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
   Repair of the engine 1AZ-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
      System of change of phases of gas distribution (VVT — Variable Valve Timing)
      Chain of the drive of the gas-distributing mechanism and asterisk
      Camshafts and pushers of valves
      Inlet collector
      Final collector
      Head of the block of cylinders
      Pulley/quencher of fluctuations
      Forward sealing ring of a bent shaft
      Oil pallet
      Oil pump
      Drive flywheel / plate
      Back sealing ring of a bent shaft
      Support of the power unit
   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 1AZ-FE without its removal from the car>> Chain of the drive of the gas-distributing mechanism and asterisk
Removal
You carry out removal of a chain on the cold engine in the following order:
– switch off ignition and disconnect a wire of "weight" from the rechargeable battery;
– take off a belt of the drive of hinged units;
– remove the generator;
– uncover a head of the block of cylinders;
– in the presence remove the ABS block;
– 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;
– merge cooling liquid;
– turn out bolts, remove and take aside the pump of the amplifier of steering with the hoses connected to it. Fix by a soft wire the pump on a body;

Fig. 3.52. Combination of a tag on a quencher of fluctuations with sign BMT or 0 on a forward cover of a chain


– install the piston of the first cylinder in VMT in a compression step, at the same time the tag on a quencher of fluctuations has to be combined with sign BMT or 0 on a forward cover of a chain (see fig. 3.52 ), and tags on asterisks of camshafts have to be combined with tags on covers of bearings of camshafts (fig. 3.55) ;

Fig. 3.55. Combination of tags on asterisks of camshafts with tags on covers of bearings of camshafts (on distributive the knot of the pulley / drive of the VVT system is visible to a shaft of inlet valves)


– remove a pulley / quencher of fluctuations from a bent shaft, at the same time do not turn a bent shaft. If there was a provorachivaniye of a bent shaft, return it to situation corresponding to installation of the piston of the first cylinder in VMT in a compression step;
– a jack, through the wooden whetstone established under the oil pallet lift the engine so that its weight was perceived by a jack.
– remove the left support of the engine;

Fig. 3.56. Arrangement of bolts of fastening of the mechanism of a tension of a chain


– remove the mechanism of a tension of a chain (fig. 3.56) and the sensor of an angle of rotation of a bent shaft from a forward cover of a chain. Turn out a bolt of fastening of a plait of wires of the sensor of an angle of rotation of a bent shaft to a chain cover;
– remove the oil pallet;
– turn out bolts and remove the holder of a plait of wires from a chain cover;

Fig. 3.57. Arrangement of nuts of fastening of a natyazhitel of a chain


– turn out nuts (fig. 3.57) and uncover a natyazhitel a chain with back the parties;

Fig. 3.58. Arrangement of the top bolts of fastening of a cover of a chain


Fig. 3.59. Arrangement of the lower bolts of fastening of a cover of a chain


– turn out bolts (fig. 3.58, 3.59) and mount separate, and uncover a chain the block of cylinders. Note an arrangement of bolts as they have different length;
– remove the sensor of an angle of rotation of a bent shaft;

Fig. 3.60. Guides and natyazhitel of a chain: 1 – hinged bolt; 2 – natyazhitel of a chain; 3 – bolts of fastening of the directing chain; 4 – motionless guide of a chain; 5 – lower guide of a chain


– turn out bolts of 1,3 (fig. 3.60) and remove a natyazhitel 2 and the lower guide of a chain 5;
– remove a chain from asterisks of camshafts and an asterisk together with a chain from a bent shaft. If the chain is repeatedly established, chalk, a marker or paint note the forward party of a chain. If at installation the chain rotates in other party, in connection with the available development of a chain, wear of elements of the mechanism of gas distribution will increase and the noise created by a chain will increase;
– remove a motionless guide of a chain 4;

Fig. 3.61. Use of keys for deduction of the camshaft from a provorachivaniye and an otvorachivaniye of a bolt of fastening of an asterisk


– keeping a wrench, the camshaft from a provorachivaniye for a hexagon, turn out a bolt of fastening and remove an asterisk from the camshaft (fig. 3.61) .

       PREVENTION
On distributive the knot of the pulley / drive of system of change of phases of gas distribution (VVT) is established to a shaft of inlet valves except an asterisk. At removal of an asterisk of the camshaft of inlet valves, turn out only the central bolt of fastening of the pulley / drive of system of change of phases of gas distribution. Do not turn out 4 bolts of fastening of the pulley / drive of system of change of phases of gas distribution to an asterisk.

Check

Fig. 3.62. Measurement of distance between chain links: X = 122,6 mm for a chain of the drive of the gas-distributing mechanism between 16 rollers or 8 links of a chain; Х = 52,4 mm for a chain of the drive of the oil pump between 8 rollers or 4 links of a chain


Visual survey check a condition of details for lack of wear and damages. Check chain links for lack of cracks, wear of rollers and side plates. Check a condition of teeths of asterisks which have to be symmetric. Pull a chain and measure distance between 8 links of a chain which has to be equal to 122,6 mm (fig. 3.62) . Carry out this inspection on several sites of a chain. If the chain was extended, replace a chain and asterisks in a set.

