compression TOYOTA RAV4 2006 Service Repair Manual

ENGINE - 2AZ-FE ENGINE
01MEG02Y
Valve Timing : Intake Valve Opening Angle
: Exhaust Valve Opening Angle
VVT-i Operation
Range
VVT-i Operation
RangeTDC
3
3
43
65
25
45
BDCEG-3
Engine Specifications
No. of Cyls. & Arrangement4-cylinder, In-line
Valve Mechanism16-valve DOHC, Chain Drive (with VVT-i)
Combustion ChamberPentroof Type
ManifoldsCross-flow
Fuel SystemSFI
Ignition SystemDIS
Displacement cm3 (cu. in.)2362 (144.1)
Bore x Stroke mm (in.)88.5 x 96.0 (3.48 x 3.78)
Compression Ratio9.8 : 1
Max. Output*1(SAE-NET)124 kW @ 6000 rpm (166 HP @ 6000 rpm)
Max. Torque*1(SAE-NET)224 N.m @ 4000 rpm (165 ft-lbf @ 4000 rpm)
IntakeOpen3 - 43 BTDC
Valve Timing
IntakeClose65 - 25 ABDCVa l v e T i m i n g
ExhaustOpen45 BBDCExhaustClose3 ATDC
Firing Order1 - 3 - 4 - 2
Research Octane Number91 or higher
Octane Rating87 or higher
Oil GradeILSAC
Tailpipe Emission RegulationULEV-II, SFTP
Evaporative Emission RegulationLEV-II, ORVR
Engine Service Mass*2 (Reference) kg (lb)138 (304.2)
*1: Maximum output and torque rating is determined by revised SAE J1349 standard.
*
2: Weight shows the figure with oil and water fully filled.

ENGINE - 2GR-FE ENGINEEG-69
Engine Specifications
No. of Cyls. & Arrangement6-cylinder, V Type
Valve Mechanism24-valve DOHC, Chain Drive (with Dual VVT-i)
Combustion ChamberPentroof-type
ManifoldsParallel-flow
Fuel SystemSFI
Ignition SystemDIS
Displacement cm3
(cu. in.)3456 (210.9)
Bore x Stroke mm (in.)94.0 x 83.0 (3.70 x 3.27)
Compression Ratio10.8 : 1
Max. Output (SAE-NET)*1201 kW @ 6200 rpm (269 HP @ 6200 rpm)
Max. Torque (SAE-NET)*1333 N.m @ 4700 rpm (247 ft.lbf @ 4700 rpm)
Intake ValveOpen-3 to 37 BTDC
Valve Timing
Intake ValveClose71 to 31 ABDCVa l v e T i m i n g
Exhaust ValveOpen60 to 25 BBDCExhaust ValveClose4 to 39 ATDC
Firing Order1 - 2 - 3 - 4 - 5 - 6
Octane Rating91 or higher
Engine Oil GradeILSAC multigrade engine oil
CaliforniaULEVII, SFTP
EmissionTailpipeExceptTier2 Bin5 SFTPEmission
Regulation
ppExcept
CaliforniaTier2-Bin5, SFTPg
EvaporativeLEVII, ORVR
Engine Service Mass*2 (Reference) kg (lb)163 (359)
*1: Maximum output and torque rating is determined by revised SAE J1349 standard.
*
2: Weight shows the figure with the oil and engine coolant fully filled.

EX–42AZ-FE EXHAUST – EXHAUST PIPE
EX
(b) Remove the gasket from the exhaust manifold.
INSTALLATION
1. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Using a vernier caliper, measure the free length of
the compression spring.
Minimum length:
41.5 mm (1.634 in.)
If the length is less than the minimum, replace the
compression spring.
(b) Install a new gasket by hand so that its surface is
flush with the exhaust manifold.
NOTICE:
• Make sure the gasket is facing the correct
direction.
• Do not reuse the removed gasket.
• Do not push in the gasket while installing the
front exhaust pipe.
(c) Install the front exhaust pipe with the 2 compression
springs and 2 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
A126831
A077857E03
A133205E01

