshaft.
Standard cylinder head journal bore diameter
Standard bearing center wall thickness
Standard camshaft journal diameter:
35.971 to 35.985 mm (1.4162 to 1.4167 in.)
8. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the 2 camshafts (see page EM-84).
(b) Using a dial indicator, measure the thrust clearance
while moving the camshaft back and forth.
Standard thrust clearance
Maximum thrust clearance
If the thrust clearance is greater than the maximum,
replace the cylinder head.
If damage is found on the camshaft thrust surfaces,
replace the camshaft.
Mark Standard Condition
Mark 1 40.000 to 40.008 mm (1.5748 to
1.5751 in.)
Mark 2 40.009 to 40.017 mm (1.5752 to
1.5755 in.)
Mark 3 40.018 to 40.025 mm (1.5755 to
1.5758 in.)
Mark Standard Condition
Mark 1 2.000 to 2.004 mm (0.0787 to 0.0789
in.)
Mark 2 2.005 to 2.008 mm (0.0789 to 0.0791
in.)
Mark 3 2.009 to 2.012 mm (0.0791 to 0.0792
in.)
A036626E02
Item Standard Condition
Intake 0.040 to 0.095 mm (0.0016 to 0.0037
in.)
Exhaust 0.080 to 0.135 mm (0.0032 to 0.0053
in.)
Item Standard Condition
Intake 0.11 mm (0.0043 in.)
Exhaust 0.15 mm (0.0059 in.)

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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