Engine Mechanical: Overhaul — Toyota RAV4 II (2000-2003)

REASSEMBLY

Note. Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace oil seals with new ones.

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Scheme 302: REASSEMBLY

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Install valves . Using SST, push in a new oil seal. SST 09201-41020 NOTE: The intake valve oil seal is light brown and the exhaust valve oil seal is gray. NOTE: Pay much attention to assemble the oil seal for intake and exhaust. Assembling the wrong one may cause a failure. Install the valve (1), spring seat (2), valve spring (3) and spring retainer (4). Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202-70020 (09202-00010) Using a plastic-faced hammer and the valve stem (not in use) tip wound with vinyl tape, lightly tap the valve stem tip to ensure a proper fit. NOTE: Be careful not to damage the valve stem tip.
Install valve lifters . Install the valve lifter. Check that the valve lifter rotates smoothly by hand.
Install camshaft position sensor . Install the camshaft position sensor with the bolt. Torque: 9.0 N.m (90 kgf. cm, 80 in. lbf)
Install ECT sensor . Install a new gasket and the ECT sensor. Torque: 20 N.m (200 kgf. cm, 15 ft. lbf)
Install oil pressure switch . Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent. Install the oil pressure switch. Torque: 13 N.m (130 kgf. cm, 10 ft. lbf)

Note. Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace all gaskets, O-rings and oil seals with new parts.

Scheme 308

Scheme 308: REASSEMBLY

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Assemble piston and connecting rod . Using a small screwdriver, install a new snap ring at one end of the piston pin hole. NOTE: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. Gradually heat the piston to 80 - 90°C (176 - 194°F). Coat the piston pin with engine oil. Align the front marks on the piston and connecting rod, and push in the piston with your thumb. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole. NOTE: Be sure that end gap of the snap ring is not as aligned with the pin hole cutout portion of the piston.
Install piston rings . Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Code mark: Position the piston rings so that the ring ends are as shown. NOTE: Do not align the ring ends.
Install connecting rod bearings . Align the bearing claw with the groove of the connecting rod or connecting cap. Install the bearings in the connecting rod and connecting rod cap.
Install main bearings . NOTE: Upper bearings have an oil groove and oil holes; Lower bearings do not. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings. NOTE: Install the bearing with the oil hole in the cylinder block. Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings. NOTE: Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick.
Install thrust washers . Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.
Place crankshaft on cylinder block .
Install main bearing caps . Install the 5 main bearing caps in their proper locations. NOTE: A number is marked on each main bearing cap to indicate the installation position. Install the main bearing cap bolts. NOTE: The main bearing cap bolts are tightened in 2 progressive steps (steps (2), (3) and (5)). If any one of the main bearing cap bolts is broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the main bearing cap bolts. Install and uniformly tighten the 10 main bearing cap bolts in several passes, in the sequence shown. Torque: 20 N.m (205 kgf. cm, 15 ft. lbf) Retighten the 10 main bearing cap bolts in several passes, in the sequence shown. Torque: 40 N.m (410 kgf. cm, 30 ft. lbf) If any one of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt. Mark the front of the main bearing cap bolt with paint. Retighten the main bearing cap bolts by 90° in the numerical order shown. Check that the painted mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly.
Check crankshaft thrust clearance (See «DISASSEMBLY»(ref-159218-S08874033862005060800000) ) .
Install piston and connecting rod assembles . Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.
Install connecting rod cap . Place the connecting rod cap on the connecting rod. Match the numbered connecting rod cap with the connecting rod. Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the connecting rod. NOTE: Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick. Check that the protrusion of the connecting rod cap is facing in the correct direction. Install the connecting rod cap bolts. NOTE: The connecting rod cap bolts are tightened in 2 steps (steps (3) and (4)). If any of the connecting rod cap bolts is broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. Install and alternately tighten the 2 connecting rod cap bolts in several passes. Torque: 24.5 N.m (250 kgf. cm, 18 ft. lbf) If any of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts. Mark the front of the connecting cap bolts with paint. Retighten the cap bolts by 90° as shown. Check that the painted mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly.
Check connecting rod thrust clearance (See «INSPECTION»(ref-159218-S17089288602005060800000) ) .
Install rear crankshaft oil seal (See «REPLACEMENT»(ref-159218-S27181638222005060800000) ) . NOTE: Wipe seal packing away from the contact surface of the cylinder block assembly and oil seal.
Install crank case . Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the crank case and cylinder block. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces. Apply seal packing to the crank case or cylinder block as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that has been cut to a 2.5 - 3.0 mm (0.10 - 0.12 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Install a new O-ring to the cylinder block. Temporarily install the crank case with the 11 bolts. NOTE: Each bolt length is indicated in the illustration. Bolt length: 112 mm (4.41 in.) for A of 12 mm head, 35 mm (1.38 in.) for B of 12 mm head Uniformly tighten the bolts, stud bolts and nuts in several passes. Torque: 32.5 N.m (330 kgf. cm, 24 ft. lbf)
Install oil filter union . Using a 12 mm hexagon wrench, install the oil filter union. Torque: 29.5 N.m (300 kgf. cm, 22 ft. lbf)
Install oil filter (See «REPLACEMENT»(ref-177929-S27903999012005060800000) ) .
Install oil pump (See «INSTALLATION»(ref-177929-S10627409592005060800000) ) .
Install water by-pass pipe . Install a new gasket, the water bypass pipe with the 2 nuts. Torque: 9 N.m (90 kgf. cm, 80 in. lbf)
Install oil dipstick and guide . Install a new O-ring to the dipstick guide. Apply soapy water to the O-ring. Push in the dipstick guide end into the guide hole of the No. 1 oil pan. Install the dipstick guide with the bolt. Torque: 9 N.m (90 kgf. cm, 80 in. lbf) Install the dipstick.
Install engine coolant drain union . Apply adhesive to 2 or 3 threads. Seal packing: Part No. 08826-00100 or equivalent Install the drain union. Torque: 25 N.m (255 kgf. cm, 18 ft. lbf) or more NOTE: After applying the specified torque, rotate the drain union clockwise until its drain port is facing downward.
Install thermostat (See «INSTALLATION»(ref-177866-S07560847752005060700000) ) .
Install plug .
Install wire clamps .
Install knock sensor (See «KNOCK SENSOR»(ref-133226-S04347412862002021900000) ) .
Install water pump (See «INSTALLATION»(ref-177866-S31141315052005060700000) ) .
Install OCV filter Using a 12 mm hexagon wrench, install the OCV filter with a new gasket and the plug. Torque: 30 N.m (305 kgf. cm, 22 ft. lbf)
Install cylinder head (See «INSTALLATION»(ref-159218-S31817310542005060800000) ) .
Install timing chain (See «INSTALLATION»(ref-159218-S28145665832005060800000) ) .
Remove engine stand .

Engine Mechanical: Overhaul Toyota RAV4 II