Toyota RAV4 2009–2010 Repair Manual Set — 2006 Edition (P/N RM01M1U)

New Car Features explains system construction and operation through section views, control charts, and component layouts. The Repair Manual supplies the workshop procedures, while the Electrical Wiring Diagram supports circuit tracing.

Coverage: These are 2006 North American publications, rather than a 2009–2010 model-year edition. The model tables distinguish U.S. 2WD and 4WD vehicles from Canadian 4WD entries, with Standard, Limited, and Sport grades. Affected repair sections separate 2005/11–2006/01 production from 2006/01-onward versions.

Searchable PDFs and Wiring Detail

Search, bookmarks, and small labels: All three PDFs contain searchable text and embedded bookmarks. Dense wiring pages may require zooming to read small connector numbers, terminal labels, and wire codes comfortably.

The ZIP download contains three printable PDFs totaling 6,883 pages. That total includes the New Car Features foreword and final memo page, along with repeated sections within New Car Features and the Repair Manual.

Engine, Driveline, and Control-System Work

The following selected repair and diagnostic topics show the range of coverage. Other included subjects include cruise-control diagnosis and engine-immobilizer troubleshooting.

• Engine repair: 2AZ-FE and 2GR-FE engine removal, timing-chain work, cylinder-head service, and engine-unit disassembly, inspection, and reassembly.

• Fuel and engine controls: SFI diagnosis, ETCS-i, VVT-i, returnless fuel and EVAP systems, plus air-fuel ratio and heated oxygen sensor testing.

• Automatic transaxles: DTC diagnosis, internal repair, fluid service, speed-sensor testing, and A/T reset-memory procedures for U140F, U241E, U151E, and U151F units.

• 4WD and chassis: GF1A transfer and active torque control 4WD diagnosis, rear differential repair, propeller and drive shafts, hydraulic brakes, EPS, and wheel alignment.

• Calibration and registration: Tester-assisted brake-actuator bleeding, yaw/deceleration-sensor zero-point calibration, SRS and occupant-classification procedures, and tire-pressure transmitter registration.

• Body and cabin: Manual and power seats, door locks, windows, sliding roof, lighting, mirrors, and automatic and manual A/C diagnosis and service.

• Electrical reference: System circuits, relay locations, wire routing, connector views, ground points, power-source current-flow charts, and overall wiring diagrams.

This material suits technicians and experienced owners who can follow electrical test procedures and have access to the specified diagnostic equipment and Toyota Special Service Tools.

Engine Service and ECU Diagnosis

Engine-specific work: Step-by-step procedures distinguish 2AZ-FE valve-clearance adjustment from 2GR-FE valve lash-adjuster inspection. Separate engine sections address ignition, charging, starting, cooling, and lubrication.

ECU chapters combine parts locations and system diagrams with troubleshooting flowcharts, DTC charts, freeze-frame data, Data List readings, Active Tests, problem-symptom tables, ECU terminal checks, and circuit inspection. These references let the reader connect a recorded fault with the relevant component and wiring checks.

Tester routines use the Toyota intelligent tester with CAN VIM. Replacement-related instructions include applicable resets, registration, and calibration, including VIN registration after ECM replacement.

The cylinder-head procedures flag a specific damage risk: an incorrect bolt-removal sequence can warp or crack the head.

Transaxle Internals and 4WD Diagnosis

Internal transaxle coverage extends to valve bodies, torque converters, oil pumps, clutches, brakes, planetary-gear assemblies, and differential cases. Preparation sections identify Toyota Special Service Tools and Special Service Materials; SST 09387-00020 is specified for clutch return-spring compression.

The active torque control 4WD section explains how faults in other systems and CAN communication affect diagnosis. Matching the model code, production date, and transaxle before choosing a procedure helps avoid applying instructions for different driveline hardware or controls.

Drive-shaft procedures also warn that vehicle weight can damage the hub bearing when the shaft is removed.

Brake Controls, Restraints, and Cabin Equipment

Chassis controls: Coverage includes ABS, TRAC, enhanced VSC, Brake Assist, downhill assist, hill-start assist, and Auto LSD. The VSC calibration table links sensor zero-point work to specified component replacements and front-wheel alignment.

Seats and body equipment: Seat sections distinguish manual and power front seats, rear No. 1 and optional rear No. 2 assemblies, stow and walk-in mechanisms, remote operation, seat heaters, and lumbar components. Power and wireless door locks receive separate system treatment.

SRS, fuel, brake, and refrigerant work carries system-specific isolation and handling precautions.

Circuit Diagrams and Factory Reference Tables

Representative diagrams include Multiplex Communication System–CAN, engine control for 2AZ-FE and 2GR-FE, 4WD, ABS/TRAC/VSC/Downhill Assist/Hill-Start Assist/Auto LSD, SRS, and standard and JBL audio circuits. Connector lists and connector part numbers support the circuit drawings and harness-routing information.

The New Car Features appendix covers dimensions, vehicle weights, engine performance, transaxle gear and final-drive ratios, plus brake, suspension, steering, generator, and speaker specifications.

The Repair Manual adds component torque tables, approved fluids and capacities, adjustment data, clearances, wear limits, and electrical test values.

A Sample of 2AZ-FE Valve-Clearance Data

For the 2AZ-FE, specified cold valve clearance is 0.19–0.29 mm on the intake side and 0.38–0.48 mm on the exhaust side. The adjustment section pairs these specifications with separate intake and exhaust valve-lifter selection charts.