ignition 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
165EG25
Camshaft
Position
Sensor
Crankshaft
Position
Sensor
Va r i o u s
SensorG2
NE
ECMIGT1
IGT2
IGT3
IGT4
IGF+BIgnition Coil
(with Igniter)
No.1 Cylinder
No.2 Cylinder
No.3 Cylinder
No.4 Cylinder
185EG38
0.7 mm
(0.028 in.)
Iridium Tip EG-24
IGNITION SYSTEM
1. General
A DIS (Direct Ignition System) is used. The DIS improves the ignition timing accuracy, reduces
high-voltage loss, and enhances the overall reliability of the ignition system by eliminating the distributor.
The DIS in this engine is an independent ignition system which has one ignition coil (with igniter) for each
cylinder.
Iridium-tipped spark plugs are used.
2. Spark Plug
Iridium-tipped spark plugs are used to improve ignition performance while maintaining the same durability
of the platinum-tipped spark plugs.
Specifications
DENSOSK20R11
NGKIFR6A11
Plug Gap1.0 - 1.1 mm
(0.039 - 0.043 in.)

ENGINE - 2AZ-FE ENGINE
01NEG45Y
RegulatorB
M
IG
RLO
L
Ignition Switch
To Discharge
Wa r n i n g L i g h t
Generator
ECM
281EG13
281EG12
Coil SpringPulley
Helical Coil Type One-way Clutch EG-26
Wiring Diagram
2. Generator Pulley
A helical coil type one-way clutch is used on the generator pulley in order to reduce the load that acts on
the auxiliary equipment belt.
The pulley mounting nut and the generator pulley have been integrated to achieve a compact construction.

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 ENGINEEG-31
System
Outline
Engine
Immobilizer*
2
Prohibits fuel delivery and ignition if an attempt is made to start the engine with
an invalid ignition key.
Diagnosis
(See page EG-67)When the ECM detects a malfunction, the ECM diagnoses and memorizes the
failed section.
Fail-safe
(See page EG-67)When the ECM detects a malfunction, the ECM stops or controls the engine
according to the data already stored in memory.
*2: Models with Engine Immobilizer System

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
01MEG31Y
DLC3
Accelerator Pedal
Position Sensor
Mass Air Flow Meter
(Built-in Intake Air
Temperature Sensor)
VSV (for EVAP)
Battery Current
Sensor
Fuel Pump
Canister Pump Module
Ve n t Va l v e
Leak Detection Pump
Canister Pressure Sensor
ECM
Heated Oxygen Sensor
(Bank 1, Sensor 2) Air Fuel Ratio Sensor
(Bank 1, Sensor 1)
Camshaft Timing
Oil Control ValveInjectorKnock Sensor
Ignition Coil with Igniter
Throttle Position
Sensor
Camshaft Position
Sensor
Water Temperature
Sensor
Crakshaft Position
SensorEG-35
4. Layout of Main Components

ENGINE - 2AZ-FE ENGINE
214CE04
: Conventional Type
: Flat Type
(V)
Vo l t a g e
Frequency (Hz)A
BA: Detection Band of
Conventional Type
B: Detection Band of
Flat Type
Characteristic of Knock Sensor
214CE01214CE02
Steel Weight
Insulator
Piezoelectric
ElementOpen / Short Circuit
Detection Resistor
Flat Type Knock Sensor
(Non-resonant Type)Piezoelectric
Element
Vibration Plate
Conventional Type Knock Sensor
(Resonant Type)EG-39
Knock Sensor (Flat Type)
1) General
In the conventional type knock sensor (resonant type), a vibration plate which has the same resonance
point as the knocking frequency of the engine is built in and can detect the vibration in this frequency
band.
On the other hand, a flat type knock sensor (non-resonant type) has the ability to detect vibration in a
wider frequency band from about 6 kHz to 15 kHz, and has the following features.
The engine knocking frequency will change a bit depending on the engine speed. The flat type knock
sensor can detect the vibration even when the engine knocking frequency is changed. Thus the
vibration detection ability is increased compared to the conventional type knock sensor, and a more
precise ignition timing control is possible.
2) Construction
The flat type knock sensor is installed on the engine through the stud bolt installed on the cylinder
block. For this reason, a hole for the stud bolt is running through the center of the sensor.
Inside of the sensor, a steel weight is located on the upper portion and a piezoelectric element is located
under the weight through the insulator.
The open / short circuit detection resistor is integrated.

ENGINE - 2AZ-FE ENGINE
214CE08
Steel Weight
Inertia
Piezoelectric
Element
214CE06
Knock Sensor
200 k
Piezoelectric
ElementOpen / Short Circuit
Detection ResistorKNK1
EKNKECM
5 V
200 k
IC
Service Tip
In accordance with the adoption of an open / short circuit detection resistor, the inspection
method for the sensor has been changed. For details, refer to the 2006 RAV4 Repair Manual
(Pub. No. RM01M1U).
To prevent the water accumulation in the connecter, make sure to install the flat type knock
sensor in the position as shown in the following illustration.
251EG12
10
10
Knock Sensor EG-40
3) Operation
The knocking vibration is transmitted to the
steel weight and its inertia applies pressure to
the piezoelectric element. The action
generates electromotive force.
4) Open / Short Circuit Detection Resistor
While the ignition is ON, the open / short circuit detection resistor in the knock sensor and the resistor
in the ECM keep constant the voltage at the terminal KNK1 of engine.
An IC (Integrated Circuit) in the ECM is always monitoring the voltage of the terminal KNK1. If the
open / short circuit occurs between the knock sensor and the ECM, the voltage of the terminal KNK1 will
change and the ECM detects the open / short circuit and stores DTC (Diagnostic Trouble Code).