TOYOTA RAV4 2006 Service Repair Manual

SP–16SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING (for Sport Package)
SP
DISASSEMBLY
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. REMOVE FRONT SUSPENSION SUPPORT PLATE LH
(a) Remove the plate from the shock absorber.
2. REMOVE FRONT SUSPENSION SUPPORT DUST
COVER LH
(a) Using a screwdriver, remove the dust cover from the
suspension support.
HINT:
Tape the screwdriver tip before use.
3. REMOVE FRONT SUPPORT TO FRONT SHOCK
ABSORBER NUT
(a) Install 2 nuts and 2 bolts to the bracket at the lower
portion of the shock absorber and secure it with a
vise.
(b) Using SST, compress the coil spring.
SST 09727-30021 (09727-00010, 09727-00021,
09727-00031)
HINT:
To prevent the coil spring from being damaged, wind
vinyl tape on the coil spring.
NOTICE:
• When holding the shock absorber with the
coil spring removed, do not hold it by the
spring lower seat. Also, do not knock the
spring lower seat.
• Do not use an impact wrench which will
damage SST.
(c) Using SST to hold the suspension support, remove
the nut.
SST 09729-22031
4. REMOVE COLLAR
(a) Remove the collar from the suspension support.
5. REMOVE FRONT SUSPENSION SUPPORT SUB-
ASSEMBLY LH
(a) Remove the suspension support from the shock
absorber.
6. REMOVE STRUT MOUNTING BEARING LH
(a) Remove the mounting bearing from the suspension
support.
NOTICE:
• When removing the bearing, the suspension
support may become stuck. Use a
screwdriver or equivalent to remove the
bearing.
• Make sure not to use excessive force when
removing the bearing as it may come apart.
C127543E01
C127544E01

SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING (for Sport Package)SP–17
SP
7. REMOVE FRONT COIL SPRING INSULATOR UPPER
LH
(a) Remove the insulator upper from the shock
absorber.
8. REMOVE FRONT SPRING BUMPER LH
(a) Remove the spring bumper from the shock
absorber.
9. REMOVE FRONT COIL SPRING LH
(a) Remove the coil spring from the shock absorber.
(b) Remove SST from the coil spring.
10. REMOVE FRONT COIL SPRING INSULATOR LOWER
LH
(a) Remove the insulator lower from the shock
absorber.
INSPECTION
1. INSPECT FRONT SHOCK ABSORBER ASSEMBLY
LH
(a) Compress and extend the shock absorber rod 4
times or more. Check that there is no abnormal
resistance or unusual sound during the operation.
If there is any abnormality, replace the shock
absorber assembly with a new one.
NOTICE:
When disposing of the shock absorber, see
DISPOSAL (see page SP-19).
C127545

SP–18SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING (for Sport Package)
SP
REASSEMBLY
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. INSTALL FRONT COIL SPRING INSULATOR LOWER
LH
(a) Install the insulator lower to the shock absorber.
2. INSTALL FRONT SPRING BUMPER LH
(a) Install the spring bumper to the shock absorber.
3. INSTALL FRONT COIL SPRING LH
(a) Using SST, compress the coil spring.
SST 09727-30021 (09727-00010, 09727-00021,
09727-00031)
HINT:
To prevent the coil spring from being damaged, wind
vinyl tape around the coil spring.
NOTICE:
Do not use an impact wrench which will damage
SST.
(b) Install the coil spring to the shock absorber.
HINT:
Fit the lower end of the coil spring to the gap of the
lower spring seat.
4. INSTALL FRONT COIL SPRING INSULATOR UPPER
LH
(a) Install the insulator upper to the shock absorber.
5. INSTALL STRUT MOUNTING BEARING LH
(a) Install the mounting bearing to the insulator upper.
6. INSTALL COLLAR
(a) Install the collar to the suspension support side.
7. INSTALL FRONT SUSPENSION SUPPORT SUB-
ASSEMBLY LH
(a) Install the suspension support to the shock
absorber.
8. REMOVE FRONT SUPPORT TO FRONT SHOCK
ABSORBER NUT
(a) Using SST to hold the spring upper seat, install a
new nut.
SST 09729-22031
(b) Remove SST.
SST 09727-30021 (09727-00021, 09727-00031)
NOTICE:
When removing SST, make sure that the
suspension support is not in an inclined
position, as the bearing may come apart.
C127549
C127550E01
C127544E01

SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING (for Sport Package)SP–19
SP
9. INSTALL FRONT SUSPENSION SUPPORT DUST
COVER LH
(a) Install the dust cover to the shock absorber.
10. INSTALL FRONT SUSPENSION SUPPORT PLATE LH
(a) Install the support plate to the shock absorber with
coil spring.

SP–20SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING (for Sport Package)
SP
INSTALLATION
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. INSTALL FRONT SHOCK ABSORBER WITH COIL
SPRING
(a) Install the front shock absorber with coil spring
(upper side) with the 3 nuts.
Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf)
(b) Install the front shock absorber with coil spring to
the steering knuckle with the 2 bolt and 2 nuts.
Torque: 240 N*m (2,447 kgf*cm, 177 ft.*lbf)
NOTICE:
Do not tighten the bolts.
2. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
(See page SP-31)
3. INSTALL FRONT SPEED SENSOR LH (See page BC-
193)
4. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
5. STABILIZE SUSPENSION
(a) Lower the vehicle.
(b) Press down on the vehicle several times to stabilize
the suspension.
6. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment (see
page SP-3).
DISPOSAL
1. DISPOSE OF FRONT SHOCK ABSORBER
ASSEMBLY LH
(a) Fully extend the shock absorber piston rod, and
clamp it in a vise at an angle.
(b) Using a drill or similar tool, gradually make a hole in
area A to discharge the gas inside of the absorber.
CAUTION:
As metal debris may be blown outward by the
gas, you must.
• Wear protective glasses.
• Cover the area being cut.
NOTICE:
The gas is colorless and harmless.
C127542
C127533
C127546E01

SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARMSP–23
SP
INSTALLATION
1. TEMPORARILY INSTALL FRONT SUSPENSION
LOWER NO. 1 ARM LH
(a) Temporarily install the lower arm with the bolt and
nut to the front side.
(b) Temporarily install the lower arm with the bolt and
nut to the rear side.
2. TEMPORARILY INSTALL FRONT SUSPENSION NO. 1
LOWER ARM SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
3. CONNECT FRONT CROSSMEMBER SUB-
ASSEMBLY
(a) Slowly raise the crossmember jack, and connect the
crossmember to the body.
(b) Using SST, align the holes of the suspension
member and body.
SST 09670-00020
(c) Perform the procedure above on the other side.
(d) Install the member reinforcement with the 4 bolts
labeled A.
(e) Install the suspension member brace with the 6
bolts labeled B.
C131838
C131833
C131841E01
C131835E01

SP–24SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARM
SP
(f) Install the suspension member with the bolt to the
body.
(g) Perform the procedure above on the other side.
(h) Install the engine mounting insulator rear with the 2
nuts and 2 bolts.
4. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
(See page SP-30)
5. CONNECT FRONT SUSPENSION LOWER NO. 1 ARM
SUB-ASSEMBLY LH
(a) Connect the lower arm with the 2 bolts and nut to
the ball joint.
Torque: 92 N*m (938 kgf*cm, 68 ft.*lbf)
6. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
7. STABILIZE SUSPENSION (See page SP-12)
8. TIGHTEN FRONT CROSS MEMBER SUB-ASSEMBLY
(a) Tighten the bolts and nuts.
Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) for bolt A
93 N*m (948 kgf*cm, 69 ft.*lbf) for bolt B
145 N*m (1,479 kgf*cm, 107 ft.*lbf) for
body
95 N*m (969 kgf*cm, 70 ft.*lbf) for
engine mounting insulator
9. TIGHTEN FRONT SUSPENSION LOWER NO. 1 ARM
SUB-ASSEMBLY LH
(a) Using SST, and tighten the bolt on the front side.
SST 09961-01270
Torque: 223 N*m (2,376 kgf*cm, 172 ft.*lbf) for
use without SST
175 N*m (1,785 kgf*cm, 129 ft.*lbf) for
use with SST
NOTICE:
Do not tighten the nut.
(b) Fix the nut in place and tighten the bolt on the rear
side.
Torque: 223 N*m (2,376 kgf*cm, 172 ft.*lbf)
NOTICE:
Do not tighten the nut.
10. TIGHTEN FRONT SUSPENSION LOWER NO. 1 ARM
SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
11. INSTALL HOOD SUB-ASSEMBLY (See page ED-7)
C131836
A124842
C117420E01

SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARMSP–25
SP
12. INSPECT AND ADJUST HOOD SUB-ASSEMBLY
(a) Inspect and adjust the hood (see page ED-5).
13. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment (see
page SP-3).

SP–28SUSPENSION – FRONT LOWER BALL JOINT
SP
INSTALLATION
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. INSTALL FRONT LOWER BALL JOINT ASSEMBLY
LH
(a) Install the ball joint with the 2 bolts and nut to the
lower arm.
Torque: 92 N*m (938 kgf*cm, 68 ft.*lbf)
(b) Install the lower ball joint with the nut to the steering
knuckle.
Torque: 133 N*m (1,360 kgf*cm, 98 ft.*lbf)
(c) Install a new cotter pin.
If the holes for the cotter pin are not aligned, tighten
the nut further up to 60
.
2. INSTALL STEERING KNUCKLE WITH AXLE HUB
(See page AH-9)
3. CONNECT FRONT SUSPENSION LOWER NO. 1 ARM
SUB-ASSEMBLY LH (See page AH-10)
4. CONNECT TIE ROD END SUB-ASSEMBLY LH (See
page PS-45)
5. INSTALL FRONT DISC (See page BR-43)
6. INSTALL FRONT DISC BRAKE CYLINDER
ASSEMBLY LH (See page BR-46)
7. INSTALL FRONT AXLE HUB NUT (See page AH-10)
8. INSTALL FRONT SPEED SENSOR LH (See page BC-
193)
9. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
10. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment (see
page SP-3).

SP–34SUSPENSION – REAR COIL SPRING
SP
INSTALLATION
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. INSTALL REAR COIL SPRING INSULATOR LOWER
LH
(a) Install the insulator lower to the suspension No. 2
arm.
2. REMOVE REAR COIL SPRING LH
(a) Install the coil spring to the suspension No. 2 arm.
3. INSTALL REAR COIL SPRING INSULATOR UPPER
LH
(a) Align the stopper part of the insulator upper with the
coil spring tip, and install the insulator upper.
4. TEMPORARILY INSTALL REAR SUSPENSION NO. 2
ARM ASSEMBLY LH
(a) Slowly raise the suspension No. 2 arm with a jack,
and connect the suspension No. 2 arm to the axle
carrier.
(b) Install the bolt and nut.
NOTICE:
Install the arm so that the coil spring's
distinguishing mark is on the outer side of the
vehicle.
5. INSTALL REAR STABILIZER LINK ASSEMBLY LH
(See page SP-50)
6. CONNECT NO. 2 PARKING BRAKE CABLE
ASSEMBLY (See page PB-9)
7. INSTALL SKID CONTROL SENSOR WIRE (for 2WD)
(See page BC-201)
8. INSTALL REAR SPEED SENSOR LH (for 4WD) (See
page BC-206)
9. INSTALL REAR WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
10. STABILIZE SUSPENSION (See page SP-37)
11. TIGHTEN REAR SUSPENSION NO. 2 ARM
ASSEMBLY LH (See page SP-46)
12. CHECK SPEED SENSOR SIGNAL
(a) Check the speed sensor signal (see page BC-44).
13. INSPECT AND ADJUST REAR WHEEL ALIGNMENT
(a) Inspect and adjust the rear wheel alignment (see
page SP-7).
C129676E01