light TOYOTA RAV4 2006 Service User Guide

ENGINE - 2AZ-FE ENGINE
185EG48
185EG49
185EG50
287EG34
185EG48
185EG48
TDCLatest Timing
EX IN
BDC
To Advance Side
EX IN
EX IN
To Advance Side
EX IN
To Retard Side
Latest Timing
EX IN
Latest Timing
EX INEG-49
Effectiveness of the VVT-i System
Operation State
ObjectiveEffect
During Idling
At Light Load
Minimizing overlap to
reduce blowback to the
intake sideStabilized idling rpm
Better fuel economy
At Medium Load
Increasing overlap
increases internal EGR,
reducing pumping lossBetter fuel economy
Improved emission
control
In Low to Medium
Speed Range with
Heavy LoadAdvancing the intake
valve close timing for
volumetric efficiency
improvement
Improved torque in low
to medium speed range
In High Speed Range
with Heavy Load
Retarding the intake
valve close timing for
volumetric efficiency
improvement
Improved output
At LowTemperature
Minimizing overlap to
prevent blowback to
the intake side leads to
the lean burning
condition, and
stabilizes the idling
speed at fast idle
Stabilized fast
idle rpm
Better fuel economy
Upon Starting
Stopping the
Engine
Minimizing overlap to
minimize blowback to
the intake side
Improved startability

ENGINE - 2GR-FE ENGINEEG-71
FEATURES OF 2GR-FE ENGINE
The 2GR-FE engine has achieved the following performance through the use of the items listed below.
(1) High performance and reliability
(2) Low noise and vibration
(3) Lightweight and compact design
(4) Good serviceability
(5) Clean emission and fuel economy
Item
(1)(2)(3)(4)(5)
A steel laminate type cylinder head gasket is used.
An upright intake port is used.
EngineA taper squish shape is used for combustion chamber.Engine
ProperA cylinder block made of aluminum alloy is used.Proper
The skirt portion of the piston is applied with resin to
reduce friction.
An oil pan No. 1 made of aluminum alloy is used.
The Dual VVT-i (Variable Valve Timing-intelligent)
system is used.
Va l v e
Mh i
Hydraulic lash adjusters are used.
MechanismTiming chains and chain tensioners are used.
Roller rocker arms are used.
Lubrication
SystemAn oil filter with a replaceable element is used.
Cooling SystemThe TOYOTA Genuine SLLC (Super Long Life Coolant)Cooling SystemThe TOYOTA Genuine SLLC (Super Long Life Coolant)
is used for the engine coolant.
The linkless-type throttle body is used.
Intake andThe intake air chamber made of plastic is used.Intake and
Exhaust
S
A stainless steel exhaust manifold is used.
SystemAn ultra thin-wall, high-cell density ceramic type TWC
(Three-Way Catalytic converter) is used.
The fuel delivery pipe made of plastic is used.
Fuel SystemA compact 12-hole type injector is used.Fuel SystemQuick connectors are used to connect the fuel hose with
the fuel pipe.
Ignition System
The DIS (Direct Ignition System) makes ignition timing
adjustment unnecessary.
Ignition System
The long-reach type spark plugs are used.
(Continued)

ENGINE - 2GR-FE ENGINE
285EG05
Oil Delivery PipeCylinder Head Covers
Cylinder Head
Cover Gaskets
Oil Delivery Pipe
285EG06
Engine
FrontShim A A
For Right Bank
For Left BankA - A Cross SectionEG-73
ENGINE PROPER
1. Cylinder Head Cover
Lightweight yet high-strength aluminum cylinder head covers are used.
An oil delivery pipe is installed inside the cylinder head cover. This ensures lubrication to the sliding parts
of the roller rocker arm, improving reliability.
2. Cylinder Head Gasket
A steel-laminate type cylinder head gasket is used. A shim is used around the cylinder bore of the gasket to
help enhance sealing performance and durability.

