TOYOTA RAV4 2006 Service Repair Manual

EM–1242AZ-FE ENGINE MECHANICAL – ENGINE UNIT
EM
20. REMOVE SPARK PLUG
21. REMOVE OIL FILLER CAP SUB-ASSEMBLY
22. REMOVE OIL FILLER CAP GASKET
23. REMOVE VENTILATION VALVE SUB-ASSEMBLY
(See page EC-18)
24. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(See page EM-24)
25. REMOVE CYLINDER HEAD COVER GASKET
26. REMOVE OIL FILTER SUB-ASSEMBLY (See page LU-
4)
27. REMOVE OIL FILTER UNION
(a) Using a 12 mm hexagon wrench, remove the oil
filter union.
28. REMOVE CRANKSHAFT POSITION SENSOR (See
page ES-402)
29. REMOVE WATER PUMP PULLEY (See page CO-11)
30. REMOVE WATER PUMP ASSEMBLY (See page CO-
11)
A132575
A128158
A128159
A128166
A126912E01

2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–125
EM
31. REMOVE OIL PAN DRAIN PLUG
(a) Remove the oil pan drain plug and gasket.
32. REMOVE OIL PAN SUB-ASSEMBLY (See page EM-
24)
33. REMOVE CRANKSHAFT PULLEY (See page EM-25)
34. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (See
page EM-26)
35. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
(See page EM-26)
36. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR
PLATE
37. REMOVE TIMING CHAIN GUIDE (See page EM-28)
38. REMOVE CHAIN TENSIONER SLIPPER (See page
EM-28)
39. REMOVE NO. 1 CHAIN VIBRATION DAMPER (See
page EM-28)
40. REMOVE CHAIN SUB-ASSEMBLY
41. REMOVE CRANKSHAFT TIMING SPROCKET
42. REMOVE NO. 2 CHAIN SUB-ASSEMBLY (See page
EM-29)
43. REMOVE OIL PUMP DRIVE GEAR
44. REMOVE OIL PUMP ASSEMBLY (See page LU-12)
45. REMOVE CAMSHAFT
(a) Using several steps, uniformly loosen and remove
the 20 bearing cap bolts in the sequence shown in
the illustration.
(b) Remove the 10 bearing caps, then remove the
camshaft and No. 2 camshaft.
46. REMOVE CYLINDER HEAD SUB-ASSEMBLY (See
page EM-62)
A128176
A132571
A128185
A128186
F050596E02

EM–1262AZ-FE ENGINE MECHANICAL – ENGINE UNIT
EM
47. REMOVE CYLINDER HEAD GASKET
48. REMOVE CYLINDER BLOCK WATER JACKET
SPACER
(a) Using needle-nose pliers, remove the cylinder block
water jacket spacer from the water jacket.
NOTICE:
Before turning the cylinder block upside down,
make sure that the water jacket spacer is
removed, as it will fall out.
49. REMOVE CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSEMBLY
50. REMOVE OIL CONTROL VALVE FILTER
(a) Using a 6 mm socket hexagon wrench, remove the
plug and gasket.
(b) Remove the oil control valve filter.
51. INSPECT BALANCE SHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance
while moving the balance shaft back and forth.
Standard thrust clearance:
0.05 to 0.09 mm (0.0020 to 0.0035 in.)
Maximum thrust clearance:
0.09 mm (0.0035 in.)
If the thrust clearance is greater than the maximum,
replace the balance shaft housing and bearings. If
necessary, replace the balance shaft.
A126929
A128208
A128209
A128210
A128196

2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–127
EM
52. INSPECT BALANCE SHAFT OIL CLEARANCE
(a) Using several steps, uniformly loosen and remove
the 8 bolts in the sequence shown in the illustration.
(b) Remove the balance shaft housing from the
crankcase.
HINT:
Keep the lower bearing and balance shaft housing
together.
(c) Lift out the No. 1 and No. 2 balance shafts.
HINT:
Keep the upper bearing with the crankcase.
(d) Clean each bearing and journal.
(e) Check each bearing and journal for pitting and
scratches.
If a bearing or journal is damaged, replace the
bearings. If necessary, replace the balance shaft.
(f) Inspect the balance shaft housing bolt.
(1) Using a vernier caliper, measure the length of
the bolts from the seat to the end.
Standard bolt length:
58.3 to 59.7 mm (2.295 to 2.350 in.)
Maximum bolt length:
60.3 mm (2.374 in.)
If the bolt length is greater than the maximum,
replace the balance shaft bolt.
(g) Place the No. 1 and No. 2 balance shafts onto the
crankcase.
(h) Lay a strip of Plastigage across each journal.
(i) Install the balance shaft housing.
(j) Apply a light coat of engine oil on the threads and
under the heads of the bolts.
(k) Using several steps, uniformly install and tighten the
8 bolts in the sequence shown in the illustration.
Torque: 21.6 N*m (220 kgf*cm, 16 ft.*lbf)
A128197E01
A132569E01
A131575E01
A090849E04
A128197E03

EM–1282AZ-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(l) Mark the front of the bolts with paint.
(m) Retighten the bolts 90
as shown in the illustration.
(n) Check that the paint mark is now at a 90
angle to
the front.
(o) Remove the balance shaft housing from the
crankcase.
(p) Measure the Plastigage at its widest point.
Standard oil clearance:
0.004 to 0.049 mm (0.0002 to 0.0019 in.)
Maximum oil clearance:
0.049 mm (0.0019 in.)
NOTICE:
Remove the Plastigage completely after the
measurement.
If the oil clearance is greater than the maximum,
replace the bearing. If necessary, replace the
balance shaft.
HINT:
If replacing a bearing, select a new one with the
same number.
Standard balance shaft housing journal bore
diameter
Standard balance shaft journal diameter:
22.985 to 23.000 mm (0.9049 to 0.9055 in.)
Standard bearing center wall thickness
53. REMOVE BALANCE SHAFT
A037134E02
Item Specified Condition
Mark 1 26.000 to 26.006 mm (1.0236 to
1.0239 in.)
Mark 2 26.007 to 26.012 mm (1.0239 to
1.0214 in.)
Mark 3 26.013 to 26.018 mm (1.0241 to
1.0243 in.)
Item Specified Condition
Mark 1 1.486 to 1.489 mm (0.05850 to
0.05862 in.)
Mark 2 1.490 to 1.492 mm (0.05866 to
0.05874 in.)
Mark 3 1.493 to 1.495 mm (0.0585 to 0.0586
in.)
A132569E01

2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–129
EM
54. REMOVE NO. 1 BALANCE SHAFT BEARING
55. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the lip of the oil seal.
(b) 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.
56. REMOVE STIFFENING CRANKCASE ASSEMBLY
(a) Using several steps, uniformly loosen and remove
the 11 bolts in the sequence shown in the
illustration.
A128204E01
A098356E01
A112229E01

EM–1302AZ-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(b) Remove the crankcase by prying the portions
between the crankcase and cylinder block.
NOTICE:
Be careful not to damage the contact surfaces of
the crankcase and cylinder bock.
(c) Remove the O-ring from the cylinder block.
57. 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:
0.160 to 0.362 mm (0.0063 to 0.0143 in.)
Maximum thrust clearance:
0.362 mm (0.0143 in.)
If the thrust clearance is greater than the maximum,
replace the connecting rod. If necessary, replace
the crankshaft.
58. INSPECT CONNECTING ROD OIL CLEARANCE
NOTICE:
Do not turn the crankshaft during the measurement.
A128205
A128206
A112172

2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–131
EM
(a) Using marking paint, write the matched cylinder
number on each connecting rod and cap.
HINT:
The matchmarks in the connecting rods and caps
are for ensuring correct reassembly.
(b) Using a 12 mm socket wrench, remove the 2 bolts
and connecting rod cap.
(c) Clean the crank pin and bearing.
(d) Check the crank pin and bearing for pitting and
scratches.
(e) Lay a strip of Plastigage on the crank pin.
(f) Check that the front mark of the connecting rod cap
is facing in the correct direction.
(g) Apply a light coat of engine oil to the threads and
under the heads of the connecting rod bolts.
(h) Using a 12 mm socket wrench, tighten the bolts in
several passes to the specified torque.
Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)
(i) Mark the front of the connecting rod bolts with paint.
(j) Retighten the cap bolts 90
as shown in the
illustration.
(k) Check that the crankshaft turns smoothly.
(l) Using a 12 mm socket wrench, remove the 2 bolts
and connecting rod cap.
A063893E01
A013397E01
A013400E01
A036691E01
A101478E03

EM–1322AZ-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(m) Measure the Plastigage at its widest point.
Standard oil clearance:
0.024 to 0.048 mm (0.0009 to 0.0019 in.)
Maximum oil clearance:
0.08 mm (0.0032 in.)
NOTICE:
Remove the Plastigage completely after the
measurement.
If the oil clearance is greater than the maximum,
replace the connecting rod bearing. If necessary,
grind or replace the crankshaft.
HINT:
If replacing a bearing, select a new one with the
same number as marked on the connecting rod.
There are 3 sizes of standard bearings, marked "1",
"2" and "3" accordingly.
Standard connecting rod large end bore
diameter
Standard connecting rod bearing thickness
Standard crankshaft pin diameter:
47.990 to 48.000 (1.8894 to 1.8898 in.)
59. REMOVE PISTON WITH CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from
the top of the cylinder.
(b) Push the piston, connecting rod assembly and
upper bearing through the top of the cylinder block.
HINT:
• Keep the bearing, connecting rod and cap
together.
• Arrange the piston and connecting rod
assemblies in the correct order.
60. REMOVE CONNECTING ROD BEARING
A129453E01
Mark Specified Condition
Mark 1 51.000 to 51.007 mm (2.0079 to
2.0082 in.)
Mark 2 51.008 to 51.013 mm (2.0082 to
2.0084 in.)
Mark 3 51.014 to 51.020 mm (2.0084 to
2.0087 in.)
Mark Specified Condition
Mark 1 1.485 to 1.488 mm (0.0585 to 0.0586
in.)
Mark 2 1.489 to 1.491 mm (0.0586 to 0.0587
in.)
Mark 3 1.492 to 1.494 mm (0.0587 to 0.0588
in.)
A112232

2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–133
EM
61. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2
compression rings.
(b) Remove the oil ring and expander by hand.
62. REMOVE PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, pry out the 2 snap rings.
63. REMOVE PISTON
(a) Gradually heat the piston up to 80 to 90
C (176 to
194
F).
(b) Using a plastic-faced hammer and brass bar, lightly
tap out the piston pin, then remove the connecting
rod.
HINT:
• The piston and pin are a matched set.
• Arrange the piston, pin, ring, connecting rod and
bearings in the correct order.
64. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance
while prying the crankshaft back and forth with a
screwdriver.
Standard thrust clearance:
0.04 to 0.24 mm (0.0016 to 0.0095 in.)
Maximum thrust clearance:
0.30 mm (0.012 in.)
If the thrust clearance is greater than the maximum,
replace the thrust washers as a set.
A112320E01
A112234
A112235
A112236
A112237