fender TOYOTA RAV4 2006 Service Repair Manual

2AZ-FE ENGINE MECHANICAL – DRIVE BELTEM–7
EM
REMOVAL
1. REMOVE RADIATOR SUPPORT OPENING COVER
2. REMOVE FRONT WHEEL RH
3. REMOVE FRONT FENDER APRON RH
4. REMOVE FRONT SUSPENSION MEMBER
REINFORCEMENT RH
(a) Remove the 4 bolts and reinforcement RH.
5. REMOVE FAN AND GENERATOR V BELT
(a) Using SST and 19 mm socket wrench, loosen the V-
ribbed belt tensioner arm clockwise, then remove
the fan and generator V belt.
SST 09216-42010
NOTICE:
• Be sure to connect SST and the tools so that
they are in line during use.
• When retracting the tensioner, turn it
clockwise slowly for 3 seconds or more. Do
not apply force rapidly.
• After the tensioner is fully retracted, do not
apply force any more than necessary.
INSTALLATION
1. INSTALL FAN AND GENERATOR V BELT
(a) Using SST and 19 mm socket wrench, loosen the V-
ribbed belt tensioner arm clockwise, then install the
fan and generator V belt.
SST 09216-42010
NOTICE:
• Be sure to connect SST and the tools so that
they are in line during use.
• When retracting the tensioner, turn it
clockwise slowly for 3 seconds or more. Do
not apply force rapidly.
• After the tensioner is fully retracted, do not
apply force any more than necessary.
2. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH
(a) Install the reinforcement RH with the 4 bolts.
Torque: 96 N*m (979 kgf*cm, 71 ft.*lbf)
3. INSTALL FRONT FENDER APRON RH
4. INSTALL FRONT WHEEL RH
5. INSTALL RADIATOR SUPPORT OPENING COVER
A114351E01
A114351E01

ET–4EXTERIOR – FRONT BUMPER
ET
REMOVAL
1. 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.
2. REMOVE FRONT FENDER LINER LH
(a) Using a screwdriver, remove the fender liner
retainer.
(b) Remove the screw, nut and bolt.
(c) w/ Splash Shield:
Remove the front fender splash shield LH.
(d) Partially remove the fender liner.
HINT:
It is not necessary to fully remove the fender liner.
Partially remove it so that the bumper cover can be
removed later.
3. REMOVE FRONT FENDER LINER RH
HINT:
Use the same procedures described for the LH side.
4. REMOVE RADIATOR SUPPORT OPENING COVER
(a) Remove the 2 clips.
(b) Partially remove the radiator support opening cover.
HINT:
It is not necessary to fully remove the radiator
support opening cover. Partially remove it so that
the bumper cover can be removed later.
5. REMOVE RADIATOR GRILLE PROTECTOR
(a) Remove the 2 radiator grille protectors.
B133187
B130259
B137680

EXTERIOR – FRONT BUMPERET–5
ET
6. REMOVE FRONT BUMPER COVER
(a) Remove the 8 screws.
(b) Apply protective tape under the front fender and
headlight.
(c) Using a screwdriver, detach the 4 claws.
HINT:
Tape the screwdriver tip before use.
(d) w/ Fog Light:
Disconnect the 2 fog light connectors.
(e) Using a clip remover, remove the hood cushion
center.
(f) Using a clip remover, remove the 4 clips and
remove the front bumper cover.
7. REMOVE NO. 2 FRONT BUMPER ENERGY
ABSORBER
(a) Remove the absorber.
B136793
B127932
B136791
B136792
B139377

EM–222AZ-FE ENGINE MECHANICAL – TIMING CHAIN
EM
REMOVAL
1. 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.
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE FRONT WHEEL RH
4. REMOVE NO. 1 ENGINE UNDER COVER
5. REMOVE FRONT FENDER APRON RH
6. REMOVE NO. 1 ENGINE COVER
(a) Remove the 2 nuts and cover.
7. DRAIN ENGINE OIL (See page LU-4)
8. REMOVE FRONT EXHAUST PIPE (See page EX-3)
9. REMOVE FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-6)
10. REMOVE FAN AND GENERATOR V BELT (See page
EM-6)
11. REMOVE GENERATOR ASSEMBLY (See page CH-9)
12. REMOVE RADIATOR RESERVOIR
(a) Remove the 2 bolts and radiator reservoir.
13. REMOVE ENGINE MOUNTING INSULATOR RH
(a) Remove the bolt of the wire harness protector.
(b) Disconnect the 2 clamps of the engine wire.
A112206
A124838
A098189E02

