fuel pump circuit TOYOTA RAV4 2006 Service Repair Manual

ENGINE - 2AZ-FE ENGINE
185EG16
Pulsation
Dumper
Pressure Regulator
Fuel Pump
AssemblyFuel Tank
Fuel Filter
Fuel Pump
DR011EG18
EG-23
2. Fuel Returnless System
Fuel returnless 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 Injector
The 12-hole type injector is used. By modifying its
injector nozzle to a taper shape, this injector has
achieved high atomizing performance of fuel. In
addition, the injector provides good performance
with the lightweight moving parts and the
optimized magnetic circuit.

ENGINE - 2AZ-FE ENGINE
01MEG04Y
SENSORSACTUATORS
MASS AIR FLOW METER
INTAKE AIR TEMPERATURE
SENSOR
ENGIEN COOLANT
TEMPERATURE SENSOR
THROTTLE POSITION
SENSOR
CRANKSHAFT POSITION
SENSOR
CAMSHAFT POSITION
SENSOR
ACCELERATOR PEDAL
POSITION SENSOR
AIR-FUEL RATIO SENSOR
(Bank 1, Sensor 1)
HEATED OXYGEN SENSOR
(Bank 1, Sensor 2)
KNOCK SENSOR
COMBINATION METER
Vehicle Speed Signal
IGNITION SWITCH
Ignition Signal
Starter Signal
PA R K / N E U T R A L P O S I T I O N
SWITCH
TRANSMISSION CONTROL
SWITCH
CRUISE CONTROL SWITCHVG
THA
THW
VTA1
VTA2
NE
G2
VPA
VPA2
A1A
OX1B
KNK1
SPD
IGSW
STA
D, 2, L
R, P, N
3
CCSECM#10
#20
#30
#40
IGT1 IGT4
IGF1
M
OC1
FC
HA1A
HT1BSFI
No.1 INJECTOR
No.2 INJECTOR
No.3 INJECTOR
No.4 INJECTOR
ESA
IGNITION COIL
with IGNITER
SPARK PLUGS
ETCS-i
THROTTLE CONTROL
MOTOR
VVT-i
CAMSHAFT TIMING OIL
CONTROL VALVE
FUEL PUMP CONTROL
CIRCUIT OPENING
RELAY
AIR-FUEL RATIO AND
HEATED OXYGEN SENSOR
HEATER CONTROL
AIR-FUEL RATIO SENSOR
HEATER (Bank1, Sensor1)
HEATED OXYGEN SENSOR
HEATER (Bank1, Sensor2)
EG-32
2. Construction
The configuration of the engine control system in the 2AZ-FE engine is shown in the following chart.
(Continued)

ENGINE - 2AZ-FE ENGINE
01MEG09Y
Accelerator Pedal
Position Sensor
Generator
MIL
DLC3Park / Neutral
Position Switch
Ignition
Switch
Circuit Opening RelayECM
Battery
Throttle
Position
Sensor
Throttle
Control
Motor
Purge VSVMass Air Flow Meter
Intake Air Temperature
Sensor
Camshaft Position
Sensor
Camshaft
Timing
Oil Control
Va l v e
Ignition Coil
with Igniter
Injector
Knock Sensor
Engine
Coolant
Temperature
Sensor
Crankshaft Position
Sensor
Canister
Filter
Fuel Pump
Canister Pump Module
Ve n t Va l v e
Leak Detection Pump
Canister Pressure SensorTWCs
Heated Oxygen Sensor
(Bank 1, Sensor 2)
Air-fuel Ratio Sensor
(Bank 1, Sensor 1) EG-34
3. Engine Control System Diagram

