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Home >> Toyota >> 2013 >> RAV4 LE, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2AR-FE) (Service Information) (1 Of 2) (Except Hybrid) >> Cylinder Head Gasket >> Installation [12/2012 - 11/2013] >> Procedure

Installation [12/2012 - 11/2013]: Procedure

  1. INSTALL CYLINDER HEAD GASKET 
    1. Clean the cylinder block and cylinder head with solvent.
    2. Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.
      GTY365162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Lot No.
      *2 Cylinder Block
      *3 Cylinder Head Gasket
      *a 3.0 to 7.0 mm (0.118 to 0.276 in.)
      *b 20 mm (0.787 in.) or more
      *c 7.0 mm (0.276 in.)
      *d 3.0 mm (0.118 in.) or more
      Seal Packing
      Front

      Seal packing

      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Standard seal dimension

      3.0 to 7.0 mm (0.118 to 0.276 in.) wide and 3.0 mm (0.118 in.) thick

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head gasket within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      HINT: 

      Apply at least 20 mm (0.787 in.) of seal packing from the inside edge of the protrusion of the cylinder block.

    3. Place a new cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.
      NOTE:

      Pay attention to the installation direction.

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    HINT: 

    Perform "Inspection After Repairs" after replacing the cylinder head sub-assembly.

    Refer to INITIALIZATION [12/2012 - ]

    1. Place the cylinder head on the cylinder block.
      NOTE:
      • Make sure that no oil is on the mounting surface of the cylinder head.
      • Place the cylinder head on the cylinder block gently in order not to damage the gasket with the bottom part of the head.

      HINT: 

      The cylinder head bolts are tightened in 4 progressive steps.

    2. Install the plate washers to the cylinder head bolts.
    3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
    4. Step 1:
      1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts in several steps in the sequence shown in the illustration.

        Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 

        Fig 1: Cylinder Head Bolts Tightening Sequence
        GTY382197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Do not drop the plate washer for the cylinder head bolt into the cylinder head.

    5. Step 2:
      1. Tighten the cylinder head bolts again in the sequence shown in the illustration to make sure that they are tightened to the specified torque.

        Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 

    6. Step 3:
      1. Mark the front side of each cylinder head bolt head with paint.
      2. Tighten the cylinder head bolts 90° in the sequence shown in step 1.
    7. Step 4:
      1. Tighten the cylinder head bolts another 90° in the sequence shown in step 1.
      2. Check that the paint marks are now at a 180° angle to the front.
        NOTE:
        • Do not apply oil for at least 4 hours after the installation.
        • Do not start the engine for at least 4 hours after installation.
        • After installation, if the seal packing has seeped out, wipe it off.
  3. INSTALL VALVE STEM CAP 
    1. Apply a light coat of engine oil to the valve stem ends.
    2. Install the 16 valve stem caps to the cylinder head.
      NOTE:

      Do not drop the valve stem caps into the cylinder head.

  4. SET CAMSHAFT TIMING GEAR ASSEMBLY 

    HINT: 

    • When reusing the camshaft timing gear, release the lock pin and set the camshaft timing gear to the advanced position before installation.
    • If the camshaft timing gear is new or has already been set to the advanced position, install the camshaft timing gear after the camshafts have been installed to the engine.
    1. Check the camshaft timing gear position.
      GTY367543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Knock Pin Hole
      *2 Alignment Mark
      *a Advanced Position
      *b Retarded Position
      NOTE:

      If the camshaft timing gear is set to the advanced position, do not let the camshaft timing gear rotate clockwise during installation.

      If the camshaft timing gear rotates to the retarded position, release the lock pin and set the camshaft timing gear to the advanced position.

    2. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear and attach the gear to the camshaft.
      GTY378805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Pin Hole
      *2 Knock Pin
    3. Check that there is no clearance between the camshaft timing gear and camshaft flange.
      GTY363933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Gear
      *2 Clearance
      *3 Camshaft Flange
      *a INCORRECT
      *b CORRECT
      *c No Clearance
    4. Fix the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.
      NOTE:

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    5. Release the lock pin.
      1. Clean the camshaft journal with non-residue solvent.
      2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
        GTY380978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Retard Side Path *2 Advance Side Path
        *3 Port A *4 Knock Pin
        *a Open *b Closed
        Rubber Vinyl Tape

        HINT: 

        There are 4 oil paths in the grooves of the camshaft. Plug three of the paths with pieces of rubber.

