engine TOYOTA RAV4 2006 Service Repair Manual

PP–26PREPARATION – 2GR-FE LUBRICATION
PP
LUBRICANT
Item Capacity Classification
Oil grade - ILSAC multigrade engine oil is
recommended. SAE 5W-30 is the
best choice for good fuel
economy and good starting in
cold weather.
Drain and refill With oil filter change 6.1 liters ( 6.4 US qts, 5.4 Imp.
qts)-
Without oil filter change 5.7 liters ( 6.0 US qts, 5.0 Imp.
qts)-
Dry fill 6.5 liters ( 6.9 US qts, 5.7 Imp.
qts)-

PREPARATION – U151E AUTOMATIC TRANSMISSIONPP–39
PP
RECOMMENDED TOOLS
09011-12301 Socket Wrench 30 mm -
09031-00030 Pin Punch -
09031-00040 Pin Punch . -
09040-00011 Hexagon Wrench Set -
(09043-20050) Socket Hexagon Wrench 5 -
(09043-20060) Socket Hexagon Wrench 6 -
(09043-20100) Socket Hexagon Wrench 10 -
09070-20010 Moulding Remover -
09090-04020 Engine Sling Device -
09905-00012 Snap Ring No.1 Expander -
09905-00013 Snap Ring Pliers -

PREPARATION – U151F AUTOMATIC TRANSMISSIONPP–45
PP
RECOMMENDED TOOLS
09011-12301 Socket Wrench 30 mm -
09031-00030 Pin Punch -
09031-00040 Pin Punch . -
09040-00011 Hexagon Wrench Set -
(09043-20050) Socket Hexagon Wrench 5 -
(09043-20060) Socket Hexagon Wrench 6 -
(09043-20100) Socket Hexagon Wrench 10 -
09070-20010 Moulding Remover -
09090-04020 Engine Sling Device -
09905-00012 Snap Ring No.1 Expander -
09905-00013 Snap Ring Pliers -

CH–42AZ-FE CHARGING – CHARGING SYSTEM
CH
ON-VEHICLE INSPECTION
1. CHECK BATTERY CONDITION
NOTICE:
If the battery is weak or if the engine is difficult to
start, perform the following procedures.
(a) Check the battery for damage and deformation. If
severe damage, deformation or leakage is found,
replace the battery.
(b) Check the electrolyte quantity of each cell.
(1) For maintenance-free batteries:
• If the electrolyte quantity is below the lower
line, replace the battery.
• If the electrolyte quantity is above the lower
line, check the battery voltage when
cranking the engine. If the voltage is less
than 9.6 V, recharge or replace the battery.
HINT:
Before checking the battery voltage, turn off
all the electrical systems (headlights, blower
motor, rear defogger, etc.).
(2) For non-maintenance-free batteries:
• If the electrolyte quantity is below the lower
line, add distilled water to each cell. Then,
recharge the battery and check the
electrolyte's specific gravity.
Standard specific gravity:
1.25 to 1.29 at 20
C (68F)
If the electrolyte quantity is above the lower
line, check the battery voltage when
cranking the engine. If the voltage is less
than 9.6 V, recharge or replace the battery.
HINT:
Before checking the battery voltage, turn off
all the electrical systems (headlights, blower
motor, rear defogger, etc.).
2. INSPECT BATTERY TERMINAL AND FUSE
(a) Visually check the battery terminals.
(1) Check that the battery terminals are not loose
or corroded.
(b) Measure the resistance of the H-fuses and fuses.
Standard resistance:
Below 1
If the results are not as specified, replace the fuses
as necessary.
A116909
A116907

2AZ-FE CHARGING – CHARGING SYSTEMCH–5
CH
3. INSPECT V-RIBBED BELT
(a) Visually check the belt for excessive wear, frayed
cords, etc.
If any defects are found, replace the V-ribbed belt.
HINT:
Cracks on the rib side of the belt are considered
acceptable. If the belt has chunks missing from the
ribs, it should be replaced.
(b) Check that the belt fits properly in the ribbed
grooves.
HINT:
Confirm by hand that the belt has not slipped out of
the grooves on the bottom of the pulley.
4. INSPECT GENERATOR WIRING
(a) Visually check the generator wiring.
(1) Check that the wiring is in good condition.
5. CHECK FOR ABNORMAL NOISES
(a) Listen for abnormal noises from the generator.
(1) Check that no abnormal noises are heard from
the generator while the engine is running.
6. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ON. Check that the charge
warning light comes on.
(b) Start the engine and check that the light goes off.
If the light does not operate as specified,
troubleshoot the charge warning light circuit.
7. INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) Connect a voltmeter and ammeter to the charging
circuit as follows.
(1) Disconnect the wire from terminal B of the
generator, then connect it to the negative (-)
lead of an ammeter.
(2) Connect the positive (+) lead of the ammeter to
terminal B of the generator.
(3) Connect the positive (+) lead of a voltmeter to
terminal B of the generator.
(4) Ground the negative (-) lead of the voltmeter.
(b) Check the charging circuit.
(1) Keep the engine speed at 2,000 rpm and check
the reading on the ammeter and voltmeter.
Standard amperage:
10 A or less
Standard voltage:
12.1 to 15.4 V
If the result is not as specified, replace the
generator.
HINT:
If the battery is not fully charged, the ammeter
reading will sometimes be more than the
standard amperage.
A095340E01
A111819E01
A088419E04

CH–62AZ-FE CHARGING – CHARGING SYSTEM
CH
8. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn the high
beam headlights ON and turn the heater blower
switch to the "HI" position.
(b) Check the reading on the ammeter.
Standard amperage:
30 A or more
If the ammeter reading is less than the standard
amperage, repair the generator.
HINT:
If the battery is fully charged, the indication will
sometimes be less than the standard amperage. If
this is the case, add more electrical load (operate
the wipers, rear window defogger, etc.) and check
the reading on the ammeter again.

