Manual de Mecánica Toyota Rav4 2004

2004 Toyota RAV4
2004 BRAKES ABS With EBD & BA & TRAC & VSC System - Diagnostics - RAV4
DataCar-ManualRepair.com
2004 BRAKES
ABS With EBD & BA & TRAC & VSC System - Diagnostics - RAV4
HOW TO PROCEED WITH TROUBLESHOOTING

Troubleshoot in accordance with the procedure.
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Tuesday, July 21, 2009 4:27:48
4:27:42 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.
2004 Toyota RAV4
Fig. 1: Troubleshooting Flow Chart

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
CUSTOMER PROBLEM ANALYSIS CHECK
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Tuesday, July 21, 2009 4:27:42 PM Page 2 © 2005 Mitchell Repair Information Company, LLC.
2004 Toyota RAV4
Fig. 2: Customer Problem Analysis Check Sheet (ABS & EBD & BA System)
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Fig. 3: Customer Problem Analysis Check Sheet (TRAC & VSC System)
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PRE-CHECK
1. DIAGNOSIS SYSTEM
a. Check the warning lights.
1. Release the parking brake pedal.
2. When the ignition switch is turned ON, check that the ABS warning light, VSC warning
light, TRAC OFF indicator light, brake warning light and slip indicator light comes on for
approx. 3 seconds.
HINT:
 When the parking brake is applied or the level of the brake fluid is low, the brake
warning light comes on.
 If the indicator check result is not normal, proceed to troubleshooting for the ABS
warning light circuit, TRAC warning light circuit, TRAC OFF indicator light circuit,
brake warning light circuit or slip indicator light circuit.
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Fig. 4: Identifying Warning Lights

WARNING LIGHT TROUBLE AREAS

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Trouble Area See

ABS warning light circuit ABS Warning Light Circuit (Does not light up)
VSC warning light circuit VSC Warning Light Circuit (Does not light up)
TRAC OFF indicator light TRAC OFF Indicator Light, TRAC OFF Switch
circuit Circuit
Brake warning light circuit Brake Warning Light Circuit
Slip indicator light circuit Slip Indicator Light Circuit
b. When not using the hand-held tester:
Check the DTC.
1. Using SST, connect terminals TC and CG of the DLC3.
SST 09843-18040
Fig. 5: Connecting Terminals TC & CG of DLC3 Using SST

2. Turn the ignition switch ON.

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3. Read the DTC from the ABS warning light and VSC warning light on the combination meter.
HINT:
 If no code appears, inspect the diagnostic circuit, ABS warning light circuit or VSC
warning light circuit.
WARNING LIGHT TROUBLE AREAS

Trouble Area See
TC terminal circuit TC Terminal Circuit
VSC warning light circuit VSC Warning Light Circuit (Does not light up)
 As an example, the blinking patterns for normal code and codes 11 and 21 are shown
in Fig. 6 .
4. Codes are explained in DIAGNOSTIC TROUBLE CODE CHART .
5. After completing the check, disconnect terminals TC and CG of the DLC3, and turn off the
display.
If 2 or more malfunction codes are identified at the same time, the DTC will be displayed in
ascending order.
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Fig. 6: Reading DTC Codes

c. When not using the hand-held tester:

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Clear the DTC.
SST 09843-18040

3. Clear the DTC stored in the ECU by depressing the brake pedal 8 times or more within 5
seconds.
4. Check that the warning light indicates the normal code.
5. Remove the SST from the terminals of the DLC3.
SST 09843-18040
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Fig. 7: Inspecting Brake Switch

HINT:
Cancellation cannot be performed by removing the battery cable or ECU-IG fuse.
d. When using the hand-held tester:
Check the DTC.
1. Connect hand-held tester to the DLC3.
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Fig. 8: Connecting Hand-Held Tester to DLC3


3. Read the DTC by following the prompts on the tester screen.
HINT:
Refer to the hand-held tester operator's manual for further details.
e. When using the hand-held tester:
Clear the DTC.
1. Connect the hand-held tester to the DLC3.
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3. Operate the hand-held tester to erase the codes.
HINT:
Refer to the hand-held tester operator's manual for further details.
2. DATA LIST
HINT:
According to the DATA LIST displayed by the hand-held tester, you can read the value of the switch,
sensor, actuator and so on without removing any parts. Reading the DATA LIST as a first step of
troubleshooting is one of the method to shorten the labor time.
a. Connect the hand-held tester to the DLC3.

b. Turn the ignition switch ON.
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c. Read the "DATA LIST" on the tester.
Fig. 10: Data List Table (1 Of 2)

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Fig. 11: Data List Table (2 Of 2)

3. ACTIVE TEST
HINT:
Performing the ACTIVE TEST using the hand-held tester allows the relay, VSV, actuator and so on to
operate without removing any parts. Performing the ACTIVE TEST as a first step of troubleshooting is
one of the methods to reduce troubleshooting time.
It is possible to display the DATA LIST during the ACTIVE TEST.

c. Perform the "ACTIVE TEST", according to the display on the tester.
HINT:
Ignition switch must be turned ON to proceed to Active Test using a hand-held tester.
ACTIVE TEST
Item Test Details Diagnostic Note
Turns ABS solenoid (SFRR) ON / Operation of solenoid (clicking sound)
SFRR
OFF can be heard
Turns ABS solenoid (SFRH) ON / Operation of solenoid (clicking sound)
SFRH
OFF can be heard
Turns ABS solenoid (SFLR) ON / Operation of solenoid (clicking sound)
SFLR
OFF can be heard
Turns ABS solenoid (SFLH) ON / Operation of solenoid (clicking sound)
SFLH
OFF can be heard
Turns ABS solenoid (SRRR) ON / Operation of solenoid (clicking sound)
SRRR
OFF can be heard
Turns ABS solenoid (SRRH) ON / Operation of solenoid (clicking sound)
SRRH
OFF can be heard
Turns ABS solenoid (SRLR) ON / Operation of solenoid (clicking sound)
SRLR
OFF can be heard
Turns ABS solenoid (SRLH) ON / Operation of solenoid (clicking sound)
SRLH
OFF can be heard
Turns ABS solenoid (SMF) ON / Operation of solenoid (clicking sound)
SMF (BA-SOL)
OFF can be heard
Turns ABS solenoid (SRMR) ON / Operation of solenoid (clicking sound)
SMR
OFF can be heard
Operation of solenoid (clicking sound)
SOL RELAY Turns ABS solenoid relay ON/OFF
can be heard
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ABS MOT Operation of motor (clicking sound) can

Turns ABS motor relay ON/OFF
RELAY be heard
ABS WARN
Turns ABS warning light ON / OFF Observe combination meter
LIGHT
VSC WARN
Turns VSC warning light ON / OFF Observe combination meter
LIGHT
VSC/ TRAC OFF Turns VSC / TRAC OFF indicator
Observe combination meter
IND ON / OFF
SLIP INDI LIGHT Turns slip indicator light ON / OFF Observe combination meter
BRAKE WRN Turns brake warning light ON /
Observe combination meter
LIGHT OFF
VSC/BR WARN Turns VSC / brake warning buzzer
Buzzer can be heard
BUZ ON / OFF
4. FREEZE FRAME DATA
HINT:
 Whenever a DTC is detected or the ABS operates, the skid control ECU stores the current vehicle
(sensor) state as freeze frame data.
 The skid control ECU stores the number of times (maximum: 31) the ignition switch has been
turned from OFF to ON since the last time ABS was activated. However, if the vehicle was stopped
or driver at low speed (7 km/h (4.3 mph) or less), or if a DTC is detected, the skid control ECU will
not count the number since then.
 Freeze frame data at the time the ABS operates:
The skid control ECU stores and updates data whenever the ABS system operates.
When the ECU stores data at the time a DTC is detected, the data stored when the ABS operated is
erased.
 Freeze frame data at the time a DTC is detected:
When the skid control ECU stores data at the time a DTC is detected, no updates will be performed
until the data is cleared.

b. Turn the ignition switch to the ON position.
c. From the display on the tester, select the "FREEZE FRAME DATA".
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Fig. 12: Freeze Frame Data Table

5. When not using hand-held tester: ABS SENSOR SIGNAL CHECK (TEST MODE)
NOTE: When having replaced the yaw rate sensor, deceleration sensor and/or
ECU, perform zero point calibration of the yaw rate and deceleration
sensors (see step 9 ).
HINT:
If the ignition switch is turned from ON to ACC or LOCK during test mode, DTC will be erased.
a. Procedures for test mode:

1. Turn the ignition switch OFF.
2. Move the shift lever to the P position.
3. Using SST, connect terminals TS and CG of the DLC3.
SST 09843-18040
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Fig. 13: Connecting Terminals TS & CG of DLC3 Using SST

4. Check that the steering wheel is in the straight-ahead position.

6. Check that the ABS warning light blinks.
HINT:
If the ABS warning light does not blink, inspect the ABS warning light circuit or Ts terminal
circuit.
WARNING LIGHT TROUBLE AREA

Trouble Area See
Ts terminal circuit TS Terminal Circuit
b. Check the brake pedal load sensing switch.

1. By pumping the brake pedal, release the booster vacuum.
2. Turn the ignition switch to ON (do not start the engine) and keep depressing the brake pedal
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for 1 seconds or more with a force of approximately 59 N (6 kgf, 14 lbf) or more.

3. Check that the brake warning light is illuminated and the operating sound of the ABS motor
is heard.
4. Start the engine and depress the brake pedal with a force of approximately 59 N (6 kgf, 14
lbf) or more.
5. Check that the brake warning light turns off.
HINT:
When rechecking, once exit test mode and then activate test mode again.
c. Check the deceleration sensor.
Keep the vehicle in a stationary condition on a level place for 1 second or more.
d. Check the master cylinder pressure sensor.

1. Leaving the vehicle in a stationary condition and the brake pedal in free condition for 1
second or more, continue to depress the brake pedal with a force of 98 N (10 kgf, 22 lbf) or
more for 1 second or more.
2. While the vehicle is stopped, release the brake pedal.
3. While the vehicle is stopped, quickly depress the brake pedal once or more and check that the
ABS warning light is illuminated for 3 seconds.
HINT:
Repeat the operation until the ABS warning light is illuminated.
e. Check the speed sensor signal.
Drive the vehicle straightforward.
Drive the vehicle with the speed faster than 45 km/h (28 mph) for several seconds and check that
the ABS warning light turns off.
HINT:
The sensor check may not be completed if the wheels spin or the steering wheel is steered during
this check.
f. Stop the vehicle.

g. Using SST, connect terminals TC and CG of the DLC3.
SST 09843-18040
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Fig. 14: Connecting Terminals TC & C4 of DLC3 Using SST

h. Read the number of blinks of the ABS warning light.
HINT:
 See the list of DTC in Fig. 17 .

 If every sensor is normal, the normal code is output (a cycle of 0.25 seconds ON and 0.25
seconds OFF is repeated).
 If 2 or more malfunctions are detected at the same time, the lowest numbered will be
displayed 1st.
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Fig. 15: Reading Malfunction Code Chart (e.g. 72,76)

i. After doing the check, disconnect the SST from terminals TS and CG, TC and CG of the DLC3 and
turn the ignition switch OFF.
SST 09843-18040
6. When using hand-held tester: ABS SENSOR SIGNAL CHECK (TEST MODE)
sensors (see step 9 ). Make sure that this operation should be done before
starting the following.
HINT:
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b. Do steps 4 and from a to e .

c. Read the DTC by following the prompts on the tester screen.
HINT:
Please refer to the hand-held tester operator's manual for further details.
DTC of ABS sensor check function:
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Fig. 17: DTC Of ABS Sensor Function Check Table

7. When not using hand-held tester: VSC SENSOR SIGNAL CHECK (TEST MODE)
sensors (see step 9 ).
HINT:
a. Procedures for test mode:

2. Check that the shift lever position is P. Turn the steering wheel to the straight-ahead position.
SST 09843-18040
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Fig. 18: Connecting Terminals TS & C4 Of DLC3 Using SST

4. Start the engine.

5. Check that the VSC warning light blinks.
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Fig. 19: Reading VSC Warning Light Blinking Pattern

b. Check the yaw rate sensor.

1. Move the shift lever to the D position and drive the vehicle at the vehicle speed of
approximately 5 km/h (3 mph). Turn the steering wheel either to left or right for 90° or more,
and maintain 180° circular drive for the vehicle.
2. Stop the vehicle and move the shift lever to the P position. Check that the VSC warning
buzzer sounds for 3 seconds
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Fig. 20: Checking Yaw Rate Sensors

If the VSC warning buzzer sounds, the sensor check is completed normally.
If the VSC warning buzzer does not sound, check the VSC warning buzzer circuit, then do
the sensor check again.
VSC WARNING BUZZER TROUBLE AREA

Trouble Area See
VSC warning buzzer circuit VSC Warning Buzzer Circuit
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If the VSC warning buzzer still does not sound, there is malfunction in the VSC sensor, so
check the DTC.
HINT:
Drive the vehicle circularly 180°. At the end of the turn, the direction of the vehicle
should be within 180° +/- 5° from its start position.
 Do not spin the wheels.
3. Check the steering angle sensor.
Turn the steering wheel to either left or right to the full lock position, from the vehicle
stationary condition, and turn back the steering wheel to the neutral position.
c. Read the DTC.

SST 09843-18040
Fig. 21: Connecting Terminals TC & CG Of DLC3 Using SST

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2. Read the number of blinks of the VSC warning light.
HINT:
 See the list of DTC shown in Fig. 23 .

 If every sensor is normal, a normal code is output (a cycle of 0.25 seconds ON and
0.25 seconds OFF is repeated).
3. After doing the check, disconnect the SST from terminals TS and CG, TC and CG of the
DLC3 and turn the ignition switch OFF.
SST 09843-18040
8. When using hand-held tester: VSC SENSOR SIGNAL CHECK (TEST MODE)
sensors (see step 9). Make sure that this operation should be done before
starting the following.
HINT:
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Fig. 22: Connecting Hand Held Tester To DLC3

b. Do steps (a)-(2), (a)-(4) and (b) in step 5 .

c. Read the DTC by following the prompts on the tester screen.
HINT:
DTC of VSC sensor check function:
Fig. 23: DTC Of VSC Sensor Check Function Table

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9. When not using hand-held tester:
IF NECESSARY, PERFORM ZERO POINT CALIBRATION OF YAW RATE AND

DECELERATION SENSORS
HINT:
 When having replaced the yaw rate sensor, deceleration sensor or/and the ECU, make sure to
perform yaw rate sensor (including deceleration sensor) zero point calibration.
 This operation is also required when the deceleration sensor or yaw rate sensor has been replaced
since the calibrated zero point of both sensors will be erased.
NOTE:  While obtaining the zero point, do not give any vibration to the
vehicle by tilting, moving or shaking it and keep it in a stationary
condition (do not start the engine).
 Be sure to do this on a level surface (within an inclination of 1 %).
a. Clear the zero points of the yaw rate and deceleration sensors.
1. Move the shift lever to P position.
2. Turn the ignition switch ON in a stationary condition.
3. With the ignition switch ON, using SST, repeat a cycle of short and open between terminals
Ts and CG of the DLC3 4 times or more within 8 seconds. Check that the TRAC OFF
indicator and VSC warning lights are illuminated, indicating that the recorded zero point is
erased.
SST 09843-18040
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Fig. 24: Connecting Terminals CG & TS Of DLC3 Using SST

4. Turn the ignition switch OFF and VSC within 15 seconds.

b. Obtain zero point of the yaw rate sensor.
1. Disconnect terminals TS and CG of the DLC3.
HINT:
The vehicle should be in a stationary condition with the shift lever in P position.
3. Check that the TRAC OFF indicator and VSC warning light turns off about 15 seconds after
the ignition switch is turned ON.
HINT:
Even if the ignition is not turned OFF in step 4 and remains ON, the yaw rate sensor zero
point calibration can be completed. In this case, the TRAC OFF indicator and VSC warning
lights are illuminated for about 15 seconds and then the VSC warning light starts blinking
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(normal code).
4. After ensuring that the TRAC OFF indicator and VSC warning light remains OFF for 2
seconds, turn the ignition switch OFF.
HINT:
If the ignition switch is not turned OFF in step 4 , make sure that the TRAC OFF indicator
and VSC warning light blinks for 2 seconds Then turn the ignition switch OFF.
c. Perform deceleration sensor zero point calibration.
NOTE: After step (b) (the yaw rate sensor zero point calibration), the VSC
warning light turns off. At this time, if the vehicle is driven without
performing step (c) (deceleration sensor zero point calibration),
deceleration sensor zero point calibration malfunction will be
detected and the TRAC OFF indicator light and VSC warning light will
light up. Therefore, perform step (c) right after step (b).
SST 09843-18040
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Fig. 25: Connecting Terminals TS & CG Of DLC3 Using SST

HINT:
Place the vehicle in a stationary condition with the shift lever in P position.
3. After turning the ignition switch ON, check that the VSC warning light is illuminated for
about 4 seconds and then starts quick blinking at 0.13 seconds intervals.
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Fig. 26: Reading VSC Warning Light Blinking Pattern

4. After ensuring the blinking of the VSC warning light for 2 seconds, turn the ignition switch
OFF.
5. Remove the SST and disconnect terminals TS and CG of the DLC3.
SST 09843-18040
10. When using hand-held tester: IF NECESSARY, PERFORM ZERO POINT CALIBRATION OF
YAW RATE SENSOR AND DECELERATION SENSOR
HINT:
When having replaced the yaw rate sensor and/or the brake actuator assembly, make sure to perform yaw
rate sensor and deceleration sensor zero point calibration.
NOTE:  While obtaining the zero point, do not give any vibration to the
vehicle by tilting, moving or shaking it and keep it in a stationary
condition (do not start the engine).
 Be sure to do this on a level surface (within an inclination of 1 %).

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c. Move the shift lever to P position.

d. Operate the hand-held tester to clear zero point calibration.
e. Operate the hand-held tester to test mode.
HINT:
When the zero point memorized in the skid control ECU was cleared, the VSC warning light turns
ON. When the zero point calibration is completed, the VSC warning light blinks.
f. Keep the vehicle in the stationary condition on the level surface for 2 seconds or more.
g. Check that the VSC warning light blinks.
HINT:
If the VSC warning light does not blink, perform the zero point calibration.
h. Turn the ignition switch OFF.
DIAGNOSTIC TROUBLE CODE CHART
NOTE:  When removing the part, turn the ignition switch OFF.
 When replacing yaw rate sensors and/or the brake actuator assembly (skid
control ECU), make sure to perform yaw rate sensor zero point calibration
(see PRE-CHECK ).
HINT:
 Using SST 09843-18040, connect terminals TC and CG.

 If any abnormality is not found when inspecting parts, inspect the ECU.
 If a malfunction code is displayed during the DTC check, check the circuit listed for that code.
DTC chart of ABS:
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Fig. 27: Diagnostic Trouble Code Chart (ABS)

DTC chart of VSC:

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Fig. 28: Diagnostic Trouble Code Chart (VSC)

HINT:
In some cases, the hand-held tester cannot be used when the VSC warning light is always on.
DIAGNOSTIC TROUBLE CODES (DTC) LIST

DTC Description
DTC C0200/31, C0205/32, 0210/33, Speed Sensor Circuit
C0215/34, C1235/35, C1236/36, C1238/38,
C1239/39
DTC C0226/21, C0236/22, C0246/23, ABS Solenoid Circuit
C0256/24
DTC C0273/13, C0274/14, C1361/91 Pump Motor Circuit & Short circuit in ABS Motor Fail
Safe Relay Circuit
DTC C0278/11, C0279/12 ABS Solenoid Valve Relay Circuit
DTC C1201/51 Engine Control System Malfunction
DTC C1203/53 Malfunction in ECM Communication Circuit
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DTC C1210/36, C1336/39 Zero Point Calibration Deceleration Sensor undone & Zero
Point Calibration Malfunction in Yaw Rate Sensor undone
DTC C1223/43 ABS Control System Malfunction
DTC C1224/44 NEO Signal Circuit
DTC C1225/25 VSC Solenoid Circuit
DTC C1231/31 Steering Angle Sensor Circuit
DTC C1232/32, C1234/34, C1243/43, Deceleration Sensor Circuit, Yaw Rate Sensor Circuit,
C1244/44, C1245/45, C1381/97 Malfunction in Deceleration Sensor & Malfunction in
Power Supply Voltage Yaw/Deceleration Sensor
DTC C1241/41 IG Power Source Circuit
DTC C1246/46 Master Cylinder Pressure Sensor Circuit
DTC C1249/49 Stop Light Switch Circuit
DTC C1251/51 ABS Pump Motor Lock
DTC C1337/37 Tires of Different Size (Only for 2WD)
PARTS LOCATION
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Fig. 29: Locating Parts Of ABS & VSC

TERMINALS OF ECU
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Fig. 30: Identifying ECU Connector Terminals

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Fig. 31: Terminals Of ECU Reference Table

PROBLEM SYMPTOMS TABLE

If a normal code is indicated during the DTC check but the problem still occurs, check the circuits for each
problem symptom in the order given in Fig. 32 .
NOTE:  When replacing brake actuator assembly, sensor or etc., turn the ignition
switch OFF.
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 When replacing yaw rate sensor and/or the brake actuator assembly, make
sure to perform yaw rate sensor zero point calibration (see PRE-CHECK ).
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Fig. 32: Problem Symptoms Table

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CIRCUIT INSPECTION
DTC C0200/31, C0205/32, 0210/33, C0215/34, C1235/35, C1236/36, C1238/38, C1239/39: SPEED
SENSOR CIRCUIT
CIRCUIT DESCRIPTION
The speed sensor detects wheel speed and sends appropriate signals to the ECU. These signals are used to
control the ABS control system. The front and rear rotors have 48 serrations, respectively.
When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an
AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the
frequency is used by the ECU to detect the speed of each wheel.
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Fig. 33: Speed Sensor Circuit

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Fig. 34: DTC (C0200/31, C0205/32, C0210/33, C0215/34, C1235/35, C1236/36, C1238/38, C12239/39)
Table
HINT:
 DTC No. C0200/31 and C1235/35 are for the right front speed sensor.
 DTC No. C0205/32 and C1236/36 are for the left front speed sensor.
 DTC No. C0210/33 and C1238/38 are for the right rear speed sensor.
 DTC No. C0215/34 and C1239/39 are for the left rear speed sensor.
WIRING DIAGRAM
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Fig. 35: Speed Sensor Wiring Diagram

INSPECTION PROCEDURE
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HINT:
Start the inspection from step 1 when using the hand-held tester and start from step 2 when not using handheld
tester.
1. Check output value of speed sensor.
PREPARATION:

b. Turn the ignition switch ON and push the hand-held tester main switch ON.
c. Select the DATA LIST mode on the hand-held tester.
CHECK:
Check that there is no difference between the speed value output from the speed sensor displayed on the
hand-held tester and the speed value displayed on the speedometer when driving the vehicle.
OK:
There is almost no difference from the displayed speed values.
HINT:
There is tolerance of +/- 10 % in the speedometer indication.
OK: Go to step 4 .
NG: Go to next step.
2. Check speed sensor.
Front speed sensor:
PREPARATION:
a. Remove the front fender liner.

b. Make sure that there is no looseness at the connector lock part and connecting part of the connector.
c. Disconnect the speed sensor connector.
CHECK:
Measure the resistance between terminals 1 and 2 of the speed sensor connector.
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Fig. 36: Measuring Resistance Between Terminals 1 & 2 Of Front Speed Sensor Connector
OK:
Resistance: 0.6 to 2.5 kohm at -40 to 120°C (-40 to 248°F)
CHECK:
Measure the resistance between terminals 1 and 2 of the speed sensor connector and the body ground.
OK:
Resistance: 10 Mohm or higher
Rear speed sensor (2WD):
PREPARATION:
a. Make sure that there is no looseness at the connector lock part and connecting part of the connector.
b. Disconnect the speed sensor connector at the hub bearing.
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CHECK:
Measure the resistance between terminals 1 and 2 of the speed sensor connector.
Fig. 37: Measuring Resistance Between Terminals 1 & 2 Of Rear (2WD) Speed Sensor Connector
OK:
CHECK:
OK:
Rear speed sensor (4WD):

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PREPARATION:
a. Make sure that there is no looseness at the connector lock part and connecting part of the connector.
b. Disconnect the speed sensor connector at the hub bearing.
CHECK:
Measure the resistance between terminals 1 and 2 of the speed sensor connectors.
Fig. 38: Measuring Resistance Between Terminals 1 & 2 Of Rear (4WD) Speed Sensor Connector
OK:
CHECK:
OK:
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Rear speed sensor sub-wire harness (2WD):
PREPARATION:
a. Remove the seat cushion and seat back.

b. Make sure that there is no looseness at the connector lock part and connecting part of the connector.
c. Disconnect the speed sensor connector inside the vehicle.
CHECK:
a. Measure the resistance between terminal 1 of connector 1 and terminal 2 of connector 2.

b. Measure the resistance between terminal 2 of connector 1 and terminal 1 of connector 2.
Fig. 39: Measuring Resistance Between Terminals 1 & 2 Of Rear Speed Sensor Sub-Wire
Harness (2WD)
OK:
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Resistance: Below 1 ohm
CHECK:
Measure the resistance between terminals 1 and 2 of the speed sensor connector 1 and the body ground.
OK:
NG: Replace speed sensor or sub-wire harness.
NOTE: Finally, check the speed sensor signal (see PRE-CHECK ).
OK: Go to next step.

3. Check for open and short circuit in harness and connector between each speed sensor and skid
control actuator with ECU (See HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION
PROCEDURE ).
NG: Repair or replace harness and connector.
4. Check sensor installation.
CHECK:
Check the speed sensor installation.
OK:
FRONT (2WD, 4WD), Rear (4WD):
The installation bolt is tightened properly and there is no clearance between the sensor and steering
knuckle or rear axle carrier.
Torque: 8.0 N.m (8.2 kgf.cm, 71 in.lbf).
Rear (2WD):
There is no clearance between the sensor and rear axle carrier
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Fig. 40: Checking Speed Sensor Installation

NG: Replace speed sensor.

5. Check speed sensor and sensor rotor serrations.
(REFERENCE) INSPECTION USING OSCILLOSCOPE
PREPARATION:
Connect an oscilloscope to terminals FR+ - FR-, FL+ - FL-, RR+ - RR- and RL+ - RL- of the ABS
actuator with ECU.
CHECK:
Drive the vehicle at about 20 km/h (12 mph), and check the signal waveform.
OK:
A waveform as shown in a figure should be output.
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Fig. 41: Speed Sensor & Sensor Rotor Serrations Waveform

HINT:
 As the vehicle speed (wheel revolution speed) increases, a cycle of the waveform becomes shorter
and the fluctuation in the output voltage becomes greater.
 When noise is identified in the waveform on the oscilloscope, error signals are generated due to the
speed sensor rotor's scratches, looseness or foreign matter deposited on it.
OK: Replace brake actuator assembly.
NOTE: When replacing the brake actuator assembly, perform the zero point
calibration (see PRE-CHECK ).

6. Check sensor rotor and sensor tip.
Front:
PREPARATION:
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Remove the front drive shaft (see REMOVAL ).
CHECK:
Check the sensor rotor serrations.
Fig. 42: Checking Sensor Rotor Serrations

OK:
No scratches, missing teeth or foreign objects.
PREPARATION:
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Remove the front speed sensor (see REMOVAL ).
CHECK:
Check the sensor tip.
OK:
No scratches or foreign objects on the sensor tip.
Rear (2WD):
PREPARATION:
Remove the axle hub and disconnect the rear speed sensor (see REMOVAL ).
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Fig. 43: Removing Axle Hub & Disconnecting Rear (2WD) Speed Sensor
CHECK:
OK:
No scratches or missing teeth or no foreign objects.
CHECK:
OK:
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No scratches or no foreign objects on the sensor tip.
Rear (4WD):
PREPARATION:
Remove the rear drive shaft (see REMOVAL ).
Fig. 44: Removing Rear Drive Shaft (4WD)

CHECK:

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OK:
No scratches or missing teeth or no foreign objects.
HINT:
If foreign objects are stuck to the rotor, remove them.
PREPARATION:
Remove the rear drive shaft (see REMOVAL ).
CHECK:
OK:
No scratches or no foreign objects on the sensor tip.
HINT:
If foreign objects are stuck to the sensor tip, remove them before reuse. Check the rotor for the presence
of foreign objects and remove them if they are stuck.
NG: Replace speed sensor or rear axle hub assembly.
HINT:
Remove any foreign matters if identified.
Check the output waveform again after reassembling.
DTC C0226/21, C0236/22, C0246/23, C0256/24: ABS SOLENOID CIRCUIT
CIRCUIT DESCRIPTION
This solenoid turns on when signals are received from the ECU and controls the pressure acting on the wheel
cylinders to control the braking force.
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Fig. 45: DTC (C0226/21, C0236/22, C0246/23, C0256/24) Table

WIRING DIAGRAM
Fig. 46: ABS Solenoid Wiring Diagram

1. Check DTC once more (See PRE-CHECK ).
PREPARATION:
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a. Clear the DTC.

b. Turn the ignition switch OFF.
CHECK:
a. Turn the ignition switch ON.

b. Is the same DTC output again?
NO : END
YES : Replace brake actuator assembly.
DTC C0273/13, C0274/14, C1361/91: PUMP MOTOR CIRCUIT & SHORT CIRCUIT IN ABS MOTOR
FAIL SAFE RELAY CIRCUIT
CIRCUIT DESCRIPTION
The ABS motor relay supplies power to the ABS pump motor. While the ABS & TRC & VSC are activated, the
ECU switches the ABS motor relay ON and operates the ABS pump motor.
Fig. 47: DTC (C0273/13, C0274/14, C1361/91) Table

WIRING DIAGRAM
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Fig. 48: ABS Motor Fail Safe & Pump Motor Wiring Diagram
HINT:
Start the inspection from step 1 when using the hand-held tester and start from step 2 when not using the hand-
held tester.
1. Check ABS motor relay operation.
PREPARATION:

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b. Turn the ignition switch ON and press the hand-held tester main switch ON.
c. Select the item "ABS MTR RELAY" in the ACTIVE TEST and operating it using the hand-held
tester.
CHECK:
Check the operation sound of the ABS motor relay when operating it using the hand-held tester.
OK:
The operation sound of the ABS motor relay should be heard.

2. Measure voltage between terminal 5 of ABS R/B and body ground.
PREPARATION:
a. Remove the ABS MTR relay from the ABS R/B.

