TOYOTA RAV4 2006 Service Repair Manual

EM–1062AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
INSTALLATION
1. INSTALL DRIVE PLATE SUB-ASSEMBLY
(a) Clean the 8 bolts and 8 bolt holes.
(b) Apply adhesive to 2 or 3 threads of the 8 bolts.
Adhesive:
Toyota Genuine Adhesive 1342, Three Bond
1342 or Equivalent
(c) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
(d) Install the front spacer.
HINT:
Align the pin of the front spacer with the pin hole of
the crankshaft.
(e) Install the drive plate and rear spacer onto the
crankshaft.
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2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–107
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(f) Using several steps, uniformly install and tighten the
8 bolts in the sequence shown in the illustration.
Torque: 98 N*m (1,000 kgf*cm, 72 ft.*lbf)
2. INSTALL TORQUE CONVERTER CLUTCH
ASSEMBLY
(a) Install the torque converter clutch for U241E (2WD)
(see page AX-148).
(b) Install the torque converter clutch for U140F (4WD)
(see page AX-149).
3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
(a) Install the automatic transaxle for U241E (2WD)
(see page AX-149).
(b) Install the automatic transaxle for U140F (4WD)
(see page AX-150).
4. INSTALL STARTER ASSEMBLY (See page ST-14)
5. INSTALL TRANSFER ASSEMBLY (for 4WD) (See
page TF-75)
6. INSTALL DRIVE SHAFT BEARING BRACKET (for
2WD)
(a) Install the bracket with the 3 bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
7. INSTALL DRIVE SHAFT BEARING BRACKET (for
4WD)
(a) Install the bracket with the 3 bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
8. INSTALL ENGINE HANGER
(a) Install the No. 1 and No. 2 engine hangers.
Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf)
Part No.
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ITEM Part No.
No. 1 engine hanger 12281-28010
No. 2 engine hanger 12282-28010
Bolt 91512-61020

