transaxle TOYOTA RAV4 2006 Service Manual PDF

MA–12MAINTENANCE – CHASSIS
MA
GENERAL MAINTENANCE
(2006/01- )
1. INSPECT STEERING LINKAGE AND GEAR HOUSING
(a) Check the steering wheel free play.
(b) Check the steering linkage for looseness or
damage.
(1) Check that the tie rod ends do not have
excessive play.
(2) Check that the dust seals and boots are not
damaged.
(3) Check that the boot clamps are not loose.
(4) Check that the steering gear housing is not
damaged.
(5) Check that the connectors are properly
connected to the steering gear housing.
2. INSPECT BALL JOINTS AND DUST COVERS
(a) Inspect the ball joints for excessive looseness.
(1) Jack up the front of the vehicle and place
wooden blocks with a height of 180 to 200 mm
(7.09 to 7.87 in.) under the front tires.
(2) Lower the vehicle until the front coil spring has
about half its ordinary load. Place stands under
the vehicle for safety.
(3) Check that the front wheels are pointing
straight ahead. Use wheel chocks on all 4
wheels.
(4) Using a lever, pry up the end of the lower arm.
Check the amount of play.
Maximum ball joint vertical play:
0 mm (0 in.)
If there is any play, replace the ball joint.
(b) Check the dust cover for damage.
3. INSPECT DRIVE SHAFT BOOTS
(a) Check the drive shaft boots for loose clamps,
grease leakage, kinks or damage.
4. INSPECT AUTOMATIC TRANSAXLE FLUID LEVEL
(a) Visually check the transmission for fluid leakage. If
oil is leaking, find the cause and repair it.
5. INSPECT TRANSFER OIL (for 4WD)
(a) Visually check the transfer for oil leakage. If oil is
leaking, find the cause and repair it.
6. INSPECT REAR DIFFERENTIAL OIL (for 4WD)
(a) For the rear differential oil inspection, refer to the
following procedures (see page DF-3).
Type See procedures
U151E See page AX-126
U151F See page AX-126
Type See procedures
Front Oil See page TF-45
Rear Oil See page TF-45

EM–982AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE (See page
FU-9)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
3. REMOVE HOOD SUB-ASSEMBLY (See page ED-4)
4. REMOVE RADIATOR SUPPORT OPENING COVER
5. REMOVE BATTERY CLAMP SUB-ASSEMBLY
(a) Loosen the bolt and nut, and remove the battery
clamp.
6. REMOVE BATTERY
7. REMOVE BATTERY TRAY
8. REMOVE FRONT WHEEL
9. REMOVE NO. 1 ENGINE UNDER COVER
10. REMOVE NO. 2 ENGINE UNDER COVER
11. REMOVE FRONT FENDER APRON RH
12. REMOVE NO. 1 ENGINE COVER (See page EM-22)
13. DRAIN ENGINE COOLANT (See page CO-6)
14. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Drain automatic transaxle fluid for U241E (2WD)
(see page AX-146).
(b) Drain automatic transaxle fluid for U140F (4WD)
(see page AX-147).
15. REMOVE RADIATOR ASSEMBLY
(a) Remove the radiator (see page CO-29).
16. REMOVE RADIATOR RESERVOIR
(a) Remove the 2 bolts and reservoir.
17. REMOVE PURGE VSV (See page EC-15)
18. REMOVE AIR CLEANER CAP (See page ES-411)
19. REMOVE AIR CLEANER FILTER ELEMENT SUB-
ASSEMBLY
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25. DISCONNECT HEATER WATER INLET HOSE
(a) Disconnect the heater water inlet hose from the
heater unit.
26. DISCONNECT HEATER WATER OUTLET HOSE
(a) Disconnect the heater water outlet hose from the
heater unit.
27. DISCONNECT FUEL TUBE (See page FU-10)
28. REMOVE THROTTLE BODY (See page ES-412)
29. DISCONNECT NO. 2 VENTILATION HOSE (See page
FU-10)
30. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
(See page FU-10)
31. REMOVE INTAKE MANIFOLD (See page ES-419)
32. REMOVE INTAKE MANIFOLD INSULATOR (See page
ES-420)
33. REMOVE TRANSAXLE CONTROL CABLE
ASSEMBLY
(a) Remove the transaxle control cable for U241E
(2WD) (see page AX-129).
(b) Remove the transaxle control cable for U140F
(4WD) (see page AX-129).
34. REMOVE FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-6)
35. REMOVE FAN AND GENERATOR V BELT (See page
EM-6)
36. REMOVE GENERATOR ASSEMBLY (See page CH-9)
37. REMOVE COOLER COMPRESSOR ASSEMBLY
(a) Remove the cooler compressor (see page AC-216).
HINT:
Disconnect the compressor together with the low-
pressure and high-pressure hoses, then secure it to
the vehicle side using rope.
38. REMOVE ECM (See page ES-429)
39. DISCONNECT ENGINE WIRE
(a) Remove the engine room relay block cover.
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2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–103
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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
A114336
A124843
A124844

