Engine Mechanical (2GR-FE): Overview Toyota RAV4 III

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1. INSPECT VALVE LASH ADJUSTER NOISE Rev up the engine several times. Check that the engine does not emit unusual noises. If unusual noises occur, warm up the engine and idle it for over 30 minutes. Then perform the inspection above again. If any defects or problems are found during the inspection above, perform a lash adjuster inspection.
2. INSPECT IGNITION TIMING Warm up the engine and stop the engine. NOTE: A warmed up engine should have an engine coolant temperature of over 80°C (176°F), have an engine oil temperature of 60°C (140°F), and the engine RPM should be stabilized. When using the intelligent tester: Connect the intelligent tester to the DLC3. Start the engine and idle it. Push the intelligent tester main switch ON. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / IGN ADVANCE. Standard ignition timing: 8 to 12° BTDC @ idle HINT: Refer to the intelligent tester operator's manual for further details. When not using the intelligent tester: Remove the V-bank cover (see «REMOVAL»(ref-265059-S01631031182007092000000) ). Connect the tester terminal of a timing light to the red lead wire as shown in the illustration. HINT: Use a timing light that detects primary signals. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST 09843-18040 NOTE: Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine. When checking the ignition timing, the transmission should be in the neutral position. Using a timing light, check the ignition timing. Standard ignition timing: 8 to 12° BTDC @ idle NOTE: When checking the ignition timing, the transmission should be in the neutral position. HINT: Run the engine at 1,000 to 1,300 RPM for 5 seconds, and then check that the engine RPM returns to idle speed. Remove the SST from the DLC3. Check the ignition timing. Standard ignition timing: 5 to 15° BTDC @ idle Check that the ignition timing advances immediately when the engine speed is increased. Disconnect the timing light from the engine. Install the V-bank cover (see «INSTALLATION»(ref-265059-S19240684252007092000000) ).
3. INSPECT ENGINE IDLE SPEED Warm up and stop the engine. NOTE: A warmed up engine should have an engine coolant temperature of over 80°C (176°F) and an engine oil temperature of 60°C (140°F), and the engine RPM should be stabilized. When using the intelligent tester: Connect the intelligent tester to the DLC3. NOTE: Switch off all accessories and A/C before connecting the intelligent tester. Race the engine at 2,500 RPM for approximately 90 seconds. Push the intelligent tester main switch ON. Select the tester menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / ENGINE SPD. Standard idle speed: 600 to 700 RPM NOTE: When checking the idle speed, the transmission should be in the neutral position. HINT: Refer to the intelligent tester operator's manual for further details. If the idle speed is not as specified, check the air intake system. Disconnect the intelligent tester from the DLC3. When not using the intelligent tester: Using SST, connect the tachometer probe to terminal 9 (TAC) of the DLC3. SST 09843-18040 NOTE: Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine. Race the engine at 2,500 RPM for approximately 90 seconds. Check the idle speed. Standard idle speed: 600 to 700 RPM (Transmission neutral position) If the speed is not as specified, check the air intake system. Disconnect the tachometer from the DLC3.
4. INSPECT COMPRESSION Warm up and stop the engine. NOTE: A warmed up engine should have an engine coolant temperature of over 80°C (176°F) and an engine oil temperature of 60°C (140°F), and the engine RPM should be stabilized. Disconnect the injector connectors. Remove the intake air surge tank (see «REMOVAL»(ref-265059-S01631031182007092000000) ). Remove the 6 ignition coils (see «REMOVAL»(ref-265059-S01631031182007092000000) ). Remove the 6 spark plugs. Inspect the cylinder compression pressure. Insert a compression gauge into the spark plug hole. While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain an engine speed of 250 RPM or more. NOTE: The measurement must be done as quickly as possible. Compression pressure: 1,400 kPa (14 kgf/cm 2, 199 psi) or more Minimum pressure: 980 kPa (10.0 kgf/cm 2, 142 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm 2, 15 psi) or less Perform the inspection above for each cylinder. If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole. Then perform the first 3 steps under "Inspect the cylinder compression pressure" for the cylinders with low compression. HINT: If adding oil helps the compression, it is likely that the piston rings and / or cylinder bore are worn or damaged. If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket. Install the 6 spark plugs. Install the 6 ignition coils (see «INSTALLATION»(ref-265059-S19240684252007092000000) ). Install the intake air surge tank (see «INSTALLATION»(ref-265059-S19240684252007092000000) ). Connect the injector connectors.
5. INSPECT CO/HC HINT: This check is for determining whether or not the idle CO / HC complies with regulations. Start the engine. Keep the engine speed at 2,500 RPM for approximately 180 seconds. Insert a CO / HC meter testing probe at least 40 cm (1.3 ft.) into the tailpipe during idling. Immediately check the CO / HC concentration at idle and / or 2,500 RPM. HINT: When performing the 2 mode (2,500 RPM and idle) test, follow the measurement order prescribed by the applicable local regulations. If the CO / HC concentration does not comply with regulations, troubleshoot in the order given below. Check the air fuel ratio sensor and heated oxygen sensor operation. See the table below for the possible cause, then inspect and correct the applicable causes if necessary. PROBLEM SYMPTOMS CHART CO HC Symptom Causes Normal High Rough idle Faulty ignitions Incorrect timing Fouled, shorted or improperly gapped plugs Leaky intake and exhaust valves Leaky cylinder Low High Rough idle (Fluctuating HC reading) Vacuum leaks PCV hose Intake manifold Throttle body Lean mixture causing misfire High High Rough idle (Black smoke from exhaust) Restricted air filter Faulty fuel SFI system Faulty pressure Defective ECT sensor Faulty ECM Faulty injector Faulty throttle position sensor Faulty MAF sensor

