Introduction: Overview Toyota RAV4 II рестайлинг

Scheme 1

1. INDEX To assist you in finding your way through these articles, the task heading are given at the top of each procedure.
2. PRECAUTION At the beginning of each procedure, PRECAUTIONS that pertain to repair operations contained in that article are given. Read these precautions before starting any repair work.
3. TROUBLESHOOTING The TROUBLESHOOTING tables are included for each system. Be sure to read the fundamentals of how to proceed with troubleshooting in «HOW TO PROCEED WITH TROUBLESHOOTING»(ref-180907-S41160105272005073000000).
4. PREPARATION Preparation lists the Special Service Tools (SST), recommended tools, equipment, lubricants and Special Service Materials (SSM) that should be prepared before beginning. It also explains the purpose of each one.
5. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: The procedures are presented in a step-by-step format: The illustration shows what to do and where to do it. The task heading briefly describes what you will be doing. The detailed text tells how to perform the task and gives information such as specifications and warnings. Example: This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task headings are easy to read and the text below it provides detailed information. Important specifications and warnings are always written in bold-faced text.
6. REFERENCES References have been kept to a minimum.
7. SPECIFICATIONS Specifications are printed in bold-faced text throughout the article where needed. They are also found in Service Specifications for quick reference.
8. CAUTIONS, NOTICES, HINTS: CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired. HINTS are separated from the detailed text but are not bold. HINTS provide additional information to help you perform repairs.
9. SI UNIT The UNITS used comply with the SI UNITS (International System of Units) standard. For your convenience, we also provide units from the metric system and the English system. Example: Torque: 30 N.m (310 kgf.cm, 22 ft.lbf)

Scheme 2

Scheme 3

1. VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped in the following 2 places: A: Engine compartment (Vehicle Identification Number) B: Certification Label
2. ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block (Scheme 3)

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

1. Prevent damage and maintain vehicle cleanliness by protective covering on the fender, seat and floor.
2. During disassembly, line up parts in the order they were removed to facilitate reassembly.
3. Installation and removal of battery terminal: Before performing electrical work, disconnect the negative (-) terminal cable from the battery. If it is necessary to disconnect the battery for inspection or repair, first disconnect the negative (-) terminal cable. To prevent damage to the battery terminal when disconnecting the terminal cable, loosen the cable nut and raise the cable straight up. Do not twist or pry the cable off. Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or other abrasive objects. Install the cable ends to the battery terminals after loosening the nut, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals. Be sure the cover for the positive (+) terminal is properly in place.
4. Check hose and wiring connectors to make sure that they are connected securely and correctly.
5. Non-reusable parts: Always replace cotter pins, gaskets, O-rings, oil seals, etc. with new ones. Non-reusable parts are indicated in component illustrations by the "diamond" symbols.
6. Precoated parts Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory. If a precoated part is retightened, loosened or move caused to in any way, it must be recoated with the specified adhesive. When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply new seal lock adhesive to the bolt, nut or threads. Precoated parts are indicated in component illustrations by the "*" symbols.
7. When necessary, use a sealer on gaskets to prevent leaks.
8. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
9. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found in Preparation in this information.
10. When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating.
11. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (see «VEHICLE LIFT AND SUPPORT LOCATIONS»(ref-180907-S01370260612005073000000) ). Release the parking brake on a level surface and shift to in Neutral or N range. When jacking up the front wheels of the vehicle, at first place chocks behind the rear wheels. When jacking up the rear wheels of the vehicle, place chocks in front of the front wheels. When jacking up only the front or rear wheels, set rigid racks and place chocks on front and behind the wheels in contact with the ground. After the vehicle is jacked up, be sure to support it on rigid racks. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly.
12. Observe the following precautions to avoid damage to the following parts: Do not open the cover or case of the ECU unless absolutely necessary. (Static electricity transmitted through human touch may destroy the IC.) To disconnect vacuum hoses, pull off the end of the hose, not the middle. To pull apart electrical connectors, pull on the connector itself, not the wires. Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. When steam cleaning an engine, protect the electronic components, air filter and emission-related components from water. Never use an impact wrench to remove or install temperature switches or temperature sensors. When checking continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending. When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step-down adapter for adjustment. Once the hose has been stretched, it may leak air.
13. Installation and removal of vacuum hose: When disconnecting vacuum hoses, use tags to identify where they should be reconnected to. After completing a job, double check that the vacuum hoses are properly connected. A label under the hood shows the proper layout.
14. Unless otherwise stated, all resistance should be measured at an ambient temperature of 20°C (68°F). Measurement should be made after the engine has cooled down. If measured at high temperatures immediately after the vehicle has been running, resistance may be outside specifications.

