coil TOYOTA RAV4 2006 Service Owner's Manual

ENGINE - 2GR-FE ENGINE
238EG62
To VVT-i Controller
(Advance Side) *To VVT-i Controller
(Retard Side) *
Sleeve
Spring
Drain
Oil PressureDrain
Spool ValveCoil
PlungerEG-123
2) Camshaft Timing Oil Control Valve
This camshaft timing oil control valve controls the spool valve using duty-cycle control from the ECM.
This allows hydraulic pressure to be applied to the VVT-i controller advance or retard side. When the
engine is stopped, the camshaft timing oil control valve is in the most retard position.
Intake Camshaft Timing Oil Control Valve
*: The advance and retard sides of the exhaust camshaft timing oil control valve are reverse of the intake
side.

EM–282GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
(g) Disconnect the connector.
(h) Using a 5 mm socket hexagon wrench, remove the
4 bolts.
(i) Remove the 2 nuts, 2 bolts and surge tank.
(j) Remove the gasket from the surge tank.
54. REMOVE IGNITION COIL ASSEMBLY
(a) Remove the 6 bolts and 6 coils from the cylinder
head.
55. REMOVE NO. 2 ENGINE MOUNTING STAY RH
(a) Remove the bolt and mounting stay.
56. REMOVE FUEL INJECTOR ASSEMBLY (See page
FU-14)
57. REMOVE INTAKE MANIFOLD
(a) Remove the 6 bolts, 4 nuts, intake manifold and 2
gaskets.
58. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Disconnect the air fuel ratio sensor connector
clamp.
(b) Uniformly loosen and remove the 6 nuts.
(c) Remove the manifold and gasket.
59. REMOVE FAN AND GENERATOR V BELT (See page
EM-8)
60. REMOVE COMPRESSOR WITH PULLEY ASSEMBLY
(See page AC-220)
61. REMOVE GENERATOR ASSEMBLY (See page CH-12)
A129467
A129468
A076533E01
A139491

SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICALSS–21
SS
TORQUE SPECIFICATIONS
Part Tightened N*m kgf*cm ft.*lbf
Front suspension member reinforcement RH x Front
crossmember95 969 70
Front suspension member reinforcement RH x Front
suspension crossmember95 969 70
Radiator reservoir tank x Bract 5.0 51 44 in.*lbf
Engine coolant temperature sensor x Water outlet 20 204 14
Engine oil pressure sensor x Oil pan 21 214 15
No. 1 front engine mounting bracket LH x Timing chain
cover54 551 40
No. 2 idler pulley x Timing chain cover 43 438 32
No. 2 timing gear cover x Timing chain cover 6.0 61 53 in.*lbf
V-ribbed belt tensioner x Timing chain cover 43 438 32
V-ribbed belt tensioner x Cylinder block 43 438 32
Drive shaft bearing bracket x Cylinder block 64 653 47
Exhaust manifold LH x Cylinder head 21 214 15
No. 2 exhaust heat insulator x Exhaust manifold 8.5 87 75 in.*lbf
No. 2 manifold stay x Exhaust manifold 34 347 25
No. 2 manifold stay x Cylinder block 34 347 25
No. 1 oil dipstick guide x Cylinder block 21 214 15
No. 2 oil dipstick guide x Cylinder head 21 214 15
Exhaust manifold RH x Cylinder head 21 214 15
Intake manifold x Cylinder head 21 214 15
No. 2 engine mounting stay RH x Intake manifold 21 214 15
No. 2 engine mounting stay RH x Timing chain cover 21 214 15
Ignition coil x Cylinder head cover 10 102 7
Intake air surge tank x
Intake manifold5 mm hexagon wrench 18 184 13
for Bolt 21 214 15
for Nut 16 163 12
Vacuum hose clamp x Intake air surge tank 5.4 55 48 in.*lbf
Drive plate and ring gear x Crankshaft 178 1,815 132
Engine mounting bracket RR x Engine mounting
insulator RR95 969 70
Engine mounting bracket FR x Engine mounting
insulator FR145 1,479 107
Engine mounting bracket LH x Engine mounting
insulator LH56 571 41
Engine mounting insulator
RH x Front No. 1 engine
mounting bracketfor Bolt and nut A 95 969 70
for Nut B 52 530 38
Front crossmember x
Bodyfor Bolt A 96 979 71
Front suspension member
x Bodyfor Bolt B 145 1,478 107
Front suspension member
brace rear x Bodyfor Bolt C 145 1,478 107
for Bolt D 93 948 69
Air cleaner case x Engine mounting insulator LH 5.0 51 44 in.*lbf
Battery bracket reinforcement x Body 19 194 14
Front battery bracket x Body 19 194 14
Front battery bracket x Battery bracket reinforcement 19 194 14
Battery clamp x Body 5.0 51 44 in.*lbf

