check engine TOYOTA RAV4 2006 Service Repair Manual

ENGINE - 2AZ-FE ENGINE
01NEG34Y
Oil Jets
Check
Va l v e
Oil
Bottom Side View Oil Jet Cross SectionEG-15
Oil Capacity
Liters (US qts, Imp. qts)
Dry
5.0 (5.3, 4.4)
with Oil Filter4.3 (4.5, 3.8)
without Oil Filter4.1 (3.8, 3.1)
2. Oil Jet
Piston oil jets for cooling and lubricating the pistons are used in the cylinder block.
These oil jets contain a check valve to prevent oil from being fed when the oil pressure is low. This prevents
the overall oil pressure in the engine from dropping.

ENGINE - 2AZ-FE ENGINE
Service Tip
The canister pump module performs the EVAP leak check. This check is done approximately five
hours after the engine is turned off. So you may hear sound coming from underneath the luggage
compartment for several minutes. It does not indicate a malfunction.
The pinpoint pressure test procedure is carried out by pressurizing the fresh air line that runs from
the pump module to the air filler neck. For details, refer to the 2006 RAV4 Repair Manual (Pub.
No. RM01M1U).
EG-54
10. EVAP (evaporative Emission) Control System
General
The EVAP (evaporative emission) control system prevents the vapor gas that is created in the fuel tank from
being released directly into the atmosphere.
The canister stores the vapor gas that has been created in the fuel tank.
The ECM controls the purge VSV in accordance with the driving conditions in order to direct the vapor
gas into the engine, where it is burned.
In this system, the ECM checks the evaporative emission leak and outputs DTC (Diagnostic Trouble
Code) in the event of a malfunction. An EVAP (evaporative emission) leak check consists of an
application of a vacuum pressure to the system and monitoring the changes in the system pressure in order
to detect a leakage.
This system consists of the purge VSV, canister, refueling valve, canister pump module, and ECM.
The ORVR (Onboard Refueling Vapor Recovery) function is provided in the refueling valve.
The canister pressure sensor has been included to the canister pump module.
The canister filter has been provided on the fresh air line. This canister filter is maintenance-free.
The followings are the typical conditions for enabling an EVAP leak check:
Typical Enabling
Condition
Five hours have elapsed after the engine has been turned OFF*.
Altitude: Below 2400 m (8000 feet)
Battery voltage: 10.5 V or more
Ignition switch: OFF
Engine coolant temperature: 4.4 to 35C (40 to 95F)
Intake air temperature: 4.4 to 35C (40 to 95F)
*: If engine coolant temperature does not drop below 35C (95F), this time should be extended to 7hours.
Even after that, if the temperature is not less than 35
C (95F), the time should be extended to 9.5 hours.

ENGINE - 2AZ-FE ENGINE
275TU47
Purge
VSV
Ve n t
Va l v e
Pump Motor
System
PressureON (Open)
OFF (Close)
ON
OFF (Vent)
ON
OFF
Atmospheric Pressure
0.02 in. Leak Pressure
1) 2) 3) 4) 5) 6)EG-59
3) EVAP Leak Check
a. General
The EVAP leak check operates in accordance with the following timing chart:
Timing Chart
OrderOperationDescriptionTime
1)Atmospheric Pressure
MeasurementECM turns vent valve OFF (vent) and measures EVAP
control system pressure to memorize atmospheric pressure.10 sec.
2)0.02 in. Leak
Pressure MeasurementLeak detection pump creates negative pressure (vacuum)
through 0.02 in. orifice and the pressure is measured. ECM
determines this as 0.02 in. leak pressure.
60 sec.
3)EVAP Leak Check
Leak detection pump creates negative pressure (vacuum) in
EVAP control system and EVAP control system pressure is
measured. If stabilized pressure is larger than 0.02 in. leak
pressure, ECM determines EVAP control system has a
leakage.
If EVAP control system pressure does not stabilize within 12
minutes, ECM cancels EVAP monitor.
Within
12 min.
4)Purge VSV Monitor
ECM opens purge VSV and measures EVAP control system
pressure increase. If increase is large, ECM interprets this as
normal.
10 sec.
5)Repeat 0.02 in. Leak
Pressure MeasurementLeak detection pump creates negative pressure (vacuum)
through 0.02 in. orifice and pressure is measured. ECM
determines this as 0.02 in. leak pressure.
60 sec.
6)Final CheckECM measures atmospheric pressure and records monitor
result.—

