engine TOYOTA RAV4 2006 Service Repair Manual

2GR-FE COOLING – COOLING FAN SYSTEMCO–7
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(c) Check that the cooling fan rotates.
If it does not, check the engine coolant temperature
sensor, cooling fan, harness or connector.
A132415

2GR-FE COOLING – WATER PUMPCO–15
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(b) Install the water inlet with the 2 bolts and nut.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
NOTICE:
Be careful not to allow the O-ring to get caught
between the parts.
(c) Connect the water hose.
7. INSTALL FRONT NO. 1 ENGINE MOUNTING
BRACKET LH
(a) Install the front No. 1 engine mounting bracket LH
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 installation.
8. INSTALL ENGINE ASSEMBLY
(a) Install the engine (see page EM-31).
A132442
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2GR-FE COOLING – THERMOSTATCO–19
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REMOVAL
1. REMOVE FRONT WHEEL RH
2. REMOVE NO. 1 ENGINE UNDER COVER (See page
EM-21)
3. REMOVE ENGINE UNDER COVER REAR RH (See
page EM-21)
4. REMOVE FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-7)
5. DRAIN ENGINE COOLANT (See page CO-8)
6. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page EM-21)
7. REMOVE RADIATOR SUPPORT OPENING COVER
(See page EM-22)
8. REMOVE RADIATOR RESERVOIR TANK
(a) Remove the 2 bolts and radiator reservoir.
9. REMOVE FAN AND GENERATOR V BELT (See page
EM-8)
10. REMOVE ENGINE MOUNTING INSULATOR RH
(a) Remove the 5 bolts, 2 nuts and engine mounting
insulator RH.
11. REMOVE FRONT NO. 1 ENGINE MOUNTING
BRACKET LH (See page CO-12)
12. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the bolt, No. 2 idler pulley cover plate and
No. 2 idler pulley.
13. DISCONNECT NO. 2 RADIATOR HOSE
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A136837
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2GR-FE COOLING – THERMOSTATCO–21
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INSTALLATION
1. INSTALL THERMOSTAT
(a) Install a new gasket to the thermostat.
(b) Install the thermostat with the jiggle valve facing
upward.
HINT:
The jiggle valve can be set to within 10
of either
side of the upward position.
2. INSTALL WATER INLET
(a) Install the water inlet with the 2 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
3. CONNECT NO. 2 RADIATOR HOSE
4. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the No. 2 idler pulley cover plate and No. 2
idler pulley with the bolt.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
5. INSTALL FRONT NO. 1 ENGINE MOUNTING
BRACKET LH (See page CO-15)
6. INSTALL ENGINE MOUNTING INSULATOR RH
(a) Install the engine mounting insulator RH with the 2
nuts and 5 bolts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) for bolt
95 N*m (969 kgf*cm, 70 ft.*lbf) for nut A
52 N*m (530 kgf*cm, 38 ft.*lbf) for nut B
7. INSTALL FAN AND GENERATOR V BELT (See page
EM-8)
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CO–222GR-FE COOLING – THERMOSTAT
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8. INSTALL RADIATOR RESERVOIR TANK
(a) Install the radiator reservoir with the 2 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
9. INSTALL RADIATOR SUPPORT OPENING COVER
(See page EM-42)
10. INSTALL V-BANK COVER SUB-ASSEMBLY (See
page EM-42)
11. ADD ENGINE COOLANT (See page CO-8)
12. CHECK FOR ENGINE COOLANT LEAKAGE (See
page CO-1)
13. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-9)
14. INSTALL ENGINE UNDER COVER REAR RH (See
page EM-41)
15. INSTALL NO. 1 ENGINE UNDER COVER (See page
EM-41)
16. INSTALL FRONT WHEEL RH
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CO–362GR-FE COOLING – RADIATOR
CO
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag activation.
2. REMOVE BATTERY CLAMP SUB-ASSEMBLY (See
page ST-6)
3. REMOVE BATTERY INSULATOR
4. REMOVE BATTERY
5. REMOVE NO. 1 ENGINE UNDER COVER (See page
EM-21)
6. DRAIN ENGINE COOLANT (See page CO-8)
7. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page EM-21)
8. REMOVE RADIATOR SUPPORT OPENING COVER
(See page EM-22)
9. REMOVE RADIATOR GRILLE SUB-ASSEMBLY (See
page ET-6)
10. DISCONNECT HOOD LOCK SWITCH CONNECTOR
11. DISCONNECT NO. 1 WATER BY-PASS HOSE
(a) Disconnect the hose from the radiator reservoir.
12. DISCONNECT NO. 5 WATER BY-PASS HOSE
(a) Disconnect the hose from the radiator.
13. REMOVE NO. 1 WATER BY-PASS PIPE
(a) Disconnect the pipe from the No. 1 radiator hose.
A112308

