head TOYOTA RAV4 2006 Service Repair Manual

ENGINE - 2AZ-FE ENGINE EG-4
FEATURES OF 2AZ-FE ENGINE
The 2AZ-FE engine has achieved the following performance through the use of the items listed below.
(1) High performance and reliability
(2) Low noise and vibration
(3) Lightweight and compact design
(4) Good serviceability
(5) Clean emission and fuel economy
Section
Item(1)(2)(3)(4)(5)
Engine
A cylinder block made of aluminum alloy along with a
magnesium alloy die-cast cylinder head cover is used.
Engine
ProperA taper squish shape is used for the combustion chamber.p
A resin gear balance shaft is used.
Vl
A timing chain and chain tensioner are used.
Va l v e
MechanismThe shim-less type valve lifters are used.MechanismThe VVT-i system is used.
A chacoal filter is used in the air cleaner cap.
Intake andIntake manifold made of plastic is used.Intake and
ExhaustThe linkless-type throttle body is used.
SystemA thin-wall ceramic TWC (Three-Way Catalytic converter)
is used.
The fuel returnless system is used.
Fuel
System
Quick connectors are used to connect the fuel hose with the
fuel pipe.
System12-hole type fuel injectors with high atomizing performance
are used.
Ignition
SystemIridium-tipped spark plugs are used.
Charging
SystemThe segment conductor type generator is used.
Starting
SystemPS (Planetary reduction-Segment conductor motor) type
starter is used.
The ETCS-i is used.
Engine
Control
The DIS (Direct Ignition System) makes ignition timing
adjustment unnecessary.
Control
SystemThe non-contact type sensor is used in the throttle position
sensor.
The planar type air-fuel ratio sensor is used.

ENGINE - 2AZ-FE ENGINE
DR011EG20
Cylinder Head Cover
Cylinder Head Cover Gasket
02AEG02Y 02AEG01Y
Cylinder
Bore Side
FrontOuter
Side
Shim A
A
A - A Cross SectionEG-5
ENGINE PROPER
1. Cylinder Head Cover
A lightweight magnesium alloy die-cast
cylinder head cover is used.
Acrylic rubber, which excels in heat resistance
and reliability, is used for the cylinder head
cover gasket.
2. Cylinder Head Gasket
A steel-laminate type cylinder head gasket is used. A shim has been added around the cylinder bore to
increase the sealing surface, thus improving the sealing performance and durability.

ENGINE - 2AZ-FE ENGINE
208EG67 DR011EG21
Exhaust Side
Intake Side A A
A - A Cross Section Injector
IN
EX
Bypass
Passage
Ta p e r S q u i s h EG-6
3. Cylinder Head
Through the adoption of the taper squish combustion chamber, the engine knocking resistance and fuel
efficiency have been improved.
An upright intake port is used to improve the intake efficiency.
Installing the injectors in the cylinder head enables the injectors inject fuel as close as possible to the
combustion chamber. This prevents the fuel from adhering to the intake port walls, which reduces HC
exhaust emissions.
The routing of the water jacket in the cylinder head has been optimized to realize the high cooling
performance. In addition, a water bypass passage has been provided below the exhaust ports to reduce the
number of parts and the weight.

ENGINE - 2AZ-FE ENGINE
01MEG01Y
Taper Squish Shape : Resin Coating
240EG45
Plastic Region Tightening BoltsEG-9
5. Piston
The piston is made of aluminum alloy and skirt area is made compact and lightweight.
The piston head portion uses a taper squish shape to improve the fuel combustion efficiency.
The piston skirt has been coated with resin to reduce the friction loss.
6. Connecting Rod
The connecting rods and caps are made of
high-strength steel for weight reduction.
Nut-less type plastic region tightening bolts are
used on the connecting rod for a lighter design.
The connecting rod bearings are reduced in
width to reduce friction.

ENGINE - 2AZ-FE ENGINE
208EG07
VVT-i Controller
Camshaft Timing
Oil Control Valve
Oil Return
Hole
Oil PumpOil Filter Chain
Te n s i o n e r
01NEG33Y
Bypass
Va l v e
Relief
Va l v eMain Oil Hole
Oil Filter
Oil Pump
Oil StrainerChain
Te n s i o n e rCylinder Head
Exhaust
Camshaft
Journal
Oil Control
Va l v e
VVT-i Controller
Oil Pan
Intake
Camshaft
Journal
Crankshaft
Journal
Crankshaft
Pin
Oil Jet
Piston
Cylinder
Block
Barance
Shaft
Timing
Chain EG-14
LUBRICATION SYSTEM
1. General
The lubrication circuit is fully pressurized and oil passes through an oil filter.
The trochoid gear type oil pump is chain-driven by the crankshaft.
The oil filter is attached downward from the crankcase to improve serviceability.
Along with the adoption of the VVT-i system, the cylinder head is provided with a VVT-i controller and
a camshaft timing oil control valve. This system is operated by the engine oil.
Oil Circuit