Fig. 3.63. Measurement of diameter of an asterisk on chain rollers


Wrap up each asterisk a chain and measure diameter of an asterisk on rollers of a chain (fig. 3.63) . If the received size exceeds the minimum diameter of a chain, replace a chain and asterisks in a set.

Fig. 3.64. Places of measurement of depth of dredging on chain guides: X = no more than 1,0 mm


Fig. 3.95. Combination of color tags on a chain with tags on asterisks


Check the directing chains for lack of excessive wear. Keep in mind that insignificant wear of guides is a normal phenomenon. Depth of dredging on guides of a chain has to be no more than 1,0 mm (fig. 3.64) . With excessive wear check a lubricant opening of the directing chain on the forward party of the block of cylinders for lack of pollution and a contamination (see fig. 3.95 ).
Installation
You make installation in the following order:
1) remove with a scraper the remains of old sealant from privalochny surfaces of a cover of a chain and a head and the block of cylinders;
2) be convinced that camshafts are turned by adjusting pins up, in situation "12 h", establish to an invention both asterisks, combining an opening for a pin from a reverse side of an asterisk with a camshaft pin. Apply the kontrovochny structure interfering their self-unscrewing on a carving of bolts of fastening of asterisks and screw bolts by hand. Keeping a wrench, the camshaft from a provorachivaniye for a hexagon, tighten a bolt of fastening of an asterisk the moment of 54 N • m (see fig. 3.61 );
3) if necessary tighten camshafts in situation at which tags on asterisks of camshafts will be combined with tags on covers of bearings of camshafts (see fig. 3.55 );
4) if the bent shaft turned from the provision of VMT, turn it in situation at which the shponochny groove will not be sent up, to situation "12 h";
5) establish a motionless guide of a chain 4 (see fig. 3.60 );
6) put on a chain an asterisk of a bent shaft, at the same time combine a color tag No. 1 on a chain with a tag on an asterisk. Establish an asterisk with the chain established on it on a bent shaft, then establish the lower guide of a chain;

       PREVENTION
On a chain there are three color tags. The tag No. 1 is located at bigger distance from two other tags which are located closely to each other.


Fig. 3.65. Combination of color tags on a chain with tags on asterisks of camshafts at installation of a chain


7) establish a chain on a boot of a motionless guide of a chain, then on an asterisk of the camshaft of final valves and, at last, on an asterisk of the camshaft of inlet valves. Check that color tags on a chain were combined with tags on asterisks (fig. 3.65) . At installation of a chain exclude sagging of the right branch of a chain;

Fig. 3.66. A ledge arrangement on the tension mechanism


8) remove sagging of the left branch of a chain, establish a natyazhitel of a chain, screw a hinged bolt and tighten its moment 19 N • m. After installation, be convinced that the ledge on the mechanism of a tension (fig. 3.66) does not pass by an emphasis to a head of the block of cylinders;
9) repeatedly check that the piston of the first cylinder is in VMT in a compression step, at the same time the tag on a quencher of fluctuations has to be combined with sign BMT or 0 on a forward cover of a chain (see fig. 3.52 ), and tags on asterisks of camshafts have to be combined with tags on covers of bearings of camshafts (see fig. 3.55 );
10) install the sensor of an angle of rotation of a bent shaft and a ring, F tag on which has to be directed outside;

Fig. 3.67. Places (1) of drawing a layer of sealant on privalochny surfaces of a cover of a chain


11) apply a layer of RTV sealant with a diameter of 3-4 mm on privalochny surfaces of a cover of a chain of 1 (fig. 3.67) . Also apply a small amount of sealant on junctions of a head and the block of cylinders. Install a cover on the engine and fix by bolts, having established them in initial provisions. Gradually, for several passes, tighten bolts the required moment;
12) establish a chain tension mechanism plunger in a starting position as follows:

Fig. 3.68. A raising of a doggie of a ratchet and moving of a plunger of the mechanism of a tension of a chain in a starting position (inside)


– lift a doggie of a ratchet and move a plunger inside while it does not reach the lower limit (fig. 3.68) ;
– hook on a hook on the tension mechanism case for a pin on a plunger therefore the plunger will be fixing in a starting position;
13) oil engine sealing rings of a plunger of the mechanism of a tension and establish it in a chain cover;
14) establish a pulley/quencher of fluctuations on a bent shaft;

Fig. 3.69. For release of a hook on the mechanism case from a pin on a plunger, it is necessary to turn slightly a bent shaft of the engine counterclockwise: 1 – hook; 2 – pin


15) slightly turn a bent shaft of the engine counterclockwise to establish a chain tension. At the same time the hook of 1 (fig. 3.69) on the case of the mechanism of a tension has to be released from a pin 2 on a plunger therefore the plunger will carry out a chain tension. If the plunger was not released independently, wring out a natyazhitel of a chain and release a pin on a plunger a screw-driver edge;
16) turn a bent shaft of the engine clockwise on several turns and install the piston of the first cylinder in VMT in a compression step. Check that the tag on a quencher of fluctuations is combined with sign BMT or 0 on a forward cover of a chain (see fig. 3.52 ), and tags on asterisks of camshafts are combined with tags on covers of bearings of camshafts (see fig. 3.55 ).
Further installation is carried out to the sequences, the return to removal.