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>> Camshafts and pushers of valves
Removal

       NOTE
At removal and installation of camshafts it is necessary to use 2 additional technological bolts of M6x1 16-20 mm long

You make removal in the following order:
– uncover a head of the block of cylinders;
– remove the ignition distributor;
– take off a gear belt, a pulley of the camshaft and a back casing of a gear belt;

Fig. 3.25. Installation of the indicator of hour type for measurement of an axial gap of the camshaft


– check an axial gap of the camshaft. Establish on the block of cylinders of the engine an arm with the indicator of hour type so that the measuring tip of the indicator rested against an end face of the camshaft (fig. 3.25) ;
– move the camshaft along an axis to one party against the stop and install the indicator on 0. Move the camshaft along an axis to other party against the stop and record value on the indicator. If the size of a gap exceeds admissible size, it is necessary to replace the camshaft and / or a head of the block of cylinders;

Camshaft of final valves

Fig. 3.26. Position of the camshaft of inlet valves in situation at which the adjusting pin (1) settles down at the left at an angle 10–45 ° from a vertical axis


– turn the camshaft of inlet valves so that the adjusting pin of 1 (fig. 3.26) settled down at the left at an angle 10–45 ° from a vertical axis. In this case the camshaft of final valves will turn in situation at which pressure of valvate springs upon all cams of the camshaft will be uniform;

Fig. 3.27. An arrangement of a bolt of fastening of an auxiliary gear wheel of the camshaft of final valves to the main gear wheel


– an additional technological bolt of M6x1 attach an auxiliary gear wheel of the camshaft of final valves to the main gear wheel (fig. 3.27) ;
– turn out 2 bolts and remove a back cover of the bearing of the camshaft;
– in turn, turning on 1/4 turns, weaken, then turn out completely bolts of fastening of covers 1, 2 and 4 fastenings of bearings of the camshaft. Remove 1, 2 and 4 covers of bearings of the camshaft;
– in turn, turning on 1/4 turns, weaken, then turn out completely bolts of fastening of a cover 3 bearings of the camshaft. Uncover 3 bearings of the camshaft;
– remove the camshaft;
– for removal of a gear wheel from the camshaft of final valves fix the camshaft for a hexagon in a vice with soft sponges;
– establish the second additional bolt of M6x1 in a technological opening of an auxiliary gear wheel of the camshaft. The screw-driver inserted between the camshaft and the second auxiliary bolt turn an auxiliary gear wheel clockwise and turn out the first auxiliary bolt;
– remove a spring lock ring of fastening of an auxiliary gear wheel;
– remove a spring washer, an auxiliary gear wheel and a spring ring of a gear wheel of the camshaft.

       PREVENTION
During the easing and a reversing of bolts of fastening of covers of bearings of the camshaft be convinced that the camshaft evenly, without distortion separates from a head of the block of cylinders. Otherwise establish to the place of a cover of bearings and turn the camshaft of inlet valves so that the adjusting pin settled down at the left at an angle 10–45 ° from a vertical axis (see fig. 3.26 ).

Camshaft of inlet valves

Fig. 3.28. Position of the camshaft of inlet valves in situation at which the adjusting pin (1) settles down at the left at an angle 80–115 ° from a vertical axis


– turn the camshaft of inlet valves so that the adjusting pin of 1 (fig. 3.28) settled down at the left at an angle 80–115 ° from a vertical axis;
– turn out bolts and remove a forward cover of bearings of the camshaft of inlet valves and a sealing ring;
– in turn, turning on 1/4 turns, weaken, then turn out completely bolts of fastening of covers 1, 3 and 4 fastenings of bearings of the camshaft. Remove 1, 3 and 4 covers of bearings of the camshaft;
– in turn, turning on 1/4 turns, weaken, then turn out completely bolts of fastening of a cover 2 bearings of the camshaft. Uncover 2 bearings of the camshaft;
– remove the camshaft.
Check
You make check in the following order:

Fig. 3.29. The place of measurement of distance between the ends of a spring of a gear wheel of the camshaft: X = 22,5–22,9 mm


1) measure distance between the ends of a spring of a gear wheel of the camshaft which has to make 22,5–22,9 mm (fig. 3.29) . Otherwise replace a spring;

       PREVENTION
Do not uncover, using levers. If it is not uncovered, leave it on the place.

2) wipe from oil and mark adjusting washers and pushers, the magnetized tool remove them from a head of the block of cylinders and arrange them so that at installation they were established on the places;
3) check each pusher for lack of wear and zadir;
4) measure the outer diameter of each pusher and the corresponding nests of pushers. For definition of a gap subtract diameter of a pusher from diameter of a nest. Nominal rate of a gap of a pusher of 0,024-0,052 mm, maximum permissible value – 0,07 mm. If the gap exceeds maximum permissible value, replace pushers;
5) visually investigate cams and necks of bearings of camshafts on lack of development, corrosion traces, navolakivany metal and existence of the flowers of a pobezhalost testifying to a local overheat;
6) a micrometer measure height by a camshaft cam. Nominal rate of height of cams of the camshaft of inlet valves of 42,01-42,11 mm, maximum permissible value – 41,9 mm. Nominal rate of height of cams of the camshaft of final valves of 40,06-40,16 mm, maximum permissible value – 39,95 mm. If height of cams is less than maximum permissible value, replace the camshaft.
7) measure by a micrometer diameter of each neck of bearings of the camshaft. Measure necks in several points, both on diameter, and on length, it will allow to reveal ovality and conicity at their existence. Nominal rate of diameter of necks of bearings of the camshaft of 26,959-26,975 mm. If diameter of any neck is less than nominal rate, replace the camshaft;
8) check gaps in camshaft bearings as follows;
9) the method of check consists in using the product known as Plastigage. It is the round calibrated plastic core which contracts between a cover of the bearing and a neck of the camshaft. After removal of a cover of the bearing the deformed plastic core is measured by a special template which is available in Plastigage set.
10) the procedure for Plastigage use following:
– clear necks of the camshaft, a cover of bearings and an installation site of the camshaft in a head of the block of cylinders;
– install camshafts in a head of the block of cylinders without lubricant and pushers;
– cut off several pieces of a plastic core of Plastigage (they have to be slightly shorter, than width of bearings) and establish them on each neck of the camshaft;
– establish covers of bearings which identification shooters have to be directed towards a gear belt and tighten fastening bolts the required moment. You carry out tightening of bolts in turn, consistently turning each bolt on 1/4 turns;

