Friday, March 30, 2012

How To Replace Engine on Toyota RAV4?

Replacing Toyota Rav4 Engine.2.0L and 2.4L engine removal for Toyota Rav4.
The details and diagrams to replace Engine and Engine related components.
All this details are provided here.



NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.


NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2. Relieve the fuel system pressure.
  3. Remove or disconnect the following:

    Negative battery cable
    Battery
    Hood
    Engine undercover
  4. Drain the engine coolant and oil.
  5. Drain the transaxle assembly.
  6. Remove or disconnect the following:

    Air cleaner and case
    Accelerator cable from the throttle body, bracket and clamps
  7. Disconnect and remove the engine wire from the No. 2 relay block, as follows:

    No. 2 relay block from the body by removing the 2 bolts
    Upper cover to the relay block
    Electrical connectors
    Engine wire, by removing the 2 nuts
    Charcoal canister
    Alternator
    Upper and lower radiator hoses
    Water inlet from the engine by removing the 2 nuts
    Heater hoses
    Fuel hose, by placing a rag under the fuel inlet hose
    Starter by disconnecting the electrical connectors and 2 bolts, if equipped with manual transmission
    Ground cable from the transaxle by removing the bolt
    Clutch release cylinder from the transaxle, if equipped with manual transmission
    Transaxle control cables (2 cable for manual transmission or 1 for automatic transmission) from the transaxle.
    Transaxle cable from the front suspension crossmember and engine mounting centermember by removing the 2 bolts, if equipped with an automatic transmission
    Transaxle oil cooler hoses, if equipped with an automatic transmission or 4WD with manual transmission
  8. Detach the following:

    Vapor pressure sensor connector
    Igniter connector
    Ignition coil connector
    Noise filter connector
    Ignition coil wire
    Manifold Absolute Pressure (MAP) sensor connector
    MAP sensor vacuum hose from the gas filter on the intake manifold
    Brake booster hose from the intake manifold
    Differential lock control solenoid connector, if equipped with a 4WD manual transmission
    Ground strap from cowl
  9. Detach the engine wire from the passenger compartment, as follows:

    Right-hand scuff plate
    Right-hand side trim
    Right-hand carpet center cover
    2 ECM connectors
    2 connectors from the bracket connectors
    No. 4 junction block connector
    Wire clamp from the bracket
    Engine wire from the passenger compartment
  10. Remove the front exhaust pipe, as follows:

    3 nuts and the front exhaust pipe from the exhaust manifold, using a 14mm deep socket wrench; discard the gasket
    2 bolts and 2 nuts holding the front exhaust pipe to the catalytic converter
    Front exhaust pipe and 2 gaskets
  11. Remove the compressor from the engine and suspend the compressor securely.

NOTE
It is not necessary to remove the air conditioning compressor lines in order to remove the engine.

  1. Remove or disconnect the following:

    Driveshaft, if equipped with 4WD
    Halfshaft
    Sway bar
  2. Remove the front suspension crossmember assembly, as follows:

    2 centermember set nuts holding the centermember to the middle of the crossmember.
    2 rack and pinion assembly set bolts/nuts from the crossmember. Securely suspend the steering gear assembly.
    Catalytic converter with pipe from the ring
    Support the suspension crossmember with a jack
    6 bolts from the suspension crossmember
    Suspension crossmember with the lower suspension arms
  3. Remove the engine mounting centermember, as follows:

    2 bolts holding the centermember to the front engine mounting insulator
    2 bolts holding the centermember to the body
    Centermember
  4. Disconnect the power steering pump from the engine, as follows:

    2 vacuum hoses from the steering pump
    Adjusting bolt for the power steering unit. Loosen the pivot bolt to the power steering pump and remove the drive belt. Use Torque Wrench Adapter tool 09249-63010 and a deep socket to loosen the pivot bolt.
    Power steering pump from the engine by removing the 3 bracket bolts
  5. Install a engine hanger to the engine.
  6. Attach the engine sling device to the engine hangers.
  7. Remove or disconnect the following:

    Left-hand engine mounting bracket from the mounting insulator by removing the 2 nuts and 2 bolts
    Ground connector next to the right-hand engine mount
    Right-hand engine mounting bracket from the mounting insulator by removing the bolt and 2 nuts
  8. Lower the engine and transaxle and at the same time, raise the vehicle to gain clearance to the remove the engine.
  9. Place the assembly on a stand and separate the engine from the transaxle.
To install:


image
Fig. Exploded view of the engine accessory removal components-2.0L


image
Fig. Exploded view of the engine removal-2.0L
  1. Install or connect the following:

