TOYOTA RAV4 2006 Service Repair Manual

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEMES–5
ES
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ES–62GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM
ES
A127722E03

ES–4702GR-FE ENGINE CONTROL SYSTEM – ECM
ES
REMOVAL
1. 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.
2. REMOVE AIR CLEANER CAP (See page EM-23)
3. REMOVE AIR CLEANER CASE (See page EM-23)
4. REMOVE ECM
(a) Remove the 3 bolts of the ECM bracket.
(b) Disconnect the 2 ECM connectors.
NOTICE:
After disconnecting the connector, make sure
that dirt, water and other foreign matter does not
contact the connecting part of the connector.
(1) Raise the 2 levers while pushing the locks on
the 2 levers, and disconnect the 2 ECM
connectors.
(c) Remove the ECM with bracket.
(d) Remove the 4 screws and 2 ECM brackets.
A124570
A124571E01
A124573

2GR-FE ENGINE CONTROL SYSTEM – ECMES–471
ES
INSTALLATION
1. INSTALL ECM
(a) Install the 2 brackets to the ECM with the 4 screws.
Torque: 3.0 N*m (30 kgf*cm, 27 in.*lbf)
(b) Connect the 2 ECM connectors.
NOTICE:
When connecting the connector, make sure that
dirt, water and other foreign matter does not
become stuck between the connector and other
part.
(1) Connect the 2 ECM connectors and lower the 2
levers.
NOTICE:
Make sure that the 2 levers are securely
lowered.
(c) Install the ECM with the 3 bolts.
Torque: 6.5 N*m (66 kgf*cm, 57 in.*lbf)
2. INSTALL AIR CLEANER CASE (See page EM-39)
3. INSTALL AIR CLEANER CAP (See page EM-39)
4. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
5. PERFORM REGISTRATION
(a) When replacing the ECM, the Vehicle Identification
Number (VIN) must be input into the replacement
the new ECM (see page ES-14).
(b) When replacing the ECM, perform the vehicle
stability control system recognition in the ECM (see
page CC-12).
6. RESET MEMORY
(a) 2WD:
When replacing the ECM, perform the RESET
MEMORY procedure (A/T initialization) (see page
AX-20).
(b) 4WD:
When replacing the ECM, perform the RESET
MEMORY procedure (A/T initialization) (see page
AX-20).
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A124572
A124570

2AZ-FE ENGINE MECHANICAL – DRIVE BELTEM–7
EM
REMOVAL
1. REMOVE RADIATOR SUPPORT OPENING COVER
2. REMOVE FRONT WHEEL RH
3. REMOVE FRONT FENDER APRON RH
4. REMOVE FRONT SUSPENSION MEMBER
REINFORCEMENT RH
(a) Remove the 4 bolts and reinforcement RH.
5. REMOVE FAN AND GENERATOR V BELT
(a) Using SST and 19 mm socket wrench, loosen the V-
ribbed belt tensioner arm clockwise, then remove
the fan and generator V belt.
SST 09216-42010
NOTICE:
• Be sure to connect SST and the tools so that
they are in line during use.
• When retracting the tensioner, turn it
clockwise slowly for 3 seconds or more. Do
not apply force rapidly.
• After the tensioner is fully retracted, do not
apply force any more than necessary.
INSTALLATION
1. INSTALL FAN AND GENERATOR V BELT
(a) Using SST and 19 mm socket wrench, loosen the V-
ribbed belt tensioner arm clockwise, then install the
fan and generator V belt.
SST 09216-42010
NOTICE:
• Be sure to connect SST and the tools so that
they are in line during use.
• When retracting the tensioner, turn it
clockwise slowly for 3 seconds or more. Do
not apply force rapidly.
• After the tensioner is fully retracted, do not
apply force any more than necessary.
2. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH
(a) Install the reinforcement RH with the 4 bolts.
Torque: 96 N*m (979 kgf*cm, 71 ft.*lbf)
3. INSTALL FRONT FENDER APRON RH
4. INSTALL FRONT WHEEL RH
5. INSTALL RADIATOR SUPPORT OPENING COVER
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A114351E01

2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–21
EM
REMOVAL
1. DISCHARGE REFRIGERANT FROM
REFRIGERATION SYSTEM (See page AC-172)
2. DISCHARGE FUEL SYSTEM PRESSURE (See page
FU-13)
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
(a) Remove the 4 bolts, 12 clips and under cover.
5. REMOVE REAR ENGINE UNDER COVER RH
(a) Remove the 2 clips and under cover.
6. REMOVE REAR ENGINE UNDER COVER LH
(a) Remove the 2 clips and under cover.
7. REMOVE NO. 2 ENGINE UNDER COVER
(a) Remove the 2 clips and under cover.
8. REMOVE FRONT FLOOR COVER (See page FU-34)
9. DRAIN ENGINE COOLANT (See page CO-8)
10. DRAIN ENGINE OIL (See page LU-4)
11. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) 2WD:
Drain automatic transaxle fluid (see page AX-172).
(b) 4WD:
Drain automatic transaxle fluid (see page AX-173)
12. DRAIN TRANSFER OIL (for 4WD)
13. REMOVE HOOD SUB-ASSEMBLY (See page ED-4)
14. REMOVE V-BANK COVER SUB-ASSEMBLY
(a) Detach the 3 clips and remove the V-bank cover.
A137900

