TOYOTA RAV4 2006 Service Repair Manual

EM–1242GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(b) Turn the camshaft timing gear on the bank 1
counterclockwise to tighten the chain between the
banks.
NOTICE:
If reusing the idle sprocket, align one of the idle
sprocket's chain plate marks with one of the
chain's chain plates when installing the idle
sprocket.
(c) Align the mark plate and timing mark as shown in
the illustration and install the chain onto the
crankshaft timing gear.
HINT:
The chain mark plate is yellow.
(d) Temporarily tighten the pulley set bolt.
(e) Turn the crankshaft clockwise to set it to the bank 1
block bore center line (TDC / compression).
35. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–125
EM
36. INSTALL 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 hole of the
stopper plate.
(c) Install the chain tensioner with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
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EM–1262GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(d) Remove the lock pin of the chain tensioner. Check
that each timing mark is aligned with the crankshaft
at the TDC / compression.
(e) Remove the pulley set bolt.
37. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (w/
Oil Pump) (See page LU-17)
38. INSTALL WATER PUMP ASSEMBLY (See page CO-
13)
39. INSTALL ENGINE REAR OIL SEAL RETAINER
(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:
2.0 to 3.0 mm (0.079 to 0.118 in.)
NOTICE:
• Remove any oil from the contact surface.
• Install the crankcase within 3 minutes after
applying seal packing.
• Do not start the engine for at least 2 hours
after the installation.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–127
EM
(b) Install the oil seal retainer with the 6 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
NOTICE:
Apply adhesive 1324 to the 2 bolts labeled A.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond
1324 or Equivalent
40. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the
pulley, and slide on the pulley.
(b) Using SST, install the pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021
Torque: 250 N*m (2,549 kgf*cm, 184 ft.*lbf)
41. INSTALL OIL PAN BAFFLE PLATE
(a) Install the oil pan baffle plate with the 7 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
42. INSTALL OIL PAN SUB-ASSEMBLY (See page LU-21)
43. INSTALL OIL STRAINER SUB-ASSEMBLY (See page
LU-22)
44. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY (See page
LU-22)
45. INSTALL OIL FILTER ELEMENT (See page LU-5)
46. INSTALL OIL FILTER CAP SUB-ASSEMBLY (See
page LU-5)
47. INSTALL WATER INLET HOUSING (See page CO-14)
48. INSTALL FRONT NO. 1 ENGINE MOUNTING
BRACKET
(a) Install the engine mounting bracket with the 6 bolts.
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
NOTICE:
• Install the water inlet and mounting bracket
within 15 minutes after installing the chain
cover.
• Do not start the engine for at least 2 hours
after the installation.
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EM–1282GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
49. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 1)
(a) Apply seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Block, Three
Bond 1207B or Equivalent
NOTICE:
• Remove any oil from the contact surface.
• Install the crankcase within 3 minutes after
applying seal packing.
• Do not start the engine for at least 2 hours
after the installation.
(b) Install the gasket to the head cover.
(c) Install the head cover with the 12 bolts in the order
shown in the illustration.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A
10 N*m (102 kgf*cm, 7 ft.*lbf) for except
bolt A
HINT:
Make sure the tightening torque of bolt 1and 11 in
correct.
50. INSTALL OIL PIPE
(a) Make sure that there is no foreign matter on the
mesh of the oil control valve filter.
(b) Install the oil control valve filter to the oil pipe union.
Install 2 new gaskets and temporarily install the oil
pipe (on the head cover side) with the oil pipe union.
NOTICE:
Remove any oil from the contact surface.
(c) Install a new gasket and temporarily install the oil
pipe (on the cylinder head side) with the oil pipe
union.
NOTICE:
Remove any oil from the contact surface.
(d) Install bolt A to the cylinder head.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(e) Tighten the 2 oil pipe union bolts.
Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
51. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 2)
(a) Apply seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Block, Three
Bond 1207B or Equivalent
NOTICE:
• Remove any oil from the contact surface.
• Install the crankcase within 3 minutes after
applying seal packing.
• Do not start the engine for at least 2 hours
after the installation.
(b) Install the gasket to the head cover.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–129
EM
(c) Install the head cover with the 12 bolts in the order
in the illastration.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A
10 N*m (102 kgf*cm, 7 ft.*lbf) for except
bolt A
HINT:
Make sure the tightening torque of bolts 1 and 10 is
correct.
52. INSTALL NO. 1 OIL PIPE
(a) Make sure that there is no foreign matter on the
mesh of the oil control valve filter.
(b) Install the oil control valve filter to the oil pipe union.
Install 2 new gaskets and temporarily install the oil
pipe (on the head cover side) with the oil pipe union.
(c) Install a new gasket and temporarily install the oil
pipe (on the cylinder head side) with the oil pipe
union.
NOTICE:
Remove any oil from the contract surface.
(d) Tighten the 2 oil pipe union bolts.
Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
53. INSTALL WATER OUTLET
(a) Install 2 new gaskets and a new O-ring.
(b) Apply soapy water to the O-ring.
(c) Install the water outlet with the 2 bolts and 4 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
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EM–1302GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
54. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
ASSEMBLY
(a) Install the 4 camshaft timing oil control valves with
the 4 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
55. INSTALL VVT SENSOR
(a) Install the 4 VVT sensors with the 4 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
56. INSTALL SPARK PLUG
(a) Install the 6 spark plugs.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–131
EM
REPAIR
1. REPAIR INTAKE VALVE SEAT
NOTICE:
Keep the lip free from foreign matter.
(a) If the seating is too high on the valve face, use 30

