water pump TOYOTA RAV4 2006 Service Repair Manual

ENGINE - 2AZ-FE ENGINE
DR011EG22 01NEG26Y
Air Flow During Engine Revolution
Wa t e r P u m p
Swirl Chamber
Crankshaft
Bearing Cap
Plastic Region
Tightening BoltsThermostat Housing
Air Conditioning
Compressor BracketsAir Passage Holes
Air Flow
NOTICE
Never attempt to machine the cylinder because it has a thin liner thickness.
EG-7
4. Cylinder Block
Lightweight aluminum alloy is used for the cylinder block.
By producing the thin cast-iron liners and cylinder block as a unit, compaction is realized.
Air passage holes are provided in the crankshaft bearing area of the cylinder block. As a result, the air at
the bottom of the cylinder flows smoother, and pumping loss (back pressure at the bottom of the piston
generated by the piston’s reciprocal movement) is reduced to improve the engine’s output.
The oil filter and the air conditioning compressor brackets are integrated into the crankcase. Also, the
water pump swirl chamber and thermostat housing are integrated into the cylinder block.

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 - 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 - 2GR-FE ENGINE
285EG21
Timing Chain Cover
Wa t e r P u m p G a s k e t
Wa t e r P u m pWater Pump Swirl
Chamber
Oil Pump
Housing
Oil Pump RotorsTiming Chain
Cover
Oil Pump Chamber
View from Front Side View from Back Side
285EG22
Oil
Passage
Check Ball
Check Ball
Spring
Plunger SpringPlunger
Roller Rocker ArmCam
Oil
Passage
Hydraulic
Lash Adjuster
Service Tip
Valve clearance adjustment is not necessary because a hydraulic lash adjuster is used in this model.
EG-83
4. Timing Chain Cover
The timing chain cover has an integrated construction consisting of the cooling system (water pump and
water passage) and the lubrication system (oil pump and oil passage). Thus, the number of parts has been
reduced to reduce weight.
5. Hydraulic Lash Adjuster
The hydraulic lash adjuster, which is located at the fulcrum of the roller rocker arm, consists primarily of
a plunger, plunger spring, check ball, and check ball spring.
The engine oil that is supplied by the cylinder head and the built-in spring actuates the hydraulic lash
adjuster. The oil pressure and the spring force that act on the plunger push the roller rocker arm against
the cam, in order to adjust the valve clearance that is created during the opening and closing of the valve.
As a result, engine noise is reduced.

ENGINE - 2GR-FE ENGINE
285EG29
Timing Chain Cover
Wa t e r P u m p G a s k e t
Wa t e r P u m pVolute ChambersFrom Water Inlet Housing
Rotor
View from Back Side
Cross SectionEG-89
Engine Coolant Specifications
Engine
Ty p e
TOYOTA genuine Super Long Life Coolant
(SLLC) or similar high quality ethylene glycol
based non-silicate, non-amine, non-nitrite and
non-borate coolant with long-life hybrid
organic acid technology (coolant with
long-life hybrid organic acid technology is a
combination of low phosphates and organic
acids.) Do not use plain water alone.
Engine
CoolantColorPink
Capacity
Except Towing
Package Models8.9 Liters (9.4 US qts, 7.8 Imp. qts)
CapacityTowing Package
Models9.2 Liters (9.7 US qts, 8.1 Imp. qts)
Maintenance IntervalsFirst Time100,000 miles (160,000 km)Maintenance IntervalsSubsequentEvery 50,000 miles (80,000 km)
SLLC is pre-mixed (the U.S.A. models: 50 % coolant and 50 % deionized water, the Canada. models: 55
% coolant and 45 % deionized water), so no dilution is needed when SLLC in the vehicle is added or
replaced.
If LLC is mixed with SLLC, the interval for LLC (every 25,000 miles (USA), 32,000 km (CANADA) or
24 months whichever comes first) should be used.
2. Water Pump
The water pump has two volute chambers, and circulates coolant uniformly to the left and right banks of the
cylinder block.

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.