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER The RAV4 is equipped with an Supplemental Restraint System (SRS), which includes the driver airbag, front passenger airbag assembly, side airbag assembly, curtain shield airbag assembly and seat belt pretensioners. Failure to carry out service operations in the correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing and lead to serious injury. Furthermore, if a mistake is made in servicing the SRS, it is possible the SRS may fail to operate properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully. Then follow the correct procedure described in this information. GENERAL NOTICE Malfunction symptoms of the SRS are difficult to confirm, so the diagnostic trouble codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check the DTCs before disconnecting the battery (see «PRE-CHECK»(ref-180985-S27500416782005073000000) ). To avoid serious injury, servicing the SRS must be started 90 seconds after: The ignition switch is turned to the LOCK position. The negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable from the battery, the SRS may deploy.) Disconnecting the negative (-) terminal cable will erase clock memory and audio system presets. If you wish to do so, mark down data as necessary before disconnecting the cable. To avoid erasing the memory settings, never use a back-up power supply. In minor collisions where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, side airbag assembly, curtain shield airbag assembly, front airbag sensor assembly and seat belt pretensioner should be inspected before further use of the vehicle (see «AIR BAG RESTRAINT SYSTEMS»(ref-170413) and «INSPECTION»(ref-180965-S15873880172005073000000) ). Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Before repairs, remove the airbag sensor assembly if impacts are likely to be applied to the sensor during repairs. Never disassemble and repair the airbag sensor assembly, steering wheel pad, front passenger airbag assembly, side airbag assembly, curtain shield air-bag assembly, front airbag sensor or seat belt pretensioner. Replace if the airbag sensor, steering wheel pad, front passenger airbag assembly, side airbag assembly, curtain shield airbag assembly, front airbag sensor assembly or seat belt pretensioner if it has been dropped, or if there are cracks, dents or other defects in its case, bracket or connector. Do not directly expose the airbag sensor assembly, steering wheel pad, front passenger airbag assembly, front airbag sensor assembly or seat belt pretensioner to hot air or flames. Use a voltmeter/ohmmeter with high impedance (10 kohm/V minimum) for troubleshooting the electrical circuit. Information labels are attached to the periphery of the SRS components. Follow the instructions on the labels. After work on the SRS is completed, check the SRS warning light (see «PRE-CHECK»(ref-180985-S27500416782005073000000) ). SPIRAL CABLE (in Combination Switch) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other troubles may result. Refer to «AIR BAG RESTRAINT SYSTEMS»(ref-170413) concerning correct steering wheel installation. STEERING WHEEL PAD (with Airbag) When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up (Scheme 15) Storing the pad with its metallic surface facing upward may lead to a serious accident if the airbag inflates. In addition, do not store a steering wheel pad on top of one another. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which is could cause serious injury. Grease or detergents of any kind should not be applied to the steering wheel pad. Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), has low humidity and is away from electrical noise. Before using an electric welder, first disconnect the airbag connector (the connector is yellow and has 4 pins) under the steering column near the combination switch connector. As a safety measure, always deploy airbags using an SST before disposal (see «AIR BAG RESTRAINT SYSTEMS»(ref-170413) ). Deploy airbags in a safe place away from electrical noise. FRONT PASSENGER AIRBAG ASSEMBLY Always store a removed or new front passenger airbag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag inflate. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which is could cause serious injury. Grease or detergents of any kind should not be applied to the steering wheel pad. Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), has low humidity and is away from electrical noise. Before using an electric welder, first disconnect the airbag connector (the connector is yellow and has 4 pins) under the steering column near the combination switch connector. As a safety measure, always deploy airbags using an SST before disposal (see «AIR BAG RESTRAINT SYSTEMS»(ref-170413) ). Deploy airbags in a safe place away from electrical noise. SIDE AIRBAG ASSEMBLY Always store a removed or new side airbag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag inflates. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury. Grease or detergents of any kind should not be applied to the steering wheel pad. Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), has low humidity and is away from electrical noise. Before using an electric welder, first disconnect the airbag connector (the connector is yellow and has 2 pins) under the steering column near the combination switch connector. As a safety measure, always deploy airbags using an SST before disposal (see «AIR BAG RESTRAINT SYSTEMS»(ref-170413) ). Deploy airbags in safe place away from electrical noise. CURTAIN SHIELD AIRBAG ASSEMBLY Always store a removed or new side airbag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag inflates. NOTE: Plastic bag is not re-useable. CAUTION: Never disassemble the curtain shield airbag assembly. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury. Grease or detergents of any kind should not be applied to the curtain shield airbag assembly. Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), has low humidity and is away from electrical noise. Before using an electric welder, first disconnect the airbag connector (the connector is yellow and has 2 pins) under the steering column near the combination switch connector. As a safety measure, always deploy airbags using an SST before disposal (see «AIR BAG RESTRAINT SYSTEMS»(ref-170413) ). Deploy airbags in a safe place away from electrical noise. SEAT BELT PRETENSIONER Never measure the resistance of the seat belt pretensioner. This may cause the seat belt pretensioner to activate, which could cause serious injury. Never disassemble the seat belt pretensioner. Never install the seat belt pretensioner in another vehicle. Store the seat belt pretensioner where the ambient temperature remains below 80°C (176°F), has low humidity and is away from electrical noise. Before using an electric welder, first disconnect the connector (the connector is yellow and has 2 pins). As a safety measure, always activate the seat belt pretensioner before disposal (see «DISPOSAL»(ref-180965-S40869603492005073000000) ). Activate the pretensioner in safe place away from electrical noise. The seat belt pretensioner becomes hot after activation. Allow it to cool before disposing. Never use water to cool seat belt pretensioner. AIRBAG SENSOR ASSEMBLY If an airbag sensor assembly has been involved in a collision where its SRS has deployed, do not reuse it. The connectors to the airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor. Failure to do so could cause undesired deployment of the SRS. To avoid serious injury, servicing the SRS must be started 90 seconds after: The ignition switch is turned to the LOCK position. The negative (-) terminal cable is disconnected from the battery. Even if only loosening the set bolts of the airbag sensor assembly, you must follow the above guidelines. WIRE HARNESS AND CONNECTOR The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken, etc., repair or replace it as shown in «AIR BAG RESTRAINT SYSTEMS»(ref-170413).
2. WHEN SERVICING FULL-TIME 4WD VEHICLES The Full-Time 4WD RAV4 is equipped with the mechanical lock type center differential system. If incorrect preparations or test procedures are used, the test will not only be unsuccessful, but may be dangerous as well. Therefore, before beginning any such servicing or test, be sure to check the following items: Whether wheels should be touching ground or jacked up Transaxle gear position Maximum testing vehicle speed Maximum testing time Manual transaxle only: Center differential lock position CAUTION: Never accelerate or decelerate the vehicle suddenly Observe the other cautions given for each individual test Manual Transaxle Only: Before Beginning Test During tests with a brake tester or chassis dynamometer, such as braking force tests or speedometer tests, if only the front or rear wheels are to be rotated, it is necessary to set the position of the center differential to the FREE position or to the LOCK position depending on the type of test being performed. Select the position of the center differential by pushing the center differential lock switch. After selecting the position, confirm the operation of indicator light. Bring Force Test (Vehicle Speed: Below 0.5 km/h or 0.3 mph) When performing low-speed type brake tester measurements, observe the following instructions. Position the wheels to be tested (front or rear) on the tester. Shift the transaxle shift lever to Neutral (or "N" range). Idle the engine, operate the brake booster and perform the test. Speedometer Test or Other Tests (Using Speedometer Tester or Chassis Dynamometer) When performing test at high