CHECK:
Measure the voltage between terminal 5 of the ABS R/B (for ABS MTR relay) and body ground.
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Fig. 49: Measuring Voltage Between Terminal 5 Of ABS R/B & Body Ground
OK:
Voltage: 10 to 14 V
NG: Go to step 5 .
3. Check ABS MTR relay.
CHECK:
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Measure the resistance between each pair of the terminal of the motor relay.
OK:
ABS MTR RELAY TESTER CONNECTION & SPECIFIED CONDITION

Tester Connection Specified Condition
Terminals 1 and 2 Approximately 80 ohm
Terminals 3 and 5 10 kohm or higher
CHECK:
a. Apply battery positive voltage between terminals 1 and 2.

b. Measure the resistance between terminals.
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Fig. 50: Measuring Resistance Between Terminals

OK:
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ABS MTR RELAY TESTER CONNECTION & SPECIFIED CONDITION

Terminals 3 and 5 Below 1 ohm
NG: Replace ABS MTR relay.

4. Check for open and short circuit in harness and connector between ABS R/B (for ABS MTR relay)
and skid control ECU (See HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION
PROCEDURE ).
OK: If same code is still output after DTC is deleted, check contact condition of each
connection. If connections are normal, ECU may be defective.
5. Check ABS MTR CUT relay.
CHECK:
Measure the resistance between each terminal of the ABS MTR CUT relay.
OK:
ABS MTR CUT RELAY TESTER CONNECTION & SPECIFIED CONDITION

Terminals 1 and 2 Approximately 100 ohm
Terminals 3 and 5 10 kohm or higher
CHECK:
a. Apply battery voltage between terminals 1 and 2.

b. Measure the resistance between terminals 3 and 5 of ABS MTR CUT relay.
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Fig. 51: Measuring Resistance Between Terminals 3 & 5 of ABS MTR Cut Relay
OK:
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ABS MTR CUT RELAY TESTER CONNECTION & SPECIFIED CONDITION

Terminals 3 and 5 Below 1 ohm
NG: Replace ABS MTR CUT relay.

6. Check ABS No. 1 fuse.
PREPARATION:
Remove the ABS No. 1 fuse from the engine room R/B No. 1.
CHECK:
Measure the resistance.
OK:
NG: Replace ABS No. 1 fuse.

OK: Repair or replace harness and connector.
DTC C0278/11, C0279/12: ABS SOLENOID VALVE RELAY CIRCUIT
CIRCUIT DESCRIPTION
This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is
OK, the relay turns on.
Fig. 52: DTC (C0278/11, C0279/12) Table

WIRING DIAGRAM
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Fig. 53: ABS Solenoid Valve Wiring Diagram

1. Measure voltage between terminals +BS and GND1 of brake actuator connector.
PREPARATION:
Disconnect the brake actuator connector.
CHECK:
Measure the voltage between terminals +BS and GND1 of the brake actuator harness side connector.
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Fig. 54: Measuring Voltage Between Terminals +BS And GND1 Of Brake Actuator Harness Side
Connector
OK:
Voltage: 10 to 14 V
NG: Go to step 2.
2. Check ABS2 fuse.
PREPARATION:
Remove the ABS2 fuse from the engine room J/B.
CHECK:

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OK:
NG: Replace ABS2 fuse.

3. Measure resistance between terminal GND1 of skid control ECU connector and body ground.
PREPARATION:
CHECK:
Measure the resistance between terminal GND1 of the skid control ECU harness side connector and body
ground.
Fig. 55: Measuring Resistance Between Terminals GND1 Of Skid Control ECU Harness Side
Connector & Body Ground
OK:
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DTC C1201/51: ENGINE CONTROL SYSTEM MALFUNCTION
CIRCUIT DESCRIPTION
If trouble occurs in the engine control system, the ECU prohibits TRC and VSC control.
Fig. 56: DTC (C1201/51) Table

1. Check DTC for engine (See PRE-CHECK ).
IDENTIFYING CODE
A Output NG code
B Output normal code
B: Replace ECM.
A: Repair engine control system according to code output.
DTC C1203/53: MALFUNCTION IN ECM COMMUNICATION CIRCUIT
CIRCUIT DESCRIPTION
The circuit is used to send TRAC & VSC control information from the skid control ECU to the ECM (TRC+,
TRC-), and engine control information from the ECM to the skid control ECU (ENG+, ENG-).
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WIRING DIAGRAM
Fig. 58: Malfunction In ECM Communication Wiring Diagram

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1. Check for open and short circuit in harness and connector between skid control ECU and ECM
(See HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE ).
2. Check for open and short circuit in harness and connector between terminal E1 of ECM and body
ground (See HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE ).
PREPARATION:
a. Remove the glove compartment (see COMPONENTS ).

b. Disconnect the ECM from the heater control assembly.
c. Turn the ignition switch ON.
CHECK:
Measure the resistance between terminal E1 of the ECM connector and body ground.
Fig. 59: Measuring Resistance Between Terminal E1 Of ECM Connector & Body Ground
OK:
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DTC C1210/36, C1336/39: ZERO POINT CALIBRATION DECELERATION SENSOR UNDONE &
ZERO POINT CALIBRATION MALFUNCTION IN YAW RATE SENSOR UNDONE
CIRCUIT DESCRIPTION
The deceleration sensor is included in the yaw rate sensor.
Fig. 60: DTC (C1210/36, C1336/39) Table

WIRING DIAGRAM
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Fig. 61: Zero Point Calibration Malfunction In Yaw Rate Sensor Wiring Diagram
HINT:
When U0073/94, U0123/62, U0124/95 or U0126/63 is output accompanied with C1210/36 or C1336/39,
inspect and repair the trouble areas indicated by U0073/94, U0123/62, U0124/95 or U0126/63 first.
1. Check installation condition of yaw rate sensor.

NG: Repair or replace yaw rate sensor.
2. Perform zero point calibration of yaw rate sensor and deceleration sensor (See PRE-CHECK ).
Go to next step.
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3. Check DTC once more.
PREPARATION:
a. Clear the DTC (see PRE-CHECK ).

CHECK:

NO : END
YES : Replace yaw rate sensor.
DTC C1223/43: ABS CONTROL SYSTEM MALFUNCTION
CIRCUIT DESCRIPTION
DIAGNOSTIC TROUBLE CODES-(C1223/43)

DTC No. DTC Detection Condition Trouble Area
C1223/43 ABS control system is abnormal. ABS control system
1. Check DTC for the ABS (See PRE-CHECK ).
IDENTIFYING CODES FOR ABS

A Output NG code
B ABS warning light remains ON
B: Check ABS warning light circuit.

A: Repair ABS control system according to code output.
DTC C1224/44: NEO SIGNAL CIRCUIT
CIRCUIT DESCRIPTION
The skid control ECU receives engine revolution speed signals (NEO signals) from the ECM.
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WIRING DIAGRAM
Fig. 63: NEO Wiring Diagram

1. Check for open and short circuit in harness and connector between terminal NEO of skid control
ECU and terminal NEO of ECM (See HOW TO USE THE DIAGNOSTIC CHART AND
INSPECTION PROCEDURE ).
2. Measure voltage between terminal NEO of ECM and body ground.
CHECK:
Measure the voltage between terminal NEO of the ECM and body ground for the engine conditions in
ENGINE CONDITION & VOLTAGE IDENTIFICATION .
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Fig. 64: Measuring Voltage Between Terminal NEO Of ECM & Body Ground
OK:
ENGINE CONDITION & VOLTAGE IDENTIFICATION

Engine Condition Voltage
OFF (ignition switch ON) 10 to 14 V or below 1 V
ON (Idling) 10 to 14 V <-> Below 1 V (Pulse)
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Fig. 65: NEO Of ECM Voltage Wave Form

NG: Replace ECM.

connection.
DTC C1225/25: VSC SOLENOID CIRCUIT
CIRCUIT DESCRIPTION
This solenoid turns on when signals are received from the ECU and controls the pressure acting on the wheel
cylinders to control the braking force.

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WIRING DIAGRAM
Fig. 67: VSC Solenoid Wiring Diagram

1. Check DTC once more (See PRE-CHECK ).
PREPARATION:
a. Clear the DTC.

CHECK:

NO : END
YES : Replace brake actuator assembly.
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DTC C1231/31: STEERING ANGLE SENSOR CIRCUIT
CIRCUIT DESCRIPTION
The steering angle sensor signal is sent to the skid control ECU through the CAN communication system. When
there is malfunction in communication, it will be detected by the diagnosis function of the CAN communication
system.

WIRING DIAGRAM
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Fig. 69: Steering Angle Sensor Wiring Diagram

HINT:
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 When U0073/94, U0123/62, U0124/95 or U0126/63 is output accompanied with C1231/31, inspect and
repair the trouble areas indicated by U0073/94, U0123/62, U0124/95 or U0126/63 first.
 When the speed sensor or the yaw rate sensor has trouble, DTCs for the steering angle sensor may be
output even when the steering angle sensor is normal. When DTCs for the speed sensor or yaw rate
sensor are output accompanied with other DTCs for the steering angle sensor, inspect and repair the speed
sensor and yaw rate sensor first, and then inspect and repair the steering angle sensor.
1. Measure input voltage of steering angle sensor.
PREPARATION:
a. Remove the steering wheel and column lower cover (see REMOVAL ).
b. Disconnect the steering angle sensor connector.
CHECK:

b. Measure the voltage between terminals 1 and 2, 2 and 3 of the steering angle sensor harness side
connector.
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Fig. 70: Measuring Voltage Between Terminals 1 & 2, 2 & 3 Of Steering Angle Sensor
Harness Side Connector
OK:
Voltage: 10 to 14 V

OK: Replace steering angle sensor.
DTC C1232/32, C1234/34, C1243/43, C1244/44, C1245/45, C1381/97: DECELERATION SENSOR

CIRCUIT, YAW RATE SENSOR CIRCUIT, MALFUNCTION IN DECELERATION SENSOR &
MALFUNCTION IN POWER SUPPLY VOLTAGE YAW/DECELERATION SENSOR
CIRCUIT DESCRIPTION
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The deceleration sensor is included in the yaw rate sensor.
The deceleration sensor and yaw rate sensor signal is sent to the skid control ECU through the CAN
communication system.
When there is malfunction in communication, it will be detected by the diagnosis function of the CAN
communication system.
Fig. 71: DTC (C123/32, C1234/34, C1243/43, C1244/44, C1245/45, C1381/97) Table
WIRING DIAGRAM
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Fig. 72: Deceleration Sensor & Yaw Rate Sensor Wiring Diagram
HINT:
When U0073/94, U0123/62, U0124/95 or U0126/63 are output accompanied with C1232/32, C1234/34,
C1244/44, C1245/45, or C1381/97, inspect and repair the trouble areas indicated by U0073/94, U0123/62,
U0124/95 or U0126/63 first.
1. Measure voltage of IG power source.
PREPARATION:
Disconnect the yaw rate sensor connector.

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CHECK:

b. Measure the voltage between terminal IG and GND of the yaw rate sensor connector.
Fig. 73: Identifying Terminals IG & GND Of Yaw Rate Sensor Connector
OK:
Voltage: 10 to 14 V
OK: Replace yaw rate sensor.

2. Check for open or short circuit in harness and connector between yaw rate sensor and battery (See
HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE ).
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3. Check resistance between terminal GND of yaw rate sensor connector and body ground.
PREPARATION:
Disconnect the yaw rate sensor connector.
CHECK:
Measure the resistance between terminal GND of the yaw rate sensor harness side connector and body
ground.
Fig. 74: Identifying GND Terminal Of Yaw Rate Sensor

OK:
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OK: Replace yaw rate sensor.
DTC C1241/41: IG POWER SOURCE CIRCUIT
CIRCUIT DESCRIPTION

WIRING DIAGRAM
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Fig. 76: IG Power Source Wiring Diagram

1. Check ECU-IG fuse.
PREPARATION:
Remove the ECU-IG fuse from the driver side J/B.
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Fig. 77: Locating ECU-IG Fuse

CHECK:
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OK:
NG: Replace fuse.

2. Measure battery positive voltage.
CHECK:
Check the battery positive voltage.
OK:
Voltage: 10 to 14 V
NG: Check and repair charging system.

3. Measure voltage of ECU IG power source.
When using the hand-held tester:
PREPARATION:

CHECK:
Measure the voltage condition output from the ECU displayed on the hand-held tester.
OK:
"Normal" is displayed.
When not using the hand-held tester:
PREPARATION:
CHECK:

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b. Measure the voltage between terminal IG1 and GND1 of brake actuator harness side connector.
Fig. 78: Measuring Voltage Between Terminal IG1 & GND1 Of Brake Actuator Harness Side
Connector
OK:
Voltage: 10 to 14 V

PREPARATION:
CHECK:
Measure the resistance between terminal GND1 of the skid control ECU harness side connector and the
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body ground.
Fig. 79: Measuring Resistance Between GND1 Of Skid Control ECU Harness Side Connector &
Body Ground
OK:

OK: Check for open circuit in harness and connector between skid control ECU and battery,
skid control ECU and body ground (See HOW TO USE THE DIAGNOSTIC CHART AND
DTC C1246/46: MASTER CYLINDER PRESSURE SENSOR CIRCUIT
CIRCUIT DESCRIPTION
The master cylinder pressure sensor is connected to the skid control ECU in the actuator.
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Fig. 80: DTC-C1246/46 Table

HINT:
held tester.
1. Check output value of master cylinder pressure sensor.
PREPARATION:

CHECK:
Check that the brake fluid pressure value of the master cylinder pressure sensor observed in the hand-held
tester changes when the brake pedal is depressed.
OK:
Brake fluid pressure value should change.
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2. Check whether or not ECU terminal STP input voltage changes when stop light switch comes on
and off.
NO : Check stop light switch circuit (See PROBLEM SYMPTOMS TABLE ).
YES : If same code is still output after DTC is deleted, check contact condition of each
DTC C1249/49: STOP LIGHT SWITCH CIRCUIT
CIRCUIT DESCRIPTION

WIRING DIAGRAM
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Fig. 82: Stop Light Circuit Diagram

1. Check operation of stop light switch.
CHECK:
Check that the stop lights turn on when the brake pedal is depressed and turn off when the brake pedal is
released.
OK: Go to step 4 .
2. Measure voltage between terminal STP of skid control ECU and body ground.
PREPARATION:

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CHECK:
Measure the voltage between terminal STP of the skid control ECU and body ground when the brake
pedal is depressed.
OK:
Voltage: 8 to 14 V
CHECK:
Measure the voltage between terminal STP of the skid control ECU and body ground when the brake
pedal is released.
Fig. 83: Locating STP Terminal

OK:
Voltage: Below 1 V
NG: Go to step 3
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3. Check stop light circuit (See PROBLEM SYMPTOMS TABLE ).

NG: Repair or replace stop light circuit.
4. Check for open circuit in harness and connector between skid control ECU and stop light switch
DTC C1251/51: ABS PUMP MOTOR LOCK
CIRCUIT DESCRIPTION
Fig. 84: DTC - C1251/51 Table

WIRING DIAGRAM
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Fig. 85: ABS Pump Motor Lock Wiring Diagram

HINT:
held tester.
1. Check ABS motor operation.
PREPARATION:

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c. Select the item "ABS MTR RELAY" in the ACTIVE TEST and operating it with the hand-held
tester.
CHECK:
Check the operation sound of the ABS motor when operating it with the hand-held tester.
OK:
The operation sound of the ABS motor should be heard.

PREPARATION:
CHECK:
ground.
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Fig. 86: Identifying GND2 Terminal

OK:

DTC C1337/37: TIRES OF DIFFERENT SIZE (ONLY FOR 2WD)
CIRCUIT DESCRIPTION
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Fig. 87: DTC - (C1337/37) Table

1. Check tire size.

NG: Replace tires so that all 4 tires are same in size.
2. Check sensor rotor (See DTC C0200/31, C0205/32, C0210/33, C1235/35, C1236/36, C1238/38,
C1239/39: SPEED SENSOR CIRCUIT ).
NG: Replace speed sensor rotor.
3. Check speed sensor (See DTC C0200/31, C0205/32, C0210/33, C1235/35, C1236/36, C1238/38,
C1239/39: SPEED SENSOR CIRCUIT ).
NG: Replace speed sensor.
4. Check for open and short circuit in harness and connector between speed sensor and skid control
ECU (See HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE ).
OK: Check and replace brake actuator assembly.
DIAGNOSTIC TROUBLE CODES ALWAYS ON* MALFUNCTION IN SKID CONTROL ECU
*: ABS warning light
CIRCUIT DESCRIPTION
Fig. 88: DTC Trouble Area Table

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HINT:
In some cases, the hand-held tester cannot be used when the ECU is abnormal.
WIRING DIAGRAM
Fig. 89: Malfunction In Skid Control ECU Wiring Diagram

1. Is DTC output?
Check for DTC (see PRE-CHECK ).
YES : Repair circuit indicated by output code.

NO : Go to next step.
2. Check that skid control ECU connector are securely connected to skid control ECU.
NG: Connect connector to skid control ECU.
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3. Measure voltage between terminals IG1 and GND1 of brake actuator connector.
PREPARATION:
CHECK:

b. Measure the voltage between terminal IG1 and GND1 of the skid control ECU harness side
connector.
Fig. 90: Measuring Voltage Between Terminal IG1 & GND1 Of Skid Control ECU Harness
Side Connector
OK:
Voltage: 10 to 14 V
NG: Check for open and short circuit in harness and connector between ECU-IG fuse and
skid control ECU (See HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION
PROCEDURE ).
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PREPARATION:
CHECK:
ground.

OK:

CHECK:
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Voltage: 10 to 14 V

6. Check operation of ABS warning light.
PREPARATION:
Turn the ignition switch OFF.
Disconnect the connector from the brake actuator.
Ground terminal WA of the skid control ECU.
Turn the ignition switch ON.
CHECK:
Check that the ABS warning light turns off.
NG: Check and repair for ABS warning light circuit (See CIRCUIT ).
7. Check ABS warning light
PREPARATION:
a. Reconnect the connector to the brake actuator.
CHECK:
Check that the ABS warning light turns off.
NG: Replace brake actuator assembly.
OK: END
DIAGNOSTIC TROUBLE CODES ALWAYS ON* MALFUNCTION IN SKID CONTROL ECU
*: VSC warning light
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CIRCUIT DESCRIPTION
Fig. 92: DTC Trouble Area Chart

HINT:
In some cases, the hand-held tester cannot be used when the ECU is abnormal.
WIRING DIAGRAM
Fig. 93: Malfunction In Skid Control ECU Wiring Diagram

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1. Is DTC output for VSC?
Check for DTC (see PRE-CHECK ).

2. Check that skid control ECU connector are securely connected to skid control ECU.
NG: Connect connector to skid control ECU.
3. Measure voltage between terminals IG1 and GND1 of brake actuator connector.
PREPARATION:
CHECK:

b. Measure the voltage between terminals IG1 and GND1 of the skid control ECU harness side
connector.
Fig. 94: Measuring Voltage Between Terminal IG1 & GND1 Of Skid Control ECU Harness
Side Connector
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OK:
Voltage: 10 to 14 V
NG: Check for open and short circuit in harness and connector between ECU-IG fuse and
skid control ECU (See HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION
PROCEDURE ).
PREPARATION:
CHECK:
ground.

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OK:

CHECK:
OK:
Voltage: 10 to 14 V

6. Check TC terminal circuit (see TC TERMINAL CIRCUIT ).
7. Check operation of VSC warning light.
PREPARATION:
a. Turn the ignition switch OFF.

b. Disconnect the connector from the brake actuator.
CHECK:
Check that the VSC warning light turns off.
OK:
The VSC warning light turns off for 2 seconds after turning the ignition switch ON.
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NG: Check and repair for VSC warning light circuit (See CIRCUIT ).
ABS WARNING LIGHT CIRCUIT (DOES NOT LIGHT UP)
CIRCUIT DESCRIPTION
If the ECU detects trouble, it turns on the ABS warning light and prohibits ABS control. At this time, ECU
stores a DTC in memory.
Connect terminals TC and CG of the DLC3 to make the ABS warning light blinks and the DTC is indicated.
WIRING DIAGRAM
Fig. 96: ABS Warning Light Circuit Wiring Diagram

HINT:
held tester.
1. Check operation of ABS warning light.

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PREPARATION:

c. Select the ACTIVE TEST mode on the hand-held tester.
CHECK:
Check that the ABS warning light can be turned ON and OFF on the combination meter using the hand-
held tester.
OK:
The ABS warning light illuminates.

2. Check ABS warning light.
See the combination meter troubleshooting in INSPECTION .
NG: Repair bulb or combination meter assembly (See CIRCUIT ).

3. Check for open and short circuit in harness and connector between skid control ECU and ABS
warning light (See HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION
PROCEDURE ).
VSC WARNING LIGHT CIRCUIT (DOES NOT LIGHT UP)
CIRCUIT DESCRIPTION
If the ECU stores DTC to shut down VSC & TRAC operation, the VSC warning light turns on the combination
meter.
WIRING DIAGRAM
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Fig. 97: VSC Warning Light Circuit Wiring Diagram

HINT:
held tester.
1. Check operation of the VSC warning light.
PREPARATION:

CHECK:
Check that the VSC warning light can be turned ON and OFF on the combination meter using the hand-
held tester.
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OK:
VSC WARNING LIGHT DIAGNOSTIC

Item Test Details Diagnostic Note
VSC/ TRAC OFF IND Turns VSC / TRAC OFF indicator ON / OFF Observe combination meter

2. Check VSC warning light.
NG: Repair bulb or combination meter assembly (See CIRCUIT ).

3. Check for open and short circuit in harness and connector between skid control ECU and VSC
warning light (See HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION
PROCEDURE ).
BRAKE WARNING LIGHT CIRCUIT
CIRCUIT DESCRIPTION
The brake warning light turns on when the brake fluid is insufficient, the parking brake is applied or the EBD is
defective.
WIRING DIAGRAM
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Fig. 98: Brake Warning Light Wiring Diagram

1. Check parking brake switch circuit (see PROBLEM SYMPTOMS TABLE ).

NG: Repair or replace parking brake switch circuit.
2. Check brake fluid level warning switch circuit (see PROBLEM SYMPTOMS TABLE ).
NG: Repair or replace brake fluid level warning switch circuit.
3. Is DTC output?
Check for DTCs (see PRE-CHECK ).

4. Check BRAKE warning light.
See the combination meter inspection in INSPECTION .
NG: Repair or replace combination meter.

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SLIP INDICATOR LIGHT CIRCUIT
CIRCUIT DESCRIPTION
The Slip indicator light blinks during VSC & TRAC operation.
WIRING DIAGRAM
Fig. 99: Slip Indicator Light Wiring Diagram

HINT:
held tester.
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2004 Toyota RAV4
1. Check operation of slip indicator light.
PREPARATION:

CHECK:
Check that the slip indicator light can be turned ON and OFF on the combination meter using the hand-
held tester.
OK:
The slip indicator light illuminates.
NG: Go to step 4 .
2. Check that slip indicator light is ON for 3 seconds immediately after ignition switch is turned ON.
OK: Proceed to next circuit inspection shown on problem symptoms table (see PROBLEM
SYMPTOMS TABLE ).
3. Check slip indicator light.

4. Check for open and short circuit in harness and connector between skid control ECU and slip
indicator light (See HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION
PROCEDURE ).
TRAC OFF INDICATOR LIGHT, TRAC OFF SWITCH CIRCUIT
CIRCUIT DESCRIPTION
This is the TRAC control main switch. When the TRAC OFF switch is pushed on, TRAC control turns off and
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2004 Toyota RAV4
the TRAC OFF indicator turns on. Turn the ignition switch OFF, and check that TRAC control turns on when
turning the ignition switch ON again.
WIRING DIAGRAM
Fig. 100: TRAC OFF Indicator Light, TRAC OFF Switch Circuit Wiring Diagram
HINT:
held tester.
1. Check operation of TRAC OFF indicator light.
PREPARATION:

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2004 Toyota RAV4
CHECK:
Check that the TRAC OFF indicator light can be turned ON and OFF on the combination meter using the
hand-held tester.
OK:
TRAC OFF INDICATOR LIGHT DIAGNOSTIC

Item Measurement Item / Range (Display) Diagnostics Note
TRAC OFF IND Turns TRAC indicator ON/OFF Observe combination meter
NG: Go to step 4 .
2. Check TRAC OFF switch.
PREPARATION:
Remove the TRAC OFF switch.
CHECK:
Measure the resistance between terminals 2 and 5 of the TRAC OFF switch when the TRAC OFF switch
is ON and OFF.
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Fig. 101: Measuring Resistance Between Terminals 2 & 5 Of TRAC Off Switch When TRAC Off
Switch Is On & Off
OK:
TRAC OFF SWITCH RESISTANCE

TRAC OFF Switch Resistance
ON Below 1 ohm
OFF 1 Mohm or higher
NG: Replace TRAC OFF switch.

3. Check for open and short circuit in harness and connector between terminal CSW of skid control
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ECU and TRAC OFF switch and body ground (See HOW TO USE THE DIAGNOSTIC CHART
AND INSPECTION PROCEDURE ).
4. Check TRAC OFF indicator light.

5. Check for open and short circuit in harness and connector between terminal WT of skid control
ECU and TRAC OFF indicator light (See HOW TO USE THE DIAGNOSTIC CHART AND
VSC WARNING BUZZER CIRCUIT
CIRCUIT DESCRIPTION
The VSC warning buzzer sounds during VSC operation.
WIRING DIAGRAM
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2004 Toyota RAV4
Fig. 102: VSC Warning Buzzer Circuit Wiring Diagram

HINT:
held tester.
1. Check operation of VSC warning buzzer.
PREPARATION:

CHECK:
Check "ON-OFF" function of the VSC warning buzzer using the hand-held tester.
OK:
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2004 Toyota RAV4
The VSC warning buzzer operates according to the tester instruction.

2. Measure voltage between terminal 2 of VSC warning buzzer and body ground.
PREPARATION:
Remove the VSC warning buzzer with the connectors being connected.
CHECK:

b. Measure the voltage between terminal 2 of the VSC warning buzzer and the body ground.
OK:
Voltage: 10 to 14 V
NG: Repair or replace harness and connector from voltage supply to VSC warning buzzer.
3. Check VSC warning buzzer.
PREPARATION:
Disconnect the VSC warning buzzer connector.
CHECK:
Apply battery positive voltage to terminals 1 and 2 of the VSC buzzer connector and check that the VSC
warning buzzer sounds.
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Fig. 103: Checking VSC Warning Buzzer Sound

NG: Replace VSC warning buzzer.