EM–222GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
15. REMOVE RADIATOR SUPPORT OPENING COVER
(a) Remove the 9 clips and cover.
16. REMOVE BATTERY CLAMP SUB-ASSEMBLY
(a) Remove the bolt and loosen the nut.
(b) Detach the 2 wire harness clamps.
(c) 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
(a) Detach the 2 wire harness clamps.
(b) Remove the 4 bolts and front bracket.
19. REMOVE BATTERY BRACKET REINFORCEMENT
(a) Remove the 2 bolts and bracket reinforcement.
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2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–23
EM
20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
(a) Disconnect the mass air flow meter connector.
(b) Disconnect the VSV (air intake control) connector.
(c) Disconnect the wire harness clamp and 3 vacuum
hoses.
(d) Disconnect the No. 2 ventilation hose from the air
cleaner hose.
(e) Loosen the No. 1 air cleaner hose clamp.
(f) Unfasten the 2 hook clamps, and then remove the
air cleaner cap.
(g) Remove the air cleaner filter element from the air
cleaner case.
21. REMOVE AIR CLEANER CASE
(a) Disconnect the harness clamp.
(b) Remove the 3 bolts and air cleaner case.
22. DISCONNECT HOSES AND CONNECTORS
(a) Remove the engine room junction block cover
(upper).
(b) Remove the nut and disconnect the engine room
junction block cover (side) with 3 connectors and
wire.
(c) Remove the nut and disconnect the starter wire.
(d) Disconnect the fuel hoses.
(e) Disconnect the 2 heater hoses.
(f) Disconnect the 2 ECM connectors.
23. REMOVE ECM (See page ES-470)
24. REMOVE RADIATOR RESERVOIR TANK ASSEMBLY
(a) Remove the 2 bolts, 2 hoses and reservoir tank.
25. REMOVE DISCHARGE HOSE SUB-ASSEMBLY (See
page AC-220)
26. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (See
page AC-220)
27. DISCONNECT RADIATOR HOSE INLET
28. DISCONNECT RADIATOR HOSE OUTLET
29. DISCONNECT OIL COOLER HOSE
30. DISCONNECT TRANSMISSION CONTROL CABLE
ASSEMBLY
(a) 2WD:
Disconnect the control cable (see page AX-154).
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EM–242GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
(b) 4WD:
Disconnect the control cable (see page AX-154).
31. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See
page EX-3)
32. REMOVE CENTER EXHAUST PIPE ASSEMBLY (See
page EX-2)
33. REMOVE PROPELLER WITH CENTER BEARING
SHAFT ASSEMBLY (See page PR-3)
34. REMOVE FRONT WHEELS
35. REMOVE FRONT AXLE HUB NUT LH
(a) Remove the hub nut (see page AH-8).
36. REMOVE FRONT AXLE HUB NUT RH
(a) Remove the hub nut (see page AH-8).
37. DISCONNECT FRONT STABILIZER LINK ASSEMBLY
LH (See page SP-30)
38. DISCONNECT FRONT STABILIZER LINK ASSEMBLY
RH (See page SP-30)
39. DISCONNECT STEERING INTERMEDIATE SHAFT
(See page PS-44)
40. DISCONNECT TIE ROD END SUB-ASSEMBLY RH
(See page PS-42)
41. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
(See page PS-42)
42. REMOVE FRONT DRIVE SHAFT LH
(a) 2WD:
Remove the drive shaft (see page DS-10).
(b) 4WD:
Remove the drive shaft (see page DS-43).
43. REMOVE FRONT DRIVE SHAFT RH
(a) 2WD:
Remove the drive shaft (see page DS-10).
(b) 4WD:
Remove the drive shaft (see page DS-43).
44. REMOVE ENGINE WITH TRANSAXLE
(a) Install the No. 1 and No. 2 engine hangers with the
4 bolts as shown in the illustration.
Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf)
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.
A129635E02
Part Name Part No.
No. 1 engine hanger 12281-31120
No. 2 engine hanger 12282-31100
Bolt 91671-10825

2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–25
EM
(b) 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.
(c) Set an engine lifter underneath the engine.
(d) Remove the column hole cover. Loosen the bolt
holding the intermediate shaft, and slide the
intermediate shaft.
(e) Put matchmarks on the intermediate shaft and
pinion.
(f) Remove the 2 bolts and 2 nuts, and disconnect the
engine mounting insulator RH.
(g) Remove the bolt and nut, and disconnect the engine
mounting insulator LH.
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