TOYOTA RAV4 2006 Service Repair Manual

2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–57
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 RADIATOR SUPPORT OPENING COVER
4. REMOVE FRONT WHEEL RH
5. REMOVE NO. 1 ENGINE UNDER COVER
6. REMOVE FRONT FENDER APRON RH
7. REMOVE NO. 1 ENGINE COVER (See page EM-22)
8. DRAIN ENGINE COOLANT (See page CO-6)
9. DRAIN ENGINE OIL (See page LU-4)
10. REMOVE AIR CLEANER CAP (See page ES-411)
11. REMOVE THROTTLE BODY (See page ES-412)
12. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
(See page FU-10)
13. REMOVE INTAKE MANIFOLD (See page ES-419)
14. REMOVE INTAKE MANIFOLD INSULATOR (See page
ES-420)
15. REMOVE FRONT EXHAUST PIPE (See page EX-3)
16. REMOVE OIL DIPSTICK
17. REMOVE OIL DIPSTICK GUIDE
(a) Remove the bolt and guide.
(b) Remove the O-ring from the guide.
18. REMOVE MANIFOLD STAY
(a) Remove the bolt, nut and stay.
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EM–582AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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19. REMOVE NO. 2 MANIFOLD STAY
(a) Remove the bolt, nut and stay.
20. REMOVE NO. 1 EXHAUST MANIFOLD HEAT
INSULATOR
(a) Remove the 4 bolts and heat insulator.
21. REMOVE EXHAUST MANIFOLD CONVERTER SUB-
ASSEMBLY
(a) Disconnect the air-fuel ratio sensor connector.
(b) Remove the 5 nuts, manifold converter and gasket.
22. DISCONNECT NO. 1 RADIATOR HOSE
(a) Disconnect the No. 1 radiator hose.
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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–59
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23. DISCONNECT ENGINE WIRE
(a) Disconnect the radio setting condenser connector.
(b) Disconnect the engine oil pressure switch
connector.
(c) Disconnect the engine coolant temperature sensor
connector.
(d) Disconnect the camshaft position sensor connector.
(e) Remove the bolt and ground cable.
24. REMOVE FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-6)
25. REMOVE FAN AND GENERATOR V BELT (See page
EM-6)
26. REMOVE GENERATOR ASSEMBLY (See page CH-9)
27. REMOVE ENGINE MOUNTING INSULATOR RH (See
page EM-22)
28. REMOVE IDLER PULLEY (See page EM-23)
29. REMOVE IGNITION COIL ASSEMBLY (See page IG-9)
30. REMOVE SPARK PLUG (See page EM-8)
31. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(See page EM-24)
32. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(See page EM-26)
33. REMOVE CRANKSHAFT POSITION SENSOR (See
page ES-402)
34. REMOVE OIL PAN SUB-ASSEMBLY (See page EM-
24)
35. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley until its groove and the
timing mark "0" of the timing chain cover are
aligned.
(b) Check that each timing mark of the camshaft timing
gear and sprocket is aligned with each timing mark
located on the No. 1 and No. 2 bearing caps as
shown in the illustration.
If not, turn the crankshaft by 1 revolution (360
) to
align the timing marks as above.
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EM–602AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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36. REMOVE NO. 2 CAMSHAFT
(a) Place paint marks on the chain in alignment with the
timing marks on the camshaft timing gear and
camshaft timing sprocket.
(b) Remove the 2 nuts, tensioner and gasket.
(c) While holding the camshaft with a wrench, loosen
the camshaft timing set bolt.
(d) Using several steps, uniformly loosen and remove
the 10 bearing cap bolts in the sequence shown in
the illustration.
(e) Remove the 5 bearing caps.
(f) While holding the No. 2 camshaft by hand, remove
the camshaft timing sprocket set bolt.
(g) Remove the camshaft timing sprocket from the No.
2 camshaft with the timing chain wrapped on the
sprocket.
(h) Remove the camshaft timing sprocket from the
timing chain.
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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–61
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37. REMOVE CAMSHAFT
(a) Using several steps, uniformly loosen and remove
the 10 bearing cap bolts in the sequence shown in
the illustration.
(b) Remove the 5 bearing caps.
(c) Remove the camshaft and camshaft timing gear
while holding the timing chain by hand.
(d) Tie the timing chain with a string as shown in the
illustration.
NOTICE:
Be careful not to drop anything inside the timing
chain cover.
38. REMOVE CRANKSHAFT PULLEY (See page EM-25)
39. REMOVE ENGINE MOUNTING BRACKET RH (See
page EM-26)
40. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
(See page EM-26)
41. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR
PLATE
42. REMOVE TIMING CHAIN GUIDE (See page EM-28)
43. REMOVE CHAIN TENSIONER SLIPPER (See page
EM-28)
44. REMOVE NO. 1 CHAIN VIBRATION DAMPER (See
page EM-28)
45. REMOVE CHAIN SUB-ASSEMBLY
46. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
ASSEMBLY (See page ES-395)
47. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
(a) Clamp the camshaft in a vise, and make sure that
the camshaft timing gear does not rotate.