SP–10SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING
SP
DISASSEMBLY
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. REMOVE FRONT SUSPENSION SUPPORT PLATE LH
(a) Remove the plate from the shock absorber.
2. REMOVE FRONT SUSPENSION SUPPORT DUST
COVER LH
(a) Using a screwdriver, remove the dust cover from the
suspension support.
HINT:
Tape the screwdriver tip before use.
3. REMOVE FRONT SUPPORT TO FRONT SHOCK
ABSORBER NUT
(a) Install 2 nuts and 2 bolts to the bracket at the lower
portion of the shock absorber and secure it with a
vise.
(b) Using SST, compress the coil spring.
SST 09727-30021 (09727-00010, 09727-00021,
09727-00031)
HINT:
To prevent the coil spring from being damaged, wind
vinyl tape on the coil spring.
NOTICE:
• When holding the shock absorber with the
coil spring removed, do not hold it by the
spring lower seat. Also, do not knock the
spring lower seat.
• Do not use an impact wrench which will
damage SST.
(c) Using SST to hold the spring upper seat, remove
the nut.
SST 09729-22031
4. REMOVE FRONT SUSPENSION SUPPORT SUB-
ASSEMBLY LH
(a) Remove the suspension support from the shock
absorber.
5. REMOVE FRONT SUSPENSION SUPPORT LH DUST
SEAL
(a) Remove the dust seal from the shock absorber.
6. REMOVE FRONT COIL SPRING SEAT UPPER LH
(a) Remove the seat upper from the shock absorber.
7. REMOVE FRONT COIL SPRING INSULATOR UPPER
LH
(a) Remove the insulator upper from the shock
absorber.
8. REMOVE FRONT SPRING BUMPER LH
(a) Disengage the spring bumper from the spring seat.
C127544E01
C127544E01

SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRINGSP–11
SP
9. REMOVE FRONT COIL SPRING LH
(a) Remove the coil spring from the shock absorber.
(b) Remove SST from the coil spring.
10. REMOVE FRONT COIL SPRING INSULATOR LOWER
LH
(a) Remove the insulator lower from the shock
absorber.
INSPECTION
1. INSPECT FRONT SHOCK ABSORBER ASSEMBLY
LH
(a) Compress and extend the shock absorber rod 4
times or more. Check that there is no abnormal
resistance or unusual sound during the operation.
If there is any abnormality, replace the shock
absorber assembly with a new one.
NOTICE:
When disposing of the shock absorber, see
DISPOSAL (see page SP-13).
C127545

SP–12SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING
SP
REASSEMBLY
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. INSTALL FRONT COIL SPRING INSULATOR LOWER
LH
(a) Install the insulator lower to the shock absorber.
2. INSTALL FRONT SPRING BUMPER LH
(a) Engage the spring bumper to the spring seat.
3. INSTALL FRONT COIL SPRING LH
(a) Using SST, compress the coil spring.
SST 09727-30021 (09727-00010, 09727-00021,
09727-00031)
HINT:
To prevent the coil spring from being damaged, wind
vinyl tape around the coil spring.
NOTICE:
Do not use an impact wrench which will damage
SST.
(b) Install the coil spring to the shock absorber.
HINT:
Fit the lower end of the coil spring to the gap of the
lower spring seat.
4. INSTALL FRONT COIL SPRING INSULATOR UPPER
LH
(a) Install the insulator upper to the shock absorber.
5. INSTALL FRONT COIL SPRING SEAT UPPER LH
(a) Install the seat upper to the shock absorber.
6. INSTALL FRONT SUSPENSION SUPPORT LH DUST
SEAL
(a) Install the dust seal to the shock absorber.
7. INSTALL FRONT SUSPENSION SUPPORT SUB-
ASSEMBLY LH
(a) Install the suspension support to the shock
absorber.
8. INSTALL FRONT SUPPORT TO FRONT SHOCK
ABSORBER NUT
(a) Using SST to hold the spring upper seat, install a
new nut.
SST 09729-22031
Torque: 47 N*m (475 kgf*cm, 34 ft.*lbf)
(b) Remove SST.
SST 09727-30021 (09727-00010, 09727-00021,
09727-00031)
C127549
C127550E01
C127544E01

SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRINGSP–13
SP
(c) Pack the suspension support with MP grease.
9. INSTALL FRONT SUSPENSION SUPPORT DUST
COVER LH
(a) Install the dust cover to the shock absorber.
10. INSTALL FRONT SUSPENSION SUPPORT PLATE LH
(a) Install the support plate to the shock absorber with
coil spring.
C127553E01

MA–12MAINTENANCE – CHASSIS
MA
GENERAL MAINTENANCE
(2006/01- )
1. INSPECT STEERING LINKAGE AND GEAR HOUSING
(a) Check the steering wheel free play.
(b) Check the steering linkage for looseness or
damage.
(1) Check that the tie rod ends do not have
excessive play.
(2) Check that the dust seals and boots are not
damaged.
(3) Check that the boot clamps are not loose.
(4) Check that the steering gear housing is not
damaged.
(5) Check that the connectors are properly
connected to the steering gear housing.
2. INSPECT BALL JOINTS AND DUST COVERS
(a) Inspect the ball joints for excessive looseness.
(1) Jack up the front of the vehicle and place
wooden blocks with a height of 180 to 200 mm
(7.09 to 7.87 in.) under the front tires.
(2) Lower the vehicle until the front coil spring has
about half its ordinary load. Place stands under
the vehicle for safety.
(3) Check that the front wheels are pointing
straight ahead. Use wheel chocks on all 4
wheels.
(4) Using a lever, pry up the end of the lower arm.
Check the amount of play.
Maximum ball joint vertical play:
0 mm (0 in.)
If there is any play, replace the ball joint.
(b) Check the dust cover for damage.
3. INSPECT DRIVE SHAFT BOOTS
(a) Check the drive shaft boots for loose clamps,
grease leakage, kinks or damage.
4. INSPECT AUTOMATIC TRANSAXLE FLUID LEVEL
(a) Visually check the transmission for fluid leakage. If
oil is leaking, find the cause and repair it.
5. INSPECT TRANSFER OIL (for 4WD)
(a) Visually check the transfer for oil leakage. If oil is
leaking, find the cause and repair it.
6. INSPECT REAR DIFFERENTIAL OIL (for 4WD)
(a) For the rear differential oil inspection, refer to the
following procedures (see page DF-3).
Type See procedures
U151E See page AX-126
U151F See page AX-126
Type See procedures
Front Oil See page TF-45
Rear Oil See page TF-45

ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEMEI–3
EI
SYSTEM DESCRIPTION
1. ENGINE IMMOBILISER SYSTEM DESCRIPTION
The engine immobiliser system is designed to prevent
the vehicle from being stolen. This system uses a
transponder key ECU that stores the key codes of
authorized ignition keys. If an attempt is made to start
the engine using an unauthorized key, the ECU sends a
signal to the ECM to prohibit fuel delivery and ignition,
effectively disabling the engine.
2. FUNCTION OF MAIN COMPONENT
3. SYSTEM FUNCTION
• When the transponder key ECU detects that the
unlock warning switch is ON, the ECU provides
current to the transponder key coil and produces a
faint electric wave. A transponder chip in the key grip
receives the wave and outputs a key ID code signal.
The transponder key coil receives this signal, the
transponder key amplifier amplifies it, and then the
signal is transmitted to the ECU. The ECU matches
the key's ID code with the vehicle's ID code, which
was previously registered in the ECU and then
communicates the results to the ECM using SFI
communication.
• After the identification results show that the key's ID
code matches the vehicle's ID code and the ECU has
confirmed their match: 1) the engine immobiliser
system is canceled and the engine starting controls
(fuel injection control and ignition control) enter
standby mode; and 2) the ECU receives a security
indicator light signal, and turns the security indicator
light OFF.
Component Outline
Transponder key coil/amplifierWhen key is inserted into ignition key cylinder, key coil receives key
code. Then amplifier amplifies ID code and outputs it to transponder
key ECU.
Unlock warning switch assemblyDetects whether key is in ignition key cylinder and outputs results to
transponder key ECU
ECMThrough SFI communication, ECM receives ID verification results
from transponder key ECU. ECM also verifies ECUs. Then ECM
judges whether or not to immobilize engine.
Security indicator lightDepending on operation of transponder key ECU, interior security
indicator light comes on or starts blinking

