Washer TOYOTA RAV4 2006 Service Repair Manual

ENGINE - 2GR-FE ENGINE
285EG81
Plastic Region
Tightening Bolts
Crankshaft
Bearing CapSeal WasherUpper Main Bearing
Oil Grooved
Micro-grooved
Lower Main Bearing
285EG80
Torsional Damper
Rubber EG-78
8. Crankshaft Bearing and Crankshaft Bearing Cap
The crankshaft bearing is made of aluminum alloy.
As the connecting rod bearings, the lining surface of the crankshaft bearings is micro-grooved to realize
an optimal amount of oil clearance. As a result, cold-engine cranking performance is improved and engine
vibration is reduced.
The upper main bearing has an oil groove around its inside circumference.
The crankshaft bearing caps are tightened using 4 plastic region tightening bolts for each journal. In
addition, each cap is tightened laterally to improve its reliability.
9. Crankshaft Pulley
The rigidity of the crankshaft pulley with its
built-in torsional damper rubber reduces noise.

SERVICE SPECIFICATIONS – STANDARD BOLTSS–3
SS
HOW TO DETERMINE NUT STRENGTH
Nut Type
HINT:
• *: Nut with 1 or more marks on one side surface of the nut.
• Use a nut with the same nut strength classification number
(or greater) as the bolt strength classification number
when tightening parts with a bolt and nut.
Example:
• Bolt = 4T
• Nut = 4N or more
Present Standard Hexagon Nut Old Standard Hexagon Nut Class
Cold Forging Nut Cutting Processed Nut
No Mark4N
No Mark (w/ Washer) No Mark (w/ Washer) No Mark 5N (4T)
6N
7N (5T)
8N
No Mark 10N (7T)
11 N
12N

MAINTENANCE – UNDER HOODMA–7
MA
GENERAL MAINTENANCE
(2006/01- )
1. GENERAL NOTES
• Maintenance requirements vary depending on the
country.
• Check the maintenance schedule in the owner's
manual supplement.
• Following the maintenance schedule is mandatory.
• Determine the appropriate time to service the vehicle
using either miles driven or time elapsed, whichever
reaches the specification first.
• Maintain similar intervals between periodic
maintenance, unless otherwise noted.
• Failing to check each vehicle part could lead to poor
engine performance and increase exhaust emissions.
2. WINDSHIELD WASHER FLUID
(a) Check that there is sufficient fluid in the tank.
3. ENGINE COOLANT LEVEL
(a) Check that the coolant level is between the "FULL"
and "LOW" lines on the see-through reservoir.
4. RADIATOR AND HOSES
(a) Check that the front of the radiator is clean and not
blocked by leaves, dirt or bugs.
(b) Check the hoses for cracks, kinks, rot or loose
connections.
5. BATTERY ELECTROLYTE LEVEL
(a) Check that the electrolyte level of all the battery
cells is between the upper and lower level lines on
the case.
HINT:
If the electrolyte level is difficult to see, lightly shake
the vehicle.
6. BRAKE FLUID LEVEL
(a) Check that the brake fluid levels are near the upper
level lines on the see-through reservoirs.
7. ENGINE DRIVE BELT
(a) Check the drive belt for fraying, cracks, wear or
oiliness.
8. ENGINE OIL LEVEL
(a) Check the level on the dipstick with the engine
stopped.
9. AUTOMATIC TRANSAXLE FLUID LEVEL
10. EXHAUST SYSTEM
(a) Check for unusual exhaust sounds or abnormal
exhaust fumes. Inspect the cause and repair it.
Type See procedures
U151E See page AX-126
U151F See page AX-126

AX–288U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
AX
7. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST and a hammer, tap out the oil seal.
SST 09950-70010 (09951-07100), 09215-00013
(09215-00471)
8. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, tap out the oil seal.
SST 09950-70010 (09951-07100), 09608-10010
INSPECTION
1. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH
(a) Using a dial indicator, measure the backlash of the
side gear.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0070 in.)
Standard thrust washer thickness:
1.625 mm (0.0640 in.)
1.725 mm (0.0679 in.)
1.825 mm (0.0719 in.)
REASSEMBLY
1. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Coat the 2 front differential side gears, 2 side gear
thrust washers, 2 front differential pinions and 2
pinion thrust washers with ATF and install them to
the differential case.
2. INSTALL NO. 1 FRONT DIFFERENTIAL PINION
SHAFT
(a) Coat the No. 1 front differential pinion shaft with
ATF, and install it to the differential case.
D025599E01
D025600E01
C050252E01
C050242E02
C050241E03

