TOYOTA RAV4 2006 Service Repair Manual

EM–642GR-FE ENGINE MECHANICAL – ENGINE UNIT
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51. 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:
0.15 to 0.40 mm (0.0059 to 0.0157 in.)
Maximum thrust clearance:
0.50 mm (0.0197 in.)
If the thrust clearance is greater than the maximum,
replace one or more connecting rods as necessary.
If necessary, replace the crankshaft.
52. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check that the front mark on the connecting rod and
cap are aligned to ensure the correct reassembly.
NOTICE:
The front mark on the connecting rods and caps
are for ensuring the correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(c) Using the 2 removed connecting rod cap bolts,
remove the connecting rod cap and lower bearing
by wiggling the connecting rod cap right and left.
HINT:
Keep the lower bearing inserted to the connecting
rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and
scratches.
(f) Lay a strip of Plastigage on the crank pin.
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(g) Check that the front mark of the connecting rod cap
is facing forward.
(h) Install and alternately tighten the bolts of the
connecting rod cap in several steps.
NOTICE:
Do not turn the crankshaft.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
(i) Mark the front side of each connecting cap bolt with
paint.
(j) Retighten the cap bolts by 90
as shown.
(k) Check that the painted mark is now at a 90
angle to
the front.
NOTICE:
Do not turn the crankshaft.
(l) Remove the 2 connecting rod cap bolts.
(m) Using the 2 removed connecting rod cap bolts,
remove the connecting rod cap and lower bearing
by wiggling the connecting rod cap right and left.
HINT:
Keep the lower bearing inserted to the connecting
rod cap.
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(n) Measure the Plastigage at its widest point.
Standard oil clearance:
0.045 to 0.067 mm (0.0018 to 0.0026 in.)
Maximum oil clearance:
0.070 mm (0.0028 in.)
If the oil clearance is greater than the maximum,
replace the bearings. If necessary, replace the
crankshaft.
HINT:
If replacing a bearing, replace it with one that has
the same number as its respective connecting rod
cap. Each bearing's standard thickness is indicated
by a 1, 2, 3 and 4 mark on its surface.
Reference:
Connecting rod big end inside diameter
Standard sized bearing center wall thickness
Crankshaft pin diameter:
52.992 to 53.000 mm (2.0863 to 2.0866 in.)
(o) Completely remove the Plastigage.
53. REMOVE PISTON SUB-ASSEMBLY WITH
CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from
the top of the cylinder.
(b) Push the piston, connecting rod 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 in the
correct order.
54. REMOVE CONNECTING ROD BEARING
HINT:
Arrange the removed parts in the correct order.
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Mark Thickness
1 56.000 to 56.006 mm (2.2047 to 2.2050 in.)
2 56.007 to 56.012 mm (2.2050 to 2.2052 in.)
3 56.013 to 56.018 mm (2.2052 to 2.2054 in.)
4 56.019 to 56.024 mm (2.2055 to 2.2057 in.)
Mark Thickness
1 1.481 to 1.484 mm (0.0583 to 0.0584 in.)
2 1.484 to 1.497 mm (0.0584 to 0.0585 in.)
3 1.487 to 1.490 mm (0.0585 to 0.0587 in.)
4 1.490 to 1.493 mm (0.0587 to 0.0588 in.)
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55. 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 0.0094 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than the maximum,
replace the thrust washers as a set. If necessary,
replace the crankshaft.
Standard thrust washer thickness:
2.43 to 2.48 mm (0.0957 to 0.0976 in.)
56. REMOVE CRANKSHAFT AND CRANKSHAFT OIL
CLEARANCE
(a) Uniformly loosen and remove the 8 main bearing
cap bolts and seal washers in several steps, in the
sequence shown in the illustration.
(b) Uniformly loosen the 16 bearing cap bolts in several
steps, in the sequence shown in the illustration.
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(c) Using a screwdriver, pry out the main bearing caps.
Remove the 4 main bearing caps and lower
bearings.
NOTICE:
• Pry up the main cap little by little to the right
and left in turns.
• Be careful not to damage the joint surface of
the cylinder block and main bearing caps.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
HINT:
If the journal or bearing is damaged, replace the
bearing.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Examine the front marks and numbers and install
the bearing caps on the cylinder block.
HINT:
A number is marked on each main bearing cap to
indicate the installation position.
(i) Apply a light coat of engine oil on the threads and
under the heads of the bearing cap bolts.
(j) Place the crankshaft bearing cap on the cylinder
block.
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(k) Install the main bearing cap with your hand until the
clearance between the main bearing cap and the
cylinder block is less than 6 mm (0.23 in.) by
marking the 2 internal bearing cap bolts as a guide.
Bolt length:
100 to 102 mm (3.94 to 4.02 in.)
(l) Using a plastic-faced hammer, lightly tap the
bearing cap to ensure a proper fit.
(m) Apply a light coat of engine oil on the threads and
under the heads of the 8 main bearing cap bolts.
(n) Install the 8 main bearing cap bolts to the outside
positions.
Bolt length:
105.5 to 107.5 mm (4.15 to 4.23 in.)
HINT:
The main bearing cap bolts are tightened in 2
progressive steps.
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(o) Step 1
(1) Install and uniformly tighten the 16 main
bearing cap bolts in the sequence shown in the
illustration.
Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)
HINT:
If any of the main bearing cap bolts does not
meet the torque specification, replace the main
bearing cap bolt.
NOTICE:
Do not turn the crankshaft.
(p) Step 2
(1) Mark the front of the bearing cap bolts with
paint.
(2) Retighten the bearing cap bolts by 90
as
shown in the order shown in step 1.
(3) Check that the painted mark is now at a 90

