TOYOTA RAV4 2006 Service Repair Manual

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

GF1A TRANSFER – TRANSFER SYSTEMTF–3
TF
PROBLEM SYMPTOMS TABLE
(2006/01- )
HINT:
Use the table below to help determine the cause of the
problem symptom. The potential causes of the symptoms are
listed in order of probability in the "Suspected area" column of
the table. Check each symptom by checking the suspected
areas in the order they are listed. Replace parts as
necessary.
Transfer system
Symptom Suspected Area See page
Noise1. Oil (level low)TF-45
2. Oil (wrong)TF-45
3. Transfer (faulty)TF-60
Oil leakage1. Oil (level too high)TF-45
2. Gasket (damaged)TF-55
3. Oil seal (worn or damaged)TF-55
4. O-ring (worn or damaged)TF-55

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

SS–22SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICAL
SS
Connecting rod x
Connecting cap1st 25 255 18
2nd Turn 90
Turn 90Turn 90
Cylinder block x
Crankshaft bearing cap1st 61 622 45
2nd Turn 90
Turn 90Turn 90
Main bearing cap bolt 52 530 38
Camshaft timing gear x Intake camshaft 100 1,020 74
Camshaft timing exhaust gear x Exhaust camshaft 100 1,020 74
Stud bolt x Cylinder block 10 102 7
Stud bolt x Cylinder head for Stud bolt A and B 10 102 7
for Stud bolt C 4.0 41 35 in.*lbf
No. 1 oil nozzle x Cylinder block 9.0 92 80
Cylinder block water drain
cock x Cylinder block1st 25 255 18
Adjusting position 45 or less 459 or less 33 or less
Water drain cock plug x Water drain cock 13 130 9
Crankshaft position sensor x Cylinder block 10 102 7
No. 2 straight screw plug x Cylinder head 80 816 59
No. 1 straight screw plug x Cylinder head 44 449 32
Water inlet pipe x Cylinder block 10 102 7
Cylinder head (for Bank 1)
x Cylinder block1st 36 367 27
2nd Turn 90
Turn 90Turn 90
3rd Turn 90Turn 90Turn 90
Cylinder head (for Bank2)
x Cylinder block1st 36 367 27
2nd Turn 90
Turn 90Turn 90
3rd Turn 90Turn 90Turn 90
Except bolt 30 306 22
Camshaft bearing cap x
Camshaft housing
(for Bank 1)1st 10 102 7
Camshaft housing x Cylinder head
(for Bank 1)28 286 21
Camshaft bearing cap x
Camshaft housing
(for Bank 1)2nd 16 163 12
Camshaft bearing cap x
Camshaft housing
(for Bank 2)1st 10 102 7
Camshaft housing x Cylinder head
(for Bank 2)28 286 21
Camshaft bearing cap x
Camshaft housing
(for Bank 2)2nd 16 163 12
No. 2 chain tensioner x Camshaft housing (for Bank 1) 21 214 15
No. 3 chain tensioner x Camshaft housing (for Bank 2) 21 214 15
No. 1 chain vibration damper x Cylinder block 23 235 17
Idle sprocket x Cylinder block 60 612 44
No. 1 chain tensioner x Cylinder block 10 102 7
Engine rear oil seal retainer x Cylinder block 10 102 7
Crankshaft pulley x Crankshaft 250 2,549 184
Oil pan baffle plate x Cylinder block 10 102 7
Front No. 1 engine mounting bracket x Timing chain
cover54 551 40 Part Tightened N*m kgf*cm ft.*lbf

SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICALSS–23
SS
Cylinder head cover x
Cylinder head
(for Bank 1)for Bolt A 21 214 15
for Except bolt A 10 102 7
Oil pipe bracket x Cylinder head (for Bank 1) 10 102 7
Oil pipe union bolt x Cylinder head cover
(for Bank 1)65 663 48
Oil pipe union bolt x Cylinder head
(for Bank 1)65 663 48
Cylinder head cover x
Cylinder headfor Bolt A 21 214 15
for Except bolt A 10 102 7
No. 1 oil pipe union bolt x Cylinder head cover (for Bank
2)65 663 48
No. 1 oil pipe union bolt x Cylinder head (for Bank 2) 65 663 48
Water outlet x Cylinder head 10 102 7
Camshaft timing oil control valve x Cylinder head cover 10 102 7
VVT sensor x Cylinder head cover 10 102 7
Spark plug x Cylinder head 18 184 13 Part Tightened N*m kgf*cm ft.*lbf

SERVICE SPECIFICATIONS – U151F AUTOMATIC TRANSMISSIONSS–53
SS
TORQUE SPECIFICATIONS
Automatic Transaxle Assembly
Part Tightened N*m kgf*cm ft*lbf
Park/neutral position switch Nut 6.9 70 61 in.*lbf
Bolt 5.4 55 48 in.*lbf
Control shaft lever x Control shaft 13 133 10
Shift control cable x Control shaft lever 15 153 11
Transaxle housing x Engine block Upper side
bolt64 653 47
Lower side
bolt A37 377 27
Lower side
bolt B46 470 34
Torque converter clutch x Drive plate 41 418 30
Flywheel housing under cover x Automatic transaxle 7.8 80 69 in.*lbf
Front engine mounting bracket x Transaxle 64 653 47
Rear engine mounting bracket x Transaxle 45 459 33
Engine mounting bracket LH x Transaxle 64 653 47
Oil filler tube x Transaxle
Oil filler tube x Front engine mounting bracket5.5 56 49 in.*lbf
Control cable bracket No. 1 x Transaxle 12 122 9
Control cable bracket No. 2 x Transaxle 12 122 9
Oil cooler inlet elbow x Transaxle 27 276 20
Oil cooler outlet elbow x Transaxle 27 276 20
Starter x Transaxle37 377 27
Starter wire x Starter9.8 100 88 in.*lbf
Speed sensor (NC) x Transaxle11 11 2 8
Speed sensor (NT) x Transaxle11 11 2 8
Drain plug x Oil pan47 479 35
Transmission wire x Transaxle5.4 55 48 in.*lbf
ATF temperature sensor x Valve body 6.6 67 58 in.*lbf
Oil pan x Transaxle7.8 80 69 in.*lbf
Solenoid valve x Valve body SL2, DSL,
S411 11 0 8
SL1, SL3 6.6 67 58 in.*lbf
Valve body x Transaxle11 11 2 8
Oil strainer x Valve body11 11 2 8
Floor shift assembly x Body12 122 9
Control cable clamp x Engine mounting insulator 12 122 9
Differential gear lube apply tube x Transaxle housing 9.8 100 87 in.*lbf
Front planetary gear lock nut280 3,355 207
Brake apply tube clamp x Transaxle case 5.4 55 48 in.*lbf
Transaxle case No. 1 plug x Transaxle rear cover 7.4 75 65 in.*lbf
Transaxle rear cover x Transaxle case Bolt A 19 194 14
Other bolt 25 255 18
Parking lock pawl shaft x Transaxle case 9.8 100 87 in.*lbf
Oil pump assembly x Transaxle case 22 226 16
Transaxle housing x Transaxle case Bolt A 22 254 16
Bolt B 29 295 21
Bolt C 29 295 21
Bolt D 22 254 16
Automatic transmission case plug x Transaxle housing 7.4 75 65 in.*lbf

SS–54SERVICE SPECIFICATIONS – U151F AUTOMATIC TRANSMISSION
SS
Automatic transmission case plug x Transaxle case 7.4 75 65 in.*lbf
Parking lock pawl bracket x Transaxle case 20 205 15
Manual detent spring x Transaxle case Bolt A 20 205 15
Bolt B 12 120 9
Automatic transaxle oil pan sub-assembly x Transaxle case 7.6 77 67 in.*lbf
Speed sensor x Transaxle case11 11 2 8
Park/neutral start switch x Control shaft lever 13 130 9
Speedometer driven hole cover sub-assembly x Transaxle case 5.5 56 49 in.*lbf
Oil pump body x Stator shaft assembly 9.8 100 87 in.*lbf
Front differential case x Front differential ring gear 95 969 70Part Tightened N*m kgf*cm ft*lbf

