rese TOYOTA RAV4 2006 Service Repair Manual

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
00REG21Y
D13N11
Air-fuel
Ratio
SensorA1A+
(3.3V)
A1A -
(2.9V)ECMHeated
Oxygen
SensorOX1B
EX1BECM
Air-fuel Ratio Sensor Circuit Heated Oxygen Sensor
: Air-fuel Ratio Sensor
: Heated Oxygen Sensor
Air-fuel Ratio Sensor Data
Displayed on Hand-held
Te s t e r4.2
2.2
11 (Rich) 14.7 19 (Lean)0.11
Heated Oxygen
Sensor Output (V)
Air-fuel RatioEG-37
Air-fuel Ratio Sensor and Heated Oxygen Sensor
1) General
The air-fuel ratio sensor and heated oxygen sensor differ in output characteristics.
Approximately 0.4V is constantly applied to the air-fuel ratio sensor, which outputs an amperage that
varies in accordance with the oxygen concentration in the exhaust emission. The ECM converts the
changes in the output amperage into voltage in order to linearly detect the present air-fuel ratio. The
air-fuel ratio sensor data is read out by the hand-held tester.
The output voltage of the heated oxygen sensor changes in accordance with the oxygen concentration
in the exhaust emission. The ECM uses this output voltage to determine whether the present air-fuel
ratio is richer or leaner than the stoichiometric air-fuel ratio.

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 ENGINE
285EG27
Air Bleeder PlugTo Throttle Body
From Throttle Body
To H e a t e r
From Heater
To Radiator
From Radiator Thermostat
Opening Temperature:
80 - 84
C (176 - 183F)
01MEG35Y
ThermostatBypass Pipe
Heater Return Pipe
Air Bleeder Plug
Cylinder Head
Cylinder Block
Wa t e r P u m p
Radiator
Throttle
Body
Heater
Reservoir
Ta n k
EG-88
COOLING SYSTEM
1. General
The cooling system is a pressurized, forced-circulation type.
A thermostat with a bypass valve is located on the water inlet housing to maintain suitable temperature
distribution in the cooling system.
A cooling fan control system in which the ECM optimally controls cooling fan speed is used. For details,
see page EG-129.
An air bleeder plug is provided on the water inlet assembly to improve the efficiency of changing the
engine coolant. For details, refer to the 2006 RAV4 Repair Manual (Pub. No. RM01M1U).
The TOYOTA genuine SLLC (Super Long Life Coolant) is used for the engine coolant.
System Diagram

SERVICE SPECIFICATIONS – STANDARD BOLTSS–3
SS
HOW TO DETERMINE NUT STRENGTH
Nut Type
HINT:
• *: Nut with 1 or more marks on one side surface of the nut.
• Use a nut with the same nut strength classification number
(or greater) as the bolt strength classification number
when tightening parts with a bolt and nut.
Example:
• Bolt = 4T
• Nut = 4N or more
Present Standard Hexagon Nut Old Standard Hexagon Nut Class
Cold Forging Nut Cutting Processed Nut
No Mark4N
No Mark (w/ Washer) No Mark (w/ Washer) No Mark 5N (4T)
6N
7N (5T)
8N
No Mark 10N (7T)
11 N
12N

MAINTENANCE – UNDER HOODMA–7
MA
GENERAL MAINTENANCE
(2006/01- )
1. GENERAL NOTES
• Maintenance requirements vary depending on the
country.
• Check the maintenance schedule in the owner's
manual supplement.
• Following the maintenance schedule is mandatory.
• Determine the appropriate time to service the vehicle
using either miles driven or time elapsed, whichever
reaches the specification first.
• Maintain similar intervals between periodic
maintenance, unless otherwise noted.
• Failing to check each vehicle part could lead to poor
engine performance and increase exhaust emissions.
2. WINDSHIELD WASHER FLUID
(a) Check that there is sufficient fluid in the tank.
3. ENGINE COOLANT LEVEL
(a) Check that the coolant level is between the "FULL"
and "LOW" lines on the see-through reservoir.
4. RADIATOR AND HOSES
(a) Check that the front of the radiator is clean and not
blocked by leaves, dirt or bugs.
(b) Check the hoses for cracks, kinks, rot or loose
connections.
5. BATTERY ELECTROLYTE LEVEL
(a) Check that the electrolyte level of all the battery
cells is between the upper and lower level lines on
the case.
HINT:
If the electrolyte level is difficult to see, lightly shake
the vehicle.
6. BRAKE FLUID LEVEL
(a) Check that the brake fluid levels are near the upper
level lines on the see-through reservoirs.
7. ENGINE DRIVE BELT
(a) Check the drive belt for fraying, cracks, wear or
oiliness.
8. ENGINE OIL LEVEL
(a) Check the level on the dipstick with the engine
stopped.
9. AUTOMATIC TRANSAXLE FLUID LEVEL
10. EXHAUST SYSTEM
(a) Check for unusual exhaust sounds or abnormal
exhaust fumes. Inspect the cause and repair it.
Type See procedures
U151E See page AX-126
U151F See page AX-126

2AZ-FE ENGINE CONTROL SYSTEM – ECMES–431
ES
2. INSTALL AIR CLEANER CASE
(a) Install the air cleaner case with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(b) Connect the harness clamp.
3. INSTALL AIR CLEANER CAP (See page ES-413)
4. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
5. PERFORM REGISTRATION
(a) When replacing the ECM, the Vehicle Identification
Number (VIN) must be input into the replacement
ECM (see page ES-13).
(b) When replacing the ECM, perform the vehicle
stability control system recognition in the ECM (see
page CC-12).
6. RESET MEMORY
(a) When replacing the ECM, perform the RESET
MEMORY procedure (A/T initialization) (see page
AX-18).
A124563

