2006 TOYOTA RAV4 2gr

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–91
EM
27. INSPECT CYLINDER BORE
(a) Using a cylinder gauge, measure the cylinder bore
diameter at positions A and B in the thrust and axial
directions.
Standard diameter:
94.000 to 94.012 mm (3.7008 to 3.7013 in.)
Maximum diameter:
94.200 mm (3.7087 in.)
If the diameter is greater than the maximum, replace
the cylinder block.
28. INSPECT PISTON SUB-ASSEMBLY WITH PIN
(a) Using a micrometer, measure the piston diameter at
right angles to the piston center line where the
distance from the bottom edge of the piston is as
specified.
Distance:
9.8 mm (0.3858 in.)
Standard diameter:
93.960 to 93.980 mm (3.6992 to 3.6999 in.)
Maximum diameter:
93.830 mm (3.6941 in.)
29. INSPECT PISTON OIL CLEARANCE
(a) Measure the cylinder bore diameter in the thrust
direction.
(b) Subtract the piston diameter measurement from the
cylinder bore diameter measurement.
Standard oil clearance:
0.020 to 0.052 mm (0.0007 to 0.0020 in.)
Maximum oil clearance:
0.06 mm (0.0024 in.)
If the oil clearance is greater than the maximum,
replace all the pistons. If necessary, replace the
cylinder block.
A131994E01
A131969E02

EM–922GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
30. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance
between a new piston ring and the wall of the ring
groove.
Standard ring groove clearance
If the clearance is not as specified, replace the
piston.
31. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond
the bottom of the ring travel, 110 mm (4.33 in.) from
the top of the cylinder block.
(c) Using a feeler gauge, measure the end gap.
Standard end gap
Maximum end gap
If the end gap is greater than the maximum, replace
the piston ring. If the end gap is greater than the
maximum even with a new piston ring, replace the
cylinder block.
A131948
Item Specified Condition
No. 1 0.020 to 0.070 mm (0.0008 to 0.0028 in.)
No. 2 0.020 to 0.060 mm (0.0008 to 0.0024 in.)
Oil 0.070 to 0.150 mm (0.0028 to 0.0059 in.)
A132059E01
A101491
Item Specified Condition
No. 1 0.25 to 0.35 mm (0.0098 to 0.0138 in.)
No. 2 0.50 to 0.60 mm (0.0197 to 0.0236 in.)
Oil 0.10 to 0.40 mm (0.0039 to 0.0157 in.)
Item Specified Condition
No. 1 0.50 mm (0.0197 in.)
No. 2 0.85 mm (0.0335 in.)
Oil 0.60 mm (0.0236 in.)

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–93
EM
32. INSPECT PISTON PIN OIL CLEARANCE
(a) Check each mark on the piston, piston pin and
connecting rod.
(b) Using a caliper gauge, measure the inside diameter
of the piston pin hole.
Standard piston pin hole inside diameter
(c) Using a micrometer, measure the piston pin
diameter.
Standard piston pin diameter
(d) Subtract the piston pin diameter measurement from
the piston pin hole diameter measurement.
Standard oil clearance:
0.001 to 0.007 mm (0.00004 to 0.0003 in.)
Maximum oil clearance:
0.015 mm (0.0006 in.)
HINT:
If the oil clearance is greater than the maximum,
replace the piston and piston pin as a set.
A131950E01
A131823
Mark Specified Condition
A 22.001 to 22.004 mm (0.8662 to 0.8663 in.)
B 22.005 to 22.007 mm (0.8663 to 0.8664 in.)
C 22.008 to 22.010 mm (0.8665 to 0.8665 in.)
A132060E01
Mark Specified Condition
A 21.997 to 22.000 mm (0.8660 to 0.8661 in.)
B 22.001 to 22.003 mm (0.8662 to 0.8663 in.)
C 22.004 to 22.006 mm (0.8663 to 0.8664 in.)

EM–942GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(e) Using a caliper gauge, measure the inside diameter
of the connecting rod bush.
Standard bush inside diameter
(f) Subtract the piston pin diameter measurement from
the bush inside diameter measurement.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance:
0.03 mm (0.0012 in.)
HINT:
If the oil clearance is greater than the maximum,
replace the bush. If necessary, replace the
connecting rod and piston pin as a set.
33. INSPECT CONNECTING ROD SUB-ASSEMBLY
(a) Using a rod aligner and feeler gauge, check the
connecting rod alignment.
(1) Check for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If the bend is greater than the maximum,
replace the connecting rod.
(2) Check for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than the maximum,
replace the connecting rod.
34. INSPECT CONNECTING ROD BOLT
(a) Using a vernier caliper, measure the tension portion
diameter of the bolt.
Standard diameter:
7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter:
7.0 mm (0.276 in.)
If the diameter is less than the minimum, replace the
bolt.
A132061
Mark Specified Condition
A 22.005 to 22.008 mm (0.8663 to 0.8665 in.)
B 22.009 to 22.011 mm (0.8665 to 0.8666 in.)
C 22.012 to 22.014 mm (0.8666 to 0.8667 in.)
A132171
A132172
A132062E01