4. Check for open and short circuit in harness and connector between skid control ECU and VSC
warning buzzer (See HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION
PROCEDURE ).
TC TERMINAL CIRCUIT
CIRCUIT DESCRIPTION
Connecting terminals TC and CG of the DLC3 causes the ECU to indicate the DTC by blinking the ABS
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2004 Toyota RAV4
warning light, VSC warning light and Brake warning light.
TC signal is sent to the skid control ECU from the ECM.
WIRING DIAGRAM
Fig. 104: TC Terminal Circuit Wiring Diagram

1. Measure voltage between terminals TC and CG of DLC3.
PREPARATION:
CHECK:
Measure the voltage between terminals TC and CG of the DLC3.
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Fig. 105: Measuring Voltage Between Terminals TC & CG Of DLC3

OK:
Voltage: 10 to 14 V
NG: Go to step 4 .
2. With ignition switch OFF, check for open and short circuit in harness and connector between ECM
and DLC3, and DLC3 and body ground (See HOW TO USE THE DIAGNOSTIC CHART AND
3. Check for open and short circuit in harness and connector between skid control ECU and ECM
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4. Check for open and short circuit in harness and connector between terminals TC of the DLC3 and
ECM (See HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE ).
OK: Replace ECM.
TS TERMINAL CIRCUIT
CIRCUIT DESCRIPTION
The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with the
DTC check. Connecting terminals TS and CG of the DLC3 starts the check.
WIRING DIAGRAM
Fig. 106: TS Terminal Circuit Wiring Diagram

1. Measure voltage between terminals TS and CG of DLC3.
CHECK:

b. Measure the voltage between terminals TS and CG of the DLC3.
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Fig. 107: Measuring Voltage Between Terminals TS & CG Of DLC3

OK:
Voltage: 10 to 14 V
OK: If ABS warning light does not blink even after TS and CG have been connected, the
ECU may be defective.
2. Check for open and short circuit in harness and connector between skid control ECU and DLC3,
and DLC3 and body ground (See HOW TO USE THE DIAGNOSTIC CHART AND
OK: Check and replace skid control ECU (See HOW TO USE THE DIAGNOSTIC CHART
AND INSPECTION PROCEDURE ).
CHECK FOR FLUID LEAKAGE
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Check for fluid leakage from actuator or hydraulic lines.
Fig. 108: Locating Fluid Leakage Points

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2004 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems
2004 ACCESSORIES/SAFETY EQUIPMENT
Toyota - Air Bag Restraint Systems
DESCRIPTION & OPERATION
WARNING: Accidental air bag deployment is possible. Personal injury may result.
Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS
before working on air bag system or related components.
Supplemental Restraint System (SRS), also known as air bag system, is designed to provide increased accident
protection for driver and passenger by deploying air bag modules and seat belt pretensioners in a front impact
collision. In the event a side impact occurs, curtain and side air bag modules will deploy on side of collision.
The air bag system is designed to be used in conjunction with 3-point safety belts.
The air bag system includes the following components: dual-stage driver-side air bag module (steering wheel
pad), dual-stage passenger-side air bag module, spiral cable, right and left side air bag modules, right and left
side curtain air bag modules, right and left side air bag sensor, right and left rear air bag sensors, right and left
front air bag sensors, driver seat position sensor, right and left front seat belt pretensioners, AIR BAG warning
light, air bag sensor assembly and associated wiring harnesses.
COMPONENT LOCATIONS
Refer to illustration for component locations. See Fig. 1 & Fig. 2 .
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2004 Toyota RAV4
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Fig. 1: Locating Restraint System Components (1 Of 2)

Fig. 2: Locating Restraint System Components (2 Of 2)

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SYSTEM OPERATION CHECK

Turn ignition switch to ON position. AIR BAG warning light should come on for about 6 seconds and then go
out. If AIR BAG warning light does not operate as specified, see DIAGNOSTICS .
AIR BAG SAFETY PRECAUTIONS

Observe these precautions when servicing the air bag system:
 Disable air bag system before servicing any air bag system or steering column component. Failure to do
this could result in accidental air bag deployment and possible personal injury. See DISABLING &
ACTIVATING AIR BAG SYSTEM .
 When diagnosing air bag system, always check for diagnostic codes before disconnecting battery.
 After turning ignition switch to LOCK position and disconnecting negative battery cable, wait at least 90
seconds before working on air bag system. Air bag system is equipped with a back-up power source that
may allow air bag to deploy until 90 seconds after disconnecting negative battery cable.
 If vehicle was in a minor collision but air bags did not deploy, inspect all system components for any sign
of damage, and replace as necessary.
 Never use air bag system components from another vehicle. Replace air bag system components with new
parts.
 Remove air bag sensor assembly if repairing the vehicle requires impacting (shocking) the vehicle.
 Air bag sensor assembly contains mercury. After replacement, DO NOT destroy old part. When
scrapping vehicle or replacing air bag sensor assembly, remove air bag sensor assembly and dispose of it
as toxic waste.
 Never disassemble and repair air bag sensor assembly, front air bag sensors, passenger-side or driver-side
air bag modules or seat belt pretensioners.
 Replace dropped, cracked, dented or otherwise damaged components.
 DO NOT expose air bag sensor assembly, front air bag sensors or air bag modules directly to heat or
flame.
 When diagnosing electrical circuits, use a volt/ohm meter with high impedance (10,000 ohms minimum).
 Information labels are attached to air bag components. Follow all notices on labels.
 After work on air bag system is complete, check AIR BAG warning light to ensure system is functioning
properly. See SYSTEM OPERATION CHECK .
 Always wear safety glasses when servicing or handling an air bag.
 When placing a live air bag on a bench or other surface, always face air bag and trim cover up and away
from surface. This will reduce motion of module if it is accidentally deployed.
 After deployment, air bag surface may contain deposits of sodium hydroxide, which irritates skin. Always
wear safety glasses, rubber gloves, and long-sleeved shirt during clean- up. After clean-up, wash hands
using mild soap and water.
 Carry a live air bag module with trim cover (air bag) pointed away from your body to minimize injury in
case accidental deployment.
 If air bag system is not fully functional for any reason, vehicle should not be driven until system is
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repaired and again becomes operational. DO NOT remove bulbs, modules, sensors or other components,
or in any way disable system from operating normally. If air bag system is not functional, park vehicle
until it is repaired and functions properly.
DISABLING & ACTIVATING AIR BAG SYSTEM
WARNING: Unintentional air bag module deployment is possible. Personal injury may
result. Never use memory savers when working on air bag system.
Back-up power supply maintains air bag system voltage for about 90
seconds after battery is disconnected. After disabling air bag system, wait
at least 90 seconds before servicing air bag system.
DISABLING SYSTEM
For Component Replacement
Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds
before starting any work on vehicle.
For Diagnostics
1. Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90
seconds. Disconnect air bag sensor assembly connectors. See AIR BAG SENSOR ASSEMBLY under
REMOVAL & INSTALLATION. Remove driver-side air bag module. See DRIVER-SIDE AIR BAG
MODULE under REMOVAL & INSTALLATION. Disconnect passenger-side air bag module
connector, accessible by removal of glove box assembly. See Fig. 3 .
2. Disconnect right and left side air bag module connectors. See SIDE AIR BAG MODULE under
REMOVAL & INSTALLATION. Disconnect right and left side curtain air bag module connectors. See
SIDE CURTAIN AIR BAG MODULE under REMOVAL & INSTALLATION. Disconnect right and
left front seat belt pretensioner connectors. See SEAT BELT PRETENSIONER under REMOVAL &
INSTALLATION.
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Fig. 3: Disconnecting Passenger-side Air Bag Module Connector

ACTIVATING SYSTEM
For Component Replacement
Ensure ignition switch is in LOCK position. Reconnect negative battery cable. Perform SYSTEM
OPERATION CHECK .
For Diagnostics
Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds.
Reconnect right and left seat belt pretensioner connectors. Reconnect right and left side curtain air bag module
connectors. Reconnect right and left side air bag module connectors. Reconnect passenger-side air bag
connector. Install driver-side air bag module. Reconnect air bag sensor assembly connectors. Reconnect
negative battery cable. Perform SYSTEM OPERATION CHECK .
DISPOSAL PROCEDURES
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WARNING: Undeployed air bags contain substances that can cause illness or injury if
improperly handled. Disposing of an undeployed air bag may violate
federal, state and/or local laws. If scrapping vehicle, air bag must be
deployed while still mounted in vehicle. Air bags should not be deployed
inside vehicle unless vehicle is to be scrapped. If not scrapping vehicle,
use off-vehicle deployment procedures. See OFF-VEHICLE
DEPLOYMENT . Wear gloves and safety glasses when handling air bag.
Wrap deployed air bag in a sturdy plastic bag and dispose of it like any
other part.
TESTING DEPLOYMENT TOOL
WARNING: Malfunctioning deployment tool may cause accidental air bag

deployment. Personal injury may result. If deployment light illuminates
without pressing deployment button, deployment tool is malfunctioning
and should not be used.
Connect Red clip of Deployment Tool (09082-00700) to positive battery terminal of 12 volt battery. Connect
Black clip of deployment tool to negative terminal of battery. Press deployment tool activation switch and
ensure deployment light illuminates on deployment tool. Disconnect deployment tool Red and Black clips from
battery.
ON-VEHICLE DEPLOYMENT (SCRAPPED VEHICLES ONLY)
Driver-side AIR Bag Module
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Ensure steering wheel and driver-side
air bag module are not loose. If components are loose, deploy air bag(s) using OFF-VEHICLE
DEPLOYMENT procedure. Test Deployment Tool (09082-00700). See TESTING DEPLOYMENT
TOOL .
2. Remove lower steering column cover. Disconnect spiral cable connector. Connect Deployment Tools
(09082-00700 and 09082-00760 single inflator] or 09082-00780 double inflator]) to air bag module
connector. Position deployment tool at least 33 feet (10 m) from front of vehicle.
3. Close all doors and windows of vehicle. Connect deployment tool Red clip to positive battery terminal
and Black clip to negative battery terminal. Ensure no one is inside or within 33 feet (10 m) of vehicle.
Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal.
Press activation switch to deploy air bag. Because of heat, DO NOT touch air bag for at least 30 minutes
after deployment.
Passenger-side AIR Bag Module
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Ensure passenger-side air bag module is
not loose. If air bag is loose, deploy air bag using OFF-VEHICLE DEPLOYMENT procedure. Test
Deployment Tool (09082-00700). See TESTING DEPLOYMENT TOOL .
2. Remove glove box. Disconnect passenger-side air bag connector. See Fig. 3 . Connect Deployment Tools
(09082-00700 and 09082-00760 single inflator] or 09082-00780 double inflator]) to air bag module
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connector. Position deployment tool at least 33 feet (10 m) from front of vehicle.
3. Close all doors and windows of vehicle. Connect deployment tool Red clip to positive battery terminal
and Black clip to negative battery terminal. Ensure no one is inside or within 33 feet (10 m) of vehicle.
Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal.
Press activation switch to deploy air bag. Because of heat, DO NOT touch air bag for at least 30 minutes
after deployment.
Side AIR Bag Module
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See
DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Ensure seat back is
not loose. If components are loose, remove and deploy air bag(s) using OFF-VEHICLE
TOOL . Disconnect appropriate side air bag connector, located under seat.
2. Connect Deployment Tool (09082-00700) and adapter (09082-00750) to side air bag connector, located
under appropriate front seat cushion. Position deployment tool at least 33 feet (10 m) from front of
vehicle. Close all doors and windows of vehicle. Connect deployment tool Red clip to positive battery
terminal and Black clip to negative battery terminal.
3. Ensure no one is inside vehicle or within 33 feet (10 m) of vehicle. Press activation switch to deploy air
bag. Because of heat, DO NOT touch air bag for at least 30 minutes after deployment. Scrap vehicle with
air bag(s) still installed.
Side Curtain AIR Bag Module
DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Ensure there are no
loose components in vehicle. If components are loose, remove and deploy air bag(s) using OFF-
VEHICLE DEPLOYMENT procedure. Test Deployment Tool (09082-00700). See TESTING
DEPLOYMENT TOOL .
2. Disconnect side curtain air bag module harness connector. See SIDE CURTAIN AIR BAG MODULE
under REMOVAL & INSTALLATION. Connect Deployment Tool (09082-00700) and Adapter (09082-
00802) to side curtain air bag module connector. Position deployment tool at least 33 feet (10 m) from
front of vehicle. Close all doors and windows of vehicle. Connect deployment tool Red clip to positive
battery terminal and Black clip to negative battery terminal.
3. Ensure no one is inside vehicle or within 33 feet (10 m) of vehicle. Press activation switch to deploy air
bag. Because of heat, DO NOT touch air bag for at least 30 minutes after deployment. Scrap vehicle with
air bag(s) still installed.
Seat Belt Pretensioner
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Ensure seat belt pretensioner is not
loose. If components are loose, remove seat belt pretensioner and deploy using OFF-VEHICLE
TOOL . Access and disconnect appropriate seat belt pretensioner connector. See SEAT BELT
PRETENSIONER under REMOVAL & INSTALLATION.
2. Connect Deployment Tools (09082-00700 and 09082-00770) to appropriate seat belt pretensioner
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connector. Position deployment tool at least 33 feet (10 m) from front of vehicle. Close all doors and
windows of vehicle. Connect deployment tool Red clip to positive battery terminal and Black clip to
negative battery terminal.
3. Ensure no one is inside vehicle or within 33 feet (10 m) of vehicle. Connect deployment tool Red clip to
positive battery terminal and Black clip to negative battery terminal. Press activation switch to deploy air
bag. Because of heat, DO NOT touch pretensioner for at least 30 minutes after deployment. Scrap vehicle
with pretensioner(s) still installed.
OFF-VEHICLE DEPLOYMENT
Driver-side AIR Bag Module
DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Test Deployment
Tool (09082-00700). See TESTING DEPLOYMENT TOOL . Remove driver-side air bag module. See
DRIVER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION.
2. Install 2 bolts (6 mm X 35 mm) with washers into holes located in rear of driver-side air bag module.
Tighten bolts by hand. DO NOT overtighten bolts. Wrap strong wire at least twice around each bolt. See
Fig. 4 . Ensure no slack is present in wire. If slack is present, or wire is not strong enough, driver-side air
bag module may become loose due to shock when air bag is deployed.
3. Position driver-side air bag module on rim of a scrap wheel and tire assembly with pad side facing
upward. See Fig. 5 . Securely tie driver-side air bag module to wheel rim through lug nut holes. Place a
large cardboard box (weighted at sides) or 3 scrap tires on top of driver-side air bag module.
4. Connect Deployment Tools (09082-00700 and 09082-00802) to driver-side air bag module connector.
Position deployment tool at least 33 feet (10 m) away from driver-side air bag module. Connect
deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal. Press
activation switch to deploy driver-side air bag module. Because of heat, wait 30 minutes before handling
driver-side air bag module. Seal deployed air bag module in vinyl bag and dispose of in usual manner.
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Fig. 4: Securing Wire To Driver-side Air Bag Module

Fig. 5: Securing Driver-side Air Bag Module To Wheel

Passenger-side AIR Bag Module
Tool (09082-00700). See TESTING DEPLOYMENT TOOL . Remove passenger-side air bag module.
See PASSENGER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION.
2. Position passenger-side air bag module inside a scrap tire with air bag trim cover facing inside. See Fig.
6 . Secure passenger-side air bag module to tire with wire. Place this tire between 4 other tires (top tire
should have wheel installed). Securely tie all tires together with wire.
3. Connect Deployment Tools (09082-00700 and 09082-00802) to passenger-side air bag connector.
Position deployment tool at least 33 feet (10 m) away from passenger-side air bag. Connect deployment
tool Red clip to positive battery terminal and Black clip to negative battery terminal. Press activation
switch to deploy passenger-side air bag. Because of heat, wait 30 minutes before handling passenger-side
air bag module. Seal deployed air bag module in vinyl bag and dispose of in usual manner.
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Fig. 6: Preparing Passenger-side Air Bag Module For Deployment

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Side AIR Bag Module
Tool (09082-00700). See TESTING DEPLOYMENT TOOL . Remove appropriate side air bag. See
SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. Install 2 nuts on stud located on
rear side of air bag module. Wrap strong wire at least twice around each stud. See Fig. 7 . Ensure no slack
is present in wire.
2. Position side air bag inside a scrap tire with deployment side facing inside of tire and secure with strong
wire. Place this tire between 4 other tires (top tire should have wheel installed). Securely tie all tires
together with strong wire.
3. Connect Deployment Tool (09082-00700) and Adapter (09082-00750) to side air bag connector. Position
deployment tool at least 33 feet (10 m) away from side air bag. Press activation switch to deploy side air
bag. Because of heat, wait 30 minutes before handling side air bag. Seal deployed air bag module in vinyl
bag and dispose of in usual manner.
Fig. 7: Securing Wire To Side Air Bag Module

Side Curtain AIR Bag Module
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Tool (09082-00700). See TESTING DEPLOYMENT TOOL . Remove appropriate side curtain air bag
module. See SIDE CURTAIN AIR BAG MODULE under REMOVAL & INSTALLATION.
2. Cut off deployment section (air bag) from inflator. Position side curtain air bag inflator inside a scrap tire
and secure with strong wire. See Fig. 8 . Place this tire between 4 other tires (top tire should have wheel
installed). Securely tie all tires together with wire.
3. Connect Deployment Tool (09082-00700) and Adapter (09082-00801) to inflator connector. Position
deployment tool at least 33 feet (10 m) away from side air bag. Press activation switch to deploy side air
bag. Because of heat, wait 30 minutes before handling inflator. Seal deployed inflator in vinyl bag and
dispose of in usual manner.
Fig. 8: Preparing Air Bag Inflator For Deployment

Seat Belt Pretensioner
Tool (09082-00700). See TESTING DEPLOYMENT TOOL . Remove appropriate seat belt
pretensioner. See SEAT BELT PRETENSIONER under REMOVAL & INSTALLATION.
2. Connect Deployment Tools (09082-00700 and 09082-00770) to seat belt pretensioner connector. Position
seat belt pretensioner on ground and cover with wheel and tire assembly. See Fig. 9 . Position deployment
tool at least 33 feet (10 m) away from seat belt pretensioner. Connect deployment tool Red clip to
positive battery terminal and Black clip to negative battery terminal. Press activation switch to deploy
seat belt pretensioner. Because of heat, wait 30 minutes before handling. Dispose of deployed
pretensioner in usual manner.
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Fig. 9: Deploying Seat Belt Pretensioner

POST-COLLISION INSPECTION
When a vehicle has been involved in a collision, certain components of the passive restraint system must be
inspected or replaced. See AIR BAG/SRS COMPONENT INSPECTION & REPLACEMENT TABLES
article in the GENERAL INFORMATION section.
REMOVAL & INSTALLATION
Unintentional air bag module deployment is possible. Failure to follow
service precautions may result in air bag deployment and personal injury.
Read and carefully follow all WARNINGS and AIR BAG SAFETY
PRECAUTIONS before working on air bag system or related components.
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See AIR BAG SAFETY PRECAUTIONS . After component replacement,

check system operation. See SYSTEM OPERATION CHECK .
AIR BAG SENSOR ASSEMBLY
Removal & Installation
DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM.
2. Remove instrument cluster finish center panel. See Fig. 10 . Remove upper console panel. Remove front
and rear console boxes. Remove No. 1 and 2 instrument panel under covers. Remove shifter assembly.
Remove 3 Torx screws retaining air bag sensor assembly. Remove air bag sensor assembly.
3. To install, reverse removal procedure. Tighten air bag sensor assembly Torx screws to specification. See
TORQUE SPECIFICATIONS . Activate air bag system. See ACTIVATING SYSTEM under
DISABLING & ACTIVATING AIR BAG SYSTEM.
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Fig. 10: Identifying Air Bag Sensor Assembly

DRIVER-SIDE AIR BAG MODULE
NOTE: If steering wheel horn button contact plate is deformed, replace steering wheel
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assembly.
DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Working from back
of steering wheel, loosen air bag module Torx screws until groove around screw circumference catches
on screw case. See Fig. 11 .
2. Pull driver-side air bag module from steering wheel and disconnect driver-side air bag module connector.
Place driver-side air bag module on a flat surface with pad side facing up.
3. To install, reverse removal procedure. Ensure front wheels are in straight-ahead position and spiral cable
is properly aligned. See SPIRAL CABLE under ADJUSTMENTS. Tighten driver-side air bag module
Torx screws to specification. See TORQUE SPECIFICATIONS . Activate air bag system. See
ACTIVATING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM.
Fig. 11: Identifying Driver-side Air Bag Module Torx Screws

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FRONT AIR BAG SENSOR
2. Disconnect appropriate front air bag sensor connector with sensor installed. See Fig. 12 . Remove 2
mounting bolts and remove front air bag sensor.
3. To install, reverse removal procedure. Tighten front air bag sensor mounting bolts to specification. See
Fig. 12: Identifying Front Air Bag Sensors

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FRONT SEAT
DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Remove seat belt
anchor bolt and anchor. Remove front seat anchor bolts. Disconnect electrical connectors, under front
seat. Remove front seat.
2. To install, reverse removal procedure. Tighten front seat and seat belt anchor bolts to specification. See
HEADLINER
2. Remove rear seats. See REAR SEAT . Using screwdriver, disengage clips and remove rear floor finish
plate. See Fig. 13 . Disengage claws and remove rear door scuff plates. Using screwdriver, pry out room
light cover. Remove screws, disconnect connector and remove room light. Remove assist grips and
covers. Disengage claws and remove front door scuff plates.
3. Remove screws from right and left sun visors. Using screwdriver, pry out roof console cover. Remove
screws from roof console box, disconnect connector and remove roof console box. Remove bolt and left
rear seat belt floor anchor. Remove screws, and using screwdriver, pry out left deck side trim, disconnect
connector and remove left deck side trim. Repeat procedure to remove right deck side trim.
4. Remove bolt and rear seat belt shoulder anchor. Remove clips, bolt and using screwdriver, disengage
clips and remove left roof side inner garnish. Repeat procedure to remove right roof side inner garnish.
Remove bolt and left front seat outer belt floor anchor. Pull garnish upward and remove left center pillar
lower garnish. Repeat procedure to remove right center pillar lower garnish.
5. Remove bolt and left front seat outer belt shoulder anchor. Using screwdriver, pry out and remove center
pillar upper garnish. Repeat procedure to remove right center pillar upper garnish.
6. Using screwdriver, disengage clips on left front pillar garnish. Pull pillar garnish and rotate 90 degrees
and remove pillar garnish. Using cloth or nylon, 27.56" (700 mm) X 4.72" (120 mm), cover exposed
portion of curtain air bag module. Secure cover material with tape. Repeat procedure for right front pillar
garnish and curtain air bag module.
7. Using screwdriver, remove roof headliner trim garnish. Remove sun visor holders and room partition net
hooks. Remove clips and roof headliner.
8. To install, reverse removal procedure. Activate air bag system. See ACTIVATING SYSTEM under
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Fig. 13: Identifying Headliner

PASSENGER-SIDE AIR BAG MODULE
NOTE: If instrument panel or instrument panel reinforcement is deformed, replace with

new part.
2. Remove glove box door. Disconnect passenger-side air bag module connector. See Fig. 3 . Remove 2
nuts, one bolt and passenger-side air bag module.
3. To install, reverse removal procedure. Tighten passenger-side air bag module bolt to specification. See
TORQUE SPECIFICATIONS . There should be no interference between passenger-side air bag door
and instrument panel and clearance should be uniform. Activate air bag system. See ACTIVATING
SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM.
REAR AIR BAG SENSOR
2. Remove appropriate rear seat. See REAR SEAT . Remove rear door scuff plate, door opening trim and
rear quarter trim. Disconnect connector, remove bolts, and rear air bag sensor.
3. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS . Activate air bag system. See ACTIVATING SYSTEM under DISABLING &
ACTIVATING AIR BAG SYSTEM.
REAR SEAT
Rear seat removal and installation procedure is not available.
SEAT BELT BUCKLE SWITCH
DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Seat belt buckle
switch is integrated with front seat belt buckle. Remove appropriate front seat. Remove bolt and seat belt
buckle with switch.
2. To install, reverse removal procedure. Tighten seat belt buckle bolt to specification. See TORQUE
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SEAT BELT PRETENSIONER
2. Remove appropriate front and rear door scuff plates. Remove front seat belt floor anchor bolt and floor
anchor. Pulling center pillar lower garnish upward to disengage, remove garnish. Remove front seat belt
shoulder anchor bolt and shoulder anchor. Disconnect pretensioner connector. Remove 2 bolts and seat
belt pretensioner assembly.
3. To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE
SEAT POSITION SENSOR
2. Remove left front seat. Remove bolt, disconnect connector and remove seat position sensor.
3. To install, reverse removal procedure. Tighten seat position sensor bolt to specification. See TORQUE
SIDE AIR BAG MODULE
2. Remove appropriate front seat. See FRONT SEAT . Remove power seat knobs. See Fig. 14 . Remove
seat cushion shield and seat cushion inner shield. Remove front seat back board and seat back. Remove
headrest and headrest supports. Remove seat back cover, bolts and seat back frame.
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Fig. 14: Identifying Front Seat Components

SIDE AIR BAG SENSOR

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2. Remove appropriate front and rear door scuff plates. See Fig. 15 . Remove seat belt anchor bolt and
anchor. Remove center pillar lower garnish. Disconnect electrical connector, remove bolt, and position
front seat belt retractor (pretensioner) aside. Disconnect electrical connector, remove bolts and remove
side air bag sensor.
Fig. 15: Identifying Side Air Bag Sensor

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SIDE CURTAIN AIR BAG MODULE
2. Remove headliner. See HEADLINER . Remove bolts "A". See Fig. 16 . Bind front and rear sections of
curtain air bag to center section. Remove bolts "B" and curtain air bag module. Remove bolt and curtain
air bag module bracket. Place air bag module in plastic bag and store in safe place, if reusing air bag
module.
3. To install, reverse removal procedure. Ensure deployment section of air bag is not twisted during
installation. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Activate air bag system.
See ACTIVATING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM.
Fig. 16: Identifying Side Curtain Air Bag Module

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SPIRAL CABLE
2. Remove driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE . Remove steering
wheel. See STEERING WHEEL . Remove 3 screws and lower steering column cover. Disengage upper
steering column cover from steering column tube. Disconnect electrical connectors from spiral cable.
Disengage spiral cable attaching claws and remove spiral cable.
3. To install, reverse removal procedure. Before installing spiral cable, ensure front wheels are in straight-
ahead position and spiral cable is properly aligned. See SPIRAL CABLE under ADJUSTMENTS.
Tighten steering wheel nut and driver-side air bag module Torx screws to specification. See TORQUE
STEERING WHEEL
2. Remove driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE . Remove steering wheel
nut. Match mark steering wheel and steering shaft for reassembly reference. Using appropriate puller,
remove steering wheel.
3. To install, reverse removal procedure. Ensure front wheels are in straight-ahead position and spiral cable
is properly aligned. See SPIRAL CABLE under ADJUSTMENTS. Tighten steering wheel nut and
driver-side air bag module Torx screws to specification. See TORQUE SPECIFICATIONS . Activate
air bag system. See ACTIVATING SYSTEM under DISABLING & ACTIVATING AIR BAG
SYSTEM.
ADJUSTMENTS
SPIRAL CABLE
Ensure front wheels are in straight-ahead position. Turn spiral cable counterclockwise until it becomes difficult
to turn. Turn spiral cable clockwise about 2 1/2 turns to align match marks. See Fig. 17 . Install steering wheel.
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Fig. 17: Adjusting Spiral Cable

WIRE REPAIR
DO NOT attempt wiring harness repairs. Replace entire wiring harness.
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Front seat anchor bolts 27 (37)
Front seat back bolts 32 (44)
Passenger-side air bag module bolt 15 (20)
Rear air bag sensor bolts 15 (20)
Seat belt buckle bolt 32 (43)
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Seat belt floor anchor bolt 32 (43)

Seat belt shoulder anchor bolt 32 (43)
Side air bag sensor bolts 15 (20)
Steering wheel nut 25 (34)
INCH Lbs. (N.m)
Air bag sensor assembly Torx screws 133 (15)
Driver-side air bag module Torx screws 78 (8.8)
Front air bag sensor mounting bolts 71 (8.0)
Seat position sensor 71 (8.0)
Seat belt pretensioner upper bolt 75 (8.5)
Side curtain air bag module bolts "A" & "B" 87 (9.8)
DIAGNOSTICS
AIR BAG WARNING LIGHT CHECK
Turn ignition switch to ON position. If AIR BAG warning light comes on for about 6 seconds and then goes off,
system is functioning properly. If AIR BAG warning light comes on and stays on (or flashes), Diagnostic
Trouble Code (DTC) is stored in air bag sensor assembly. Go to RETRIEVING CODES . If AIR BAG
warning light responds in any other way, go to DIAGNOSTIC TESTS .
RETRIEVING CODES
CAUTION: Air bag system damage is possible. System may be damaged if jumper
wire is incorrectly connected across terminals of Data Link Connector 3
(DLC 3). Use Diagnosis Check Wire (09843-18020) when connecting
terminals of DLC 3.
Retrieving AIR Bag System Dtcs Using Diagnosis Check Wire
1. Turn ignition switch to ON position. Wait about 20 seconds. Using Diagnosis Check Wiring (09843-
18020), connect terminals Tc and CG of Data Link Connector 3 (DLC 3), located under lower left side of
instrument panel. See Fig. 18 .
2. If AIR BAG warning light flashes 2 times per second, system is normal (normal code). If AIR BAG
warning light does not flash Diagnostic Trouble Codes (DTCs) or flashes DTCs without DLC 3
connection, proceed to DIAGNOSTIC TROUBLE CODES (DTCS) CANNOT BE DISPLAYED, OR
DTCS ARE DISPLAYED WITHOUT DATA LINK CONNECTOR 3 (DLC 3) CONNECTION . If
AIR BAG warning light is on continuously and DTC is normal (flashes 2 times per second), source
voltage is low. See SOURCE VOLTAGE DROP under DIAGNOSTIC TESTS.
3. If AIR BAG warning light flashes, count number of flashes to determine DTCs that are set. For example,
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DTC 12 is: FLASH, 1.5-second pause, FLASH, FLASH. If more than one DTC is displayed, a 2.5-
second pause will occur between each DTC. Lowest numbered DTC will be displayed first, followed by
next higher number DTC until all DTCs have been displayed.
4. After all DTCs are displayed, a 4-second pause will occur, and DTC display will be repeated. See
appropriate DTC under DIAGNOSTIC TESTS . After repairing, clear DTCs. See CLEARING
CODES .
NOTE: If DTCs other than those listed under DIAGNOSTIC TESTS are displayed,
replace air bag sensor assembly. If AIR BAG warning light does not
function as described, proceed to appropriate test under DIAGNOSTIC
TESTS .
Retrieving AIR Bag System Dtcs Using Toyota Hand-held Tester
Install Toyota hand-held tester to Data Link Connector 3 (DLC 3), located under left lower side of instrument
panel. See Fig. 18 . Read DTC by following prompts on tester. See tester operator"s manual for instructions.
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Fig. 18: Identifying Data Link Connector 3 (DLC 3) Terminals

CLEARING CODES
Clearing AIR Bag System Dtcs Using Jumper Wire
1. Using one jumper wire, connect one end of jumper wire to DLC 3 terminal Tc. See Fig. 18 . Connect
other end of jumper wire to ground. Turn ignition switch to ON position. Wait 3-10 seconds for DTC to
begin to be output.
2. After DTC has begun to be output, release jumper wire from ground. Wait 2-4 seconds for AIR BAG
warning light to illuminate. Reconnect jumper to ground within 1-5 seconds after AIR BAG warning light
has illuminated. Wait 2-4 seconds for AIR BAG warning light to turn off. Release jumper from ground
within 1-5 seconds after AIR BAG warning light has turned off. Wait 2-4 seconds for AIR BAG warning
light to illuminate. Reconnect jumper to ground within 1-5 seconds after AIR BAG warning light has
illuminated. Wait 2-4 seconds for AIR BAG warning light to turn off. Wait one second for AIR BAG
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warning light to output normal code (2 flashes per second). If AIR BAG warning light does not output
normal code, repeat procedure until codes are cleared.
Clearing AIR Bag System Dtcs Using Toyota Hand-held Tester
Connect Toyota hand-held tester to DLC 3. Clear DTCs by following prompts on tester. See tester operator"s
manual for instructions.
CHECK MODE PROCEDURE
1. Check mode using Toyota hand-held tester
Connect Toyota hand-held tester to DLC 3. Turn ignition switch to ON position. Select "TEST MODE",
and proceed checking with hand-held tester.
RELEASING SHORT SPRING
CAUTION: Damage to air bag electrical connector terminal is possible. If paper

thicker than male terminal is used, connector terminal could be damaged.
Damaged connector terminal could result in system fault. Always use
paper that is same thickness as male terminal.
NOTE: Perform this procedure only if you were sent here from DIAGNOSTIC TESTS.
1. Air bag squib circuit consists of circuit between air bag sensor assembly and air bag. If voltage is
accidentally applied across squib circuit (as when testing, for example), air bag will deploy.
2. To prevent accidental deployment, squib circuit connectors contain a spring-loaded shorting bar short
spring. When squib circuit connector is disconnected, short spring automatically shorts squib circuit
positive and negative circuits together. This prevents air bag deployment if voltage is accidentally applied
across squib circuit.
3. When connector halves are attached, shorting bar is in released position (no continuity exists between
terminals). When connector is disconnected, shorting bar is engaged (continuity exists between
terminals).
4. Some testing procedures require short spring to be in released position with connector disconnected (this
is opposite of its normal position). To hold short spring in released position, obtain a piece of paper that is
same thickness as male terminal blade that slides under short spring when connector is connected. See
Fig. 19 .
5. With squib circuit connector disconnected, insert paper into female terminal, sliding it under short spring.
This lifts spring, breaking circuit and allowing test procedure to be performed.
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Fig. 19: Releasing Short Spring

