TOYOTA RAV4 2006 Service Repair Manual

EM–742GR-FE ENGINE MECHANICAL – ENGINE UNIT
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60. REMOVE PISTON WITH PIN SUB-ASSEMBLY
(a) Check the fitting condition between the piston and
piston pin.
(1) Try to move the piston back and forth on the
piston pin.
HINT:
If any movement is felt, replace the piston and
pin as a set.
(b) Disconnect the connecting rod from the piston.
(1) Using a screwdriver, pry off the snap rings from
the piston.
(2) Gradually heat the piston to approximately
80
C (176F).
(3) Using a brass bar and plastic-faced hammer,
lightly tap out the piston pin and remove the
connecting rod.
HINT:
• The piston and pin are a matched set.
• Arrange the pistons, pins, rings, connecting
rods and bearings in the correct order.
(c) Clean piston.
(1) Using a gasket scraper, remove the carbon
from the piston top.
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(2) Using a groove cleaning tool or broken ring,
clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean
the piston.
NOTICE:
Do not use a wire brush.
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EM–762GR-FE ENGINE MECHANICAL – ENGINE UNIT
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INSPECTION
1. INSPECT VALVE LASH ADJUSTER ASSEMBLY
NOTICE:
• Keep the lash adjuster free from dirt and foreign
objects.
• Only use clean engine oil.
(a) Place the lash adjuster into a container full of engine
oil.
(b) Insert the SST's tip into the lash adjuster's plunger
and use the tip to press down on the checkball
inside the plunger.
SST 09276-75010
(c) Squeeze the SST and lash adjuster together to
move the plunger up and down 5 to 6 times.
(d) Check the movement of the plunger and bleed the
air.
OK:
Plunger moves up and down.
NOTICE:
When bleeding high-pressure air from the
compression chamber, make sure that the tip of
the SST is actually pressing the checkball as
shown in the illustration. If the checkball is not
pressed, air will not bleed.
(e) After bleeding the air, remove SST. Then try to
quickly and firmly press the plunger with a finger.
OK:
Plunger is very difficult to move.
If the result is not as specified, replace the lash
adjuster.
2. INSPECT CAMSHAFT
(a) Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout
at the center journal.
Maximum circle runout:
0.04 mm (0.0016 in.)
If the circle runout is greater than the
maximum, replace the camshaft.
HINT:
Check the oil clearance after replacing the
camshaft.
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(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height
Maximum cam lobe height
If the cam lobe height is less than the minimum,
replace the camshaft.
(c) Using a micrometer, measure the journal diameter.
Standard journal diameter
If the journal diameter is not as specified, check the
oil clearance.
3. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Clamp the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft in the
vise.
(b) Put the camshaft timing gear and camshaft together
by aligning the key groove and straight pin.
(c) Lightly press the gear against the camshaft, and
turn the gear. Push further at the position where the
pin enters the groove.
NOTICE:
Be sure not to turn the camshaft timing gear in
the retard direction (the right angle).
(d) Check that there is no clearance between the gear's
fringe and the camshaft.
(e) Tighten the flange bolt with the camshaft timing gear
fixed in place.
Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
(f) Check the lock of the camshaft timing gear.
(1) Clamp the camshaft in a vise, and confirm that
the camshaft timing gear is locked.
NOTICE:
Be careful not to damage the camshaft.
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Item Specified Condition
Intake 44.316 to 44.416 mm (1.7447 to 1.7487 in.)
Exhaust 44.262 to 44.362 mm (1.7426 to 1.7465 in.)
Item Specified Condition
Intake 44.166 mm (1.7388 in.)
Exhaust 44.112 mm (1.7367 in.)
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Item Specified Condition
No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journal 25.959 to 25.975 mm (1.0220 to 1.0226 in.)
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EM–782GR-FE ENGINE MECHANICAL – ENGINE UNIT
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(g) Release the lock pin.
(1) Cover the 4 oil paths of the cam journal with
vinyl tape as shown in the illustration.
