engine TOYOTA RAV4 2006 Service Repair Manual

2GR-FE LUBRICATION – OIL PUMPLU–17
LU
(d) Check the side clearance.
(1) Using a feeler gauge and precision
straightedge, measure the clearance between
the rotors and precision straightedge.
Standard side clearance:
0.030 to 0.090 mm (0.0012 to 0.0035 in.)
Maximum side clearance:
0.090 mm (0.0035 in.)
If the side clearance is greater than the
maximum, replace the timing chain cover.
REPLACEMENT
1. REPLACE TIMING CHAIN COVER OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
HINT:
Tape the screwdriver tip before use.
NOTICE:
Do not damage the surface of the oil seal press
fit hole.
(b) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the timing chain cover edge.
SST 09316-60011 (09316-00011)
NOTICE:
• Keep the lip free from foreign matter.
• Do not tap the oil seal at an angle.
• Make sure that the oil seal edge does not
stick out of the timing chain case.
(c) Apply MP grease to the lip of the oil seal.
REASSEMBLY
1. INSTALL OIL PUMP COVER
(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) Install the oil pump cover with the 8 bolts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
HINT:
Bolt length:
22 mm (0.87 in.) for bolt A
40 mm (1.58 in.) for bolt B
2. INSTALL OIL PUMP RELIEF VALVE
(a) Coat the oil pump relief valve with engine oil.
(b) Install the relief valve and relief valve spring into the
timing chain cover hole.
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2GR-FE LUBRICATION – OIL PUMPLU–19
LU
(c) Apply seal packing in a continuous bead to the
engine unit as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Block, Three
Bond 1207B or Equivalent.
Standard seal diameter:
3.0 mm (0.118 in.) or more
Standard length:
10 mm (0.394 in.)
NOTICE:
• Be sure to clean and degrease the contact
surfaces, especially the hatched areas in the
illustration.
• When the contact surfaces are wet, wipe them
off with an oil-free cloth before applying seal
packing.
• Install the timing chin cover 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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2GR-FE LUBRICATION – OIL PUMPLU–21
LU
Standard seal diameter
NOTICE:
• When the contact surfaces are wet, wipe them
off with an oil-free cloth before applying seal
packing.
• Install the timing chain cover 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.
(e) Temporarily install the timing chain cover with the 23
bolts and 2 nuts.
NOTICE:
Make sure there is no oil on the bolts. If there is
oil on the bolts, clean them before installing
them.
HINT:
Bolt length:
40 mm (1.57 in.) for bolt A
55 mm (2.17 in.) for bolt B
25 mm (0.98 in.) for bolt C
Position Specified Condition
A - A 6.0 mm (0.236 in.)
B - B 6.5 mm (0.256 in.)
Continuous line area 4.5 mm (0.138 in.) or more
Dashed line area 3.5 mm (0.138 in.) or more
Alternate long and short dashed line
area3.5 mm (0.138 in.) or more
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LU–222GR-FE LUBRICATION – OIL PUMP
LU
(f) Tighten the bolts in this order: Area 1, Area 2, Area
3, Area 4.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for Area
1, 2 bolt
21 N*m (214 kgf*cm, 15 ft.*lbf) for Area 3
bolt, nut
43 N*m (438 kgf*cm, 32 ft.*lbf) for Area 4
bolt A
21 N*m (214 kgf*cm, 15 ft.*lbf) for Area 4
except bolt A
2. INSTALL CRANKSHAFT PULLEY (See page EM-126)
3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 2) (See page EM-127)
4. INSTALL NO. 1 OIL PIPE (See page EM-128)
5. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 1) (See page EM-127)
6. INSTALL OIL PIPE (See page EM-127)
7. INSTALL WATER INLET HOUSING (See page CO-14)
8. INSTALL OIL PAN SUB-ASSEMBLY
(a) Install 2 new O-rings to the timing chain cover.
(b) Apply seal packing in a continuous line as shown in
the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three
Bond 1207B or Equivalent
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.156 in.)
NOTICE:
• Remove any oil from the contact surface.
• Install the oil pan 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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2GR-FE LUBRICATION – OIL PUMPLU–23
LU
(c) Install the oil pan with the 16 bolts and 2 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A
21 N*m (214 kgf*cm, 15 ft.*lbf) for
except bolt A, nut
9. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Install a new gasket and the oil strainer with the bolt
and 2 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
10. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
(a) Apply seal packing in a continuous line as shown in
the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three
Bond 1207B or Equivalent
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.156 in.)
NOTICE:
• Remove any oil from the contact surface.
• Install the oil pan within 3 minutes and tighten
the bolts within 10 minutes after applying seal
packing.
• Do not start the engine for at least 2 hours
after the installation.
(b) Install the oil pan with the 16 bolts and 2 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(c) Install a new gasket and the drain plug.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
11. INSTALL OIL FILTER ELEMENT KIT (See page LU-5)
12. INSTALL OIL FILTER CAP ASSEMBLY (See page LU-
5)
13. INSTALL OIL DIPSTICK GUIDE
(a) Install a new O-ring to the dipstick guide.
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LU–242GR-FE LUBRICATION – OIL PUMP
LU
(b) Install the dipstick guide with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
14. INSTALL NO. 2 OIL DIPSTICK GUIDE
(a) Install a new O-ring to the dipstick guide.
(b) Install the dipstick guide with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(c) Install the oil dipstick.
15. REMOVE ENGINE FROM STAND
16. INSTALL ENGINE ASSEMBLY
(a) Install the engine to the vehicle (see page EM-31).
17. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
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2AZ-FE IGNITION – IGNITION SYSTEMIG–5
IG
ON-VEHICLE INSPECTION
1. CHECK IGNITION COIL ASSEMBLY AND PERFORM
SPARK TEST
NOTICE:
In this section, the terms "cold" and "hot" refer to
the temperature of the coils. "Cold" means
approximately -10 to 50
C (14 to 122F). "Hot" means
approximately 50 to 100
C (122 to 212F).
(a) Check the DTCs.
NOTICE:
If a DTC is present, perform troubleshooting in
accordance with the procedure for that DTC.
(b) Check that sparks occur.
(1) Remove the No. 1 engine cover.
(2) Remove the bolt and ignition coil.
(3) Using a 16 mm spark plug wrench, remove the
spark plug.
(4) Disconnect the 4 fuel injector connectors.
(5) Install the spark plug into the ignition coil, and
then connect the ignition coil connectors.
(6) Ground the spark plug.
(7) Check that sparks occur at the spark plug while
the engine is being cranked.
NOTICE:
• Be sure to ground the spark plugs when
checking them.
• If the ignition coil has been struck or
dropped, replace it.
• Do not crank the engine for more than 2
seconds.
If sparks do not occur, Perform the spark test.
(8) Using a 16 mm plug wrench, install the spark
plug.
Torque: 25 N*m (254 kgf*cm, 18 ft.*lbf)
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IG–62AZ-FE IGNITION – IGNITION SYSTEM
IG
(9) Install the ignition coil with the bolt.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(10) Connect the 4 fuel injector connectors.
(11) Install the No. 1 engine cover.
(c) Spark test flow chart.
(1) Check that the ignition coil connector is
securely connected.
Result
(2) Perform the spark test on each ignition coil.
1. Replace the ignition coil with a normal one.
2. Perform the spark test again.
Result
(3) Check the power supply to the ignition coil.
1. Disconnect the ignition coil connector.
2. Turn the ignition switch ON.
3. Measure the voltage of the wire harness
side connector.
Standard voltage
Result
(4) Check the resistance of the camshaft position
sensor.
Standard resistance
Result
(5) Check the resistance of the crankshaft position
sensor.
Standard resistance
Result Proceed to
NG Connect securely
OK Go to next step
Result Proceed to
OK Replace ignition coil
NG Go to next step
A124397
Tester Connection Specified Condition
1 (+B) - 4 (GND) 9 to 14 V
Result Proceed to
NG Check wire harness and connector
OK Go to next step
Temperature Condition Specified Condition
Cold 835 to 1,400
Hot 1,060 to 1,645
Result Proceed to
NG Replace camshaft position sensor
OK Go to next step
Temperature Condition Specified Condition
Cold 985 to 1,600
Hot 1,265 to 1,890

2AZ-FE IGNITION – IGNITION SYSTEMIG–7
IG
Result
(6) Check the IGT signal from the ECM.
Result
2. CHECK SPARK PLUG
(a) Check the electrode.
(1) Using a megohmmeter, measure the insulation
resistance.
Standard insulation resistance:
10 M
or more
HINT:
• If a megohmmeter is not available, perform
the following simple inspection instead.
• If the result is 10 M
or less, clean the plug
and measure the resistance again.
(b) Alternative inspection method:
(1) Quickly accelerate the engine to 4,000 rpm 5
times.
(2) Remove the spark plug.
(3) Visually check the spark plug.
If the electrode is dry, the spark plug is
functioning properly. If the electrode is damp,
proceed to the next step.
(c) Check the spark plug for any damage on its threads
and insulator.
If there is damage, replace the spark plug.
Recommended spark plug
(d) Check the spark plug electrode gap.
Maximum electrode gap for used spark plug:
1.3 mm (0.051 in.)
If the gap is greater than the maximum, replace the
spark plug.
Electrode gap for new spark plug:
1.0 to 1.1 mm (0.039 to 0.043 in.)
Result Proceed to
NG Replace crankshaft position sensor
OK Go to next step
Result Proceed to
NG Check ECM (see page ES-183)
OK Repair wiring between ignition coil
and ECM
I039522E10
A126881
Manufacturer Spark plug type
DENSO SK20R11
NGK IFR6A11
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2GR-FE IGNITION – IGNITION SYSTEMIG–5
IG
ON-VEHICLE INSPECTION
1. CHECK IGNITION COIL ASSEMBLY AND PERFORM
SPARK TEST
NOTICE:
In this section, the terms "Cold" and "Hot" refer to
the temperature of the sensor. "Cold" means
approximately -10 to 50
C (14 to 122F). "Hot" means
approximately 50 to 100
C (122 to 212F).
(a) Check the DTCs.
NOTICE:
If a DTC is present, perform troubleshooting in
accordance with the procedure for that DTC.
(b) Check that sparks occur.
(1) Remove the V-bank cover.
(2) Remove the intake air surge tank (see page
EM-27).
(3) Remove the bolt and ignition coil.
(4) Using a 16 mm spark plug wrench, remove the
spark plug.
(5) Disconnect the 6 fuel injector connectors.
(6) Install the spark plug into the ignition coil, and
then connect the ignition coil connectors.
(7) Ground the spark plug.
(8) Check that sparks occur at the spark plug while
the engine is being cranked.
NOTICE:
• Be sure to ground the spark plugs when
checking them.
• If the ignition coil has been struck or
dropped, replace it.
• Do not crank the engine for more than 2
seconds.
If sparks do not occur, perform troubleshooting
using the spark test flowchart.
(9) Using a 16 mm plug wrench, install the spark
plug.
Torque: 25 N*m (254 kgf*cm, 18 ft.*lbf)
(10) Install the ignition coil with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(11) Connect the 6 fuel injector connectors.
(12) Install the intake air surge tank (see page EM-
34).
(13) Install the V-bank cover.
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