DIAGNOSTIC TESTS
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WARNING: Accidental air bag deployment is possible. Personal injury may result.
Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS
before working on air bag system or related components
CAUTION: Air bag center sensor may be damaged. Improper system operation
possible. Ensure ignition switch is in LOCK position before disconnecting
or connecting negative battery cable.
Connector terminal damage is possible. Improper system operation
possible. Avoid probing terminal ends. Instead, backprobe terminals
(probe terminal where wire enters harness connector).
NOTE: In the following tests, the term squib and module may be used interchangeably.
AIR BAG WARNING LIGHT IS ALWAYS ILLUMINATED WHEN DIAGNOSTIC TROUBLE CODE
(DTC) IS NOT OUTPUT
Diagnostic Procedure
1. Measure battery voltage. If battery voltage is 11-14 volts, go to next step. If battery voltage is not 11-14
volts, replace battery.
2. Disconnect negative battery cable. Wait at least 90 seconds. Inspect air bag sensor assembly and ensure
harness connectors are properly connected. See AIR BAG SENSOR ASSEMBLY under REMOVAL &
INSTALLATION. If air bag sensor assembly harness connectors are properly connected, go to next step.
If air bag sensor assembly harness connectors are not properly connected, reconnect connectors.
3. Access instrument cluster and disconnect harness connectors. Measure resistance between harness side of
air bag sensor assembly connector C7, terminal No. 14 (Black/Yellow wire, circuit LA) and harness side
of instrument cluster connector C13, terminal No. 7 (White wire, circuit LA). See Fig. 20 & Fig. 21 .
Resistance should be less than one ohm. Measure resistance between ground and harness side of air bag
sensor assembly connector C7, terminal No. 14. Resistance should be more than one megohm. Ensure
ignition switch is in ON position. Measure voltage between ground and harness side of air bag sensor
assembly connector C7, terminal No. 14. Voltage should be less than one volt. If voltage and resistance
readings are normal, go to next step. If voltage and resistance readings are not normal, replace wire
harness between instrument cluster and air bag sensor assembly.
4. Connect instrument cluster harness connectors. Ensure negative battery cable is connected and ignition
switch is in ON position. Measure voltage between ground and harness side of instrument cluster
connector C7, terminal No. 40 (White wire). If voltage is 8-14 volts, replace air bag sensor assembly. If
voltage is not 8-14 volts, replace instrument cluster.
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Fig. 20: Identifying Instrument Cluster Connector C13

Fig. 21: Identifying Air Bag Sensor Assembly Connectors

AIR BAG WARNING LIGHT DOES NOT ILLUMINATE
1. Turn ignition switch to LOCK position. Disable air bag system. See DISABLING SYSTEM under
DISABLING & ACTIVATING AIR BAG SYSTEM. Measure battery voltage. If battery voltage is 11-14
volts, go to next step. If battery voltage is not 11-14 volts, replace battery.
2. Connect negative battery cable and wait at least 2 seconds. Turn ignition switch to ON position and
observe AIR BAG warning light. If AIR BAG warning light illuminates, replace instrument cluster. If
AIR BAG warning light does not illuminate, go to next step.
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3. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds.
Disconnect instrument cluster harness connectors. Measure voltage between ground and harness side of
air bag sensor assembly connector C7, terminal No. 14 (Black/Yellow wire, circuit LA). See Fig. 21 . If
voltage is less than one volt, replace air bag sensor assembly. If voltage is more than one volt, replace
wire harness between instrument cluster and air bag sensor assembly.
SOURCE VOLTAGE DROP
DISABLING & ACTIVATING AIR BAG SYSTEM. Reconnect negative battery cable. Turn ignition
switch to ON position. Measure voltage between ground and air bag sensor assembly connector C7,
terminal No. 21 (Black/Orange wire, circuit IG2). See Fig. 21 . If voltage is 10-14 volts, go to next step.
If voltage is not 10-14 volts, repair or replace wiring harness between battery and air bag sensor assembly
and/or repair charging system. See WIRING DIAGRAMS .
Measure resistance between ground and air bag sensor assembly connector C7, terminal No. 25
(White/Black wire, circuit E1). Measure resistance between ground and air bag sensor assembly
connector C7, terminal No. 26 (White/Black wire, circuit E2). If resistance is less than one ohm, go to
next step. If resistance is more than one ohm, replace wiring harness between body ground and air bag
sensor assembly.
3. Activate air bag system. See ACTIVATING SYSTEM under DISABLING & ACTIVATING AIR BAG
SYSTEM. Turn on electrical accessories (defogger, wipers, headlights, blower motor, etc.). If AIR BAG
warning light does not come on, test is complete. If AIR BAG warning light does come on, replace air
bag sensor assembly. See AIR BAG SENSOR ASSEMBLY under REMOVAL & INSTALLATION.
DIAGNOSTIC TROUBLE CODES (DTCS) CANNOT BE DISPLAYED, OR DTCS ARE DISPLAYED

WITHOUT DATA LINK CONNECTOR 3 (DLC 3) CONNECTION
DISABLING & ACTIVATING AIR BAG SYSTEM. Measure resistance between DLC 3 connector
terminal No. 13 and harness side of air bag sensor assembly connector C7, terminal No. 15 (Pink/Black
wire, circuit TC). See Fig. 18 & Fig. 21 . If resistance is less than one ohm, go to next step. If resistance
is more than one ohm, replace wire harness between DLC 3 and air bag sensor assembly.
2. Measure resistance between ground and DLC 3 connector terminal No. 4. If resistance is less than one
ohm, go to next step. If resistance is more than one ohm, repair or replace wire harness between DLC 3
and body ground.
3. Measure resistance between ground and harness side of air bag sensor assembly connector C7, terminal
No. 15. If resistance is more than one megohm, replace air bag sensor assembly. If resistance is less than
one megohm, repair or replace appropriate wire harness, replace appropriate electronic control unit.
AIR BAG WARNING LIGHT INTERMITTENT
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If AIR BAG warning light comes on intermittently, perform following tests to simulate driving conditions. If
problem cannot be found, replace all air bag system components including wiring harness.
 Wiggle-test wiring harness.

 Apply heat to components with a hair dryer.
 Spray water onto entire vehicle (not directly onto electrical components) to simulate humidity.
DTC 31/B1000: AIR BAG SENSOR ASSEMBLY MALFUNCTION
Possible Causes
Diagnostic Trouble Code (DTC) 31/B1000 could be caused by air bag sensor assembly malfunction.
NOTE: If a DTC other than DTCs 31/B1000 is displayed at same time as DTCs 31/B1000,
repair fault indicated by DTC other than DTCs 31/B1000 before using this
procedure.
Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Connect
negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON position. Wait at least 60 seconds.
Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait
at least 20 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Retrieve DTCs. See
RETRIEVING CODES under DIAGNOSTICS. If DTC 31/B1000 is displayed, replace air bag sensor
assembly. If DTC 31/B1000 is not displayed, system is functioning properly at this time. Check for intermittent
fault. See AIR BAG WARNING LIGHT INTERMITTENT .
DTC 13/B1610: RIGHT FRONT AIR BAG SENSOR MALFUNCTION
Possible Causes
Diagnostic Trouble Code (DTC) 13/B1610 could be caused by an short to battery, short to ground or open in
right front air bag sensor wiring harness, right front air bag sensor malfunction or air bag sensor assembly
malfunction.
NOTE: During testing, if DTCs other than DTC 13/B1610 are displayed, disregard them.
DISABLING & ACTIVATING AIR BAG SYSTEM. Reconnect air bag sensor assembly harness
connectors. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON position.
Wait at least 60 seconds. Clear Diagnostic Trouble Codes (DTCs). See CLEARING CODES under
DIAGNOSTICS. Turn ignition switch to LOCK position. Turn ignition switch to ON position. Wait at
least 60 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 13/B1610
is displayed, go to next step. If DTC 13/B1610 is not displayed, system is functioning properly at this
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time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT .
2. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90 seconds.
Inspect air bag sensor assembly for proper connection of harness connectors. See AIR BAG SENSOR
ASSEMBLY under REMOVAL & INSTALLATION. Access right front air bag sensor and inspect for
proper connection of harness connector. See FRONT AIR BAG SENSOR under REMOVAL &
INSTALLATION. If right front air bag sensor and air bag sensor assembly connectors are not properly
connected, reconnect connectors and go to step 1 . If right front air bag sensor and air bag sensor
assembly connectors are properly connected, go to next step.
3. Disconnect air bag sensor assembly harness connector C7. Disconnect right front air bag sensor
connector. Connect jumper wire between Black/White wire (circuit SR+) and Brown/White wire (circuit
SR-) on harness side of front air bag sensor connector. Measure resistance between harness air bag sensor
assembly connector C7, terminals No. 29 (Black/White wire) and No. 27 (Brown/White wire). See Fig.
21 . If resistance is more then one ohm, go to step 8 . If resistance is less than one ohm, go to next step.
4. Remove jumper wire. Measure resistance between harness side air bag sensor assembly connector C7,
terminals No. 29 and (Black/White wire) and No. 27 (Brown/White wire). If resistance is less then one
megohm, go to step 9 . If resistance is more than one megohm, go to next step.
5. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON position. Measure
voltage between ground and harness side air bag sensor assembly connector C7, terminals No. 29
(Black/White wire) and No. 27 (Brown/White wire). If voltage is more than one volt, go to step 10 . If
voltage is less then one volt, go to next step.
Measure resistance between ground and harness side of air bag sensor assembly connector C7, terminals
No. 29 (Black/White wire) and No. 27 (Brown/White wire). If resistance is less then one megohm, go to
step 11 . If resistance is more than one megohm, go to next step.
7. Connect air bag sensor assembly connector C7. Remove right and left front air bag sensors. Install right
front air bag sensor on left side and connect to left front air bag sensor harness connector. Install left front
air bag sensor on right side and connect to right front air bag sensor harness connector. Connect negative
battery cable. Wait at least 2 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear
DTCs. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ON
position. Wait at least 60 seconds. Retrieve DTCs. If DTC 13/B1610 and 14/B1615 are not displayed,
system is operating normally at this time. Check for intermittent fault. If DTC 13/B1610 is displayed,
replace air bag sensor assembly. If DTC 14/B1615 is displayed, replace right front air bag sensor.
8. Disconnect engine room main wire harness connector from instrument panel harness connector, located
behind right kick panel. See WIRING DIAGRAMS . Measure resistance between Black/White wire and
Brown/White wire on harness side of engine room main wire harness connector. If resistance is more then
one ohm, replace engine room main wire harness. If resistance is less than one ohm, replace instrument
panel harness.
behind right kick panel. See WIRING DIAGRAMS . Measure resistance in Black/White wire and
Brown/White wire on harness side of engine room main wire harness connector. If resistance is less then
one megohm, replace engine room main wire harness. If resistance is more than one megohm, replace
instrument panel harness.
behind right kick panel. See WIRING DIAGRAMS . Measure voltage between Black/White wire and
Brown/White wire on harness side of engine room main wire harness connector. If voltage is more than
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one volt, replace instrument panel harness. If voltage is less then one volt, replace engine room main wire
harness.
behind right kick panel. See WIRING DIAGRAMS . Measure resistance in Black/White wire between
ground and harness side of engine room main wire harness connector. Measure resistance in
Brown/White wire between ground and harness side of engine room main wire harness connector. If
resistance is less then one megohm, replace engine room main wire harness. If resistance is more than one
megohm, replace instrument panel harness.
DTC 14/B1615: LEFT FRONT AIR BAG SENSOR MALFUNCTION
Possible Causes
Diagnostic Trouble Code (DTC) 14/B1615 could be caused by an short to battery, short to ground or open in
left front air bag sensor wiring harness, left front air bag sensor malfunction or air bag sensor assembly
malfunction.
connectors. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON position.
Wait at least 60 seconds. Clear Diagnostic Trouble Codes (DTCs). See CLEARING CODES under
DIAGNOSTICS. Turn ignition switch to LOCK position. Turn ignition switch to ON position. Wait at
least 60 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 14/B1615
is displayed, go to next step. If DTC 14/B1615 is not displayed, system is functioning properly at this
time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT .
Inspect air bag sensor assembly for proper connection of harness connectors. See AIR BAG SENSOR
ASSEMBLY under REMOVAL & INSTALLATION. Access left front air bag sensor and inspect for
proper connection of harness connector. See FRONT AIR BAG SENSOR under REMOVAL &
INSTALLATION. If left front air bag sensor and air bag sensor assembly connectors are not properly
connected, reconnect connectors and go to step 1 . If left front air bag sensor and air bag sensor assembly
connectors are properly connected, go to next step.
3. Disconnect air bag sensor assembly harness connector C7. Disconnect left front air bag sensor connector.
Connect jumper wire between White/Red wire (circuit SL+) and Brown wire (circuit SL-) on harness side
of front air bag sensor connector. Measure resistance between harness air bag sensor assembly connector
C7, terminals No. 30 (White/Red wire) and No. 28 (Brown wire). See Fig. 21 . If resistance is more then
one ohm, go to step 8 . If resistance is less than one ohm, go to next step.
4. Remove jumper wire. Measure resistance between harness side air bag sensor assembly connector C7,
terminals No. 30 (White/Red wire) and No. 28 (Brown wire). If resistance is less then one megohm, go to
step 9 . If resistance is more than one megohm, go to next step.
voltage between ground and harness side air bag sensor assembly connector C7, terminals No. 30
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(White/Red wire) and No. 28 (Brown wire). If voltage is more than one volt, go to step 10 . If voltage is
less then one volt, go to next step.
No. 30 (White/Red wire) and No. 28 (Brown wire). If resistance is less then one megohm, go to step 11 .
If resistance is more than one megohm, go to next step.
7. Connect air bag sensor assembly connector C7. Remove left and right front air bag sensors. Install left
front air bag sensor on right side and connect to right front air bag sensor harness connector. Install right
front air bag sensor on left side and connect to left front air bag sensor harness connector. Connect
negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON position. Wait at least 60
seconds. Clear DTCs. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition
switch to ON position. Wait at least 60 seconds. Retrieve DTCs. If DTC 14/B1615 and 13/B1610 are not
displayed, system is operating normally at this time. Check for intermittent fault. If DTC 14/B1615 is
displayed, replace air bag sensor assembly. If DTC 13/B1610 is displayed, replace left front air bag
sensor.
behind left kick panel. See WIRING DIAGRAMS . Measure resistance between White/Red wire and
Brown wire on harness side of engine room main wire harness connector. If resistance is more then one
ohm, replace engine room main wire harness. If resistance is less than one ohm, replace instrument panel
harness.
behind left kick panel. See WIRING DIAGRAMS . Measure resistance in White/Red wire and Brown
wire on harness side of engine room main wire harness connector. If resistance is less then one megohm,
replace engine room main wire harness. If resistance is more than one megohm, replace instrument panel
harness.
behind left kick panel. See WIRING DIAGRAMS . Measure voltage between White/Red wire and
Brown wire on harness side of engine room main wire harness connector. If voltage is more than one volt,
replace instrument panel harness. If voltage is less then one volt, replace engine room main wire harness.
behind left kick panel. See WIRING DIAGRAMS . Measure resistance in White/Red wire between
ground and harness side of engine room main wire harness connector. Measure resistance in Brown wire
between ground and harness side of engine room main wire harness connector. If resistance is less then
one megohm, replace engine room main wire harness. If resistance is more than one megohm, replace
instrument panel harness.
DTC 21/B1620: LEFT SIDE AIR BAG SENSOR MALFUNCTION
Possible Causes
Diagnostic Trouble Code (DTC) 21/B1620 could be caused by short to ground, short to battery or open in left
side air bag sensor wiring harness, left side air bag sensor malfunction or air bag sensor assembly malfunction.
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connectors. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. See CLEARING
CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn
ignition switch to ON position. Wait at least 60 seconds. Retrieve DTCs. See RETRIEVING CODES
under DIAGNOSTICS. If DTC 21/B1620 is not displayed, system is functioning normally at this time.
Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 21/B1620
is displayed, go to next step.
Access air bag sensor assembly. See AIR BAG SENSOR ASSEMBLY under REMOVAL &
INSTALLATION. Access left side air bag sensor. See SIDE AIR BAG SENSOR under REMOVAL &
INSTALLATION. Ensure left side air bag sensor and air bag sensor assembly harness connectors are
properly connected. If left side air bag sensor and air bag sensor assembly harness connectors are not
properly connected, reconnect connectors. If left side air bag sensor and air bag sensor assembly harness
3. Disconnect left side air bag sensor harness connector. Disconnect air bag sensor assembly harness
connector C6. Connect jumper wire between Pink/Blue wire (circuit VUP L) and Gray/Blue wire (circuit
ESL) on harness side of left side air bag sensor harness connector. Measure resistance between air bag
sensor assembly harness connector C6, terminals No. 19 and 21. See Fig. 21 . If resistance is less than
one ohm, go to next step. If resistance is more than one ohm, replace harness between left side air bag
sensor and air bag sensor assembly.
4. Remove jumper wire. Measure resistance between air bag sensor assembly harness connector C6,
terminals No. 19 and 21. If resistance is more than one megohm, go to next step. If resistance is less than
one megohm, replace harness between left side air bag sensor and air bag sensor assembly.
voltage between ground and air bag sensor assembly harness connector C6, terminals No. 19 and 21. If
voltage is less than one volt, go to next step. If voltage is more than one volt, replace harness between left
side air bag sensor and air bag sensor assembly.
6. Measure resistance between ground and air bag sensor assembly harness connector C6, terminals No. 19
and 21. If resistance is more than one megohm, go to next step. If resistance is less than one megohm,
replace harness between left side air bag sensor and air bag sensor assembly.
Remove right and left side air bag sensors. Install right side air bag sensor on left side and connect to left
side air bag sensor harness connector. Install left side air bag sensor on right side and connect to right side
air bag sensor harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition
switch to ON position. Wait at least 60 seconds. Clear DTCs. Turn ignition switch to LOCK position.
Wait at least 20 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Retrieve DTCs. If
DTC 21/B1620 and 22/B1625 are not displayed, check for intermittent fault. If DTC 21/B1620 is
displayed, replace air bag sensor assembly. If DTC 22/B1625 is displayed, replace left side air bag sensor.
DTC 22/B1625: RIGHT SIDE AIR BAG SENSOR MALFUNCTION
Possible Causes
Diagnostic Trouble Code (DTC) 22/B1625 could be caused by short to ground, short to battery or open in right
side air bag sensor wiring harness, right side air bag sensor malfunction or air bag sensor assembly malfunction.
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2004 Toyota RAV4
DISABLING & ACTIVATING AIR BAG SYSTEM. Turn ignition switch to ON position. Wait at least
60 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to
LOCK position. Wait at least 20 seconds. Turn ignition switch to ON position. Wait at least 60 seconds.
Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 22/B1625 is not displayed,
system is functioning normally at this time. Check for intermittent fault. See AIR BAG WARNING
LIGHT INTERMITTENT . If DTC 22/B1625 is displayed, go to next step.
INSTALLATION. Access right side air bag sensor. See SIDE AIR BAG SENSOR under REMOVAL &
INSTALLATION. Ensure right side air bag sensor and air bag sensor assembly harness connectors are
properly connected. If right side air bag sensor and air bag sensor assembly harness connectors are not
properly connected, reconnect connectors and go to step 1 . If right side air bag sensor and air bag sensor
assembly harness connectors are properly connected, go to next step.
3. Disconnect right side air bag sensor harness connector. Disconnect air bag sensor assembly harness
connector C8. Connect jumper wire between Pink wire (circuit VUPR) and Gray wire (circuit ESR) on
harness side of right side air bag sensor harness connector. Measure resistance between air bag sensor
assembly harness connector C7, terminals No. 20 and 22. See Fig. 21 . If resistance is less than one ohm,
go to next step. If resistance is more than one ohm, replace harness between right side air bag sensor and
air bag sensor assembly.
4. Remove jumper wire. Measure resistance between ground and air bag sensor assembly harness connector
C8, terminals No. 20 and 22. If resistance is more than one megohm, go to next step. If resistance is less
than one megohm, replace harness between right side air bag sensor and air bag sensor assembly.
voltage is less than one volt, go to next step. If voltage is more than one volt, replace harness between
right side air bag sensor and air bag sensor assembly.
7. Connect air bag sensor assembly connector C8. Remove left and right side air bag sensors. Install left side
air bag sensor on right side and connect to right side air bag sensor harness connector. Install right side air
bag sensor on left side and connect to left side air bag sensor harness connector. Connect negative battery
cable. Wait at least 2 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs.
Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ON position.
Wait at least 60 seconds. Retrieve DTCs. If DTC 21/B1620 and 22/B1625 are not displayed, check for
intermittent fault. If DTC 22/B1625 is displayed, replace air bag sensor assembly. If DTC 21/B1620 is
displayed, replace right side air bag sensor.
DTC 23/B1630: LEFT REAR AIR BAG SENSOR MALFUNCTION
Possible Causes
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2004 Toyota RAV4
rear air bag sensor wiring harness, left rear air bag sensor malfunction or air bag sensor assembly malfunction.
connectors. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. See CLEARING
under DIAGNOSTICS. If DTC 23/B1630 is not displayed, system is functioning normally at this time.
Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 23/B1630
is displayed, go to next step.
INSTALLATION. Access left rear air bag sensor. See REAR AIR BAG SENSOR under REMOVAL &
INSTALLATION. Ensure left rear air bag sensor and air bag sensor assembly harness connectors are
properly connected. If left rear air bag sensor and air bag sensor assembly harness connectors are not
properly connected, reconnect connectors. If left rear air bag sensor and air bag sensor assembly harness
3. Disconnect left rear air bag sensor harness connector. Disconnect air bag sensor assembly harness
connector C6. Connect jumper wire between Red wire (circuit VUCL) and Green wire (circuit ESCL) on
harness side of left rear air bag sensor harness connector. Measure resistance between air bag sensor
assembly harness connector C6, terminals No. 20 and 22. See Fig. 21 . If resistance is less than one ohm,
go to next step. If resistance is more than one ohm, replace harness between left rear air bag sensor and
air bag sensor assembly.
4. Remove jumper wire. Measure resistance between air bag sensor assembly harness connector C6,
one megohm, replace harness between left rear air bag sensor and air bag sensor assembly.
voltage is less than one volt, go to next step. If voltage is more than one volt, replace harness between left
rear air bag sensor and air bag sensor assembly.
replace harness between left rear air bag sensor and air bag sensor assembly.
Remove right and left rear air bag sensors. Install right side air bag sensor on left side and connect to left
rear air bag sensor harness connector. Install left rear air bag sensor on right side and connect to right rear
air bag sensor harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition
switch to ON position. Wait at least 60 seconds. Clear DTCs. Turn ignition switch to LOCK position.
Wait at least 20 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Retrieve DTCs. If
DTC 23/B1630 and 24/B1635 are not displayed, check for intermittent fault. If DTC 23/B1630 is
displayed, replace air bag sensor assembly. If DTC 24/B1635 is displayed, replace left rear air bag sensor.
DTC 22/B1635: RIGHT REAR AIR BAG SENSOR MALFUNCTION
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2004 Toyota RAV4
Possible Causes
Diagnostic Trouble Code (DTC) 24/B1635 could be caused by short to ground, short to battery or open in right
rear air bag sensor wiring harness, right rear air bag sensor malfunction or air bag sensor assembly malfunction.
DISABLING & ACTIVATING AIR BAG SYSTEM. Turn ignition switch to ON position. Wait at least
60 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to
LOCK position. Wait at least 20 seconds. Turn ignition switch to ON position. Wait at least 60 seconds.
Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 24/B1635 is not displayed,
system is functioning normally at this time. Check for intermittent fault. See AIR BAG WARNING
LIGHT INTERMITTENT . If DTC 24/B1635 is displayed, go to next step.
INSTALLATION. Access right rear air bag sensor. See REAR AIR BAG SENSOR under REMOVAL
& INSTALLATION. Ensure right rear air bag sensor and air bag sensor assembly harness connectors are
properly connected. If right rear air bag sensor and air bag sensor assembly harness connectors are not
properly connected, reconnect connectors and go to step 1 . If right rear air bag sensor and air bag sensor
assembly harness connectors are properly connected, go to next step.
3. Disconnect right rear air bag sensor harness connector. Disconnect air bag sensor assembly harness
connector C8. Connect jumper wire between White/Black wire (circuit VUCR) and Black/Orange wire
(circuit ESCR) on harness side of right rear air bag sensor harness connector. Measure resistance between
air bag sensor assembly harness connector C8, terminals No. 19 and 21. See Fig. 21 . If resistance is less
than one ohm, go to next step. If resistance is more than one ohm, replace harness between right rear air
bag sensor and air bag sensor assembly.
4. Remove jumper wire. Measure resistance between ground and air bag sensor assembly harness connector
C8, terminals No. 19 and 21. If resistance is more than one megohm, go to next step. If resistance is less
than one megohm, replace harness between right rear air bag sensor and air bag sensor assembly.
voltage is less than one volt, go to next step. If voltage is more than one volt, replace harness between
right rear air bag sensor and air bag sensor assembly.
7. Connect air bag sensor assembly connector C8. Remove left and right rear air bag sensors. Install left side
air bag sensor on right side and connect to right rear air bag sensor harness connector. Install right rear air
bag sensor on left side and connect to left side air bag sensor harness connector. Connect negative battery
cable. Wait at least 2 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs.
Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ON position.
Wait at least 60 seconds. Retrieve DTCs. If DTC 23/B1630 and 24/B1635 are not displayed, check for
intermittent fault. If DTC 24/B1635 is displayed, replace air bag sensor assembly. If DTC 23/B1630 is
displayed, replace right rear air bag sensor.
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2004 Toyota RAV4
DTC 35/B1653: SEAT POSITION SENSOR MALFUNCTION
Possible Causes
Diagnostic Trouble Code (DTC) 35/B1653 could be caused by open, short to ground or short circuit in seat
position sensor wire harness, seat position sensor malfunction or air bag sensor assembly malfunction.
DISABLING & ACTIVATING AIR BAG SYSTEM. Connect negative battery cable. Wait at least 2
seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. Turn ignition switch
to LOCK position. Turn ignition switch to ON position. Wait at least 60 seconds. Retrieve DTCs. See
RETRIEVING CODES under DIAGNOSTICS. If DTC 35/B1653 is displayed, go to next step. If DTC
35/B1653 is not displayed, check for intermittent fault. See AIR BAG WARNING LIGHT
INTERMITTENT .
2. Turn ignition switch to LOCK position. Disconnect negative battery cable. and wait at least 90 seconds.
INSTALLATION. Access seat position sensor. See SEAT POSITION SENSOR under REMOVAL &
INSTALLATION. Ensure harness connectors are properly connected to seat position sensor and air bag
sensor assembly. If connectors are properly connected, go to next step. If connectors are not properly
connected, reconnect connector and go to step 1 .
3. Disconnect air bag center connector C6. Disconnect left front seat harness connector. Connect jumper
wire between Green/Red wire (circuit DSP+) and Green/Black wire (circuit DSP-) on harness side of
front seat connector. Measure resistance between ground and harness side of air bag sensor assembly
connector C6, terminals No. 9 and 17. See Fig. 21 . If resistance is less than one ohm, go to next step. If
resistance is more than one ohm, replace wiring harness between front seat harness connector and air bag
sensor assembly. See WIRING DIAGRAMS .
4. Remove jumper wire. Measure resistance between harness side of air bag sensor assembly connector C6,
one megohm, replace wiring harness between front seat harness connector and air bag sensor assembly.
voltage between ground and harness side of air bag sensor assembly connector C6, terminals No. 9 and
No. 17. If voltage is less than one volt, go to next step. If voltage is more than one volt, replace wiring
harness between front seat harness connector and air bag sensor assembly.
No. 9 and No. 17. If resistance is more than one megohm, go to next step. If resistance is less than one
megohm, replace wiring harness between front seat harness connector and air bag sensor assembly.
7. Connect air bag sensor assembly and seat position sensor connectors. Connect negative battery cable.
Wait at least 2 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. Turn
ignition switch to LOCK position. Turn ignition switch to ON position. Wait at least 60 seconds. Retrieve
DTCs. If DTC 35/B1653 is displayed, go to next step. If DTC 35/B1653 is not displayed, check for
intermittent fault.
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2004 Toyota RAV4
Replace seat position sensor. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch
to ON position. Wait at least 60 seconds. Clear DTCs. Turn ignition switch to LOCK position. Turn
ignition switch to ON position. Wait at least 60 seconds. Retrieve DTCs. If DTC 35/B1653 is displayed,
air bag sensor assembly. If DTC 35/B1653 is not displayed, replace wiring harness between front seat
harness connector and air bag sensor assembly.
DTC 37/B1655: LEFT SEAT BELT SWITCH MALFUNCTION
Description
The left seat belt switch circuit consists of air bag sensor assembly, left front seat belt buckle and left seat belt
switch.
Possible Causes
seat belt buckle wire harness, left front seat belt buckle switch malfunction or air bag sensor assembly
malfunction.
DISABLING & ACTIVATING AIR BAG SYSTEM. Connect negative battery cable. Wait at least 2
seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. Turn ignition switch
to LOCK position. Turn ignition switch to ON position. Wait at least 60 seconds. Retrieve DTCs. See
RETRIEVING CODES under DIAGNOSTICS. If DTC 37/B1655 is displayed, go to next step. If DTC
37/B1655 is not displayed, check for intermittent fault. See AIR BAG WARNING LIGHT
INTERMITTENT .
2. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Turn
ignition switch to ON position. Wait at least 90 seconds. Ensure harness connectors are properly
connected to left seat belt switch and air bag sensor assembly. If connectors are properly connected, go to
next step. If connectors are not properly connected, reconnect connector and go to step 1 .
3. Access air bag sensor assembly and disconnect connectors. See AIR BAG SENSOR ASSEMBLY under
REMOVAL & INSTALLATION. Disconnect seat belt switch harness connector. Connect jumper wire
between Green/Yellow wire (circuit DBE+) and Black wire (circuit DBE-) on harness side of left seat belt
switch connector. Measure resistance between harness side of air bag sensor assembly connector C6,
terminals No. 10 and 18. See Fig. 21 . If resistance is less than one ohm, go to next step. If resistance is
more than one ohm, replace wiring harness between left seat belt switch and air bag sensor assembly. See
WIRING DIAGRAMS .
4. Remove jumper wire. Measure resistance between ground and harness side of air bag sensor assembly
connector C6, terminal No. 2 (Red wire). Measure resistance between harness side of air bag sensor
assembly connector C6, terminals No. 10 and 18. If resistance is more than one megohm, go to next step.
If resistance is less than one megohm, replace wiring harness between left seat belt switch and air bag
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2004 Toyota RAV4
sensor assembly.
voltage between ground and harness side of air bag sensor assembly connector C6, terminals No. 10 and
18. If voltage is less than one volt, go to next step. If voltage is more than one volt, replace wiring harness
between left seat belt switch and air bag sensor assembly.
No. 10 and 18. If resistance is more than one megohm, go to next step. If resistance is less than one
megohm, replace wiring harness between left seat belt switch and air bag sensor assembly.
7. Reconnect left seat belt switch and air bag sensor assembly connectors. Connect negative battery cable.
Wait at least 2 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. Turn
ignition switch to LOCK position. Turn ignition switch to ON position. Wait at least 60 seconds. Retrieve
DTCs. If DTC 37/B1655 is displayed, go to next step. If DTC 37/B1655 is not displayed, system is
functioning properly at this time. Check for intermittent fault.
Replace left seat belt buckle switch. See SEAT BELT BUCKLE SWITCH under REMOVAL &
INSTALLATION. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON
position. Wait at least 60 seconds. Clear DTCs. Turn ignition switch to LOCK position. Turn ignition
switch to ON position. Wait at least 60 seconds. Retrieve DTCs. If DTC 37/B1655 is displayed, replace
air bag sensor assembly. If DTC 37/B1655 is not displayed, test is complete.
DTC 51/B1800, 51/B1801, 51/B1802, 51/B1803: DRIVER-SIDE AIR BAG NO. 1 SQUIB CIRCUIT
SHORT, OPEN, SHORT TO GROUND OR SHORT TO BATTERY
Possible Causes
Diagnostic Trouble Codes (DTCs) 51/B1800, 51/B1801, 51/B1802 or 51/B1803 could be caused by a short to
ground, open, short or short to battery in No. 1 squib circuit, squib malfunction, spiral cable malfunction or air
bag sensor assembly malfunction.
NOTE: During testing, if DTCs other than DTC 51/B1800, 51/B1801, 51/B1802 or
51/B1803 are displayed, disregard them.
DISABLING & ACTIVATING AIR BAG SYSTEM. If using Toyota hand-held tester, retrieve 5 digit
DTC. See RETRIEVING AIR BAG SYSTEM DTCS USING TOYOTA HAND-HELD TESTER
under DIAGNOSTICS. If DTC B1800 is retrieved, go to next step. If DTC B1801 is retrieved, go to step
4 . If DTC B1802 is retrieved, go to step 5 . If DTC B1803 is retrieved, go to step 6 . If using diagnosis
check wire, retrieve 2 digit DTC. See RETRIEVING AIR BAG SYSTEM DTCS USING
DIAGNOSIS CHECK WIRE under DIAGNOSTICS. If DTC 51 is retrieved, go to step 7 .
2. Inspect spiral cable connectors for disengaged lock button or deformed or damaged lock claw. If
connectors are okay, go to next step. If connectors are not okay, replace spiral cable. See SPIRAL
CABLE under REMOVAL & INSTALLATION.
3. Release short spring mechanism on air bag sensor assembly connector C7. See RELEASING SHORT
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2004 Toyota RAV4
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Black wire (circuit D+) and
Yellow wire (circuit D-) on harness side of Black upper spiral cable connector. See WIRING
DIAGRAMS . If resistance is less than one megohm, go to step 13 . If resistance is more than one
megohm, go to step 10 .
4. Measure resistance between Yellow/Black wire (circuit D+) and Yellow wire (circuit D-) on harness side
of Black upper spiral cable connector. See WIRING DIAGRAMS . If resistance is less than one ohm, go
to step 11 . If resistance is more than one ohm, go to step 15 .
5. Measure resistance between ground and Yellow/Black wire (circuit D+) on harness side of Black upper
spiral cable connector. See WIRING DIAGRAMS . Measure resistance between ground and Yellow
(circuit D-) wire on harness side of Black upper spiral cable connector. If resistance is more than one
ohm, go to step 11 . If resistance is less than one megohm, go to step 17 .
voltage between ground and Yellow/Black wire (circuit D+) on harness side of Black upper spiral cable
connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow wire (circuit D-)
on harness side of Black upper spiral cable connector. If voltage is less than one volt, go to step 11 . If
voltage is more than one volt, go to step 19 .
CABLE under ADJUSTMENTS.
voltage between ground and Yellow/Black wire (circuit D+) on harness side of Black upper spiral cable
connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow wire (circuit D-)
on harness side of Black upper spiral cable connector. Voltage should be less than one volt. Turn ignition
switch to LOCK position. Disconnect negative battery cable and wait at least 90 seconds. Measure
resistance between Yellow/Black wire and Yellow wire on harness side of Black upper spiral cable
connector. Resistance should be less than one ohm. Measure resistance between ground and
Yellow/Black wire on harness side of Black upper spiral cable connector. Measure resistance between
ground and Yellow wire on harness side of Black upper spiral cable connector. Resistance should be
more than one megohm. Release short spring mechanism on air bag sensor assembly connector C7. See
RELEASING SHORT SPRING under DIAGNOSTICS. Measure resistance between Yellow/Black
wire and Yellow wire on harness side of Black upper spiral cable connector. Resistance should be more
than one megohm. If voltage and resistance readings are normal, go to next step. If voltage and resistance
readings are not normal, go to step 21 .
9. Replace driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE under REMOVAL &
INSTALLATION. Reconnect air bag sensor assembly harness connectors. Turn ignition switch to ON
position. Wait at least 60 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn
ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ON position. Wait at
least 60 seconds. Retrieve DTCs. If DTC 51 is displayed, replace air bag sensor assembly. See AIR BAG
SENSOR ASSEMBLY under REMOVAL & INSTALLATION. If DTC 51 is not displayed, test is
complete.
10. Reconnect air bag sensor assembly connectors. Connect negative battery cable. Wait at least 2 seconds.
Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. See CLEARING CODES
under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition
switch to ON position. Wait at least 60 seconds. Retrieve DTCs. See RETRIEVING CODES under
DIAGNOSTICS. If DTC B1800 is displayed, replace air bag sensor assembly. See AIR BAG SENSOR
ASSEMBLY under REMOVAL & INSTALLATION. If DTC B1800 is not displayed, go to step 12 .
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2004 Toyota RAV4
11. If sent here from step 6 , turn ignition switch to LOCK position. Disconnect negative battery cable and
wait at least 90 seconds. If sent here from any step, reconnect air bag sensor assembly connectors.
Connect jumper wire between Yellow/Black wire and Yellow wire on harness side of Black upper spiral
cable connector. See WIRING DIAGRAMS . Connect negative battery cable. Wait at least 2 seconds.
DIAGNOSTICS. If DTCs B1801, B1802 or B1803 are displayed, replace air bag sensor assembly. See
AIR BAG SENSOR ASSEMBLY under REMOVAL & INSTALLATION. If DTC B1801, B1802 or
B1803 are not displayed, go to next step.
12. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90 seconds. If
sent here from step 11 , remove jumper wire. If sent here from any step, connect spiral cable harness
connectors to driver-side air bag module. Connect negative battery cable. Wait at least 2 seconds. Turn
ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. See CLEARING CODES under
DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch
to ON position. Wait at least 60 seconds. Retrieve DTCs. See RETRIEVING CODES under
DIAGNOSTICS. If DTCs B1800, B1801, B1802 or B1803 are displayed, replace driver-side air bag
module. See DRIVER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. If DTC
B1800, B1801, B1802 or B1803 are not displayed, ensure air bag sensor assembly is in check mode. See
CHECK MODE PROCEDURE under DIAGNOSTICS. Check for intermittent air bag system fault. See
AIR BAG WARNING LIGHT INTERMITTENT .
13. Disconnect lower spiral cable harness connector. Measure resistance between Yellow/Black wire and
Yellow wire on harness side of lower spiral cable connector. If resistance is less than one megohm,
replace wiring harness between air bag sensor assembly and spiral cable. If resistance is more than one
megohm, go to next step.
14. Release short spring mechanism on lower spiral cable harness connector. Measure resistance between
Yellow/Black wire and Yellow wire on harness side of Black upper spiral cable connector. If resistance is
less than one megohm, replace spiral cable. See SPIRAL CABLE under REMOVAL &
INSTALLATION. If resistance is more than one megohm, ensure air bag sensor assembly is in check
mode. See CHECK MODE PROCEDURE under DIAGNOSTICS. Check for intermittent air bag
system fault. See AIR BAG WARNING LIGHT INTERMITTENT .
15. Disconnect lower spiral cable harness connector. Measure resistance between Yellow/Black wire and
Yellow wire on harness side of lower spiral cable connector. If resistance is more than one ohm, replace
wiring harness between air bag sensor assembly and spiral cable. If resistance is less than one ohm, go to
next step.
16. Measure resistance between Yellow/Black wire and Yellow wire on harness side of Black upper spiral
cable connector. If resistance is more than one ohm, replace spiral cable. See SPIRAL CABLE under
REMOVAL & INSTALLATION. If resistance is less than one ohm, ensure air bag sensor assembly is in
check mode. See CHECK MODE PROCEDURE under DIAGNOSTICS. Check for intermittent air bag
17. Disconnect lower spiral cable harness connector. Measure resistance between ground and Yellow/Black
wire on harness side of lower spiral cable connector. Measure resistance between ground and Yellow wire
on harness side of lower spiral cable connector. If resistance is more than one megohm, replace wiring
harness between air bag sensor assembly and spiral cable. If resistance is less than one megohm, go to
next step.
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2004 Toyota RAV4
18. Measure resistance between ground and Yellow/Black wire on harness side of Black upper spiral cable
connector. Measure resistance between ground and Yellow wire on harness side of Black upper spiral
cable connector. If resistance is more than one megohm, replace spiral cable. See SPIRAL CABLE
under REMOVAL & INSTALLATION. If resistance is less than one megohm, ensure air bag sensor
assembly is in check mode. See CHECK MODE PROCEDURE under DIAGNOSTICS. Check for
intermittent air bag system fault. See AIR BAG WARNING LIGHT INTERMITTENT .
Disconnect lower spiral cable harness connector. Measure voltage between ground and Yellow/Black
wire on harness side of lower spiral cable connector. Measure voltage between ground and Yellow wire
on harness side of lower spiral cable connector. If voltage is more than one volt, replace wiring harness
between air bag sensor assembly and spiral cable. If voltage is less than one volt, go to next step.
20. Measure voltage between ground and Yellow/Black wire on harness side of Black upper spiral cable
connector. Measure voltage between ground and Yellow wire on harness side of Black upper spiral cable
connector. If voltage is more than one volt, replace spiral cable. See SPIRAL CABLE under REMOVAL
& INSTALLATION. If voltage is less than one volt, ensure air bag sensor assembly is in check mode.
See CHECK MODE PROCEDURE under DIAGNOSTICS. Check for intermittent air bag system fault.
See AIR BAG WARNING LIGHT INTERMITTENT .
21. Restore short spring mechanism to original condition. Disconnect lower spiral cable harness connector.
Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON position. Measure
voltage between ground and Yellow/Black wire on harness side of lower spiral cable connector. Measure
voltage between ground and Yellow wire on harness side of lower spiral cable connector. Voltage should
be less than one volt. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait
at least 90 seconds. Measure resistance between Yellow/Black wire and Yellow wire on harness side of
lower spiral cable connector. Resistance should be less than one ohm. Measure resistance between ground
and Yellow/Black wire on harness side of lower spiral cable connector. Measure resistance between
ground and Yellow wire on harness side of lower spiral cable connector. Resistance should be more than
one megohm. Release short spring mechanism on air bag sensor assembly connector C7. Measure
resistance between Yellow/Black wire and Yellow wire on harness side of lower spiral cable connector.
Resistance should be more than one megohm. If voltage and resistance readings are normal, go to next
step. If voltage and resistance readings are not normal, replace wiring harness between air bag sensor
assembly and spiral cable.
voltage between ground and Yellow/Black wire on harness side of Black upper spiral cable connector.
Measure voltage between ground and Yellow wire on harness side of Black upper spiral cable connector.
Voltage should be less than one volt. Turn ignition switch to LOCK position. Disconnect negative battery
cable and wait at least 90 seconds. Measure resistance between Yellow/Black wire and Yellow wire on
harness side of Black upper spiral cable connector. Resistance should be less than one ohm. Measure
resistance between ground and Yellow/Black wire on harness side of Black upper spiral cable connector.
Measure resistance between ground and Yellow wire on harness side of Black upper spiral cable
connector. Resistance should be more than one megohm. Release short spring mechanism on lower spiral
cable connector. Measure resistance between Yellow/Black wire and Yellow wire on harness side of
Black upper spiral cable connector. Resistance should be more than one megohm. If voltage and
resistance readings are normal, ensure air bag sensor assembly is in check mode. See CHECK MODE
PROCEDURE under DIAGNOSTICS. Check for intermittent air bag system fault. See AIR BAG
WARNING LIGHT INTERMITTENT . If voltage and resistance readings are not normal, replace
spiral cable. See SPIRAL CABLE under REMOVAL & INSTALLATION.
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2004 Toyota RAV4
DTC 52/B1805, 52/B1806, 52/B1807, 52/B1808: PASSENGER-SIDE AIR BAG NO. 1 SQUIB CIRCUIT
Possible Causes
ground, open, short or short to battery in No. 1 squib circuit, squib malfunction or air bag sensor assembly
malfunction.
2. Inspect passenger-side air bag module connectors for disengaged lock button or deformed or damaged
lock claw. If connectors are okay, go to next step. If connectors are not okay, replace instrument panel
wiring harness.
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Red wire (circuit P+) and
Yellow/Green wire (circuit P-) on harness side of passenger-side air bag module connector. See
WIRING DIAGRAMS . If resistance is less than one megohm, replace instrument panel wiring harness.
If resistance is more than one megohm, go to step 10 .
4. Measure resistance between Yellow/Red wire (circuit P+) and Yellow/Green wire (circuit P-) on harness
side of passenger-side air bag module connector. See WIRING DIAGRAMS . If resistance is less than
one ohm, go to step 11 . If resistance is more than one ohm, replace instrument panel wiring harness.
5. Measure resistance between ground and Yellow/Red wire (circuit P+) on harness side of passenger-side
air bag module connector. See WIRING DIAGRAMS . Measure resistance between ground and
Yellow/Green (circuit P-) wire on harness side of passenger-side air bag module connector. If resistance
is more than one megohm, go to step 11 . If resistance is less than one megohm, replace instrument panel
wiring harness.
voltage between ground and Yellow/Red wire (circuit P+) on harness side of passenger-side air bag
module connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow/Green
wire (circuit P-) on harness side of passenger-side air bag module connector. If voltage is less than one
volt, go to step 11 . If voltage is more than one volt, replace instrument panel wiring harness.
wiring harness.
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2004 Toyota RAV4
voltage between ground and Yellow/Red wire (circuit P+) on harness side of passenger-side air bag
wire (circuit P-) on harness side of passenger-side air bag module connector. Voltage should be less than
one volt. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90
seconds. Measure resistance between Yellow/Red wire and Yellow/Green wire on harness side of
passenger-side air bag module connector. Resistance should be less than one ohm. Measure resistance
between ground and Yellow/Red wire on harness side of passenger-side air bag module connector.
Measure resistance between ground and Yellow/Green wire on harness side of passenger-side air bag
module connector. Resistance should be more than one megohm. Release short spring mechanism on air
bag sensor assembly connector C7. See RELEASING SHORT SPRING under DIAGNOSTICS.
Measure resistance between Yellow/Red wire and Yellow/Green wire on harness side of passenger-side
air bag module connector. Resistance should be more than one megohm. If voltage and resistance
readings are normal, go to next step. If voltage and resistance readings are not normal, replace instrument
panel wiring harness.
9. Replace passenger-side air bag module. See PASSENGER-SIDE AIR BAG MODULE under
REMOVAL & INSTALLATION. Reconnect air bag sensor assembly harness connectors. Turn ignition
switch to ON position. Wait at least 60 seconds. Clear DTCs. See CLEARING CODES under
to ON position. Wait at least 60 seconds. Retrieve DTCs. If DTC 52 is displayed, replace air bag sensor
assembly. See AIR BAG SENSOR ASSEMBLY under REMOVAL & INSTALLATION. If DTC 52 is
not displayed, test is complete.
Connect jumper wire between Yellow/Red wire and Yellow/Green wire on harness side of passenger-side
air bag module connector. See WIRING DIAGRAMS . Connect negative battery cable. Wait at least 2
seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. See CLEARING
under DIAGNOSTICS. If DTCs B1806, B1807 or B1808 are displayed, replace air bag sensor assembly.
See AIR BAG SENSOR ASSEMBLY under REMOVAL & INSTALLATION. If DTC B1806, B1807
or B1808 are not displayed, go to next step.
connectors to passenger-side air bag module Connect negative battery cable. Wait at least 2 seconds. Turn
DIAGNOSTICS. If DTCs B1805, B1806, B1807 or B1808 are displayed, replace passenger-side air bag
module. See PASSENGER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. If
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2004 Toyota RAV4
DTC B1805, B1806, B1807 or B1808 are not displayed, ensure air bag sensor assembly is in check mode.
DTC 53/B1810, 53/B1811, 53/B1812, 53/B1813: DRIVER-SIDE AIR BAG NO. 2 SQUIB CIRCUIT
Possible Causes
ground, open, short or short to battery in No. 2 squib circuit, squib malfunction, spiral cable malfunction or air
bag sensor assembly malfunction.
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Violet wire (circuit D2+) and
Yellow/Orange wire (circuit D2-) on harness side of Orange upper spiral cable connector. See WIRING
DIAGRAMS . If resistance is less than one megohm, go to step 13 . If resistance is more than one
megohm, go to step 10 .
4. Measure resistance between Yellow/Violet wire (circuit D2+) and Yellow/Orange wire (circuit D2-) on
harness side of Orange upper spiral cable connector. See WIRING DIAGRAMS . If resistance is less
than one ohm, go to step 11 . If resistance is more than one ohm, go to step 15 .
5. Measure resistance between ground and Yellow/Violet wire (circuit D2+) on harness side of Orange
upper spiral cable connector. See WIRING DIAGRAMS . Measure resistance between ground and
Yellow (circuit D2-) wire on harness side of Orange upper spiral cable connector. If resistance is more
than one ohm, go to step 11 . If resistance is less than one megohm, go to step 17 .
voltage between ground and Yellow/Violet wire (circuit D2+) on harness side of Orange upper spiral
cable connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow/Orange wire
(circuit D2-) on harness side of Orange upper spiral cable connector. If voltage is less than one volt, go to
step 11 . If voltage is more than one volt, go to step 19 .
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2004 Toyota RAV4
voltage between ground and Yellow/Violet wire (circuit D2+) on harness side of Orange upper spiral
cable connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow/Orange wire
(circuit D2-) on harness side of Orange upper spiral cable connector. Voltage should be less than one volt.
Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90 seconds.
Measure resistance between Yellow/Violet wire and Yellow/Orange wire on harness side of Orange
upper spiral cable connector. Resistance should be less than one ohm. Measure resistance between ground
and Yellow/Violet wire on harness side of Orange upper spiral cable connector. Measure resistance
between ground and Yellow/Orange wire on harness side of Orange upper spiral cable connector.
Resistance should be more than one megohm. Release short spring mechanism on air bag sensor
assembly connector C7. See RELEASING SHORT SPRING under DIAGNOSTICS. Measure
resistance between Yellow/Violet wire and Yellow/Orange wire on harness side of Orange upper spiral
cable connector. Resistance should be more than one megohm. If voltage and resistance readings are
normal, go to next step. If voltage and resistance readings are not normal, go to step 21 .
9. Replace driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE under REMOVAL &
complete.
Connect jumper wire between Yellow/Violet wire and Yellow/Orange wire on harness side of Orange
upper spiral cable connector. See WIRING DIAGRAMS . Connect negative battery cable. Wait at least
2 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. See CLEARING
connectors to driver-side air bag module. Connect negative battery cable. Wait at least 2 seconds. Turn
DIAGNOSTICS. If DTCs B1810, B1811, B1812 or B1813 are displayed, replace driver-side air bag
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2004 Toyota RAV4
module. See DRIVER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. If DTC
B1810, B1811, B1812 or B1813 are not displayed, ensure air bag sensor assembly is in check mode. See
CHECK MODE PROCEDURE under DIAGNOSTICS. Check for intermittent air bag system fault. See
AIR BAG WARNING LIGHT INTERMITTENT .
13. Disconnect lower spiral cable harness connector. Measure resistance between Yellow/Violet wire and
Yellow/Orange wire on harness side of lower spiral cable connector. If resistance is less than one
megohm, replace wiring harness between air bag sensor assembly and spiral cable. If resistance is more
than one megohm, go to next step.
14. Release short spring mechanism on lower spiral cable harness connector. Measure resistance between
Yellow/Violet wire and Yellow/Orange wire on harness side of Orange upper spiral cable connector. If
resistance is less than one megohm, replace spiral cable. See SPIRAL CABLE under REMOVAL &
INSTALLATION. If resistance is more than one megohm, ensure air bag sensor assembly is in check
mode. See CHECK MODE PROCEDURE under DIAGNOSTICS. Check for intermittent air bag
15. Disconnect lower spiral cable harness connector. Measure resistance between Yellow/Violet wire and
Yellow/Orange wire on harness side of lower spiral cable connector. If resistance is more than one ohm,
replace wiring harness between air bag sensor assembly and spiral cable. If resistance is less than one
ohm, go to next step.
16. Measure resistance between Yellow/Violet wire and Yellow/Orange wire on harness side of Orange
upper spiral cable connector. If resistance is more than one ohm, replace spiral cable. See SPIRAL
CABLE under REMOVAL & INSTALLATION. If resistance is less than one ohm, ensure air bag sensor
assembly is in check mode. See CHECK MODE PROCEDURE under DIAGNOSTICS. Check for
intermittent air bag system fault. See AIR BAG WARNING LIGHT INTERMITTENT .
17. Disconnect lower spiral cable harness connector. Measure resistance between ground and Yellow/Violet
wire on harness side of lower spiral cable connector. Measure resistance between ground and
Yellow/Orange wire on harness side of lower spiral cable connector. If resistance is more than one
megohm, replace wiring harness between air bag sensor assembly and spiral cable. If resistance is less
than one megohm, go to next step.
18. Measure resistance between ground and Yellow/Violet wire on harness side of Orange upper spiral cable
connector. Measure resistance between ground and Yellow/Orange wire on harness side of Orange upper
spiral cable connector. If resistance is more than one megohm, replace spiral cable. See SPIRAL
CABLE under REMOVAL & INSTALLATION. If resistance is less than one megohm, ensure air bag
sensor assembly is in check mode. See CHECK MODE PROCEDURE under DIAGNOSTICS. Check
for intermittent air bag system fault. See AIR BAG WARNING LIGHT INTERMITTENT .
Disconnect lower spiral cable harness connector. Measure voltage between ground and Yellow/Violet
wire on harness side of lower spiral cable connector. Measure voltage between ground and
Yellow/Orange wire on harness side of lower spiral cable connector. If voltage is more than one volt,
replace wiring harness between air bag sensor assembly and spiral cable. If voltage is less than one volt,
go to next step.
20. Measure voltage between ground and Yellow/Violet wire on harness side of Orange upper spiral cable
connector. Measure voltage between ground and Yellow/Orange wire on harness side of Orange upper
spiral cable connector. If voltage is more than one volt, replace spiral cable. See SPIRAL CABLE under
REMOVAL & INSTALLATION. If voltage is less than one volt, ensure air bag sensor assembly is in
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2004 Toyota RAV4