    Engine and transaxle assembly
    Left-hand engine mounting bracket to the mounting insulator. Tighten both nuts/bolts to 47 ft. lbs. (64 Nm).
    Bolt and 2 nuts to hold the right-hand engine mounting bracket to the mounting insulator. Tighten the bolt to 27 ft. lbs. (37 Nm) and both nuts to 38 ft. lbs. (52 Nm).
    Ground connector next to the right-hand engine mount
    Engine sling and hanger
  2. Install the power steering pump, as follows:

    Pump with the bracket. Tighten the 3 bolts to 32 ft. lbs. (43 Nm).
    Pivot and adjusting bolts. Tighten the pivot bolt to 32 ft. lbs. (43 Nm) and the adjusting bolt to 29 ft. lbs. (39 Nm).
    Drive belt. Adjust the tension.
    Both air hoses to the power steering pump
  3. Install or connect the following:

    Engine mounting centermember to the body; install the 4 bolts but do not tighten the bolts at this time
  4. Install or connect the front crossmember, as follows:

    Suspension crossmember with the lower control arms. Torque both bolts crossmember-to-chassis bolts to 152 ft. lbs. (206 Nm).
    Rack and pinion. Tighten both nuts/bolts to 83 ft. lbs. (113 Nm).
    Centermember to the crossmember. Tighten both nuts to 82 ft. lbs. (112 Nm).
    Tighten the lower control arm rear brackets to 101 ft. lbs. (137 Nm).
    Tighten both engine mounting centermember-to-front engine mounting insulator bolts to 59 ft. lbs. (80 Nm).
    Tighten both engine mounting centermember-to-body bolts to 26 ft. lbs. (35 Nm).
  5. Install or connect the following:

    Sway bar
    Halfshafts
    Driveshaft, if equipped with 4WD
  6. Install the air conditioning compressor. Tighten nut/bolts, as follows:

    Stud bolt to 34 ft. lbs. (47 Nm)
    Bolt to 27 ft. lbs. (37 Nm)
    Nut to 20 ft. lbs. (27 Nm)
  7. Install or connect the following:

    Air conditioning compressor connector
    Front exhaust pipe with new gaskets. Tighten the 3 nuts to 46 ft. lbs. (62 Nm) and 2 bolts to 35 ft. lbs. (48 Nm).
  8. Attach the engine wire to the passenger compartment, as follows:

    Engine wire through the cowl panel
    Wire clamp to the bracket
    Both ECM connectors
    Both connectors on the bracket
    No. 4 junction block
    Right-hand floor carpet center cover
    Right-hand cowl side trim
    Right-hand scuff plate
  9. Connect the following:

    Vapor pressure sensor connector
    Igniter connector
    Ignition coil connector
    Noise filter connector
    Ignition coil wire
    MAP sensor connector
    MAP sensor vacuum hose to the gas filter on the intake manifold
    Brake booster hose to the intake manifold
    Differential lock control solenoid connector, if equipped with 4WD manual transmission
    Ground strap to cowl
  10. Install or connect the following:

    Transaxle oil cooler hoses, if equipped with an automatic transmission or 4WD with manual transmission
    Transaxle control cable(s) to the transaxle
    Transaxle control cable to the front crossmember and engine mounting centermember, for an automatic transmission
    Clutch release cylinder, for manual transmission Tighten both bolts to 108 inch lbs. (12 Nm).
    Ground cable to the transaxle
    Starter, for a manual transmission
    Fuel inlet hose to the fuel filter, using new gaskets. Tighten the union bolt to 22 ft. lbs. (29 Nm).
    Heater hoses
    Water inlet to the engine. Tighten both nuts to 78 inch lbs. (8.8 Nm).
    Upper and lower radiator hoses
    Alternator
    Charcoal canister
  11. Connect the engine wire to the No. 2 relay box, as follows:

    Engine wire to the No. 2 relay block with the 2 nuts
    Connector
    Upper cover
    No. 2 relay block to the body with the 2 bolts
  12. Install or connect the following:

    Accelerator cable to the throttle body, cable bracket and clamps
    Air cleaner case and cap
    Battery
    Negative battery cables
  13. Fill the transaxle with oil.
  14. Fill the engine with oil.
  15. Fill the engine coolant.
  16. Start the engine and check for leaks.
  17. Install or connect the following:

    Engine undercovers
    Hood
  18. Recheck all fluid levels.
  19. Check and/or adjust the front wheel alignment.