ENGINE - 2AZ-FE ENGINE
00REG27Y
275TU49
Purge VSV
(OFF)Atmosphere
ECMCanister Pump Module
Vent Valve
(ON)
Leak Detection Pump
& Pump Motor
Canister
Pressure Sensor
M
P
Reference Orifice
Va c u u m
Purge VSV
Ve n t Va l v e
Pump Motor
System PressureOFF (Close)
ON (Open)
ON
OFF (Vent)
ON
OFF
Atmospheric Pressure
0.02 in. Leak Pressure
EVAP Leak CheckP0455
P0456
Normal EG-62
d. EVAP Leak Check
1) While actuating the leak detection pump, the ECM turns ON the vent valve in order to introduce a
vacuum into the canister.
2) When the pressure in the system stabilizes, the ECM compares this pressure with the 0.02 in. leak
pressure in order to check for a leakage.
3) If the measurement value is below the 0.02 in. leak pressure, the ECM determines that there is no
leakage.
4) If the measurement value is above the 0.02 in. leak pressure and near atmospheric pressure, the ECM
determines that there is a gross leakage (large hole) and stores DTC P0455 in its memory.
5) If the measurement value is above the 0.02 in. leak pressure, the ECM determines that there is a small
leakage and stores DTC P0456 in its memory.

ENGINE - 2AZ-FE ENGINE
00REG28Y
275TU50 M
P
Atmosphere
Atmosphere
Purge VSV
(ON)
ECMCanister Pump Module
Vent Valve
(ON)
Leak Detection Pump
& Pump Motor
Canister
Pressure Sensor
Purge VSV Monitor
P0441
Normal
Purge VSV
Vent Valve
Pump Motor
System PressureON (Open)
OFF (Close)
ON
OFF (Vent)
ON
OFF
Atmospheric Pressure
0.02 in. Leak PressureEG-63
e. Purge VSV Monitor
1) After completing an EVAP leak check, the ECM turns ON (open) the purge VSV with the leak
detection pump actuated, and introduces the atmospheric pressure from the intake manifold to the
canister.
2) If the pressure change at this time is within the normal range, the ECM determines the condition to
be normal.
3) If the pressure is out of the normal range, the ECM will stop the purge VSV monitor and store DTC
P0441 in its memory.

ENGINE - 2AZ-FE ENGINE
01MEG03Y
275TU51
Repeat 0.02 in. Leak Pressure Measurement Atmosphere
Purge VSV
(OFF)
ECMCanister Pump Module
Ve n t Va l v e
(OFF)
Leak Detection Pump
& Pump Motor
Canister Pressure
SensorReference Orifice
Purge VSV
Ve n t Va l v e
Pump Motor
System PressureON (Open)
OFF (Close)
ON
OFF (Vent)
ON
OFF
Atmospheric Pressure
0.02 in. Leak Pressure
P0456
Normal
M
P
EG-64
f. Repeat 0.02 in. Leak Pressure Measurement
1) While the ECM operates the vacuum pump, the purge VSV and vent valve turn off and a repeat 0.02
in. leak pressure measurement is performed.
2) The ECM compares the measured pressure with the pressure during EVAP leak check.
3) If the pressure during the EVAP leak check is below the measured value, the ECM determines that
there is no leakage.
4) If the pressure during the EVAP leak check is above the measured value, the ECM determines that
there is a small leakage and stores DTC P0456 in its memory.

ENGINE - 2GR-FE ENGINE
285EG21
Timing Chain Cover
Wa t e r P u m p G a s k e t
Wa t e r P u m pWater Pump Swirl
Chamber
Oil Pump
Housing
Oil Pump RotorsTiming Chain
Cover
Oil Pump Chamber
View from Front Side View from Back Side
285EG22
Oil
Passage
Check Ball
Check Ball
Spring
Plunger SpringPlunger
Roller Rocker ArmCam
Oil
Passage
Hydraulic
Lash Adjuster
Service Tip
Valve clearance adjustment is not necessary because a hydraulic lash adjuster is used in this model.
EG-83
4. Timing Chain Cover
The timing chain cover has an integrated construction consisting of the cooling system (water pump and
water passage) and the lubrication system (oil pump and oil passage). Thus, the number of parts has been
reduced to reduce weight.
5. Hydraulic Lash Adjuster
The hydraulic lash adjuster, which is located at the fulcrum of the roller rocker arm, consists primarily of
a plunger, plunger spring, check ball, and check ball spring.
The engine oil that is supplied by the cylinder head and the built-in spring actuates the hydraulic lash
adjuster. The oil pressure and the spring force that act on the plunger push the roller rocker arm against
the cam, in order to adjust the valve clearance that is created during the opening and closing of the valve.
As a result, engine noise is reduced.

