2006 TOYOTA RAV4 head gasket

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
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.

EM–282GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
(g) Disconnect the connector.
(h) Using a 5 mm socket hexagon wrench, remove the
4 bolts.
(i) Remove the 2 nuts, 2 bolts and surge tank.
(j) Remove the gasket from the surge tank.
54. REMOVE IGNITION COIL ASSEMBLY
(a) Remove the 6 bolts and 6 coils from the cylinder
head.
55. REMOVE NO. 2 ENGINE MOUNTING STAY RH
(a) Remove the bolt and mounting stay.
56. REMOVE FUEL INJECTOR ASSEMBLY (See page
FU-14)
57. REMOVE INTAKE MANIFOLD
(a) Remove the 6 bolts, 4 nuts, intake manifold and 2
gaskets.
58. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Disconnect the air fuel ratio sensor connector
clamp.
(b) Uniformly loosen and remove the 6 nuts.
(c) Remove the manifold and gasket.
59. REMOVE FAN AND GENERATOR V BELT (See page
EM-8)
60. REMOVE COMPRESSOR WITH PULLEY ASSEMBLY
(See page AC-220)
61. REMOVE GENERATOR ASSEMBLY (See page CH-12)
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EM–302GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
73. REMOVE ENGINE OIL PRESSURE SWITCH
ASSEMBLY
(a) Using a 24 mm deep socket wrench, remove the
pressure switch.
74. REMOVE KNOCK SENSOR (See page ES-459)
75. REMOVE ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using a 19 mm deep socket wrench, remove the
sensor and gasket.
INSPECTION
1. INSPECT INTAKE MANIFOLD
(a) Using a precision straightedge and feeler gauge,
measure the warpage of the contact surface of the
cylinder head and intake air surge tank.
Maximum warpage
If the warpage is greater than the maximum, replace
the manifold.
2. INSPECT EXHAUST MANIFOLD
(a) Using a precision straightedge and feeler gauge,
measure the surface contacting the cylinder head
for warpage.
Maximum warpage:
0.70 mm (0.0028 in.)
If the warpage is greater than the maximum, replace
the manifold.
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Item Specified Condition
Intake manifold side 0.8 mm (0.031 in.)
Cylinder head side 0.2 mm (0.008 in.)
A137425

2AZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEMEC–7
EC
ON-VEHICLE INSPECTION
1. CHECK FUEL CUT RPM
(a) Increase the engine speed to at least 3,500 rpm.
(b) Use a sound scope to check for injector operating
noise.
(c) Check that the operating sounds stop momentarily
and then resume when the throttle lever is released.
HINT:
Measure with the A/C OFF.
Fuel return rpm:
1,400 rpm
2. CHECK FOR LEAKS
(a) Visually check that the hoses, connections and
gaskets have no cracks, leaks or damage.
NOTICE:
• Detachment or other problems with the
engine oil dipstick, filler cap, PCV hose and
other components may cause the engine to
run improperly.
• Disconnection, looseness or cracks in the
parts of the air induction system between the
throttle body and cylinder head will allow air
suction and cause an engine failure or engine
malfunctions.
If the result is not as specified, replace parts as
necessary.
3. CHECK LINE AND CONNECTORS
(a) Visually check for loose connections, sharp bends
or damage.
4. CHECK FUEL TANK ASSEMBLY
(a) Visually check for deformation, cracks or fuel
leakage.
5. CHECK FUEL TANK AND VENT LINE
(a) Disconnect the vent line tube from the canister.
(b) Connect a pressure gauge to the vent line tube.
A124804E01
B011449E01
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EM–582AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
EM
19. REMOVE NO. 2 MANIFOLD STAY
(a) Remove the bolt, nut and stay.
20. REMOVE NO. 1 EXHAUST MANIFOLD HEAT
INSULATOR
(a) Remove the 4 bolts and heat insulator.
21. REMOVE EXHAUST MANIFOLD CONVERTER SUB-
ASSEMBLY
(a) Disconnect the air-fuel ratio sensor connector.
(b) Remove the 5 nuts, manifold converter and gasket.
22. DISCONNECT NO. 1 RADIATOR HOSE
(a) Disconnect the No. 1 radiator hose.
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