ENGINE - 2GR-FE ENGINE
285EG10 285EG09
60
Knock Sensor Bosses
36.6 mm
(1.441 in.)
105.5 mm
(4.15 in.)
View from Top Side
285EG11
Wa t e r P a s s a g eEG-75
4. Cylinder Block
The cylinder block is made of aluminum alloy, so it is lightweight.
The cylinder block has a bank angle of 60, a bank offset of 36.6 mm (1.441 in.) and a bore pitch of 105.5
mm (4.15 in.), resulting in a compact block in its length and width even for its displacement.
Installation bosses of the two knock sensors are located on the inside of left and right banks.
A water passage has been provided between the cylinder bores. By allowing the engine coolant to flow
between the cylinder bores, this construction enables the temperature of the cylinder walls to be kept
uniform.

ENGINE - 2GR-FE ENGINE
285EG14
Knock Pin
Plastic Region
Tightening Bolts
285EG15
Balance Weight
Engine
Front
No. 1 Journal
No. 2 Journal
No. 3 JournalNo. 4 JournalEG-77
6. Connecting Rod and Connecting Rod Bearing
Connecting rods that have been forged for high strength are used for weight reduction.
Knock pins are used at the mating surfaces of the bearing caps of the connecting rod to minimize the
shifting of the bearing caps during assembly.
The connecting rods and caps are made of high-strength steel for weight reduction.
Nutless-type plastic region tightening bolts are used on the connecting rods for a lighter design.
An aluminum bearing is used for the connecting rod bearings.
The connecting rod bearings are reduced in width to reduce friction.
7. Crankshaft
A crankshaft made of forged steel, which excels in rigidity and wear resistance, is used.
The crankshaft has 4 journals and 5 balance weights.
All pin and journal fillets are IH-finished to maintain adequate strength.

ENGINE - 2GR-FE ENGINE
285EG33
Intake Air
Control Valve
ACIS ActuatorLaser-welding
285EG34GasketsRubber Coating
Outer SideIntake
Port Side
A
A
A - A Cross Section EG-92
4. Intake Air Chamber
The intake air chamber is made of plastic to realize lightweight.
The intake air chamber contains an intake air control valve. This valve is activated by ACIS (Acoustic
Control Induction System) and is used to alter the intake pipe length to improve the engine performance
in all speed range. For details, see page EG-126.
The ACIS actuator uses an electric actuator and is laser-welded onto the intake air chamber. Many of the
components are made of plastic for weight reduction.
— REFERENCE —
Laser-welding:
In laser-welding, a laser-absorbing material (for the intake air chamber) is joined to a laser-transmitting
material (for the ACIS actuator). Laser beams are then irradiated from the laser-transmitting side. The
beams penetrate the laser-transmitting material to heat and melt the surface of the laser-absorbing material.
Then, the heat of the laser-absorbing material melts the laser-transmitting material and causes both
materials to become welded.
5. Intake Manifold
Lightweight aluminum alloy is used for the intake manifold.
The intake manifold gaskets have rubber coating applied onto surface, and provide superior durability.

ENGINE - 2GR-FE ENGINE
01MEG34Y
Pulsation Damper
Fuel Filter
Fuel PumpPressure Regulator
Fuel Pump
Assembly
Fuel Tank
285EG38
Fuel Delivery PipesPulsation Damper
Holder
O-ring
Nylon TubeEG-95
2. Fuel Returnless System
This type of fuel system is used to reduce the evaporative emission. As shown below, by integrating the fuel
filter and pressure regulator with fuel pump assembly, the fuel return system in which the fuel returns from
the engine area is discontinued and temperature rise inside the fuel tank is prevented.
3. Fuel Delivery Pipe
The fuel delivery pipe made of plastic is used to realize lightweight.
The right and left fuel delivery pipes are connected by a nylon tube.
The pulsation damper is sealed with an O-ring and secured with a holder.

