engine TOYOTA RAV4 2006 Service Repair Manual

2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–129
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54. REMOVE NO. 1 BALANCE SHAFT BEARING
55. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the lip of the oil seal.
(b) Using a screwdriver with its tip wrapped with tape,
pry out the oil seal.
NOTICE:
After removing, check the crankshaft for
damage. If damaged, smooth the surface with
400-grit sandpaper.
56. REMOVE STIFFENING CRANKCASE ASSEMBLY
(a) Using several steps, uniformly loosen and remove
the 11 bolts in the sequence shown in the
illustration.
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(b) Remove the crankcase by prying the portions
between the crankcase and cylinder block.
NOTICE:
Be careful not to damage the contact surfaces of
the crankcase and cylinder bock.
(c) Remove the O-ring from the cylinder block.
57. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance
while moving the connecting rod back and forth.
Standard thrust clearance:
0.160 to 0.362 mm (0.0063 to 0.0143 in.)
Maximum thrust clearance:
0.362 mm (0.0143 in.)
If the thrust clearance is greater than the maximum,
replace the connecting rod. If necessary, replace
the crankshaft.
58. INSPECT CONNECTING ROD OIL CLEARANCE
NOTICE:
Do not turn the crankshaft during the measurement.
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(a) Using marking paint, write the matched cylinder
number on each connecting rod and cap.
HINT:
The matchmarks in the connecting rods and caps
are for ensuring correct reassembly.
(b) Using a 12 mm socket wrench, remove the 2 bolts
and connecting rod cap.
(c) Clean the crank pin and bearing.
(d) Check the crank pin and bearing for pitting and
scratches.
(e) Lay a strip of Plastigage on the crank pin.
(f) Check that the front mark of the connecting rod cap
is facing in the correct direction.
(g) Apply a light coat of engine oil to the threads and
under the heads of the connecting rod bolts.
(h) Using a 12 mm socket wrench, tighten the bolts in
several passes to the specified torque.
Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)
(i) Mark the front of the connecting rod bolts with paint.
(j) Retighten the cap bolts 90
as shown in the
illustration.
(k) Check that the crankshaft turns smoothly.
(l) Using a 12 mm socket wrench, remove the 2 bolts
and connecting rod cap.
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(m) Measure the Plastigage at its widest point.
Standard oil clearance:
0.024 to 0.048 mm (0.0009 to 0.0019 in.)
Maximum oil clearance:
0.08 mm (0.0032 in.)
NOTICE:
Remove the Plastigage completely after the
measurement.
If the oil clearance is greater than the maximum,
replace the connecting rod bearing. If necessary,
grind or replace the crankshaft.
HINT:
If replacing a bearing, select a new one with the
same number as marked on the connecting rod.
There are 3 sizes of standard bearings, marked "1",
"2" and "3" accordingly.
Standard connecting rod large end bore
diameter
Standard connecting rod bearing thickness
Standard crankshaft pin diameter:
47.990 to 48.000 (1.8894 to 1.8898 in.)
59. REMOVE PISTON WITH CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from
the top of the cylinder.
(b) Push the piston, connecting rod assembly and
upper bearing through the top of the cylinder block.
HINT:
• Keep the bearing, connecting rod and cap
together.
• Arrange the piston and connecting rod
assemblies in the correct order.
60. REMOVE CONNECTING ROD BEARING
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Mark Specified Condition
Mark 1 51.000 to 51.007 mm (2.0079 to
2.0082 in.)
Mark 2 51.008 to 51.013 mm (2.0082 to
2.0084 in.)
Mark 3 51.014 to 51.020 mm (2.0084 to
2.0087 in.)
Mark Specified Condition
Mark 1 1.485 to 1.488 mm (0.0585 to 0.0586
in.)
Mark 2 1.489 to 1.491 mm (0.0586 to 0.0587
in.)
Mark 3 1.492 to 1.494 mm (0.0587 to 0.0588
in.)
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61. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2
compression rings.
(b) Remove the oil ring and expander by hand.
62. REMOVE PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, pry out the 2 snap rings.
63. REMOVE PISTON
(a) Gradually heat the piston up to 80 to 90
C (176 to
194
F).
(b) Using a plastic-faced hammer and brass bar, lightly
tap out the piston pin, then remove the connecting
rod.
HINT:
• The piston and pin are a matched set.
• Arrange the piston, pin, ring, connecting rod and
bearings in the correct order.
64. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance
while prying the crankshaft back and forth with a
screwdriver.
Standard thrust clearance:
0.04 to 0.24 mm (0.0016 to 0.0095 in.)
Maximum thrust clearance:
0.30 mm (0.012 in.)
