belt TOYOTA RAV4 2006 Service Service Manual

2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–85
EM
(c) Examine the front marks and numbers, and check
that the order is as shown in the illustration. Then
install the bearing caps onto the cylinder head.
(d) Apply a light coat of engine oil to the threads and
under the heads of the bearing cap bolts.
(e) Using several steps, uniformly tighten the 20
bearing cap bolts in the sequence shown in the
illustration.
Torque: 29.5 N*m (301 kgf*cm, 22 ft.*lbf) for No.
1 and No. 2 bearing cap
9.0 N*m (92 kgf*cm, 80 in.*lbf) for No. 3
bearing cap
NOTICE:
Install the camshaft with the timing mark of the
camshaft timing gear on top.
6. INSTALL NO. 1 CHAIN VIBRATION DAMPER (See
page EM-33)
7. INSTALL CHAIN SUB-ASSEMBLY (See page EM-33)
8. INSTALL CHAIN TENSIONER SLIPPER (See page
EM-34)
9. INSTALL TIMING CHAIN GUIDE (See page EM-34)
10. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR
PLATE (See page EM-35)
11. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(See page EM-35)
12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (See
page EM-37)
13. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(See page EM-38)
14. INSTALL ENGINE MOUNTING BRACKET RH (See
page EM-38)
15. INSTALL CRANKSHAFT PULLEY (See page EM-38)
16. INSTALL OIL PAN SUB-ASSEMBLY (See page EM-39)
17. INSTALL CRANKSHAFT POSITION SENSOR (See
page ES-402)
18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(See page EM-40)
19. INSTALL SPARK PLUG (See page EM-16)
20. INSTALL IGNITION COIL ASSEMBLY (See page IG-9)
21. INSTALL IDLER PULLEY (See page EM-41)
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EM–862AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
EM
22. INSTALL ENGINE MOUNTING INSULATOR RH (See
page EM-41)
23. INSTALL RADIATOR RESERVOIR (See page EM-112)
24. INSTALL GENERATOR ASSEMBLY (See page CH-15)
25. INSTALL FAN AND GENERATOR V BELT (See page
EM-7)
26. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-7)
27. CONNECT ENGINE WIRE
(a) Connect the ground cable with the bolt.
Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
(b) Connect the camshaft position sensor connector.
(c) Connect the engine coolant temperature sensor
connector.
(d) Connect the engine oil pressure switch connector.
(e) Connect the radio setting condenser connector.
(f) Connect the heater water inlet hose.
28. CONNECT NO. 1 RADIATOR HOSE
(a) Connect the hose to the cylinder head.
29. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
ASSEMBLY (See page ES-396)
30. INSTALL EXHAUST MANIFOLD CONVERTER SUB-
ASSEMBLY
(a) Install a new gasket onto the cylinder head.
(b) Temporarily tighten the exhaust manifold converter
with the 5 nuts.
(c) Tighten the 5 nuts in the sequence shown in the
illustration.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
(d) Connect the air-fuel ratio sensor connector.
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EM–982AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE (See page
FU-9)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
3. REMOVE HOOD SUB-ASSEMBLY (See page ED-4)
4. REMOVE RADIATOR SUPPORT OPENING COVER
5. REMOVE BATTERY CLAMP SUB-ASSEMBLY
(a) Loosen the bolt and nut, and remove the battery
clamp.
6. REMOVE BATTERY
7. REMOVE BATTERY TRAY
8. REMOVE FRONT WHEEL
9. REMOVE NO. 1 ENGINE UNDER COVER
10. REMOVE NO. 2 ENGINE UNDER COVER
11. REMOVE FRONT FENDER APRON RH
12. REMOVE NO. 1 ENGINE COVER (See page EM-22)
13. DRAIN ENGINE COOLANT (See page CO-6)
14. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Drain automatic transaxle fluid for U241E (2WD)
(see page AX-146).
(b) Drain automatic transaxle fluid for U140F (4WD)
(see page AX-147).
15. REMOVE RADIATOR ASSEMBLY
(a) Remove the radiator (see page CO-29).
16. REMOVE RADIATOR RESERVOIR
(a) Remove the 2 bolts and reservoir.
17. REMOVE PURGE VSV (See page EC-15)
18. REMOVE AIR CLEANER CAP (See page ES-411)
19. REMOVE AIR CLEANER FILTER ELEMENT SUB-
ASSEMBLY
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EM–1002AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
25. DISCONNECT HEATER WATER INLET HOSE
(a) Disconnect the heater water inlet hose from the
heater unit.
26. DISCONNECT HEATER WATER OUTLET HOSE
(a) Disconnect the heater water outlet hose from the
heater unit.
27. DISCONNECT FUEL TUBE (See page FU-10)
28. REMOVE THROTTLE BODY (See page ES-412)
29. DISCONNECT NO. 2 VENTILATION HOSE (See page
FU-10)
30. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
(See page FU-10)
31. REMOVE INTAKE MANIFOLD (See page ES-419)
32. REMOVE INTAKE MANIFOLD INSULATOR (See page
ES-420)
33. REMOVE TRANSAXLE CONTROL CABLE
ASSEMBLY
(a) Remove the transaxle control cable for U241E
(2WD) (see page AX-129).
(b) Remove the transaxle control cable for U140F
(4WD) (see page AX-129).
34. REMOVE FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-6)
35. REMOVE FAN AND GENERATOR V BELT (See page
EM-6)
36. REMOVE GENERATOR ASSEMBLY (See page CH-9)
37. REMOVE COOLER COMPRESSOR ASSEMBLY
(a) Remove the cooler compressor (see page AC-216).
