check oil TOYOTA RAV4 2006 Service Service Manual

EM–642GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
51. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance
while moving the connecting rod back and forth.
Standard thrust clearance:
0.15 to 0.40 mm (0.0059 to 0.0157 in.)
Maximum thrust clearance:
0.50 mm (0.0197 in.)
If the thrust clearance is greater than the maximum,
replace one or more connecting rods as necessary.
If necessary, replace the crankshaft.
52. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check that the front mark on the connecting rod and
cap are aligned to ensure the correct reassembly.
NOTICE:
The front mark on the connecting rods and caps
are for ensuring the correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(c) Using the 2 removed connecting rod cap bolts,
remove the connecting rod cap and lower bearing
by wiggling the connecting rod cap right and left.
HINT:
Keep the lower bearing inserted to the connecting
rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and
scratches.
(f) Lay a strip of Plastigage on the crank pin.
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EM–682GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(c) Using a screwdriver, pry out the main bearing caps.
Remove the 4 main bearing caps and lower
bearings.
NOTICE:
• Pry up the main cap little by little to the right
and left in turns.
• Be careful not to damage the joint surface of
the cylinder block and main bearing caps.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
HINT:
If the journal or bearing is damaged, replace the
bearing.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Examine the front marks and numbers and install
the bearing caps on the cylinder block.
HINT:
A number is marked on each main bearing cap to
indicate the installation position.
(i) Apply a light coat of engine oil on the threads and
under the heads of the bearing cap bolts.
(j) Place the crankshaft bearing cap on the cylinder
block.
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(v) Remove the upper bearings and upper thrust
washers from the cylinder block.
HINT:
Arrange the bearings and thrust washers in the
correct order.
57. REMOVE CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSEMBLY
(a) Remove the 2 water drain cocks from the cylinder
block.
(b) Remove the water drain cock plugs from the water
drain cocks.
58. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, remove the 3 oil
nozzles.
(b) Check the oil nozzles for damage or clogging.
If necessary, replace the oil nozzle.
59. REMOVE PISTON RING SET
HINT:
Arrange the piston rings in the correct order.
(a) Using a piston ring expander, remove the 2
compression rings.
(b) Using a piston ring expander, remove the 2 side
rails.
(c) Remove the oil ring expander by hand.
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EM–762GR-FE ENGINE MECHANICAL – ENGINE UNIT
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INSPECTION
1. INSPECT VALVE LASH ADJUSTER ASSEMBLY
NOTICE:
• Keep the lash adjuster free from dirt and foreign
objects.
• Only use clean engine oil.
(a) Place the lash adjuster into a container full of engine
oil.
(b) Insert the SST's tip into the lash adjuster's plunger
and use the tip to press down on the checkball
inside the plunger.
SST 09276-75010
(c) Squeeze the SST and lash adjuster together to
move the plunger up and down 5 to 6 times.
(d) Check the movement of the plunger and bleed the
air.
OK:
Plunger moves up and down.
NOTICE:
When bleeding high-pressure air from the
compression chamber, make sure that the tip of
the SST is actually pressing the checkball as
shown in the illustration. If the checkball is not
pressed, air will not bleed.
(e) After bleeding the air, remove SST. Then try to
quickly and firmly press the plunger with a finger.
OK:
Plunger is very difficult to move.
If the result is not as specified, replace the lash
adjuster.
2. INSPECT CAMSHAFT
(a) Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout
at the center journal.
Maximum circle runout:
0.04 mm (0.0016 in.)
If the circle runout is greater than the
maximum, replace the camshaft.
HINT:
Check the oil clearance after replacing the
camshaft.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–77
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(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height
Maximum cam lobe height
If the cam lobe height is less than the minimum,
replace the camshaft.
(c) Using a micrometer, measure the journal diameter.
Standard journal diameter
If the journal diameter is not as specified, check the
oil clearance.
3. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Clamp the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft in the
vise.
(b) Put the camshaft timing gear and camshaft together
by aligning the key groove and straight pin.
(c) Lightly press the gear against the camshaft, and
turn the gear. Push further at the position where the
pin enters the groove.
NOTICE:
Be sure not to turn the camshaft timing gear in
the retard direction (the right angle).
(d) Check that there is no clearance between the gear's
fringe and the camshaft.
(e) Tighten the flange bolt with the camshaft timing gear
fixed in place.
Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
(f) Check the lock of the camshaft timing gear.
(1) Clamp the camshaft in a vise, and confirm that
the camshaft timing gear is locked.
NOTICE:
Be careful not to damage the camshaft.
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Item Specified Condition
Intake 44.316 to 44.416 mm (1.7447 to 1.7487 in.)
Exhaust 44.262 to 44.362 mm (1.7426 to 1.7465 in.)
Item Specified Condition
Intake 44.166 mm (1.7388 in.)
Exhaust 44.112 mm (1.7367 in.)
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Item Specified Condition
No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journal 25.959 to 25.975 mm (1.0220 to 1.0226 in.)
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EM–782GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(g) Release the lock pin.
(1) Cover the 4 oil paths of the cam journal with
vinyl tape as shown in the illustration.
HINT:
2 advance side paths are provided in the
groove of the camshaft. Plug one of the paths
with a rubber piece.