EM–1082AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
(b) Attach the sling device and the engine with the
chain block.
9. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Lift the engine assembly (with transaxle) with the
chain block.
(b) Lower the engine out of the vehicle slowly and
carefully.
NOTICE:
Make sure the engine is clear of all wiring, hoses
and cables.
10. INSTALL ENGINE MOUNTING INSULATOR LH
(a) Install the engine mounting insulator LH with the 4
bolts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
(b) Install the engine mounting insulator LH with the
through bolt and nut.
HINT:
Install the through bolt by tightening the nut.
Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf)
11. INSTALL ENGINE MOUNTING INSULATOR RH
(a) Install the engine mounting insulator RH with the 2
bolts and 2 nuts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) for bolt
95 N*m (969 kgf*cm, 70 ft.*lbf) for nut A
52 N*m (530 kgf*cm, 38 ft.*lbf) for nut B
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12. REMOVE ENGINE HANGER
(a) Remove the No. 1 and No. 2 engine hangers.
13. INSTALL ENGINE MOUNTING INSULATOR RR
(a) Install the engine mounting insulator RR with the 2
nuts and 2 bolts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
(b) Install the through bolt which is used to secure the
rear engine mounting insulator, into the rear engine
mounting bracket.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
14. INSTALL ENGINE MOUNTING INSULATOR FR
(a) Install the engine mounting insulator FR with the 2
bolts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
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EM–1102AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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(b) Install the through bolt and nut which is used to
secure the front engine mounting bracket FR.
HINT:
Install the through bolt by tightening the nut.
Torque: 145 N*m (1,479 kgf*cm, 107 ft.*lbf)
15. INSTALL PROPELLER SHAFT ASSEMBLY (for 4WD)
(a) Install the propeller shaft (see page PR-5).
16. INSTALL FRONT DRIVE SHAFT ASSEMBLY
(a) Install the front drive shaft RH (for 2WD) (see page
DS-32).
(b) Install the front drive shaft RH (for 4WD) (see page
DS-65).
17. INSTALL FRONT EXHAUST PIPE (See page EX-4)
18. CONNECT ENGINE WIRE
(a) Install the ground cable with the bolt located near
the starter.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
(b) Connect the ground cable to the clamp located near
the starter.
(c) Connect the engine wire to the positive (+) battery
terminal with the nut.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
(d) Connect the ground cable connector.
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2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–111
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(e) Connect the 2 engine wire connectors and install
the nut.
(f) Install the engine room relay block cover.
(g) Attach the clamp of the engine wire cover.
(h) Install the engine wire cover to with the bolt.
19. INSTALL ECM (See page ES-430)
20. INSTALL COOLER COMPRESSOR ASSEMBLY (See
page AC-217)
21. INSTALL GENERATOR ASSEMBLY (See page CH-15)
22. INSTALL FAN AND GENERATOR V BELT (See page
EM-7)
23. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-7)
24. INSTALL TRANSAXLE CONTROL CABLE
ASSEMBLY
(a) Install the transaxle control cable for U241E (see
page AX-130).
(b) Install the transaxle control cable for U140F (see
page AX-130).
25. INSTALL INTAKE MANIFOLD INSULATOR (See page
ES-421)
26. INSTALL INTAKE MANIFOLD (See page ES-421)
27. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
(See page FU-13)
28. CONNECT NO. 2 VENTILATION HOSE (See page FU-
14)
29. INSTALL THROTTLE BODY ASSEMBLY (See page
ES-413)
30. CONNECT FUEL TUBE (See page FU-14)
31. CONNECT HEATER WATER OUTLET HOSE
(a) Connect the heater water outlet hose to the air
conditioner tube.
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EM–1122AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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32. CONNECT HEATER WATER INLET HOSE
(a) Connect the heater water inlet hose to the air
conditioner tube.
33. CONNECT UNION TO CONNECTOR TUBE HOSE
(a) Connect the 2 union to connector tube hoses to the
booster vacuum tube.
34. INSTALL BATTERY CARRIER BRACKET
(a) Install the battery carrier bracket with the nut and 2
bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
35. INSTALL BATTERY BRACKET REINFORCEMENT
(a) Install the battery bracket reinforcement with the 2
bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
36. INSTALL FRONT BATTERY CARRIER
(a) Install the front battery carrier with the 4 bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
(b) Connect the 2 clamps of the engine wire.
37. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
(a) Connect the air cleaner case to the No. 1 air cleaner
inlet.
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2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–113
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(b) Install the air cleaner case with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
38. INSTALL AIR CLEANER FILTER ELEMENT SUB-
ASSEMBLY
39. INSTALL AIR CLEANER CAP (See page ES-413)
40. INSTALL PURGE VSV (See page EC-16)
41. INSTALL RADIATOR RESERVOIR
(a) Install the reservoir with the 2 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
42. INSTALL RADIATOR ASSEMBLY
(a) Install the radiator (see page CO-32).
43. INSTALL BATTERY TRAY
44. INSTALL BATTERY
(a) Install the battery.
(b) Install the battery clamp with the bolt and nut.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) for bolt
5.0 N*m (51 kgf*cm, 44 in.*lbf) for nut
45. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
46. ADD AUTOMATIC TRANSAXLE FLUID
(a) Add automatic transaxle fluid for U241E (2WD) (see
page AX-151).
(b) Add automatic transaxle fluid for U140F (4WD) (see
page AX-152).
47. CHECK FOR FUEL LEAKS (See page FU-14)
48. ADD ENGINE COOLANT (See page CO-6)
49. CHECK FOR ENGINE COOLANT LEAKS
(a) Check for engine coolant leaks (see page CO-1).
50. CHECK FOR AUTOMATIC TRANSAXLE FLUID
LEAKS
51. ADJUST SHIFT LEVER POSITION
(a) Adjust the shift lever position for U241E (2WD) (see
page AX-138).
(b) Adjust the shift lever position for U140F (4WD) (see
page AX-138).
52. INSTALL NO. 1 ENGINE COVER (See page EM-43)
53. INSTALL FRONT FENDER APRON RH
54. INSTALL NO. 2 ENGINE UNDER COVER
55. INSTALL NO. 1 ENGINE UNDER COVER
56. INSTALL FRONT WHEEL
57. INSTALL RADIATOR SUPPORT OPENING COVER
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EM–1142AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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58. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood (see page ED-7).
(b) Adjust the hood (see page ED-5).
59. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment (see
page SP-3).
60. PERFORM REGISTRATION
(a) When replacing the engine assembly, perform
vehicle stability control system recognition in ECM
(see page CC-12).
61. RESET MEMORY (for Automatic Transaxle)
(a) When replacing the engine assembly, perform the
RESET MEMORY procedure (A/T initialization) for
U241E (2WD) (see page AX-18) and for U140F
(4WD) (see page AX-18).

2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–123
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DISASSEMBLY
1. REMOVE IDLER PULLEY (See page EM-23)
2. REMOVE OIL DIPSTICK
3. REMOVE OIL DIPSTICK GUIDE (See page EM-57)
4. REMOVE MANIFOLD STAY (See page EM-57)
5. REMOVE NO. 2 MANIFOLD STAY (See page EM-58)
6. REMOVE NO. 1 EXHAUST MANIFOLD HEAT
INSULATOR (See page EM-58)
7. REMOVE EXHAUST MANIFOLD CONVERTER SUB-
ASSEMBLY (See page EM-58)
8. REMOVE WATER INLET (See page CO-15)
9. REMOVE THERMOSTAT
10. REMOVE NO. 1 WATER BY-PASS PIPE
(a) Remove the bolt, 2 nuts, pipe and gasket.
11. REMOVE NO. 3 WATER BY-PASS PIPE
(a) Remove the bolt, 2 nuts, pipe and gasket.
12. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(See page EM-26)
13. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
ASSEMBLY (See page ES-395)
14. REMOVE KNOCK SENSOR (See page ES-420)
15. REMOVE RADIO SETTING CONDENSER (See page
EM-63)
16. REMOVE OIL PRESSURE SWITCH ASSEMBLY (See
page EM-63)
17. REMOVE ENGINE COOLANT TEMPERATURE
SENSOR (See page EM-63)
18. REMOVE CAMSHAFT POSITION SENSOR (See page
EM-64)
19. REMOVE IGNITION COIL ASSEMBLY (See page IG-9)
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