HINT:
Disconnect the compressor together with the low-
pressure and high-pressure hoses, then secure it to
the vehicle side using rope.
38. REMOVE ECM (See page ES-429)
39. DISCONNECT ENGINE WIRE
(a) Remove the engine room relay block cover.
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2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–111
EM
(e) Connect the 2 engine wire connectors and install
the nut.
(f) Install the engine room relay block cover.
(g) Attach the clamp of the engine wire cover.
(h) Install the engine wire cover to with the bolt.
19. INSTALL ECM (See page ES-430)
20. INSTALL COOLER COMPRESSOR ASSEMBLY (See
page AC-217)
21. INSTALL GENERATOR ASSEMBLY (See page CH-15)
22. INSTALL FAN AND GENERATOR V BELT (See page
EM-7)
23. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-7)
24. INSTALL TRANSAXLE CONTROL CABLE
ASSEMBLY
(a) Install the transaxle control cable for U241E (see
page AX-130).
(b) Install the transaxle control cable for U140F (see
page AX-130).
25. INSTALL INTAKE MANIFOLD INSULATOR (See page
ES-421)
26. INSTALL INTAKE MANIFOLD (See page ES-421)
27. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
(See page FU-13)
28. CONNECT NO. 2 VENTILATION HOSE (See page FU-
14)
29. INSTALL THROTTLE BODY ASSEMBLY (See page
ES-413)
30. CONNECT FUEL TUBE (See page FU-14)
31. CONNECT HEATER WATER OUTLET HOSE
(a) Connect the heater water outlet hose to the air
conditioner tube.
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2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–123
EM
DISASSEMBLY
1. REMOVE IDLER PULLEY (See page EM-23)
2. REMOVE OIL DIPSTICK
3. REMOVE OIL DIPSTICK GUIDE (See page EM-57)
4. REMOVE MANIFOLD STAY (See page EM-57)
5. REMOVE NO. 2 MANIFOLD STAY (See page EM-58)
6. REMOVE NO. 1 EXHAUST MANIFOLD HEAT
INSULATOR (See page EM-58)
7. REMOVE EXHAUST MANIFOLD CONVERTER SUB-
ASSEMBLY (See page EM-58)
8. REMOVE WATER INLET (See page CO-15)
9. REMOVE THERMOSTAT
10. REMOVE NO. 1 WATER BY-PASS PIPE
(a) Remove the bolt, 2 nuts, pipe and gasket.
11. REMOVE NO. 3 WATER BY-PASS PIPE
(a) Remove the bolt, 2 nuts, pipe and gasket.
12. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(See page EM-26)
13. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
ASSEMBLY (See page ES-395)
14. REMOVE KNOCK SENSOR (See page ES-420)
15. REMOVE RADIO SETTING CONDENSER (See page
EM-63)
16. REMOVE OIL PRESSURE SWITCH ASSEMBLY (See
page EM-63)
17. REMOVE ENGINE COOLANT TEMPERATURE
SENSOR (See page EM-63)
18. REMOVE CAMSHAFT POSITION SENSOR (See page
EM-64)
19. REMOVE IGNITION COIL ASSEMBLY (See page IG-9)
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2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–145
EM
REPLACEMENT
1. REPLACE TIMING CHAIN COVER OIL SEAL
HINT:
There are 2 methods to replace the oil seal.
(a) If the timing chain cover is removed from the
cylinder block:
(1) Using a screwdriver and hammer, tap out the
oil seal.
(2) Apply multi-purpose grease to the lip of a new
oil seal.
NOTICE:
Keep the lip free of foreign objects.
(3) Using SST and a hammer, tap in the new oil
seal until its surface is flush with the timing
chain cover edge.
SST 09223-22010
NOTICE:
Do not tap the oil seal at an angle.
(b) If the timing chain cover oil seal is installed to the
cylinder block:
(1) Remove the fan and generator V belt (see page
EM-6).
(2) Remove the crankshaft pulley (see page EM-
25).
(3) Using a knife, cut off the lip of the oil seal.
(4) 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.
(5) Apply multi-purpose grease to the lip of a new
oil seal.
NOTICE:
Keep the lip free of foreign objects.
(6) Using SST and a hammer, tap in the new oil
seal until its surface is flush with the timing
chain cover edge.
SST 09223-22010
NOTICE:
Do not tap the oil seal at an angle.
(7) Install the crankshaft pulley (see page EM-38).
(8) Install the fan and generator V belt (see page
EM-7).
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2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–31
EM
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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A 70 mm (2.76 in.)

2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–33
EM
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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2AZ-FE FUEL – FUEL INJECTORFU–9
FU
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
• DISCHARGE FUEL SYSTEM PRESSURE
procedures must be performed before
disconnecting any part of the fuel system.
• After performing the DISCHARGE FUEL SYSTEM
PRESSURE procedures, pressure will remain in
the fuel line. When disconnecting the fuel line,
place a cloth or equivalent over fittings to reduce
the risk of fuel spray.
(a) Remove the console box (see page IR-83).
(b) Disconnect the connector.
(c) Start the engine. After the engine has stopped, turn
the ignition switch off.
HINT:
DTC P0171 (system too lean) may be set.
(d) Check that the engine does not start.
(e) Remove the fuel tank cap, and let the air out of the
fuel tank.
(f) Connect the connector.
(g) Install the console box (see page IR-90).
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
3. REMOVE NO. 1 ENGINE COVER (See page ES-410)
4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-411)
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