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1. INSPECT FAN AND GENERATOR V BELT Visually check the drive belt for excessive wear, frayed cords, etc. If any defect is found, replace the drive belt. HINT: Cracks on the rib side of a drive belt are considered acceptable. If the drive belt has chunks missing from the ribs, it should be replaced. After installing the drive belt, check that it fits properly in the ribbed grooves. Check with your hand to confirm that the belt has not slipped out of the grooves on the bottom of the crank pulley.

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1. DISCONNECT RADIATOR RESERVOIR TANK ASSEMBLY Remove the 2 bolts and disconnect the reservoir tank.
2. REMOVE NO. 1 ENGINE UNDER COVER SUBASSEMBLY (See «REMOVAL»(ref-265059-S01631031182007092000000) )
3. REMOVE ENGINE UNDER COVER RH Remove the 2 clips and engine under cover.
4. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH Remove the 4 bolts and reinforcement.
5. REMOVE FAN AND GENERATOR V BELT Rotate the tensioner pulley counterclockwise to loosen the belt tension. Then remove the V-ribbed belt. While turning the belt tensioner counterclockwise, align its holes, and then insert the 5 mm bi-hexagon wrench into the holes to fix the V-ribbed belt tensioner in place.

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1. INSTALL FAN AND GENERATOR V BELT Rotate the tensioner pulley counterclockwise, and then install the V-ribbed belt. If it is difficult to install the V-ribbed belt, perform the following procedure. Put the V-ribbed belt on everything except the tensioner pulley as shown in the illustration. While releasing the belt tension by turning the belt tensioner counterclockwise, put the V-ribbed belt on the tensioner pulley. NOTE: Put the backside of the V-ribbed belt on the tensioner pulley and idler pulley. Check that the V-ribbed belt is properly set to each pulley.
2. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH Install the reinforcement with the 4 bolts. Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
3. INSTALL ENGINE UNDER COVER RH Install the engine under cover with the 2 clips.
4. INSTALL NO. 1 ENGINE UNDER COVER (See «INSTALLATION»(ref-265059-S19240684252007092000000) )
5. CONNECT RADIATOR RESERVOIR TANK ASSEMBLY Connect the reservoir tank with the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