speed or high load, use the methods (Scheme 24) NOTE: Confirm that the vehicle is securely immobilized. Never operate the clutch or brakes to drive the wheels or stop them suddenly. On-Vehicle Wheel Balancing When doing on-vehicle wheel balancing on a full-time 4WD vehicle, to prevent the wheels from rotating at different speeds in different directions from each other (which could damage the center differential), always be sure to observe the following precautions: All 4 wheels should be jacked up, clearing the ground completely. The parking brake lever should be fully released. None of the brakes should be allowed to drag. The wheels should be driven on the wheel balancer with the engine running. HINT: When doing this, be careful of the other wheels, which will rotate at the same time. Avoid sudden acceleration, deceleration and braking. Carry out the wheel balancing with the transaxle in 3rd or 4th gear (automatic transaxle in D range).
3. WHEN TOWING FULL-TIME 4WD VEHICLES Use one of the methods (Scheme 26)to tow the vehicle. If the vehicle has trouble in the chassis and drive train, use method 1 (flat bed truck). NOTE: Do not use any towing method other than those (Scheme 26) For example, the towing methods (Scheme 27)are dangerous or damage the vehicle, so do not use them.
4. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amounts of unburned gasoline flow into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer. Use only unleaded gasoline. Avoid prolonged idling. Avoid idling the engine for more than 20 minutes. Avoid spark jump test. Perform spark jump tests only when absolutely necessary. Perform this test as rapidly as possible. While testing, never race the engine. Avoid prolonged engine compression measurement. Engine compression tests must be done as rapidly as possible. Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. Avoid coasting with ignition turned off. Do not dispose of used catalyst with gasoline or oil contaminated parts.
5. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM For vehicles with mobile communication systems such as two-way radios and cellular telephones, observe the following precautions. Install the antenna as far away as possible from the ECU and sensors of the vehicle's electronic system. Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle's electronic systems. For details about ECU and sensors locations, refer to the applicable component's information Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid running the antenna feeder parallel with other wire harnesses. Check that the antenna and feeder are correctly adjusted. Do not install powerful mobile communications system.
6. FOR USING OBD II SCAN TOOL OR HAND-HELD TESTER CAUTION: Observe the following items for safety reasons: Before using the hand-held tester or OBD II scan tool, the hand-held tester's operator manual or OBD II scan tool's instruction book should be read thoroughly. Be sure to route all cables securely when driving with the hand-held tester or OBD II scan tool connected to the vehicle. (I.e. keep cables away from feet, pedals, steering wheel and shift lever.) Two persons are required when test-driving with the hand-held tester or OBD II scan tool: one person to drive the vehicle and another to operate the hand-held tester or OBD II scan tool.
7. FOR VEHICLES EQUIPPED WITH VEHICLE SKID CONTROL (VSC) SYSTEM NOTE: When using a 2-wheel drum tester such as a speedometer tester or chassis dynamometer, etc., or jacking up the rear wheels and driving the wheels, always push in the VSC OFF switch to turn the TRAC & VSC system OFF. Notice for using 2-wheel drum tester. Press the VSC OFF switch. Check that the VSC OFF indicator light comes on. HINT: The VSC OFF indicator light should be always OFF when the engine is restarted. Begin measurements. Press the VSC OFF switch again to change the TRAC & VSC system to operational condition and check that the VSC OFF indicator light goes off. HINT: The SLIP indicator light blinks and the VSC buzzer sounds when the TRAC & VSC system is operational.

GENERAL INFORMATION

A large number of ECU controlled systems are used in the RAV4. In general, ECU controlled systems are considered to be a very intricate, requiring a high level of technical knowledge to troubleshoot. However, following the problem checking procedures of the ECU controlled system's circuits carefully is not complex. If you have an adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed.

This information emphasizes the above standpoint to help service technicians perform accurate and effective troubleshooting. Detailed information on major ECU controlled systems in this vehicle are outlined below

ECU SYSTEM DESCRIPTION

ABBREVIATIONS USED IN THIS INFORMATION

ABBREVIATIONS

See also:
• HOW TO PROCEED WITH TROUBLESHOOTING