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

SS–14SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL
SS
ENGINE UNIT
Part Tightened N*m kgf*cm ft.*lbf
Balance shaft housing x
Stiffening crankcase1 st 21.6 220 16
2 nd Turn 90
Tu r n 9 0Tu r n 9 0
Connecting rod bolt
Connecting rod cap x
connecting rod1 st 24.5 250 18
2 nd Turn 90
Tu r n 9 0Tu r n 9 0
Crankshaft bearing cap
set bolt
Crankshaft bearing cap
x Cylinder block1 st 40 408 30
2 nd Turn 90
Tu r n 9 0Tu r n 9 0
Stud bolt x Cylinder
blockBolt A, C and D 5.0 51 44 in.*lbf
Bolt B 21.5 219 16
No. 1 oil nozzle x Cylinder block 7.0 71 62 in.*lbf
Connecting rod cap x
Connecting rod1 st 24.5 250 18
2 nd Turn 90
Tu r n 9 0Tu r n 9 0
Stiffening crankcase x Cylinder block 24 245 18
Oil control valve filter x Cylinder block 30 306 22
Cylinder block water drain cock x Cylinder block 25 255 18
Camshaft timing oil control valve x Cylinder head 9.0 92 80 in.*lbf
Oil pan drain plug x Oil pan 40 408 30
Oil filter union x Stiffening crankcase 29.5 301 22
Oil filler cap x Cylinder head cover 3.0 31 26 in.*lbf
Spark plug x Cylinder head 25 254 18
Ventilation valve x Cylinder head cover 19 194 14
No. 3 water by-pass hose x Cylinder head 9.0 92 80 in.*lbf
No. 1 water by-pass pipe x Cylinder head 9.0 92 80 in.*lbf
Idler pulley bracket x Cylinder block 60 612 44
Union bolt With oil cooler 25 255 18
Oil cooler pipe x Cylinder head 9.0 92 80 in.*lbf

SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICALSS–21
SS
TORQUE SPECIFICATIONS
Part Tightened N*m kgf*cm ft.*lbf
Front suspension member reinforcement RH x Front
crossmember95 969 70
Front suspension member reinforcement RH x Front
suspension crossmember95 969 70
Radiator reservoir tank x Bract 5.0 51 44 in.*lbf
Engine coolant temperature sensor x Water outlet 20 204 14
Engine oil pressure sensor x Oil pan 21 214 15
No. 1 front engine mounting bracket LH x Timing chain
cover54 551 40
No. 2 idler pulley x Timing chain cover 43 438 32
No. 2 timing gear cover x Timing chain cover 6.0 61 53 in.*lbf
V-ribbed belt tensioner x Timing chain cover 43 438 32
V-ribbed belt tensioner x Cylinder block 43 438 32
Drive shaft bearing bracket x Cylinder block 64 653 47
Exhaust manifold LH x Cylinder head 21 214 15
No. 2 exhaust heat insulator x Exhaust manifold 8.5 87 75 in.*lbf
No. 2 manifold stay x Exhaust manifold 34 347 25
No. 2 manifold stay x Cylinder block 34 347 25
No. 1 oil dipstick guide x Cylinder block 21 214 15
No. 2 oil dipstick guide x Cylinder head 21 214 15
Exhaust manifold RH x Cylinder head 21 214 15
Intake manifold x Cylinder head 21 214 15
No. 2 engine mounting stay RH x Intake manifold 21 214 15
No. 2 engine mounting stay RH x Timing chain cover 21 214 15
Ignition coil x Cylinder head cover 10 102 7
Intake air surge tank x
Intake manifold5 mm hexagon wrench 18 184 13
for Bolt 21 214 15
for Nut 16 163 12
Vacuum hose clamp x Intake air surge tank 5.4 55 48 in.*lbf
Drive plate and ring gear x Crankshaft 178 1,815 132
Engine mounting bracket RR x Engine mounting
insulator RR95 969 70
Engine mounting bracket FR x Engine mounting
insulator FR145 1,479 107
Engine mounting bracket LH x Engine mounting
insulator LH56 571 41
Engine mounting insulator
RH x Front No. 1 engine
mounting bracketfor Bolt and nut A 95 969 70
for Nut B 52 530 38
Front crossmember x
Bodyfor Bolt A 96 979 71
Front suspension member
x Bodyfor Bolt B 145 1,478 107
Front suspension member
brace rear x Bodyfor Bolt C 145 1,478 107
for Bolt D 93 948 69
Air cleaner case x Engine mounting insulator LH 5.0 51 44 in.*lbf
Battery bracket reinforcement x Body 19 194 14
Front battery bracket x Body 19 194 14
Front battery bracket x Battery bracket reinforcement 19 194 14
Battery clamp x Body 5.0 51 44 in.*lbf