engine TOYOTA RAV4 2006 Service Repair Manual

EM–822AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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(b) Align the bearing claw with the claw groove of No. 1
and No. 2 bearing cap, and push in the No. 1
camshaft bearing.
6. INSTALL NO. 2 CAMSHAFT BEARING
(a) Clean the contact surface of the bearing and the
bearing cap.
NOTICE:
Do not apply engine oil to the contact surfaces
of the camshaft bearing and cylinder block.
(b) Install the No. 2 camshaft bearing onto the cylinder
head.
7. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the camshaft position sensor with the bolt.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
8. INSTALL ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using SST, install a new gasket and the ECT
sensor.
SST 09817-33190
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–83
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9. INSTALL OIL PRESSURE SWITCH
(a) Apply adhesive to 2 or 3 threads of the oil pressure
switch.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond
1344 or equivalent
(b) Using a 24 mm deep socket wrench, install the oil
pressure switch.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
10. INSTALL RADIO SETTING CONDENSER
(a) Install the condenser with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALLATION
1. INSTALL CYLINDER HEAD GASKET
(a) Place a new gasket on the cylinder block surface
with the Lot No. stamp facing upward.
NOTICE:
• Remove any oil from contact surface.
• Be careful of the installation direction.
2. INSTALL CYLINDER HEAD SUB-ASSEMBLY
(a) Place the cylinder head on the head gasket.
NOTICE:
Place the cylinder head gently in order to avoid
damaging the gasket.
(b) Install the cylinder head bolts.
NOTICE:
The cylinder head bolts are tightened in 2
successive steps.
(1) Apply a light coat of engine oil to the threads
and under the heads of the cylinder head set
bolts.
(2) Using several steps, uniformly install and
tighten the 10 cylinder head set bolts and plate
washers with a 10 mm bi-hexagon wrench in
the order shown in the illustration.
Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf)
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EM–842AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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(c) Mark the front of the cylinder head bolts with paint.
(d) Retighten the cylinder head bolts by 90
as shown
in the illustration.
(e) Check that the paint mark is now at a 90
angle to
the front.
3. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
(a) Put the camshaft timing gear and camshaft together
with the straight pin and key groove misaligned, as
shown in the illustration.
(b) Turn the camshaft timing gear as shown in the
illustration while pushing it gently against the
camshaft. Push further at the position where the pin
fits into the groove.
NOTICE:
Be sure not to turn the camshaft timing gear to
the retard angle side (the right angle).
(c) Check that there is no clearance between the gear
fringe and camshaft.
(d) Tighten the flange bolt with the camshaft timing gear
fixed in place.
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
(e) Check that the camshaft timing gear can move to
the retard angle side (the right direction) and is
locked in the most retarded position.
4. INSTALL NO. 2 CAMSHAFT TIMING SPROCKET
(a) Clamp the camshaft in a vise, then install the
camshaft timing sprocket with the bolt.
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
NOTICE:
Do not damage the camshaft.
5. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil to the journal portion
of the camshaft.
(b) Place the 2 camshafts on the cylinder head with the
No. 1 cam lobes facing the directions shown in the
illustration.
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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–85
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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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EM–862AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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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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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–87
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31. INSTALL NO. 1 EXHAUST MANIFOLD HEAT
INSULATOR
(a) Install the exhaust manifold heat insulator with the 4
bolts.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
32. INSTALL NO. 2 MANIFOLD STAY
(a) Install the stay with the bolt and nut.
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
33. INSTALL MANIFOLD STAY
(a) Install the stay with the bolt and nut.
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
34. INSTALL FRONT EXHAUST PIPE (See page EX-4)
35. INSTALL OIL DIPSTICK GUIDE
(a) Apply a light coat of engine oil to a new O-ring and
install it onto the guide.