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1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See «REPLACEMENT»(ref-265087-S42514689952007092000000) )
2. DISCHARGE FUEL SYSTEM PRESSURE (See «REMOVAL»(ref-265101-S42423597592007092000000) )
3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
4. REMOVE NO. 1 ENGINE UNDER COVER Remove the 4 bolts, 12 clips and under cover.
5. REMOVE REAR ENGINE UNDER COVER RH Remove the 2 clips and under cover.
6. REMOVE REAR ENGINE UNDER COVER LH Remove the 2 clips and under cover.
7. REMOVE NO. 2 ENGINE UNDER COVER Remove the 2 clips and under cover.
8. REMOVE FRONT FLOOR COVER (See appropriate step(s) under «REMOVAL»(ref-265101-S34387399612007092000000) )
9. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-265076-S03413639462007092000000) )
10. DRAIN ENGINE OIL (See «REPLACEMENT»(/toyota/rav4/iii-2005-2010/remont/lubrication-system/#engine-lubrication-system-2gr-fe__replacement) )
11. DRAIN AUTOMATIC TRANSAXLE FLUID 2WD: Drain automatic transaxle fluid, (see appropriate step(s) under «REMOVAL»(ref-265069-S24715623572007092000000) ). 4WD: Drain automatic transaxle fluid,, (see appropriate step(s) under «REMOVAL»(ref-265070-S37025400492007092000000) ). Remove the drain plug and gasket, and drain the ATF. Install a new gasket and the drain plug. Torque: 47 N*m (479 kgf*cm, 35 ft.*lbf)
12. DRAIN TRANSFER OIL (for 4WD)
13. REMOVE HOOD SUB-ASSEMBLY (See «REMOVAL»(ref-265086-S00985256432007092000000) )
14. REMOVE V-BANK COVER SUB-ASSEMBLY Detach the 3 clips and remove the V-bank cover.
15. REMOVE RADIATOR SUPPORT OPENING COVER Remove the 9 clips and cover.
16. REMOVE BATTERY CLAMP SUB-ASSEMBLY Remove the bolt and loosen the nut. Detach the 2 wire harness clamps. Detach the hook of the battery clamp from the battery bracket front, and then remove the battery clamp.
17. REMOVE BATTERY
18. REMOVE FRONT BATTERY BRACKET Detach the 2 wire harness clamps. Remove the 4 bolts and front bracket.
19. REMOVE BATTERY BRACKET REINFORCEMENT Remove the 2 bolts and bracket reinforcement.
20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY Disconnect the mass air flow meter connector. Disconnect the VSV (air intake control) connector. Disconnect the wire harness clamp and 3 vacuum hoses. Disconnect the No. 2 ventilation hose from the air cleaner hose. Loosen the No. 1 air cleaner hose clamp. Unfasten the 2 hook clamps, and then remove the air cleaner cap. Remove the air cleaner filter element from the air cleaner case.
21. REMOVE AIR CLEANER CASE Disconnect the harness clamp. Remove the 3 bolts and air cleaner case.
22. DISCONNECT HOSES AND CONNECTORS Remove the engine room junction block cover (upper). Remove the nut and disconnect the engine room junction block cover (side) with 3 connectors and wire. Remove the nut and disconnect the starter wire. Disconnect the fuel hoses. Disconnect the 2 heater hoses. Disconnect the 2 ECM connectors.
23. REMOVE ECM (See «REMOVAL»(/toyota/rav4/iii-2005-2010/remont/testing-diagnostics/#engine-control-system-2gr-fe) )
24. REMOVE RADIATOR RESERVOIR TANK ASSEMBLY Remove the 2 bolts, 2 hoses and reservoir tank.
25. REMOVE DISCHARGE HOSE SUB-ASSEMBLY (See «REMOVAL»(ref-265087-S27380569962007092000000) )
26. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (See «REMOVAL»(ref-265087-S27380569962007092000000) )
27. DISCONNECT RADIATOR HOSE INLET
28. DISCONNECT RADIATOR HOSE OUTLET
29. DISCONNECT OIL COOLER HOSE
30. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 2WD: Disconnect the control cable (see «TRANSMISSION CONTROL CABLE ASSEMBLY»(ref-265069-S17090592262007092000000) ). 4WD: Disconnect the control cable (see «TRANSMISSION CONTROL CABLE ASSEMBLY»(ref-265070-S23275282202007092000000) ).
31. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See «EXHAUST (2GR-FE)»(/toyota/rav4/iii-2005-2010/remont/exhaust/#engine-exhaust-assembly-2gr-fe) )
32. REMOVE CENTER EXHAUST PIPE ASSEMBLY (See «EXHAUST (2GR-FE)»(/toyota/rav4/iii-2005-2010/remont/exhaust/#engine-exhaust-assembly-2gr-fe) )
33. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (See «REMOVAL»(/toyota/rav4/iii-2005-2010/remont/driveshaft-universal-joints/#propeller-shaft) )
34. REMOVE FRONT WHEELS
35. REMOVE FRONT AXLE HUB NUT LH Remove the hub nut (see «REMOVAL»(ref-265061-S27499624032007092000000) ).
36. REMOVE FRONT AXLE HUB NUT RH Remove the hub nut (see «REMOVAL»(ref-265061-S27499624032007092000000) ).
37. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH (See «REMOVAL»(ref-265090-S33657762732007092000000) )
38. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH (See «REMOVAL»(ref-265090-S33657762732007092000000) )
39. DISCONNECT STEERING INTERMEDIATE SHAFT (See appropriate step(s) under «REMOVAL»(ref-265098-S37712327532007092000000) )
40. DISCONNECT TIE ROD END SUB-ASSEMBLY RH (See «INSPECTION PROCEDURE»(ref-265098-S06713056242007092000000) )
41. DISCONNECT TIE ROD END SUB-ASSEMBLY LH (See «INSPECTION PROCEDURE»(ref-265098-S06713056242007092000000) )
42. REMOVE FRONT DRIVE SHAFT LH 2WD: Remove the drive shaft (see appropriate procedure under «FRONT DRIVE SHAFT ASSEMBLY (FOR 2WD)»(ref-265082-S38070655732007092000000) ). 4WD: Remove the drive shaft (see appropriate procedure under «FRONT DRIVE SHAFT ASSEMBLY (FOR 4WD)»(ref-265082-S12556932162007092000000) ).
43. REMOVE FRONT DRIVE SHAFT RH 2WD: Remove the drive shaft (see appropriate procedure under «FRONT DRIVE SHAFT ASSEMBLY (FOR 2WD)»(ref-265082-S38070655732007092000000) ). 4WD: Remove the drive shaft (see appropriate procedure under «FRONT DRIVE SHAFT ASSEMBLY (FOR 4WD)»(ref-265082-S12556932162007092000000) ).
44. REMOVE ENGINE WITH TRANSAXLE Install the No. 1 and No. 2 engine hangers with the 4 bolts (Scheme 483) Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) PARTS DESCRIPTION Part Name Part No. No. 1 engine hanger 12281-31120 No. 2 engine hanger 12282-31100 Bolt 91671-10825 HINT: Insert the claw of the hanger into hole of the cylinder head. Fit the fork part of the hanger onto the rib of the cylinder head. Install an engine sling device to the engine and hold the engine with a chain block. CAUTION: Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up. Set an engine lifter underneath the engine. Remove the column hole cover. Loosen the bolt holding the intermediate shaft, and slide the intermediate shaft. Put matchmarks on the intermediate shaft and pinion. Remove the 2 bolts and 2 nuts, and disconnect the engine mounting insulator RH. Remove the bolt and nut, and disconnect the engine mounting insulator LH. Remove the 6 bolts and front suspension member brace rear RH and LH. Remove the 6 bolts, crossmember and suspension member. Using the chain block, slowly remove the engine from the vehicle and the intermediate shaft from the pinion. Then set the engine on the engine lifter. NOTE: Make sure that the engine is clear of all wiring and hoses. While lowering the engine from the vehicle, do not allow it to contact the vehicle. HINT: Place the engine on wooden blocks or an equivalent so that the engine is level. Remove the sling device from the engine.
45. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY Install a chain block. Remove the bolt, nut and crossmember.
46. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Remove the bolt and suspension crossmember.
47. REMOVE ENGINE WIRE Remove the engine wire from the engine.
48. REMOVE STARTER ASSEMBLY (See «REMOVAL»(ref-265089-S37099865802007092000000) )
49. REMOVE TRANSFER ASSEMBLY (for 4WD) (See «REMOVAL»(ref-265079-S41514093852007092000000) )
50. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY 2WD: Remove the automatic transaxle (see «REMOVAL»(ref-265069-S24715623572007092000000) ). 4WD: Remove the automatic transaxle (see «REMOVAL»(ref-265070-S37025400492007092000000) ).
51. REMOVE DRIVE PLATE AND RING GEAR SUBASSEMBLY Using SST, hold the crankshaft. SST 09213-70011, 09330-00021 Remove the 8 bolts, front spacer, drive plate and rear spacer. NOTE: Do not reuse the bolts.
52. INSTALL ENGINE TO ENGINE STAND Install the engine to an engine stand. Remove the sling device and chain block from the engine.
53. REMOVE INTAKE AIR SURGE TANK ASSEMBLY Disconnect the 2 water by-pass hoses from the throttle body. Disconnect the vapor feed hose. Disconnect the throttle body connector and clamp. Disconnect the No. 2 ventilation hose. Disconnect the union to check valve hose. Remove the bolt and vacuum hose clamp. Disconnect the connector. Using a 5 mm socket hexagon wrench, remove the 4 bolts. Remove the 2 nuts, 2 bolts and surge tank. Remove the gasket from the surge tank.
54. REMOVE IGNITION COIL ASSEMBLY Remove the 6 bolts and 6 coils from the cylinder head.
55. REMOVE NO. 2 ENGINE MOUNTING STAY RH Remove the bolt and mounting stay.
56. REMOVE FUEL INJECTOR ASSEMBLY (See «REMOVAL»(ref-265101-S42423597592007092000000) )
57. REMOVE INTAKE MANIFOLD Remove the 6 bolts, 4 nuts, intake manifold and 2 gaskets.
58. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Disconnect the air fuel ratio sensor connector clamp. Uniformly loosen and remove the 6 nuts. Remove the manifold and gasket.
59. REMOVE FAN AND GENERATOR V BELT (See «REMOVAL»(ref-265059-S09095606772007092000000) )
60. REMOVE COMPRESSOR WITH PULLEY ASSEMBLY (See «REMOVAL»(ref-265087-S27380569962007092000000) )
61. REMOVE GENERATOR ASSEMBLY (See «REPLACEMENT»(/toyota/rav4/iii-2005-2010/remont/charging-system/#charging-system-2az-fe) )
62. REMOVE OIL DIPSTICK GUIDE Remove the dipstick. Remove the 2 bolts, and the No. 1 and No. 2 guides. Remove the O-rings from the guide.
63. REMOVE NO. 2 MANIFOLD STAY Remove the bolt, nut and manifold stay.
64. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Remove the 3 bolts and insulator.
65. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH Uniformly loosen and remove the 6 nuts. Remove the manifold and gasket.
66. REMOVE ENGINE MOUNTING BRACKET RH Remove the 3 bolts and bracket.
67. REMOVE DRIVE SHAFT BEARING BRACKET Remove the 3 bolts and drive shaft bearing bracket.
68. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Remove the 5 bolts and V-ribbed belt tensioner assembly.
69. REMOVE NO. 2 TIMING GEAR COVER Remove the 2 bolts and gear cover.
70. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY Remove the bolt, plate and idler pulley.
71. REMOVE WATER PUMP PULLEY (See «REMOVAL»(ref-265076-S20979264552007092000000) )
72. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH Remove the 6 bolts and bracket.
73. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY Using a 24 mm deep socket wrench, remove the pressure switch.
74. REMOVE KNOCK SENSOR (See «REMOVAL»(/toyota/rav4/iii-2005-2010/remont/testing-diagnostics/#engine-control-system-2gr-fe) )
75. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Using a 19 mm deep socket wrench, remove the sensor and gasket.