21. Restore short spring mechanism to original condition. Disconnect lower spiral cable harness connector.
Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON position. Measure
voltage between ground and Yellow/Violet wire on harness side of lower spiral cable connector. Measure
voltage between ground and Yellow/Orange wire on harness side of lower spiral cable connector. Voltage
should be less than one volt. Turn ignition switch to LOCK position. Disconnect negative battery cable
and wait at least 90 seconds. Measure resistance between Yellow/Violet wire and Yellow/Orange wire on
harness side of lower spiral cable connector. Resistance should be less than one ohm. Measure resistance
between ground and Yellow/Violet wire on harness side of lower spiral cable connector. Measure
resistance between ground and Yellow/Orange wire on harness side of lower spiral cable connector.
assembly connector C7. Measure resistance between Yellow/Violet wire and Yellow/Orange wire on
harness side of lower spiral cable connector. Resistance should be more than one megohm. If voltage and
resistance readings are normal, go to next step. If voltage and resistance readings are not normal, replace
wiring harness between air bag sensor assembly and spiral cable.
voltage between ground and Yellow/Violet wire on harness side of Orange upper spiral cable connector.
Measure voltage between ground and Yellow/Orange wire on harness side of Orange upper spiral cable
connector. Voltage should be less than one volt. Turn ignition switch to LOCK position. Disconnect
negative battery cable and wait at least 90 seconds. Measure resistance between Yellow/Violet wire and
Yellow/Orange wire on harness side of Orange upper spiral cable connector. Resistance should be less
than one ohm. Measure resistance between ground and Yellow/Violet wire on harness side of Orange
upper spiral cable connector. Measure resistance between ground and Yellow/Orange wire on harness
side of Orange upper spiral cable connector. Resistance should be more than one megohm. Release short
spring mechanism on lower spiral cable connector. Measure resistance between Yellow/Violet wire and
Yellow/Orange wire on harness side of Orange upper spiral cable connector. Resistance should be more
than one megohm. If voltage and resistance readings are normal, ensure air bag sensor assembly is in
system fault. See AIR BAG WARNING LIGHT INTERMITTENT . If voltage and resistance readings
are not normal, replace spiral cable. See SPIRAL CABLE under REMOVAL & INSTALLATION.
DTC 54/B1815, 54/B1816, 54/B1817, 54/B1818: PASSENGER-SIDE AIR BAG NO. 2 SQUIB CIRCUIT
Possible Causes
ground, open, short or short to battery in No. 2 squib circuit, squib malfunction or air bag sensor assembly
malfunction.
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2004 Toyota RAV4
wiring harness.
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Gray wire (circuit P2+) and
Yellow/Pink wire (circuit P2-) on harness side of passenger-side air bag module connector. See WIRING
DIAGRAMS . If resistance is less than one megohm, replace instrument panel wiring harness. If
resistance is more than one megohm, go to step 10 .
4. Measure resistance between Yellow/Gray wire (circuit P2+) and Yellow/Pink wire (circuit P2-) on
harness side of passenger-side air bag module connector. See WIRING DIAGRAMS . If resistance is
less than one ohm, go to step 11 . If resistance is more than one ohm, replace instrument panel wiring
harness.
5. Measure resistance between ground and Yellow/Gray wire (circuit P2+) on harness side of passenger-side
air bag module connector. See WIRING DIAGRAMS . Measure resistance between ground and
Yellow/Pink (circuit P2-) wire on harness side of passenger-side air bag module connector. If resistance is
more than one megohm, go to step 11 . If resistance is less than one megohm, replace instrument panel
wiring harness.
voltage between ground and Yellow/Gray wire (circuit P2+) on harness side of passenger-side air bag
module connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow/Pink wire
(circuit P2-) on harness side of passenger-side air bag module connector. If voltage is less than one volt,
go to step 11 . If voltage is more than one volt, replace instrument panel wiring harness.
wiring harness.
voltage between ground and Yellow/Gray wire (circuit P2+) on harness side of passenger-side air bag
module connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow/Pink wire
(circuit P2-) on harness side of passenger-side air bag module connector. Voltage should be less than one
volt. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90
seconds. Measure resistance between Yellow/Gray wire and Yellow/Pink wire on harness side of
passenger-side air bag module connector. Resistance should be less than one ohm. Measure resistance
between ground and Yellow/Gray wire on harness side of passenger-side air bag module connector.
Measure resistance between ground and Yellow/Pink wire on harness side of passenger-side air bag
Measure resistance between Yellow/Gray wire and Yellow/Pink wire on harness side of passenger-side
readings are normal, go to next step. If voltage and resistance readings are not normal, replace instrument
panel wiring harness.
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2004 Toyota RAV4
9. Replace passenger-side air bag module. See PASSENGER-SIDE AIR BAG MODULE under
Connect jumper wire between Yellow/Gray wire and Yellow/Pink wire on harness side of passenger-side
air bag module connector. See WIRING DIAGRAMS . Connect negative battery cable. Wait at least 2
connectors to passenger-side air bag module Connect negative battery cable. Wait at least 2 seconds. Turn
DIAGNOSTICS. If DTCs B1815, B1816, B1817 or B1818 are displayed, replace passenger-side air bag
module. See PASSENGER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. If
DTC B1815, B1816, B1817 or B1818 are not displayed, ensure air bag sensor assembly is in check mode.
DTC 55/B1820, 55/B1821, 55/B1822, 55/B1823: LEFT SIDE AIR BAG SQUIB CIRCUIT SHORT,
OPEN, SHORT TO GROUND OR SHORT TO BATTERY
Possible Causes
ground, open, short or short to battery in left side air bag squib circuit, squib malfunction or air bag sensor
assembly malfunction.
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2004 Toyota RAV4
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Red wire (circuit SFD+) and
Yellow/Green wire (circuit SFD-) on harness side of left side curtain air bag module connector. See
WIRING DIAGRAMS . If resistance is less than one megohm, replace wire harness between left side air
bag module and air bag sensor assembly. If resistance is more than one megohm, go to step 8 .
3. Measure resistance between Yellow/Red wire (circuit SFD+) and Yellow/Green wire (circuit SFD-) on
harness side of left side curtain air bag module connector. See WIRING DIAGRAMS . If resistance is
less than one ohm, go to step 9 . If resistance is more than one ohm, replace wire harness between left
side air bag module and air bag sensor assembly.
4. Measure resistance between ground and Yellow/Red wire (circuit SFD+) on harness side of left side
curtain air bag module connector. See WIRING DIAGRAMS . Measure resistance between ground and
Yellow/Green (circuit SFD-) wire on harness side of left side curtain air bag module connector. If
resistance is more than one megohm, go to step 9 . If resistance is less than one megohm, replace wire
harness between left side air bag module and air bag sensor assembly.
voltage between ground and Yellow/Red wire (circuit SFD+) on harness side of left side curtain air bag
wire (circuit SFD-) on harness side of left side curtain air bag module connector. If voltage is less than
one volt, go to step 9 . If voltage is more than one volt, replace wire harness between left side air bag
module and air bag sensor assembly.
voltage between ground and Yellow/Red wire (circuit SFD+) on harness side of left side curtain air bag
wire (circuit SFD-) on harness side of left side curtain air bag module connector. Voltage should be less
than one volt. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least
90 seconds. Measure resistance between Yellow/Red wire and Yellow/Green wire on harness side of left
side curtain air bag module connector. Resistance should be less than one ohm. Measure resistance
between ground and Yellow/Red wire on harness side of left side curtain air bag module connector.
Measure resistance between ground and Yellow/Green wire on harness side of left side curtain air bag
Measure resistance between Yellow/Red wire and Yellow/Green wire on harness side of left side curtain
harness between left side air bag module and air bag sensor assembly.
7. Replace left side air bag module. See SIDE AIR BAG MODULE under REMOVAL &
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2004 Toyota RAV4
complete.
Connect jumper wire between Yellow/Red wire and Yellow/Green wire on harness side of left side
curtain air bag module connector. See WIRING DIAGRAMS . Connect negative battery cable. Wait at
least 2 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. See
CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20
seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Retrieve DTCs. See
RETRIEVING CODES under DIAGNOSTICS. If DTCs B1821, B1822 or B1823 are displayed, replace
air bag sensor assembly. See AIR BAG SENSOR ASSEMBLY under REMOVAL & INSTALLATION.
If DTC B1821, B1822 or B1823 are not displayed, go to next step.
sent here from step 9 , remove jumper wire. If sent here from any step, connect left side air bag module
harness connectors. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON
least 60 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTCs B1820,
B1821, B1822 or B1823 are displayed, replace left side air bag module. See SIDE AIR BAG MODULE
under REMOVAL & INSTALLATION. If DTC B1820, B1821, B1822 or B1823 are not displayed,
ensure air bag sensor assembly is in check mode. See CHECK MODE PROCEDURE under
DIAGNOSTICS. Check for intermittent air bag system fault. See AIR BAG WARNING LIGHT
INTERMITTENT .
DTC 56/B1825, 56/B1826, 56/B1827, 56/B1828: RIGHT SIDE AIR BAG SQUIB CIRCUIT SHORT,
OPEN, SHORT TO GROUND OR SHORT TO BATTERY
Possible Causes
ground, open, short or short to battery in right side air bag squib circuit, squib malfunction or air bag sensor
assembly malfunction.
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2004 Toyota RAV4
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Red wire (circuit SFP+) and
Yellow/Green wire (circuit SFP-) on harness side of right side air bag module connector. See WIRING
DIAGRAMS . If resistance is less than one megohm, replace wire harness between right side air bag
module and air bag sensor assembly. If resistance is more than one megohm, go to step 8 .
3. Measure resistance between Yellow/Red wire (circuit SFP+) and Yellow/Green wire (circuit SFP-) on
harness side of right side air bag module connector. See WIRING DIAGRAMS . If resistance is less
than one ohm, go to step 9 . If resistance is more than one ohm, replace wire harness between right side
air bag module and air bag sensor assembly.
4. Measure resistance between ground and Yellow/Red wire (circuit SFP+) on harness side of right side air
bag module connector. See WIRING DIAGRAMS . Measure resistance between ground and
Yellow/Green (circuit SFP-) wire on harness side of right side air bag module connector. If resistance is
more than one megohm, go to step 9 . If resistance is less than one megohm, replace wire harness
between right side air bag module and air bag sensor assembly.
voltage between ground and Yellow/Red wire (circuit SFP+) on harness side of right side air bag module
connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow/Green wire
(circuit SFP-) on harness side of right side air bag module connector. If voltage is less than one volt, go to
step 9 . If voltage is more than one volt, replace wire harness between right side air bag module and air
bag sensor assembly.
voltage between ground and Yellow/Red wire (circuit SFP+) on harness side of right side air bag module
connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow/Green wire
(circuit SFP-) on harness side of right side air bag module connector. Voltage should be less than one
seconds. Measure resistance between Yellow/Red wire and Yellow/Green wire on harness side of right
side air bag module connector. Resistance should be less than one ohm. Measure resistance between
ground and Yellow/Red wire on harness side of right side air bag module connector. Measure resistance
between ground and Yellow/Green wire on harness side of right side air bag module connector.
assembly connector C8. See RELEASING SHORT SPRING under DIAGNOSTICS. Measure
resistance between Yellow/Red wire and Yellow/Green wire on harness side of right side air bag module
connector. Resistance should be more than one megohm. If voltage and resistance readings are normal, go
to next step. If voltage and resistance readings are not normal, replace wire harness between right side air
bag module and air bag sensor assembly.
7. Replace right side air bag module. See SIDE AIR BAG MODULE under REMOVAL &
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2004 Toyota RAV4
complete.
Connect jumper wire between Yellow/Red wire and Yellow/Green wire on harness side of right side air
bag module connector. See WIRING DIAGRAMS . Connect negative battery cable. Wait at least 2
sent here from step 9 , remove jumper wire. If sent here from any step, connect right side air bag module
B1826, B1827 or B1828 are displayed, replace right side air bag module. See SIDE AIR BAG
MODULE under REMOVAL & INSTALLATION. If DTC B1825, B1826, B1827 or B1828 are not
displayed, ensure air bag sensor assembly is in check mode. See CHECK MODE PROCEDURE under
DIAGNOSTICS. Check for intermittent air bag system fault. See AIR BAG WARNING LIGHT
INTERMITTENT .
DTC 57/B1830, 57/B1831, 57/B1832, 57/B1833: LEFT SIDE CURTAIN AIR BAG SQUIB CIRCUIT
Possible Causes
ground, open, short or short to battery in left side curtain air bag squib circuit, squib malfunction or air bag
sensor assembly malfunction.
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2004 Toyota RAV4
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Violet wire (circuit ICD+) and
Yellow/Orange wire (circuit ICD-) on harness side of left side curtain air bag module connector. See
WIRING DIAGRAMS . If resistance is less than one megohm, replace wire harness between left side
curtain air bag module and air bag sensor assembly. If resistance is more than one megohm, go to step 8 .
3. Measure resistance between Yellow/Violet wire (circuit ICD+) and Yellow/Orange wire (circuit ICD-) on
less than one ohm, go to step 9 . If resistance is more than one ohm, replace wire harness between left
side curtain air bag module and air bag sensor assembly.
4. Measure resistance between ground and Yellow/Violet wire (circuit ICD+) on harness side of left side
Yellow/Orange (circuit ICD-) wire on harness side of left side curtain air bag module connector. If
harness between left side curtain air bag module and air bag sensor assembly.
voltage between ground and Yellow/Violet wire (circuit ICD+) on harness side of left side curtain air bag
module connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow/Orange
wire (circuit ICD-) on harness side of left side curtain air bag module connector. If voltage is less than
one volt, go to step 9 . If voltage is more than one volt, replace wire harness between left side curtain air
bag module and air bag sensor assembly.
voltage between ground and Yellow/Violet wire (circuit ICD+) on harness side of left side curtain air bag
wire (circuit ICD-) on harness side of left side curtain air bag module connector. Voltage should be less
90 seconds. Measure resistance between Yellow/Violet wire and Yellow/Orange wire on harness side of
left side curtain air bag module connector. Resistance should be less than one ohm. Measure resistance
between ground and Yellow/Violet wire on harness side of left side curtain air bag module connector.
Measure resistance between ground and Yellow/Orange wire on harness side of left side curtain air bag
Measure resistance between Yellow/Violet wire and Yellow/Orange wire on harness side of left side
curtain air bag module connector. Resistance should be more than one megohm. If voltage and resistance
harness between left side curtain air bag module and air bag sensor assembly.
7. Replace left side curtain air bag module. See SIDE CURTAIN AIR BAG MODULE under REMOVAL
& INSTALLATION. Reconnect air bag sensor assembly harness connectors. Turn ignition switch to ON
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2004 Toyota RAV4
complete.
Connect jumper wire between Yellow/Violet wire and Yellow/Orange wire on harness side of left side
B1831, B1832 or B1833 are displayed, replace left side curtain air bag module. See SIDE CURTAIN
AIR BAG MODULE under REMOVAL & INSTALLATION. If DTC B1830, B1831, B1832 or B1833
are not displayed, ensure air bag sensor assembly is in check mode. See CHECK MODE
WARNING LIGHT INTERMITTENT .
DTC 58/B1835, 58/B1836, 58/B1837, 58/B1838: RIGHT SIDE CURTAIN AIR BAG SQUIB CIRCUIT
Possible Causes
ground, open, short or short to battery in right side curtain air bag squib circuit, squib malfunction or air bag
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2004 Toyota RAV4
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Violet wire (circuit ICP+) and
Yellow/Orange wire (circuit ICP-) on harness side of left side curtain air bag module connector. See
WIRING DIAGRAMS . If resistance is less than one megohm, replace wire harness between right side
curtain air bag module and air bag sensor assembly. If resistance is more than one megohm, go to step 8 .
3. Measure resistance between Yellow/Violet wire (circuit ICP+) and Yellow/Orange wire (circuit ICP-) on
less than one ohm, go to step 9 . If resistance is more than one ohm, replace wire harness between right
side curtain air bag module and air bag sensor assembly.
4. Measure resistance between ground and Yellow/Violet wire (circuit ICP+) on harness side of left side
Yellow/Orange (circuit ICP-) wire on harness side of left side curtain air bag module connector. If
harness between right side curtain air bag module and air bag sensor assembly.
voltage between ground and Yellow/Violet wire (circuit ICP+) on harness side of left side curtain air bag
wire (circuit ICP-) on harness side of left side curtain air bag module connector. If voltage is less than one
volt, go to step 9 . If voltage is more than one volt, replace wire harness between right side curtain air bag
module and air bag sensor assembly.
voltage between ground and Yellow/Violet wire (circuit ICP+) on harness side of left side curtain air bag
wire (circuit ICP-) on harness side of left side curtain air bag module connector. Voltage should be less
90 seconds. Measure resistance between Yellow/Violet wire and Yellow/Orange wire on harness side of
left side curtain air bag module connector. Resistance should be less than one ohm. Measure resistance
between ground and Yellow/Violet wire on harness side of left side curtain air bag module connector.
Measure resistance between ground and Yellow/Orange wire on harness side of left side curtain air bag
Measure resistance between Yellow/Violet wire and Yellow/Orange wire on harness side of left side
curtain air bag module connector. Resistance should be more than one megohm. If voltage and resistance
harness between right side curtain air bag module and air bag sensor assembly.
7. Replace right side curtain air bag module. See SIDE CURTAIN AIR BAG MODULE under
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2004 Toyota RAV4