EM–1042AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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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
A124845
A098759E01
A114345
A126932E01

2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–107
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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

EM–1082AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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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
A114336
A114337
A124845
A124844E01
A124843E01

2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–111
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(e) Connect the 2 engine wire connectors and install
the nut.
(f) Install the engine room relay block cover.
(g) Attach the clamp of the engine wire cover.
(h) Install the engine wire cover to with the bolt.
19. INSTALL ECM (See page ES-430)
20. INSTALL COOLER COMPRESSOR ASSEMBLY (See
page AC-217)
21. INSTALL GENERATOR ASSEMBLY (See page CH-15)
22. INSTALL FAN AND GENERATOR V BELT (See page
EM-7)
23. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-7)
24. INSTALL TRANSAXLE CONTROL CABLE
ASSEMBLY
(a) Install the transaxle control cable for U241E (see
page AX-130).
(b) Install the transaxle control cable for U140F (see
page AX-130).
25. INSTALL INTAKE MANIFOLD INSULATOR (See page
ES-421)
26. INSTALL INTAKE MANIFOLD (See page ES-421)
27. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
(See page FU-13)
28. CONNECT NO. 2 VENTILATION HOSE (See page FU-
14)
29. INSTALL THROTTLE BODY ASSEMBLY (See page
ES-413)
30. CONNECT FUEL TUBE (See page FU-14)
31. CONNECT HEATER WATER OUTLET HOSE
(a) Connect the heater water outlet hose to the air
conditioner tube.
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2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–113
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(b) Install the air cleaner case with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
38. INSTALL AIR CLEANER FILTER ELEMENT SUB-
ASSEMBLY
39. INSTALL AIR CLEANER CAP (See page ES-413)
40. INSTALL PURGE VSV (See page EC-16)
41. INSTALL RADIATOR RESERVOIR
(a) Install the reservoir with the 2 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
42. INSTALL RADIATOR ASSEMBLY
(a) Install the radiator (see page CO-32).
43. INSTALL BATTERY TRAY
44. INSTALL BATTERY
(a) Install the battery.
(b) Install the battery clamp with the bolt and nut.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) for bolt
5.0 N*m (51 kgf*cm, 44 in.*lbf) for nut
45. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
46. ADD AUTOMATIC TRANSAXLE FLUID
(a) Add automatic transaxle fluid for U241E (2WD) (see
page AX-151).
(b) Add automatic transaxle fluid for U140F (4WD) (see
page AX-152).
47. CHECK FOR FUEL LEAKS (See page FU-14)
48. ADD ENGINE COOLANT (See page CO-6)
49. CHECK FOR ENGINE COOLANT LEAKS
(a) Check for engine coolant leaks (see page CO-1).
50. CHECK FOR AUTOMATIC TRANSAXLE FLUID
LEAKS
51. ADJUST SHIFT LEVER POSITION
(a) Adjust the shift lever position for U241E (2WD) (see
page AX-138).
(b) Adjust the shift lever position for U140F (4WD) (see
page AX-138).
52. INSTALL NO. 1 ENGINE COVER (See page EM-43)
53. INSTALL FRONT FENDER APRON RH
54. INSTALL NO. 2 ENGINE UNDER COVER
55. INSTALL NO. 1 ENGINE UNDER COVER
56. INSTALL FRONT WHEEL
57. INSTALL RADIATOR SUPPORT OPENING COVER
A112221
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EM–1142AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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58. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood (see page ED-7).
(b) Adjust the hood (see page ED-5).
59. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment (see
page SP-3).
60. PERFORM REGISTRATION
(a) When replacing the engine assembly, perform
vehicle stability control system recognition in ECM
(see page CC-12).
61. RESET MEMORY (for Automatic Transaxle)
(a) When replacing the engine assembly, perform the
RESET MEMORY procedure (A/T initialization) for
U241E (2WD) (see page AX-18) and for U140F
(4WD) (see page AX-18).