2GR-FE ENGINE CONTROL SYSTEM – ECMES–471
ES
INSTALLATION
1. INSTALL ECM
(a) Install the 2 brackets to the ECM with the 4 screws.
Torque: 3.0 N*m (30 kgf*cm, 27 in.*lbf)
(b) Connect the 2 ECM connectors.
NOTICE:
When connecting the connector, make sure that
dirt, water and other foreign matter does not
become stuck between the connector and other
part.
(1) Connect the 2 ECM connectors and lower the 2
levers.
NOTICE:
Make sure that the 2 levers are securely
lowered.
(c) Install the ECM with the 3 bolts.
Torque: 6.5 N*m (66 kgf*cm, 57 in.*lbf)
2. INSTALL AIR CLEANER CASE (See page EM-39)
3. INSTALL AIR CLEANER CAP (See page EM-39)
4. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
5. PERFORM REGISTRATION
(a) When replacing the ECM, the Vehicle Identification
Number (VIN) must be input into the replacement
the new ECM (see page ES-14).
(b) When replacing the ECM, perform the vehicle
stability control system recognition in the ECM (see
page CC-12).
6. RESET MEMORY
(a) 2WD:
When replacing the ECM, perform the RESET
MEMORY procedure (A/T initialization) (see page
AX-20).
(b) 4WD:
When replacing the ECM, perform the RESET
MEMORY procedure (A/T initialization) (see page
AX-20).
A124573
A124572
A124570

2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–23
EM
20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
(a) Disconnect the mass air flow meter connector.
(b) Disconnect the VSV (air intake control) connector.
(c) Disconnect the wire harness clamp and 3 vacuum
hoses.
(d) Disconnect the No. 2 ventilation hose from the air
cleaner hose.
(e) Loosen the No. 1 air cleaner hose clamp.
(f) Unfasten the 2 hook clamps, and then remove the
air cleaner cap.
(g) Remove the air cleaner filter element from the air
cleaner case.
21. REMOVE AIR CLEANER CASE
(a) Disconnect the harness clamp.
(b) Remove the 3 bolts and air cleaner case.
22. DISCONNECT HOSES AND CONNECTORS
(a) Remove the engine room junction block cover
(upper).
(b) Remove the nut and disconnect the engine room
junction block cover (side) with 3 connectors and
wire.
(c) Remove the nut and disconnect the starter wire.
(d) Disconnect the fuel hoses.
(e) Disconnect the 2 heater hoses.
(f) Disconnect the 2 ECM connectors.
23. REMOVE ECM (See page ES-470)
24. REMOVE RADIATOR RESERVOIR TANK ASSEMBLY
(a) Remove the 2 bolts, 2 hoses and reservoir tank.
25. REMOVE DISCHARGE HOSE SUB-ASSEMBLY (See
page AC-220)
26. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (See
page AC-220)
27. DISCONNECT RADIATOR HOSE INLET
28. DISCONNECT RADIATOR HOSE OUTLET
29. DISCONNECT OIL COOLER HOSE
30. DISCONNECT TRANSMISSION CONTROL CABLE
ASSEMBLY
(a) 2WD:
Disconnect the control cable (see page AX-154).
A137897
A137898
A124838

SS–12SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL
SS
TORQUE SPECIFICATIONS
DRIVE BELT
VALVE CLEARANCE
TIMING CHAIN
Part Tightened N*m kgf*cm ft.*lbf
Front suspension member
reinforcement RH x Front cross
member, Front suspension
crossmember96 979 71
Part Tightened N*m kgf*cm ft.*lbf
No. 1 camshaft bearing cap x
Cylinder head29.5 301 22
No. 2 camshaft bearing cap x
Cylinder head29.5 301 22
No. 3 camshaft bearing cap x
Cylinder head9.0 92 80 in.*lbf
No. 1 chain tensioner x Timing
chain cover9.0 92 80 in.*lbf
Part Tightened N*m kgf*cm ft.*lbf
Chain tensioner plate x Crankshaft bearing cap 12 122 9
Oil pump drive shaft sprocket x Oil pump 29.5 301 22
No. 1 chain vibration damper x Cylinder head,
Cylinder block9.0 92 80 in.*lbf
Chain tensioner slipper x Cylinder head, Cylinder
block19 194 14
Timing chain guide x Crankshaft bearing cap 9.0 92 80 in.*lbf
Timing chain cover x
Cylinder head, Cylinder
blockBolt A
(Head: 10 mm)9.0 92 80 in.*lbf
Bolt B
(Head: 12 mm)25 255 18
Bolt C
(Head: 14 mm)55 561 41
Nut 11 112 8
V-ribbed belt tensioner x Timing chain cover 59.5 607 44
Engine mounting bracket RH x Timing chain cover 55 561 41
Crankshaft pulley x Crankshaft 180 1,835 133
Oil pan x Stiffening
crankcaseBolt, Nut 9.0 92 80 in.*lbf
Cylinder head cover x
Cylinder headBolt A 11 112 8
Bolt B 14 143 10
Nut 11 112 8
Engine wire x Cylinder head cover 8.4 86 74 in.*lbf
Idler pulley bracket x Cylinder block 60 612 44
Engine mounting insulator FR x Front cross
member95 969 70
Engine mounting
insulator FRThrough bolt x Nut 145 1,479 107
Engine mounting insulator RH x Body 95 969 70
Engine mounting
insulator RH x Engine
mounting bracketNut A 95 969 70
Nut B 52 530 38
Radiator reservoir x Radiator support RH, Engine
mounting insulator RH5.0 51 44 in.*lbf
No. 1 engine cover x Cylinder head 7.0 71 62 in.*lbf