      3. Open a hole at port A shown in the illustration.
      4. While applying compressed air at approximately 200 kPa (2.0 kgf/ cm2 , 29 psi) to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).
        GTY383765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        WARNING:

        Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.

        NOTE:

        Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

        HINT: 

        • The camshaft timing gear assembly may be turned in the advance direction without applying any force.
        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.
      5. Remove the vinyl tape and pieces of rubber from the camshaft.
    6. Remove the bolt and camshaft timing gear.
      NOTE:

      Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

  5. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    1. Inspect the valve lash adjuster before installing it.

      Refer to PROCEDURE - Step 2

    2. Install the 16 lash adjusters to the cylinder head.
      NOTE:

      Install the lash adjuster to the same place it was removed from.

  6. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Apply engine oil to the lash adjuster tips and valve stem caps.
      GTY365026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Valve Rocker Arm
      *2 Valve Lash Adjuster
      *3 Valve Stem Cap
    2. Install the 16 valve rocker arms as shown in the illustration.
  7. INSTALL NO. 2 CAMSHAFT BEARING 

    Refer to PROCEDURE - Step 18

  8. INSTALL NO. 1 CAMSHAFT BEARING 

    Refer to PROCEDURE - Step 17

  9. INSTALL OIL CONTROL VALVE FILTER 

    Refer to PROCEDURE - Step 19

  10. INSTALL CAMSHAFT 

    HINT: 

    Perform "Inspection After Repairs" after replacing the camshaft.

    Refer to INITIALIZATION [12/2012 - ]

    1. Clean the camshaft journals, camshaft housing and camshaft bearing caps.
    2. Apply a light coat of engine oil to the camshaft journal, camshaft housing and camshaft bearing caps.
    3. Install the camshaft and No. 2 camshaft to the camshaft housing.
  11. INSTALL CAMSHAFT BEARING CAP 
    1. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.
      GTY195075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 11 bearing cap bolts in the order shown in the illustration.

      Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 

      NOTE:

      Make sure that the camshaft rotates smoothly after installing the bearing caps.

    Fig 2: Camshaft Bearing Caps Bolt Tightening Sequence
    GTY367606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 
    1. Check that the valve rocker arms are installed as shown in the illustration.
      GTY370793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Valve Rocker Arm
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster
      *a INCORRECT
      *b CORRECT
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY368076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Packing

      Seal packing

      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Standard seal diameter

      3.0 to 4.0 mm (0.118 to 0.157 in.)

      NOTE:
      • Remove any oil from the contact surface.
      • Install the camshaft housing within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
    3. Position the knock pin of the camshaft and No. 2 camshaft as shown in the illustration.
      GTY378523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Knock Pin
      *a Approximately 17°
      *b Approximately 2°
    4. Install the camshaft housing, and then install the 20 bearing cap bolts in the order shown in the illustration.

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

      Fig 3: Camshaft Bearing Caps Bolt Tightening Sequence
      GTY365872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply oil for at least 4 hours after the installation.
      • Do not start the engine for at least 4 hours after the installation.
      • Thoroughly wipe clean any seal packing.
  13. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 

    HINT: 

    Perform "Inspection After Repairs" after replacing the camshaft timing gear assembly.

    Refer to INITIALIZATION [12/2012 - ]

    1. Check the camshaft timing gear position.
      GTY366934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Knock Pin Hole
      *2 Alignment Mark

      If the camshaft timing gear is not set to the advanced position, release the lock pin and reset the camshaft timing gear (Refer to the Set Camshaft Timing Gear Assembly procedures).

    2. Align the knock pin of the camshaft with the knock pin hole of the camshaft timing gear and attach the gear to the camshaft.
      GTY378805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Knock Pin Hole
      *2 Knock Pin
    3. Check that there is no clearance between the camshaft timing gear and camshaft flange.
      GTY381646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Gear
      *2 Clearance
      *3 Camshaft Flange
      *a INCORRECT
      *b CORRECT
      *c No Clearance
    4. Using a wrench to hold the hexagonal portion of the camshaft, install the bolt.
      GTY372100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

      NOTE:
      • Be careful not to damage the cylinder head or spark plug tube with the wrench.
      • Do not disassemble the camshaft timing gear.
  14. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 

    HINT: 

    Perform "Inspection After Repairs" after replacing the camshaft timing exhaust gear assembly.