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1. INSPECT INTAKE MANIFOLD Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head and intake air surge tank. Maximum warpage WARPAGE SPECIFIED CONDITION Item Specified Condition Intake manifold side 0.8 mm (0.031 in.) Cylinder head side 0.2 mm (0.008 in.) If the warpage is greater than the maximum, replace the manifold.
2. INSPECT EXHAUST MANIFOLD Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.70 mm (0.0028 in.) If the warpage is greater than the maximum, replace the manifold.

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1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Using a 19 mm deep socket wrench, install the sensor and a new gasket. Torque: 20 N*m (204 kgf*cm, 14 ft.*lbf)
2. INSTALL KNOCK SENSOR (See «INSTALLATION»(/toyota/rav4/iii-2005-2010/remont/testing-diagnostics/#engine-control-system-2gr-fe) )
3. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
4. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH Install the mounting bracket with the 6 bolts. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
5. INSTALL WATER PUMP PULLEY (See «INSTALLATION»(ref-265076-S18026697172007092000000) )
6. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY Install the idler pulley and cover plate with the bolt. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
7. INSTALL NO. 2 TIMING GEAR COVER Install the gear cover with the 2 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Temporarily install the V-ribbed belt tensioner with the 5 bolts. Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Tighten the other bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Each bolt length is as follows: BOLT LENGTH SPECIFICATION A 70 mm (2.76 in.) B 35 mm (1.37 in.)
9. INSTALL DRIVE SHAFT BEARING BRACKET Install the drive shaft bearing bracket with the 3 bolts. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
10. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Install a new gasket as shown in the illustration. Install the manifold with the 6 nuts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
11. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Install the No. 2 heat insulator with the 3 bolts. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
12. INSTALL NO. 2 MANIFOLD STAY Install the No. 2 manifold stay with the bolt and nut. Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf)
13. INSTALL OIL DIPSTICK GUIDE Install 2 new O-rings to the guide. Apply a light coat of engine oil to the O-rings. Push in the guide end into the guide hole. Install the No. 1 guide with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Install the No. 2 guide with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Install the dipstick.
14. INSTALL GENERATOR ASSEMBLY (See «INSTALLATION»(/toyota/rav4/iii-2005-2010/remont/charging-system/#charging-system-2gr-fe) )
15. INSTALL COMPRESSOR WITH PULLEY ASSEMBLY (See «INSTALLATION»(ref-265087-S39789332692007092000000) )
16. INSTALL FAN AND GENERATOR V BELT (See «REMOVAL»(ref-265059-S09095606772007092000000) )
17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Install a new gasket as shown in the illustration. Install the manifold with the 6 nuts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
18. INSTALL INTAKE MANIFOLD Set a new gasket on each cylinder head. NOTE: Align the port holes of the gasket and cylinder head. Be careful of the installation direction. Set the intake manifold on the cylinder heads. Install and uniformly tighten the 6 bolts and 4 nuts in several passes. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Connect the 6 fuel injector connectors.
19. INSTALL FUEL INJECTOR ASSEMBLY (See «INSTALLATION»(ref-265101-S33268206972007092000000) )
20. INSTALL NO. 2 ENGINE MOUNTING STAY RH Install the mounting stay with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
21. INSTALL IGNITION COIL ASSEMBLY Install the 6 ignition coils with the 6 bolts to the cylinder head. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
22. INSTALL INTAKE AIR SURGE TANK ASSEMBLY NOTE: Make sure there is no oil on the bolts. If there is oil on the bolts, clean them before installing them. Install a new gasket to the surge tank. Using a 5 mm hexagon socket wrench, install the 4 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) Install the surge tank with the 2 nuts and 2 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt 16 N*m (163 kgf*cm, 12 ft.*lbf) for nut Connect the connector. Install the vacuum hose clamp with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Connect the union to check valve hose. Connect the No. 2 ventilation hose. Install the clamp and connect the throttle body connector. Connect the vapor feed hose. Connect the 2 water by-pass hoses to the throttle body.
23. REMOVE ENGINE FROM ENGINE STAND Install a sling device and chain block to the engine. Remove the engine from the engine stand.