ES–322AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM
ES
VPA (A9-55) - EPA (A9-59) W - YAccelerator pedal position
sensor (for engine control)Ignition switch ON,
Accelerator pedal released0.5 to 1.1 V
Ignition switch ON,
Accelerator pedal fully depressed2.6 to 4.5 V
VPA2 (A9-56) - EPA2 (A9-60) R - OAccelerator pedal position
sensor (for sensor
malfunctioning detection)Ignition switch ON,
Accelerator pedal released1.2 to 2.0 V
Ignition switch ON,
Accelerator pedal fully depressed3.4 to 5.0 V
VCPA (A9-57) - EPA (A9-59) B - YPower source of
accelerator pedal position
sensor (for VPA)Ignition switch ON 4.5 to 5.5 V
VCP2 (A9-58) - EPA2 (A9-60) L - OPower source of
accelerator pedal position
sensor (for VPA2)Ignition switch ON 4.5 to 5.5 V
HA1A (B30-109) - E04 (B30-46) L - W-B A/F sensor heaterIdling Below 3.0 V
Ignition switch ON 9 to 14 V
A1A+ (B30-112) - E1 (B30-104) B -BR A/F sensor Ignition switch ON 3.3 V*
A1A- (B30-113) - E1 (B30-104) R - BR A/F sensor Ignition switch ON3.0 V*
HT1B (B30-47) - E03 (B30-86) R - W-BHeated oxygen sensor
heaterIdling Below 3.0 V
Ignition switch ON 9 to 14 V
OX1B (B30-64) - EX1B (B30-87) B - BR Heated oxygen sensorEngine speed maintained at 2,500
rpm for 2 minutes after warming up
sensorPulse generation (see
waveform 2)
#10 (B30-108) - E01 (B30-45)
#20 (B30-107) - E01 (B30-45)
#30 (B30-106) - E01 (B30-45)
#40 (B30-105) - E01 (B30-45)L - W-B
G - W-B
B - W-B
W - W-BInjectorIgnition switch ON 9 to 14 V
IdlingPulse generation (see
waveform 3)
KNK1 (B30-110) - EKNK (B30-
111 )B - W Knock sensorEngine speed maintained at 4,000
after warming up enginePulse generation (see
waveform 4)
G2+ (B30-99) - G2- (B30-98) L - Y Camshaft position sensor IdlingPulse generation (see
waveform 5)
NE+ (B30-122) - NE- (B30-121) W - B Crankshaft position sensor IdlingPulse generation (see
waveform 5)
IGT1 (B30-85) - E1 (B30-104)
IGT2 (B30-84) - E1 (B30-104)
IGT3 (B30-83) - E1 (B30-104)
IGT4 (B30-82) - E1 (B30-104)R - BR
P - BR
G - BR
L - BRIgnition coil (ignition
signal)IdlingPulse generation (see
waveform 6)
IGF1 (B30-81) - E1 (B30-104) W - BRIgnition coil (ignition
confirmation signal)Ignition switch ON 4.5 to 5.5 V
IdlingPulse generation (see
waveform 6)
PRG (B30-49) - E1 (B30-104) G - BR Purge VSVIgnition switch ON 9 to 14 V
IdlingPulse generation (see
waveform 7)
SPD (A9-8) - E1 (B30-104) V - BRSpeed signal from
combination meterDriving at 20 km/h (12 mph)Pulse generation (see
waveform 8)
STA (A9-48) - E1 (B30-104) LG - BR Starter signal Cranking 5.5 V or
more
STAR (B30-52) - E1 (B30-104) W - BR Starter relay controlIgnition switch ON Below 1.5 V
Cranking 6.0 V or more
STP (A9-36) - E1 (B30-104) L - BR Stop light switchBrake pedal depressed 7.5 to 14 V
Brake pedal released Below 1.5 V
ST1- (A9-35) - E1 (B30-104) GR - BRStop light switch
(opposite to STP terminal)Ignition switch ON,
Brake pedal depressedBelow 1.5 V
Ignition switch ON,
Brake pedal released7.5 to 14 V
M+ (B30-42) - ME01 (B30-43) B - W-B Throttle actuator Idling with warm enginePulse generation (see
waveform 9) Symbols (Terminal No.) Wiring Colors Terminal Descriptions ConditionsSpecified
Conditions