engine TOYOTA RAV4 2006 Service Repair Manual

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–109
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(c) Install the lower bearing.
(1) Install the lower bearing to the bearing cap.
(2) Using a vernier caliper, measure the distance
between the bearing cap's edge and the lower
bearing's edge.
Dimension (A - B):
0.7 mm (0.028 in.) or less.
NOTICE:
Do not apply engine oil to the bearing's
contact area and underside.
6. INSTALL CRANKSHAFT
(a) Install the 2 thrust washers under the No. 2 journal
position of the cylinder block with the oil grooves
facing outward.
(b) Apply engine oil to the upper bearing, then place the
crankshaft on the cylinder block.
(c) Confirm the front marks and numbers of the main
bearing caps and install the bearing caps on the
cylinder block.
HINT:
A number is marked on each main bearing cap to
indicate the installation position.
(d) Apply a light coat of engine oil on the threads and
under the heads of the bearing cap bolts.
(e) Temporarily install the 8 main bearing cap bolts to
the inside positions.
(f) Insert the main bearing cap by hand until the
clearance between the main bearing cap and the
cylinder block is less than 6 mm (0.23 in.) by
marking the 2 internal bearing cap bolts as a guide.
Bolt length:
100.0 to 102.0 mm (3.937 to 4.016 in.)
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(g) Using a plastic-faced hammer, lightly tap the
bearing cap to ensure a proper fit.
(h) Apply a light coat of engine oil to the threads and
under the heads of the 8 main bearing cap bolts.
(i) Install the 8 main bearing cap bolts to the outside
positions.
Bolt length:
105.5 to 107.5 mm (4.154 to 4.232 in.)
(j) Install the crankshaft bearing cap bolts.
HINT:
The main bearing cap bolts are tightened in 2
progressive steps.
(k) Step 1
(1) Install and uniformly tighten the 16 main
bearing cap bolts in the sequence shown in the
illustration.
Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)
If any of the main bearing cap bolts does not
meet the specified torque, replace it.
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(l) Step 2
(1) Mark the front of the bearing cap bolts with
paint.
(2) Tighten the bearing cap bolts another 90
in the
order shown in step 1.
(3) Check that the painted mark is now at a 90

angle to the front.
(m) Check that the crankshaft turns smoothly.
(n) Install and uniformly tighten the 8 main bearing cap
bolts in several steps, in the sequence shown in the
illustration.
Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf)
Bolt length:
45 mm (1.77 in.) for bolt A
30 mm (1.18 in.) for except bolt A
(o) Check that the crankshaft turns smoothly.
7. INSTALL CONNECTING ROD BEARING
(a) Install the connecting rod bearing to the connecting
rod and bearing cap.
(b) Using a vernier caliper, measure the distance
between the connecting rod's and bearing cap's
edges, and each connecting rod bearing's edge.
Dimension (A - B):
0.7 mm (0.028 in.) or less
NOTICE:
Do not apply engine oil to the bearing's contact
area and underside.
8. INSTALL PISTON SUB-ASSEMBLY WITH
CONNECTING ROD
(a) Apply engine oil to the cylinder walls, the pistons,
and the surfaces of the connecting rod bearings.
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(b) Position the piston rings so that the ring ends are as
shown in the illustration.
NOTICE:
Do not align the ring ends.
(c) Using a piston ring compressor, push the correctly
numbered piston and connecting rod into the
cylinder with the front mark of the piston facing
forward.
NOTICE:
Match the numbered connecting rod cap with
the connecting rod.
(d) Check that the front mark of the connecting rod cap
is facing forward.
(e) Apply a light coat of engine oil to the threads and
under the heads of the connecting rod cap bolts.
(f) Install the connecting cap bolts.
HINT:
The connecting cap bolts are tightened in 2
progressive steps.
(g) Step 1
(1) Install and alternately tighten the bolts of the
connecting rod cap in several steps.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
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(h) Step 2
(1) Mark the front side of each connecting cap bolt
with paint.
(2) Tighten the cap bolts another 90
as shown in
the illustration in the order in step 1.
(3) Check that the painted mark is now at a 90

