2006 TOYOTA RAV4 2gr

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–59
EM
34. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (for
Bank 2)
(a) While pushing down the 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.
35. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Remove the bolt and chain tensioner.
36. REMOVE CAMSHAFT SUB-ASSEMBLY (for Bank 2)
(a) Remove the 3 gaskets.
A132082E01
A132083E01
A132048
A132130

EM–602GR-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 13 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. 3 and No. 4 camshafts.
37. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY
(for Bank 2)
(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.
38. REMOVE NO. 1 VALVE ROCKER ARM SUB-
ASSEMBLY
(a) Remove the 24 valve rocker arms.
HINT:
Arrange the removed parts in the correct order.
A132141E01
A132131E01
A132132E01
A132084

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–61
EM
39. REMOVE VALVE LASH ADJUSTER ASSEMBLY
(a) Remove the 24 valve lash adjusters from the
cylinder head.
HINT:
Arrange the removed parts in the correct order.
40. REMOVE CYLINDER HEAD SUB-ASSEMBLY (for
Bank 1)
(a) Using a 10 mm bi-hexagon wrench, uniformly
loosen the 8 bolts in the sequence shown in the
illustration. Remove the 8 cylinder head bolts and
plate washers.
NOTICE:
• Be careful not to drop washers into the
cylinder head.
• Head warpage or cracking could result from
removing bolts in an incorrect order.
HINT:
Be sure to keep the removed parts separate for
each installation position.
(b) Remove the cylinder head and gasket.
41. REMOVE CYLINDER HEAD SUB-ASSEMBLY (for
Bank 2)
(a) Uniformly loosen and remove the 2 bolts in the
sequence shown in the illustration.
(b) Using a 10 mm bi-hexagon wrench, uniformly
loosen the 8 bolts in the sequence shown in the
illustration. Remove the 8 cylinder head bolts and
plate washers.
NOTICE:
• Be careful not to drop washers into the
cylinder head.
• Head warpage or cracking could result from
removing bolts in an incorrect order.
HINT:
Be sure to keep the removed parts separate for
each installation position.
(c) Remove the cylinder head and gasket.
42. REMOVE WATER INLET PIPE
(a) Disconnect the knock sensor wire.
A132143E03
A132144
A132145E03

EM–622GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(b) Remove the 2 bolts and water outlet pipe.
(c) Disconnect the water by-pass hose.
43. REMOVE VALVE STEM CAP
(a) Remove the valve stem caps from the cylinder
head.
HINT:
Arrange the removed parts in the correct order.
44. REMOVE INTAKE VALVE
(a) Using SST and wooden blocks, compress the
compression spring and remove the valve retainer
lock.
SST 09202-70020 (09202-00010)
(b) Remove the retainer, compression spring and valve.
HINT:
Arrange the removed parts in the correct order.
45. REMOVE EXHAUST VALVE
(a) Using SST and wooden blocks, compress the
compression spring and remove the valve retainer
lock.
SST 09202-70020 (09202-00010)
(b) Remove the retainer, compression spring and valve.
HINT:
Arrange the removed parts in the correct order.
46. REMOVE VALVE STEM OIL SEAL
(a) Using needle-nose pliers, remove the oil seals.
47. REMOVE VALVE SPRING SEAT
(a) Using compressed air and a magnetic finger,
remove the valve spring seat by blowing air onto it.
48. REMOVE NO. 1 STRAIGHT SCREW PLUG
NOTICE:
If water leaks from the No. 1 screw plug or the plug is
corroded, replace it.
A129713
A131991E01
A131992E01
A132167
A132168

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–63
EM
(a) Using a 10 mm hexagon wrench, remove the 4
screw plugs and 4 gaskets.
49. REMOVE NO. 2 STRAIGHT SCREW PLUG
(a) Using a 14 mm hexagon wrench, remove the 2
screw plugs and 2 gaskets.
NOTICE:
If water leaks from the No. 2 screw plug or the
plug is corroded, replace it.
50. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the bolt and crankshaft position sensor.
A131995E01
A131996E01
A129663

EM–642GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
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.
A131979
A131980E01
A131981
A131982E01

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–65
EM
(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.
A131983E01
A131984
A101478E06

EM–662GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(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.
A131985E01
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.)
A129720E01