SERVICE SPECIFICATIONS – U140F AUTOMATIC TRANSAXLESS–59
SS
TORQUE SPECIFICATIONS
Automatic Transaxle Assembly
Automatic Transaxle Unit
Part Tightened N*m kgf*cm ft.*lbf
Park/neutral position switch Nut 6.9 70 61 in.*lbf
Bolt 5.4 55 48 in.*lbf
Control shaft lever x Control shaft 12.7 130 9
Shift control cable x Control shaft lever 15 153 11
Transaxle housing x Engine block A bolt 64 653 47
B bolt 46 470 34
Lower side bolt 37 377 27
Torque converter clutch x Drive plate 41 418 30
Engine mounting bracket FR x Transaxle 64 653 47
Oil filler tube x Transaxle 5.5 56 49 in.*lbf
Control cable bracket No.1 x Transaxle 12 122 9
Oil cooler tube clamp x Control cable bracket 5.4 55 48 in.*lbf
Oil cooler inlet tube x Transaxle 34 347 25
Oil cooler outlet tube x Transaxle 34 347 25
Starter x Transaxle37 377 27
Wire harness x Transaxle 13 133 10
Speed sensor (NC) x Transaxle 11 115 8
Speed sensor (NT) x Transaxle 11 112 8
Air cleaner x No. 1 air cleaner inlet 5.0 51 44 in.*lbf
Drain plug x Oil pan47 479 35
Transmission wire x Transaxle 5.4 55 48 in.*lbf
ATF temperature sensor x Valve body 6.6 67 58 in.*lbf
Oil pan x Transaxle7.6 77 67 in.*lbf
Solenoid valve x Valve body Bolt A 6.6 67 58 in.*lbf
Bolt B 11 110 8
Valve body x Transaxle 10.8 110 8
Oil strainer x Valve body 11 110 8
Floor shift assembly x Body 12 120 9
Control cable x Body5.0 51 44 in.*lbf
Transfer x Transaxle69 704 51
Engine mount bracket RR x Transfer stiffener, plate RH 45 459 34
Part Tightened N*m kgf*cm ft.*lbf
Differential gear lube apply tube x Transaxle housing 9.8 100 7
Front planetary gear lock nut 268 2,732 198
Brake apply tube clamp x Transaxle case 5.4 55 48 in.*lbf
Transaxle case No. 1 plug x Transaxle rear cover 7.4 75 65 in.*lbf
Transaxle rear cover plate x transaxle rear cover sub-assembly 7.5 76 66 in.*lbf
Transaxle rear cover x Transaxle case Bolt A 18.6 190 14
Other bolt 24.5 250 18
Pawl shaft clamp x Transaxle case 9.8 100 7
Oil pump assembly x Transaxle case 22 226 16
Transaxle housing x Transaxle case Bolt A 22.1 225 16.3
Bolt B, C 29.4 300 21.7
Transaxle case No. 1 plug x Transaxle housing 7.4 75 65 in.*lbf
Parking lock pawl bracket x Transaxle case 20 205 15

