engine TOYOTA RAV4 2006 Service Repair Manual

2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–149
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6. REPLACE STRAIGHT PIN (for Cylinder Block)
NOTICE:
It is not necessary to remove with straight pin unless
it is being replaced.
(a) Remove the 8 straight pins.
(b) Using a plastic-faced hammer, install 8 new straight
pins.
Standard protrusion height
Item Specified Condition
A 8.0 mm (0.315 in.)
B 7.5 mm (0.295 in.)
C 12.0 mm (0.472 in.)
D 5.0 mm (0.197 in.)
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INSTALLATION
1. INSTALL ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using a 19 mm deep socket wrench, install the
sensor and a new gasket.
Torque: 20 N*m (204 kgf*cm, 14 ft.*lbf)
2. INSTALL KNOCK SENSOR (See page ES-459)
3. INSTALL ENGINE OIL PRESSURE SWITCH
ASSEMBLY
(a) Clean the threads of the oil pressure switch. 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: 21 N*m (214 kgf*cm, 15 ft.*lbf)
4. INSTALL NO. 1 FRONT ENGINE MOUNTING
BRACKET LH
(a) Install the mounting bracket with the 6 bolts.
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
5. INSTALL WATER PUMP PULLEY (See page CO-14)
6. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler pulley and cover plate with the bolt.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
7. INSTALL NO. 2 TIMING GEAR COVER
(a) Install the gear cover with the 2 bolts.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Temporarily install the V-ribbed belt tensioner with
the 5 bolts.
(b) Install the V-ribbed belt tensioner by tightening the
bolt 1 and bolt 2 in the order shown in the
illustration.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
(c) Tighten the other bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
Each bolt length is as follows:
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9. INSTALL DRIVE SHAFT BEARING BRACKET
(a) Install the drive shaft bearing bracket with the 3
bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
10. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Install a new gasket as shown in the illustration.
(b) Install the manifold with the 6 nuts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
11. INSTALL NO. 2 EXHAUST MANIFOLD HEAT
INSULATOR
(a) Install the No. 2 heat insulator with the 3 bolts.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
12. INSTALL NO. 2 MANIFOLD STAY
(a) Install the No. 2 manifold stay with the bolt and nut.
Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf)
B 35 mm (1.37 in.)
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13. INSTALL OIL DIPSTICK GUIDE
(a) Install 2 new O-rings to the guide.
(b) Apply a light coat of engine oil to the O-rings.
(c) Push in the guide end into the guide hole.
(d) Install the No. 1 guide with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(e) Install the No. 2 guide with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(f) Install the dipstick.
14. INSTALL GENERATOR ASSEMBLY (See page CH-19)
15. INSTALL COMPRESSOR WITH PULLEY ASSEMBLY
(See page AC-221)
16. INSTALL FAN AND GENERATOR V BELT (See page
EM-8)
17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Install a new gasket as shown in the illustration.
(b) Install the manifold with the 6 nuts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
18. INSTALL INTAKE MANIFOLD
(a) Set a new gasket on each cylinder head.
NOTICE:
• Align the port holes of the gasket and
cylinder head.
• Be careful of the installation direction.
(b) Set the intake manifold on the cylinder heads.
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(c) Install and uniformly tighten the 6 bolts and 4 nuts in
several passes.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(d) Connect the 6 fuel injector connectors.
19. INSTALL FUEL INJECTOR ASSEMBLY (See page FU-
16)
20. INSTALL NO. 2 ENGINE MOUNTING STAY RH
(a) Install the mounting stay with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
21. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 6 ignition coils with the 6 bolts to the
cylinder head.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
22. INSTALL INTAKE AIR SURGE TANK ASSEMBLY
NOTICE:
Make sure there is no oil on the bolts. If there is oil
on the bolts, clean them before installing them.
(a) Install a new gasket to the surge tank.
(b) Using a 5 mm hexagon socket wrench, install the 4
bolts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
(c) Install the surge tank with the 2 nuts and 2 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt
16 N*m (163 kgf*cm, 12 ft.*lbf) for nut
(d) Connect the connector.
(e) Install the vacuum hose clamp with the bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
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(f) Connect the union to check valve hose.
(g) Connect the No. 2 ventilation hose.
(h) Install the clamp and connect the throttle body
connector.
(i) Connect the vapor feed hose.
(j) Connect the 2 water by-pass hoses to the throttle
body.
23. REMOVE ENGINE FROM ENGINE STAND
(a) Install a sling device and chain block to the engine.
(b) Remove the engine from the engine stand.
24. INSTALL DRIVE PLATE AND RING GEAR SUB-
ASSEMBLY
(a) Clean the bolt and its hole.
(b) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond
1324 or Equivalent
(c) Using SST, hold the crankshaft.
SST 09213-70011, 09330-00021
(d) Install the flywheel, drive plate and drive plate
spacer on the crankshaft.
(e) Uniformly install and tighten the 8 bolts in the
sequence shown in the illustration.
Torque: 178 N*m (1,815 kgf*cm, 132 ft.*lbf)
NOTICE:
Do not start the engine for at least 1 hour after
the installation.
25. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
(a) 2WD:
Install the automatic transaxle (see page AX-174).
