TOYOTA RAV4 2006 Service Repair Manual

EM–542GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
18. REMOVE CRANKSHAFT PULLEY
(a) Using SST, loosen the crankshaft pulley set bolt.
SST 09213-70011 (09213-70020), 09330-00021
(b) Using the pulley set bolt and SST, remove the
crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05021)
19. REMOVE WATER PUMP ASSEMBLY (See page CO-
13)
20. REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Using a screwdriver, pry out the oil seal retainer.
HINT:
Tape the screwdriver tip before use.
21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
(w/ Oil Pump) (See page LU-14)
22. SET NO. 1 CYLINDER TO TDC / COMPRESSION
(a) Temporarily tighten the pulley set bolt.
A132066E01
A132067E01
A129686
A129687E01

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–55
EM
(b) Set the timing mark on the crank angle sensor plate
to the RH block bore center line (TDC /
compression).
(c) Check that the timing marks of the camshaft timing
gears are aligned with the timing marks of the
bearing cap as shown in the illustration. If not, turn
the crankshaft 1 revolution (360
) and align the
timing marks as above.
23. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Move the stopper plate upward to release the lock,
and push the plunger deep into the tensioner.
(b) Move the stopper plate downward to set the lock,
and insert a hexagon wrench into the stopper plate
hole.
(c) Remove the 2 bolts and chain tensioner.
24. REMOVE CHAIN TENSIONER SLIPPER
A132112E01
A132113E01
A131978E01

EM–562GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
25. REMOVE NO. 1 CHAIN SUB-ASSEMBLY
(a) Turn the crankshaft counterclockwise 10
to loosen
the chain of the crankshaft timing gear.
(b) Remove the chain from the crankshaft timing gear
and place it on the crankshaft.
(c) Turn the camshaft timing gear on the RH bank
clockwise (approximately 60
) and set it as shown in
the illustration. Be sure to loosen the chain between
the center banks.
(d) Remove the chain.
26. REMOVE IDLE SPROCKET ASSEMBLY
(a) Using a 10 mm hexagon wrench, remove the No. 2
idle gear shaft, idle sprocket and No. 1 idle gear
shaft.
27. REMOVE NO. 1 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts and vibration damper.
28. REMOVE NO. 2 CHAIN VIBRATION DAMPER
(a) Remove the 2 chain vibration dampers.
29. REMOVE CRANKSHAFT TIMING GEAR OR
SPROCKET
(a) Remove the pulley set bolt.
(b) Remove the crankshaft timing gear from the
crankshaft.
(c) Remove the 2 pulley set keys from the crankshaft.
A132114E01
A132098E01
A129695
A132136
A131972

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–57
EM
30. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (for
Bank 1)
(a) While raising up the No. 2 chain tensioner, insert a
pin of
1.0 mm (0.039 in.) into the hole to fix it in
place.
(b) Hold the hexagonal portion of the camshaft with a
wrench, and remove the 2 bolts and 2 camshaft
timing gears.
NOTICE:
• Be careful not to damage the cylinder head
with the wrench.
• Do not disassemble the camshaft timing gear.
(c) Remove the No. 2 chain.
31. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Remove the bolt and chain tensioner.
32. REMOVE CAMSHAFT (for Bank 1)
(a) Remove the 3 gaskets.
A132072E01
A132073E01
A132046
A132121

EM–582GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(b) Make sure that the knock pin of the camshaft is
positioned as shown in the illustration.
(c) Uniformly loosen and remove the 8 bearing cap
bolts in the sequence shown in the illustration.
(d) Uniformly loosen and remove the 12 bearing cap
bolts in the sequence shown in the illustration.
NOTICE:
Uniformly loosen the bolts while keeping the
camshaft level.
(e) Remove the 5 bearing caps.
(f) Remove the No. 1 and No. 2 camshafts.
33. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY
(for Bank 1)
(a) Remove the camshaft housing by prying between
the cylinder head and camshaft housing with a
screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of
the cylinder head and camshaft housing.
HINT:
Tape the screwdriver tip before use.
A132139E01
A132122E01
A132123E01
A132124

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–59
EM
34. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (for
Bank 2)
(a) While pushing down the chain tensioner, insert a pin
of
1.0 mm (0.039 in.) into the hole to fix it in place.
(b) Hold the hexagonal portion of the camshaft with a
wrench and remove the 2 bolts and 2 camshaft
timing gears.
NOTICE:
• Be careful not to damage the cylinder head
with the wrench.
• Do not disassemble the camshaft timing gear.
(c) Remove the No. 2 chain.
35. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Remove the bolt and chain tensioner.
36. REMOVE CAMSHAFT SUB-ASSEMBLY (for Bank 2)
(a) Remove the 3 gaskets.
A132082E01
A132083E01
A132048
A132130