SS–60SERVICE SPECIFICATIONS – U140F AUTOMATIC TRANSAXLE
SS
Detent spring x Transaxle case Bolt A 20 205 15
Bolt B 12 120 9
Solenoid wire retaining bolt x Transaxle housing 5.4 55 48 in.*lbf
Transmission valve body x Transaxle case 11 110 8
ATF temperature sensor clamp x Valve body 6.6 67 58 in.*lbf
Valve body oil strainer x Transmission valve 11 110 8
Automatic transaxle oil pan sub-assembly x Transaxle case 7.8 80 69 in.*lbf
Speed sensor x Transaxle case 11.3 115 8
Transmission revolution sensor x Transaxle case 11.3 115 8
Oil cooler tube union x Transaxle case 27 276 20
Oil cooler tube union x Transaxle case 27 280 20
Speedometer driven hole cover sub-assembly x Transaxle case 7.0 7061
Oil pump body x Stator shaft assembly 9.8 100 7
Under drive planetary gear x Lock nut 280 2,855 207
Line pressure control solenoid assembly x Transmission valve body assembly 11 110 8
No. 1 clutch control solenoid assembly x Transmission valve body a s s e m b l y 11 11 0 8
Automatic transmission 3 way solenoid assembly x Transmission valve body assembly 11 110 8
No. 2 clutch control solenoid assembly x Transmission valve body a s s e m b l y 11 11 0 8
No. 2 transmission 3 way solenoid assembly x Transmission valve body assembly 11 110 8
Front differential case x Front differential ring gear 95.1 970 70Part Tightened N*m kgf*cm ft.*lbf

SS–64SERVICE SPECIFICATIONS – U241E AUTOMATIC TRANSAXLE
SS
TORQUE SPECIFICATIONS
Automatic Transaxle Assembly
Automatic Transaxle Unit
Part Tightened N*m kgf*cm ft.*lbf
Park/neutral position switch Nut 6.9 70 61 in.*lbf
Bolt 5.4 55 48 in.*lbf
Control shaft lever x Control shaft 12.7 130 9
Shift control cable x Control shaft lever 15 153 11
Transaxle housing x Engine block A bolt 64 653 47
B bolt 46 470 34
Lower side bolt 37 377 27
Torque converter clutch x Drive plate 41 418 30
Engine mounting bracket FR x Transaxle 64 653 47
Oil filler tube x Transaxle 5.5 56 49 in.*lbf
Control cable bracket No.1 x Transaxle 12 122 9
Oil cooler tube clamp x Control cable bracket 5.4 55 48 in.*lbf
Oil cooler inlet tube x Transaxle 34 347 25
Oil cooler outlet tube x Transaxle 34 347 25
Starter x Transaxle37 377 27
Wire harness x Transaxle 13 133 10
Speed sensor (NC) x Transaxle 11 115 8
Speed sensor (NT) x Transaxle 11 112 8
Air cleaner x No. 1 air cleaner inlet 5.0 51 44 in.*lbf
Drain plug x Oil pan47 479 35
Transmission wire x Transaxle 5.4 55 48 in.*lbf
ATF temperature sensor x Valve body 6.6 67 58 in.*lbf
Oil pan x Transaxle7.6 77 67 in.*lbf
Solenoid valve x Valve body Bolt A 6.6 67 58 in.*lbf
B o l t B 11 11 0 8
Valve body x Transaxle 10.8 110 8
Oil strainer x Valve body 11 110 8
Floor shift assembly x Body 12 120 9
Control cable x Body5.0 51 44 in.*lbf
Engine mount bracket RR x Transfer stiffener, plate RH 45 459 34
Part Tightened N*m kgf*cm ft.*lbf
Differential gear lube apply tube x Transaxle housing 9.8 100 7
Front planetary gear lock nut 268 2,732 198
Brake apply tube clamp x Transaxle case 5.4 55 48 in.*lbf
Transaxle case No. 1 plug x Transaxle rear cover 7.4 75 65 in.*lbf
Transaxle rear cover plate x transaxle rear cover sub-assembly 7.5 76 66 in.*lbf
Transaxle rear cover x Transaxle case Bolt A 18.6 190 14
Other bolt 24.5 250 18
Pawl shaft clamp x Transaxle case 9.8 100 7
Oil pump assembly x Transaxle case 22 226 16
Transaxle housing x Transaxle case Bolt A 22.1 225 16.3
Bolt B, C 29.4 300 21.7
Transaxle case No. 1 plug x Transaxle housing 7.4 75 65 in.*lbf
Parking lock pawl bracket x Transaxle case 20 205 15
Detent spring x Transaxle case Bolt A 20 205 15
Bolt B 12 120 9