TOYOTA RAV4 2006 Service Repair Manual

EM–1142GR-FE ENGINE MECHANICAL – ENGINE UNIT
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11. INSTALL NO. 1 STRAIGHT SCREW PLUG
(a) Using a 10 mm hexagon wrench, install 4 new
gaskets and the straight screw plugs.
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
12. INSTALL VALVE SPRING SEAT
(a) Install the valve spring seats to the cylinder head.
13. INSTALL INTAKE VALVE STEM OIL SEAL
(a) Apply a light coat of engine oil to new oil seals.
NOTICE:
Pay attention when installing the intake and
exhaust oil seals. For example, installing the
intake oil seal into the exhaust side or installing
the exhaust oil seal to the intake side can cause
installation problems later.
HINT:
The intake valve oil seals are white and the exhaust
valve oil seals are black.
(b) Using SST, push in the oil seals.
SST 09201-41020
NOTICE:
Failure to use SST will cause the seal to be
damaged or improperly seated.
14. INSTALL INTAKE VALVE
(a) Apply plenty of engine oil to the tip area of the intake
valve shown in the illustration.
(b) Install the valve, compression spring and spring
retainer to the cylinder head.
NOTICE:
Install the same parts in the same combination
to original locations.
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(c) Using SST and wooden blocks, compress the
spring and install the retainer lock.
SST 09202-70020 (09202-00010)
(d) Using a plastic-faced hammer, lightly tap the valve
stem tip to ensure a proper fit.
NOTICE:
Be careful not to damage the retainer.
15. INSTALL EXHAUST VALVE
(a) Apply plenty of engine oil to the tip area of the
exhaust valve shown in the illustration.
(b) Install the valve, compression spring and spring
retainer to the cylinder head.
NOTICE:
Install the same parts in the same combination
to their original locations.
(c) Using SST and wooden blocks, compress the
spring and install the retainer lock.
SST 09202-70020 (09202-00010)
(d) Using a plastic-faced hammer, lightly tap the valve
stem tip to ensure a proper fit.
NOTICE:
Be careful not to damage the retainer.
16. INSTALL VALVE STEM CAP
(a) Apply a light coat of engine oil to the valve stem
caps.
(b) Install the valve stem caps to the cylinder head.
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EM–1162GR-FE ENGINE MECHANICAL – ENGINE UNIT
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17. INSTALL WATER INLET PIPE
(a) Install the water inlet pipe with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(b) Install the water by-pass hose.
18. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for
Bank 1)
(a) Check the piston protrusions for each cylinder.
(1) Clean the cylinder block with solvent.
(2) Set the piston of the cylinder to be measured to
slightly before TDC.
(b) Place the cylinder head gasket on the cylinder block
surface with the front face of the Lot No. stamp
upward.
NOTICE:
• Be careful of the installation direction.
• Gently place the cylinder head in order not to
damage the gasket with the bottom part of the
head.
(c) Place the cylinder head on the cylinder block.
NOTICE:
Ensure that no oil is on the mounting surface of
the cylinder head.
HINT:
The cylinder head bolts are tightened in 3
progressive steps.
(d) Apply a light coat of engine oil to the threads and
under the heads of the cylinder head bolts.
(e) Step 1
(1) Using a 10 mm bi-hexagon wrench, install and
uniformly tighten the 8 cylinder head bolts with
the plate washers in several steps, in the
sequence shown in the illustration.
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
(f) Step 2
(1) Mark the cylinder head bolt head with paint as
shown in the illustration.
(2) Tighten the cylinder heads bolts another 90
in
the sequence shown in step 1.
(g) Step 3
(1) Tighten the cylinder head bolts by an additional
90
in the sequence shown in step 1.
(2) Check that the painted mark is now facing
rearward.
19. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for
Bank 2)
(a) Check the piston protrusions for each cylinder.
(1) Clean the cylinder block with solvent.
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(2) Set the piston of the cylinder to be measured to
slightly before TDC.
(b) Place the cylinder head gasket on the cylinder block
surface with the front face of the Lot No. stamp
upward.
NOTICE:
• Be careful of the installation direction.
• Gently place the cylinder head in order not to
dama ge the gaske t wi th t he b ottom part of t he
head.
(c) Place the cylinder head on the cylinder block.
NOTICE:
Ensure that no oil is on the mounting surface of
the cylinder head.
HINT:
The cylinder head bolts are tightened in 3
progressive steps.
(d) Apply a light coat of engine oil to the threads and
under the heads of the cylinder head bolts.
(e) Step 1
(1) Using a 10 mm bi-hexagon wrench, install and
uniformly tighten the 8 cylinder head bolts with
the plate washers in several steps, in the
sequence shown in the illustration.
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
(f) Step 2
(1) Mark the cylinder head bolt heads with paint as
shown in the illustration.
(2) Tighten the cylinder head bolts another 90
in
the sequence shown in step 1.
(g) Step 3
(1) Tighten the cylinder head bolts by an additional
90
in the sequence shown in step 1.
(2) Check that the painted mark is now facing
rearward.
(h) Install the 2 bolts in the order shown in the
illustration.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
20. INSTALL VALVE LASH ADJUSTER ASSEMBLY
(a) Be sure to inspect the valve lash adjuster before
installing it (see page EM-75).
(b) Install the lash adjusters.
NOTICE:
Install the lash adjuster at the same place it was
removed from.
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21. INSTALL NO. 1 VALVE ROCKER ARM SUB-
ASSEMBLY
(a) Apply engine oil to the lash adjuster tips and valve
stem cap ends.
(b) Make sure that the valve rocker arms are installed
as shown in the illustration.