2AZ-FE ENGINE MECHANICAL – TIMING CHAINEM–43
EM
30. INSTALL NO. 1 ENGINE COVER
(a) Install the engine cover with the 2 nuts.
Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
31. INSTALL FRONT FENDER APRON RH
32. INSTALL NO. 1 ENGINE UNDER COVER
33. INSTALL FRONT WHEEL RH
34. INSTALL RADIATOR SUPPORT OPENING COVER
A112206

2AZ-FE ENGINE MECHANICAL – CYLINDER HEADEM–57
EM
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 RADIATOR SUPPORT OPENING COVER
4. REMOVE FRONT WHEEL RH
5. REMOVE NO. 1 ENGINE UNDER COVER
6. REMOVE FRONT FENDER APRON RH
7. REMOVE NO. 1 ENGINE COVER (See page EM-22)
8. DRAIN ENGINE COOLANT (See page CO-6)
9. DRAIN ENGINE OIL (See page LU-4)
10. REMOVE AIR CLEANER CAP (See page ES-411)
11. REMOVE THROTTLE BODY (See page ES-412)
12. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
(See page FU-10)
13. REMOVE INTAKE MANIFOLD (See page ES-419)
14. REMOVE INTAKE MANIFOLD INSULATOR (See page
ES-420)
15. REMOVE FRONT EXHAUST PIPE (See page EX-3)
16. REMOVE OIL DIPSTICK
17. REMOVE OIL DIPSTICK GUIDE
(a) Remove the bolt and guide.
(b) Remove the O-ring from the guide.
18. REMOVE MANIFOLD STAY
(a) Remove the bolt, nut and stay.
A112218
A112193

EM–882AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
EM
47. CHECK FOR ENGINE OIL LEAKS
48. CHECK FOR EXHAUST GAS LEAKS
49. INSPECT IGNITION TIMING (See page EM-1)
50. INSPECT ENGINE IDLING SPEED (See page EM-2)
51. INSPECT COMPRESSION (See page EM-3)
52. INSPECT CO/HC (See page EM-4)
53. INSTALL NO. 1 ENGINE COVER (See page EM-43)
54. INSTALL FRONT FENDER APRON RH
55. INSTALL NO. 1 ENGINE UNDER COVER
56. INSTALL FRONT WHEEL RH
57. INSTALL RADIATOR SUPPORT OPENING COVER
REPAIR
1. REPAIR VALVE SEATS
(a) If the seating is too high on the valve face, use 30

and 45
cutters to correct the seat.
(b) If the seating is too low on the valve face, use 75

and 45
cutters to correct the seat.
Standard width
(c) Lap the valve and valve seat by hand with an
abrasive compound.
(d) Recheck the valve seating position.
A128227E01
Item Standard Condition
Intake 1.0 to 1.4 mm (0.0394 to 0.0551 in.)
Exhaust 1.2 to 1.6 mm (0.0427 to 0.0630 in.)

EM–982AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
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
A124838

2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–113
EM
(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
A124838

2AZ-FE COOLING – WATER PUMPCO–11
CO
REMOVAL
1. 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.
2. REMOVE NO. 1 ENGINE UNDER COVER
3. REMOVE FRONT FENDER APRON RH
4. REMOVE RADIATOR SUPPORT OPENING COVER
5. DRAIN ENGINE COOLANT (See page CO-6)
6. REMOVE FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-6)
7. REMOVE FAN AND GENERATOR V BELT (See page
EM-6)
8. REMOVE GENERATOR ASSEMBLY (See page CH-9)
9. REMOVE WATER PUMP PULLEY
(a) Using SST, remove the 4 bolts and water pump
pulley.
SST 09960-10010 (09962-01000, 09963-00700)
10. REMOVE WATER PUMP ASSEMBLY
(a) Remove the clamp of the crankshaft position sensor
from the water pump.
(b) Disconnect the wire of the crankshaft position
sensor from the clamp bracket.
(c) Remove the 4 bolts, 2 nuts and clamp bracket.
A098715E03
A094516E01
B012052E03