EX–62AZ-FE EXHAUST – EXHAUST PIPE
EX
3. INSTALL TAILPIPE ASSEMBLY
(a) Using a vernier caliper, measure the free length of
the compression spring.
Minimum length:
38.5 mm (1.516 in.)
If the length is less than the minimum, replace the
compression spring.
(b) Install a new gasket by hand so that its surface is
flush with the center exhaust pipe.
NOTICE:
• Make sure the gasket is facing the correct
direction.
• Do not reuse the removed gasket.
• Do not push in the gasket while installing the
tailpipe.
(c) Connect the 2 exhaust pipe supports, and install the
tailpipe.
(d) Install the 2 compression springs and 2 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
4. INSTALL HEATED OXYGEN SENSOR (for Bank 1
Sensor 2) (See page EC-24)
5. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
6. CHECK FOR EXHAUST GAS LEAKS
If gas is leaking, tighten the areas necessary to stop the
leak. Replace damaged parts as necessary.
A077857E03
A133205E01
A126834

2GR-FE EXHAUST – EXHAUST PIPEEX–5
EX
4. INSTALL TAILPIPE ASSEMBLY
(a) Using a vernier caliper, measure the free length of
the compression spring.
Minimum length:
38.5 mm (1.516 in.)
If the length is less than the minimum, replace the
compression spring.
(b) Install a new gasket by hand so that its surface is
flush with the center exhaust pipe.
NOTICE:
• Tap in the gasket in the correct direction.
• Do not reuse the removed gasket.
• Do not push in the gasket while installing the
tailpipe.
(c) Connect the 2 exhaust pipe supports, and install the
tailpipe.
(d) Install the 2 compression springs and 2 bolts.
Torque: 43 N*m (440 kgf*cm, 32 ft.*lbf)
A132426
A077857E03
A076194E10

PP–10PREPARATION – 2GR-FE ENGINE MECHANICAL
PP
EQUIPMENT
Alignment tester -
Angle gauge -
Brass bar -
Caliper gauge -
Chain block -
Compression gauge -
CO/HC meter -
Connecting rod aligner -
Cylinder gauge -
Dial indicator with magnetic base -
Engine stand -
Feeler gauge -
Gasket scraper -
Magnetic finger -
Micrometer -
Needle-nose pliers -
No. 1 engine hanger -
No. 2 engine hanger -
Pin hole grinder -
Piston ring compressor -
Piston ring expander -
Piston heater -
Plastigage -
Plastic-faced hammer -
Press -
Radiator cap tester -
Reamer (5.5 mm) -
Ridge reamer -
Rod aligner -
Sandpaper (#400) -
Slide calipers -
Straightedge -
Spring scale -
Spring tension gauge -
Steel square -
Tachometer -
Timing light -
Toe-in gauge -
To r q u e w r e n c h -
Valve seat cutter -
V-block -
Vernier calipers -
Vise -
Wooden block -

2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEMES–29
ES
PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help determine the cause of the
problem symptom. The potential causes of the symptoms are
listed in order of probability in the "Suspected area" column of
the table. Check each symptom by checking the suspected
areas in the order they are listed. Replace parts as
necessary.
SFI system
Symptom Suspected area See page
Engine does not crank (Does not start)1. BatteryCH-4
2. StarterST-8
3. Starter relayST-16
4. Park/neutral position switchAX-108
5. Immobiliser systemEI-3
No initial combustion (Does not start)1. ECM power source circuitES-366
2. Crankshaft position sensorES-402
3. Camshaft position sensorES-399
4. Ignition systemIG-4
5. Fuel pump control circuitES-378
6. ECMES-26
7. VC output circuitES-373
Engine cranks normally but difficult to start1. Fuel pump control circuitES-378
2. CompressionEM-3
Difficult to start with cold engine1. Ignition systemIG-4
2. Spark plugIG-7
3. Fuel pump control circuitES-378
4. InjectorFU-11
Difficult to start with warm engine1. InjectorFU-11
2. Ignition systemIG-4
3. Spark plugIG-7
4. Fuel pump control circuitES-378
High engine idle speed1. Electronic throttle control systemES-265
2. A/C signal circuit -
3. ECM power source circuitES-366
Low engine idle speed (Poor idling)1. Electronic throttle control systemES-265
2. A/C signal circuit -
3. Fuel pump control circuitES-378
4. Air induction systemEC-7
5. PCV hoseEC-7
Rough idling1. CompressionEM-3
2. Spark plugIG-7
3. InjectorFU-11
4. Ignition systemIG-4
5. Fuel pump control circuitES-378
6. Electronic throttle control systemES-265
7. Air induction systemEC-7
8. PCV hoseEC-7
9. Mass air flow meterES-391