ENGINE - 2AZ-FE ENGINE
01NEG35Y
Throttle Body
To H e a t e r C o r e
To R a d i a t o r
Thermostat
From Radiator Wa t e r P u m pBypass Passage
01NEG59Y
Bypass PassageCylinder Head
Wa t e r P u m p
Cylinder Block
Thermostat
Reservoir
Ta n k
RadiatorThrottle
BodyHeater Core EG-16
COOLING SYSTEM
The cooling system uses a pressurized forced-circulation system with pressurized reservoir tank.
A thermostat with a bypass valve is located on the water inlet housing to maintain suitable temperature
distribution in the cooling system.
An aluminum radiator core is used for weight reduction.
The flow of the engine coolant makes a U-turn in the cylinder block to ensure a smooth flow of the engine
coolant. In addition, a bypass passage is enclosed in the cylinder head and the cylinder block.
Warm water from the engine is sent to the throttle body to prevent freeze-up.
The TOYOTA genuine Super Long Life Coolant (SLLC) is used.
System Diagram

ENGINE - 2AZ-FE ENGINE
01NEG37Y
Mesh Type Gasket
01NEG38Y
TWC EG-20
4. Intake Manifold
The intake manifold has been made of plastic to reduce the weight and the amount of heat transferred from
the cylinder head. As a result, it has become possible to reduce the intake air temperature and improve the
intake volumetric efficiency.
A mesh type gasket is used, in order to reduce the intake noise.
5. Exhaust Manifold
A stainless steel exhaust manifold is used for improving the warm-up of TWC (Three-Way Catalytic
converter) and for weight reduction.

ENGINE - 2GR-FE ENGINEEG-71
FEATURES OF 2GR-FE ENGINE
The 2GR-FE engine has achieved the following performance through the use of the items listed below.
(1) High performance and reliability
(2) Low noise and vibration
(3) Lightweight and compact design
(4) Good serviceability
(5) Clean emission and fuel economy
Item
(1)(2)(3)(4)(5)
A steel laminate type cylinder head gasket is used.
An upright intake port is used.
EngineA taper squish shape is used for combustion chamber.Engine
ProperA cylinder block made of aluminum alloy is used.Proper
The skirt portion of the piston is applied with resin to
reduce friction.
An oil pan No. 1 made of aluminum alloy is used.
The Dual VVT-i (Variable Valve Timing-intelligent)
system is used.
Va l v e
Mh i
Hydraulic lash adjusters are used.
MechanismTiming chains and chain tensioners are used.
Roller rocker arms are used.
Lubrication
SystemAn oil filter with a replaceable element is used.
Cooling SystemThe TOYOTA Genuine SLLC (Super Long Life Coolant)Cooling SystemThe TOYOTA Genuine SLLC (Super Long Life Coolant)
is used for the engine coolant.
The linkless-type throttle body is used.
Intake andThe intake air chamber made of plastic is used.Intake and
Exhaust
S
A stainless steel exhaust manifold is used.
SystemAn ultra thin-wall, high-cell density ceramic type TWC
(Three-Way Catalytic converter) is used.
The fuel delivery pipe made of plastic is used.
Fuel SystemA compact 12-hole type injector is used.Fuel SystemQuick connectors are used to connect the fuel hose with
the fuel pipe.
Ignition System
The DIS (Direct Ignition System) makes ignition timing
adjustment unnecessary.
Ignition System
The long-reach type spark plugs are used.
(Continued)

ENGINE - 2GR-FE ENGINE
285EG05
Oil Delivery PipeCylinder Head Covers
Cylinder Head
Cover Gaskets
Oil Delivery Pipe
285EG06
Engine
FrontShim A A
For Right Bank
For Left BankA - A Cross SectionEG-73
ENGINE PROPER
1. Cylinder Head Cover
Lightweight yet high-strength aluminum cylinder head covers are used.
An oil delivery pipe is installed inside the cylinder head cover. This ensures lubrication to the sliding parts
of the roller rocker arm, improving reliability.
2. Cylinder Head Gasket
A steel-laminate type cylinder head gasket is used. A shim is used around the cylinder bore of the gasket to
help enhance sealing performance and durability.

ENGINE - 2GR-FE ENGINE
285EG08 285EG07
Intake
Va l v e
Spark
Plug
Hole
Exhaust
Va l v eIntake Side
Exhaust SideCamshaft Housing
Exhaust
SideIntake
Side
Upright
Intake Port
Taper Squish A
A
View from Back Side A - A Cross Section
215EG19 215EG18
Siamese Type Independent Type EG-74
3. Cylinder Head
The cylinder head structure has been simplified by separating the cam journal portion (camshaft housing)
from the cylinder head.
The cylinder head, which is made of aluminum, contains a pentroof-type combustion chamber. The spark
plug is located in the center of the combustion chamber in order to improve the engine’s anti-knocking
performance.
The intake ports are on the inside and the exhaust ports are on the outside of the left and right banks
respectively.
Upright intake ports are used to improve the intake efficiency.
A taper squish combustion chamber is used to improve anti-knocking performance and intake efficiency.
In addition, engine performance and fuel economy have been improved.
The siamese type intake port is used to reduce the overall surface area of the intake port walls. This
prevents the fuel from adhering onto the intake port walls, thus reducing HC exhaust emissions.
— REFERENCE —