2006 TOYOTA RAV4 2gr

EM–422GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
79. INSTALL V-BANK COVER SUB-ASSEMBLY
(a) Attach the 3 clips to install the engine cover.
80. INSTALL RADIATOR SUPPORT OPENING COVER
(a) Install the cover with the 9 clips.
81. ADJUST FRONT WHEEL ALIGNMENT
(a) Adjust the front wheel alignment (see page SP-3).
82. INSPECT IDLE SPEED (See page EM-2)
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EM–522GR-FE ENGINE MECHANICAL – ENGINE UNIT
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DISASSEMBLY
1. REMOVE OIL FILLER CAP SUB-ASSEMBLY
2. REMOVE SPARK PLUG
3. REMOVE CAMSHAFT TIMING CONTROL VALVE
ASSEMBLY (See page ES-440)
4. REMOVE VVT SENSOR (See page ES-443)
5. REMOVE WATER OUTLET
(a) Remove the 2 bolts, 4 nuts and water outlet.
(b) Remove the 2 gaskets and O-ring.
6. REMOVE OIL PIPE
(a) Remove the bolt, 2 union bolts and oil pipe.
(b) Remove the oil control valve filter RH and gaskets.
7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 1)
(a) Remove the 12 bolts, cylinder head cover and
gasket.
HINT:
Make sure the removed parts are returned to the
same places they were remove a from.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–53
EM
8. REMOVE NO. 1 OIL PIPE
(a) Remove the 2 union bolts and oil pipe.
(b) Remove the oil control valve filter LH and gaskets.
9. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 2)
(a) Remove the 12 bolts, cylinder head cover and
gasket.
HINT:
Make sure the removed parts are returned to the
same places they were remove a from.
10. REMOVE FRONT NO. 1 ENGINE MOUNTING
BRACKET
(a) Remove the 6 bolts and mounting bracket.
11. REMOVE WATER INLET HOUSING (See page CO-12)
12. REMOVE OIL FILTER CAP ASSEMBLY (See page LU-
4)
13. REMOVE OIL FILTER ELEMENT (See page LU-5)
14. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY (See page
LU-12)
15. REMOVE OIL STRAINER SUB-ASSEMBLY (See page
LU-13)
16. REMOVE OIL PAN SUB-ASSEMBLY (See page LU-13)
17. REMOVE OIL PAN BAFFLE PLATE
(a) Remove the 7 bolts and baffle plate.
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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.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–55
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(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
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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.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–57
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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.
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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.
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