Toyota PAB4-Toyota RAV4
1. Operation of the car
2. Maintenance
3. Engines
   Repair of the engine 3S-FE without its removal from the car
      General information
      Specifications
      Installation of the piston of the first cylinder in the top dead point (TDP)
      Cover of a head of the block of cylinders
      Inlet collector
      Final collector
      Gear belt and pulleys of a gear belt
      Forward sealing ring of a bent shaft
      Sealing ring of the camshaft
      Camshafts and pushers of valves
      Head of the block of cylinders
      Oil pallet
      Oil pump
      Drive flywheel / plate
      Back sealing ring of a bent shaft
      Support of the power unit
   Repair of the engine 1AZ-FE without its removal from the car
   Diagnostics and preparation of the engine for capital repairs
4. Cooling systems and conditioning
5. Fuel system and system of production of the fulfilled gases
6. System of ignition
7. The control system and decrease in toxicity of the fulfilled gases
8. Coupling
9. Transmission
10. Driveshaft and shaft of the drive of driving wheels
11. Brake system
12. Suspension bracket
13. Steering and running gear
14. Body
15. Electric equipment
Schemes of electric equipment


Toyota RAV4>> Engines>> Repair of the engine 3S-FE without its removal from the car>> Gear belt and pulleys of a gear belt
Removal
You make removal in the following order:
– switch off ignition and disconnect a wire of "weight" from the rechargeable battery;
– tighten the parking brake and block back wheels an emphasis;
– weaken nuts of fastening of the right forward wheel. Lift a forward part of the car and establish on support. Remove the right forward wheel and an antisplash guard of an arch of the right forward wheel;
– remove a filling tank of the amplifier of steering together with an arm. If the car is equipped with anti-blocking system of brakes (ABS), remove the ABS block together with an arm;

Fig. 3.11. Drive of the gas-distributing mechanism: 1 – pulley of a bent shaft; 2 – lower casing of a gear belt; 3 – top casing of a gear belt; 4 – gear belt; 5 – guide of a gear belt; 6 – high-voltage wires with candle tips; 7 – spark plug; 8 – spring; 9 – pulley of a gear belt of a bent shaft; 10 – pulley of the oil pump; 11 – single roller; 12 – tension roller; 13 – pulley of a gear belt of the camshaft; 14 – a protective box for a plait of wires


– having pulled up and at the same time turning, remove tips with high-voltage wires 6 (fig. 3.11) from spark plugs;
– a stream of compressed air clear candles that will exclude hit of dirt in the engine cylinder after a reversing of spark plugs. Turn out spark plugs;
– take off poliklinovy belts of the drive of hinged units;
– remove the generator and an arm of the generator;
– separate from a forward part of the engine a protective box 14 for a plait of wires;
– by a jack through wooden whetstone, for the oil pallet support the engine. Turn out 3 bolts and remove the right support of the engine;
– turn out screws, disconnect drafts and wires and remove the top casing 3 gear belts and laying;

Fig. 3.12. VMT tag on a cover of a head of the block of cylinders observed through a small opening of a pulley of a gear belt of the camshaft


– install the piston of the first cylinder in VMT (in the provision of a step of compression). Check that through a small opening of a pulley of a gear belt of the camshaft VMT tag on a cover of a head of the block of cylinders (fig. 3.12) is visible ;
– chalk, a marker or paint note the direction of rotation of a gear belt, and also apply combination tags on a pulley of the camshaft and a gear belt. If at installation the gear belt rotates in other party, it will lead to its destruction;

Fig. 3.13. Arrangement of a bolt of fastening of a tension roller and removal of a spring


– weaken a bolt of fastening of a tension roller and remove a spring (fig. 3.13) . Take off a gear belt from pulleys. If it is necessary to remove a head of the block of cylinders, the camshaft or to replace a sealing ring of the camshaft, it is not required to take off a gear belt from a pulley of a bent shaft;

Fig. 3.14. Use of keys for deduction of the camshaft from a provorachivaniye and an otvorachivaniye of a bolt of fastening of a pulley of a gear belt


– if the pulley of a gear belt of the camshaft is worn-out or damaged, uncover a head of the block of cylinders. Holding a wrench the camshaft from a provorachivaniye (fig. 3.14) for a hexagon, turn out a bolt of fastening and remove a pulley of a gear belt from the camshaft;

Fig. 3.15. Fixing by a flywheel screw-driver edge from a provorachivaniye and an otvorachivaniye of a bolt of fastening of a pulley of a bent shaft


– uncover, closing an opening for survey of a flywheel, and an edge of the big flat screw-driver for a gear wreath of a flywheel record it from a provorachivaniye (fig. 3.15) . Turn out a bolt of fastening of a pulley of a bent shaft. As the bolt is strongly tightened, use a key with a big shoulder. Using mount or a stripper of a quencher of fluctuations, remove a pulley from a bent shaft (fig. 3.16) . Before removal of a pulley be convinced that the piston of the first cylinder is installed in VMT;

