transaxle TOYOTA RAV4 2006 Service Manual PDF

2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–35
EM
(f) Connect the union to check valve hose.
(g) Connect the No. 2 ventilation hose.
(h) Install the clamp and connect the throttle body
connector.
(i) Connect the vapor feed hose.
(j) Connect the 2 water by-pass hoses to the throttle
body.
23. REMOVE ENGINE FROM ENGINE STAND
(a) Install a sling device and chain block to the engine.
(b) Remove the engine from the engine stand.
24. INSTALL DRIVE PLATE AND RING GEAR SUB-
ASSEMBLY
(a) Clean the bolt and its hole.
(b) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond
1324 or Equivalent
(c) Using SST, hold the crankshaft.
SST 09213-70011, 09330-00021
(d) Install the flywheel, drive plate and drive plate
spacer on the crankshaft.
(e) Uniformly install and tighten the 8 bolts in the
sequence shown in the illustration.
Torque: 178 N*m (1,815 kgf*cm, 132 ft.*lbf)
NOTICE:
Do not start the engine for at least 1 hour after
the installation.
25. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
(a) 2WD:
Install the automatic transaxle (see page AX-174).
A139490
A129464
A054047E01
A076326E04
A076327E03

EM–362GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
(b) 4WD:
Install the automatic transaxle (see page AX-175).
26. INSTALL TRANSFER ASSEMBLY (for 4WD) (See
page TF-75)
27. INSTALL STARTER ASSEMBLY (See page ST-14)
28. INSTALL ENGINE WIRE
(a) Install the engine wire to the engine.
29. INSTALL FRONT SUSPENSION CROSSMEMBER
SUB-ASSEMBLY
(a) Attach the engine together with the transaxle to the
suspension crossmember and mounting.
(b) Install the bolt which secures the engine mounting
bracket to the mounting insulator.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
30. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY
(a) Install the bolt and nut which secures the engine
mounting bracket to the mounting insulator.
Torque: 145 N*m (1,479 kgf*cm, 107 ft.*lbf)
31. INSTALL ENGINE WITH TRANSAXLE
(a) Place the engine on an engine lifter.
HINT:
Place the engine on wooden blocks or an equivalent
so that the engine is level.
(b) Using the chain block, slowly install the engine to
the vehicle and the intermediate shaft to the pinion.
CAUTION:
Do not raise the engine more than necessary. If
the engine is raised excessively, the vehicle may
also be lifted up.
NOTICE:
• Make sure that the engine is clear of all wiring
and hoses.
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2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–41
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62. ADD AUTOMATIC TRANSAXLE FLUID
(a) 2WD:
Add automatic transmission fluid (see page AX-
177).
(b) 4WD:
Add automatic transmission fluid (see page AX-
178).
63. ADD TRANSFER OIL (for 4WD) (See page TF-45)
64. ADD ENGINE OIL (See page LU-6)
65. ADD ENGINE COOLANT (See page CO-8)
66. CHARGE REFRIGERANT (See page AC-172)
67. CHECK FOR LEAKAGE OF REFRIGERANT (See
page AC-173)
68. CHECK FOR ENGINE OIL LEAKS (See page LU-6)
69. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
70. CHECK FOR FUEL LEAKS
71. INSPECT EXHAUST GAS LEAKS
72. INSPECT SHIFT LEVER POSITION
(a) 2WD:
Inspect the shift lever position (see page AX-159).
(b) 4WD:
Inspect the shift lever position (see page AX-158).
73. ADJUST TRANSMISSION CONTROL CABLE
(a) 2WD:
Adjust the shift lever position (see page AX-159).
(b) 4WD:
Adjust the shift lever position (see page AX-159).
74. INSTALL FRONT FLOOR COVER (See page FU-39)
75. INSTALL NO. 2 ENGINE UNDER COVER
(a) Install the under cover with the 2 clips.
76. INSTALL REAR ENGINE UNDER COVER LH
(a) Install the under cover with the 2 clips.
77. INSTALL REAR ENGINE UNDER COVER RH
(a) Install the under cover with the 2 clips.
78. INSTALL NO. 1 ENGINE UNDER COVER
(a) Install the under cover with the 4 bolts and 12 clips.

AX–6U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
SYSTEM DIAGRAM
The configuration of the electronic control system in the
U140F automatic transaxle is as shown in the following chart.
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U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEMAX–7
AX
C116585E02

AX–8U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
C132118E02

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEMAX–9
AX
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AX–10U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
SYSTEM DESCRIPTION
1. SYSTEM DESCRIPTION
(a) The Electronic Controlled Automatic Transaxle
(ECT) is an automatic transaxle that electronically
controls shift timing using the Engine Control
Module (ECM). The ECM detects electrical signals
that indicate engine and driving conditions, and
controls the shift point based on driver habits and
road conditions. As a result, fuel efficiency and
power transaxle performance are improved.
Shift shock is reduced by controlling the engine and
transaxle simultaneously.
In addition, the ECT has the following features:
• Diagnostic function.
• Fail-safe function when a malfunction occurs.

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEMAX–11
AX
HOW TO PROCEED WITH
TROUBLESHOOTING
HINT:
• The ECM of this system is connected to the CAN and
multiplex communication system. Therefore, before
starting troubleshooting, make sure to check that there is
no trouble in the CAN and multiplex communication
systems.
• *: Use the intelligent tester.
NEXT
NEXT
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery
before proceeding.
NEXT
NEXT
(a) Refer to the DTC CHECK / CLEAR (see page AX-29).
NEXT
NEXT
(a) Refer to the CHECK MODE PROCEDURE (see page
AX-30).
1VEHICLE BROUGHT TO WORKSHOP
2CUSTOMER PROBLEM ANALYSIS
3INSPECT BATTERY VOLTAGE
4CONNECT INTELLIGENT TESTER TO DLC3*
5CHECK AND CLEAR DTCS AND FREEZE FRAME DATA*
6VISUAL INSPECTION
7SETTING CHECK MODE DIAGNOSIS*

AX–12U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
NEXT
(a) Refer to the ROAD TEST (see page AX-12).
Result
B
A
(a) Refer to the ELECTRONIC CIRCUIT INSPECTION
PROCEDURE (see page IN-37).
NEXT
(a) Refer to the DTC CHECK / CLEAR (see page AX-29).
Result
B
A
(a) Refer to the AUTOMATIC TRANSMISSION FLUID (see
page AX-102).
(b) Refer to the PARK/NEUTRAL POSITION SWITCH (see
page AX-108).
(c) Refer to the FLOOR SHIFT ASSEMBLY (see page AX-
136).
NG
OK
(a) Refer to the MECHANICAL SYSTEM TESTS (see page
AX-15).
8PROBLEM SYMPTOM CONFIRMATION
Result Proceed to
Symptom does not occur A
Symptom occurs B
GO TO STEP 10
9SYMPTOM SIMULATION
10DTC CHECK*
Result Proceed to
DTC is not output A
DTC is output B
GO TO STEP 18
11BASIC INSPECTION
GO TO STEP 21
12MECHANICAL SYSTEM TESTS