Connect jumper wire between Yellow/Violet wire and Yellow/Orange wire on harness side of left side
B1836, B1837 or B1838 are displayed, replace right side curtain air bag module. See SIDE CURTAIN
AIR BAG MODULE under REMOVAL & INSTALLATION. If DTC B1835, B1836, B1837 or B1838
are not displayed, ensure air bag sensor assembly is in check mode. See CHECK MODE
WARNING LIGHT INTERMITTENT .
DTC 73/B1900, 73/B1901, 73/B1902, 73/B1903: LEFT SEAT BELT PRETENSIONER SQUIB CIRCUIT
Possible Causes
ground, open, short or short to battery in left seat belt pretensioner squib circuit, squib malfunction or air bag
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2004 Toyota RAV4
2. Inspect left seat belt pretensioner connector for disengaged lock button or deformed or damaged lock
claw. If connectors are okay, go to next step. If connectors are not okay, replace wire harness between left
seat belt pretensioner and air bag sensor assembly.
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Black wire (circuit PD+) and
Yellow wire (circuit PD-) on harness side of left seat belt pretensioner connector. See WIRING
DIAGRAMS . If resistance is less than one megohm, replace wire harness between left seat belt
pretensioner and air bag sensor assembly. If resistance is more than one megohm, go to step 10 .
4. Measure resistance between Yellow/Black wire (circuit PD+) and Yellow wire (circuit PD-) on harness
side of left seat belt pretensioner connector. See WIRING DIAGRAMS . If resistance is less than one
ohm, go to step 11 . If resistance is more than one ohm, replace wire harness between left seat belt
pretensioner and air bag sensor assembly.
5. Measure resistance between ground and Yellow/Black wire (circuit PD+) on harness side of left seat belt
pretensioner connector. See WIRING DIAGRAMS . Measure resistance between ground and Yellow
(circuit PD-) wire on harness side of left seat belt pretensioner connector. If resistance is more than one
megohm, go to step 11 . If resistance is less than one megohm, replace wire harness between left seat belt
voltage between ground and Yellow/Black wire (circuit PD+) on harness side of left seat belt pretensioner
connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow wire (circuit PD-)
on harness side of left seat belt pretensioner connector. If voltage is less than one volt, go to step 11 . If
voltage is more than one volt, replace wire harness between left seat belt pretensioner and air bag sensor
assembly.
7. Inspect left seat belt pretensioner connector for disengaged lock button or deformed or damaged lock
claw. If connectors are okay, go to next step. If connectors are not okay, replace wire harness between left
seat belt pretensioner and air bag sensor assembly.
voltage between ground and Yellow/Black wire (circuit PD+) on harness side of left seat belt pretensioner
connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow wire (circuit PD-)
on harness side of left seat belt pretensioner connector. Voltage should be less than one volt. Turn
ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90 seconds.
Measure resistance between Yellow/Black wire and Yellow wire on harness side of left seat belt
pretensioner connector. Resistance should be less than one ohm. Measure resistance between ground and
Yellow/Black wire on harness side of left seat belt pretensioner connector. Measure resistance between
ground and Yellow wire on harness side of left seat belt pretensioner connector. Resistance should be
more than one megohm. Release short spring mechanism on air bag sensor assembly connector C6. See
RELEASING SHORT SPRING under DIAGNOSTICS. Measure resistance between Yellow/Black
wire and Yellow wire on harness side of left seat belt pretensioner connector. Resistance should be more
than one megohm. If voltage and resistance readings are normal, go to next step. If voltage and resistance
readings are not normal, replace wire harness between left seat belt pretensioner and air bag sensor
assembly.
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9. Replace left seat belt pretensioner. See SEAT BELT PRETENSIONER under REMOVAL &
complete.
Connect jumper wire between Yellow/Black wire and Yellow wire on harness side of left seat belt
pretensioner connector. See WIRING DIAGRAMS . Connect negative battery cable. Wait at least 2
B1901, B1902 or B1903 are displayed, replace left seat belt pretensioner. See SEAT BELT
PRETENSIONER under REMOVAL & INSTALLATION. If DTC B1900, B1901, B1902 or B1903 are
not displayed, ensure air bag sensor assembly is in check mode. See CHECK MODE PROCEDURE
under DIAGNOSTICS. Check for intermittent air bag system fault. See AIR BAG WARNING LIGHT
INTERMITTENT .
DTC 74/B1905, 74/B1906, 74/B1907, 74/B1908: RIGHT SEAT BELT PRETENSIONER SQUIB
CIRCUIT SHORT, OPEN, SHORT TO GROUND OR SHORT TO BATTERY
Possible Causes
ground, open, short or short to battery in right seat belt pretensioner squib circuit, squib malfunction or air bag
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2. Inspect right seat belt pretensioner connector for disengaged lock button or deformed or damaged lock
claw. If connectors are okay, go to next step. If connectors are not okay, replace right seat belt
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Black wire (circuit PP+) and
Yellow wire (circuit PP-) on harness side of right seat belt pretensioner connector. See WIRING
DIAGRAMS . If resistance is less than one megohm, replace wire harness between right seat belt
pretensioner and air bag sensor assembly. If resistance is more than one megohm, go to step 10 .
4. Measure resistance between Yellow/Black wire (circuit PP+) and Yellow wire (circuit PP-) on harness
side of right seat belt pretensioner connector. See WIRING DIAGRAMS . If resistance is less than one
ohm, go to step 11 . If resistance is more than one ohm, replace wire harness between right seat belt
5. Measure resistance between ground and Yellow/Black wire (circuit PP+) on harness side of right seat belt
pretensioner connector. See WIRING DIAGRAMS . Measure resistance between ground and Yellow
(circuit PP-) wire on harness side of right seat belt pretensioner connector. If resistance is more than one
megohm, go to step 10 . If resistance is less than one megohm, replace wire harness between right seat
belt pretensioner and air bag sensor assembly.
voltage between ground and Yellow/Black wire (circuit PP+) on harness side of right seat belt
pretensioner connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow wire
(circuit PP-) on harness side of right seat belt pretensioner connector. If voltage is less than one volt, go to
step 11 . If voltage is more than one volt, replace wire harness between right seat belt pretensioner and air
bag sensor assembly.
7. Inspect right seat belt pretensioner connector for disengaged lock button or deformed or damaged lock
claw. If connectors are okay, go to next step. If connectors are not okay, replace right seat belt
voltage between ground and Yellow/Black wire (circuit PP+) on harness side of right seat belt
pretensioner connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow wire
(circuit PP-) on harness side of right seat belt pretensioner connector. Voltage should be less than one
seconds. Measure resistance between Yellow/Black wire and Yellow wire on harness side of right seat
belt pretensioner connector. Resistance should be less than one ohm. Measure resistance between ground
and Yellow/Black wire on harness side of right seat belt pretensioner connector. Measure resistance
between ground and Yellow wire on harness side of right seat belt pretensioner connector. Resistance
should be more than one megohm. Release short spring mechanism on air bag sensor assembly connector
C8. See RELEASING SHORT SPRING under DIAGNOSTICS. Measure resistance between
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Yellow/Black wire and Yellow wire on harness side of right seat belt pretensioner connector. Resistance
should be more than one megohm. If voltage and resistance readings are normal, go to next step. If
voltage and resistance readings are not normal, replace wire harness between right seat belt pretensioner
and air bag sensor assembly.
9. Replace right seat belt pretensioner. See SEAT BELT PRETENSIONER under REMOVAL &
complete.
Connect jumper wire between Yellow/Black wire and Yellow wire on harness side of right seat belt
pretensioner connector. See WIRING DIAGRAMS . Connect negative battery cable. Wait at least 2
B1906, B1907 or B1908 are displayed, replace right seat belt pretensioner. See SEAT BELT
PRETENSIONER under REMOVAL & INSTALLATION. If DTC B1905, B1906, B1907 or B1908 are
not displayed, ensure air bag sensor assembly is in check mode. See CHECK MODE PROCEDURE
under DIAGNOSTICS. Check for intermittent air bag system fault. See AIR BAG WARNING LIGHT
INTERMITTENT .
WIRING DIAGRAMS
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Fig. 22: Air Bag System Wiring Diagram (RAV4-1 Of 2)
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Fig. 23: Air Bag System Wiring Diagram (RAV4-2 Of 2)
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2001-05 AUTOMATIC TRANSMISSIONS U240E & U241E Overhaul
2001-05 AUTOMATIC TRANSMISSIONS
U240E & U241E Overhaul
APPLICATION
CAUTION: Flush oil cooler and oil cooler lines prior to transaxle installation. Oil
cooling system contamination may cause premature transaxle failure.
TRANSAXLE APPLICATION
Application Transaxle Model
Camry U241E
Camry Solara U241E
Celica U240E
Highlander U241E
Matrix U240E
RAV4 U241E
Scion tC (2005-08 Model Year) U241E
IDENTIFICATION
TRANSAXLE
Vehicle Identification Number (VIN) is used for correct identification of component parts and assemblies. VIN
is located at top left corner of instrument panel. Vehicle certification label is located at left corner of driver's
door. See Fig. 1. This label also contains the VIN.
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9:42:58 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
2005 Toyota RAV4
Fig. 1: Locating Vehicle Identification Number Plate & Certification Label (Typical)
GEAR RATIOS
TRANSAXLE GEAR RATIOS

Gear Range Gear Ratio
1st 3.943:1
2nd 2.197:1
3rd 1.413:1
OD 1.020:1
Reverse 3.145:1

INTRODUCTION
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2005 Toyota RAV4
The U240 series transaxle is a 4-speed electronically controlled transaxle. Transaxle uses a lock-up torque
converter, direct clutch, forward clutch, underdrive clutch, underdrive brake, 3 planetary gears, 2nd brake, 2
one-way clutches, 1st/reverse brake, and hydraulic and electronic control systems. See Fig. 2.
Fig. 2: Identifying Transaxle Component Locations

LUBRICATION
NOTE: See appropriate SERVICING article.
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TROUBLE SHOOTING
NOTE: Transmission malfunctions may be caused by poor engine performance,

improper adjustments, fluid condition or failure of hydraulic, mechanical or
electronic components. Ensure all concerns have been properly checked prior
to transmission overhaul. See appropriate DIAGNOSIS article.
COMPONENT TESTS
TORQUE CONVERTER
NOTE: Torque converter is a sealed unit and is serviced as complete assembly.

Perform the following tests to check for defective converter. Torque converter
and transaxle cooler must be thoroughly cleaned and flushed if transaxle is
contaminated.
Torque Converter One-Way Clutch Test
1. Insert a turning tool into inner race of one-way clutch. Install Tester (09351-32010) so it fits in notch of
converter hub and outer race of one-way clutch.
2. With converter in normal operating position, clutch should lock-up when turned counterclockwise and
should rotate freely and smoothly when turned clockwise. See Fig. 3. If one-way clutch fails test in either
direction, clean converter. Retest clutch. If clutch fails test, replace torque converter.
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Fig. 3: Checking Torque Converter One-Way Clutch

Torque Converter Sleeve Runout Test
1. Temporarily mount torque converter to drive plate. Mount a dial indicator with needle resting on
converter sleeve. See Fig. 4. Rotate converter. If runout exceeds .012" (.30 mm), ensure converter is
properly mounted to drive plate.
2. If converter is properly mounted and runout exceeds specification, replace torque converter. Mark
position of converter to ensure correct installation. Remove converter from drive plate.
Drive Plate (Flexplate) Runout Test
Measure drive plate runout. See Fig. 5. If runout exceeds .008" (.20 mm), or if ring gear is damaged, replace
drive plate. If installing a NEW drive plate, note position of spacers. Tighten bolts to 65 ft. lbs. (88 N.m).
Fig. 4: Checking Torque Converter Sleeve Runout

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Fig. 5: Checking Drive Plate Runout

TRANSAXLE DISASSEMBLY
1. Remove nut, washer and control shift lever. Using a screwdriver, unstake lock tab. Remove 2 bolts and
nut, and remove park/neutral position switch. See Fig. 9.
2. Remove oil line union and elbow. Remove and discard "O" rings from union and elbow (if equipped).
Remove input turbine and counter gear speed sensors from top of transaxle. See Fig. 6. Remove and
discard speed sensor "O" rings. Remove transaxle test plug from transaxle case. See Fig. 7. Remove
solenoid connector bolt located above park/neutral position switch. DO NOT attempt to remove solenoid
connector from transaxle case at this time.
3. Place transaxle on wooden blocks. Remove 18 bolts, oil pan and gasket. Disconnect 5 shift solenoid
connectors. Remove bolts, clamps and fluid temperature sensor. See Fig. 8. Remove transaxle wiring
harness with solenoid connector from transaxle case. Remove oil strainer and gasket. See Fig. 9.
4. Remove 17 valve body bolts. Note bolt length and location for reassembly reference. See Fig. 10.
Remove valve body assembly.
5. Remove 3 apply gaskets, check ball body and spring. See Fig. 11. Remove brake drum gasket, located
near apply gaskets. See Fig. 9. Remove underdrive clutch accumulator spring. Using 57 psi (4 kg/cm2 ) of
compressed air applied to transaxle case, remove underdrive clutch accumulator piston. See Fig. 12.
Cover piston with shop towel during removal.
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Fig. 6: Identifying Transaxle External Components

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Fig. 7: Locating Transaxle Test Plug

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Fig. 8: Locating Fluid Temperature Sensor & Solenoid Connectors

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Fig. 9: Exploded View Of Transaxle Valve Body & Parking Lock Components
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Fig. 10: Identifying Valve Body Bolt Locations

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Fig. 11: Locating Check Ball Body & Spring, & Apply Gaskets (3)
Fig. 12: Removing Underdrive Clutch Accumulator Piston

6. Using 57 psi (4 kg/cm2 ) of compressed air applied to transaxle case, remove forward clutch accumulator
piston and spring, and underdrive brake accumulator piston. Cover pistons with shop towel during
removal. See Fig. 13 and Fig. 14 .
7. Using needle nose pliers, remove manual valve lever retainer spring. Remove 2 bolts, manual detent
spring and cover. See Fig. 9. Remove 2 bolts and parking lock pawl bracket. Using a hammer and chisel,
unstake and remove spacer. Using a pin punch and hammer, drive out roll pin. Ensure pin does not fall
into transaxle case.
8. Remove manual valve lever shaft and manual valve lever. Remove parking lock pawl rod from manual
valve lever. Using a screwdriver, remove shaft oil seal. See Fig. 9. Position transaxle case with oil pump
assembly facing upward.
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CAUTION: Use caution when removing transaxle housing. Differential assembly

may attach to transaxle housing during removal.
9. Using a dial indicator, measure input shaft end play. See Fig. 15. End play should be .011-.049" (.27-1.25
mm). Remove 16 transaxle housing bolts. Note bolt length and location during removal for reassembly
reference. See Fig. 16.
Fig. 13: Removing Forward Clutch Accumulator Piston

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Fig. 14: Removing Underdrive Brake Accumulator Piston

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Fig. 15: Measuring Input Shaft End Play

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Fig. 16: Removing & Installing Transaxle Housing Bolts

10. Remove 7 oil pump bolts and oil pump. Remove thrust bearing and bearing race from underdrive
planetary gear assembly. See Fig. 17. Remove differential assembly. Remove 2 apply gaskets from front
of transaxle case. See Fig. 23. Remove forward clutch from transaxle case. Remove multiple disc clutch
hub and needle roller bearing from transaxle case. See Fig. 18.
11. Remove one bolt and parking lock pawl clamp. See Fig. 17. Remove parking lock pawl shaft. Push
parking lock pawl toward transaxle case to prevent interference during underdrive planetary gear
assembly removal. See Fig. 24. Using both hands, remove underdrive planetary gear assembly. DO NOT
allow planetary gear assembly to separate.
NOTE: No. 2 one-way clutch may also be known as underdrive one-way clutch.
12. Remove spring, pawl pin and parking lock pawl. Remove underdrive clutch assembly. See Fig. 18.
Remove thrust bearing and bearing race. Using a screwdriver, remove No. 2 one-way clutch snap ring.
Remove No. 2 one-way clutch from transaxle case. Note position of index marks on No. 2 one-way clutch
for reassembly reference. See Fig. 73. Note position of outer race retainer on No. 2 one-way clutch for
reassembly reference. See Fig. 25. Remove outer race retainer from No. 2 one-way clutch.
13. Using a screwdriver, remove underdrive brake snap ring. Remove flange, 3 discs and 3 plates from
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transaxle case. Note location of components during removal for reassembly reference. Using appropriate
press, compress underdrive brake piston return spring. Using snap ring expander, remove snap ring from
underdrive brake. Remove piston return spring. See Fig. 18.
14. Remove 11 bolts and transaxle rear cover. If necessary, tap on circumference of rear cover with plastic
hammer to remove cover. Remove 2 oil seal rings from rear cover. Using appropriate puller, remove
needle roller bearing, if necessary. See Fig. 20. Remove bolt, clamp and 2 brake apply pipes. Using a
screwdriver, remove 2 apply gaskets from rear of transaxle case. See Fig. 17.
15. Remove direct clutch with thrust bearing from back of transaxle case. Remove bearing race from direct
clutch (shaft side). Remove rear planetary sun gear assembly from transaxle case. Remove thrust bearing
from rear planetary sun gear. Remove thrust washer No. 1 from rear planetary sun gear.
16. Remove No. 1 one-way clutch and thrust bearing from transaxle case. Remove inner race from one-way
clutch. Remove one-way clutch outer sleeve from transaxle case. Note direction of components for
reassembly reference. Using a screwdriver, remove 2nd brake snap ring. Remove flange, 4 discs and 4
plates (3 discs and 3 plates on U241E) from transaxle case. Note location of components during removal
for reassembly reference. See Fig. 19.
17. Using a screwdriver, remove 2nd brake cylinder assembly snap ring. Remove 2nd brake cylinder from
transaxle. See Fig. 19.
18. Using appropriate press, position press on piston return springs and compress springs. Using a
screwdriver, remove snap ring. Remove press and piston return springs. See Fig. 21. While holding 2nd
brake piston, apply 57 psi (4 kg/cm2 ) of compressed air to 2nd brake cylinder to remove piston. See Fig.
22. Remove 2 "O" rings from piston.
19. Using vernier calipers, measure 2nd brake piston return spring free length with spring mounted to spring
seat. Free length should be .654" (16.61 mm). Replace springs as necessary. Coat NEW "O" rings with
ATF and install on piston.
20. Remove 1st/reverse brake flange, 5 discs and 5 plates from transaxle case. Note location of components
during removal for reassembly reference.
NOTE: Front planetary sun gear may also be known as input sun gear.
21. Using a screwdriver, remove rear planetary gear snap ring. Remove rear planetary gear from transaxle
case. Remove thrust washer No. 2 from rear planetary gear. Remove 2 bearing races, thrust bearings and
front planetary sun gear from transaxle case. See Fig. 20.
22. Using a hammer and chisel, unstake washer located on counter drive gear. See Fig. 18. Ensure all claws
on washer are pushed down to allow socket to fit securely on nut. Using holding tool and socket, remove
nut. See Fig. 26. Using appropriate adapter and press, remove front planetary gear from counter drive
gear. See Fig. 27.
23. Using a screwdriver, remove snap ring and front planetary ring gear from brake hub.
NOTE: In the following step, do not compress piston return spring cover more
than .079" (2.00 mm) past snap ring groove. This prevents piston from
becoming deformed. DO NOT expand snap ring excessively.
24. Using appropriate press, compress 1st/reverse brake piston return spring. Using snap ring expander,
remove snap ring from underdrive brake. Remove piston return spring. Using 57 psi (4 kg/cm2 ) of
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compressed air applied to transaxle case, remove 1st/reverse brake piston from case. See Fig. 28. Cover
piston with shop towel during removal.
25. Using appropriate adapter and press, remove counter drive gear from transaxle case. Install and tighten 2
bolts opposite each other evenly on counter drive gear. Ensure clearance between counter drive gear and
bearing race is about .79" (20.0 mm). Using bearing puller, remove rear tapered roller bearing from
counter drive gear.
26. Using a brass drift and hammer, remove bearing inner and outer races. Remove snap ring at underdrive
brake piston from transaxle case. Using 57 psi (4 kg/cm2 ) of compressed air applied to transaxle case,
remove underdrive brake piston from case. See Fig. 29. Cover piston with shop towel during removal.
27. Using appropriate puller, remove needle roller bearing from transaxle case. Remove 2 oil seal rings from
transaxle case. See Fig. 18. Using appropriate puller, remove cylindrical roller bearing from transaxle
case.
28. Remove oil seal ring from transaxle housing. See Fig. 30. Remove bolt, clamp and apply pipe from
transaxle case. Remove 3 bolts and oil deflector from transaxle case (U240E).
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Fig. 17: Exploded View Of Transaxle Internal Components (1 Of 4)