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(b) 4WD:
Install the automatic transaxle (see page AX-175).
26. INSTALL TRANSFER ASSEMBLY (for 4WD) (See
page TF-75)
27. INSTALL STARTER ASSEMBLY (See page ST-14)
28. INSTALL ENGINE WIRE
(a) Install the engine wire to the engine.
29. INSTALL FRONT SUSPENSION CROSSMEMBER
SUB-ASSEMBLY
(a) Attach the engine together with the transaxle to the
suspension crossmember and mounting.
(b) Install the bolt which secures the engine mounting
bracket to the mounting insulator.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
30. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY
(a) Install the bolt and nut which secures the engine
mounting bracket to the mounting insulator.
Torque: 145 N*m (1,479 kgf*cm, 107 ft.*lbf)
31. INSTALL ENGINE WITH TRANSAXLE
(a) Place the engine on an engine lifter.
HINT:
Place the engine on wooden blocks or an equivalent
so that the engine is level.
(b) Using the chain block, slowly install the engine to
the vehicle and the intermediate shaft to the pinion.
CAUTION:
Do not raise the engine more than necessary. If
the engine is raised excessively, the vehicle may
also be lifted up.
NOTICE:
• Make sure that the engine is clear of all wiring
and hoses.
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• While raising the engine into the vehicle, do
not allow it to contact the vehicle.
• Align the matchmarks on the intermediate
shaft and pinion.
(c) Temporarily install the suspension member and
crossmember with the 10 bolts.
(d) Temporarily install the member brace rear RH and
LH with the 6 bolts.
(e) Install the engine mounting insulator LH with the bolt
and nut.
Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf)
NOTICE:
While holding the bolt in place, tighten the nut.
(f) Install the engine mounting insulator RH with the 2
bolts and 2 nuts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) for bolt
and nut A
52 N*m (530 kgf*cm, 38 ft.*lbf) for nut B
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(g) Tighten the suspension member and
crossmember's bolts.
Torque: 96 N*m (979 kgf*cm, 71 ft.*lbf) for bolt A
145 N*m (1,478 kgf*cm, 107 ft.*lbf) for
bolt B
(h) Tighten the member brace rear's bolts.
Torque: 145 N*m (1,478 kgf*cm, 107 ft.*lbf) for
bolt C
93 N*m (948 kgf*cm, 69 ft.*lbf) for bolt D
(i) Remove the sling device and chain block.
(j) Remove the 2 bolts and No. 1 and No. 2 engine
hangers.
32. INSTALL FRONT DRIVE SHAFT LH
(a) 2WD:
Install the drive shaft (see page DS-33).
(b) 4WD:
Install the drive shaft (see page DS-66).
33. INSTALL FRONT DRIVE SHAFT RH
(a) 2WD:
Install the drive shaft (see page DS-33).
(b) 4WD:
Install the drive shaft (see page DS-66).
34. CONNECT TIE ROD END SUB-ASSEMBLY LH (See
page PS-45)
35. CONNECT TIE ROD END SUB-ASSEMBLY RH (See
page PS-45)
36. CONNECT STEERING INTERMEDIATE SHAFT (See
page PS-44)
37. CONNECT FRONT STABILIZER LINK ASSEMBLY LH
(See page SP-31)
38. CONNECT FRONT STABILIZER LINK ASSEMBLY RH
(See page SP-31)
39. INSTALL FRONT AXLE HUB NUT LH
(a) Install the hub nut (see page AH-11).
40. INSTALL FRONT AXLE HUB NUT RH
(a) Install the hub nut (see page AH-11).
41. INSTALL FRONT WHEELS
42. INSTALL PROPELLER WITH CENTER BEARING
SHAFT ASSEMBLY (See page PR-5)
43. INSTALL CENTER EXHAUST PIPE ASSEMBLY (See
page EX-4)
44. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See
page EX-4)
45. CONNECT TRANSMISSION CONTROL CABLE
ASSEMBLY
(a) 2WD:
Connect the control cable (see page AX-154).
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(b) 4WD:
Connect the control cable (see page AX-154).
46. CONNECT RADIATOR HOSE INLET
47. CONNECT RADIATOR HOSE OUTLET
48. CONNECT OIL COOLER HOSE
49. CONNECT SUCTION HOSE SUB-ASSEMBLY (See
page AC-221)
50. INSTALL DISCHARGE HOSE SUB-ASSEMBLY (See
page AC-221)
51. INSTALL RADIATOR RESERVOIR TANK ASSEMBLY
(a) Install the reservoir tank with the 2 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(b) Connect the 2 hoses
52. INSTALL ECM (See page ES-471)
53. CONNECT HOSES AND CONNECTORS
(a) Connect the 2 ECM connectors.
(b) Connect the 2 heater hoses.
(c) Connect the fuel hoses.
(d) Connect the starter wire with the nut.
Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
(e) Connect the 3 connectors and wire with the nut.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
(f) Install the engine room junction block cover (upper).
54. INSTALL AIR CLEANER CASE
(a) Install the air cleaner case with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(b) Connect the harness clamp.
55. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
(a) Install the air cleaner filter element onto the air
cleaner case.
(b) Insert the hinge part of the air cleaner cap into the
air cleaner case, then hang the 2 hook clamps.
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