angle to the front.
(q) Install and uniformly tighten the 8 main bearing cap
bolts in several steps and in the sequence shown in
the illustration.
Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf)
Bolt length:
45 mm (1.77 in.) for bolt A
30 mm (1.18 in.) for except bolt A
(r) Remove the 24 bolts and bearing cap bolts.
(s) Completely remove the Plastigage.
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(t) If replacing a bearing, replace it with one having the
same number. If the number of the bearing cannot
be determined, select the correct bearing by adding
together the numbers imprinted on the cylinder
block and crankshaft, then refer to the table below
for the appropriate bearing number. There are 5
sizes of standard bearings, marked "1", "2", "3", "4"
and "5" accordingly.
Journal bearing
EXAMPLE:
Cylinder block "11" + Crankshaft "06" = Total
number 17 (Use bearing "3")
Standard crankshaft main journal diameter
Standard upper bearing center wall thickness
No. 1 and No. 4 journal
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Use Bearing Cylinder Block Number Mark +
Crankshaft Number Mark
1 0 - 5
2 6 - 11
312 - 17
418 - 23
524 - 28
Mark Specified Condition
00 60.999 to 61.000 mm (2.4015 to
2.4016 in.)
01 60.998 to 60.999 mm (2.4015 to
2.4015 in.)
02 60.997 to 60.998 mm (2.4015 to
2.4015 in.)
03 60.996 to 60.997 mm (2.4014 to
2.4015 in.)
04 60.995 to 60.996 mm (2.4014 to
2.4014 in.)
05 60.994 to 60.995 mm (2.4013 to
2.4014 in.)
06 60.93 to 60.994 mm (2.4013 to 2.4013
in.)
07 60.992 to 60.993 mm (2.4013 to
2.4013 in.)
08 60.991 to 60.992 mm (2.4012 to
2.4013 in.)
09 60.990 to 60.991 mm (2.4012 to
2.4012 in.)
10 60.989 to 60.990 mm (2.4011 to
2.4012 in.)
11 60.988 to 60.989 mm (2.4.11 to 2.4011
in.)
Mark Specified Condition
1 2.500 to 2.503 mm (0.0984 to 0.0985
in.)
2 2.503 to 2.506 mm (0.0985 to 0.0987
in.)
3 2.506 to 2.509 mm (0.0987 to 0.0988
in.)

EM–722GR-FE ENGINE MECHANICAL – ENGINE UNIT
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No. 2 and No. 3 journal
Standard lower bearing center wall thickness
No. 1 and No. 4 journal
No. 2 and No. 3 journal
(u) Lift out the crankshaft.
4 2.509 to 2.512 mm (0.0988 to 0.0989
in.)
5 2.512 to 2.515 mm (0.0989 to 0.0990
in.)
Mark Specified Condition
1 2.478 to 2.481 mm (0.0976 to 0.0977
in.)
2 2.481 to 2.484 mm (0.0977 to 0.0978
in.)
3 2.484 to 2.487 mm (0.0978 to 0.0979
in.)
4 2.487to 2.490 mm (0.0979 to 0.0980
in.)
5 2.490 to 2.493 mm (0.0980 to 0.0981
in.)
Mark Specified Condition
1 2.478 to 2.481 mm (0.0976 to 0.0977
in.)
2 2.481 to 2.484 mm (0.0977 to 0.0780
in.)
3 2.484 to 2.487 mm (0.0978 to 0.0979
in.)
4 2.487 to 2.490 mm (0.0979 to 0.0980
in.)
5 2.490 to 2.493 mm (0.0980 to 0.0981
in.)
Mark Specified Condition
1 2.500 to 2.503 mm (0.0984 to 0.0985
in.)
2 2.503 to 2.506 mm (0.0985 to 0.0987
in.)
3 2.506 to 2.509 mm (0.0987 to 0.0988
in.)
4 2.509 to 2.512 mm (0.0988 to 0.0989
in.)
5 2.512 to 2.515 mm (0.0989 to 0.0990
in.) Mark Specified Condition

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(v) Remove the upper bearings and upper thrust
washers from the cylinder block.
HINT:
Arrange the bearings and thrust washers in the
correct order.
57. REMOVE CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSEMBLY
(a) Remove the 2 water drain cocks from the cylinder
block.
(b) Remove the water drain cock plugs from the water
drain cocks.
58. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, remove the 3 oil
nozzles.
(b) Check the oil nozzles for damage or clogging.
If necessary, replace the oil nozzle.
59. REMOVE PISTON RING SET
HINT:
Arrange the piston rings in the correct order.
(a) Using a piston ring expander, remove the 2
compression rings.
(b) Using a piston ring expander, remove the 2 side
rails.
(c) Remove the oil ring expander by hand.
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