Fig. 3.16. Use of mount for removal of a pulley from a bent shaft


Fig. 3.17. Arrangement of bolts of fastening of the lower casing of a gear belt


– turn out bolts (fig. 3.17) and remove the lower casing of a gear belt and its laying. Remove a guide of a gear belt from a bent shaft;
– if the gear belt is repeatedly established, apply combination tags on a pulley of a bent shaft and a gear belt;
– shift a gear belt from a pulley and remove it from the engine;

Fig. 3.18. Use of a stripper for removal of a pulley from a bent shaft


– if the pulley is worn-out or damaged or it is necessary to replace a forward sealing ring of a bent shaft, remove a pulley of a gear belt from a bent shaft. The pulley has to be removed easily from a bent shaft. If the pulley is put very densely, remove its stripper (fig. 3.18) . For fastening of captures of a stripper drill 2 openings in a pulley and cut in them a carving.
Check

       PREVENTION
Do not overwind and do not bend a gear belt. Exclude hit on a gear belt of oil, cooling liquid or fuel.
Do not turn a bent shaft of the engine at the taken-off gear belt as pistons can hit against valves.

Check a state and smoothness of rotation of single and tension rollers. Check a state and measure length of a spring which for engines from 1996 to 1997 has to be equal to 46,0 mm, and for engines from 1998 to 2000 – 42,0 mm.
The rupture of a gear belt on the working engine can lead to blow of pistons about valves therefore valves can be deformed. Check gaps of valves. On the deformed valves they will be much more demanded.
If there was a vykroshivaniye of teeths of a gear belt, perhaps, jammed the water pump , the oil pump or the camshaft.
If the external surface of a gear belt is considerably worn-out or stratified, check conditions of racetracks of single and tension rollers.
If wear or damage are found only on one party of a belt, check a guide of a gear belt and alignment of pulleys of a gear belt.

       PREVENTION
With any defects on a gear belt replace it surely.

       NOTE
Professionals recommend replacement of a gear belt every time when he acts as the rupture of a belt on the working engine can lead to serious damage of the engine and expensive repair.

Installation
You make installation in the following order:
– wipe all dirt and lubricant in a forward part of the engine, in a zone of work of a gear belt;
– if acted, then establish to the place of single and tension rollers and a spring of a tension roller. Take away a tension roller to the maximum tension of a spring and temporarily enshrine by a bolt it in this provision;
– establish pulleys of a gear belt on distributive and cranked shaft. Establish a pulley of a bent shaft so that teeths of the sensor of a bent shaft settled down from a forward cover of the engine;
– check that through a small opening of a pulley of a gear belt of the camshaft VMT tag on a cover of a head of the block of cylinders is visible (see fig. 3.12 ), and the spline of a pulley of a bent shaft is directed to sign VMT on a forward cover. In this case the piston of the first cylinder is in VMT in a compression step;
– establish a gear belt on pulleys of a bent shaft, the oil pump, water pump and single and tension rollers. At repeated installation of a gear belt, combine earlier put tags;

Fig. 3.19. The party of a guide of a gear belt which has to be located from a belt


– establish on a bent shaft a guide of a gear belt, the party with the drawing of teeths to a gear belt (fig. 3.19) ;

Fig. 3.21. Places of drawing a layer of sealant on the top and lower casing of a gear belt


– apply on a privalochny surface a sealant layer (see fig. 3.21 ), establish the lower casing of a gear belt and fix it by bolts;
– establish a pulley of a bent shaft and check combination of a tag on a pulley with sign VMT on a forward cover. Screw and tighten a bolt of fastening of a pulley the moment of 108 N • m;

Fig. 3.20. The branch tense at installation of a gear belt on a camshaft pulley


– establish a gear belt on a camshaft pulley, at the same time pulling the belt branch located from the forward party of the engine (fig. 3.20) ;
– weaken a bolt of fastening of a tension roller in the taken-away situation, at the same time the spring will turn a roller therefore there will be a belt tension;
– for a bolt of fastening of a pulley of a bent shaft, slowly turn a bent shaft clockwise on 1 7/8 turns before combination of a tag on a pulley of a bent shaft with a sign 45 ° to VMT located on the lower casing of a gear belt then tighten a bolt of fastening of a tension roller the moment of 42 N • m;

Fig. 3.1. Combination of a tag on a quencher of fluctuations with sign VMT on a forward cover


– for a bolt of fastening of a pulley of a bent shaft turn a bent shaft clockwise on 2 1/8 turns before combination of a tag on a quencher of fluctuations with sign VMT on a forward cover (see fig. 3.1 ). Check that through a small opening of a pulley of a gear belt of the camshaft VMT tag on a cover of a head of the block of cylinders is visible, otherwise repeat operations on installation of a gear belt (see fig. 3.12 ).

       PREVENTION
Do not launch the engine until are not sure absolutely not that the gear belt is established correctly. If the belt is established incorrectly, perhaps serious and expensive damage of the engine.

Further installation is carried out to the sequences, the return to removal, taking into account the following.
Apply a sealant layer on a privalochny surface, establish the top casing of a gear belt and fix it by screws (fig. 3.21) .