ENGINE - 2GR-FE ENGINE
285EG24
Timing Chain Cover
Oil Pump
Housing
Oil Pump Rotors
(Cycloid Rotor)Crankshaft
To Cylinder
Block
From Oil
Filter
To
Oil FilterFrom
Oil Strainer
Oil passage in the oil pump
285EG25
Oil Jet Cross Section
Oil JetsCheck
Va l v eEngine Oil EG-86
2. Oil Pump
A compact cycloid rotor type oil pump directly driven by the crankshaft is used.
This oil pump has used an internal relief method which circulates relief oil to the suction passage in the
oil pump. This aims to minimize oil level change in the oil pan, reduce friction, and reduce air mixing rate
in the oil.
3. Oil Jet
Oil jets for cooling and lubricating the pistons have been provided in the cylinder block, in the center of
the right and left banks.
These oil jets contain a check valve to prevent oil from being fed when the oil pressure is low. This prevents
the overall oil pressure in the engine from dropping.

MAINTENANCE – UNDER HOODMA–7
MA
GENERAL MAINTENANCE
(2006/01- )
1. GENERAL NOTES
• Maintenance requirements vary depending on the
country.
• Check the maintenance schedule in the owner's
manual supplement.
• Following the maintenance schedule is mandatory.
• Determine the appropriate time to service the vehicle
using either miles driven or time elapsed, whichever
reaches the specification first.
• Maintain similar intervals between periodic
maintenance, unless otherwise noted.
• Failing to check each vehicle part could lead to poor
engine performance and increase exhaust emissions.
2. WINDSHIELD WASHER FLUID
(a) Check that there is sufficient fluid in the tank.
3. ENGINE COOLANT LEVEL
(a) Check that the coolant level is between the "FULL"
and "LOW" lines on the see-through reservoir.
4. RADIATOR AND HOSES
(a) Check that the front of the radiator is clean and not
blocked by leaves, dirt or bugs.
(b) Check the hoses for cracks, kinks, rot or loose
connections.
5. BATTERY ELECTROLYTE LEVEL
(a) Check that the electrolyte level of all the battery
cells is between the upper and lower level lines on
the case.
HINT:
If the electrolyte level is difficult to see, lightly shake
the vehicle.
6. BRAKE FLUID LEVEL
(a) Check that the brake fluid levels are near the upper
level lines on the see-through reservoirs.
7. ENGINE DRIVE BELT
(a) Check the drive belt for fraying, cracks, wear or
oiliness.
8. ENGINE OIL LEVEL
(a) Check the level on the dipstick with the engine
stopped.
9. AUTOMATIC TRANSAXLE FLUID LEVEL
10. EXHAUST SYSTEM
(a) Check for unusual exhaust sounds or abnormal
exhaust fumes. Inspect the cause and repair it.
Type See procedures
U151E See page AX-126
U151F See page AX-126

2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–27
EM
51. REMOVE DRIVE PLATE AND RING GEAR SUB-
ASSEMBLY
(a) Using SST, hold the crankshaft.
SST 09213-70011, 09330-00021
(b) Remove the 8 bolts, front spacer, drive plate and
rear spacer.
NOTICE:
Do not reuse the bolts.
52. INSTALL ENGINE TO ENGINE STAND
(a) Install the engine to an engine stand. Remove the
sling device and chain block from the engine.
53. REMOVE INTAKE AIR SURGE TANK ASSEMBLY
(a) Disconnect the 2 water by-pass hoses from the
throttle body.
(b) Disconnect the vapor feed hose.
(c) Disconnect the throttle body connector and clamp.
(d) Disconnect the No. 2 ventilation hose.
(e) Disconnect the union to check valve hose.
(f) Remove the bolt and vacuum hose clamp.
A076326E04
A076327E03
A129464
A139490
A129466