2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–29
EM
62. REMOVE OIL DIPSTICK GUIDE
(a) Remove the dipstick.
(b) Remove the 2 bolts, and the No. 1 and No. 2
guides.
(c) Remove the O-rings from the guide.
63. REMOVE NO. 2 MANIFOLD STAY
(a) Remove the bolt, nut and manifold stay.
64. REMOVE NO. 2 EXHAUST MANIFOLD HEAT
INSULATOR
(a) Remove the 3 bolts and insulator.
65. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Uniformly loosen and remove the 6 nuts.
(b) Remove the manifold and gasket.
66. REMOVE ENGINE MOUNTING BRACKET RH
(a) Remove the 3 bolts and bracket.
67. REMOVE DRIVE SHAFT BEARING BRACKET
(a) Remove the 3 bolts and drive shaft bearing bracket.
68. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Remove the 5 bolts and V-ribbed belt tensioner
assembly.
69. REMOVE NO. 2 TIMING GEAR COVER
(a) Remove the 2 bolts and gear cover.
70. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the bolt, plate and idler pulley.
71. REMOVE WATER PUMP PULLEY (See page CO-12)
72. REMOVE NO. 1 FRONT ENGINE MOUNTING
BRACKET LH
(a) Remove the 6 bolts and bracket.
A129638
A139521
A139492
A139522

IN–48INTRODUCTION – TERMS
IN
GLOSSARY OF SAE AND TOYOTA
TERMS
This glossary lists all SAE-J1930 terms and abbreviations
used in this manual in compliance with SAE
recommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMS TOYOTA TERMS ( )-ABBREVIATIONS
3GR Third Gear -
4GR Fourth Gear -
A/C Air Conditioning Air Conditioner
ACL Air Cleaner Air Cleaner, A/CL
AIR Secondary Air Injection Air Injection (AI)
AP Accelerator Pedal -
B+ Battery Positive Voltage +B, Battery Voltage
BARO Barometric Pressure HAC
CAC Charge Air Cooler Intercooler
CARB Carburetor Carburetor
CFI Continuous Fuel Injection -
CKP Crankshaft Position Crank Angle
CL Closed Loop Closed Loop
CMP Camshaft Position Cam Angle
CPP Clutch Pedal Position -
CTOX Continuous Trap Oxidizer -
CTP Closed Throttle Position LL ON, Idle ON
DFI Direct Fuel Injection Direct Injection (DI/INJ)
DI Distributor Ignition -
DLC3 Data Link Connector 3 OBD II Diagnostic Connector
DTC Diagnostic Trouble Code Diagnostic Trouble Code
DTM Diagnostic Test Mode -
ECL Engine Coolant Level -
ECM Engine Control Module Engine Electronic Control Unit (ECU)
ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW)
EEPROM Electrically Erasable Programmable Read Only MemoryElectrically Erasable Programmable Read Only Memory
(EEPROM)
EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV)
EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR)
EI Electronic Ignition Distributorless Ignition (DLI)
EM Engine Modification Engine Modification (EM)
EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)
EVAP Evaporative Emission Evaporative Emission Control (EVAP)
FC Fan Control -
FEEPROMFlash Electrically Erasable Programmable Read Only
Memory-
FEPROM Flash Erasable Programmable Read Only Memory -
FF Flexible Fuel -
FP Fuel Pump Fuel Pump
GEN Generator Alternator
GND Ground Ground (GND)
HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S)
IAC Idle Air Control Idle Speed Control (ISC)

LU–142GR-FE LUBRICATION – OIL PUMP
LU
(c) Remove the 2 O-rings from the oil pump.
12. REMOVE WATER INLET HOUSING (See page CO-12)
13. REMOVE OIL PIPE (See page EM-52)
14. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 1) (See page EM-52)
15. REMOVE NO. 1 OIL PIPE (See page EM-53)
16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(for Bank 2) (See page EM-53)
17. REMOVE CRANKSHAFT PULLEY (See page EM-54)
18. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
(w/ Oil Pump)
(a) Remove the 23 bolts and 2 nuts as shown in the
illustration.
(b) Remove the timing chain cover by prying between
the timing chain cover and cylinder head or cylinder
block with a screwdriver.
HINT:
Tape the screwdriver tip before use.
NOTICE:
Do not damage the contact surfaces of the
cylinder head, cylinder block and timing chain
cover.
A132111
A132150
A132099

EM–1242AZ-FE ENGINE MECHANICAL – ENGINE UNIT
EM
20. REMOVE SPARK PLUG
21. REMOVE OIL FILLER CAP SUB-ASSEMBLY
22. REMOVE OIL FILLER CAP GASKET
23. REMOVE VENTILATION VALVE SUB-ASSEMBLY
(See page EC-18)
24. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(See page EM-24)
25. REMOVE CYLINDER HEAD COVER GASKET
26. REMOVE OIL FILTER SUB-ASSEMBLY (See page LU-
4)
27. REMOVE OIL FILTER UNION
(a) Using a 12 mm hexagon wrench, remove the oil
filter union.
28. REMOVE CRANKSHAFT POSITION SENSOR (See
page ES-402)
29. REMOVE WATER PUMP PULLEY (See page CO-11)
30. REMOVE WATER PUMP ASSEMBLY (See page CO-
11)
A132575
A128158
A128159
A128166
A126912E01