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Fig. 21: Exploded View Of 2nd Brake Assembly

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Fig. 22: Removing 2nd Brake Piston

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Fig. 23: Locating Transaxle Case Apply Gaskets

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Fig. 24: Pushing Parking Lock Pawl Toward Case

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Fig. 25: Removing & Installing Outer Race Retainer

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Fig. 26: Removing & Installing Counter Drive Gear Nut

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Fig. 27: Removing Front Planetary Gear From Counter Drive Gear
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Fig. 28: Removing 1st/Reverse Brake Piston

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Fig. 29: Removing Underdrive Brake Piston

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Fig. 30: Removing & Installing Transaxle Housing Oil Seal Ring
COMPONENT DISASSEMBLY & REASSEMBLY

OIL PUMP ASSEMBLY
Disassembly
Using 2 screwdrivers, turn drive gear and check for smooth rotation. Remove 2 oil seal rings. Using T30 Torx
socket, remove 11 bolts attaching oil pump body and stator shaft. Remove "O" ring from oil pump body. See
Fig. 31. Note direction and location of drive and driven gears. Leave gears in oil pump body for inspection.
Inspection
1. Check body clearance of driven gear. Push driven gear to one side of body. Using a feeler gauge, measure
clearance. See Fig. 32. Body clearance should be .003-.006" (.07-.15 mm). Maximum body clearance
is .012" (.30 mm). If body clearance exceeds specification, replace oil pump body.
2. Using a feeler gauge, check tip clearance of driven gear. Measure between gear teeth and crescent-shaped
part of oil pump body. See Fig. 33. Tip clearance should be .004-.006" (.11-.15 mm). Maximum tip
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clearance is .012" (.30 mm). If tip clearance exceeds specification, replace oil pump body.
3. Check side clearance of both gears. Use a steel straightedge and feeler gauge to measure side clearance of
both gears. See Fig. 34. Side clearance should be .0008-.0016" (.020-.040 mm). Maximum side clearance
is .004" (.10 mm). Replace gears as necessary. If side clearance is not within specification after gear
replacement, replace oil pump body.
4. Using a dial indicator, measure inside diameter of oil pump body bushing. See Fig. 35. Maximum inside
diameter is 1.503" (38.18 mm). If inside diameter exceeds specification, replace oil pump body.
5. Using a dial indicator, measure inside diameter of stator shaft bushing. See Fig. 36. Maximum inside
diameter is .849" (21.57 mm). If inside diameter exceeds specification, replace stator shaft.
6. Inspect front oil seal for cracks, damage or wear. Replace oil seal (if necessary). Remove oil seal with
appropriate slide hammer. Install a NEW oil seal. Seal is properly installed when it is flush with outer
edge of pump body.
Reassembly
1. Install front oil seal. Install driven gear and drive gear. Ensure top of gears are facing upward. Install
stator shaft on oil pump body. Align bolt holes. Install 11 stator shaft-to-oil pump body bolts. Tighten
bolts in crisscross pattern to 87 INCH lbs. (9.8 N.m).
2. Install 2 oil seal rings on oil pump. DO NOT expand ring ends excessively. Turn drive gear with
screwdrivers to ensure a smooth rotation. DO NOT damage oil seal lip.
Fig. 31: Exploded View Of Oil Pump Assembly

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Fig. 32: Checking Oil Pump Driven Gear Clearance

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Fig. 33: Checking Oil Pump Driven Gear Tip Clearance

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Fig. 34: Checking Oil Pump Gear Side Clearance

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Fig. 35: Checking Oil Pump Body Bushing Diameter

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Fig. 36: Checking Stator Shaft Bushing Diameter (Multiple Clutch Hub & Underdrive Clutch Drum
Bushings Are Similar)
DIRECT CLUTCH
Disassembly
1. Prior to disassembly, measure piston stroke of direct clutch. Install direct clutch and needle roller bearing
on transaxle rear cover. Using a dial indicator, measure direct clutch piston stroke by applying and
releasing 57 psi (4 kg/cm2 ) of compressed air to transaxle rear cover. See Fig. 37. Piston stroke should
be .024-.029" (.62-.74 mm). If piston stroke is not within specification, inspect each component during
disassembly.
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2. Remove direct clutch from transaxle rear cover. Using a screwdriver, remove snap ring from direct clutch
drum. Remove flange, 4 discs and 4 plates. Note location of components during removal for reassembly
reference. Position clutch balancer on a press. Compress piston return springs and remove snap ring. See
Fig. 38.
3. Remove clutch balancer and piston return springs from clutch drum. Install direct clutch on transaxle rear
cover. While holding direct clutch piston, apply 57 psi (4 kg/cm2 ) of compressed air to transaxle rear
cover to remove direct clutch piston. See Fig. 37.
Fig. 37: Measuring Direct Clutch Piston Stroke

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Fig. 38: Exploded View Of Direct Clutch Assembly

Inspection
1. Clean all parts (except discs) with solvent. Dry parts using compressed air. Inspect discs and plates for
wear or burnt areas. If disc lining is peeled or discolored, replace discs as necessary. Replace all damaged
components.
2. Using vernier calipers, measure direct clutch piston return spring free length with spring mounted to
spring seat. Free length should be .889" (22.58 mm). Replace springs as necessary.
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NOTE: New discs must be soaked in ATF at least 15 minutes prior to reassembly.
Reassembly
1. Coat piston with ATF. Using hand pressure, press piston into direct clutch drum. Ensure piston lip seal is
not damaged. Install piston return springs and clutch balancer onto direct clutch drum. Set snap ring in
position.
2. Using appropriate press positioned on clutch balancer, compress piston return springs. Using snap ring
expander, install snap ring in direct clutch drum groove. Ensure end gap of spring is not aligned with gaps
in clutch balancer hub.
3. Install 4 plates and 4 discs, starting with plate and alternating with disc. Install flange on top of disc. See
Fig. 38. Install snap ring. Ensure end gap of snap ring is not aligned with cutouts of direct clutch drum.
4. If disc, plate or flange have been replaced, check piston stroke. Install direct clutch and needle roller
bearing on transaxle rear cover. Using a dial indicator, measure direct clutch piston stroke by applying
and releasing 57 psi (4 kg/cm2 ) of compressed air to transaxle rear cover. See Fig. 37.
5. Piston stroke should be .024-.029" (.62-.74 mm). If piston stroke is not within specification, disassemble
and reassemble direct clutch components.
6. Measure piston stroke again. If measurement is still not within specification, replace flange. Flange is
available in 6 thicknesses, from .118" (3.00 mm) to .138" (3.50 mm) in increments of .004" (.10 mm).
7. Check direct clutch operation. Insert rear planetary sun gear into direct clutch. Ensure rear planetary sun
gear rotates in both directions. If sun gear does not rotate as described, disassemble and inspect direct
clutch.
FORWARD CLUTCH
Disassembly
1. Prior to disassembly, measure piston stroke of forward clutch. Install forward clutch on oil pump
assembly. Using a dial indicator, measure forward clutch piston stroke by applying and releasing 57 psi (4
kg/cm2 ) of compressed air to oil pump. See Fig. 39. Opening in oil pump is large. To prevent air from
discharging, surround air nozzle with shop towel. Piston stroke should be .056-.069" (1.41-1.75 mm). If
piston stroke is not within specification, inspect each component during disassembly.
2. Remove forward clutch from oil pump assembly. Using a screwdriver, remove snap ring from forward
clutch drum. Remove flange, 4 discs and 4 plates. Note location of components during removal for
reassembly reference. Position clutch balancer on a press. Compress piston return springs. Using snap
ring expander, remove snap ring. See Fig. 40.
3. Remove press, clutch balancer and piston return springs. Install forward clutch on oil pump assembly.
While holding forward clutch piston, apply 57 psi (4 kg/cm2 ) of compressed air to oil pump to remove
forward clutch piston. See Fig. 39. Opening in oil pump is large. To prevent air from discharging,
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surround air nozzle with shop towel.

4. If piston cannot be removed using compressed air, wrap needle nose pliers tips with vinyl tape and
remove piston using pliers. Remove 2 "O" rings from piston.
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Fig. 39: Measuring Forward Clutch Piston Stroke

Fig. 40: Exploded View Of Forward Clutch Assembly

Inspection
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components.
2. Using vernier calipers, measure forward clutch piston return spring free length with spring mounted to
spring seat. Free length should be 1.114" (28.23 mm). Replace springs as necessary.
3. Using a dial indicator, measure inside diameter of multiple clutch hub bushing. See Fig. 36. Maximum
inside diameter is .909" (23.09 mm). If inside diameter exceeds specification, replace multiple clutch hub.
NOTE: New discs must be soaked in ATF for 15 minutes prior to reassembly.
Reassembly
1. Coat NEW piston "O" rings with ATF. Install "O" rings on forward clutch piston. Using hand pressure,
press piston into forward clutch drum. Ensure "O" rings are not damaged. Set piston return springs in
position.
2. Install clutch balancer on spring seat. Install press on clutch balancer. Compress piston return springs.
Using snap ring expander, install snap ring in forward clutch drum groove. Ensure end gap of spring is
not aligned with gap in spring retainer hub
Fig. 40. Install snap ring. Ensure end gap of snap ring is not aligned with cutouts of forward clutch drum.
4. If disc, plate or flange have been replaced, check piston stroke. Install forward clutch on oil pump
piston stroke is not within specification, disassemble and reassemble forward clutch components.
available in 5 thicknesses from .118" (3.00 mm) to .142" (3.60 mm) in increments of .006" (.15 mm).
Coat thrust bearings with ATF and install.
6. Check forward clutch operation. Insert multiple clutch hub into forward clutch. Ensure forward clutch
rotates in both directions. If forward clutch does not rotate as described, disassemble and inspect forward
clutch.
UNDERDRIVE PLANETARY GEAR
Disassembly
1. Using gear stand, lock nut socket, adapter and INCH-lb. torque wrench with a fulcrum length of
6.30" (160.0 mm), measure underdrive input shaft starting torque for reference. See Fig. 41. Starting
torque should be 6.2-39.0 INCH lbs. (.7-4.4 N.m).
2. Using pin punch and hammer, loosen staked part of lock nut. Clamp underdrive planetary gear in a soft-
jawed vise. Use care not to damage differential drive pinion. Using appropriate socket, remove lock nut.
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See Fig. 42. Remove gear from vise. Using appropriate puller, remove cylindrical roller bearing inner
race. See Fig. 43.
3. Using gear stand and appropriate press, remove differential drive pinion, parking lock gear, counter
driven gear with underdrive planetary ring gear and front tapered roller bearing. See Fig. 43.
4. Clamp underdrive planetary gear in soft-jawed vise. Using a hammer and chisel, cut off rear tapered roller
bearing cover. Remove roller and cover. Using appropriate puller, remove rear tapered roller bearing from
underdrive planetary gear. Using snap ring pliers, remove snap ring. Remove underdrive planetary ring
gear from counter driven gear.
Fig. 41: Measuring Underdrive Planetary Gear Input Shaft Starting Torque
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Fig. 42: Removing/Installing Underdrive Planetary Gear Lock Nut

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Fig. 43: Exploded View Of Underdrive Planetary Gear Assembly

Reassembly
1. Install NEW snap ring onto tapered roller bearing outer race. Using a piston ring compressor, squeeze
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snap ring and install outer race into counter driven gear (if removed). Install underdrive planetary ring
gear into counter driven gear. Install snap ring. Using appropriate press, install rear tapered roller bearing
onto underdrive planetary gear. Press bearing until it becomes flat at the bottom.
2. Install counter driven gear with underdrive planetary ring gear onto underdrive planetary gear. Using
appropriate press, install front tapered roller bearing onto underdrive planetary gear while rotating counter
driven gear.
3. Using appropriate press, install parking lock gear while rotating counter driven gear. Using press, install
differential drive pinion, then install cylindrical roller bearing inner race while rotating counter driven
gear.
4. Clamp underdrive planetary gear in a soft-jawed vise. Use care not to damage differential drive pinion.
Using appropriate socket, install NEW lock nut and tighten to 207 ft. lbs. (280 N.m). Remove gear from
vise. Using gear stand, lock nut socket, adapter and INCH-lb. torque wrench with a fulcrum length of
6.30" (160.0 mm), ensure underdrive input shaft starting torque is 6.2-39.0 INCH lbs. (.7-4.4 N.m). See
Fig. 41. Using pin punch and hammer, stake lock nut. Ensure lock nut is not cracked.
UNDERDRIVE CLUTCH
Disassembly
1. Prior to disassembly, check piston stroke of underdrive clutch. Install underdrive clutch into transaxle
case. DO NOT damage oil seal rings. Install dial indicator onto underdrive clutch flange. Apply and
release 57 psi (4 kg/cm2 ) of compressed air to transaxle case. See Fig. 44.
2. Piston stroke should be .059-.075" (1.51-1.90 mm). If piston stroke is not within specification, inspect
discs and plates during disassembly. Using a screwdriver, remove drum snap ring. Remove flange, 3 discs
and 3 plates from underdrive clutch drum. Note location of components during removal for reassembly
3. Using appropriate press placed on clutch balancer, compress piston return springs. Using snap ring
expander, remove snap ring. Remove press, clutch balancer and piston return springs.
4. Install underdrive clutch into transaxle case. DO NOT damage oil seal rings. While holding underdrive
clutch piston, apply 57 psi (4 kg/cm2 ) of compressed air to transaxle case to remove underdrive clutch
piston. See Fig. 44. Remove "O" ring from underdrive clutch drum.
Inspection
components.
2. Using vernier calipers, measure underdrive clutch piston return spring free length with spring mounted to
3. Using a dial indicator, measure inside diameter of underdrive clutch drum bushing. See Fig. 36.
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Maximum inside diameter is 1.285" (32.64 mm). If inside diameter exceeds specification, replace
underdrive clutch drum.
Reassembly
1. Coat NEW "O" ring with ATF and install on underdrive clutch drum. Coat underdrive clutch piston with
ATF. Using hand pressure, install piston into underdrive clutch drum. Use care not to damage "O" ring.
Install piston return springs and clutch balancer to underdrive clutch drum. Set snap ring in position.
expander, install snap ring in underdrive clutch drum groove. Ensure end gap of spring is not aligned with
gap in clutch balancer hub.
Fig. 45. Install snap ring. Ensure end gap of snap ring is not aligned with cutouts of underdrive clutch
drum.
4. Check underdrive clutch piston stroke. Install underdrive clutch into transaxle case. DO NOT damage oil
seal rings. Install dial indicator onto underdrive clutch flange. Apply and release 57 psi (4 kg/cm2 ) of
compressed air to transaxle case. See Fig. 44.
5. Piston stroke should be .059-.075" (1.51-1.90 mm). If piston stroke is not within specification, replace
flange. Flange is available in thicknesses of .118" (3.00 mm), .126" (3.20 mm) and .134" (3.40 mm).
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Fig. 44: Measuring Underdrive Clutch Piston Stroke

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Fig. 45: Exploded View Of Underdrive Clutch Assembly

VALVE BODY ASSEMBLY
NOTE: Following procedure, specifications and exploded component views apply to all
models except Highlander and Matrix. Manufacturer does not supply exploded
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views or specifications for Highlander and Matrix. Solenoid locations are the
same for all models.
NOTE: All valve body components must be installed in original location. Lay all
components in sequence during removal for reassembly reference. Primary
regulator valve position controls line pressure. Note location of primary
regulator valve sleeve, plug and pin prior to disassembly. See Fig. 48.
Disassembly
1. Remove 5 bolts and 5 shift solenoids. See Fig. 46 and Fig. 49 . Using snap ring pliers, remove 2 snap
rings securing accumulator assemblies. Remove 2 washers, 4 springs and 2 pistons from upper valve
body. See Fig. 47.
2. Remove 8 upper valve body bolts. See Fig. 50. Remove 7 upper valve body cover bolts. See Fig. 51.
Remove bolt, cover and 2 pressure relief check balls. See Fig. 52.
3. Remove 7 lower valve body bolts. See Fig. 53. Hold plate against lower valve body and carefully remove
lower valve body from upper valve body. Remove plate from lower valve body. DO NOT lose check
balls. Note location of check balls, keys, plugs and pins in valve body. See Fig. 54-Fig. 57 .
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Fig. 46: Exploded View Of Valve Body Assembly

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Fig. 47: Locating Upper Valve Body Accumulator Pistons, Check Balls & Bolts
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Fig. 48: Identifying Primary Regulator Valve Position

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Fig. 49: Identifying Shift Solenoid Locations

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Fig. 50: Removing & Installing 8 Upper Valve Body Bolts

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Fig. 51: Removing & Installing Upper Valve Body Cover Bolts
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Fig. 52: Locating Pressure Relief Check Balls

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Fig. 53: Removing & Installing 7 Lower Valve Body Bolts

Inspection
1. Clean all parts with solvent. Dry parts with compressed air. Ensure all valve body oil passages are clear.
Inspect valves for scoring or roughness. See Fig. 54 and Fig. 55 . Inspect valve springs for damage,
squareness, rust and collapsed coils. Measure spring free length and outer diameter.
2. Replace spring if not within specification. See appropriate VALVE BODY SPRING SPECIFICATIONS
table. Ensure valve body springs correspond with appropriate valve. Ensure keys are installed in
appropriate locations. See appropriate VALVE BODY KEY SPECIFICATIONS table.
VALVE BODY SPRING SPECIFICATIONS (LOWER)

Application (Color) (1) Outer Diameter - In. (mm) Free Length - In. (mm)
Direct Clutch (C2) Control Valve .390 (9.90) 1.346 (34.20)
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(Brown)
Primary Regulator Valve (Orange) .783 (19.90) 2.267 (57.58)
1st/Reverse Brake (B2) Control .386 (9.80) 2.247 (57.08)
Valve (Pink)
2nd Brake (B1) Control Valve .386 (9.80) 1.912 (48.57)
(Green)
3-4 Shift Valve (None) .382 (9.70) 1.152 (29.25)
(1) For spring locations, refer to illustration. See Fig. 55.
VALVE BODY SPRING SPECIFICATIONS (UPPER)

Clutch Apply Control Valve .354 (9.00) 1.586 (40.29)
(Purple)
Direct Clutch (C2) Exhaust Valve .291 (7.40) 1.585 (40.27)
(Orange)
Direct Clutch (C2) Lock Valve .291 (7.40) 1.325 (33.66)
(Yellow)
Lock-Up Control Valve (None) .213 (5.40) .944 (23.98)
Lock-Up Relay Valve (None) .382 (9.70) 1.152 (29.27)
Secondary Regulator Valve (Blue) .343 (8.70) 2.298 (58.36)
Solenoid Modulator Valve (Red) .386 (9.80) 2.457 (62.40)
Underdrive Brake (B3) Orifice .307 (7.80) 2.467 (62.65)
Control Valve (Gray)
2nd Brake (B1) Lock Valve .386 (9.80) 1.473 (37.42)
(White)
(1) For spring locations, refer to illustration. See Fig. 54.
VALVE BODY KEY SPECIFICATIONS (LOWER)

Key I.D. Letter (1) (2) Height - In. (mm)
A 1.004 (25.50)
B, C & D .571 (14.50)
(1) For key locations, refer to illustration. See Fig. 57.
(2) Thickness for key "A" is .091" (2.30 mm). Width is not available. For keys "B", "C" and "D", key
width is .197" (5.00 mm). Thickness is .126" (3.20 mm).
VALVE BODY KEY SPECIFICATIONS (UPPER)

Key I.D. Letter (1) (2) Height - In. (mm)
A, B & D .394 (10.00)

F .728 (18.50)
All Other Keys .315 (8.00)
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(1) For key locations, refer to illustration. See Fig. 56.
(2) Thickness for key "F" is .091" (2.30 mm). Width is not available. For all other keys, width
is .197" (5.00 mm). Thickness is .126" (3.20 mm).
Fig. 54: Exploded View Of Upper Valve Body

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Fig. 55: Exploded View Of Lower Valve Body

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Fig. 56: Identifying Upper Valve Body Check Ball & Key Locations
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Fig. 57: Identifying Lower Valve Body Check Ball & Key Locations
Reassembly
1. Install check balls in upper and lower valve bodies. Ensure check balls are installed in correct locations.
See Fig. 56 and Fig. 57 . Install plate to lower valve body. Install lower valve body with plate to upper
valve body. Install 7 lower valve body bolts and tighten to 97 INCH lbs. (11 N.m). Bolts are
1.614" (41.00 mm) in length.
2. Install accumulator pistons, springs, washers and snap rings. Ensure spring free length and outer diameter
are within specification. For spring specifications, see ACCUMULATOR VALVE SPRING
SPECIFICATIONS table. Ensure components are installed in correct locations. Install pressure relief
check balls, retainer and bolt. Tighten bolt to 97 INCH lbs. (11 N.m). See Fig. 52.
3. Turn valve body over. Install upper valve body cover bolts. Tighten bolts to 58 INCH lbs. (6.6 N.m).
Install upper valve body bolts. Tighten bolts to 97 INCH lbs. (11 N.m). Ensure bolts are installed in
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correct locations. For bolt identification, see Fig. 58.
Fig. 58: Identifying Upper Valve Body Cover Bolts

4. Install 5 shift solenoids and bolts. Tighten shift solenoid SLT and SL1 bolts to 58 INCH lbs. (6.6 N.m).
Bolt length is .47" (12.0 mm). Tighten all other shift solenoid bolts to 97 INCH lbs. (11 N.m). Bolt length
is 1.77" (45.0 mm). See Fig. 49. Ensure primary regulator valve is installed in correct position. See Fig.
48.
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ACCUMULATOR VALVE SPRING SPECIFICATIONS

Outer Diameter - In.
Application (Color) Free Length - In. (mm) (mm)
Direct Clutch Accumulator
Inner Spring (Brown) 1.873 (47.58) .441 (11.20)
Outer Spring (Brown) 1.874 (47.61) .472 (12.00)
2nd Brake Accumulator
Inner Spring (Purple) 1.728 (43.88) .433 (11.00)
Outer Spring (White) 1.776 (45.12) .465 (11.80)
DIFFERENTIAL ASSEMBLY
Disassembly
1. Perform pre-disassembly inspection. Position dial indicator assembly on transaxle case. Position dial
indicator tip against side gear. See Fig. 60. Measure side gear backlash while holding one pinion gear
toward case. Backlash should be .002-.008" (.05-.20 mm). Note and record reading.
2. Mark ring gear and differential case for reassembly reference. Unstake lock plates on ring gear bolts.
Remove 4 lock plates and 8 ring gear bolts. Using a plastic hammer, tap on ring gear to remove it from
differential case. See Fig. 59.
3. Using appropriate puller, remove front and rear tapered roller bearings (if necessary). Using a pin punch
and hammer, drive out pinion shaft pin from ring gear side of case. Remove differential pinion shaft from
differential case.
4. Remove 2 differential pinion gears, side gears, and 4 thrust washers. Using appropriate puller, remove
side gear bearing outer races and shim from transaxle housing and transaxle case. Remove oil seals from
transaxle housing and transaxle case.
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Fig. 59: Exploded View Of Differential Assembly

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Fig. 60: Measuring Side Gear Backlash

Cleaning & Inspection
Clean all parts with solvent. Dry with compressed air. Check bearings, races and gears for wear or damage.
Replace if necessary.
Reassembly
1. Install original shim (if removed) into transaxle case. Using appropriate race installer and hammer, install
outer race into transaxle housing and transaxle case (if removed). Drive outer races in until shim and
outer race contact housing or case surface.
2. Coat thrust washers, side gears and pinion gears with ATF. Install 2 thrust washers onto 2 differential side
gears. Install 2 thrust washers with 2 side gears, and 2 thrust washers with pinion gears into differential
case. Install pinion shaft, aligning lock pin holes on pinion shaft and differential case.
3. Mount differential case in a soft-jawed vise. Using a dial indicator, check side gear backlash. Hold one
pinion gear against case. Measure side gear backlash. See Fig. 60. Backlash must be .002-.008" (.05-.20
mm). If backlash is not within specification, side gear thrust washers must be replaced.
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4. Select thrust washers that will ensure correct side gear backlash. Thrust washers are available in
thicknesses of .037-.047" (.95-1.20 mm) in .002" (.05 mm) increments. Install thrust washers and side
gears in differential case. If possible, install same size thrust washers on both sides. Install pinion gears
and pinion shaft. Check side gear backlash to ensure proper thrust washers are used.
5. Using a pin punch and hammer, drive pinion shaft pin through transaxle case and pinion shaft. Stake
differential case. Using appropriate press, install differential case tapered roller bearings.
6. Remove any material from transaxle housing and case mating surfaces. DO NOT allow oil to contact
surfaces. Install differential assembly into transaxle case. Install transaxle housing onto transaxle case.
Install 16 transaxle housing bolts. Apply thread sealant to 5 lower bolts inside torque converter housing,
and tighten these bolts to 16 ft. lbs. (22 N.m) within 10 minutes of installation. Tighten all other bolts to
22 ft. lbs. (29 N.m). Ensure bolts are in correct locations. Longest bolts go inside torque converter
housing. See Fig. 16.
7. Using appropriate adapter and ratchet, rotate differential assembly in both directions to seat bearings.
Using an INCH-lb. torque wrench, measure differential side bearing preload. See Fig. 61. Preload should
be 9.0-14.0 INCH lbs. (1.0-1.6 N.m) for NEW bearings and 4.4-7.1 INCH lbs. (.5-.8 N.m) for used
bearings.
8. If preload is not within specification, remove 16 transaxle housing bolts. Using a plastic hammer, remove
transaxle housing from transaxle case. Remove differential assembly from transaxle case and replace
shim at rear tapered roller bearing with appropriate shim.
9. Adjustment shims are marked in numeric and alphabetic order and available in thicknesses from .114
(2.90 mm), marked with a zero, to .132" (3.35 mm), marked with the number "9", and from .134" (3.40
mm), marked with the letter "A", to .150" (3.80 mm), marked with the letter "H". Shims increase in
increments of .002" (.05 mm). Recheck preload after shim replacement.
10. Clean contact surface of differential case and ring gear using cleaning solvent. Heat ring gear to 212°F
(100°C) in water. DO NOT heat ring gear above 230°F (110°C).
11. After moisture on ring gear has completely evaporated, quickly align match marks made during
disassembly. Install ring gear on differential case. Install lock plates and ring gear bolts and tighten to 71
ft. lbs. (96 N.m). Install NEW oil seals in transaxle housing and transaxle case. Coat lip of oil seals with
lubricant. Ensure transaxle case oil seal depth is .087-.126" (2.20-3.20 mm) from case lip.
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Fig. 61: Measuring Side Bearing Preload

TRANSAXLE REASSEMBLY
NOTE: Coat all oil seal rings, clutch discs, clutch plates, rotating parts and sliding
surfaces with ATF prior to reassembly. All gaskets and rubber "O" rings should
be replaced. Ensure ends of snap rings are not aligned with cutouts of drum.
Check thrust bearings and races for wear or damage. Use petroleum jelly to
secure parts in place. Clutch discs should be soaked in ATF for at least 15
minutes before installation.
NOTE: For thrust bearing and race locations, refer to illustration. See Fig. 80. For
component dimensions, see THRUST BEARING & RACE SPECIFICATIONS
table.
1. Install oil deflector with 3 bolts to transaxle housing (U240E). Install apply pipe and clamp. See Fig. 17.
Install bolt and tighten to 87 INCH lbs. (9.8 N.m). Ensure pipe is installed to stopper. Install oil seal ring
to transaxle housing. See Fig. 30. Using appropriate adapter and press, install underdrive cylindrical roller
bearing into transaxle housing. DO NOT apply excessive pressure to bearing.
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2. Using vernier calipers, measure underdrive brake piston return spring free length with spring mounted to
spring seat. Free length should be .521" (13.24 mm) on U240E models or .553" (14.04 mm) on U241E
models. Replace springs as necessary. Install 2 oil seal rings to transaxle case.
3. For needle roller bearing installation, wrap vinyl tape around bearing installer at a position .157" (4.00
mm) above bottom end of installer, until thickness of tape is about .197" (5.00 mm). Using bearing
installer and press, install needle roller bearing to transaxle case until wound vinyl tape contacts transaxle
case.
4. Coat 2 NEW "O" rings with ATF and install on underdrive brake piston. See Fig. 18. Using hand
pressure, install piston into transaxle case. Using appropriate adapter and press, compress underdrive
brake piston return springs into transaxle case and install snap ring. DO NOT apply excessive force.
5. Install snap ring into transaxle case. Using appropriate bearing race adapter and press, install 2 bearing
outer races into transaxle case. Press each outer race into transaxle case until race contacts snap ring.
Using appropriate adapter and press, install tapered roller bearing to counter drive gear until bearing
contacts gear. DO NOT apply excessive force.
6. Using appropriate adapter and press, install counter drive gear and bearing into transaxle case. DO NOT
apply excessive pressure. Using vernier calipers, measure 1st/reverse brake piston return spring free
length with spring mounted to spring seat. Free length should be .693" (17.61 mm). Replace springs as
necessary.
NOTE: In the following step, stop press when piston return spring seat is
lowered .039-.079" (1.00-2.00 mm) from snap ring groove. This prevents
spring seat from becoming deformed. DO NOT expand snap ring
excessively.
7. Coat 2 NEW "O" rings with ATF and install on 1st/reverse brake piston. Using hand pressure, install
piston into transaxle case. See Fig. 19. Using appropriate adapter and press, compress 1st/reverse brake
piston return springs into transaxle case and install snap ring. DO NOT apply excessive force.
8. Install front planetary ring gear and snap ring to brake hub. Install front planetary gear to brake hub.
Using appropriate adapter and press, install brake hub with front planetary gear into transaxle case. See
Fig. 62. Install washer on counter drive gear in correct direction. See Fig. 63.
9. Using holding tool, socket and torque wrench, install nut and tighten to 207 ft. lbs. (280 N.m). Using
socket, adapter and INCH-lb. torque wrench, measure counter drive gear tapered roller bearing starting
torque. Starting torque should be 4.4-9.0 INCH lbs. (.5-1.0 N.m). See Fig. 64. If starting torque is not
within specification, gradually tighten nut until starting torque is within specification. Stake lock washer
to nut.
10. Install 2 thrust bearings, bearing race and front planetary sun gear to front planetary gear. Coat bearing
race with ATF and install race to rear planetary gear. Install thrust washer No. 2. Install rear planetary
gear into transaxle case. Install snap ring.
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Fig. 62: Installing Front Planetary Gear With Brake Hub Into Transaxle Case
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Fig. 63: Installing Counter Drive Gear Washer

