air conditioning TOYOTA RAV4 2006 Service Repair Manual

ENGINE - 2AZ-FE ENGINE
DR011EG22 01NEG26Y
Air Flow During Engine Revolution
Wa t e r P u m p
Swirl Chamber
Crankshaft
Bearing Cap
Plastic Region
Tightening BoltsThermostat Housing
Air Conditioning
Compressor BracketsAir Passage Holes
Air Flow
NOTICE
Never attempt to machine the cylinder because it has a thin liner thickness.
EG-7
4. Cylinder Block
Lightweight aluminum alloy is used for the cylinder block.
By producing the thin cast-iron liners and cylinder block as a unit, compaction is realized.
Air passage holes are provided in the crankshaft bearing area of the cylinder block. As a result, the air at
the bottom of the cylinder flows smoother, and pumping loss (back pressure at the bottom of the piston
generated by the piston’s reciprocal movement) is reduced to improve the engine’s output.
The oil filter and the air conditioning compressor brackets are integrated into the crankcase. Also, the
water pump swirl chamber and thermostat housing are integrated into the cylinder block.

ENGINE - 2AZ-FE ENGINE
240EG98
Idler Pulley for Automatic Tensioner
Generator Pulley
Water Pump Pulley
Air Conditioning
Compressor Pulley Crankshaft Pulley Idler Pulley
258RV77
ArmIdler Pulley
Te n s i o n e r
A - A Cross SectionAAEG-29
SERPENTINE BELT DRIVE SYSTEM
1. General
Accessory components are driven by a serpentine belt consisting of a single V-ribbed belt. It reduces the
overall engine length, weight and the number of engine parts.
An automatic tensioner eliminates the need for tension adjustment.
2. Automatic Tensioner
The automatic tensioner consists of an idler pulley and a tensioner. The idler pulley maintains belt tension
by the force of the spring that is located in the tensioner.

ENGINE - 2AZ-FE ENGINE EG-30
ENGINE CONTROL SYSTEM
1. General
The engine control system for the 2AZ-FE engine has the following systems.
System
Outline
SFI
Sequential Multiport
Fuel InjectionAn L-type SFI system directly detects the intake air volume with a hot-wire
type mass air flow meter.
The fuel injection system is a sequential multiport fuel injection system.
ESA
Electronic Spark
AdvanceIgnition timing is determined by the ECM based on signals from various sensors.
The ECM corrects ignition timing in response to engine knocking.
ETCS-i
Electronic
Optimally controls the throttle valve opening in accordance with the amount of
accelerator pedal effort and the condition of the engine and the vehicle.
Electronic
Throttle Control
System-intelligent
(See page-43)A linkless-type is used, without an accelerator cable.
An accelerator pedal position sensor is provided on the accelerator pedal.
A non-contact type throttle position sensor and accelerator pedal position
sensor are used.
VVT-i
Va r i a b l e Va l v e
Timing-intelligent
(See page EG-48)
Controls the intake camshaft to an optimal valve timing in accordance with the
engine condition.
Air-fuel Ratio
Sensor, Oxygen
Sensor Heater
ControlMaintains the temperature of the air-fuel ratio sensor or oxygen sensor at an
appropriate level to realize accuracy of detection of the oxygen concentration in
the exhaust gas.
Air Conditioning
Cut-off ControlBy turning the air conditioning compressor ON or OFF in accordance with the
engine condition, drivability is maintained.
Cooling Fan Control
(See page EG-52)Radiator cooling fan operation is controlled by signals from ECM based on the
engine coolant temperature sensor signal and the condition of the air
conditioning operation.
Fuel Pump Control
(See page EG-53)Fuel pump operation is controlled by signal from the ECM.
The fuel pump is stopped when the SRS driver’s and front passenger’s airbags
are deployed.
Evapotative Emission
The ECM controls the purge flow of evaporative emissions (HC) in the canister
in accordance with engine conditions.
Evapotative Emission
Control
(See page EG-54)Approximately five hours after the ignition switch has been turned OFF, the
ECM operates the canister pump module to detect any evaporative emission
leakage occurring in the EVAP (evaporative emission) control system through
changes in the 0.02 in. leak pressure.
Charging Control
(See page EG-65)The ECM regulates the charging voltage of the generator in accordance with the
driving conditions and the charging state of the battery.
(Continued)

ENGINE - 2AZ-FE ENGINE
01MEG05Y
DEFGGER SWITCH
TA I L L I G H T S W I T C H
STOP LIGHT SWITCH
CURRENT SENSOR
CANISTER PUMP MODULE
CANISTER PRESSURE
SENSOR
TRANSPONDER KEY ECU*
AIRBAG SENSOR ASSEMBLY
EPS ECU
AIR CONDITIONING ECU
SKID CONTROL ECU
DLC3
BATTERYELS1
ELS3
STP
ST1-
THB
VCIB
PPMP
IMI
IMO
CANH,
CANL
TC
TA C H
BATTECMFA N H
FA N L
MPMP
VPMP
PRG
RLO
DF
MREL
+B
WCOOLING FAN CONTROL
COOLING FAN RELAY No.1
COOLING FAN RELAY No.2
COOLING FAN RELAY No.3
EVAPORATIVE EMISSION
CONTROL
CANISTER PUMP MODULE
LEAK DETECTION PUMP
VENT VALVE
GENERATOR
MAIN RELAY
COMBINATION METER
MIL
PURGE VSV
: CANEG-33
*: Models with Engine Immobilizer System