HINT:
2 advance side paths are provided in the
groove of the camshaft. Plug one of the paths
with a rubber piece.
(2) Break through the tape of the advance side
path and the retard side path on the opposite
side to the hole of the advance side path, as
shown in the illustration.
(3) Apply approximately 200 kPa (2.0 kgf/cm
2, 28
psi) of air pressure to the two broken paths.
CAUTION:
Cover the paths with a piece of cloth when
applying pressure to keep oil from
splashing.
(4) Check that the camshaft timing gear revolves in
the advance direction when reducing the air
pressure applied to the retard side path.
HINT:
This operation releases the lock pin for the
most retarded position.
(5) When the camshaft timing gear reaches the
most advanced position, release the air
pressure from the retard side path and advance
side path, in that order.
NOTICE:
Do not release the air pressure from the
advance side path first. The gear may
abruptly shift in the retard direction and
break the lock pin.
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(h) Check for smooth rotation.
(1) Turn the camshaft timing gear within its
movable range (21
) 2 or 3 times, but do not
turn it to the most retarded position. Make sure
that the gear turns smoothly.
NOTICE:
Do not use air pressure to perform the
smooth rotation check.
(i) Check the lock in the most retarded position.
(1) Confirm that the camshaft timing gear is locked
at the most retarded position.
(j) Remove the flange bolt and camshaft timing gear.
NOTICE:
• Be sure not to remove the other 3 bolts.
• If planning to reuse the gear, be sure to
release the straight pin lock before installing
the gear.
4. INSPECT CAMSHAFT TIMING EXHAUST GEAR
ASSEMBLY
(a) Clamp the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft in the
vise.
(b) Put the camshaft timing exhaust gear and camshaft
together by aligning the key groove and straight pin.
(c) Lightly press the gear against the camshaft, and
turn the gear. Push further at the position where the
pin enters the groove.
CAUTION:
Be sure not to turn the camshaft timing exhaust
gear in the retard direction (the right angle).
(d) Check that there is no clearance between the gear's
fringe and the camshaft.
(e) Tighten the flange bolt with the camshaft timing
exhaust gear fixed in place.
Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
(f) Check the camshaft timing exhaust gear lock.
(1) Make sure that the camshaft timing exhaust
gear is locked.
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(g) Release the lock pin.
(1) Cover the 4 oil paths of the cam journal with
vinyl tape as shown in the illustration.
HINT:
4 oil paths are provided in the groove. Plug 2
paths with rubber pieces.
(2) Prick a hole in the tape placed on the advance
side path. Prick a hole in the tape placed on the
retard side path on the opposite side to that of
the advance side path, as shown in the
illustration.
(3) Apply approximately 200 kPa (2.0 kgf/cm
2, 28
psi) of air pressure to the two broken paths (the
advance side path and the retard side path).
CAUTION:
Cover the paths with a piece of cloth when
applying pressure to keep oil from
splashing.
(4) Make sure that the camshaft timing exhaust
gear turns in the retard direction when reducing
the air pressure applied to the advance side
path.
HINT:
The lock pin is released and the camshaft
timing exhaust gear turns in the retard
direction.
(5) When the camshaft timing exhaust gear moves
to the most retarded position, release the air
pressure from the advance side path, and then
release the air pressure from the retard side
path.
NOTICE:
Be sure to release the air pressure from the
advance side path first. If the air pressure of
the retard side path is released first, the
camshaft timing exhaust gear may abruptly
shift in the advance direction and break the
lock pin or other parts.
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(h) Check for smooth rotation.
(1) Turn the camshaft timing exhaust gear within
its movable range (18.5
) 2 or 3 times, but do
not turn it to the most advanced position. Make
sure that the gear turns smoothly.
NOTICE:
When the air pressure is released from the
advance side path and then from the retard
side path, the gear automatically returns to
the most advanced position due to the
advance assist spring operation and locks.
Gradually release the air pressure from the
retard side path before performing the
smooth rotation check.
