torque TOYOTA RAV4 2006 Service Repair Manual

BRAKE – BRAKE MASTER CYLINDERBR–29
BR
INSTALLATION
(2005/11-2006/01)
1. INSTALL BRAKE MASTER CYLINDER SUB-
ASSEMBLY
NOTICE:
• The master cylinder and piston are designed so
that the piston can easily fall out. Prevent this by
making sure that the tip of the master cylinder
points downward when handling the master
cylinder.
• Make sure foreign matter does not attach to the
master cylinder's piston. If foreign matter
attaches, clean it off with a cloth. Then apply
lithium soap base glycol grease to the entire outer
circumference contact surface area of the piston.
(a) Install a new O-ring to the master cylinder.
(b) Install the master cylinder to the booster with the 2
nuts.
Torque: 12.5 N*m (127 kgf*cm, 9 ft.*lbf)
(c) Using SST, connect the 2 brake lines labeled B to
the master cylinder.
SST 09023-00101
Torque: 15.2 N*m (155 kgf*cm, 11 ft.*lbf) without
SST
14 N*m (144 kgf*cm, 10 ft.*lbf) with SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.).
(d) Connect the brake fluid level warning switch
connector labeled A to the master cylinder.
2. FILL RESERVOIR WITH BRAKE FLUID (See page BR-
6)
3. BLEED AIR FROM BRAKE MASTER CYLINDER (See
page BR-7)
4. BLEED AIR FROM BRAKE LINE (See page BR-7)
5. BLEED AIR FROM ABS AND TRACTION ACTUATOR
ASSEMBLY (See page BR-8)
6. CHECK BRAKE FLUID LEVEL IN RESERVOIR (See
page BR-6)
7. CHECK FOR BRAKE FLUID LEAKAGE
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C127053E01

BRAKE – BRAKE MASTER CYLINDERBR–31
BR
INSTALLATION
(2006/01- )
1. INSTALL BRAKE MASTER CYLINDER SUB-
ASSEMBLY
NOTICE:
• The master cylinder and piston are designed so
that the piston can easily fall out. Prevent this by
making sure that the tip of the master cylinder
points downward when handling the master
cylinder.
• Make sure foreign matter does not attach to the
master cylinder's piston. If foreign matter
attaches, clean it off with a cloth. Then apply
lithium soap base glycol grease to the entire outer
circumference contact surface area of the piston.
(a) Install a new O-ring to the master cylinder.
(b) Install the master cylinder to the booster with the 2
nuts.
Torque: 12.5 N*m (127 kgf*cm, 9 ft.*lbf)
(c) Using SST, connect the 2 brake lines labeled B to
the master cylinder.
SST 09023-00101
Torque: 15.2 N*m (155 kgf*cm, 11 ft.*lbf) without
SST
14 N*m (144 kgf*cm, 10 ft.*lbf) with SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.).
(d) Connect the brake fluid level warning switch
connector labeled A to the master cylinder.
2. FILL RESERVOIR WITH BRAKE FLUID (See page BR-
6)
3. BLEED AIR FROM BRAKE MASTER CYLINDER (See
page BR-7)
4. BLEED AIR FROM BRAKE LINE (See page BR-7)
5. BLEED AIR FROM ABS AND TRACTION ACTUATOR
ASSEMBLY (See page BR-8)
6. CHECK BRAKE FLUID LEVEL IN RESERVOIR (See
page BR-6)
7. CHECK FOR BRAKE FLUID LEAKAGE
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C127053E01

BRAKE – BRAKE BOOSTERBR–33
BR
INSTALLATION
(2005/11-2006/01)
1. INSTALL CHECK VALVE GROMMET
(a) Install the grommet to the booster.
2. INSTALL BRAKE VACUUM CHECK VALVE
ASSEMBLY
(a) Install the check valve to the grommet.
3. INSTALL BRAKE BOOSTER GASKET
(a) Install a new gasket to the booster.
4. INSTALL BRAKE MASTER CYLINDER PUSH ROD
CLEVIS
(a) Install the push rod clevis to the booster.
(b) Temporarily tighten the push rod clevis lock nut.
HINT:
The push rod clevis lock nut will be tightened to a
torque specification in the "CHECK AND ADJUST
BRAKE PEDAL HEIGHT" procedures.
5. INSTALL BRAKE BOOSTER ASSEMBLY
(a) Install the booster with the 4 nuts.
Torque: 12.7 N*m (130 kgf*cm, 9 ft.*lbf)
6. INSTALL PUSH ROD PIN
(a) Apply lithium soap base glycol grease to the push
rod pin.
(b) Install the push rod pin to the push rod clevis.
NOTICE:
The push rod pin must be installed as shown in
the illustration.
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C130666E04

PB–10PARKING BRAKE – PARKING BRAKE CABLE
PB
INSTALLATION
1. INSTALL PARKING BRAKE CABLE
(a) Connect the cable to the backing plate and parking
brake shoe lever.
(1) Pass the cable through the backing plate, and
then connect the cable to the lever.
(2) Install the cable to the backing plate with the
bolt.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(b) Install the clamp and clamp bolt (labeled F) to the
trailing arm.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
NOTICE:
Securely install the clamp.
(c) Install the clamp and clamp bolt (labeled E) to the
rear suspension crossmember.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
NOTICE:
Securely install the clamp.
C127323E01