(2) Break through the tape of the advance side
path and the retard side path on the opposite
side to the hole of the advance side path, as
shown in the illustration.
(3) Apply approximately 200 kPa (2.0 kgf/cm
2, 28
psi) of air pressure to the two broken paths.
CAUTION:
Cover the paths with a piece of cloth when
applying pressure to keep oil from
splashing.
(4) Check that the camshaft timing gear revolves in
the advance direction when reducing the air
pressure applied to the retard side path.
HINT:
This operation releases the lock pin for the
most retarded position.
(5) When the camshaft timing gear reaches the
most advanced position, release the air
pressure from the retard side path and advance
side path, in that order.
NOTICE:
Do not release the air pressure from the
advance side path first. The gear may
abruptly shift in the retard direction and
break the lock pin.
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(b) Using a caliper gauge, measure the inside diameter
of the idle gear.
Standard idle gear inside diameter:
23.02 to 23.03 mm (0.9062 to 0.9067 in.)
(c) Subtract the idle gear shaft diameter measurement
from the idle gear inside diameter measurement.
Standard oil clearance:
0.02 to 0.043 mm (0.0001 to 0.0017 in.)
Maximum oil clearance:
0.043 mm (0.0017 in.)
If the thrust oil clearance is greater than the
maximum, replace the idle gear shaft and idle gear.
11. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Move the stopper plate upward to release the lock.
Push the plunger and check that it moves smoothly.
If necessary, replace the chain tensioner.
12. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Check that the plunger moves smoothly.
(b) Measure the worn depth of the chain tensioner.
Maximum depth:
0.9 mm (0.035 in.)
If the depth is greater than the maximum, replace
the chain tensioner.
13. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Check that the plunger moves smoothly.
(b) Measure the worn depth of the chain tensioner.
Maximum depth:
0.9 mm (0.035 in.)
If the depth is greater than the maximum, replace
the chain tensioner.
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EM–902GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(l) Measure the Plastigage at its widest point.
Standard oil clearance
Maximum oil clearance
If the oil clearance is greater than the maximum,
replace the camshaft. If necessary, replace the
camshaft housing.
26. INSPECT CYLINDER BLOCK FOR WARPAGE
(a) Using a precision straightedge and feeler gauge,
measure the warpage of the contact surface of the
cylinder head gasket.
Maximum warpage:
0.07 mm (0.0028 in.)
If the warpage is greater than the maximum, replace
the cylinder block.
(b) Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all 6 cylinders.
If necessary, replace the cylinder block.
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Item Specified Condition
No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journal 0.025 to 0.062 mm (0.0010 to 0.0024 in.)
Item Specified Condition
No. 1 journal 0.10 mm (0.0039 in.)
Other journal 0.09 mm (0.0035 in.)
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–93
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32. INSPECT PISTON PIN OIL CLEARANCE
(a) Check each mark on the piston, piston pin and
connecting rod.
(b) Using a caliper gauge, measure the inside diameter
of the piston pin hole.
Standard piston pin hole inside diameter
(c) Using a micrometer, measure the piston pin
diameter.
Standard piston pin diameter
(d) Subtract the piston pin diameter measurement from
the piston pin hole diameter measurement.
Standard oil clearance:
0.001 to 0.007 mm (0.00004 to 0.0003 in.)
Maximum oil clearance:
0.015 mm (0.0006 in.)
HINT:
If the oil clearance is greater than the maximum,
replace the piston and piston pin as a set.
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Mark Specified Condition
A 22.001 to 22.004 mm (0.8662 to 0.8663 in.)
B 22.005 to 22.007 mm (0.8663 to 0.8664 in.)
C 22.008 to 22.010 mm (0.8665 to 0.8665 in.)
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Mark Specified Condition
A 21.997 to 22.000 mm (0.8660 to 0.8661 in.)
B 22.001 to 22.003 mm (0.8662 to 0.8663 in.)
C 22.004 to 22.006 mm (0.8663 to 0.8664 in.)

EM–942GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(e) Using a caliper gauge, measure the inside diameter
of the connecting rod bush.
Standard bush inside diameter
(f) Subtract the piston pin diameter measurement from
the bush inside diameter measurement.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance:
0.03 mm (0.0012 in.)
HINT:
If the oil clearance is greater than the maximum,
replace the bush. If necessary, replace the
connecting rod and piston pin as a set.
33. INSPECT CONNECTING ROD SUB-ASSEMBLY
(a) Using a rod aligner and feeler gauge, check the
connecting rod alignment.
(1) Check for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If the bend is greater than the maximum,
replace the connecting rod.
(2) Check for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than the maximum,
replace the connecting rod.
34. INSPECT CONNECTING ROD BOLT
(a) Using a vernier caliper, measure the tension portion
diameter of the bolt.
Standard diameter:
7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter:
7.0 mm (0.276 in.)
If the diameter is less than the minimum, replace the
bolt.
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Mark Specified Condition
A 22.005 to 22.008 mm (0.8663 to 0.8665 in.)
B 22.009 to 22.011 mm (0.8665 to 0.8666 in.)
C 22.012 to 22.014 mm (0.8666 to 0.8667 in.)
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