(i) Check the lock at the most advanced position.
(1) Make sure that the camshaft timing exhaust
gear is locked at the most advanced position.
(j) Remove the flange bolt and camshaft timing
exhaust gear.
NOTICE:
• Be sure not to remove the other 3 bolts.
• If planning to reuse the gear, be sure to
release the straight pin lock before installing
the gear.
5. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier caliper, measure the minimum
diameter of the elongated thread at the measuring
point.
Minimum outside diameter:
10.70 mm (0.4213 in.)
HINT:
• If a visual check reveals no excessively thin
areas, check the center of the bolt (see
illustration) and find the area that has the lowest
diameter.
• If the diameter is less than the minimum, replace
the cylinder head bolt.
6. INSPECT CHAIN SUB-ASSEMBLY
(a) Using a spring scale, pull the chain with a force of
147 N (15 kgf, 33 lbf) as shown in the illustration.
(b) Using a vernier caliper, measure the length of 16
links.
Maximum chain elongation:
136.9 mm (5.389 in.)
If the elongation is greater than the maximum,
replace the chain.
NOTICE:
Perform the measurement at 3 random places.
Inspect using the average of the measurements.
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EM–822GR-FE ENGINE MECHANICAL – ENGINE UNIT
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7. INSPECT NO. 2 CHAIN SUB-ASSEMBLY
(a) Pull the chain with a force of 147 N (15 kgf, 33 lbf)
as shown in the illustration.
(b) Using a vernier caliper, measure the length of 16
links.
Maximum chain elongation:
137.6 mm (5.417 in.)
If the elongation is greater than the maximum,
replace the chain.
NOTICE:
Perform the measurement at 3 random places.
Inspect using the average of the measurements.
8. INSPECT CRANKSHAFT TIMING GEAR OR
SPROCKET
(a) Wrap the chain around the sprocket.
(b) Using a vernier caliper, measure the sprocket
diameter with the chain.
Minimum sprocket diameter (w/ chain):
61.4 mm (2.417 in.)
HINT:
• The vernier caliper must contact the chain rollers
for the measurement.
• If the diameter is less than the minimum, replace
the chain and sprocket.
9. INSPECT IDLE SPROCKET ASSEMBLY
(a) Wrap the chain around the sprocket.
(b) Using a vernier caliper, measure the sprocket
diameter with the chain.
Minimum sprocket diameter (w/ chain):
61.4 mm (2.417 in.)
HINT:
• The vernier caliper must contact the chain rollers
for the measurement.
• If the diameter is less than the minimum, replace
the chain and sprocket.
10. INSPECT IDLE GEAR SHAFT OIL CLEARANCE
(a) Using a micrometer, measure the idle gear shaft
diameter.
Standard idle gear shaft diameter:
22.987 to 23.000 mm (0.9050 to 0.9055 in.)
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(b) Using a caliper gauge, measure the inside diameter
of the idle gear.
Standard idle gear inside diameter:
23.02 to 23.03 mm (0.9062 to 0.9067 in.)
(c) Subtract the idle gear shaft diameter measurement
from the idle gear inside diameter measurement.
Standard oil clearance:
0.02 to 0.043 mm (0.0001 to 0.0017 in.)
Maximum oil clearance:
0.043 mm (0.0017 in.)
If the thrust oil clearance is greater than the
maximum, replace the idle gear shaft and idle gear.
11. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Move the stopper plate upward to release the lock.
Push the plunger and check that it moves smoothly.
If necessary, replace the chain tensioner.
12. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Check that the plunger moves smoothly.
(b) Measure the worn depth of the chain tensioner.
Maximum depth:
0.9 mm (0.035 in.)
If the depth is greater than the maximum, replace
the chain tensioner.
13. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Check that the plunger moves smoothly.
(b) Measure the worn depth of the chain tensioner.
Maximum depth:
0.9 mm (0.035 in.)
If the depth is greater than the maximum, replace
the chain tensioner.
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