U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–291
AX
(d) Using SST, turn the differential assembly right and
left 2 or 3 times to allow the bearing to settle.
SST 09564-32011
(e) Using SST and a torque wrench, measure the
turning torque of the differential.
SST 09564-32011
Torque: Standard turning torque at 60 rpm
0.20 to 0.69 N*m (2.0 to 7.0 kgf*cm, 1.8
to 6.1 in.*lbf)
HINT:
If the turning torque is not within the specified value,
refer to the table below and select a thrust washer
so that the turning torque is within the specified
value.
Flange thickness
D025604E03
Mark Thickness Mark Thickness
0 2.00 mm (0.0787
in.)J 2.025 mm
(0.07972 in.)
1 2.05 mm (0.0807
in.)K 2.075 mm
(0.08169 in.)
2 2.10 mm (0.0827
in.)L 2.125 mm
(0.08366 in.)
3 2.15 mm (0.0846
in.)M 2.175 mm
(0.08563 in.)
4 2.20 mm (0.0866
in.)N 2.225 mm
(0.08760 in.)
5 2.25 mm (0.0886
in.)P 2.275 mm
(0.08957 in.)
6 2.30 mm (0.0906
in.)Q 2.325 mm
(0.09154 in.)
7 2.35 mm (0.0925
in.)R 2.375 mm
(0.09350 in.)
8 2.40 mm (0.0945
in.)S 2.425 mm
(0.09547 in.)
9 2.45 mm (0.0965
in.)T 2.475 mm
(0.09744 in.)
A 2.50 mm (0.0984
in.)U 2.525 mm
(0.09941 in.)
B 2.55 mm (0.1004
in.)V 2.575 mm
(0.10138 in.)
C 2.60 mm (0.1024
in.)W 2.625 mm
(0.10335 in.)
D 2.65 mm (1.1043
in.)X 2.675 mm
(0.10531 in.)
E 2.70 mm (0.1063
in.)Y 2.725 mm
(0.10728 in.)
F 2.75 mm (0.1083
in.)AA 2.775 mm
(0.10925 in.)
G 2.80 mm (0.1102
in.)AB 2.825 mm
(0.11122 in.)
H 2.85 mm (0.1122
in.)--

PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLYPR–5
PR
(e) If the result is not as specified, replace the center
support bearing adjusting washer with a more
appropriate one.
NOTICE:
• Use washers of the same thickness on the left
and right sides.
• Do not use 2 or more washers stacked
together.
Standard adjusting washer
INSTALLATION
1. TEMPORARILY INSTALL PROPELLER SHAFT WITH
CENTER BEARING SHAFT ASSEMBLY
(a) Align the matchmarks of the transfer and propeller
shaft.
(b) Temporarily install the propeller shaft with center
bearing with the 4 nuts and 4 washers.
C127521E01
Part No. Thickness
90201-10123 2.0 mm (0.08 in.)
90201-10081 4.5 mm (0.18 in.)
90201-10083 6.5 mm (0.26 in.)
90201-10084 9.0 mm (0.35 in.)
90201-10085 11.0 mm (0.43 in.)
C127526E01

PR–6PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY
PR
(c) Align the matchmarks of the differential carrier and
propeller shaft.
(d) Temporarily install the propeller shaft with center
bearing with the 4 bolts and 4 washers.
(e) Temporarily install the center support bearing and
center support bearing washer with the 2 bolts.
2. TIGHTEN PROPELLER SHAFT WITH CENTER
BEARING SHAFT ASSEMBLY
(a) Tighten the 4 nuts of the propeller shaft and transfer
to the torque specification.
Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
(b) Tighten the 4 nuts of the propeller shaft and
differential carrier to the torque specification.
Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
(c) Check that the center line of the center support
bearing housing is perpendicular to the axis of the
propeller shaft.
(d) Tighten the 2 bolts of the center support bearing to
the torque specification.
Torque: 36.8 N*m (375 kgf*cm, 27 ft.*lbf)
3. INSPECT JOINT ANGLE (See page PR-4)
C127525E01
C127524

