engine TOYOTA RAV4 2006 Service Repair Manual

2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–101
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(b) Remove the nut and disconnect the 2 engine wire
connectors.
(c) Remove the bolt and engine wire cover. Then
disconnect the engine wire from the engine wire
cover.
(d) Disconnect the ground cable connector.
(e) Remove the nut from the positive (+) battery
terminal to disconnect the engine wire.
(f) Disconnect the ground cable from the clamp located
near the starter.
(g) Remove the bolt and ground cable located near the
starter.
40. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See
page EX-3)
41. REMOVE FRONT DRIVE SHAFT ASSEMBLY
(a) Remove the front drive shaft (for 2WD) (see page
DS-7).
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(b) Remove the front drive shaft (for 4WD) (see page
DS-40).
42. REMOVE PROPELLER SHAFT ASSEMBLY (for 4WD)
(See page PR-3)
43. REMOVE ENGINE MOUNTING INSULATOR FR
(a) Remove the through bolt and nut.
(b) Remove the 2 bolts and engine mounting insulator
FR.
44. REMOVE ENGINE MOUNTING INSULATOR RR
(a) Remove the through bolt.
(b) Remove the 2 nuts, 2 bolts and engine mounting
insulator RR.
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45. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the No. 1 and No. 2 engine hangers with the
bolts as shown in the illustration.
Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf)
Part No.
(b) Attach the sling device to the engine hangers and
chain block.
(c) Carefully remove the engine with transaxle from the
vehicle.
46. REMOVE ENGINE MOUNTING INSULATOR RH
(a) Remove the 2 nuts, 4 bolts and engine mounting
insulator RH.
47. REMOVE ENGINE MOUNTING INSULATOR LH
(a) Remove the through bolt and nut.
A112213E01
Item Part No.
No. 1 engine hanger 12281-28010
No. 2 engine hanger 12282-28010
Bolt 91512-61020
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(b) Remove the 4 bolts and engine mounting insulator
LH.
48. REMOVE DRIVE SHAFT BEARING BRACKET (for
2WD)
(a) Remove the 3 bolts and bracket.
49. REMOVE DRIVE SHAFT BEARING BRACKET (for
4WD)
(a) Remove the 3 bolts and bracket.
50. REMOVE TRANSFER ASSEMBLY (for 4WD) (See
page TF-59)
51. REMOVE STARTER ASSEMBLY (See page ST-7)
52. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY
(a) Remove the automatic transaxle for U241E (2WD)
(see page AX-147).
(b) Remove the automatic transaxle for U140F (4WD)
(see page AX-148).
53. REMOVE TORQUE CONVERTER CLUTCH
ASSEMBLY
(a) Remove the torque converter clutch for U241E
(2WD) (see page AX-148).
(b) Remove the torque converter clutch for U140F
(4WD) (see page AX-149).
54. REMOVE DRIVE PLATE SUB-ASSEMBLY
(a) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
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2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–105
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(b) Remove the 8 bolts, rear spacer, drive plate and
front spacer.
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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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(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.
A112224E01
A098759E01
A114345
A114375E02
ITEM Part No.
No. 1 engine hanger 12281-28010
No. 2 engine hanger 12282-28010
Bolt 91512-61020

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(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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(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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