24. INSTALL DRIVE PLATE AND RING GEAR SUBASSEMBLY Clean the bolt and its hole. Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent Using SST, hold the crankshaft. SST 09213-70011, 09330-00021 Install the flywheel, drive plate and drive plate spacer on the crankshaft. Uniformly install and tighten the 8 bolts in the sequence (Scheme 527) Torque: 178 N*m (1,815 kgf*cm, 132 ft.*lbf) NOTE: Do not start the engine for at least 1 hour after the installation.
25. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY 2WD: Install the automatic transaxle (see «INSTALLATION»(ref-265069-S41184364212007092000000) ). 4WD: Install the automatic transaxle (see «INSTALLATION»(ref-265070-S41134284182007092000000) ).
26. INSTALL TRANSFER ASSEMBLY (for 4WD) (See «INSTALLATION»(ref-265079-S04194645832007092000000) )
27. INSTALL STARTER ASSEMBLY (See «INSTALLATION»(ref-265089-S03487941332007092000000) )
28. INSTALL ENGINE WIRE Install the engine wire to the engine.
29. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Attach the engine together with the transaxle to the suspension crossmember and mounting. Install the bolt which secures the engine mounting bracket to the mounting insulator. Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
30. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY Install the bolt and nut which secures the engine mounting bracket to the mounting insulator. Torque: 145 N*m (1,479 kgf*cm, 107 ft.*lbf)
31. INSTALL ENGINE WITH TRANSAXLE Place the engine on an engine lifter. HINT: Place the engine on wooden blocks or an equivalent so that the engine is level. Using the chain block, slowly install the engine to the vehicle and the intermediate shaft to the pinion. CAUTION: Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up. NOTE: Make sure that the engine is clear of all wiring and hoses. While raising the engine into the vehicle, do not allow it to contact the vehicle. Align the matchmarks on the intermediate shaft and pinion. Temporarily install the suspension member and crossmember with the 10 bolts. Temporarily install the member brace rear RH and LH with the 6 bolts. Install the engine mounting insulator LH with the bolt and nut. Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf) NOTE: While holding the bolt in place, tighten the nut. Install the engine mounting insulator RH with the 2 bolts and 2 nuts. Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) for bolt and nut A 52 N*m (530 kgf*cm, 38 ft.*lbf) for nut B Tighten the suspension member and crossmember's bolts. (Scheme 533) Torque: 96 N*m (979 kgf*cm, 71 ft.*lbf) for bolt A 145 N*m (1,478 kgf*cm, 107 ft.*lbf) for bolt B Tighten the member brace rear's bolts. (Scheme 533) Torque: 145 N*m (1,478 kgf*cm, 107 ft.*lbf) for bolt C 93 N*m (948 kgf*cm, 69 ft.*lbf) for bolt D Remove the sling device and chain block. Remove the 2 bolts and No. 1 and No. 2 engine hangers.
32. INSTALL FRONT DRIVE SHAFT LH 2WD: Install the drive shaft (see «INSTALLATION»(ref-265082-S23704580212007092000000) ). 4WD: Install the drive shaft (see «INSTALLATION»(ref-265082-S40964793842007092000000) ).
33. INSTALL FRONT DRIVE SHAFT RH 2WD: Install the drive shaft (see «INSTALLATION»(ref-265082-S23704580212007092000000) ). 4WD: Install the drive shaft (see «INSTALLATION»(ref-265082-S40964793842007092000000) ).
34. CONNECT TIE ROD END SUB-ASSEMBLY LH (See «INSTALLATION»(ref-265098-S10857037352007092000000) )
35. CONNECT TIE ROD END SUB-ASSEMBLY RH (See «INSTALLATION»(ref-265098-S10857037352007092000000) )
36. CONNECT STEERING INTERMEDIATE SHAFT (See «INSTALLATION»(ref-265098-S10857037352007092000000) )
37. CONNECT FRONT STABILIZER LINK ASSEMBLY LH (See «INSTALLATION»(ref-265090-S17093430592007092000000) )
38. CONNECT FRONT STABILIZER LINK ASSEMBLY RH (See «INSTALLATION»(ref-265090-S17093430592007092000000) )
39. INSTALL FRONT AXLE HUB NUT LH Install the hub nut (see «INSTALLATION»(ref-265061-S31517204642007092000000) ).
40. INSTALL FRONT AXLE HUB NUT RH Install the hub nut (see «INSTALLATION»(ref-265061-S31517204642007092000000) ).
41. INSTALL FRONT WHEELS
42. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (See «INSTALLATION»(/toyota/rav4/iii-2005-2010/remont/driveshaft-universal-joints/#propeller-shaft) )
43. INSTALL CENTER EXHAUST PIPE ASSEMBLY (See «EXHAUST (2GR-FE)»(/toyota/rav4/iii-2005-2010/remont/exhaust/#engine-exhaust-assembly-2gr-fe) )
44. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See «EXHAUST (2GR-FE)»(/toyota/rav4/iii-2005-2010/remont/exhaust/#engine-exhaust-assembly-2gr-fe) )
45. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 2WD: Connect the control cable (see «REPLACEMENT»(ref-265069-S35450330952007092000000) ). 4WD: Connect the control cable (see «REPLACEMENT»(ref-265070-S09236516432007092000000) ).
46. CONNECT RADIATOR HOSE INLET
47. CONNECT RADIATOR HOSE OUTLET
48. CONNECT OIL COOLER HOSE
49. CONNECT SUCTION HOSE SUB-ASSEMBLY (See «INSTALLATION»(ref-265087-S39789332692007092000000) )
