Toyota RAV4 manuals

Toyota RAV4 Service Manual: Installation

  1. Install drive plate sub-assembly

  1. Clean the 8 bolts and 8 bolt holes.
  2. Apply adhesive to 2 or 3 threads of the 8 bolts.

Adhesive:

Toyota genuine adhesive 1342, three bond 1342 or equivalent

  1. Using sst, hold the crankshaft.

Sst 09213-54015 (91651-60855), 09330-00021

Toyota RAV4. Install drive plate sub-assembly


  1. Install the front spacer.

Toyota RAV4. Install drive plate sub-assembly


Hint:

Align the pin of the front spacer with the pin hole of the crankshaft.

  1. Install the drive plate and rear spacer onto the crankshaft.

Toyota RAV4. Install drive plate sub-assembly


  1. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

    Torque: 98 n*m (1,000 kgf*cm, 72 ft.*Lbf)

  1. Install torque converter clutch assembly

Toyota RAV4. Install torque converter clutch assembly


  1. Install the torque converter clutch for u241e (2wd) (see page ax-148).
  2. Install the torque converter clutch for u140f (4wd) (see page ax-149).
  1. Install automatic transaxle assembly

  1. Install the automatic transaxle for u241e (2wd) (see page ax-149).
  2. Install the automatic transaxle for u140f (4wd) (see page ax-150).
  1. Install starter assembly (see page st-14)

  2. Install transfer assembly (for 4wd) (see page tf-75)

  3. Install drive shaft bearing bracket (for 2wd)

Toyota RAV4. Install drive shaft bearing bracket (for 2wd)


  1. Install the bracket with the 3 bolts.

Torque: 64 n*m (653 kgf*cm, 47 ft.*Lbf)

  1. Install drive shaft bearing bracket (for 4wd)

Toyota RAV4. Install drive shaft bearing bracket (for 4wd)


  1. Install the bracket with the 3 bolts.

Torque: 64 n*m (653 kgf*cm, 47 ft.*Lbf)

  1. Install engine hanger

Toyota RAV4. Install engine hanger


  1. Install the no. 1 And no. 2 Engine hangers.

Torque: 38 n*m (387 kgf*cm, 28 ft.*Lbf) part no.


  1. Attach the sling device and the engine with the chain block.
  1. Install engine assembly with transaxle

Toyota RAV4. Install engine assembly with transaxle


  1. Lift the engine assembly (with transaxle) with the chain block.
  2. Lower the engine out of the vehicle slowly and carefully.

Toyota RAV4. Install engine assembly with transaxle


Notice:

Make sure the engine is clear of all wiring, hoses and cables.

  1. Install engine mounting insulator lh

Toyota RAV4. Install engine mounting insulator lh


  1. Install the engine mounting insulator lh with the 4 bolts.

Torque: 95 n*m (969 kgf*cm, 70 ft.*Lbf)

Toyota RAV4. Install engine mounting insulator lh


  1. Install the engine mounting insulator lh with the through bolt and nut.

Hint:

Install the through bolt by tightening the nut.

Torque: 56 n*m (571 kgf*cm, 41 ft.*Lbf)

  1. Install engine mounting insulator rh

Toyota RAV4. Install engine mounting insulator rh


  1. Install the engine mounting insulator rh with the 2 bolts and 2 nuts.

Torque: 95 n*m (969 kgf*cm, 70 ft.*Lbf) for bolt

95 N*m (969 kgf*cm, 70 ft.*Lbf) for nut a

52 N*m (530 kgf*cm, 38 ft.*Lbf) for nut b

  1. Remove engine hanger

  1. Remove the no. 1 And no. 2 Engine hangers.

Toyota RAV4. Remove engine hanger


  1. Install engine mounting insulator rr

Toyota RAV4. Install engine mounting insulator rr


  1. Install the engine mounting insulator rr with the 2 nuts and 2 bolts.

Torque: 95 n*m (969 kgf*cm, 70 ft.*Lbf)

  1. Install the through bolt which is used to secure the rear engine mounting insulator, into the rear engine mounting bracket.

Toyota RAV4. Install engine mounting insulator rr


Torque: 95 n*m (969 kgf*cm, 70 ft.*Lbf)

  1. Install engine mounting insulator fr

Toyota RAV4. Install engine mounting insulator fr


  1. Install the engine mounting insulator fr with the 2 bolts.

Torque: 95 n*m (969 kgf*cm, 70 ft.*Lbf)

  1. Install the through bolt and nut which is used to secure the front engine mounting bracket fr.

Hint:

Install the through bolt by tightening the nut.

Torque: 145 n*m (1,479 kgf*cm, 107 ft.*Lbf)

Toyota RAV4. Install engine mounting insulator fr


  1. Install propeller shaft assembly (for 4wd)

  1. Install the propeller shaft (see page pr-5).
  1. Install front drive shaft assembly

  1. Install the front drive shaft rh (for 2wd) (see page ds-32).
  2. Install the front drive shaft rh (for 4wd) (see page ds-65).
  1. Install front exhaust pipe (see page ex-4)

  2. Connect engine wire

  1. Install the ground cable with the bolt located near the starter.

Torque: 13 n*m (133 kgf*cm, 10 ft.*Lbf)

  1. Connect the ground cable to the clamp located near the starter.

Toyota RAV4. Connect engine wire


  1. Connect the engine wire to the positive (+) battery terminal with the nut.

Torque: 13 n*m (133 kgf*cm, 10 ft.*Lbf)