ENGINE - 2AZ-FE ENGINE
01NEG09Y
01NEG10Y
Air
Conditioning
ECU
Engine Coolant
Temperature SensorFANL
ECM
FA N HCooling Fan
Relay No.3
Cooling Fan
Motor No.2
Cooling Fan
Relay No.1
Cooling Fan
Motor No.1
Low Speed (Series Connection)
High Speed (Parallel Connection) Air
Conditioning
ECU
Engine Coolant
Temperature SensorFA N L
ECM
FA N HCooling Fan
Relay No.3
Cooling Fan
Motor No.2
Cooling Fan
Relay No.1
Cooling Fan
Relay No.2
Cooling Fan
Motor No.1 : CAN
Cooling Fan
Relay No.2
EG-52
8. Cooling Fan Control
On the models with air conditioning, the ECM controls the operation of the cooling fan in two speeds (Low
and High) based on the engine coolant temperature sensor signal and the air conditioning ECU signal. This
control is accomplished by operating the 2 fan motors in 2 stages through low speed (series connection) and
high speed (parallel connection).
Wiring Diagram
Cooling Fan Operation
Air Conditioning ConditionEngine Coolant Temperature C (F)
A / C CompressorRefrigerant Pressure94 (201.2) or lower95.5 (203.9) or higher
OFF1.2 MPa (12.5 kgf / cm2, 178 psi) or lowerOFFHigh
ON1.2 MPa (12.5 kgf / cm2, 178 psi) or lowerLowHighON1.2 MPa (12.5 kgf / cm2, 178 psi) or higherHighHigh

ENGINE - 2GR-FE ENGINE
01MEG38Y
Water Pump Pulley
Crankshaft Pulley
Air Conditioning
Compressor PulleyIdler Pulley for
Automatic
Te n s i o n e rGenerator Pulley Belt Idler
285EG78
Idler
PulleySpring
Arm
BracketBelt Pulling
Direction
Belt Tension
Direction
Fulcrum
Cross Section EG-98
STARTING SYSTEM
The 2GR-FE engine uses the same starter as the 2AZ-FE engine. For details, see page EG-27.
SERPENTINE BELT DRIVE SYSTEM
1. General
Accessory components are driven by a serpentine belt consisting of a single V-ribbed belt. It reduces the
overall engine length, weight and the number of engine parts.
An automatic tensioner eliminates the need for tension adjustment.
2. Automatic Tensioner
The tension of the V-ribbed belt is properly maintained by the tension spring that is enclosed in the automatic
tensioner.

ENGINE - 2GR-FE ENGINEEG-101
ENGINE CONTROL SYSTEM
1. General
The engine control system of the 2GR-FE engine has the following features.
System
Outline
SFI
(Sequential Multiport
Fuel Injection)
[See page EG-117]
An L-type SFI system detects the intake air mass with a hot-wire type air
flow meter.
ESA
(Electronic Spark
Advance)
Ignition timing is determined by the ECM based on signals from various
sensors. The ECM corrects ignition timing in response to engine
knocking.
This system selects the optimal ignition timing in accordance with the
signals received from the sensors and sends the (IGT) ignition signal to
the igniter.
ETCS-i
(Electronic Throttle
Control
System-intelligent)
[See page EG-118]
Optimally controls the throttle valve opening in accordance with the amount
of accelerator pedal effort and the condition of the engine and the vehicle.
Dual VVT-i
(Variable Valve
Timing-intelligent)
System
[See page EG-120]
Controls the intake and exhaust camshafts to an optimal valve timing in
accordance with the engine condition.
ACIS
(Acoustic Control
Induction System)
[See page EG-126]The intake air passages are switched according to the engine speed and
throttle valve opening angle to provided high performance in all speed
ranges.
Air Intake Control
System
[See page EG-128]The intake air duct is divided into two areas, and the ECM controls the air
intake control valve and the actuator that are provided in one of the areas to
reduce the amount of engine noise.
Fuel Pump Control
[See page EG-53 in
2AZ-FE section]Fuel pump operation is controlled by signals from the ECM.
The fuel pump is stopped, when the SRS airbag is deployed in a frontal,
side, and rear side collision.
Air Conditioning Cut-off
ControlBy turning the air conditioning compressor ON or OFF in accordance with
the engine condition, drivability is maintained.
Charging Control
[See page EG-65 in
2AZ-FE section]The engine ECU regulates the charging voltage of the generator in
accordance with the driving conditions and the charging state of the battery.
Cooling Fan Control
[See page EG-129]
The cooling fan ECU steplessly controls the speed of the fans in accordance
with the engine coolant temperature, vehicle speed, engine speed, and air
conditioning operating conditions. As a result, the cooling performance is
improved.
(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
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