TOYOTA RAV4 2006 Service Repair Manual

AX–4U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
PARTS LOCATION
C127571E03

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEMAX–5
AX
C127581E03

AX–136U241E AUTOMATIC TRANSAXLE – FLOOR SHIFT ASSEMBLY
AX
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 SHIFT LEVER KNOB SUB-ASSEMBLY
3. REMOVE REAR CONSOLE BOX SUB-ASSEMBLY
(a) Remove the console box (see page IP-20).
4. DISCONNECT TRANSMISSION CONTROL CABLE
ASSEMBLY
(a) Disconnect the control cable from the shift lever.
(b) Turn the nut and disconnect the control cable from
the shift lever retainer.
5. REMOVE FLOOR SHIFT ASSEMBLY
(a) Remove the 4 bolts and floor shift.
C130920
C127813E01
C127815

U241E AUTOMATIC TRANSAXLE – FLOOR SHIFT ASSEMBLYAX–137
AX
(b) Disconnect the 2 connectors and detach the clamp.
DISASSEMBLY
1. REMOVE LOWER POSITION INDICATOR HOUSING
(a) Detach the 4 claws and remove the housing.
(b) Remove the position indicator slide cover with slide
No. 2 cover.
2. REMOVE POSITION INDICATOR LIGHT HOUSING
(a) Detach the 2 claws and remove the indicator light
housing from the floor shift position indicator
housing.
3. REMOVE INDICATOR LIGHT WIRE SUB-ASSEMBLY
C127814
C127818
C127816

AX–138U241E AUTOMATIC TRANSAXLE – FLOOR SHIFT ASSEMBLY
AX
4. REMOVE SHIFT LOCK RELEASE BUTTON
(a) Detach the 2 claws and remove the button and
spring from the position indicator light housing.
C127817

AX–248U241E AUTOMATIC TRANSAXLE – UNDERDRIVE CLUTCH
AX
INSPECTION
1. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal rings.
(b) Install a dial indicator as shown in the illustration.
(c) Measure the underdrive clutch pack clearance while
applying and releasing compressed air (392 kPa,
4.0 kgf/cm
2, 57 psi).
Standard pack clearance:
1.51 to 1.90 mm (0.0594 to 0.0748 in.)
If the pack clearance is not as specified, inspect the
discs, plates and flange.
2. INSPECT NO. 1 UNDERDRIVE CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate
and flange are worn or burnt. If necessary, replace
them.
HINT:
• If the lining of the disc is peeling off or discolored,
or even if a part of the printed mark is defaced,
replace all discs.
• Before assembling new discs, soak them in ATF
for at least 15 minutes.
3. INSPECT UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Using a vernier caliper, measure the free length of
the spring together with the spring seat.
Standard free length:
17.14 mm (0.6748 in.)
D008123E01
D008124E01
D004077E01
D009214E01

U241E AUTOMATIC TRANSAXLE – UNDERDRIVE CLUTCHAX–249
AX
4. INSPECT UNDERDRIVE CLUTCH DRUM SUB-
ASSEMBLY
(a) Using a caliper gauge, measure the inside diameter
of the underdrive clutch drum bush.
Standard drum bush:
32.56 to 32.58 mm (1.2818 to 1.2826 in.)
Maximum drum bush:
32.63 mm (1.2846 in.)
If the inside diameter is greater than the maximum,
replace the underdrive clutch drum sub-assembly.
REASSEMBLY
1. INSTALL UNDERDRIVE CLUTCH DRUM O-RING
(a) Coat a new O-ring with ATF and install it to the
underdrive clutch drum.
2. INSTALL UNDERDRIVE CLUTCH PISTON SET
(a) Coat the underdrive clutch piston with ATF, and
install it to the underdrive clutch piston drum.
NOTICE:
Be careful not to damage the O-ring.
(b) Install the piston return spring and clutch balancer to
the underdrive clutch drum.
NOTICE:
Be careful not to damage the lip seal of the
clutch balancer.
(c) Place SST on the clutch balancer and compress the
piston return spring with a press.
SST 09350-32014 (09351-32070)
(d) Using a snap ring expander, install the snap ring to
underdrive clutch drum.
NOTICE:
• Be sure the end gap of the snap ring is not
aligned with the clutch balancer's claw.
• Stop the press when the spring sheet is
lowered to the place 1 to 2 mm (0.039 to 0.078
in.) from the sap ring groove.
D008129E02
D004078E01
D003860E01
D003704E01
D003703E02

AX–250U241E AUTOMATIC TRANSAXLE – UNDERDRIVE CLUTCH
AX
• This prevents the spring sheet from being
deformed.
• Do not expand the snap ring excessively.
3. INSTALL NO. 1 UNDERDRIVE CLUTCH DISC
(a) Install the 3 plates, 3 discs and flange.
Install in order:
P - D - P - D - P - D - F
HINT:
P = Plate
D = Disc
F = Flange
(b) Using a screwdriver, install the snap ring.
(c) Check that the end gap of the snap ring is not
aligned with one of the cutouts.
4. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal rings.
(b) Set a dial indicator as shown in the illustration.
(c) Measure the underdrive clutch piston stroke while
applying and releasing compressed air (392 kPa,
4.0 kgf/cm
2, 57 psi).
Standard pack clearance:
1.51 to 1.90 mm (0.0594 to 0.0748 in.)
If the pack clearance is less than the minimum,
parts may have been assembled incorrectly, so
check and reassemble again.
If the park clearance is not as specified, select
another flange.
HINT:
There are 3 flanges in different thickness.
Standard flange thickness
C129394E01
D008125E01
D008123E01
D008124E01
No. Thickness No. Thickness
A 3.0 mm (0.118 in.) C 3.4 mm (0.134 in.)
B 3.2 mm (0.126 in.) - -