ENGINE - 2AZ-FE ENGINE
00REG18Y
Front Airbag
Sensor
(RH and LH)
Curtain Shield
Airbag Sensor*
(RH and LH)Airbag
Sensor
Side Airbag
Sensor*
(RH or LH)ECMCircuit
Opening
Relay
Fuel
Pump
Motor
: CANEG-53
9. Fuel Pump Control
A fuel cut control is used to stop the fuel pump when the SRS airbag is deployed at the front collision. In this
system, the airbag deployment signal from the airbag sensor is detected by the ECM, which turns OFF the
circuit opening relay.
After the fuel cut control has been activated, turning the ignition switch from OFF to ON cancels the fuel cut
control, and the engine can be restarted.
*: Models with SRS Driver, Front Passenger, Side and Curtain Shield Airbags

ENGINE - 2GR-FE ENGINE
01MEG06Y
COMBINATION METER
Vehicle Speed Signal
AIR-FUEL RATIO SENSOR
Bank 1, Sensor 1
Bank 2, Sensor 1
HEATED OXYGEN SENSOR
Bank 1, Sensor 2
Bank 2, Sensor 2
CANISTER PUMP MODULE
CANISTER PRESSURE
SENSOR
PARK / NEUTRAL POSITION
SWITCH
TRANSMISSION CONTROL
SWITCH
TRANSPONDER KEY ECU
GENERATOR
BATTERY CURRENT SENSOR
(BUILT-IN BATTERY
TEMPERATURE SENSOR)
WIPER CONTROL SWITCHSPD
A1A
A2A
OX1B
OX2B
PPMP
STA
P, R, N, D
4, L
IMI
IMO
DF
THB VCIB
INHECMACIS
AICV
FC
FPR
HA1A
HA2A
HT1B
HT2B
RLOACIS
ACIS ACTUATOR
AIR INTAKE CONTROL
SYSTEM
VSV
FUEL PUMP CONTROL
CIRCUIT OPENING RELAY
FUEL PUMP RELAY
AIR-FUEL RATIO SENSOR
HEATER CONTROL
AIR-FUEL RATIO SENSOR
HEATER
Bank 1, Sensor 1
Bank 2, Sensor 1
HEATED OXYGEN SENSOR
HEATER CONTROL
HEATED OXYGEN SENSOR
HEATER
Bank 1, Sensor 2
Bank 2, Sensor 2
CHARGING CONTROL
GENERATOR EG-104
(Continued)

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

FU–62AZ-FE FUEL – FUEL SYSTEM
FU
ON-VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION
(a) Connect the intelligent tester to the DLC3.
(b) Turn the ignition switch ON. Do not start the engine.
(c) Select the following tester menus: DIAGNOSIS,
ENHANCED OBD II, ACTIVE TEST and FUEL
PUMP/SPD. Operate the fuel pump.
(d) Touch the fuel hose in the engine compartment to
check the fuel flow, and you will be able to hear the
sound of the fuel pump.
(e) Stop the fuel pump.
If there is no fuel flow, the fuel pump may not
operate. Check the fuel pump circuit (see page FU-
33).
2. CHECK FUEL PRESSURE
(a) Check that the battery positive voltage is above 12
V.
(b) Discharge the fuel system pressure (see page FU-
9).
(c) Disconnect the cable from the negative (-) battery
terminal.
(d) Disconnect the fuel main tube (see page FU-10).
(e) Install SST (pressure gauge) as shown in the
illustration.
SST 09268-31011 (95336-08070, 90467-13001,
09268-41500), 09268-45014 (09268-41200,
09268-41220, 09268-41250)
(f) Wipe off any gasoline.
(g) Reconnect the cable to the negative (-) battery
terminal.
(h) Start the engine.
(i) Measure the fuel pressure at idle.
Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
If the pressure is not as specified, check the fuel
pump and injectors.
(j) After checking the fuel pressure, disconnect the
cable from the negative (-) battery terminal and
carefully remove SST and the fuel tube connector to
prevent fuel from spilling.
(k) Reconnect the fuel main tube (see page FU-14).
(l) Check for fuel leaks (see page FU-14).
B127989E01
A088229E05

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 -