ENGINE - 2GR-FE ENGINE
01NEG63Y
01MEG36Y
Generator
Stator
RotorRegulator
EB
IG
M
RLOL
Ignition Switch
ECM
Towing Package Models and Models with RSES
Other Models Generator
Rectifier
Stator
Rotor
ERegulatorB
IG
M
RLOL
Ignition Switch
ECM
Discharge
Warning Light
Discharge
Warning Light
EG-98
CHARGING SYSTEM
1. General
A compact and lightweight segment conductor type generator is used. For details of the segment conductor
type generator, see page EG-25.
Specification
ModelTowing PackageWith RSES*Others
Ty p eSC2SE0
Rated Voltage12 V12 V
Output Rated150 A100 A
*: Rear Seat Entertainment System
Wiring Diagram

ENGINE - 2GR-FE ENGINE
01MEG08Y
DEFOGGER RELAY
TA I L L A M P R E L AY
STOP LIGHT SWITCH
CRUISE CONTROL SWITCH
AIR CONDITIONING ECU
AIRBAG SENSOR
ASSEMBLY
SKID CONTROL ECU
DLC3
MAIN RELAY
BATTERYELS
ELS2
STP
CCS
CANH,
CANL
TC
TA C H
MREL
+B
BATTECMRFC
RFC
MPMP
VPMP
PRG
WCOOLING FAN CONTROL*1
COOLING FAN ECU
FAN MOTOR NO. 1 AND
NO. 2
COOLING FAN CONTROL*
2
COOLING FAN ECU NO. 1
FAN MOTOR NO. 1
COOLING FAN ECU NO. 2
FAN MOTOR NO. 2
EVAPORATIVE EMISSION
CONTROL
LEAK DETECTION
PUMP
VENT VALVE
PURGE VSV
COMBINATION METER
MIL
: CANEG-105
*
1: Except Towing Package Models
*
2: Towing Package Models

ENGINE - 2GR-FE ENGINE
01MEG29Y
Ignition SwitchCombination Meter
Vehicle Speed Signal
MIL
Battery Current Sensor
(Built-in Battery
Temperature Sensor)
Park / Neutral
Position Switch
Battery
Generator
Fuel Pump Relay
Fuel Pump
Vent Valve
Circuit Opening
RelayDLC3*1*2*3
CAN
ECM
Cruise Control Switch
Accelerator Pedal
Position Sensor
Stop Light Switch
Canister
Pressure
SensorLeak
Detection
Pump
Intake Air
Temp. Sensor
VSV (For
Air Intake
Control)Mass Air
Flow Meter
AirThrottle Position
Sensor
Purge VSV
Throttle
Control
Motor
*4*5
Fan
Motor No. 1Fan
Motor
No. 2
Cooling
Fan
ECUCooling
Fan
ECU
No. 1Cooling
Fan
ECU
No. 2
Fan Motor No. 1
Fan Motor No. 2
ACIS Actuator
Intake Camshaft Timing
Oil Control Valve (Bank 2)Injector Injector
Intake Camshaft Timing
Oil Control Valve (Bank 1)
Intake VVT Sensor (Bank 1)
Ignition Coil With Igniter
Exhaust VVT Sensor (Bank 1)
Exhaust Camshaft Timing
Oil Control Valve (Bank 1)
Air-fuel Ratio Sensor
(Bank1, Sensor1)
TWC
Knock
Sensor
Intake VVT
Sensor (Bank 2)
Exhaust VVT
Sensor (Bank 2)
Air-fuel Ratio Sensor
(Bank2, Sensor1)Exhaust Camshaft
Timing Oil Control
Valve (Bank 2)
Crankshaft Position
Sensor
Engine Coolant
Temperature Sensor Heated Oxygen Sensor
(Bank1, Sensor2)Heated Oxygen Sensor
(Bank2, Sensor2)TWCTWC
EG-106
3. Engine Control System Diagram
*1: Air Conditioning ECU
*
2: Airbag Sensor Assembly
*
3: Skid Control ECU
*
4: Except Towing Package Models
*
5: Towing Package Models