2GR-FE COOLING – RADIATORCO–43
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15. CONNECT NO. 5 WATER BY-PASS HOSE
(a) Connect the by-pass hose to the radiator.
16. CONNECT NO. 1 WATER BY-PASS HOSE
(a) Connect the by-pass hose to the radiator reservoir.
17. CONNECT HOOD LOCK SWITCH CONNECTOR
18. INSTALL RADIATOR GRILLE SUB-ASSEMBLY (See
page ET-10)
19. INSTALL BATTERY
20. INSTALL BATTERY INSULATOR
21. INSTALL BATTERY CLAMP SUB-ASSEMBLY (See
page ST-15)
22. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
23. INSTALL RADIATOR SUPPORT OPENING COVER
(See page EM-42)
24. INSTALL V-BANK COVER SUB-ASSEMBLY (See
page EM-42)
25. ADD ENGINE COOLANT (See page CO-8)
26. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
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A112308

CO–442GR-FE COOLING – RADIATOR
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27. INSTALL NO. 1 ENGINE UNDER COVER (See page
EM-41)

2AZ-FE LUBRICATION – OIL PUMPLU–15
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REASSEMBLY
1. INSTALL OIL PUMP ROTOR
(a) Coat the drive rotor and driven rotor with engine oil.
(b) Place the drive and driven rotors into the oil pump
with the marks facing the pump cover side.
2. INSTALL OIL PUMP COVER
(a) Install the oil pump cover with the 5 bolts.
Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf)
3. INSTALL OIL PUMP RELIEF VALVE
(a) Coat the relief valve with engine oil.
(b) Insert the relief valve and spring into the pump body
hole.
(c) Using a 27 mm socket wrench, install the plug.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
4. INSTALL OIL PUMP STRAINER
(a) Install a new gasket and the oil strainer with the 2
nuts.
Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf)
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LU–162GR-FE LUBRICATION – OIL PUMP
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INSPECTION
1. INSPECT OIL PUMP RELIEF VALVE
(a) Coat the relief valve with engine oil and drop it into
the relief valve hole.
(b) Check that the relief valve falls in smoothly by its
own weight.
If it does not, replace the relief valve. If necessary,
replace the timing chain cover.
2. INSPECT OIL PUMP ROTOR SET
(a) Install the drive and driven rotors into the timing
chain cover with the rotors' marks facing the
cylinder block side. Check that the rotors revolve
smoothly.
(b) Check the tip clearance.
(1) Using a feeler gauge, measure the clearance
between the drive rotor and driven rotor tips.
Standard tip clearance:
0.060 to 0.160 mm (0.0024 to 0.0063 in.)
Maximum tip clearance:
0.16 mm (0.0063 in.)
If the tip clearance is greater than the
maximum, replace the timing chain cover.
(c) Check the body clearance.
(1) Using a feeler gauge, measure the clearance
between the timing chain cover and driven
rotor.
Standard body clearance:
0.250 to 0.325 mm (0.0098 to 0.0128 in.)
Maximum body clearance:
0.325 mm (0.0128 in.)
If the body clearance is greater than the
maximum, replace the timing chain cover.
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