If the thrust clearance is greater than the maximum,
replace the thrust washers as a set.
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HINT:
The thrust washer thickness is 1.93 to 1.98 mm
(0.0760 to 0.0780 in.).
65. INSPECT CRANKSHAFT OIL CLEARANCE
NOTICE:
Do not turn the crankshaft during the measurement.
(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 from the cylinder block.
HINT:
• Keep the No. 2 crankshaft bearings and
crankshaft bearing caps together.
• Arrange the bearing caps in correct order.
(c) Remove the crankshaft.
HINT:
Keep the crankshaft bearings and crankshaft thrust
washer uppers together with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
• If the journal or bearing is damaged, replace the
bearings.
• If necessary, replace the crankshaft.
(f) Place the crankshaft onto the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Examine the front marks and numbers, and install
the bearing caps onto the cylinder block in the order
shown in the illustration.
(i) Apply a light coat of engine oil to the threads and
under the heads of the crankshaft bearing cap set
bolts.
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(j) Using several steps, uniformly install and tighten the
10 bearing cap bolts in the sequence shown in the
illustration.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
(k) Mark the front of the bearing cap bolts with paint.
(l) Retighten the 10 bearing cap bolts by 90
.
(m) Check that the paint marks are at a 90
angle to the
front.
(n) Remove the crankshaft bearing caps.
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(o) Measure the Plastigage at its widest point.
Standard oil clearance:
0.008 to 0.024 mm (0.0003 to 0.0010 in.)
Maximum oil clearance:
0.050 mm (0.0020 in.)
NOTICE:
Remove the Plastigage completely after the
measurement.
If the oil clearance is greater than the maximum,
replace the crankshaft bearing. If necessary,
replace the crankshaft.
HINT:
If replacing a bearing, select a new one with the
same number. If the number of the bearing cannot
be determined, calculate the correct bearing
number by adding together the numbers imprinted
on the cylinder block and crankshaft. Then select a
new bearing with the calculated number. There are
4 sizes of standard bearings, marked "1", "2", "3"
and "4" accordingly.
EXAMPLE
• Imprinted number on the cylinder block is 3.
• Imprinted number on the crankshaft is 4.
3 + 4 = 7
Select the bearing marked "3".
Standard cylinder block journal bore diameter
Standard crankshaft journal diameter
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Cylinder block
+ Crankshaft0 to 2 3 to 5 6 to 8 9 to 11
Use bearing "1" "2" "3" "4"
Mark Specified Condition
0 59.000 to 59.002 mm (2.3228 to
2.3229 in.)
1 59.003 to 59.004 mm (2.3230 to
2.3230 in.)
2 59.005 to 59.006 mm (2.3230 to
2.3231 in.)
3 59.007 to 59.009 mm (2.3231 to
2.3232 in.)
4 59.010 to 59.011 mm (2.3232 to
2.3233 in.)
5 59.012 to 59.013 mm (2.3233 to
2.3234 in.)
6 59.014 to 59.016 mm (2.3234 to
2.3235 in.)
Mark Specified Condition
0 54.999 to 55.000 mm (2.1653 to
2.1654 in.)
1 54.997 to 54.998 mm (2.1652 to
2.1653 in.)
2 54.995 to 54.996 mm (2.1652 to
2.1652 in.)
3 54.993 to 54.994 mm (2.1651 to
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Standard bearing center wall thickness
66. REMOVE CRANKSHAFT
(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 from the cylinder block.
(c) Remove the crankshaft from the cylinder block.
67. REMOVE CRANKSHAFT THRUST WASHER UPPER
68. REMOVE CRANKSHAFT BEARING
HINT:
Arrange the bearings in the correct order.
4 54.991 to 54.992 mm (2.1650 to
2.1650 in.)
5 54.988 to 54.990 mm (2.1649 to
2.1650 in.)
Mark Specified Condition
1 1.993 to 1.996 mm (0.0785 to 0.0786
in.)
2 1.997 to 1.999 mm (0.0786 to 0.0787
in.)
3 2.000 to 2.002 mm (0.0787 to 0.0788
in.)
4 2.003 to 2.005 mm (0.0789 to 0.0789
in.) Mark Specified Condition
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69. REMOVE NO. 2 CRANKSHAFT BEARING
HINT:
Arrange the bearings in the correct order.
70. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Remove the 4 bolts and 4 oil nozzles.
INSPECTION
1. INSPECT CYLINDER BLOCK FOR WARPAGE
(a) Using a precision straightedge and feeler gauge,
measure the warpage of the surface that is in
contact with the cylinder head gasket.
Maximum warpage:
0.05 mm (0.0020 in.)
If the warpage is greater than the maximum, replace
the cylinder block.
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