front suspension 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

EM–262GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
(h) Remove the 6 bolts and front suspension member
brace rear RH and LH.
(i) Remove the 6 bolts, crossmember and suspension
member.
(j) Using the chain block, slowly remove the engine
from the vehicle and the intermediate shaft from the
pinion. Then set the engine on the engine lifter.
NOTICE:
• Make sure that the engine is clear of all wiring
and hoses.
• While lowering the engine from the vehicle,
do not allow it to contact the vehicle.
HINT:
Place the engine on wooden blocks or an equivalent
so that the engine is level.
(k) Remove the sling device from the engine.
45. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY
(a) Install a chain block.
(b) Remove the bolt, nut and crossmember.
46. REMOVE FRONT SUSPENSION CROSSMEMBER
SUB-ASSEMBLY
(a) Remove the bolt and suspension crossmember.
47. REMOVE ENGINE WIRE
(a) Remove the engine wire from the engine.
48. REMOVE STARTER ASSEMBLY (See page ST-6)
49. REMOVE TRANSFER ASSEMBLY (for 4WD) (See
page TF-60)
50. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY
(a) 2WD:
Remove the automatic transaxle (see page AX-
172).
(b) 4WD:
Remove the automatic transaxle (see page AX-
173).
A123580
A139135
A139136E01

SS–12SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL
SS
TORQUE SPECIFICATIONS
DRIVE BELT
VALVE CLEARANCE
TIMING CHAIN
Part Tightened N*m kgf*cm ft.*lbf
Front suspension member
reinforcement RH x Front cross
member, Front suspension
crossmember96 979 71
Part Tightened N*m kgf*cm ft.*lbf
No. 1 camshaft bearing cap x
Cylinder head29.5 301 22
No. 2 camshaft bearing cap x
Cylinder head29.5 301 22
No. 3 camshaft bearing cap x
Cylinder head9.0 92 80 in.*lbf
No. 1 chain tensioner x Timing
chain cover9.0 92 80 in.*lbf
Part Tightened N*m kgf*cm ft.*lbf
Chain tensioner plate x Crankshaft bearing cap 12 122 9
Oil pump drive shaft sprocket x Oil pump 29.5 301 22
No. 1 chain vibration damper x Cylinder head,
Cylinder block9.0 92 80 in.*lbf
Chain tensioner slipper x Cylinder head, Cylinder
block19 194 14
Timing chain guide x Crankshaft bearing cap 9.0 92 80 in.*lbf
Timing chain cover x
Cylinder head, Cylinder
blockBolt A
(Head: 10 mm)9.0 92 80 in.*lbf
Bolt B
(Head: 12 mm)25 255 18
Bolt C
(Head: 14 mm)55 561 41
Nut 11 112 8
V-ribbed belt tensioner x Timing chain cover 59.5 607 44
Engine mounting bracket RH x Timing chain cover 55 561 41
Crankshaft pulley x Crankshaft 180 1,835 133
Oil pan x Stiffening
crankcaseBolt, Nut 9.0 92 80 in.*lbf
Cylinder head cover x
Cylinder headBolt A 11 112 8
Bolt B 14 143 10
Nut 11 112 8
Engine wire x Cylinder head cover 8.4 86 74 in.*lbf
Idler pulley bracket x Cylinder block 60 612 44
Engine mounting insulator FR x Front cross
member95 969 70
Engine mounting
insulator FRThrough bolt x Nut 145 1,479 107
Engine mounting insulator RH x Body 95 969 70
Engine mounting
insulator RH x Engine
mounting bracketNut A 95 969 70
Nut B 52 530 38
Radiator reservoir x Radiator support RH, Engine
mounting insulator RH5.0 51 44 in.*lbf
No. 1 engine cover x Cylinder head 7.0 71 62 in.*lbf

SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICALSS–13
SS
CYLINDER HEAD
ENGINE ASSEMBLY
Part Tightened N*m kgf*cm ft.*lbf
Camshaft position sensor x Cylinder head 9.0 92 80 in.*lbf
Oil pressure switch x Cylinder head 13 133 10
Radio setting condenser x Cylinder head 10 102 7
Cylinder head set bolt
Cylinder head x Cylinder
block1 st 70 714 52
2 nd Turn 90
Tu r n 9 0Tu r n 9 0
Camshaft timing gear x Camshaft 54 551 40
No. 2 camshaft timing sprocket x No. 2 camshaft 54 551 40
No. 1 and No. 2 camshaft bearing cap x Cylinder
head29.5 301 22
No. 3 camshaft bearing cap x Cylinder head 9.0 92 80 in.*lbf
Exhaust manifold x Cylinder head 37 377 27
No. 1 exhaust manifold heat insulator x Exhaust
manifold12 122 9
No. 1 and No. 2 manifold stay x Cylinder block,
Exhaust manifold44 449 32
Oil dipstick guide x Cylinder block 9.0 92 80 in.*lbf
Part Tightened N*m kgf*cm ft.*lbf
Drive plate x Crankshaft 98 1,000 72
Drive shaft bearing bracket x Cylinder block 64 653 47
No. 1 and No. 2 engine hanger x Cylinder head 38 387 28
Engine mounting insulator LH x Body 95 969 70
Engine mounting
insulator LHThrough bolt 56 571 41
Engine mounting insulator RH x Body 95 969 70
Engine mounting
insulator RH x Engine
mounting bracketNut A 95 969 70
Nut B 52 530 38
Engine mounting
insulator RR x Front
suspension
crossmemberBolt and Nut 95 969 70
Engine mounting
insulator RR x Engine
mounting bracketThough bolt 95 969 70
Engine mounting insulator FR x Front cross
member95 969 70
Engine mounting
insulator FRThough bolt 145 1,479 107
Battery carrier bracket x Body 20 204 15
Battery bracket reinforcement x Battery carrier 20 204 15
Front battery carrier x Battery bracket
reinforcement20 204 15
Air cleaner filter element x Body 5.0 51 44 in.*lbf
Radiator reservoir x Radiator support RH, Engine
mounting insulator RH5.0 51 44 in.*lbf
Battery clamp x Upper
Radiator supportFor bolt 8.5 87 75 in.*lbf
Battery clamp x Battery
clamp boltFor nut 5.0 51 44 in.*lbf

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–72SERVICE SPECIFICATIONS – DRIVE SHAFT
SS
TORQUE SPECIFICATIONS
(2005/11-2006/01)
Drive shaft
Part Tightened N*m kgf*cm ft.*lbf
Front wheel
Rear wheel103 1,050 76
front suspension lower arm x Lower ball joint 92 938 68
Front axle hub nut 216 2,203 159
Drive shaft bearing bracket x Engine 63.7 650 47
Drive shaft bearing case
bolt2WD 63.7 650 47
Drive shaft bearing
bracket x Drive shaft4WD 32.4 330 24

SERVICE SPECIFICATIONS – DRIVE SHAFTSS–73
SS
TORQUE SPECIFICATIONS
(2006/01- )
Drive shaft
Part Tightened N*m kgf*cm ft.*lbf
Front wheel
Rear wheel103 1,050 76
front suspension lower arm x Lower ball joint 92 938 68
Front axle hub nut
26 216 2,203 159
30 292 2,978 215
Drive shaft bearing bracket x Engine 63.7 650 47
Drive shaft bearing case
bolt2WD 63.7 650 47
Drive shaft bearing
bracket x Drive shaft4WD 32.4 330 24

AXLE – FRONT AXLE HUBAH–7
AH
REMOVAL
(2005/11-2006/01)
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. REMOVE FRONT WHEEL
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Drain the automatic transaxle fluid for U140F (see
page AX-147).
(b) Drain the automatic transaxle fluid for U241E (see
page AX-146).
3. 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.
4. REMOVE FRONT AXLE HUB NUT
(a) Using SST and a hammer, unstake the staked part
of the nut.
SST 09930-00010
NOTICE:
Loosen the staked part of the nut completely,
otherwise the screw of the drive shaft may be
damaged.
(b) While applying the brakes, remove the lock axle hub
nut.
5. REMOVE FRONT SPEED SENSOR LH (See page BC-
191)
6. REMOVE FRONT DISC BRAKE CYLINDER
ASSEMBLY LH (See page BR-40)
7. REMOVE FRONT DISC (See page BR-42)
8. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
(See page PS-42)
9. DISCONNECT FRONT SUSPENSION NO. 1 LOWER
ARM SUB-ASSEMBLY LH
(a) Remove the bolt and 2 nuts.
(b) Disconnect the lower arm from the ball joint.
C129483E01
C127531

SP–10SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING
SP
DISASSEMBLY
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. REMOVE FRONT SUSPENSION SUPPORT PLATE LH
(a) Remove the plate from the shock absorber.
2. REMOVE FRONT SUSPENSION SUPPORT DUST
COVER LH
(a) Using a screwdriver, remove the dust cover from the
suspension support.
HINT:
Tape the screwdriver tip before use.
3. REMOVE FRONT SUPPORT TO FRONT SHOCK
ABSORBER NUT
(a) Install 2 nuts and 2 bolts to the bracket at the lower
portion of the shock absorber and secure it with a
vise.
(b) Using SST, compress the coil spring.
SST 09727-30021 (09727-00010, 09727-00021,
09727-00031)
HINT:
To prevent the coil spring from being damaged, wind
vinyl tape on the coil spring.
NOTICE:
• When holding the shock absorber with the
coil spring removed, do not hold it by the
spring lower seat. Also, do not knock the
spring lower seat.
• Do not use an impact wrench which will
damage SST.
(c) Using SST to hold the spring upper seat, remove
the nut.
SST 09729-22031
4. REMOVE FRONT SUSPENSION SUPPORT SUB-
ASSEMBLY LH
(a) Remove the suspension support from the shock
absorber.
5. REMOVE FRONT SUSPENSION SUPPORT LH DUST
SEAL
(a) Remove the dust seal from the shock absorber.
6. REMOVE FRONT COIL SPRING SEAT UPPER LH
(a) Remove the seat upper from the shock absorber.
7. REMOVE FRONT COIL SPRING INSULATOR UPPER
LH
(a) Remove the insulator upper from the shock
absorber.
8. REMOVE FRONT SPRING BUMPER LH
(a) Disengage the spring bumper from the spring seat.
C127544E01
C127544E01

SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRINGSP–11
SP
9. REMOVE FRONT COIL SPRING LH
(a) Remove the coil spring from the shock absorber.
(b) Remove SST from the coil spring.
10. REMOVE FRONT COIL SPRING INSULATOR LOWER
LH
(a) Remove the insulator lower from the shock
absorber.
INSPECTION
1. INSPECT FRONT SHOCK ABSORBER ASSEMBLY
LH
(a) Compress and extend the shock absorber rod 4
times or more. Check that there is no abnormal
resistance or unusual sound during the operation.
If there is any abnormality, replace the shock
absorber assembly with a new one.
NOTICE:
When disposing of the shock absorber, see
DISPOSAL (see page SP-13).
C127545