PARKING BRAKE – PARKING BRAKE CABLEPB–11
PB
(d) Install the clamp and clamp bolt (labeled D) to the
crossmember.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
NOTICE:
Securely install the clamp.
(e) Install the clamp and clamp bolt (labeled C) to the
body.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
NOTICE:
Securely install the clamp.
(f) Install the casing cap and casing cap bolt (labeled
B) to the body.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
NOTICE:
Securely install the casing cap.
(g) Install the cable clamp (labeled A) to the body.
NOTICE:
Securely install the clamp.
2. INSTALL PARKING BRAKE EQUALIZER
(a) Connect the 3 cable ends to the equalizer.
3. INSTALL REAR WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
4. ADJUST PARKING BRAKE LEVER TRAVEL (See
page PB-2)
5. INSTALL REAR CONSOLE BOX SUB-ASSEMBLY
(a) Install the rear console box (see page IP-23).
HINT:
Refer to the procedures from the installation of the
rear console box sub-assembly up until the
installation of the No. 1 console upper panel
garnish.
C129065E02

PB–18PARKING BRAKE – PARKING BRAKE ASSEMBLY
PB
12. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE
PLUG
(a) Install the shoe adjusting hole plug to the rear disc.
13. CONNECT REAR DISC BRAKE CYLINDER
MOUNTING LH (See page BR-60)
14. INSTALL REAR WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
15. DRIVE VEHICLE
(a) Pull the parking brake lever with a force of 147 N
(15 kgf, 33 lbf).
(b) Drive the vehicle at approximately 50 km/h (31 mph)
for approximately 400 m (0.25 miles).
NOTICE:
Drive the vehicle on a safe, level and dry road.
(c) Repeat the above steps 2 or 3 times.
16. CHECK PARKING BRAKE LEVER TRAVEL (See page
PB-1)
17. ADJUST PARKING BRAKE LEVER TRAVEL (See
page PB-2)

STEERING COLUMN – STEERING COLUMN ASSEMBLYSR–13
SR
(b) Detach the claw and remove the upper steering
column cover.
6. REMOVE SPIRAL CABLE SUB-ASSEMBLY
(a) Disconnect all connectors from the turn signal
switch with spiral cable.
7. REMOVE COMBINATION SWITCH ASSEMBLY
(a) Detach the clamp shown in the illustration and
remove the combination switch from the steering
column.
8. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
(a) Remove the instrument panel (see page IP-4).
9. DISCONNECT POWER STEERING ECU
(a) Detach the power steering motor wire harness and
torque sensor wire harness clamps from the power
steering ECU side.
(b) Disconnect the 2 steering column connectors from
the power steering ECU.
10. REMOVE LOWER INSTRUMENT PANEL FINISH
PANEL (See page IP-20)
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C128493
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STEERING COLUMN – STEERING COLUMN ASSEMBLYSR–17
SR
INSPECTION
1. CHECK TORQUE SENSOR
(a) Check the torque sensor (see page PS-19).
2. CHECK POWER STEERING MOTOR
(a) Check the power steering motor (see page PS-22).
3. CHECK MOTOR ROTATION ANGLE SENSOR
(a) Check the motor rotation angle sensor (see page
PS-25).
REASSEMBLY
1. INSTALL IGNITION OR STARTER SWITCH
ASSEMBLY
(a) Attach the 2 claws to install the ignition switch onto
the steering column bracket upper.
2. INSTALL KEY INTERLOCK SOLENOID
(a) for Automatic Transaxle:
(1) Install the key interlock solenoid onto the
steering column bracket upper with the 2
screws.
3. INSTALL UNLOCK WARNING SWITCH ASSEMBLY
(a) Attach the 2 claws to install the unlock warning
switch onto the steering column bracket upper.
HINT:
Slide the unlock warning switch in the direction
shown by the arrow in the illustration to install it.
4. INSTALL IGNITION SWITCH LOCK CYLINDER
ASSEMBLY
(a) Turn the ignition switch to ON (ACC).
(b) Install the ignition switch lock cylinder into the
steering column bracket upper.
(c) Make sure that the ignition switch lock cylinder is
securely fixed onto the ignition switch lock cylinder.
C128812
C128811
C128815
C128816

STEERING COLUMN – STEERING COLUMN ASSEMBLYSR–19
SR
INSTALLATION
1. INSTALL STEERING COLUMN ASSEMBLY
(a) Install the steering column onto the instrument panel
reinforcement with the 3 bolts.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
(b) Connect all the connectors and clamp the wire
harnesses onto the steering column bracket.
2. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY
(a) Install the brake pedal support (see page BR-16).
3. INSTALL NO.2 STEERING INTERMEDIATE SHAFT
ASSEMBLY
(a) Align the matchmarks on steering intermediate shaft
and the steering sliding yoke and temporarily install
them with bolt B.
Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf)
(b) Align the matchmarks on the steering sliding yoke
and steering gear and install them with bolt A.
Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf)
4. INSTALL COLUMN HOLE COVER SILENCER SHEET
(a) Install the column hole cover plate with the 2 clips.
(b) Install the floor carpet.
5. INSTALL LOWER INSTRUMENT PANEL FINISH
PANEL (See page IP-25)
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C128486

SR–20STEERING COLUMN – STEERING COLUMN ASSEMBLY
SR
6. CONNECT POWER STEERING ECU
(a) Connect the 2 steering column connectors to the
power steering ECU.
(b) Install the power steering motor wire harness and
torque sensor wire harness clamps onto the side of
the power steering ECU.
(c) Tilt the steering column assembly up and down to
make sure that the power steering motor wire
harness and torque sensor wire harness do not
interfere with any components.
7. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
(a) Install the instrument panel (see page IP-9).
8. INSTALL COMBINATION SWITCH ASSEMBLY
(a) Install the turn signal switch onto the steering
column with the clamp.
9. INSTALL SPIRAL CABLE SUB-ASSEMBLY
(a) Install the spiral cable onto the turn signal switch.
(b) Connect all the connectors to the turn signal switch
with spiral cable.
10. INSTALL STEERING COLUMN COVER
(a) Attach the claw to install the upper steering column
cover.
C128905E02
C128800
C128493E04
C128492