engine TOYOTA RAV4 2006 Service Repair Manual

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–119
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(b) Install the camshaft housing, and install the 12 bolts
in the order shown in the illustration.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
NOTICE:
Make sure that the knock pin of the camshaft is
positioned as shown in the illustration before
installing the camshaft housing.
(c) Tighten the 8 bolts in the order shown in the
illustration.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
NOTICE:
Thoroughly wipe clean any seal packing.
(d) Install 3 new gaskets.
24. INSTALL CAMSHAFT BEARING CAP (for Bank 2)
(a) Apply engine oil to the camshaft journals, camshaft
housings and bearing caps.
(b) Install the camshaft No. 3 and camshaft No. 4 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.
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(d) Temporarily install the 8 bolts in the order shown in
the illustration.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for
Bank 2)
(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.
(b) Install the camshaft housing and tighten the 13 bolts
in the order shown in the illustration.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
NOTICE:
Make sure that the knock pin of the camshaft is
positioned as shown in the illustration before
installing the camshaft housing.
(c) Tighten the 8 bolts in the order shown in the
illustration.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
NOTICE:
Thoroughly wipe clean any seal packing.
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(d) Install 3 new gaskets.
26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Install the chain tensioner with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(b) While pushing in the tensioner, insert a pin of
1.0
mm (0.039 in.) into the hole to fix it in place.
27. INSTALL CAMSHAFT TIMING GEARS AND NO. 2
CHAIN (for Bank 1)
(a) Align the mark plate (yellow) with the timing marks
(1 dot mark) of the camshaft timing gears as shown
in the illustration.
(b) Apply a small amount of engine oil to the bolt
threads and bolt-seating surface.
(c) Align the knock pin of the camshaft with the pin hole
of the camshaft timing gear. Install the camshaft
timing gear and camshaft timing exhaust gear with
the No. 2 chain installed.
(d) Hold the hexagonal portion of the camshaft with a
wrench, and tighten the 2 bolts.
Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
(e) Remove the pin from the No. 2 chain tensioner.
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28. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Install the chain tensioner with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(b) While pushing in the tensioner, insert a pin of
1.0
mm (0.039 in.) into the hole to fix it in place.
29. INSTALL CAMSHAFT TIMING GEARS AND NO. 2
CHAIN (for Bank 2)
(a) Align the mark plate (yellow) with the timing marks
(2 dot mark) of the camshaft timing gears as shown
in the illustration.
(b) Apply a small amount of engine oil to the bolt
threads and bolt-seating surface.
(c) Align the knock pin of the camshaft with the pin hole
of the camshaft timing gear. Install the camshaft
timing gear and camshaft timing exhaust gear with
the No. 2 chain installed.
(d) Hold the hexagonal portion of the camshaft with a
wrench, and tighten the 2 bolts.
Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
(e) Remove the pin from the No. 2 chain tensioner.
30. INSTALL CRANKSHAFT TIMING GEAR OR
SPROCKET
(a) Install the timing gear set keys and timing gear as
shown in the illustration.
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31. INSTALL NO. 1 CHAIN VIBRATION DAMPER
(a) Install the chain vibration damper with the 2 bolts.
Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf)
32. INSTALL NO. 2 CHAIN VIBRATION DAMPER
(a) Install the 2 chain vibration damper.
33. INSTALL IDLE SPROCKET ASSEMBLY
(a) Apply a light coat of engine oil to the rotating surface
of the No. 1 idle gear shaft.
(b) Temporarily install the No. 1 idle gear shaft and idle
sprocket with the No. 2 idle gear shaft while aligning
the knock pin of the No. 1 idle gear shaft with the
knock pin groove of the cylinder block.
NOTICE:
Be careful of the idle gear direction.
(c) Using a 10 mm hexagon wrench, tighten the No. 2
idle gear shaft.
Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
34. INSTALL CHAIN SUB-ASSEMBLY
(a) Align the mark plate and timing mark as shown in
the illustration and install the chain.
NOTICE:
Do not pass the chain over the crankshaft, just
put it on it.
HINT:
The chain mark plate is orange.