Toyota RAV4. Connect engine wire


  1. Connect the ground cable connector.

Toyota RAV4. Connect engine wire


  1. Connect the 2 engine wire connectors and install the nut.
  2. Install the engine room relay block cover.

Toyota RAV4. Connect engine wire


  1. Attach the clamp of the engine wire cover.
  2. Install the engine wire cover to with the bolt.

Toyota RAV4. Connect engine wire


  1. Install ecm (see page es-430)

  2. Install cooler compressor assembly (see page ac-217)

  3. Install generator assembly (see page ch-15)

  4. Install fan and generator v belt (see page em-7)

  5. Install front suspension member reinforcement rh (see page em-7)

  6. Install transaxle control cable assembly

  1. Install the transaxle control cable for u241e (see page ax-130).
  2. Install the transaxle control cable for u140f (see page ax-130).
  1. Install intake manifold insulator (see page es-421)

  2. Install intake manifold (see page es-421)

  3. Install fuel delivery pipe sub-assembly (see page fu-13)

  4. Connect no. 2 Ventilation hose (see page fu- 14)

  5. Install throttle body assembly (see page es-413)

  6. Connect fuel tube (see page fu-14)

  7. Connect heater water outlet hose

Toyota RAV4. Connect heater water outlet hose


  1. Connect the heater water outlet hose to the air conditioner tube.
  1. Connect heater water inlet hose

Toyota RAV4. Connect heater water inlet hose


  1. Connect the heater water inlet hose to the air conditioner tube.
  1. Connect union to connector tube hose

Toyota RAV4. Connect union to connector tube hose


  1. Connect the 2 union to connector tube hoses to the booster vacuum tube.
  1. Install battery carrier bracket

Toyota RAV4. Install battery carrier bracket


  1. Install the battery carrier bracket with the nut and 2 bolts.

Torque: 20 n*m (204 kgf*cm, 15 ft.*Lbf)

  1. Install battery bracket reinforcement

Toyota RAV4. Install battery bracket reinforcement


  1. Install the battery bracket reinforcement with the 2 bolts.

Torque: 20 n*m (204 kgf*cm, 15 ft.*Lbf)

  1. Install front battery carrier

  1. Install the front battery carrier with the 4 bolts.

    Torque: 20 n*m (204 kgf*cm, 15 ft.*Lbf)

  2. Connect the 2 clamps of the engine wire.

Toyota RAV4. Install front battery carrier


  1. Install air cleaner case sub-assembly

  1. Connect the air cleaner case to the no. 1 Air cleaner inlet.
  2. Install the air cleaner case with the 3 bolts.

    Torque: 5.0 N*m (51 kgf*cm, 44 in.*Lbf)

  1. Install air cleaner filter element subassembly

  2. Install air cleaner cap (see page es-413)

  3. Install purge vsv (see page ec-16)

Toyota RAV4. Install purge vsv (see page ec-16)


  1. Install radiator reservoir

Toyota RAV4. Install radiator reservoir


  1. Install the reservoir with the 2 bolts.

Torque: 5.0 N*m (51 kgf*cm, 44 in.*Lbf)

  1. Install radiator assembly

  1. Install the radiator (see page co-32).
  1. Install battery tray

  2. Install battery

  1. Install the battery.
  2. 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

  1. Connect cable to negative battery terminal

  2. Add automatic transaxle fluid

  1. Add automatic transaxle fluid for u241e (2wd) (see page ax-151).
  2. Add automatic transaxle fluid for u140f (4wd) (see page ax-152).
  1. Check for fuel leaks (see page fu-14)

  2. Add engine coolant (see page co-6)

  3. Check for engine coolant leaks (a) check for engine coolant leaks (see page co-1).

  4. Check for automatic transaxle fluid leaks

  5. Adjust shift lever position

  1. Adjust the shift lever position for u241e (2wd) (see page ax-138).
  2. Adjust the shift lever position for u140f (4wd) (see page ax-138).
  1. Install no. 1 Engine cover (see page em-43)

  2. Install front fender apron rh

  3. Install no. 2 Engine under cover

  4. Install no. 1 Engine under cover

  5. Install front wheel

  6. Install radiator support opening cover

  7. Install hood sub-assembly

  1. Install the hood (see page ed-7).
  2. Adjust the hood (see page ed-5).
  1. Inspect and adjust front wheel alignment

  1. Inspect and adjust the front wheel alignment (see page sp-3).
  1. Perform registration

  1. When replacing the engine assembly, perform vehicle stability control system recognition in ecm (see page cc-12).
  1. Reset memory (for automatic transaxle)

  1. When replacing the engine assembly, perform the reset memory procedure (a/t initialization) for u241e (2wd) (see page ax-18) and for u140f (4wd) (see page ax-18).
Removal
Discharge fuel system pressure (see page fu-9) Disconnect cable from negative battery terminal Caution: Wait at least 90 seconds after disconnecting the cable from the negative (-) batte ...

Engine unit
...

Other materials:

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Dtc check / clear
Notice: When the diagnosis system is changed from normal mode to check mode or vice versa, all dtcs and freeze frame data recorded in normal mode are erased. Before changing modes, always check and make a note of any dtcs and freeze frame data. Hint: Dtcs which are stored in the ecm can be ...

Problem symptoms table (2006/01- )
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 p ...

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