50. INSTALL DISCHARGE HOSE SUB-ASSEMBLY (See «INSTALLATION»(ref-265087-S39789332692007092000000) )
51. INSTALL RADIATOR RESERVOIR TANK ASSEMBLY Install the reservoir tank with the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Connect the 2 hoses
52. INSTALL ECM (See «INSTALLATION»(/toyota/rav4/iii-2005-2010/remont/testing-diagnostics/#engine-control-system-2gr-fe) )
53. CONNECT HOSES AND CONNECTORS Connect the 2 ECM connectors. Connect the 2 heater hoses. Connect the fuel hoses. Connect the starter wire with the nut. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) Connect the 3 connectors and wire with the nut. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) Install the engine room junction block cover (upper).
54. INSTALL AIR CLEANER CASE Install the air cleaner case with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Connect the harness clamp.
55. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Install the air cleaner filter element onto the air cleaner case. Insert the hinge part of the air cleaner cap into the air cleaner case, then hang the 2 hook clamps. Tighten the No. 1 air cleaner hose clamp. Connect the No. 2 ventilation hose to the air cleaner hose. Connect the wire harness clamp and 3 vacuum hoses. Connect the VSV (intake air control) connector. Connect the mass air flow meter connector.
56. INSTALL BATTERY BRACKET REINFORCEMENT Install the bracket reinforcement with the 2 bolts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
57. INSTALL FRONT BATTERY BRACKET Install the bracket front with the 4 bolts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) Attach the 2 wire harness clamps.
58. INSTALL BATTERY
59. REMOVE BATTERY CLAMP SUB-ASSEMBLY Attach the hook of the battery clamp to the battery bracket front. Temporarily tighten the nut and install the bolt. Adjust the battery clamp's position. Fully tighten the nut and bolt. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Attach the 2 wire harness clamps.
60. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
61. INSTALL HOOD SUB-ASSEMBLY Install the hood (see «INSTALLATION»(ref-265086-S35514856112007092000000) ). Adjust the hood (see «ADJUSTMENT»(ref-265086-S26898599612007092000000) ).
62. ADD AUTOMATIC TRANSAXLE FLUID 2WD: Add automatic transmission fluid (see appropriate step(s) under «INSTALLATION»(ref-265069-S41184364212007092000000) ). 4WD: Add automatic transmission fluid (see appropriate step(s) under «INSTALLATION»(ref-265070-S41134284182007092000000) ).
63. ADD TRANSFER OIL (for 4WD) (See «TRANSFER OIL»(ref-265079-S09074069462007092000000) )
64. ADD ENGINE OIL (See appropriate step(s) under «REPLACEMENT»(/toyota/rav4/iii-2005-2010/remont/lubrication-system/#engine-lubrication-system-2gr-fe__replacement) )
65. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-265076-S03413639462007092000000) )
66. CHARGE REFRIGERANT (See appropriate step(s) under «REPLACEMENT»(ref-265087-S42514689952007092000000) )
67. CHECK FOR LEAKAGE OF REFRIGERANT (See appropriate step(s) under «REPLACEMENT»(ref-265087-S42514689952007092000000) )
68. CHECK FOR ENGINE OIL LEAKS (See appropriate step(s) under «REPLACEMENT»(/toyota/rav4/iii-2005-2010/remont/lubrication-system/#engine-lubrication-system-2gr-fe__replacement) )
69. CHECK FOR ENGINE COOLANT LEAKS (See appropriate step(s) under «ON-VEHICLE INSPECTION»(ref-265076-S22677065082007092000000) )
70. CHECK FOR FUEL LEAKS
71. INSPECT EXHAUST GAS LEAKS
72. INSPECT SHIFT LEVER POSITION 2WD: Inspect the shift lever position (see «ADJUSTMENT»(ref-265069-S02445762442007092000000) ). 4WD: Inspect the shift lever position (see «ADJUSTMENT»(ref-265070-S36107721402007092000000) ).
73. ADJUST TRANSMISSION CONTROL CABLE 2WD: Adjust the shift lever position (see «ADJUSTMENT»(ref-265069-S02445762442007092000000) ). 4WD: Adjust the shift lever position (see «ADJUSTMENT»(ref-265070-S36107721402007092000000) ).
74. INSTALL FRONT FLOOR COVER (See appropriate step(s) under «INSTALLATION»(ref-265101-S24428556062007092000000) )
75. INSTALL NO. 2 ENGINE UNDER COVER Install the under cover with the 2 clips.
76. INSTALL REAR ENGINE UNDER COVER LH Install the under cover with the 2 clips.
77. INSTALL REAR ENGINE UNDER COVER RH Install the under cover with the 2 clips.
78. INSTALL NO. 1 ENGINE UNDER COVER Install the under cover with the 4 bolts and 12 clips.
79. INSTALL V-BANK COVER SUB-ASSEMBLY Attach the 3 clips to install the engine cover.
80. INSTALL RADIATOR SUPPORT OPENING COVER Install the cover with the 9 clips.
81. ADJUST FRONT WHEEL ALIGNMENT Adjust the front wheel alignment (see «FRONT WHEEL ALIGNMENT»(ref-265090-S01842655342007092000000) ).
82. INSPECT IDLE SPEED (See «ON-VEHICLE INSPECTION»(ref-265059-S39866884782007092000000) )

Scheme 542

Scheme 543

Scheme 544

Scheme 545

Scheme 546

Scheme 547

Scheme 548

Scheme 549

Scheme 550

See also:
• REPLACEMENT
• REMOVAL
• EXHAUST (2GR-FE)
• REMOVAL
• REPLACEMENT
• INSTALLATION
• REMOVAL