length TOYOTA RAV4 2006 Service Repair Manual

ENGINE - 2AZ-FE ENGINE
01NEG46Y
ArmatureSurface Commutator
Permanent Magnet
Brush
LengthEG-27
STARTING SYSTEM
1. General
A compact and lightweight PS (Planetary reduction-Segment conductor motor) type starter is used.
Because the PS type starter contains an armature that uses square-shaped conductors, and its surface
functions as a commutator, it has resulted in both improving its output torque and reducing its overall
length.
In place of the field coil used in the conventional type starter, the PS type starter uses two types of
permanent magnets: main magnets and interpolar magnets. The main magnets and interpolar magnets
have been efficiently arranged to increase the magnetic flux and to shorten the length of the yoke.
Specifications
Starter TypePS Type
Rating Output1.7 kW
Rating Voltage12 V
Length*1mm (in.)128 (5.04)
Weight g (lb)2950 (6.50)
Rotational Direction*2Counterclockwise
*1: Length from the mounted area to the rear end of the starter
*
2: Viewed from pinion side

ENGINE - 2AZ-FE ENGINE
206EG20
Conventional Type
A - A
Cross Section
(PS Type)B - B
Cross Section
(Conventional Type)
B
B
A
A Armature
ArmatureBrushCommutator Brush
Surface CommutatorSquare-shaped
ConductorRound-shaped
Conductor
PS Type
222EG15
Main Magnet
Interpolar Magnet
Yo k e
Main Magnet
Armature
Cross Section of YokeMagnetic Flux Generated by
Relationship between Main Magnets
Magnetic Flux Generated
by Interpolar Magnets
N
N
N
S
S
S EG-28
2. Construction
Instead of constructing the armature coil with conventional type round-shaped conductor wires, the PS
type starter uses square conductors. With this type of construction, the same conditions that are realized
by winding numerous round-shaped conductor wires can be achieved without increasing the mass. As a
result, the output torque has been increased, and the armature coil has been made more compact.
Because the surface of the square-shaped conductors that are used in the armature coil functions as a
commutator, the overall length of the PS type starter has been shortened.
Instead of the field coils used in the conventional type starter, the PS type starter uses two types of
permanent magnets: the main magnets and the interpolar magnets. The main and interpolar magnets are
arranged alternately inside the yoke, allowing the magnetic flux that is generated between the main and
interpolar magnets to be added to the magnetic flux that is generated by the main magnets.
In addition to increasing the amount of magnetic flux, this construction shortens the overall length of the
yoke.

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 - 2GR-FE ENGINE
285EG10 285EG09
60
Knock Sensor Bosses
36.6 mm
(1.441 in.)
105.5 mm
(4.15 in.)
View from Top Side
285EG11
Wa t e r P a s s a g eEG-75
4. Cylinder Block
The cylinder block is made of aluminum alloy, so it is lightweight.
The cylinder block has a bank angle of 60, a bank offset of 36.6 mm (1.441 in.) and a bore pitch of 105.5
mm (4.15 in.), resulting in a compact block in its length and width even for its displacement.
Installation bosses of the two knock sensors are located on the inside of left and right banks.
A water passage has been provided between the cylinder bores. By allowing the engine coolant to flow
between the cylinder bores, this construction enables the temperature of the cylinder walls to be kept
uniform.

ENGINE - 2GR-FE ENGINE
285EG33
Intake Air
Control Valve
ACIS ActuatorLaser-welding
285EG34GasketsRubber Coating
Outer SideIntake
Port Side
A
A
A - A Cross Section EG-92
4. Intake Air Chamber
The intake air chamber is made of plastic to realize lightweight.
The intake air chamber contains an intake air control valve. This valve is activated by ACIS (Acoustic
Control Induction System) and is used to alter the intake pipe length to improve the engine performance
in all speed range. For details, see page EG-126.
The ACIS actuator uses an electric actuator and is laser-welded onto the intake air chamber. Many of the
components are made of plastic for weight reduction.
— REFERENCE —
Laser-welding:
In laser-welding, a laser-absorbing material (for the intake air chamber) is joined to a laser-transmitting
material (for the ACIS actuator). Laser beams are then irradiated from the laser-transmitting side. The
beams penetrate the laser-transmitting material to heat and melt the surface of the laser-absorbing material.
Then, the heat of the laser-absorbing material melts the laser-transmitting material and causes both
materials to become welded.
5. Intake Manifold
Lightweight aluminum alloy is used for the intake manifold.
The intake manifold gaskets have rubber coating applied onto surface, and provide superior durability.

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 ENGINE
285EG58
Engine
Speed
ECM
ActuatorThrottle Opening Angle
Throttle Valve
Intake Air Control Valve
285EG64
Intake Air
Control Valve
Actuator EG-126
10. ACIS (Acoustic Control Induction System)
General
The ACIS consists of a bulkhead to divide the intake manifold into 2 stages, and an intake air control valve
in the bulkhead which opens and closes to vary the effective length of the intake manifold in accordance
with the engine speed and throttle valve opening angle. This increases the power output in all ranges from
low to high speed.
System Diagram
Construction
1) Intake Air Control Valve
The intake air control valve, which is
provided in the intake air chamber, opens and
closes to change the effective length of the
intake manifold in 2 stages.
2) Actuator (Motor)
The actuator activates the intake air control
valve based on signals from the ECM.

ENGINE - 2GR-FE ENGINE
285EG65
Intake Air Control Valve (Close)Intake Air Control Valve Close
Open
Throttle
Va l v e
Close
Low High
Engine Speed : Effective Intake Manifold Length
285EG66
Intake Air Control Valve (Open)Intake Air
Control Valve Open
Open
Throttle
Va l v e
Close
Low High
Engine Speed : Effective Intake Manifold Length
: Effective Intake Air Chamber LengthEG-127
Operation
1) When the Intake Air Control Valve Closes
While the engine is running at middle speed under high load, the ECM controls the actuator to close the
intake air control valve. As a result, the effective length of the intake manifold is lengthened and the
intake efficiency, in the medium speed range, is improved due to the dynamic effect of the intake air,
thereby increasing power output.
2) When the Intake Air Control Valve Open
Under any condition except when the engine is running at middle speed under high load, the ECM
controls the actuator to open the intake air control valve. When the intake air control valve is open, the
effective length of the intake manifold is shortened and the peak intake efficiency is shifted to the
low-to-high engine speed range, thus providing greater output at low-to-high engine speeds.

IN–24INTRODUCTION – REPAIR INSTRUCTION
IN
4. NOTICE FOR USING SWING ARM TYPE LIFT
(a) Follow safety procedures outlined in its instruction
manual.
(b) Use a swing arm equipped with a rubber
attachment, as shown in the illustration.
(c) When using the lift, make sure that the vehicle is
stabilized so that it will not tilt while work is being
performed. Stabilize the vehicle by adjusting the lift
arm's length and vehicle's position.
(d) When using the lift, its center should be as close to
the vehicle's center of gravity as possible (length of
"L" in the illustration should be as short as possible).
(e) Set the vehicle on the lift as level as possible. Then
match the groove of the cradle to the rigid rack
support location.
(f) Be sure to lock the swing arms before lifting and
during work (if equipped with arm locks).
(g) Lift the vehicle up off the ground. Stand at a safe
distance and shake the vehicle to check its stability.
5. NOTICE FOR USING PLATE TYPE LIFT
(a) Follow safety procedures outlined in its instruction
manual.
(b) Use plate lift attachments (rubber lifting blocks) on
top of the plate surface.
D100925E01

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