Engine Control System (2GR-FE) (Service Information): Removal & Installation Toyota RAV4 IV

INSTALLATION

1. INSTALL ACCELERATOR PEDAL ROD Install the accelerator pedal rod with the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Connect the accelerator pedal position sensor connector.

Scheme 722

1. INSTALL MASS AIR FLOW METER Install the mass air flow meter with the 2 screws. NOTE: Make sure that the O-ring is not cracked or jammed when installing it. Connect the mass air flow meter connector.
2. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL

Scheme 723

Scheme 724

1. PRECAUTION NOTE: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work.Refer to «PRECAUTION»(ref-493289-S42810490842012081000000) .
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. REMOVE INTAKE AIR SURGE TANK ASSEMBLY Remove the intake air surge tank assembly.Refer to «REMOVAL»(ref-493471-S41687785962012081000000) .
4. REMOVE VVT SENSOR Disconnect the 4 sensor connectors. Remove the 4 bolts and 4 sensors.

1. INSTALL VVT SENSOR Install the 4 sensors with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the 4 sensor connectors.
2. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Install the intake air surge tank assembly.Refer to «INSTALLATION»(ref-493471-S10833676122012081000000) .
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Scheme 725

Scheme 726

1. DISCONNECT COMPRESSOR WITH PULLEY ASSEMBLY Disconnect the compressor with pulley.Refer to «REMOVAL»(ref-493477-S30472081672012081000000) .
2. REMOVE CRANKSHAFT POSITION SENSOR Disconnect the sensor connector. Remove the bolt and sensor.

Scheme 727

1. INSPECT CRANKSHAFT POSITION SENSOR NOTE: In the table above, the terms "Cold" and "Hot" refer to the temperature of the coils. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). Measure the resistance between the terminals. Standard resistance Temperature Specified Condition Cold 1, 630 to 2, 740 ohms Hot 2, 065 to 3, 225 ohms If the resistance is not as specified, replace the sensor.

1. INSTALL CRANKSHAFT POSITION SENSOR Apply a coat of engine oil to an O-ring of the sensor. Install the sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the sensor connector.
2. CONNECT COMPRESSOR WITH PULLEY ASSEMBLY Connect the compressor with pulley.Refer to «INSTALLATION»(ref-493477-S09325210252012081000000) .

Scheme 728

Scheme 729

1. DRAIN ENGINE COOLANT .Refer to «REPLACEMENT - Step 2»(ref-493469-S00017665692012081000000)
2. PRECAUTION NOTE: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work. Refer to «PRECAUTION»(ref-493289-S42810490842012081000000) .
3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Disconnect the sensor connector. Using SST, remove the sensor and gasket. SST: 09817-33190

Scheme 730

1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR Measure the resistance of the sensor. Standard resistance Tester Connection Condition Specified Condition 1 (E2) - 2 (THW) 20°C (68°F) 2.32 to 2.59 kohms 1 (E2) - 2 (THW) 80°C (176°F) 0.310 to 0.326 kohms NOTE: If checking the sensor in water, be careful not to allow water to contact the terminals. After checking, wipe the water off the sensor. If the result is not as specified, replace the sensor.

Scheme 731

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Install a new gasket onto the sensor. Using SST, install the sensor. SST: 09817-33190 Torque: 19.6 N*m (200 kgf*cm, 14 ft.*lbf) Connect the sensor connector.
2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
3. ADD ENGINE COOLANT .Refer to «REPLACEMENT - Step 3»(ref-493469-S00017665692012081000000)
4. CHECK FOR COOLANT LEAKS .Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-493425-S11329179852012081000000)

Scheme 732

Scheme 733

1. PRECAUTION NOTE: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work. Refer to «PRECAUTION»(ref-493289-S42810490842012081000000) .
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. REMOVE INTAKE AIR SURGE TANK ASSEMBLY Remove the intake air surge tank assembly.Refer to «REMOVAL»(ref-493471-S41687785962012081000000) .
4. REMOVE INTAKE MANIFOLD .Refer to «REMOVAL - Step 60»(ref-493421-S02277901022012081000000)
5. REMOVE KNOCK SENSOR Disconnect the 2 sensor connectors. Remove the 2 bolts and 2 sensors.

Scheme 734

1. INSPECT KNOCK SENSOR Measure the resistance of the sensor. Standard resistance Tester Connection Condition Specified Condition 1 (Ground) - 2 (Output) 20°C (68°F) 120 to 280 kohms If the result is not as specified, replace the knock sensor.