EM–602GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(b) Make sure that the knock pin of the camshaft is
positioned as shown in the illustration.
(c) Uniformly loosen and remove the 8 bearing cap
bolts in the sequence shown in the illustration.
(d) Uniformly loosen and remove the 13 bearing cap
bolts in the sequence shown in the illustration.
NOTICE:
Uniformly loosen the bolts while keeping the
camshaft level.
(e) Remove the 5 bearing caps.
(f) Remove the No. 3 and No. 4 camshafts.
37. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY
(for Bank 2)
(a) Remove the camshaft housing by prying between
the cylinder head and camshaft housing with a
screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of
the cylinder head and camshaft housing.
HINT:
Tape the screwdriver tip before use.
38. REMOVE NO. 1 VALVE ROCKER ARM SUB-
ASSEMBLY
(a) Remove the 24 valve rocker arms.
HINT:
Arrange the removed parts in the correct order.
A132141E01
A132131E01
A132132E01
A132084

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–61
EM
39. REMOVE VALVE LASH ADJUSTER ASSEMBLY
(a) Remove the 24 valve lash adjusters from the
cylinder head.
HINT:
Arrange the removed parts in the correct order.
40. REMOVE CYLINDER HEAD SUB-ASSEMBLY (for
Bank 1)
(a) Using a 10 mm bi-hexagon wrench, uniformly
loosen the 8 bolts in the sequence shown in the
illustration. Remove the 8 cylinder head bolts and
plate washers.
NOTICE:
• Be careful not to drop washers into the
cylinder head.
• Head warpage or cracking could result from
removing bolts in an incorrect order.
HINT:
Be sure to keep the removed parts separate for
each installation position.
(b) Remove the cylinder head and gasket.
41. REMOVE CYLINDER HEAD SUB-ASSEMBLY (for
Bank 2)
(a) Uniformly loosen and remove the 2 bolts in the
sequence shown in the illustration.
(b) Using a 10 mm bi-hexagon wrench, uniformly
loosen the 8 bolts in the sequence shown in the
illustration. Remove the 8 cylinder head bolts and
plate washers.
NOTICE:
• Be careful not to drop washers into the
cylinder head.
• Head warpage or cracking could result from
removing bolts in an incorrect order.
HINT:
Be sure to keep the removed parts separate for
each installation position.
(c) Remove the cylinder head and gasket.
42. REMOVE WATER INLET PIPE
(a) Disconnect the knock sensor wire.
A132143E03
A132144
A132145E03

EM–622GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(b) Remove the 2 bolts and water outlet pipe.
(c) Disconnect the water by-pass hose.
43. REMOVE VALVE STEM CAP
(a) Remove the valve stem caps from the cylinder
head.
HINT:
Arrange the removed parts in the correct order.
44. REMOVE INTAKE VALVE
(a) Using SST and wooden blocks, compress the
compression spring and remove the valve retainer
lock.
SST 09202-70020 (09202-00010)
(b) Remove the retainer, compression spring and valve.
HINT:
Arrange the removed parts in the correct order.
45. REMOVE EXHAUST VALVE
(a) Using SST and wooden blocks, compress the
compression spring and remove the valve retainer
lock.
SST 09202-70020 (09202-00010)
(b) Remove the retainer, compression spring and valve.
HINT:
Arrange the removed parts in the correct order.
46. REMOVE VALVE STEM OIL SEAL
(a) Using needle-nose pliers, remove the oil seals.
47. REMOVE VALVE SPRING SEAT
(a) Using compressed air and a magnetic finger,
remove the valve spring seat by blowing air onto it.
48. REMOVE NO. 1 STRAIGHT SCREW PLUG
NOTICE:
If water leaks from the No. 1 screw plug or the plug is
corroded, replace it.
A129713
A131991E01
A131992E01
A132167
A132168

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–63
EM
(a) Using a 10 mm hexagon wrench, remove the 4
screw plugs and 4 gaskets.
49. REMOVE NO. 2 STRAIGHT SCREW PLUG
(a) Using a 14 mm hexagon wrench, remove the 2
screw plugs and 2 gaskets.
NOTICE:
If water leaks from the No. 2 screw plug or the
plug is corroded, replace it.
50. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the bolt and crankshaft position sensor.
A131995E01
A131996E01
A129663