2006 TOYOTA RAV4 Install oil pan sub-assembly

LU–122GR-FE LUBRICATION – OIL PUMP
LU
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE (See page
FU-9)
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 ENGINE ASSEMBLY
(a) Remove the engine from the vehicle (see page EM-
21).
4. INSTALL ENGINE TO STAND
5. REMOVE NO. 2 OIL DIPSTICK GUIDE
(a) Remove the oil dipstick.
(b) Remove the bolt and dipstick guide.
6. REMOVE OIL DIPSTICK GUIDE
(a) Remove the bolt and dipstick guide.
7. REMOVE OIL FILTER CAP ASSEMBLY (See page LU-
4)
8. REMOVE OIL FILTER ELEMENT KIT (See page LU-5)
9. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
(a) Remove the 16 bolts and 2 nuts.
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EM–242AZ-FE ENGINE MECHANICAL – TIMING CHAIN
EM
18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Disconnect the 2 ventilation hoses form the cylinder
head cover.
(b) Remove the 2 bolts and disconnect the 2 engine
wires.
(c) Remove the 8 bolts, 2 nuts and cylinder head cover.
19. REMOVE OIL PAN SUB-ASSEMBLY
(a) Install the No. 1 and No. 2 engine hangers with the
bolts.
Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf)
Part No.
(b) Attach the sling device to the engine hangers and
chain block.
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Item Part No.
No. 1 engine hanger 12281-28010
No. 2 engine hanger 12282-28010
Bolt 91512-61020

2AZ-FE ENGINE MECHANICAL – TIMING CHAINEM–39
EM
(b) Turn the crankshaft counterclockwise, then
disconnect the plunger knock pin from the hook.
(c) Turn the crankshaft clockwise, then check that the
plunger is extended.
13. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material and be careful not
to drop any oil on the contact surfaces of the
cylinder block and oil pan.
(b) Apply a continuous bead of seal packing (Diameter
3.0 to 4.0 mm (0.118 to 0.157 in.)) 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.
• Instal l the oil pan wit hin 3 mi nut es of app lyi ng
seal packing.
• Do not add engine oil for at least 2 hours after
installing the oil pan.
(c) Install the oil pan to the cylinder block.
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EM–402AZ-FE ENGINE MECHANICAL – TIMING CHAIN
EM
(d) Uniformly tighten the 12 bolts and 2 nuts in the
sequence shown in the illustration.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(e) Place a transmission jack underneath the engine,
then put a wooden block on the jack.
(f) Remove the chain block and sling device.
(g) Remove the No. 1 and No. 2 engine hangers.
14. INSTALL CRANKSHAFT POSITION SENSOR (See
page ES-402)
15. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove any old packing material from the contact
surface.
(b) Apply seal packing to the 2 locations 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 oil pan within 3 minutes of applying
seal packing.
• Do not add engine oil for at least 2 hours after
installing the oil pan.
(c) Install the cylinder head cover with the 8 bolts and 2
nuts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) for bolt A
14 N*m (143 kgf*cm, 10 ft.*lbf) for bolt B
11 N*m (112 kgf*cm, 8 ft.*lbf) for nut
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2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–85
EM
(c) Examine the front marks and numbers, and check
that the order is as shown in the illustration. Then
install the bearing caps onto the cylinder head.
(d) Apply a light coat of engine oil to the threads and
under the heads of the bearing cap bolts.
(e) Using several steps, uniformly tighten the 20
bearing cap bolts in the sequence shown in the
illustration.
Torque: 29.5 N*m (301 kgf*cm, 22 ft.*lbf) for No.
1 and No. 2 bearing cap
9.0 N*m (92 kgf*cm, 80 in.*lbf) for No. 3
bearing cap
NOTICE:
Install the camshaft with the timing mark of the
camshaft timing gear on top.
6. INSTALL NO. 1 CHAIN VIBRATION DAMPER (See
page EM-33)
7. INSTALL CHAIN SUB-ASSEMBLY (See page EM-33)
8. INSTALL CHAIN TENSIONER SLIPPER (See page
EM-34)
9. INSTALL TIMING CHAIN GUIDE (See page EM-34)
10. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR
PLATE (See page EM-35)
11. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(See page EM-35)
12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (See
page EM-37)
13. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(See page EM-38)
14. INSTALL ENGINE MOUNTING BRACKET RH (See
page EM-38)
15. INSTALL CRANKSHAFT PULLEY (See page EM-38)
16. INSTALL OIL PAN SUB-ASSEMBLY (See page EM-39)
17. INSTALL CRANKSHAFT POSITION SENSOR (See
page ES-402)
18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(See page EM-40)
19. INSTALL SPARK PLUG (See page EM-16)
20. INSTALL IGNITION COIL ASSEMBLY (See page IG-9)
21. INSTALL IDLER PULLEY (See page EM-41)
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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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LU–222GR-FE LUBRICATION – OIL PUMP
LU
(f) Tighten the bolts in this order: Area 1, Area 2, Area
3, Area 4.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for Area
1, 2 bolt
21 N*m (214 kgf*cm, 15 ft.*lbf) for Area 3
bolt, nut
43 N*m (438 kgf*cm, 32 ft.*lbf) for Area 4
bolt A
21 N*m (214 kgf*cm, 15 ft.*lbf) for Area 4
except bolt A
2. INSTALL CRANKSHAFT PULLEY (See page EM-126)
3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 2) (See page EM-127)
4. INSTALL NO. 1 OIL PIPE (See page EM-128)
5. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 1) (See page EM-127)
6. INSTALL OIL PIPE (See page EM-127)
7. INSTALL WATER INLET HOUSING (See page CO-14)
8. INSTALL OIL PAN SUB-ASSEMBLY
(a) Install 2 new O-rings to the timing chain cover.
(b) Apply seal packing in a continuous line as shown in
the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three
Bond 1207B or Equivalent
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.156 in.)
NOTICE:
• Remove any oil from the contact surface.
• Install the oil pan 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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2GR-FE LUBRICATION – OIL PUMPLU–23
LU
(c) Install the oil pan with the 16 bolts and 2 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A
21 N*m (214 kgf*cm, 15 ft.*lbf) for
except bolt A, nut
9. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Install a new gasket and the oil strainer with the bolt
and 2 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
10. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
(a) Apply seal packing in a continuous line as shown in
the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three
Bond 1207B or Equivalent
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.156 in.)
NOTICE:
• Remove any oil from the contact surface.
• Install the oil pan within 3 minutes and tighten
the bolts within 10 minutes after applying seal
packing.
• Do not start the engine for at least 2 hours
after the installation.
(b) Install the oil pan with the 16 bolts and 2 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(c) Install a new gasket and the drain plug.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
11. INSTALL OIL FILTER ELEMENT KIT (See page LU-5)
12. INSTALL OIL FILTER CAP ASSEMBLY (See page LU-
5)
13. INSTALL OIL DIPSTICK GUIDE
(a) Install a new O-ring to the dipstick guide.
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