clock TOYOTA RAV4 2006 Service User Guide

CH–102AZ-FE CHARGING – GENERATOR
CH
(d) Turn SST (B) clockwise to loosen the pulley.
(e) Remove the pulley.
2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
(a) Remove the 3 nuts and generator rear end cover.
(b) Remove the terminal insulator.
(c) Remove the 2 screws and generator brush holder.
3. REMOVE GENERATOR ROTOR ASSEMBLY
(a) Remove the bolt and cord clip.
A126779E01
A130331
A097461E01
A097462E01
A097464E01

CH–122AZ-FE CHARGING – GENERATOR
CH
(b) Check the slip ring diameter.
(1) Using a vernier caliper, measure the slip ring
diameter.
Standard diameter:
14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter:
14 mm (0.551 in.)
If the diameter is less than the minimum,
replace the generator rotor assembly.
(c) Check the appearance.
(1) Check that the bearing is not rough or worn.
OK:
The bearing rotates smoothly.
If the result is not as specified, replace the
generator rotor assembly.
3. INSPECT GENERATOR DRIVE END FRAME
BEARING
(a) Check that the bearing is not rough or worn.
OK:
The bearing rotates smoothly.
If the bearing does not rotate smoothly, replace the
bearing.
4. INSPECT GENERATOR PULLEY WITH CLUTCH
(a) Hold the center of the pulley, and confirm that the
outer ring turns counterclockwise and does not turn
clockwise.
If the result is not as specified, replace the
generator pulley with clutch.
REPLACEMENT
1. REPLACE GENERATOR DRIVE END FRAME
BEARING
(a) Remove the 4 screws and bearing retainer.
A097470E02
A097469E01
A097471E01
A126783E01
A126772

2AZ-FE CHARGING – GENERATORCH–15
CH
(d) Install the terminal insulator onto the generator
rectifier end frame.
(e) Install the generator rear end cover with the 3 nuts.
Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
3. INSTALL GENERATOR PULLEY WITH CLUTCH
(a) Install the pulley by hand.
(b) Install SST to the pulley and vise as shown in the
illustration.
SST 09820-63020
(c) Turn SST (B) counterclockwise to tighten the pulley.
Torque: 111 N*m (1125 kgf*cm, 81 ft.*lbf)
(d) Install a new cap to the pulley.
(e) Check that the generator pulley rotates smoothly.
INSTALLATION
1. INSTALL GENERATOR ASSEMBLY
(a) Confirm that the wire harness of the crankshaft
position sensor is secured to the wire harness
clamp bracket through the back of the rib of the
timing chain cover.
A097461E01
A098216E01
A126778E01
A126782E01
A097394E02

2GR-FE CHARGING – GENERATORCH–13
CH
(f) Remove the 2 bolts and generator.
DISASSEMBLY
1. REMOVE GENERATOR PULLEY WITH CLUTCH
(a) Using a screwdriver, puncture the center of the cap
and pry it off the pulley.
NOTICE:
Do not reuse the cap.
(b) Install SST to the pulley as shown in the illustration.
SST 09820-63020
(c) Mount SST (A) in a vise.
(d) Turn SST (B) clockwise to loosen the pulley.
(e) Remove the pulley.
2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
(a) Remove the bolt and wire harness clamp stay.
A132433
A136851
A136849E01
A136852E01
A132434

CH–162GR-FE CHARGING – GENERATOR
CH
(c) Check the appearance.
(1) Check that the bearing is not rough or worn.
OK:
The bearing rotates smoothly.
If the result is not as specified, replace the
generator rotor assembly.
3. INSPECT GENERATOR DRIVE END FRAME
BEARING
(a) Check that the bearing is not rough or worn.
OK:
The bearing rotates smoothly.
If the bearing does not rotate smoothly, replace the
bearing.
4. INSPECT GENERATOR PULLEY WITH CLUTCH
(a) Hold the center of the pulley, and confirm that the
outer ring turns counterclockwise and does not turn
clockwise.
If the result is not as specified, replace the
generator pulley with clutch.
REPLACEMENT
1. REPLACE GENERATOR DRIVE END FRAME
BEARING
(a) Remove the 4 screws and bearing retainer.
(b) Using SST and a hammer, tap out the bearing.
SST 09950-60010 (09951-00250), 09950-70010
(09951-07100)
A097469E01
A136846
A126783E02
A136844
A136845E01

2GR-FE CHARGING – GENERATORCH–19
CH
(f) Install the bracket with the bolt.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
(g) Install the wire harness clamp stay.
Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
3. INSTALL GENERATOR PULLEY WITH CLUTCH
(a) Install the pulley by hand.
(b) Install SST to the pulley as shown in the illustration.
SST 09820-63020
(c) Turn SST (B) counterclockwise to tighten the pulley.
Torque: 111 N*m (1125 kgf*cm, 81 ft.*lbf)
(d) Install a new cap to the pulley.
(e) Check that the generator pulley rotates smoothly.
INSTALLATION
1. INSTALL GENERATOR ASSEMBLY
(a) Install the generator with the 2 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
A132435
A132434
A136849E01
A136850E01
A132433

