engine TOYOTA RAV4 2006 Service Repair Manual

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–99
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(h) Using a sharp 5.5 mm reamer, ream the guide bush
to obtain the standard specified clearance between
the guide bush and valve stem.
5. REPLACE EXHAUST VALVE GUIDE BUSH
(a) Heat the cylinder head to approximately 80 to
100
C (176 to 212F).
(b) Place the cylinder head on wooden blocks.
(c) Using SST and a hammer, tap out the valve guide
bush.
SST 09201-10000 (09201-01050), 09950-70010
(09951-07100)
(d) Using a caliper gauge, measure the bush bore
diameter of the cylinder head.
Standard cylinder bore diameter:
10.285 to 10.306 mm (0.4049 to 0.4057 in.)
(e) Select a new guide bush (STD or O/S 0.05).
Standard bush bore diameter
HINT:
• If the bush bore diameter of the cylinder head is
greater than 10.344 mm (0.4072 in.), machine
the bush bore diameter to between 10.383 to
10.394 mm (0.4088 to 0.4092 in.).
• If the bush bore diameter of the cylinder head is
greater than 10.344 mm (0.4072 in.), replace the
cylinder head.
(f) Heat the cylinder head to approximately 80 to
100
C (176 to 212F).
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Bush Size Specified Condition
Use STD 10.335 to 10.356 mm (0.4069 to
0.4077 in.)
Use O/S 0.05 10.285 to 10.306 mm (0.4049 to
0.4057 in.)

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(g) Using SST and a hammer, tap in a new guide bush
to the specified protrusion height.
SST 09201-10000 (09201-01050), 09950-70010
(09951-07100)
Standard protrusion height:
9.30 to 9.70 mm (0.3661 to 0.3819 in.)
(h) Using a sharp 5.5 mm reamer, ream the guide bush
to obtain the standard specified clearance between
the guide bush and valve stem.
6. REPLACE CYLINDER BLOCK TIGHT PLUG
NOTICE:
If water leaks from the tight plug or the plug
corrodes, replace it.
(a) Remove the tight plugs.
(b) Apply adhesive around the tight plug.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond
1324 or Equivalent
(c) Using SST and a hammer, tap in 2 new tight plugs
as shown in the illustration.
SST 09950-60010 (09951-00340), 09950-70010
(09951-07100)
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7. REPLACE CYLINDER BLOCK STUD BOLT
NOTICE:
If a stud bolt is deformed or the threads are
damaged, replace it.
(a) Remove the stud bolts.
(b) Using an E8 "torx" socket wrench, install the stud
bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
8. REPLACE CYLINDER BLOCK STRAIGHT PIN
NOTICE:
It is not necessary to remove the straight pin unless
it is being replaced.
(a) Remove the straight pin.
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(b) Using a plastic-faced hammer, tap in new straight
pins to the cylinder block.
Standard protrusion
Item Specified Condition
Pin A 23 mm (0.91 in.)
Pin B 6 mm (0.24 in.)
Pin C 11 mm (0.43 in.)
Pin D 9 mm (0.35 in.)
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–103
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9. REPLACE CYLINDER HEAD RING PIN
NOTICE:
It is not necessary to remove the ring pin unless it is
being replaced.
(a) Remove the ring pins.
(b) Using a plastic-faced hammer, tap in a new ring pin
until the pin stops.
10. REPLACE CYLINDER HEAD STUD BOLT
NOTICE:
If a stud bolt is deformed or the threads are
damaged, replace it.
(a) Remove the stud bolts.
(b) Using E6 and E8 "torx" socket wrenches, install the
stud bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for stud
bolts A and B
4.0 N*m (41 kgf*cm, 35 in.*lbf) for stud
bolt C
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11. REPLACE CYLINDER HEAD SET STRAIGHT PIN
NOTICE:
It is not necessary to remove the straight pin unless
it is being replaced.
(a) Using a plastic-faced hammer, tap in a new straight
pin as shown in the illustration.
Standard protrusion height:
18.0 to 19.0 mm (0.71 to 0.75 in.)
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–105
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REASSEMBLY
1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, install the 3 oil
nozzles with the bolts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
2. INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSEMBLY
(a) Apply adhesive around the drain cocks.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond
1324 or Equivalent
(b) Install the cylinder block water drain cocks.
(1) Temporarily install the drain cocks.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
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(2) Within one full rotation, tighten the drain cock to
the angle shown in the illustration.
Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf)
NOTICE:
Do not loosen the drain cock to adjust it. If
an adjustment is necessary, remove the
drain cock and reinstall it.
(c) Install the water drain cock plug to the water drain
cocks.
Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
3. INSTALL PISTON WITH PIN SUB-ASSEMBLY
(a) Using a screwdriver, install a new snap ring at one
end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not
aligned with the pin hole cutout portion of the piston.
(b) Gradually heat the piston to approximately 80
C
(176
F).
(c) Coat the piston pin with engine oil.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–107
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(d) Align the front marks of the piston and connecting
rod, and push in the piston pin with your thumb.
HINT:
The piston and pin are a matched set.
(e) Check the fitting condition between the piston and
piston pin by trying to move the piston back and
forth on the piston pin.
(f) Using a screwdriver, install a new snap ring at the
other end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not
aligned with the pin hole cutout portion of the piston.
4. INSTALL PISTON RING SET
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2
compression rings so that the painted marks are
positioned as shown in the illustration.
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EM–1082GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(c) Position the piston rings so that the ring ends are as
shown in the illustration.
NOTICE:
Do not align the ring ends.
5. INSTALL CRANKSHAFT BEARING
NOTICE:
Main bearings come in widths between 18.0 mm
(0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0
mm (0.827 in.) bearings in the No. 1 and No. 4
cylinder block journal positions with the main
bearing cap. Install the 18.0 mm (0.709 in.) bearings
in the No. 2 and No. 3 positions.
(a) Clean the main journal and both surfaces of the
bearing.
(b) Install the upper bearing.
(1) Install the upper bearing to the cylinder block
as shown in the illustration.
NOTICE:
Do not apply engine oil to the bearing and
its contact surface.
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