and 45
cutters to correct the seat.
(b) If the seating is too low on the valve face, use 60

and 45
cutters to correct the seat.
(c) Hand-lap the valve and valve seat with an abrasive
compound.
(d) Check the valve seating position.
2. REPAIR EXHAUST VALVE SEAT
NOTICE:
Keep the lip free from foreign matter.
(a) If the seating is too high on the valve face, use 30

and 45
cutters to correct the seat.
(b) If the seating is too low on the valve face, use 45

and 75
cutters to correct the seat.
(c) Hand-lap the valve and valve seat with an abrasive
compound.
(d) Check the valve seating position.
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2AZ-FE FUEL – FUEL INJECTORFU–9
FU
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
• DISCHARGE FUEL SYSTEM PRESSURE
procedures must be performed before
disconnecting any part of the fuel system.
• After performing the DISCHARGE FUEL SYSTEM
PRESSURE procedures, pressure will remain in
the fuel line. When disconnecting the fuel line,
place a cloth or equivalent over fittings to reduce
the risk of fuel spray.
(a) Remove the console box (see page IR-83).
(b) Disconnect the connector.
(c) Start the engine. After the engine has stopped, turn
the ignition switch off.
HINT:
DTC P0171 (system too lean) may be set.
(d) Check that the engine does not start.
(e) Remove the fuel tank cap, and let the air out of the
fuel tank.
(f) Connect the connector.
(g) Install the console box (see page IR-90).
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
3. REMOVE NO. 1 ENGINE COVER (See page ES-410)
4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-411)
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FU–102AZ-FE FUEL – FUEL INJECTOR
FU
5. DISCONNECT FUEL MAIN TUBE
NOTICE:
Do not forcibly bend and twist the fuel main tube.
(a) Remove the fuel tube from the fuel hose clamp.
(b) Remove the fuel pipe clamp.
(c) Wipe off any dirt on the fuel tube connector.
(d) Hold the fuel tube connector, and then install SST.
SST 09268-21010
(e) Turn SST to align the retainer inside the fuel tube
connector with the chamfered part of SST.
(f) Insert SST into the fuel tube and hold it. Then push
the fuel tube connector toward SST side.
(g) Mount the retainer of the fuel tube connector onto
the chamfered part of SST.
(h) Slide SST and fuel tube connector together towards
the fuel tube until they make a "click" sound, and
then disconnect the fuel tube.
(i) Drain the fuel remaining inside the fuel tube.
(j) Cover the fuel tube and fuel pipe with a plastic bag
to protect the disconnected part.
6. DISCONNECT NO. 2 VENTILATION HOSE
(a) Disconnect the No. 2 ventilation hose from the
ventilation valve.
7. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
(a) Remove the 2 wire harness clamps.
(b) Disconnect the 4 fuel injector connectors.
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