angle to the front.
(i) Check that the crankshaft turns smoothly.
9. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the crankshaft position sensor with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
10. INSTALL NO. 2 STRAIGHT SCREW PLUG
(a) Using a 14 mm hexagon wrench, install 2 new
gaskets and the 2 straight screw plugs.
Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf)
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11. INSTALL NO. 1 STRAIGHT SCREW PLUG
(a) Using a 10 mm hexagon wrench, install 4 new
gaskets and the straight screw plugs.
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
12. INSTALL VALVE SPRING SEAT
(a) Install the valve spring seats to the cylinder head.
13. INSTALL INTAKE VALVE STEM OIL SEAL
(a) Apply a light coat of engine oil to new oil seals.
NOTICE:
Pay attention when installing the intake and
exhaust oil seals. For example, installing the
intake oil seal into the exhaust side or installing
the exhaust oil seal to the intake side can cause
installation problems later.
HINT:
The intake valve oil seals are white and the exhaust
valve oil seals are black.
(b) Using SST, push in the oil seals.
SST 09201-41020
NOTICE:
Failure to use SST will cause the seal to be
damaged or improperly seated.
14. INSTALL INTAKE VALVE
(a) Apply plenty of engine oil to the tip area of the intake
valve shown in the illustration.
(b) Install the valve, compression spring and spring
retainer to the cylinder head.
NOTICE:
Install the same parts in the same combination
to original locations.
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(c) Using SST and wooden blocks, compress the
spring and install the retainer lock.
SST 09202-70020 (09202-00010)
(d) Using a plastic-faced hammer, lightly tap the valve
stem tip to ensure a proper fit.
NOTICE:
Be careful not to damage the retainer.
15. INSTALL EXHAUST VALVE
(a) Apply plenty of engine oil to the tip area of the
exhaust valve shown in the illustration.
(b) Install the valve, compression spring and spring
retainer to the cylinder head.
NOTICE:
Install the same parts in the same combination
to their original locations.
(c) Using SST and wooden blocks, compress the
spring and install the retainer lock.
SST 09202-70020 (09202-00010)
(d) Using a plastic-faced hammer, lightly tap the valve
stem tip to ensure a proper fit.
NOTICE:
Be careful not to damage the retainer.
16. INSTALL VALVE STEM CAP
(a) Apply a light coat of engine oil to the valve stem
caps.
(b) Install the valve stem caps to the cylinder head.
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17. INSTALL WATER INLET PIPE
(a) Install the water inlet pipe with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(b) Install the water by-pass hose.
18. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for
Bank 1)
(a) Check the piston protrusions for each cylinder.
(1) Clean the cylinder block with solvent.
(2) Set the piston of the cylinder to be measured to
slightly before TDC.
(b) Place the cylinder head gasket on the cylinder block
surface with the front face of the Lot No. stamp
upward.
NOTICE:
• Be careful of the installation direction.
• Gently place the cylinder head in order not to
damage the gasket with the bottom part of the
head.
(c) Place the cylinder head on the cylinder block.
NOTICE:
Ensure that no oil is on the mounting surface of
the cylinder head.
HINT:
The cylinder head bolts are tightened in 3
progressive steps.
(d) Apply a light coat of engine oil to the threads and
under the heads of the cylinder head bolts.
(e) Step 1
(1) Using a 10 mm bi-hexagon wrench, install and
uniformly tighten the 8 cylinder head bolts with
the plate washers in several steps, in the
sequence shown in the illustration.
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
(f) Step 2
(1) Mark the cylinder head bolt head with paint as
shown in the illustration.
(2) Tighten the cylinder heads bolts another 90
in
the sequence shown in step 1.
(g) Step 3
(1) Tighten the cylinder head bolts by an additional
90
in the sequence shown in step 1.
(2) Check that the painted mark is now facing
rearward.
19. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for
Bank 2)
(a) Check the piston protrusions for each cylinder.
(1) Clean the cylinder block with solvent.
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(2) Set the piston of the cylinder to be measured to
slightly before TDC.
(b) Place the cylinder head gasket on the cylinder block
surface with the front face of the Lot No. stamp
upward.
NOTICE:
• Be careful of the installation direction.
• Gently place the cylinder head in order not to
dama ge the gaske t wi th t he b ottom part of t he
head.
(c) Place the cylinder head on the cylinder block.
NOTICE:
Ensure that no oil is on the mounting surface of
the cylinder head.
HINT:
The cylinder head bolts are tightened in 3
progressive steps.
(d) Apply a light coat of engine oil to the threads and
under the heads of the cylinder head bolts.
(e) Step 1
(1) Using a 10 mm bi-hexagon wrench, install and
uniformly tighten the 8 cylinder head bolts with
the plate washers in several steps, in the
sequence shown in the illustration.
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
(f) Step 2
(1) Mark the cylinder head bolt heads with paint as
shown in the illustration.
(2) Tighten the cylinder head bolts another 90
in
the sequence shown in step 1.
(g) Step 3
(1) Tighten the cylinder head bolts by an additional
90
in the sequence shown in step 1.
(2) Check that the painted mark is now facing
rearward.
(h) Install the 2 bolts in the order shown in the
illustration.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
20. INSTALL VALVE LASH ADJUSTER ASSEMBLY
(a) Be sure to inspect the valve lash adjuster before
installing it (see page EM-75).
(b) Install the lash adjusters.
NOTICE:
Install the lash adjuster at the same place it was
removed from.
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21. INSTALL NO. 1 VALVE ROCKER ARM SUB-
ASSEMBLY
(a) Apply engine oil to the lash adjuster tips and valve
stem cap ends.
(b) Make sure that the valve rocker arms are installed
as shown in the illustration.
22. INSTALL CAMSHAFT BEARING CAP (for Bank 1)
(a) Apply engine oil to the camshaft journals, camshaft
housings and bearing caps.
(b) Install the No. 1 camshaft and No. 2 camshaft to the
camshaft housing.
(c) Confirm the marks and numbers on the camshaft
bearing caps and place them each in their proper
position and direction.
(d) Temporarily install the 8 bolts in the order shown in
the illustration.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
23. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for
Bank 1)
(a) Apply seal packing in a continuous line as shown in
the illustration.
Seal packing:
Toyota Genuine Seal Packing Block, Three
Bond 1207B or Equivalent
Standard seal diameter:
3.5 to 4.5 mm (0.138 to 0.177 in.)
NOTICE:
• Remove any oil from the contact surface.
• Install the camshaft housing within 3 minutes
and tighten the bolts within 15 minutes after
applying seal packing.
• Do not start the engine for at least 2 hours
after the installation.
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