2006 TOYOTA RAV4 piston compression

PP–10PREPARATION – 2GR-FE ENGINE MECHANICAL
PP
EQUIPMENT
Alignment tester -
Angle gauge -
Brass bar -
Caliper gauge -
Chain block -
Compression gauge -
CO/HC meter -
Connecting rod aligner -
Cylinder gauge -
Dial indicator with magnetic base -
Engine stand -
Feeler gauge -
Gasket scraper -
Magnetic finger -
Micrometer -
Needle-nose pliers -
No. 1 engine hanger -
No. 2 engine hanger -
Pin hole grinder -
Piston ring compressor -
Piston ring expander -
Piston heater -
Plastigage -
Plastic-faced hammer -
Press -
Radiator cap tester -
Reamer (5.5 mm) -
Ridge reamer -
Rod aligner -
Sandpaper (#400) -
Slide calipers -
Straightedge -
Spring scale -
Spring tension gauge -
Steel square -
Tachometer -
Timing light -
Toe-in gauge -
To r q u e w r e n c h -
Valve seat cutter -
V-block -
Vernier calipers -
Vise -
Wooden block -

2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–133
EM
61. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2
compression rings.
(b) Remove the oil ring and expander by hand.
62. REMOVE PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, pry out the 2 snap rings.
63. REMOVE PISTON
(a) Gradually heat the piston up to 80 to 90
C (176 to
194
F).
(b) Using a plastic-faced hammer and brass bar, lightly
tap out the piston pin, then remove the connecting
rod.
HINT:
• The piston and pin are a matched set.
• Arrange the piston, pin, ring, connecting rod and
bearings in the correct order.
64. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance
while prying the crankshaft back and forth with a
screwdriver.
Standard thrust clearance:
0.04 to 0.24 mm (0.0016 to 0.0095 in.)
Maximum thrust clearance:
0.30 mm (0.012 in.)
If the thrust clearance is greater than the maximum,
replace the thrust washers as a set.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–73
EM
(v) Remove the upper bearings and upper thrust
washers from the cylinder block.
HINT:
Arrange the bearings and thrust washers in the
correct order.
57. REMOVE CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSEMBLY
(a) Remove the 2 water drain cocks from the cylinder
block.
(b) Remove the water drain cock plugs from the water
drain cocks.
58. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, remove the 3 oil
nozzles.
(b) Check the oil nozzles for damage or clogging.
If necessary, replace the oil nozzle.
59. REMOVE PISTON RING SET
HINT:
Arrange the piston rings in the correct order.
(a) Using a piston ring expander, remove the 2
compression rings.
(b) Using a piston ring expander, remove the 2 side
rails.
(c) Remove the oil ring expander by hand.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–107
EM
(d) Align the front marks of the piston and connecting
rod, and push in the piston pin with your thumb.
HINT:
The piston and pin are a matched set.
(e) Check the fitting condition between the piston and
piston pin by trying to move the piston back and
forth on the piston pin.
(f) Using a screwdriver, install a new snap ring at the
other end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not
aligned with the pin hole cutout portion of the piston.
4. INSTALL PISTON RING SET
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2
compression rings so that the painted marks are
positioned as shown in the illustration.
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U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–169
AX
18. REMOVE C-3 ACCUMULATOR PISTON
(a) Remove the compression spring from the C-3
accumulator piston.
(b) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the oil hole and remove the C-3 accumulator
piston.
NOTICE:
• Applying compressed air may cause the
piston to jump out. When removing the
piston, hold it with your hand using a waste
cloth.
• Make sure not to spatter ATF when applying
compressed air.
(c) Remove the O-ring from the C-3 accumulator
piston.
19. REMOVE C-1 ACCUMULATOR PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the oil hole and remove the C-1 accumulator
piston and compression spring.
NOTICE:
• Applying compressed air may cause the
piston to jump out. When removing the
piston, hold it with your hand using a waste
cloth.
• Make sure not to spatter ATF when applying
compressed air.
(b) Remove the 2 O-rings from the C-1 accumulator
piston.
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AX–170U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
20. REMOVE B-3 ACCUMULATOR PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the oil hole and remove the B-3 accumulator
piston and 2 compression springs.
NOTICE:
• Applying compressed air may cause the
piston to jump out. When removing the
piston, hold it with your hand using a waste
cloth.
• Make sure not to spatter ATF when applying
compressed air.
(b) Remove the O-ring from the B-3 accumulator
piston.
21. REMOVE MANUAL DETENT SPRING SUB-
ASSEMBLY
(a) Remove the 2 bolts, manual detent spring and
cover.
22. REMOVE PARKING LOCK PAWL BRACKET
(a) Remove the 2 bolts and parking lock pawl bracket.
23. REMOVE MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using needle-nose pliers, remove the retainer
spring.
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AX–212U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
(c) Install the compression spring from the C-3
accumulator piston.
53. INSTALL CHECK BALL BODY
(a) Install the check ball body and spring.
54. INSTALL TRANSMISSION WIRE
(a) Coat a new O-ring with ATF, and install it to the
transaxle solenoid wire.
(b) Install the solenoid wire retaining bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
55. INSTALL BRAKE DRUM GASKET
(a) Coat a new brake drum gasket with ATF, and install
it to the transaxle.
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