WW–4WIPER AND WASHER – WIPER AND WASHER SYSTEM
WW
PROBLEM SYMPTOMS TABLE
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.
Wiper and washer system
Symptom Suspected area See page
Front wiper and washer system does not operate1. Windshield wiper switchWW-27
2. Wire harness -
Front wiper system does not operate in LO or HI1. WIP fuseWW-1
2. Windshield wiper switchWW-27
3. Front wiper motorWW-5
4. Wire harness -
Front wiper system does not operate in INT1. WIP fuseWW-1
2. Windshield wiper switchWW-27
3. Front wiper motorWW-5
4. Wire harness -
Front washer system does not operate1. WSH fuseWW-1
2. Windshield wiper switchWW-27
3. Front washer motorWW-33
4. Wire harness -
Front wiper arms do not return to their original
positions when wiper switch is turned off1. Front wiper motorWW-5
2. Wire harness -
Rear wiper and washer system does not operate1. Windshield wiper switchWW-27
2. Wire harness -
Rear wiper system does not operate1. RR WIP fuseWW-1
2. Windshield wiper switchWW-27
3. Rear wiper motorWW-20
4. Wire harness -
Rear washer system does not operate1. WSH fuseWW-1
2. Windshield wiper switchWW-27
3. Rear washer motorWW-33
4. Wire harness -
Rear wiper arms do not return to their original positions
when wiper switch is turned off1. Rear wiper motorWW-20
2. Wire harness -

EM–622AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
EM
(c) Apply air pressure of 100 kPa (1.0 kgf/cm2, 14 psi)
to the oil path, then turn the camshaft timing gear to
the advance direction (counterclockwise) by hand.
CAUTION:
Cover the paths with a shop rag to avoid oil
splashes.
HINT:
Depending on the air pressure, the camshaft timing
gear will turn to the advance angle side without
applying force by hand. Also, under the condition
that the pressure is difficult to apply because of air
leakage from the port, there may be the case that
the lock pin is difficult to release.
(d) Remove the flange bolt of the camshaft timing gear.
NOTICE:
• Be sure not to remove the other 4 bolts.
• When reusing the camshaft timing gear,
release the straight pin lock first, then install
the gear.
48. REMOVE CYLINDER HEAD SUB-ASSEMBLY
(a) Using several steps, uniformly loosen and remove
the 10 cylinder head bolts and 10 plate washers
with a 10 mm bi-hexagon wrench in the sequence
shown in the illustration.
NOTICE:
Head warpage or cracking could result from
removing the bolts in the wrong order.
(b) Using a screwdriver with its tip wrapped with tape,
pry between the cylinder head and cylinder block,
and remove the cylinder head.
NOTICE:
Be careful not to damage the contact surfaces of
the cylinder head and cylinder block.
A031032E02
A032639E02
F050595E01
A126930

2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–83
EM
9. INSTALL OIL PRESSURE SWITCH
(a) Apply adhesive to 2 or 3 threads of the oil pressure
switch.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond
1344 or equivalent
(b) Using a 24 mm deep socket wrench, install the oil
pressure switch.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
10. INSTALL RADIO SETTING CONDENSER
(a) Install the condenser with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALLATION
1. INSTALL CYLINDER HEAD GASKET
(a) Place a new gasket on the cylinder block surface
with the Lot No. stamp facing upward.
NOTICE:
• Remove any oil from contact surface.
• Be careful of the installation direction.
2. INSTALL CYLINDER HEAD SUB-ASSEMBLY
(a) Place the cylinder head on the head gasket.
NOTICE:
Place the cylinder head gently in order to avoid
damaging the gasket.
(b) Install the cylinder head bolts.
NOTICE:
The cylinder head bolts are tightened in 2
successive steps.
(1) Apply a light coat of engine oil to the threads
and under the heads of the cylinder head set
bolts.
(2) Using several steps, uniformly install and
tighten the 10 cylinder head set bolts and plate
washers with a 10 mm bi-hexagon wrench in
the order shown in the illustration.
Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf)
A114362
A112227
A126929E01
F050595E03