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–95
EM
35. INSPECT CRANKSHAFT
(a) Inspect for circle runout.
(1) Place the crankshaft on the V-blocks.
(2) Using a dial indicator, measure the circle runout
at the center journal.
Maximum circle runout:
0.06 mm (0.0024 in.)
If the circle runout is greater than the
maximum, replace the crankshaft.
(b) Inspect the main journals.
(1) Using a micrometer, measure the diameter of
each main journal.
Standard journal diameter:
60.988 to 61.00 mm (2.4011 to 2.4016 in.)
If the diameter is not as specified, check the oil
clearance. If necessary, replace the crankshaft.
(2) Check each main journal for taper and out-of-
round as shown in the illustration.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
If the taper and out-of-round is greater than the
maximum, replace the crankshaft.
(c) Inspect the crank pin.
(1) Using a micrometer, measure the diameter of
each crank pin.
Standard crank pin diameter:
52.992 to 53.000 mm (2.0863 to 2.0866 in.)
If the diameter is not as specified, check the oil
clearance. If necessary, replace the crankshaft.
(2) Check each crank pin for taper and out-of-
round as shown in the illustration.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
If the taper and out-of-round is greater than the
maximum, replace the crankshaft.
36. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using a vernier caliper, measure the minimum
diameter of the compressed thread at the
measuring point.
Standard diameter:
10.8 to 11.0 mm (0.4252 to 0.4331 in.)
Minimum diameter:
10.70 mm (0.4213 in.)
If the diameter is less than the minimum, replace the
bolt.
A131951
A131952
A131953
A132156E02

EM–962GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
REPLACEMENT
1. REPLACE SPARK PLUG TUBE GASKET
(a) Pry up the claws of the ventilation baffle plate.
(b) Using a screwdriver with its tip taped and a hammer,
tap out the 6 spark plug tube gaskets.
(c) Using a 32 mm socket wrench, tap in 6 new spark
plug tube gaskets to the head covers.
NOTICE:
• Keep the lip free from foreign matter.
• Do not tap on the oil seal at an angle.
(d) Return the claw of the ventilation baffle plate to its
original position.
2. REPLACE ENGINE REAR OIL SEAL
(a) Place the oil seal retainer on wooden blocks.
(b) Using a screwdriver and a hammer, tap out the oil
seal.
(c) Using SST, tap in a new oil seal until its surface is
flush with the oil seal retainer edge.
SST 09223-15030
NOTICE:
• Keep the lip free from foreign matter.
• Do not tap on the oil seal at an angle.
A131832
A131833
A095166E03
A131834E03
A131835E01

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–97
EM
3. REPLACE CONNECTING ROD SMALL END BUSH
(a) Using SST and a press, push out the bush.
SST 09222-30010
(b) Align the oil holes of the new bush and connecting
rod.
(c) Using SST and a press, push in the bush.
SST 09222-30010
(d) Using a pin hole grinder, hone the bush to obtain the
standard specified clearance between the bush and
piston pin.
(e) Coat the piston pin with engine oil. Push the piston
pin into the connecting rod with your thumb to check
that the piston pin fits at normal room temperature.
4. REPLACE INTAKE VALVE GUIDE BUSH
(a) Heat the cylinder head to approximately 80 to
100
C (176 to 212F).
(b) Place the cylinder head on wooden blocks.
A132154E01
A132157E01
A132154E01
A132159
A132160

EM–982GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(c) Using SST and a hammer, tap out the valve guide
bush.
SST 09201-10000 (09201-01050), 09950-70010
(09951-07100)
(d) Using a caliper gauge, measure the bush bore
diameter of the cylinder head.
Standard cylinder bore diameter:
10.285 to 10.306 mm (0.4049 to0.4057 in.)
(e) Select a new guide bush (STD or O/S 0.05).
Standard bush bore diameter
HINT:
• If the bush bore diameter of the cylinder head is
greater than 10.344 mm (0.4072 in.), machine
the bush bore diameter to between 10.383 to
10.394 mm (0.4088 to 0.4092 in.).
• If the bush bore diameter of the cylinder head is
greater than 10.344 mm (0.4072 in.), replace the
cylinder head.
(f) Heat the cylinder head to approximately 80 to
100
C (176 to 212F).
(g) Using SST and a hammer, tap in a new guide bush
to the specified protrusion height.
Standard protrusion height:
9.1 to 9.9 mm (0.3582 to 0.3900 in.)
SST 09201-10000 (09201-01050), 09950-70010
(09951-07100)
A132034E01
A132005
Bush Size Specified Condition
Use STD 10.335 to 10.356 mm (0.4069 to
0.4077 in.)
Use O/S 0.05 10.285 to 10.306 mm (0.4049 to
0.4057 in.)
A132035E01