(b) Cover all the oil ports with vinyl tape except the
advance side port shown in the illustration.
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EM–622AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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(c) Apply air pressure of 100 kPa (1.0 kgf/cm2, 14 psi)
to the oil path, then turn the camshaft timing gear to
the advance direction (counterclockwise) by hand.
CAUTION:
Cover the paths with a shop rag to avoid oil
splashes.
HINT:
Depending on the air pressure, the camshaft timing
gear will turn to the advance angle side without
applying force by hand. Also, under the condition
that the pressure is difficult to apply because of air
leakage from the port, there may be the case that
the lock pin is difficult to release.
(d) Remove the flange bolt of the camshaft timing gear.
NOTICE:
• Be sure not to remove the other 4 bolts.
• When reusing the camshaft timing gear,
release the straight pin lock first, then install
the gear.
48. REMOVE CYLINDER HEAD SUB-ASSEMBLY
(a) Using several steps, uniformly loosen and remove
the 10 cylinder head bolts and 10 plate washers
with a 10 mm bi-hexagon wrench in the sequence
shown in the illustration.
NOTICE:
Head warpage or cracking could result from
removing the bolts in the wrong order.
(b) Using a screwdriver with its tip wrapped with tape,
pry between the cylinder head and cylinder block,
and remove the cylinder head.
NOTICE:
Be careful not to damage the contact surfaces of
the cylinder head and cylinder block.
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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–63
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49. REMOVE CYLINDER HEAD GASKET
DISASSEMBLY
1. REMOVE RADIO SETTING CONDENSER
(a) Remove the bolt and condenser.
2. REMOVE OIL PRESSURE SWITCH
(a) Using a 24 mm deep socket wrench, remove the
sensor.
3. REMOVE ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using SST, remove the sensor and gasket.
SST 09817-33190
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EM–642AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
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4. REMOVE CAMSHAFT POSITION SENSOR
(a) Remove the bolt and sensor.
5. REMOVE NO. 2 CAMSHAFT BEARING
(a) Remove the No. 2 camshaft bearing.
6. REMOVE NO. 1 CAMSHAFT BEARING
(a) Remove the No. 1 camshaft bearing.
7. REMOVE VALVE LIFTER
HINT:
Arrange the valve lifters in the correct order.
8. REMOVE INTAKE VALVE
(a) Place the cylinder head on wooden blocks.
(b) Using SST, compress the spring, then remove the 2
retainer locks.
SST 09202-70020 (09202-00010)
(c) Remove the retainer, spring and valve from the
cylinder head.
HINT:
Arrange the removed parts in the correct order.
9. REMOVE EXHAUST VALVE
(a) Place the cylinder head on wooden blocks.
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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–65
EM
(b) Using SST, compress the spring, then remove the 2
retainer locks.
SST 09202-70020 (09202-00010)
(c) Remove the retainer, spring and valve from the
cylinder head.
HINT:
Arrange the removed parts in the correct order.
10. REMOVE VALVE SPRING SEAT
(a) Using compressed air and a magnetic finger,
remove the spring seat by blowing air.
HINT:
Arrange the valves, valve springs, spring seats and
spring retainers in the correct order.
11. REMOVE VALVE STEM OIL SEAL
(a) Using needle-nose pliers, remove the 16 oil seals.
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EM–662AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
EM
INSPECTION
1. INSPECT CYLINDER HEAD FOR WARPAGE
(a) Using a precision straightedge and feeler gauge,
measure the warpage of the contact surfaces of the
cylinder block and manifolds.
Maximum warpage:
0.08 mm (0.0032 in.)
If the warpage is greater than the maximum, replace
the cylinder head sub-assembly.
2. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrant, inspect the combustion
chamber, intake ports, exhaust ports and cylinder
block surface for cracks.
If cracked, replace the cylinder head.
3. INSPECT VALVE SEAT
(a) Apply a light coat of Prussian blue to the valve face.
(b) Lightly press the valve against the seat.
NOTICE:
Do not turn the valve.
(c) Check the valve face and seat in accordance with
the following procedure.
(1) If blue appears 360
around the face, the valve
is concentric. If not, replace the valve.
(2) If blue appears 360
around the valve seat, the
guide and face are concentric. If not, resurface
the valve seat (see page EM-87).
(3) Check that the seat contact is in the middle of
the valve face with a width.
Standard width
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Item Standard Condition
Intake 1.0 to 1.4 mm (0.0039 to 0.0551 in.)
Exhaust 1.2 to 1.6 mm (0.0472 to 0.0630 in.)