22. INSTALL CAMSHAFT BEARING CAP (for Bank 1)
(a) Apply engine oil to the camshaft journals, camshaft
housings and bearing caps.
(b) Install the No. 1 camshaft and No. 2 camshaft to the
camshaft housing.
(c) Confirm the marks and numbers on the camshaft
bearing caps and place them each in their proper
position and direction.
(d) Temporarily install the 8 bolts in the order shown in
the illustration.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
23. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for
Bank 1)
(a) Apply seal packing in a continuous line as shown in
the illustration.
Seal packing:
Toyota Genuine Seal Packing Block, Three
Bond 1207B or Equivalent
Standard seal diameter:
3.5 to 4.5 mm (0.138 to 0.177 in.)
NOTICE:
• Remove any oil from the contact surface.
• Install the camshaft housing within 3 minutes
and tighten the bolts within 15 minutes after
applying seal packing.
• Do not start the engine for at least 2 hours
after the installation.
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(b) Install the camshaft housing, and install the 12 bolts
in the order shown in the illustration.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
NOTICE:
Make sure that the knock pin of the camshaft is
positioned as shown in the illustration before
installing the camshaft housing.
(c) Tighten the 8 bolts in the order shown in the
illustration.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
NOTICE:
Thoroughly wipe clean any seal packing.
(d) Install 3 new gaskets.
24. INSTALL CAMSHAFT BEARING CAP (for Bank 2)
(a) Apply engine oil to the camshaft journals, camshaft
housings and bearing caps.
(b) Install the camshaft No. 3 and camshaft No. 4 to the
camshaft housing.
(c) Confirm the marks and numbers on the camshaft
bearing caps and place them each in their proper
position and direction.
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(d) Temporarily install the 8 bolts in the order shown in
the illustration.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for
Bank 2)
(a) Apply seal packing in a continuous line as shown in
the illustration.
Seal packing:
Toyota Genuine Seal Packing Block, Three
Bond 1207B or Equivalent
Standard seal diameter:
3.5 to 4.5 mm (0.138 to 0.177 in.)
NOTICE:
• Remove any oil from the contact surface.
• Install the camshaft housing within 3 minutes
and tighten the bolts within 15 minutes after
applying seal packing.
• Do not start the engine for at least 2 hours
after the installation.
(b) Install the camshaft housing and tighten the 13 bolts
in the order shown in the illustration.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
NOTICE:
Make sure that the knock pin of the camshaft is
positioned as shown in the illustration before
installing the camshaft housing.
(c) Tighten the 8 bolts in the order shown in the
illustration.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
NOTICE:
Thoroughly wipe clean any seal packing.
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(d) Install 3 new gaskets.
26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Install the chain tensioner with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(b) While pushing in the tensioner, insert a pin of
1.0
mm (0.039 in.) into the hole to fix it in place.
27. INSTALL CAMSHAFT TIMING GEARS AND NO. 2
CHAIN (for Bank 1)
(a) Align the mark plate (yellow) with the timing marks
(1 dot mark) of the camshaft timing gears as shown
in the illustration.
(b) Apply a small amount of engine oil to the bolt
threads and bolt-seating surface.
(c) Align the knock pin of the camshaft with the pin hole
of the camshaft timing gear. Install the camshaft
timing gear and camshaft timing exhaust gear with
the No. 2 chain installed.
(d) Hold the hexagonal portion of the camshaft with a
wrench, and tighten the 2 bolts.
Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
(e) Remove the pin from the No. 2 chain tensioner.
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EM–1222GR-FE ENGINE MECHANICAL – ENGINE UNIT
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28. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Install the chain tensioner with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(b) While pushing in the tensioner, insert a pin of
1.0
mm (0.039 in.) into the hole to fix it in place.
29. INSTALL CAMSHAFT TIMING GEARS AND NO. 2
CHAIN (for Bank 2)
(a) Align the mark plate (yellow) with the timing marks
(2 dot mark) of the camshaft timing gears as shown
in the illustration.
(b) Apply a small amount of engine oil to the bolt
threads and bolt-seating surface.
(c) Align the knock pin of the camshaft with the pin hole
of the camshaft timing gear. Install the camshaft
timing gear and camshaft timing exhaust gear with
the No. 2 chain installed.
(d) Hold the hexagonal portion of the camshaft with a
wrench, and tighten the 2 bolts.
Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
(e) Remove the pin from the No. 2 chain tensioner.
30. INSTALL CRANKSHAFT TIMING GEAR OR
SPROCKET
(a) Install the timing gear set keys and timing gear as
shown in the illustration.
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31. INSTALL NO. 1 CHAIN VIBRATION DAMPER
(a) Install the chain vibration damper with the 2 bolts.
Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf)
32. INSTALL NO. 2 CHAIN VIBRATION DAMPER
(a) Install the 2 chain vibration damper.
33. INSTALL IDLE SPROCKET ASSEMBLY
(a) Apply a light coat of engine oil to the rotating surface
of the No. 1 idle gear shaft.
(b) Temporarily install the No. 1 idle gear shaft and idle
sprocket with the No. 2 idle gear shaft while aligning
the knock pin of the No. 1 idle gear shaft with the
knock pin groove of the cylinder block.
NOTICE:
Be careful of the idle gear direction.
(c) Using a 10 mm hexagon wrench, tighten the No. 2
idle gear shaft.
Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
34. INSTALL CHAIN SUB-ASSEMBLY
(a) Align the mark plate and timing mark as shown in
the illustration and install the chain.
NOTICE:
Do not pass the chain over the crankshaft, just
put it on it.
HINT:
The chain mark plate is orange.
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