Fig. 3.30. Measurement of width of the deformed Plastigage core with use of a large-scale ruler


– turn out bolts and uncover bearings of camshafts. Apply the large-scale ruler printed on packing to the deformed plastic core. Comparing width of the deformed plastic core to control width on a large-scale ruler, determine the size of a gap (fig. 3.30) . If the gap is more than maximum permissible value, replace the camshaft and / or a head of the block of cylinders;
– in conclusion carefully clear material Plastigage traces from covers of bearings and camshafts;

Fig. 3.31. Use of the indicator of hour type (1) for measurement of a side play in gear gearing of gear wheels of camshafts


11) measure a side play in gear gearing of gear wheels of camshafts. Install camshafts, without establishing pushers and an auxiliary gear wheel. Establish on a head the block of cylinders an arm with the indicator of hour type 1 (fig. 3.31) so that the measuring tip of the indicator rested in one their teeths of a gear wheel of the camshaft.

       PREVENTION
In the course of measurement of a gap by Plastigage method do not rotate camshafts.

Turn a camshaft gear wheel in one party against the stop in teeths of the second gear wheel and install the indicator on 0. Turn a gear wheel in other party within a side play and record value on the indicator. If the size of a side play exceeds admissible size, it is necessary to replace camshafts.
Installation
Camshaft of inlet valves
You make installation in the following order:
– oil engine pushers and establish them on places in which they were before removal. Make sure that adjusting washers are established on pushers;
– oil engine necks and cams of the camshaft;
– install the camshaft of inlet valves so that the adjusting pin settled down at the left at an angle 80 ° from a vertical axis (see fig. 3.28 );

Fig. 3.32. Places of putting sealant (1) on a privalochny surface of a forward cover of the bearing of the camshaft


– apply a thin film of RTV 1 sealant (fig. 3.32) 2-3 mm wide on outer edges of a privalochny surface of a forward cover of the bearing of the camshaft and immediately establish a cover;
– establish other covers of bearings of the camshaft according to their numbering, at the same time the arrows put on covers have to be directed towards a gear belt;

Fig. 3.33. Sequence of tightening of bolts of fastening of covers of bearings of the camshaft of inlet valves


– in the sequence shown in the figure 3.33 , turning for one pass on 1/4 turns, screw bolts of fastening of covers and tighten their moment 19 N • m;
– oil engine the external surface and a working edge of a new sealing ring of the camshaft. A tubular mandrel, with outer diameter a little smaller the outer diameter of a ring, establish a sealing ring into place.
Camshaft of final valves
You make installation in the following order:
– repeatedly install an auxiliary gear wheel on the camshaft of final valves. Establish a spring, an auxiliary gear wheel, a spring washer and fix them by a lock ring;
– establish the first additional bolt of M6x1 in a technological opening of an auxiliary gear wheel of the camshaft. The screw-driver inserted between the camshaft and the first auxiliary bolt turn an auxiliary gear wheel clockwise and screw and tighten the second auxiliary bolt to press an auxiliary gear wheel to a camshaft gear wheel. Remove the first auxiliary bolt;
– oil engine pushers and establish them on places in which they were before removal. Make sure that adjusting washers are established on pushers;
– oil engine necks and cams of the camshaft;
– install the camshaft of inlet valves over a head of the block of cylinders so that the adjusting pin settled down at the left at an angle 10 ° from a vertical axis (see fig. 3.26 );
– combine adjusting tags on gear wheels of camshafts of inlet and final valves and install the camshaft of final valves in a head of the block of cylinders. For installation simplification slightly turn the camshaft in one or other party;
– establish covers of bearings of the camshaft according to their numbering, at the same time the arrows put on covers have to be directed towards a gear belt;

Fig. 3.34. Sequence of tightening of bolts of fastening of covers of bearings of the camshaft of final valves


– in the sequence shown in the figure 3.34 , turning for one pass on 1/4 turns, screw bolts of fastening of covers and tighten their moment 19 N • m;
– turn out the additional bolt squeezing gear wheels of the camshaft of final valves;
– establish semicircular caps in a head of the block of cylinders;
– establish a back casing of a gear belt;
– combine an adjusting pin with dredging and install a pulley of a gear belt on the camshaft and fix by a bolt, having tightened its moment 54 N • m. When tightening a bolt of fastening of a pulley the second key established on a hexagon hold the camshaft from a provorachivaniye;
– establish a gear belt.
You carry out further installation to the sequences, the return to removal.