2.4L Engine Removal Installation Procedure is As follows:---

  1. Properly discharge the fuel system. Discharge the air conditioning system.
  2. Disconnect the negative battery cable.
    NOTE
    Wait at least 90 seconds after disconnecting the negative battery cable before starting any repair work to prevent air bag and seat belt pretensioner activation.
  3. Remove the engine undercovers.
  4. Drain the transaxle fluid. Drain the transfer case fluid, if equipped. Drain the engine oil. Drain the engine coolant.
  5. Matchmark and remove the hood.
  6. Remove the radiator reservoir. Remove the cowl top ventilation louver.
  7. Disconnect the positive battery cable. Remove the battery. Remove the battery tray. Remove the five bolts and the battery bracket.
  8. Remove the air cleaner assembly.
  9. Remove the J/B cover, located inside the engine compartment. Loosen the bolt. Remove the assembly. Pull out the wire connector. Disconnect the connector. Disconnect the wire clamp.
  10. Remove the two screws and the glove box door. Disconnect the six engine wire connectors from the ECM and the instrument panel wire. Pull out the engine wire from the cabin.
  11. Disconnect the accelerator cable. Disconnect the ground wire from the cylinder head.
  12. Remove the air conditioning hoses from the compressor. Disconnect the air conditioning hoses from the power steering pump.
  13. Remove the radiator hoses. Disconnect the heater hoses.
  14. Drain the power steering fluid. Disconnect and plug the power steering pump hoses.
  15. Remove the fuel tube connector. Disconnect the connector from the fusible link block.
  16. If equipped with manual transaxle, remove the two clips and washers and disconnect the two control cables.
  17. Remove the starter.
  18. If equipped with manual transaxle, remove the heat insulator and disconnect the clutch release cylinder and line from the transaxle.
  19. If equipped with automatic transaxle, remove the nut holding the control shift lever to the control cable. Remove the clip and disconnect the control cable. Disconnect the control cable from the cable clamp.
  20. Disconnect the ground cable from the transaxle.
  21. If equipped with automatic transaxle, disconnect and plug the transaxle cooler lines.
  22. If equipped with 4WD, remove the driveshaft.
  23. Remove the front halfshafts.
  24. Remove the four bolts, two compression rings, two gaskets and the front exhaust pipe.
  25. Disconnect the front stabilizer bar links.
  26. Remove the two bolts and disconnect the power steering gear assembly.
  27. Attach a suitable engine removal fixture to the engine using engine hanger tools 12281-28010 and 12281-28020 or equivalent.
    NOTE
    Do not attempt to hang the engine by hooking the chain to any other part.
  28. Remove the two nuts and bolt holding the right side engine mounting insulator to the timing chain cover.
  29. Remove the bolt holding the left side engine mounting insulator to the mounting bracket.
  30. Support the suspension crossmember with a jack. Remove the six bolts holding the suspension crossmember engine mounting member to the body.
  31. Carefully lower the engine assembly out of the vehicle.
    NOTE
    Be sure the assembly is clear of all wiring, hoses and cables before removing it.
  32. Separate the engine, transaxle, front suspension crossmember and center engine mounting member, as required.
To install:
  1. Installation is the reverse of the removal procedure.
  2. Tighten the six upper engine to transaxle bolts to 34 ft. lbs. for bolt -A- and 47 ft. lbs. for bolt -B-.
  3. Tighten the four lower engine to transaxle bolts to 32 ft. lbs. 

image
Fig. Engine to transaxle bolt locations-2005 2.4L engine


image 
Fig. Suspension crossmember bolt locations-2005 2.4L engine
  1. If equipped with automatic transaxle, tighten the torque converter retaining bolts to 30 ft. lbs.
    NOTE
    Install the green colored bolt first.
  2. Tighten the six suspension crossmember engine mounting bolts to 29 ft. lbs for bolt -A-, 83 ft. lbs. for bolt -B- and 116 ft. lbs. for bolt -C-.
  3. Be sure to fill the engine with the proper grade and type engine oil.
  4. Be sure to fill the transaxle with the proper grade and type transaxle fluid.
  5. Be sure to fill the cooling system with the proper grade and type engine coolant.
  6. Recharge the air conditioning system.
  7. Start the engine and check for leaks, correct as required.

These details will help.
Thanks.

FOR MORE HELP GO TO: ---

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