(b) Install the guide with the bolt.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
36. INSTALL OIL DIPSTICK
37. INSTALL INTAKE MANIFOLD INSULATOR (See page
ES-421)
38. INSTALL INTAKE MANIFOLD (See page ES-421)
39. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
(See page FU-13)
40. INSTALL THROTTLE BODY (See page ES-413)
41. INSTALL AIR CLEANER CAP (See page ES-413)
42. ADD ENGINE OIL (See page LU-4)
43. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
44. CHECK FOR FUEL LEAKS
45. ADD ENGINE COOLANT (See page CO-6)
46. CHECK FOR ENGINE COOLANT LEAKS
(a) Check for engine coolant leaks (see page CO-1).
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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.)

EM–982AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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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 HOOD SUB-ASSEMBLY (See page ED-4)
4. REMOVE RADIATOR SUPPORT OPENING COVER
5. REMOVE BATTERY CLAMP SUB-ASSEMBLY
(a) Loosen the bolt and nut, and remove the battery
clamp.
6. REMOVE BATTERY
7. REMOVE BATTERY TRAY
8. REMOVE FRONT WHEEL
9. REMOVE NO. 1 ENGINE UNDER COVER
10. REMOVE NO. 2 ENGINE UNDER COVER
11. REMOVE FRONT FENDER APRON RH
12. REMOVE NO. 1 ENGINE COVER (See page EM-22)
13. DRAIN ENGINE COOLANT (See page CO-6)
14. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Drain automatic transaxle fluid for U241E (2WD)
(see page AX-146).
(b) Drain automatic transaxle fluid for U140F (4WD)
(see page AX-147).
15. REMOVE RADIATOR ASSEMBLY
(a) Remove the radiator (see page CO-29).
16. REMOVE RADIATOR RESERVOIR
(a) Remove the 2 bolts and reservoir.
17. REMOVE PURGE VSV (See page EC-15)
18. REMOVE AIR CLEANER CAP (See page ES-411)
19. REMOVE AIR CLEANER FILTER ELEMENT SUB-
ASSEMBLY
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2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–99
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20. REMOVE AIR CLEANER CASE SUB-ASSEMBLY
(a) Remove the 3 bolts from the air cleaner case.
(b) Disconnect the case from the NO. 1 air cleaner inlet.
21. REMOVE FRONT BATTERY CARRIER
(a) Disconnect the 2 clamps of the engine wire.
(b) Remove the 4 bolts and front battery carrier.
22. REMOVE BATTERY BRACKET REINFORCEMENT
(a) Remove the 2 bolts and battery bracket
reinforcement.
23. REMOVE BATTERY CARRIER BRACKET
(a) Remove the 2 bolts, nut and battery carrier bracket.
24. DISCONNECT UNION TO CONNECTOR TUBE HOSE
(a) Disconnect the 2 union to connector tube hoses
from the booster vacuum tube.
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EM–1002AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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25. DISCONNECT HEATER WATER INLET HOSE
(a) Disconnect the heater water inlet hose from the
heater unit.
26. DISCONNECT HEATER WATER OUTLET HOSE
(a) Disconnect the heater water outlet hose from the
heater unit.
27. DISCONNECT FUEL TUBE (See page FU-10)
28. REMOVE THROTTLE BODY (See page ES-412)
29. DISCONNECT NO. 2 VENTILATION HOSE (See page
FU-10)
30. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
(See page FU-10)
31. REMOVE INTAKE MANIFOLD (See page ES-419)
32. REMOVE INTAKE MANIFOLD INSULATOR (See page
ES-420)
33. REMOVE TRANSAXLE CONTROL CABLE
ASSEMBLY
(a) Remove the transaxle control cable for U241E
(2WD) (see page AX-129).
(b) Remove the transaxle control cable for U140F
(4WD) (see page AX-129).
34. REMOVE FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-6)
35. REMOVE FAN AND GENERATOR V BELT (See page
EM-6)
36. REMOVE GENERATOR ASSEMBLY (See page CH-9)
37. REMOVE COOLER COMPRESSOR ASSEMBLY
(a) Remove the cooler compressor (see page AC-216).
HINT:
Disconnect the compressor together with the low-
pressure and high-pressure hoses, then secure it to
the vehicle side using rope.
38. REMOVE ECM (See page ES-429)
39. DISCONNECT ENGINE WIRE
(a) Remove the engine room relay block cover.
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