AX–214U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
64. INSTALL OIL COOLER OUTLET TUBE UNION
(a) Coat a new O-ring with ATF, and install it to the
union.
(b) Install the union to the transaxle.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
65. INSTALL BREATHER PLUG HOSE
66. INSTALL PARK/NEUTRAL POSITION SWITCH
ASSEMBLY
(a) Install the park/neutral position switch to the manual
valve shaft.
(b) Temporarily install the 2 bolts.
(c) Install a new lock plate and tighten the manual valve
shaft nut.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
(d) Temporarily install the control shaft lever.
(e) Turn the lever counterclockwise until it stops, and
then turn it clockwise 2 notches.
(f) Remove the control shaft lever.
(g) Align the groove with neutral basic line.
(h) Hold the switch in this position and tighten the 2
bolts.
Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
C127809
D009639E02
D009640E02
D009641E01
D009642E01

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–211
AX
HINT:
Piston stroke = Dimension A - Flange thickness
Standard flange thickness
9. INSPECT PACK CLEARANCE OF 2ND BRAKE
(a) Using a vernier caliper, measure the distance
between the disc surface and snap ring surface
(Dimension B).
(b) Select an appropriate flange so that the pack
clearance will meet the specified value.
Standard pack clearance:
0.62 to 0.91 mm (0.0244 to 0.0358 in.)
HINT:
Piston stroke = Dimension B - Flange thickness -
Snap ring thickness 1.6 mm (0.063 in.)
Standard flange thickness
10. INSPECT PACK CLEARANCE OF UNDERDRIVE
BRAKE
(a) Using a dial indicator, measure the underdrive brake
pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Standard pack clearance:
1.81 to 2.20 mm (0.0713 to 0.0866 in.)
HINT:
Select an appropriate flange from the table below so
that it will meet the specified value.
Standard flange thickness
11. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Install the underdrive clutch assembly to the 1-way
clutch.
(b) Check that the underdrive 1-way clutch locks when
turned clockwise and rotates freely when turned
counterclockwise as shown in the illustration.
If the result is not as specified, replace the
underdrive 1-way clutch.
Mark Thickness Mark Thickness
1 1.8 mm (0.071 in.) 5 2.2 mm (0.087 in.)
2 1.9 mm (0.075 in.) 6 2.3 mm (0.091 in.)
3 2.0 mm (0.079 in.) 7 2.4 mm (0.094 in.)
4 2.1 mm (0.083 in.) 8 2.5 mm (0.098 in.)
D026453E01
Mark Thickness Mark Thickness
1 3.0 mm (0.118 in.) 5 3.4 mm (0.134 in.)
2 3.1 mm (0.122 in.) 6 3.5 mm (0.138 in.)
3 3.2 mm (0.126 in.) 7 3.6 mm (0.142 in.)
4 3.3 mm (0.130 in.) - -
D008082E01
Mark Thickness Mark Thickness
1 3.0 mm (0.118 in.) 4 3.1 mm (0.122 in.)
2 3.2 mm (0.126 in.) 5 3.3 mm (0.130 in.)
3 3.4 mm (0.134 in.) - -
D003925E01

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–223
AX
(b) Check that the 1-way clutch locks when turned
clockwise and rotates freely when turned
counterclockwise as shown in the illustration.
If the result is not as specified, replace the 1-way
clutch.
(c) Install the 1-way clutch and thrust needle roller
bearing to the 1-way clutch sleeve outer.
Standard bearing diameter
NOTICE:
Install the thrust bearing properly so that the
non-colored race will be visible.
24. INSTALL NO. 1 PLANETARY CARRIER THRUST
WASHER
(a) Coat the planetary carrier thrust washer with yellow
petrolatum, and install the washer onto the
planetary sun gear.
NOTICE:
After installing the washer, confirm that the
projection of the washer is fixed firmly in the
hole of the planetary sun gear.
25. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY
(a) Coat the planetary carrier thrust washer with yellow
petrolatum, and install the washer onto the rear
planetary sun gear.
(b) Coat the bearing with yellow petrolatum, and install
the bearing onto the rear planetary sun gear.
Standard bearing diameter
D009638E03
D003588E02
Item Inside Outside
Bearing 53.6 mm (2.110 in.) 69.4 mm (2.732 in.)
D026394E07
D026393E05
D026404E07
Item Inside Outside
Race 33.0 mm (1.299 in.) 45.4 mm (1.787 in.)
Bearing 31.85 mm (1.254 in.) 45.2 mm (1.78 in.)

AX–228U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
(c) Using a screwdriver, install the snap ring.
NOTICE:
The snap ring should be fully engaged in the
groove of the drum.
37. INSPECT PACK CLEARANCE OF UNDERDRIVE
BRAKE
(a) Using a dial indicator, measure the underdrive brake
pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Standard pack clearance:
1.81 to 2.20 mm (0.0713 to 0.0866 in.)
HINT:
Select an appropriate flange from the table below so
that it will meet the specified value.
Standard flange thickness
(b) Temporarily remove the snap ring, attach the
selected flange and reinstall the snap ring.
(c) Reinstall the snap ring.
38. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Install the underdrive clutch to the 1-way clutch.
(b) Check that the underdrive 1-way clutch locks when
turned clockwise and rotates freely when turned
counterclockwise as shown in the illustration.
If the result is not as specified, replace the
underdrive 1-way clutch.
39. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Install the outer race retainer to the 1-way clutch.
NOTICE:
Fix the outer race retainer to the external tooth
of the 1-way clutch firmly.
D026466E01
D008082E01
Mark Thickness Mark Thickness
1 3.0 mm (0.118 in.) 4 3.1 mm (0.122 in.)
2 3.2 mm (0.126 in.) 5 3.3 mm (0.130 in.)
3 3.4 mm (0.134 in.) - -
D003925E01
D003907E02