ES–302AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM
ES
Idle hunting1. Electronic throttle control systemES-265
2. Air induction systemEC-7
3. ECM power source circuitES-366
Hesitation/Poor acceleration1. Fuel pump control circuitES-378
2. Spark plugIG-7
3. Ignition systemIG-4
4. InjectorFU-11
5. Mass air flow meterES-391
6. Electronic throttle control systemES-265
7. Air induction systemEC-7
8. CompressionEM-3
Surging (Poor driveability)1. Spark plugIG-7
2. Fuel pump control circuitES-378
3. Ignition systemIG-4
4. InjectorFU-11
5. Mass air flow meterES-391
6. Variable valve timing systemES-66
7. CompressionEM-3
Engine stalls soon after starting1. Fuel pump control circuitES-378
2. Spark plugIG-7
3. Ignition systemIG-4
4. InjectorFU-11
5. Variable valve timing systemES-66
6. Electronic throttle control systemES-265
7. Air induction systemEC-7
8. PCV hoseEC-7
9. CompressionEM-3
Engine stalls only during A/C operation1. A/C signal circuit -
2. ECMES-26
Unable/difficult to refuel 1. Refueling valve (canister) - Symptom Suspected area See page

ES–322GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM
ES
PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help determine the cause of the
problem symptom. The potential causes of the symptoms are
listed in order of probability in the "Suspected area" column of
the table. Check each symptom by checking the suspected
areas in the order they are listed. Replace parts as
necessary.
Symptom Suspected area See page
Engine does not crank (Does not start)1. BatteryCH-5
2. StarterST-8
3. Starter relayST-16
4. Park/neutral position switchAX-132
5. Immobiliser systemEI-3
No initial combustion (Does not start)1. ECM power source circuitES-402
2. Crankshaft position sensorES-448
3. VVT sensorES-214
4. Ignition systemIG-5
5. Fuel pump control circuitES-414
6. ECMES-470
7. VC output circuitES-408
Engine cranks normally but difficult to start1. Fuel pump control circuitES-414
2. CompressionEM-3
Difficult to start with cold engine1. Ignition systemIG-5
2. Spark plugIG-7
3. Fuel pump control circuitES-414
4. InjectorFU-15
Difficult to start with warm engine1. InjectorFU-15
2. Ignition systemIG-5
3. Spark plugIG-7
4. Fuel pump control circuitES-414
High engine idle speed1. Electronic throttle control systemES-311
2. A/C signal circuit -
3. ECM power source circuitES-402
4. Acoustic Control Induction System (ACIS)ES-423
Low engine idle speed (Poor idling)1. Electronic throttle control systemES-311
2. A/C signal circuit -
3. Fuel pump control circuitES-414
4. Air induction systemIT-5
5. Acoustic Control Induction System (ACIS)ES-423
6. PCV hose -

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEMES–33
ES
Rough idling1. CompressionEM-3
2. Spark plugIG-7
3. InjectorFU-15
4. Ignition systemIG-5
5. Fuel pump control circuitES-414
6. Electronic throttle control systemES-311
7. Air induction systemIT-5
8. Acoustic Control Induction System (ACIS)ES-423
9. PCV hose -
10. Mass air flow meterES-435
Idle hunting1. Electronic throttle control systemES-311
2. Air induction systemIT-5
3. ECM power source circuitES-402
4. Acoustic Control Induction System (ACIS)ES-423
Hesitation/Poor acceleration1. Fuel pump control circuitES-414
2. Spark plugIG-7
3. Ignition systemIG-5
4. InjectorFU-15
5. Mass air flow meterES-435
6. Electronic throttle control systemES-311
7. Air induction systemIT-5
8. CompressionEM-3
9. Air Intake Control System (AICS)ES-426
Surging (Poor driveability)1. Spark plugIG-7
2. Fuel pump control circuitES-414
3. Ignition systemIG-5
4. InjectorFU-15
5. Mass air flow meterES-435
6. Variable valve timing systemES-439
7. CompressionEM-3
Engine stalls soon after starting1. Fuel pump control circuitES-414
2. Spark plugIG-7
3. Ignition systemIG-5
4. InjectorFU-15
5. Variable valve timing systemES-439
6. Electronic throttle control systemES-311
7. Air induction systemIT-5
8. PCV hose -
9. CompressionEM-3
Engine stalls only during A/C operation1. A/C signal circuit -
2. ECMES-470
Unable/difficult to refuel 1. Refueling valve (canister) -Symptom Suspected area See page