Scheme 735

1. INSTALL KNOCK SENSOR Install the 2 sensors with the 2 bolts as shown in the illustration. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) NOTE: Make sure that the knock sensor is in the correct position. Connect the 2 sensor connectors.
2. INSTALL INTAKE MANIFOLD .Refer to «INSTALLATION - Step 18»(ref-493421-S12794407782012081000000)
3. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Install the intake air surge tank assembly.Refer to «INSTALLATION»(ref-493471-S10833676122012081000000) .
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
5. CHECK FOR ENGINE COOLANT LEAKS .Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-493425-S11329179852012081000000)
6. CHECK FOR FUEL LEAKS
7. CHECK FOR ENGINE OIL LEAKS .Refer to «REPLACEMENT - Step 7»(ref-493478-S28452834222012081000000)

Scheme 736

Scheme 737

Scheme 738

1. PRECAUTION NOTE: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work.Refer to «PRECAUTION»(ref-493289-S42810490842012081000000) .
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. INSPECT INTEGRATION RELAY NOTE: The EFI relay is built into the integration relay (unit A: EFI MAIN). Some relays are built into the integration relay. The integration relay cannot be disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration relay. Using a screwdriver, detach the 2 claws and disconnect the integration relay from the engine room No. 1 junction block. HINT: Tape the screwdriver tip before use. Disconnect the 3 connectors from the integration relay. Inspect the EFI MAIN relay. Check the resistance of the EFI MAIN fuse. If the result is not as specified, replace the EFI MAIN fuse. Measure the resistance of the integration relay. Standard resistance Tester Connection Specified Condition 1A-4 - 1C-1 10 kohms or higher 1A-4 - 1A-1 1A-4 - 1C-1 Below 1 ohms (when battery voltage is applied to terminals 1A-3 and 1A-2) 1A-4 - 1A-1 If the result is not as specified, replace the integration relay. Inspect the A/F relay. Check the resistance of the A/F fuse. If the result is not as specified, replace the A/F fuse. Measure the resistance of the integration relay. Standard resistance Tester Connection Specified Condition 1B-8 - 1C-1 10 kohms or higher 1B-8 - 1B-5 1B-8 - 1C-1 Below 1 ohms (when battery voltage is applied to terminals 1B-6 and 1B-7) 1B-8 - 1B-5 If the result is not as specified, replace the integration relay.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Scheme 739

1. PRECAUTION NOTE: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work.Refer to «PRECAUTION»(ref-493289-S42810490842012081000000) .
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. REMOVE IG1 RELAY Remove the IG1 relay from the instrument panel junction block.
4. INSPECT IG1 RELAY Measure the resistance of the IG1 relay. Standard resistance Tester Connection Specified Condition 3 - 5 10 kohms or higher 3 - 5 Below 1 ohms (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay.
5. INSTALL IG1 RELAY
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Scheme 740

1. PRECAUTION NOTE: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work.Refer to «PRECAUTION»(ref-493289-S42810490842012081000000) .
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. REMOVE IG2 RELAY Remove the engine room No. 1 relay block cover. Remove the IG2 relay from the engine room No. 1 relay block.
4. INSPECT IG2 RELAY Measure the resistance of the IG2 relay. Standard resistance Tester Connection Specified Condition 3 - 5 10 kohms or higher 3 - 5 Below 1 ohms (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay.
5. INSTALL IG2 RELAY
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Scheme 741

1. PRECAUTION NOTE: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work.Refer to «PRECAUTION»(ref-493289-S42810490842012081000000) .
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. INSPECT INSTRUMENT PANEL JUNCTION BLOCK NOTE: The circuit opening (C/OPN) relay is built into the instrument panel junction block. Measure the resistance between the terminals. Standard resistance Tester Connection Specified Condition 1B-11 - 1A-8 10 kohms or higher 1B-11 - 1A-8 Below 1 ohms (when battery voltage is applied to terminals 1E-5 and 1D-1) If the result is not as specified, replace the instrument panel junction block.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Scheme 742

1. PRECAUTION NOTE: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work.Refer to «PRECAUTION»(ref-493289-S42810490842012081000000) .
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. REMOVE FUEL PUMP RELAY Remove the fuel pump relay from the engine room No. 1 relay block.
4. INSPECT RELAY Measure the resistance of the fuel pump relay. Standard resistance Tester Connection Specified Condition 3 - 4 Below 1 ohms 3 - 5 Below 1 ohms (when battery voltage is applied to terminals 1 and 2) 3 - 5 10 kohms or more 3 - 4 10 kohms or more (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay.
5. INSTALL FUEL PUMP RELAY
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL