rail TOYOTA RAV4 2006 Service Repair Manual

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–73
EM
(v) Remove the upper bearings and upper thrust
washers from the cylinder block.
HINT:
Arrange the bearings and thrust washers in the
correct order.
57. REMOVE CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSEMBLY
(a) Remove the 2 water drain cocks from the cylinder
block.
(b) Remove the water drain cock plugs from the water
drain cocks.
58. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, remove the 3 oil
nozzles.
(b) Check the oil nozzles for damage or clogging.
If necessary, replace the oil nozzle.
59. REMOVE PISTON RING SET
HINT:
Arrange the piston rings in the correct order.
(a) Using a piston ring expander, remove the 2
compression rings.
(b) Using a piston ring expander, remove the 2 side
rails.
(c) Remove the oil ring expander by hand.
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–107
EM
(d) Align the front marks of the piston and connecting
rod, and push in the piston pin with your thumb.
HINT:
The piston and pin are a matched set.
(e) Check the fitting condition between the piston and
piston pin by trying to move the piston back and
forth on the piston pin.
(f) Using a screwdriver, install a new snap ring at the
other end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not
aligned with the pin hole cutout portion of the piston.
4. INSTALL PISTON RING SET
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2
compression rings so that the painted marks are
positioned as shown in the illustration.
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2GR-FE COOLING – RADIATORCO–37
CO
(b) Remove the 2 bolts and pipe.
14. DISCONNECT COOLING FAN ECU HARNESS (w/o
Trailer Towing System)
(a) Disconnect the fan ECU connector.
(b) Detach the 3 harness clamps from the fan shroud
and upper radiator support.
15. DISCONNECT COOLING FAN ECU HARNESS (w/
Trailer Towing System)
(a) Disconnect the 2 fan ECU connectors.
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2GR-FE COOLING – RADIATORCO–41
CO
5. INSTALL UPPER RADIATOR SUPPORT BRACKET
(a) Install the brackets with the 2 bolts.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
6. CONNECT HORN CONNECTOR
(a) Connect the 2 horn connectors.
7. CONNECT NO. 2 WATER BY-PASS HOSE
(a) Connect the by-pass hose to the radiator and
radiator reservoir.
HINT:
The direction of the hose clamp is indicated in the
illustration.
8. CONNECT NO. 2 RADIATOR HOSE
HINT:
The direction of the hose clamp is indicated in the
illustration.
9. CONNECT NO. 1 RADIATOR HOSE
HINT:
The direction of the hose clamp is indicated in the
illustration.
10. CONNECT OIL COOLER OUTLET HOSE
11. CONNECT OIL COOLER INLET HOSE
12. CONNECT COOLING FAN ECU HARNESS (w/ Trailer
Towing System)
(a) Attach the harness with the 3 clamps.
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CO–422GR-FE COOLING – RADIATOR
CO
(b) Connect the 2 fan ECU connectors.
13. CONNECT COOLING FAN ECU HARNESS (w/o
Trailer Towing System)
(a) Attach the harness with the 3 clamps.
(b) Connect the fan ECU connector.
14. INSTALL NO. 1 WATER BY-PASS PIPE
(a) Install the by-pass pipe with the 2 bolts to the upper
radiator support.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(b) Connect the No. 1 radiator hose to the pipe.
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SUSPENSION – REAR TRAILING ARMSP–49
SP
INSTALLATION
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. TEMPORARILY TIGHTEN REAR TRAILING ARM
ASSEMBLY LH
(a) Temporarily install the trailing arm with the 3 bolts
and nut to the axle carrier and suspension arm
bracket.
HINT:
While fixing the nut in place, tighten the bolt.
2. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY
(See page PB-9)
3. INSTALL REAR WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
4. TIGHTEN REAR TRAILING ARM ASSEMBLY LH
(a) Tighten the 3 bolts and nut.
Torque: 200 N*m (2,039 kgf*cm, 148 ft.*lbf) for
axle carrier
150 N*m (1,530 kgf*cm, 111 ft.*lbf) for
suspension arm bracket
5. INSPECT AND ADJUST REAR WHEEL ALIGNMENT
(a) Inspect and adjust the rear wheel alignment (see
page SP-7).
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PB–10PARKING BRAKE – PARKING BRAKE CABLE
PB
INSTALLATION
1. INSTALL PARKING BRAKE CABLE
(a) Connect the cable to the backing plate and parking
brake shoe lever.
(1) Pass the cable through the backing plate, and
then connect the cable to the lever.
(2) Install the cable to the backing plate with the
bolt.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(b) Install the clamp and clamp bolt (labeled F) to the
trailing arm.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
NOTICE:
Securely install the clamp.
(c) Install the clamp and clamp bolt (labeled E) to the
rear suspension crossmember.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
NOTICE:
Securely install the clamp.
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RS–392SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR
RS
INSTALLATION
CAUTION:
Be sure to read the precautionary notices concerning the
SRS airbag system before servicing it (see page RS-1).
1. INSTALL SEAT POSITION AIRBAG SENSOR
(a) Using a 1 mm (0.039 in.) feeler gauge, install the
seat position sensor.
NOTICE:
• If the seat position sensor has been dropped,
or there are any cracks, dents or other
defects in the case or connector, replace the
seat position sensor with a new one.
• When installing the seat position sensor, be
careful that the SRS wiring does not interfere
with other parts and that it is not pinched
between other parts.
HINT:
Be sure that the clearance between the seat
position sensor and the seat rail is within 0.6 mm to
1.4 mm (0.023 to 0.055 in.).
(b) Using a T30 "torx" socket, tighten the "torx" screw to
install the seat position sensor.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(c) Make sure that the clearance between the seat
position sensor and the seat rail is within 0.6 mm to
1.4 mm (0.023 to 0.055 in.).
(d) Connect the connector.