motor TOYOTA RAV4 2006 Service Owner's Manual

ENGINE - 2AZ-FE ENGINE
01NEG13Y
Generator
RegulatorB
DF
RLOECM
Various Electrical
Loads
Battery Current Sensor
Battery Temperature Sensor
Battery Voltage
Battery
Various Sensors and Switches
Throttle Position Sensor
Crankshaft Position Sensor
Accelerator Pedal Position
SensorEG-65
11. Charging Control
General
This system lowers the generated voltage when the vehicle is idling or is being driven at a constant speed,
and raises the generated voltage when the vehicle is decelerating. This reduces the load on the engine as
a result of the electric generation of the generator, thus contributing to the fuel economy of the engine.
During acceleration, this system regulates the generated voltage in order to place the amperage estimation
value close to the target value.
This control consists of the ECM, battery current sensor with a built-in battery temperature sensor,
generator, and various sensors and switches.
The ECM detects driving condition based on signals from various sensors and switches, and detects
charging condition based on signals from the generator, battery current sensor and battery temperature
sensor. Then the ECM outputs signals to the IC regulator to control the genetated voltage of the generator.
The ECM stops the charging control and the generator switches to normal power generation mode under
the following conditions:
Low battery capacity
Low or high battery temparature
Wipers operating or blower motor operating with tail lamp relay ON
System Diagram

ENGINE - 2GR-FE ENGINE EG-72
Item
(1)(2)(3)(4)(5)
ChargingA segment conductor type generator is used.Charging
SystemA generator pulley with a clutch is used.
Starting
SystemThe PS (Planetary reduction-Segment conductor motor)
type starter is used.
Serpentine Belt
Drive SystemA serpentine belt drive system is used.
The MRE (Magnetic Resistance Element) type VVT sensorsThe MRE (Magnetic Resistance Element) type VVT sensors
are used.
The ETCS-i (Electronic Throttle Control System-intelligent)
Engine
The ETCS i (Electronic Throttle Control System intelligent)
is used.
Control
SystemThe ACIS (Acoustic Control Induction System) is used.SystemThe air intake control system is used.
The charging control is used.
Evaporative emission control system is used.

ENGINE - 2GR-FE ENGINE
01MEG13Y
Air Cleaner Hose with
Resonator
Air Cleaner Cap
Charcoal Filter
Air Cleaner Element
(Nonwoven Fabric)
Air Cleaner Case
Actuator
(For Air Intake Control)
Air Cleaner Inlet
Resonator
285EG32
Throttle Position Sensor
Throttle Control MotorEG-91
2. Air Cleaner
A nonwoven, full-fabric type air cleaner
element is used.
A charcoal filter, which adsorbs the HC that
accumulates in the intake system when the
engine is stopped, is used in the air cleaner case
in order to reduce evaporative emissions. This
filter is maintenance-free.
Along with the use of the air intake control
system, an air intake control valve is provided
on the air cleaner case. For details, see page
EG-128.
Resonators have been provided to reduce the
amount of intake air sound.
3. Throttle Body
A linkless-type throttle body in which the throttle position sensor and the throttle control motor are integrated
is used. It realizes excellent throttle valve control. For details, see page EG-118.
In the throttle control motor, a DC motor with excellent response and minimal power consumption is used.
The ECM performs the duty ratio control of the direction and the amperage of the current that flows to
the throttle control motor in order to regulate the throttle valve angle.

ENGINE - 2GR-FE ENGINE
01MEG07Y
SENSORSACTUATORS
MASS AIR FLOW METER
INTAKE AIR TEMPERATURE
SENSOR
CRANKSHAFT POSITION
SENSOR
ENGINE COOLANT
TEMPERATURE SENSOR
ACCELERATOR PEDAL
POSITION SENSOR
THROTTLE POSITION
SENSOR
KNOCK SENSOR (Bank 1)
KNOCK SENSOR (Bank 2)
INTAKE VVT SENSOR (Bank 1)
INTAKE VVT SENSOR (Bank 2)
EXHAUST VVT SENSOR
(Bank 1)
EXHAUST VVT SENSOR
(Bank 2)
IGNITION SWITCHVG
THA
NE
THW
VPA
VPA2
VTA1
VTA2
KNK1
KNK2
VV1
VV2
EV1
EV2
IGSWECM#10
#20
#30
#40
#50
#60
IGT1 -
IGT6
IGF1
M
OC1
OC2
OE1
OE2SFI
NO. 1 INJECTOR
NO. 2 INJECTOR
NO. 3 INJECTOR
NO. 4 INJECTOR
NO. 5 INJECTOR
NO. 6 INJECTOR
ESA
IGNITION COIL with
IGNITER
SPARK PLUG
ETCS-i
THROTTLE CONTROL
MOTOR
VVT-i (INTAKE SIDE)
CAMSHAFT TIMING OIL
CONTROL VALVE (Bank 1)
CAMSHAFT TIMING OIL
CONTROL VALVE (Bank 2)
VVT-i (EXHAUST SIDE)
CAMSHAFT TIMING OIL
CONTROL VALVE (Bank 1)
CAMSHAFT TIMING OIL
CONTROL VALVE (Bank 2)EG-103
2. Construction
The configuration of the engine control system is as shown in the following chart.
(Continued)