    Refer to INITIALIZATION [12/2012 - ]

    1. Align the knock pin of the No. 2 camshaft with the knock pin hole of the camshaft timing exhaust gear and attach the gear to the No. 2 camshaft.
      GTY368255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Knock Pin Hole
      *2 Knock Pin
    2. Check that there is no clearance between the camshaft timing exhaust gear and camshaft flange.
      GTY381646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Exhaust Gear
      *2 Clearance
      *3 Camshaft Flange
      *a INCORRECT
      *b CORRECT
      *c No Clearance
    3. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the bolt.
      GTY365637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

      NOTE:
      • Be careful not to damage the cylinder head or spark plug tube with the wrench.
      • Do not disassemble the camshaft timing exhaust gear.
  15. ADD ENGINE OIL 
    1. Add 50 cc (3.1 cu. in.) of engine oil into the oil hole shown in the illustration.
      GTY195141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Oil must be added if the lash adjusters were removed.
      • Make sure that the low pressure chamber and oil paths of the lash adjusters are full of engine oil.
  16. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Temporarily install the crankshaft pulley bolt.
      GTY379014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Rotate the crankshaft 40° counterclockwise to position the crankshaft pulley key as shown in the illustration.
    3. Check that the timing marks of the camshaft timing gears are as shown in the illustration.
      GTY361369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Timing Mark
      *a Approximately 7°
      *b Approximately 32°

      HINT: 

      "A" is not a timing mark.

    4. Remove the crankshaft pulley bolt.
  17. INSTALL NO. 1 CHAIN VIBRATION DAMPER 
    1. Install the No. 1 chain vibration damper with the 2 bolts.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  18. INSTALL CHAIN SUB-ASSEMBLY 
    1. Place the chain onto the camshaft timing gears and crankshaft timing sprocket.

      HINT: 

      • Make sure the mark plate of the chain faces away from the engine.
      • It is not necessary to install the chain to the teeth of the gears and sprocket.
    2. Align the mark plate (yellow or gold) of the chain with the timing mark of the camshaft timing exhaust gear and install the chain to the camshaft timing exhaust gear.
      GTY365793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Mark Plate
      *2 Timing Mark
    3. Align the mark plate (pink or gold) of the chain with the timing mark of the crankshaft timing sprocket and install the chain to the crankshaft timing sprocket.
      GTY375999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Mark Plate
      *2 Timing Mark
    4. Tie a string above the crankshaft timing sprocket so that the chain is secure.
      GTY195062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using the hexagonal portion of the intake camshaft, rotate the intake camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing gear with the mark plate (yellow or gold) of the chain and install the chain to the camshaft timing gear.
      GTY371844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Mark Plate
      *2 Timing Mark

      HINT: 

      Hold the intake camshaft in place with a wrench until the chain tensioner is installed.

    6. Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain so that the chain tensioner slipper can be installed.
      GTY184269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure the chain is secure.

  19. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper with the bolt.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  20. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Install a new gasket and the chain tensioner with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    2. Remove the pin from the stopper plate.
  21. INSTALL TIMING CHAIN GUIDE 
    1. Install the timing chain guide with the bolt.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  22. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Temporarily install the crankshaft pulley bolt.
      GTY376774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Timing Mark *2 Key
      *a Approximately 7° *b Approximately 32°
    2. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration.

      HINT: 

      "A" is not a timing mark.

    3. Remove the crankshaft pulley bolt.
  23. INSTALL TIMING CHAIN COVER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  24. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 5

  25. CONNECT NO. 2 PCV HOSE 

    Refer to PROCEDURE - Step 6

  26. CONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 7

  27. INSTALL FUEL DELIVERY PIPE 

    Refer to PROCEDURE - Step 2

  28. CONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 3

  29. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  30. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY 

    Refer to PROCEDURE - Step 1

  31. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  32. INSTALL ENGINE AND TRANSAXLE 

    Refer to INSTALLATION [12/2012 - ] 

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