SS–12SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL
SS
TORQUE SPECIFICATIONS
DRIVE BELT
VALVE CLEARANCE
TIMING CHAIN
Part Tightened N*m kgf*cm ft.*lbf
Front suspension member
reinforcement RH x Front cross
member, Front suspension
crossmember96 979 71
Part Tightened N*m kgf*cm ft.*lbf
No. 1 camshaft bearing cap x
Cylinder head29.5 301 22
No. 2 camshaft bearing cap x
Cylinder head29.5 301 22
No. 3 camshaft bearing cap x
Cylinder head9.0 92 80 in.*lbf
No. 1 chain tensioner x Timing
chain cover9.0 92 80 in.*lbf
Part Tightened N*m kgf*cm ft.*lbf
Chain tensioner plate x Crankshaft bearing cap 12 122 9
Oil pump drive shaft sprocket x Oil pump 29.5 301 22
No. 1 chain vibration damper x Cylinder head,
Cylinder block9.0 92 80 in.*lbf
Chain tensioner slipper x Cylinder head, Cylinder
block19 194 14
Timing chain guide x Crankshaft bearing cap 9.0 92 80 in.*lbf
Timing chain cover x
Cylinder head, Cylinder
blockBolt A
(Head: 10 mm)9.0 92 80 in.*lbf
Bolt B
(Head: 12 mm)25 255 18
Bolt C
(Head: 14 mm)55 561 41
Nut 11 112 8
V-ribbed belt tensioner x Timing chain cover 59.5 607 44
Engine mounting bracket RH x Timing chain cover 55 561 41
Crankshaft pulley x Crankshaft 180 1,835 133
Oil pan x Stiffening
crankcaseBolt, Nut 9.0 92 80 in.*lbf
Cylinder head cover x
Cylinder headBolt A 11 112 8
Bolt B 14 143 10
Nut 11 112 8
Engine wire x Cylinder head cover 8.4 86 74 in.*lbf
Idler pulley bracket x Cylinder block 60 612 44
Engine mounting insulator FR x Front cross
member95 969 70
Engine mounting
insulator FRThrough bolt x Nut 145 1,479 107
Engine mounting insulator RH x Body 95 969 70
Engine mounting
insulator RH x Engine
mounting bracketNut A 95 969 70
Nut B 52 530 38
Radiator reservoir x Radiator support RH, Engine
mounting insulator RH5.0 51 44 in.*lbf
No. 1 engine cover x Cylinder head 7.0 71 62 in.*lbf

SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICALSS–13
SS
CYLINDER HEAD
ENGINE ASSEMBLY
Part Tightened N*m kgf*cm ft.*lbf
Camshaft position sensor x Cylinder head 9.0 92 80 in.*lbf
Oil pressure switch x Cylinder head 13 133 10
Radio setting condenser x Cylinder head 10 102 7
Cylinder head set bolt
Cylinder head x Cylinder
block1 st 70 714 52
2 nd Turn 90
Tu r n 9 0Tu r n 9 0
Camshaft timing gear x Camshaft 54 551 40
No. 2 camshaft timing sprocket x No. 2 camshaft 54 551 40
No. 1 and No. 2 camshaft bearing cap x Cylinder
head29.5 301 22
No. 3 camshaft bearing cap x Cylinder head 9.0 92 80 in.*lbf
Exhaust manifold x Cylinder head 37 377 27
No. 1 exhaust manifold heat insulator x Exhaust
manifold12 122 9
No. 1 and No. 2 manifold stay x Cylinder block,
Exhaust manifold44 449 32
Oil dipstick guide x Cylinder block 9.0 92 80 in.*lbf
Part Tightened N*m kgf*cm ft.*lbf
Drive plate x Crankshaft 98 1,000 72
Drive shaft bearing bracket x Cylinder block 64 653 47
No. 1 and No. 2 engine hanger x Cylinder head 38 387 28
Engine mounting insulator LH x Body 95 969 70
Engine mounting
insulator LHThrough bolt 56 571 41
Engine mounting insulator RH x Body 95 969 70
Engine mounting
insulator RH x Engine
mounting bracketNut A 95 969 70
Nut B 52 530 38
Engine mounting
insulator RR x Front
suspension
crossmemberBolt and Nut 95 969 70
Engine mounting
insulator RR x Engine
mounting bracketThough bolt 95 969 70
Engine mounting insulator FR x Front cross
member95 969 70
Engine mounting
insulator FRThough bolt 145 1,479 107
Battery carrier bracket x Body 20 204 15
Battery bracket reinforcement x Battery carrier 20 204 15
Front battery carrier x Battery bracket
reinforcement20 204 15
Air cleaner filter element x Body 5.0 51 44 in.*lbf
Radiator reservoir x Radiator support RH, Engine
mounting insulator RH5.0 51 44 in.*lbf
Battery clamp x Upper
Radiator supportFor bolt 8.5 87 75 in.*lbf
Battery clamp x Battery
clamp boltFor nut 5.0 51 44 in.*lbf