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(b) Turn the camshaft timing gear on the bank 1
counterclockwise to tighten the chain between the
banks.
NOTICE:
If reusing the idle sprocket, align one of the idle
sprocket's chain plate marks with one of the
chain's chain plates when installing the idle
sprocket.
(c) Align the mark plate and timing mark as shown in
the illustration and install the chain onto the
crankshaft timing gear.
HINT:
The chain mark plate is yellow.
(d) Temporarily tighten the pulley set bolt.
(e) Turn the crankshaft clockwise to set it to the bank 1
block bore center line (TDC / compression).
35. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper.
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36. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Move the stopper plate upward to release the lock,
and push the plunger deep into the tensioner.
(b) Move the stopper plate downward to set the lock,
and insert a hexagon wrench into the hole of the
stopper plate.
(c) Install the chain tensioner with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
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(d) Remove the lock pin of the chain tensioner. Check
that each timing mark is aligned with the crankshaft
at the TDC / compression.
(e) Remove the pulley set bolt.
37. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (w/
Oil Pump) (See page LU-17)
38. INSTALL WATER PUMP ASSEMBLY (See page CO-
13)
39. INSTALL ENGINE REAR OIL SEAL RETAINER
(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:
2.0 to 3.0 mm (0.079 to 0.118 in.)
NOTICE:
• Remove any oil from the contact surface.
• Install the crankcase within 3 minutes after
applying seal packing.
• Do not start the engine for at least 2 hours
after the installation.
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(b) Install the oil seal retainer with the 6 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
NOTICE:
Apply adhesive 1324 to the 2 bolts labeled A.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond
1324 or Equivalent
40. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the
pulley, and slide on the pulley.
(b) Using SST, install the pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021
Torque: 250 N*m (2,549 kgf*cm, 184 ft.*lbf)
41. INSTALL OIL PAN BAFFLE PLATE
(a) Install the oil pan baffle plate with the 7 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
42. INSTALL OIL PAN SUB-ASSEMBLY (See page LU-21)
43. INSTALL OIL STRAINER SUB-ASSEMBLY (See page
LU-22)
44. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY (See page
LU-22)
45. INSTALL OIL FILTER ELEMENT (See page LU-5)
46. INSTALL OIL FILTER CAP SUB-ASSEMBLY (See
page LU-5)
47. INSTALL WATER INLET HOUSING (See page CO-14)
48. INSTALL FRONT NO. 1 ENGINE MOUNTING
BRACKET
(a) Install the engine mounting bracket with the 6 bolts.
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
NOTICE:
• Install the water inlet and mounting bracket
within 15 minutes after installing the chain
cover.
• Do not start the engine for at least 2 hours
after the installation.
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49. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 1)
(a) Apply seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Block, Three
Bond 1207B or Equivalent
NOTICE:
• Remove any oil from the contact surface.
• Install the crankcase within 3 minutes after
applying seal packing.
• Do not start the engine for at least 2 hours
after the installation.
(b) Install the gasket to the head cover.
(c) Install the head cover with the 12 bolts in the order
shown in the illustration.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A
10 N*m (102 kgf*cm, 7 ft.*lbf) for except
bolt A
HINT:
Make sure the tightening torque of bolt 1and 11 in
correct.
50. INSTALL OIL PIPE
(a) Make sure that there is no foreign matter on the
mesh of the oil control valve filter.
(b) Install the oil control valve filter to the oil pipe union.
Install 2 new gaskets and temporarily install the oil
pipe (on the head cover side) with the oil pipe union.
NOTICE:
Remove any oil from the contact surface.
(c) Install a new gasket and temporarily install the oil
pipe (on the cylinder head side) with the oil pipe
union.
NOTICE:
Remove any oil from the contact surface.
(d) Install bolt A to the cylinder head.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(e) Tighten the 2 oil pipe union bolts.
Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
51. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 2)
(a) Apply seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Block, Three
Bond 1207B or Equivalent
NOTICE:
• Remove any oil from the contact surface.
• Install the crankcase within 3 minutes after
applying seal packing.
• Do not start the engine for at least 2 hours
after the installation.
(b) Install the gasket to the head cover.
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