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

ENGINE - 2GR-FE ENGINE
01MEG18Y
Accelerator Pedal
Position SensorThrottle ValveThrottle Position Sensor
Throttle Control
Motor
Mass Air
Flow Meter
Cruise Control
Switch
Skid Control
ECUECMIgnition Coil
Fuel Injection EG-118
8. ETCS-i (Electronic Throttle Control System-intelligent)
General
In the conventional throttle body, the throttle valve angle is determined invariably by the amount of the
accelerator pedal effort. In contrast, ETCS-i uses the ECM to calculate the optimal throttle valve angle that
is appropriate for the respective driving condition and uses a throttle control motor to control the angle.
System Diagram
Control
1) General
The ETCS-i consists of the following five functions:
Normal Throttle Control (Non-linear Control)
IAC (Idle Air Control)
TRAC (Traction Control)
VSC (Vehicle Stability Control)
Cruise Control

ENGINE - 2GR-FE ENGINE
285EG58
Engine
Speed
ECM
ActuatorThrottle Opening Angle
Throttle Valve
Intake Air Control Valve
285EG64
Intake Air
Control Valve
Actuator EG-126
10. ACIS (Acoustic Control Induction System)
General
The ACIS consists of a bulkhead to divide the intake manifold into 2 stages, and an intake air control valve
in the bulkhead which opens and closes to vary the effective length of the intake manifold in accordance
with the engine speed and throttle valve opening angle. This increases the power output in all ranges from
low to high speed.
System Diagram
Construction
1) Intake Air Control Valve
The intake air control valve, which is
provided in the intake air chamber, opens and
closes to change the effective length of the
intake manifold in 2 stages.
2) Actuator (Motor)
The actuator activates the intake air control
valve based on signals from the ECM.

ENGINE - 2GR-FE ENGINE
01MEG21Y
01MEG22Y
Engine Coolant Temperature
Sensor
Crankshaft Position Sensor
Combination Meter
Vehicle Speed SignalECM
CAN
Air Conditioning ECUCooling
Fan
ECUFan Motor
No. 1
Fan Motor
No. 2
Except Towing Package Models
Towing Package Models Engine Coolant Temperature
Sensor
Crankshaft Position Sensor
Combination Meter
Vehicle Speed SignalECM
CAN
Air Conditioning ECUCooling
Fan
ECU
No. 1
Cooling
Fan
ECU
No. 2Fan Motor
No. 1
Fan Motor
No. 2EG-129
12. Cooling Fan Control System
General
A cooling fan control system is used. To achieve an optimal fan speed in accordance with the engine coolant
temperature, vehicle speed, engine speed, and air conditioning operating conditions, the ECM calculates
the proper fan speed and sends the signals to the front controller. By receiving the signals from the ECM,
the front controller sends proper fan speed control signals to the cooling fan ECU.
Upon receiving the signals from the front controller, the cooling fan ECU actuates the fan motors.
Wiring Diagram

ENGINE - 2GR-FE ENGINEEG-133
15. Fail-safe
When the ECM detects a malfunction, the ECM stops or controls the engine according to the date already
stored in the memory.
Fail-safe Chart
DTC No.Fail-safe OperationFail-safe Deactivation Conditions
P0031, P0032,
P0051, P0052ECM turns off air-fuel ratio sensor heater.Ignition switch OFF.
P0037, P0038,
P0057, P0058ECM turns off heated oxygen sensor heater.Ignition switch OFF.
P0100, P0102,
P0103Ignition timing is calculated from engine speed
and throttle angle.“Pass” condition detected.
P0110, P0112,
P0113Intake air temperature is fixed at 20C (68F).“Pass” condition detected.
P0115, P0117,
P0118Engine coolant temperature is fixed at 80C
(176
F).“Pass” condition detected.
P0120, P0121,
P0122, P0123,
P0220, P0222,
P0223, P0604,
P0606, P0607,
P0657, P2102,
P2103, P2111,
P2112, P2118,
P2119, P2135
If ETCS-i (Electronic Throttle Control
System-intelligent) has a malfunction, ECM
cuts off current to throttle control motor.
Throttle control valve returns to predetermined
opening angle (approximately 6.5
) by force of
return spring. ECM then adjusts engine output
by controlling fuel injection (intermittent
fuel-cut) and ignition timing in accordance with
accelerator pedal opening angel to enable
vehicle to continue driving at minimal speed. If
accelerator pedal is depressed firmly and
slowly, vehicle can be driven slowly. If
accelerator pedal is depressed quickly, vehicle
may speed up and slow down erratically.If “Pass” condition is detected and
then the ignition switch is turned
OFF, fail-safe operation will stop
and system will return to normal
operating conditions.
P0327, P0328,
P0332, P0333Max. timing retardation.Ignition switch OFF.
P0351, P0352,
P0353, P0354,
P0355, P0356
Fuel is cut.“Pass” condition detected.
P2120, P2121,
P2122, P2123,
P2125, P2127,
P2128, P2138
Accelerator pedal position sensor has two (main
and sub) sensor circuits. If a malfunction occurs
in either of sensor circuits, ECM detects
abnormal signal voltage difference between two
sensor circuits and switches into limp mode. In
limp mode, remaining circuit is used to calculate
accelerator pedal opening to allow vehicle to
continue driving. If both circuits malfunction,
ECM regards opening angle of accelerator pedal
to be fully closed. In this case, throttle valve will
remain closed as if engine is idling.
If “Pass” condition is detected and
then the ignition switch is turned
OFF, fail-safe operation will stop
and system will return to normal
operating conditions.