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Fig. 64: Measuring Counter Drive Gear Bearing Starting Torque

11. Install 1st/reverse brake. Install 5 plates and 5 discs, starting with a plate and alternating with a disc. DO
NOT install flange. Measure 1st/reverse brake piston stroke. Using vernier calipers, measure distance
between disc surface and contact surface of 2nd brake assembly at transaxle case. See Fig. 65.
12. Piston stroke should be .040-.047" (1.02-1.21 mm). Select appropriate flange to ensure piston stroke is
within specification. Flanges are marked in numeric order and are available in thicknesses
from .071" (1.80 mm), marked with the number "1", to .098" (2.50 mm), marked with the number "8", in
increments of .004" (.10 mm). Recheck piston stroke after flange is installed.
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Fig. 65: Measuring 1st/Reverse Brake Piston Stroke

13. Install 2nd brake cylinder assembly into transaxle case. See Fig. 19. Install snap ring and measure inside
diameter. Snap ring inside diameter should be more than 6.57" (167.0 mm). Snap ring has a specific
tapered installation direction. If inside diameter is not within specification, ensure snap ring is installed in
correct direction. If snap ring is installed correctly, replace snap ring.
14. Install one-way clutch outer sleeve to 2nd brake cylinder assembly. Ensure sleeve is positioned correctly.
Install one-way clutch inner race to No. 1 one-way clutch. Ensure inner race is installed correctly. Check
No. 1 one-way clutch operating direction. One-way clutch should rotate in counterclockwise direction
and lock in clockwise direction. See Fig. 66.
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Fig. 66: Checking No. 1 One-Way Clutch Rotation

15. Install No. 1 one-way clutch and thrust bearing into outer sleeve. Ensure non-colored (natural) race on
thrust bearing is visible upon installation. See Fig. 67. Coat thrust washer No. 1 with petroleum jelly and
install on rear planetary sun gear. Coat thrust bearing with petroleum jelly and install on rear planetary
sun gear. Install rear planetary sun gear onto rear planetary gear.
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Fig. 67: Installing No. 1 One-Way Clutch

16. Install 2nd brake. Install 4 discs and 4 plates (U240E), (3 discs and 3 plates on U241E), starting with a
plate and alternating with a disc. DO NOT install flange at this time. Temporarily install snap ring. Using
vernier calipers, measure 2nd brake piston stroke between disc surface and snap ring surface. See Fig. 68.
Piston stroke should be .024-.029" (.62-.74 mm) on U240E models. Piston stroke should be .024-
.036" (.62-.91 mm) on U241E models.
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Fig. 68: Measuring 2nd Brake Piston Stroke

17. Select appropriate flange to ensure piston stroke is within specification. Use the following formula to
determine flange thickness: measured distance, minus flange thickness, minus snap ring thickness
of .063" (1.60 mm). Flanges are available in thicknesses from .118" (3.00 mm) to .142" (3.60 mm) in
increments of .004" (.10 mm), and are marked in numeric order from "1" to "7". Remove snap ring, install
appropriate flange and reinstall snap ring. Ensure snap ring end gap is visible through groove in transaxle
case.
18. Install bearing race over shaft and onto direct clutch. Install direct clutch assembly and thrust bearing onto
rear planetary sun gear assembly. See Fig. 20. Ensure discs in direct clutch completely mate with rear
planetary sun gear to ensure rear cover can be installed correctly.
19. Ensure transaxle case and rear cover mating surfaces are clean. Place a straightedge onto direct clutch
drum. Using vernier calipers, measure distance between bottom of straightedge and transaxle case
(dimension "B"). See Fig. 69.
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Fig. 69: Measuring Direct Clutch End Play (Dimension "B")

20. Measure dimension No. 1 and dimension No. 2 of rear cover in 2 places. See Fig. 70. Subtract dimension
No. 2 from dimension No. 1. This total equals dimension "C". Calculate direct clutch end play by
subtracting dimension "B" from dimension "C". End play should be .008-.037" (.20-.94 mm).
21. Select a thrust bearing to ensure end play is within specification. Thrust bearings are available in 2
thicknesses of .140" (3.55 mm) with an outside diameter of 2.74" (69.6 mm), and .152" (3.85 mm) with
an outside diameter of 2.76" (70.18 mm). Inside diameter of both thrust bearings is 2.11" (53.6 mm).
During installation, ensure Black race side of thrust bearing is facing transaxle rear cover.
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Fig. 70: Measuring Distance Between Rear Cover Surfaces (Dimensions No. 1 & No. 2)
22. Install 2 NEW apply gaskets to transaxle case. Install clamp to apply pipes prior to installing pipes to
transaxle case. This will prevent apply pipes from being deformed or damaged. Install 2 apply pipes,
clamp and bolt. See Fig. 17. Ensure pipes are securely inserted into transaxle case until they reach the
pipe stopper on pipe. Tighten bolt to 48 INCH lbs. (5.4 N.m).
23. Install needle roller bearing onto transaxle rear cover with inscribed mark on bearing facing up. Using
appropriate adapter and press, install needle roller bearing to transaxle rear cover. Press bearing in to a
depth of .474-.502" (12.05-12.75 mm). Coat 2 oil seal rings with ATF and install on transaxle rear cover.
See Fig. 20.
24. Ensure transaxle case and rear cover surfaces are clean. DO NOT allow oil to contact surfaces. Coat
needle roller bearing with ATF. Apply Three Bond (1281) or equivalent gasket sealant to rear cover
around inside edges of bolt holes. Install rear cover onto transaxle case. Install 11 bolts and tighten all
bolts except bolt at 5 o'clock position to 18 ft. lbs. (24 N.m). Tighten bolt at 5 o'clock position to 14 ft.
lbs. (19 N.m).
25. Install underdrive brake. Install 3 discs and 3 plates, starting with a plate and alternating with a disc. DO
NOT install flange at this time. Temporarily install snap ring. Using a dial indicator, measure underdrive
brake piston stroke by applying and releasing 57 psi (4 kg/cm2 ) of compressed air to transaxle case. See
Fig. 71.
within specification. Flanges are available in 3 thicknesses of .118" (3.00 mm), .126" (3.20 mm)
and .134" (3.40 mm), and are marked in numeric order from "1" to "3". Remove snap ring, install
appropriate flange and reinstall snap ring.
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Fig. 71: Measuring Underdrive Brake Piston Stroke

27. Install outer race retainer to No. 2 one-way clutch, ensuring long finger of retainer is facing up. See Fig.
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25. Install underdrive clutch to No. 2 one-way clutch. Rotate underdrive clutch to ensure correct
installation. Underdrive clutch should rotate in a counterclockwise direction, and lock in a clockwise
direction. See Fig. 72.
Fig. 72: Checking Underdrive Clutch Assembly Rotation

28. Install No. 2 one-way clutch into transaxle case. Note position of index marks on No. 2 one-way clutch.
Ensure marks are facing up. See Fig. 73. Install snap ring into transaxle case. Coat thrust bearing and
bearing race with petroleum jelly and install onto underdrive clutch. Install underdrive clutch into
transaxle case.
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Fig. 73: Installing No. 2 One-Way Clutch & Retainer

29. Install pawl pin and spring to parking lock pawl. Temporarily install parking lock pawl, shaft and spring
to transaxle case. See Fig. 17. Install underdrive planetary gear assembly into transaxle case. Engage all
clutch discs and hub spline of planetary gear assembly firmly and securely. Install parking lock pawl
shaft. Install lock pawl clamp and bolt. Tighten bolt to 87 INCH lbs. (9.8 N.m).
30. Using vernier calipers and a straightedge, measure gap between top of differential drive pinion in
underdrive planetary gear, and contact surface of transaxle case. See Fig. 74. Record measurement as
dimension "D".
31. Measure dimension No. 1 and dimension No. 2 of transaxle housing in 2 places. See Fig. 75. Subtract
dimension No. 2 from dimension No. 1. Record measurement as dimension "E". Install bearing race onto
counter drive gear in correct direction. See Fig. 18.
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2005 Toyota RAV4
Fig. 74: Measuring Gap Between Top Of Differential Drive Pinion & Transaxle Case (Dimension
"D")
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2005 Toyota RAV4
Fig. 75: Measuring Distance Between Transaxle Housing Surfaces (Dimensions No. 1 & No. 2)
32. Coat needle roller bearing with petroleum jelly and install onto multiple clutch hub (shaft side). Install
multiple clutch hub into transaxle case. Install thrust bearing onto multiple clutch hub (forward clutch
side). Install forward clutch onto multiple clutch hub. See Fig. 18. Align splines of all discs of forward
clutch with multiple clutch hub. Install thrust bearing onto forward clutch. Ensure Black side of thrust
bearing is visible.
33. Install 2 NEW apply gaskets to front of transaxle case. See Fig. 23. Install differential assembly.
Calculate transaxle housing-to-underdrive planetary gear assembly end play using the following formula:
subtract dimension "D" from dimension "E", performed in steps 30 and 31 , minus thrust bearing
thickness of .129" (3.28 mm), equals bearing race thickness. For end play specifications, see
TRANSAXLE HOUSING-TO-UNDERDRIVE PLANETARY GEAR ASSEMBLY END PLAY
SPECIFICATIONS table.
TRANSAXLE HOUSING-TO-UNDERDRIVE PLANETARY GEAR ASSEMBLY END PLAY

SPECIFICATIONS
Application In. (mm)
Camry Solara & RAV4 .020-.039 (.50-.99)
Celica, Highlander & Matrix .008-.027 (.20-.69)
34. Select a bearing race to ensure end play is within specification. See U/D PLANETARY GEAR
THRUST BEARING RACE SELECTIONS table. Install appropriate bearing race onto underdrive
planetary gear assembly to ensure end play is within specification.
U/D PLANETARY GEAR THRUST BEARING RACE SELECTIONS

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2005 Toyota RAV4
Dimension Race Thickness - In. (mm)

"E" - "D"
Camry Solara & RAV4
Less .14 (3.5)
Than .301
(7.64)
.301 .15 (3.8)
(7.64) Or
More
Celica, Highlander & Matrix
Less .14 (3.5)
Than .29
(7.42)
.29 (7.42) .15 (3.8)
Or More
35. Coat oil pump "O" ring with ATF. Install oil pump and 7 bolts. Tighten bolts to 16 ft. lbs. (22 N.m).
Ensure transaxle case and transaxle housing surfaces are clean. DO NOT allow oil to contact surfaces.
Apply Three Bond (1281) or equivalent gasket sealant about .047" (1.20 mm) wide, to transaxle case
around inside edges of bolt holes. Install transaxle housing to transaxle case.
36. Install 16 transaxle housing bolts. Apply thread sealant to 5 lower bolts inside torque converter housing,
and tighten these bolts to 16 ft. lbs. (22 N.m) within 10 minutes of installation. Tighten all other bolts to
22 ft. lbs. (29 N.m). Ensure bolts are in correct locations. Longest bolts go inside torque converter
housing. See Fig. 16.
37. Inspect input shaft end play. Using a dial indicator, measure input shaft end play. See Fig. 15. End play
should be .011-.049" (.27-1.24 mm). Recheck differential side bearing preload. Using appropriate adapter
and INCH-lb. torque wrench, measure differential preload. See Fig. 61. Preload should be 9.0-14.0 INCH
lbs. (1.0-1.6 N.m) for NEW bearings and 4.4-7.1 INCH lbs. (.5-.8 N.m) for used bearings.
38. If preload is not within specification, remove differential assembly from transaxle case and replace shim
at rear tapered roller bearing. See Fig. 59.
39. Place transaxle on 2 blocks of wood, with oil pan surface facing outward. Coat NEW manual valve lever
shaft oil seal with ATF. Install oil seal into transaxle case. Install parking lock pawl rod to manual valve
lever. Install NEW spacer and manual valve lever shaft into transaxle case. See Fig. 9.
40. Using a pin punch and hammer, drive in NEW roll pin. Turn spacer and lever shaft to align small hole for
locating staking position in spacer with position mark on lever shaft. Using a pin punch and hammer,
stake spacer through small hole. Ensure spacer does not turn.
41. Using needle nose pliers, install retainer spring. Install parking lock pawl bracket. Install bolts and tighten
to 15 ft. lbs. (20 N.m). Install cover, manual detent spring and 2 bolts. Ensure cover and detent spring are
installed correctly. See Fig. 9.
42. Tighten 1.063" (27.00 mm) bottom bolt to 15 ft. lbs. (20 N.m). Tighten .630" (16.00 mm) top bolt to 106
INCH lbs. (12 N.m). Coat NEW "O" rings with ATF and install them onto accumulator pistons. Coat 4
springs and 3 accumulator pistons with ATF, and install components into transaxle case holes. See Fig.
76. See appropriate ACCUMULATOR SPRING FREE LENGTH SPECIFICATIONS table for spring
specifications and identification.
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Fig. 76: Identifying Accumulator Piston & Spring Locations

ACCUMULATOR SPRING FREE LENGTH SPECIFICATIONS (CAMRY SOLARA & RAV4)

Application Free Length - In. Outer Diameter -
(Color) (mm) In. (mm)
Forward 3.210 (81.53) .728 (18.50)
Clutch (C1)
(Pink)
Underdrive Brake (B3)
Inner 2.372 (60.24) .626 (15.90)
(Light
Green)
Outer 2.859 (72.61) .657 (16.70)
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(Blue)
Underdrive 3.563 (90.49) .756 (19.20)
Clutch (C3)
(White)
ACCUMULATOR SPRING FREE LENGTH SPECIFICATIONS (CELICA)

Application Free Length - In. (mm) Outer Diameter - In.
(Color) (mm)
Forward 3.564 (90.53) .728 (18.50)
Clutch (C1)
(Red)
Inner 2.372 (60.24) .626 (15.90)
(Green)
Outer 2.859 (72.61) .657 (16.70)
(Blue)
Underdrive 3.412 (86.66) .756 (19.20)
Clutch (C3)
(Yellow)
ACCUMULATOR SPRING FREE LENGTH SPECIFICATIONS (HIGHLANDER & MATRIX)

(Color) (mm)
Forward 3.210 (81.53) .728 (18.50)
Clutch (C1)
(Pink)
Inner 2.372 (60.24) .626 (15.90)
(Light
Green)
Outer 2.937 (74.61) .854 (21.70)
(Blue)
Underdrive 3.563 (90.49) .756 (19.20)
Clutch (C3)
(White)
43. Install check ball body and spring. See Fig. 11. Coat NEW "O" ring with ATF and install on transaxle
solenoid connector. Install connector into transaxle case, above park/neutral position switch, and tighten
bolt to 48 INCH lbs. (5.4 N.m). Coat NEW apply gaskets with ATF and install them into transaxle case,
below valve body assembly. Install brake drum gasket located near apply gaskets. See Fig. 11.
44. Install valve body assembly. Align groove in manual valve with pin in manual valve lever. Push valve
body assembly against accumulator piston springs and check ball body to assist in installation. Install
valve body bolts. Hand tighten 2 bolts temporarily. See Fig. 10. These bolts are positioning bolts.
45. Ensure valve body is aligned. Ensure bolts are installed in correct locations. For bolt length, see VALVE
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BODY BOLT IDENTIFICATION table. Tighten bolts to 97 INCH lbs. (11 N.m). Install NEW "O" ring
on oil strainer. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
VALVE BODY BOLT IDENTIFICATION

Bolt Identification Length - In. (mm)
A .98 (25)
B 1.61 (41)
C 1.77 (45)
46. Connect 5 shift solenoid connectors. Install fluid temperature sensor, clamps and bolt. Tighten bolt to 58
INCH lbs. (6.6 N.m). See Fig. 8. Install 3 magnets into oil pan in original locations. Apply Three Bond
(2430) or equivalent to 18 oil pan bolt threads. Install NEW oil pan gasket, oil pan and bolts. Tighten
bolts to 69 INCH lbs. (7.8 N.m) within 10 minutes of installation.
47. Coat NEW "O" rings with ATF and install on speed sensors. Install input turbine and counter gear speed
sensors into top of transaxle case. See Fig. 6. Tighten bolts to 97 INCH lbs. (11 N.m). Install NEW "O"
rings on oil line union and elbow (if equipped). Install oil line union and elbow into transaxle case.
Tighten to 20 ft. lbs. (27 N.m).
48. Coat NEW "O" ring with ATF and install on transaxle test plug. Install transaxle test plug into transaxle
case. See Fig. 7. Install park/neutral position switch onto manual valve lever shaft and temporarily install
2 adjusting bolts.
49. Install NEW lock tab and nut. Tighten nut to 61 INCH lbs. (6.9 N.m). Temporarily install control shift
lever. Turn lever counterclockwise until it stops, then turn it clockwise 2 notches. Remove control shift
lever. Align groove in park/neutral position switch to neutral basic line. Tighten 2 adjusting bolts to 48
INCH lbs. (5.4 N.m). Stake lock tab onto nut. Install control shift lever, washer and nut. Tighten nut to 61
INCH lbs. (6.9 N.m).
50. Install torque converter into transaxle housing while rotating. Ensure converter is properly installed by
measuring distance from edge of transaxle housing. See Fig. 77. Distance should be .524" (13.30 mm) for
all models except Highlander and Matrix. On Highlander and Matrix models, go to next step.
measuring the following dimensions. Using vernier calipers, measure dimension "A" between transaxle
fitting part and converter fitting part of drive plate. See Fig. 78. Using vernier calipers and a straightedge,
measure dimension "B" as shown in Fig. 79. Ensure dimension "B" is greater than dimension "A". Do not
add thickness of straightedge. Standard measurement is dimension "A" plus .039" (1.00 mm) or more.
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Fig. 77: Measuring Torque Converter Depth

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Fig. 78: Measuring Dimension "A" Between Transaxle & Drive Plate
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Fig. 79: Measuring Dimension "B" Between Torque Converter & Transaxle Housing
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Fig. 80: Identifying Thrust Bearing & Race Locations

THRUST BEARING & RACE SPECIFICATIONS (1)

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Application Inner Diameter - In. (mm) Outer Diameter - In.

(mm)
A
Bearing (2) 2.252 (57.20) 3.345 (84.96)
Rear Race (3) 2.220 (56.40) 3.268 (83.00)
B
Bearing 1.485 (37.73) 2.283 (58.00)
Rear Race 1.177 (29.90) 2.185 (55.50)
C
Bearing 1.333 (33.85) 2.055 (52.20)
D
Bearing .925 (23.50) 1.732 (44.00)
E
Bearing 1.429 (36.30) 2.055 (52.20)
Rear Race 1.358 (34.50) 1.909 (48.50)
F
Bearing (4) 1.362 (34.60) 1.909 (48.50)
G
Front Race 1.587 (40.30) 2.283 (58.00)
Bearing 1.520 (38.60) 2.362 (60.00)
Rear Race 1.520 (38.60) 2.283 (58.00)
H
Bearing 2.110 (53.60) 2.740 (69.60)
I
Bearing 1.327 (33.70) 1.898 (48.20)
Rear Race 1.193 (30.30) 1.811 (46.00)
J
Bearing 2.110 (53.60) 2.740 (69.60) Or
2.763 (70.18)
(1) For component locations, refer to illustration. See Fig. 80.
(2) On U241E models, bearing inner diameter is 2.087" (53.0 mm). Outer diameter is 3.079" (78.2 mm).
(3) On U241E models, rear race inner diameter is 2.051" (52.1 mm). Outer diameter is 2.972" (75.5
mm).
(4) On U241E models, bearing inner diameter is 1.362" (34.6 mm). Outer diameter is 2.055" (52.2 mm).
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Converter-To-Drive Plate Bolt 30 (41)

Counter Drive Gear Nut 207 (280)
Differential Ring Gear Bolt 71 (96)
Drive Plate Bolt 65 (88)
Elbow 20 (27)
Manual Detent Spring Bottom Bolt 15 (20)
Oil Pan Drain Plug 36 (49)
Oil Pump Bolt 16 (22)
Parking Lock Pawl Bracket Bolt 15 (20)
Transaxle Housing-To-Transaxle Case Bolt
Lower Bolts (5) 16 (22)
All Other Bolts 22 (29)
Transaxle Rear Cover Bolt
Bolt At 5 O'Clock Position 14 (19)
Underdrive Planetary Gear Lock Nut 207 (280)
Union 20 (27)
INCH Lbs. (N.m)
Apply Pipe Clamp Bolt
Transaxle Case 48 (5.4)
Transaxle Housing 87 (9.8)
Control Shift Lever Lock Tab Nut 61 (6.9)
Manual Detent Spring Top Bolt 106 (12)
Oil Deflector Bolt 87 (9.8)
Oil Pan Bolt 69 (7.8)
Oil Strainer Bolt 97 (11)
Parking Lock Pawl Clamp Bolt 87 (9.8)
Park/Neutral Position Switch
Nut 61 (6.9)
Bolt 48 (5.4)
Pressure Relief Check Ball Retainer Bolt 97 (11)
Shift Solenoids
SLT & SL1 Solenoid Bolt 58 (6.6)
All Other Solenoid Bolts 97 (11)
Solenoid Connector Bolt 48 (5.4)
Speed Sensor Bolt 11 (97)
Stator Shaft-To-Oil Pump Bolt 87 (9.8)
Temperature Sensor Clamp Bolt 58 (6.6)
Upper Valve Body Cover Bolt 58 (6.6)
Upper & Lower Valve Body Bolt 97 (11)
Valve Body-To-Transaxle Bolt 97 (11)
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TRANSAXLE SPECIFICATIONS
Bushing Inside Diameter (Maximum)
Multiple Clutch Hub .909 (23.09)
Oil Pump Body 1.503 (38.18)
Oil Pump Stator Shaft .849 (21.57)
Underdrive Clutch Drum 1.285 (32.64)
Direct Clutch End Play .008-.035 (.20-.90)
Input Shaft End Play .011-.049 (.27-1.24)
Underdrive Planetary Gear Assembly End Play .008-.027 (.20-.69)
Oil Pump
Driven Gear-To-Body Clearance .003-.006 (.07-.15)
Driven Gear Tip-To-Cresent Clearance .004-.006 (.11-.15)
Gear Side Clearance .0008-.0016 (.020-.040)
Piston Stroke
Direct Clutch .024-.029 (.62-.74)
Forward Clutch .056-.069 (1.41-1.75)
Underdrive Brake .074-.082 (1.87-2.08)
Underdrive Clutch .058-.067 (1.47-1.69)
1st/Reverse Brake .043-.049 (1.10-1.24)
2nd Brake (1) .024-.029 (.62-.74)
Side Gear Backlash .002-.008 (.05-.20)
Torque Converter Runout (Maximum)
Drive Plate .008 (.20)
Sleeve .012 (.30)
(1) On U241E models, 2nd brake piston stroke is .024-.036" (.62-.91 mm).
CLUTCH DISC & PLATE QUANTITY

Component Discs Plates
Direct Clutch 4 4
Forward Clutch 4 4
Underdrive Brake 3 3
Underdrive Clutch 3 3
1st/Reverse Brake 5 5
2nd Brake (1) 4 4
(1) On U241E models, 2nd brake has 3 discs and 3 plates.
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2001-05 AUTOMATIC TRANSMISSIONS U140F Overhaul
2001-05 AUTOMATIC TRANSMISSIONS
U140F Overhaul
APPLICATION
CAUTION: Flush oil cooler and oil cooler lines prior to transaxle installation. Oil
cooling system contamination may cause premature transaxle failure.
TRANSAXLE APPLICATION
Application Transaxle Model
RAV4 U140F
IDENTIFICATION
TRANSAXLE
Vehicle Identification Number (VIN) is used for correct identification of component parts and assemblies. VIN
is located at top left corner of instrument panel. Vehicle certification label is located at left corner of driver's
door. This label also contains the VIN. See Fig. 1.
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Tuesday, July 21, 2009 9:44:10
9:44:04 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
2005 Toyota RAV4
Fig. 1: Locating Vehicle Identification Number Plates

GEAR RATIOS
TRANSAXLE GEAR RATIOS

Gear Range Gear Ratio
1st 3.938:1
2nd 2.194:1
3rd 1.411:1
OD 1.019:1
Reverse 3.141:1

INTRODUCTION
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2005 Toyota RAV4
The U140F transaxle is a 4-speed electronically controlled transaxle. Transaxle uses a lock-up torque converter,
direct clutch, forward clutch, underdrive clutch, underdrive brake, 3 planetary gears, 2nd brake, 2 one-way
clutches, 1st/reverse brake, and hydraulic and electronic control systems. Transaxle is equipped with a transfer
case. See Fig. 2.
Fig. 2: Identifying Transaxle Component Locations

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LUBRICATION
NOTE: See appropriate SERVICING article.
TROUBLE SHOOTING
NOTE: Transaxle malfunctions may be caused by poor engine performance, improper

adjustments, fluid condition or failure of hydraulic, mechanical or electronic
components. Ensure all concerns have been properly checked prior to
transaxle overhaul. See appropriate DIAGNOSIS article.
COMPONENT TESTS
TORQUE CONVERTER
NOTE: Torque converter is a sealed unit and is serviced as a complete assembly.

Perform the following tests to check for defective converter. Torque converter
and transaxle cooler must be thoroughly cleaned and flushed if transaxle is
contaminated.
Torque Converter One-Way Clutch Test
1. Insert a turning tool into inner race of one-way clutch. Install Tester (09351-32010) so it fits in notch of
converter hub and outer race of one-way clutch.
2. With converter in normal operating position, clutch should lock-up when turned counterclockwise and
should rotate freely and smoothly when turned clockwise. See Fig. 3. If one-way clutch fails test in either
direction, clean converter. Retest clutch. If clutch fails test, replace torque converter.
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Fig. 3: Checking Torque Converter One-Way Clutch

Torque Converter Sleeve Runout Test
1. Temporarily mount torque converter to drive plate. Mount a dial indicator with needle resting on
converter sleeve. See Fig. 4. Rotate converter. If runout exceeds .012" (.30 mm), ensure converter is
properly mounted to drive plate.
2. If converter is properly mounted and runout exceeds specifications, replace torque converter. Mark
position of converter to ensure correct installation. Remove converter from drive plate.
Drive Plate (Flexplate) Runout Test
Measure drive plate runout. See Fig. 5. If runout exceeds .008" (.20 mm), or if ring gear is damaged, replace
drive plate. If installing a NEW drive plate, note position of spacers. Tighten bolts to 72 ft. lbs. (98 N.m).
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Fig. 4: Checking Torque Converter Sleeve Runout

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Fig. 5: Checking Drive Plate Runout

TRANSAXLE DISASSEMBLY
1. Remove transfer case. Remove 2 bolts and 6 nuts. Using plastic hammer, drive transfer case from
transaxle. Pull transfer case straight up to remove from transaxle. Remove round gasket and intermediate
shaft. Remove nut, washer and control shift lever. Using a screwdriver, unstake lock tab. Remove 2 bolts
and nut, and remove park/neutral position switch. See Fig. 7.
2. Remove oil line union and elbow. Remove and discard "O" rings from union and elbow. Remove input
turbine and counter gear speed sensors from top of transaxle. See Fig. 6. Remove and discard speed
sensor "O" rings. Remove transaxle test plug from transaxle case. See Fig. 8. Remove solenoid connector
bolt located above park/neutral position switch. DO NOT try to remove solenoid connector from
transaxle case at this time.
3. Place transaxle on wooden blocks. Remove 18 bolts, oil pan and gasket. Disconnect 5 shift solenoid
connectors. Remove bolts, clamps and fluid temperature sensor. See Fig. 9. Remove transaxle wiring
harness with solenoid connector from transaxle case. Remove 3 bolts and oil strainer. Remove and
discard gasket from oil strainer.
4. Remove 17 valve body bolts. Note bolt length and location for reassembly reference. See Fig. 92.
Remove valve body assembly.
5. Remove 3 apply gaskets, check ball body and spring. See Fig. 10. Remove brake drum gasket located
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2005 Toyota RAV4
near 3 apply gaskets. See Fig. 7. Remove underdrive clutch accumulator spring. Using 57 psi (4 kg/cm2 )
of compressed air applied to transaxle case, remove underdrive clutch accumulator piston. See Fig. 11.
Cover piston with shop towel during removal.
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Fig. 6: Locating Transfer Assembly & Speed Sensors

Fig. 7: Exploded View Of Transaxle External Components

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Fig. 8: Locating Transaxle Test Plug

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Fig. 9: Locating Fluid Temperature Sensor & Solenoid Connectors

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Fig. 10: Locating Check Ball Body & Spring, & Apply Gaskets (3)
Fig. 11: Removing Underdrive Clutch Accumulator Piston

6. Using 57 psi (4 kg/cm2 ) of compressed air applied to transaxle case, remove forward clutch accumulator
piston and spring, and underdrive brake accumulator piston. Cover pistons with shop towel during
removal. See Fig. 12 and Fig. 13 .
7. Using needle nose pliers, remove manual valve lever retainer spring. Remove 2 bolts, manual detent
spring and cover. See Fig. 7. Remove 2 bolts and parking lock pawl bracket. Using a hammer and chisel,
unstake and remove spacer. Using a pin punch and hammer, drive out roll pin. Ensure pin does not fall
into transaxle case.
8. Remove manual valve lever shaft and manual valve lever. Remove parking lock pawl rod from manual
valve lever. Using a screwdriver, remove shaft oil seal. See Fig. 7. Position transaxle case with oil pump
assembly facing upward.
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CAUTION: Use caution when removing transaxle housing. Differential assembly

may attach to transaxle housing during removal.
9. Using a dial indicator, measure input shaft end play. See Fig. 14. End play should be .010-.049" (.26-1.25
mm). Remove 16 transaxle housing bolts. Note bolt length and location during removal for reassembly
Fig. 12: Removing Forward Clutch Accumulator Piston

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Fig. 13: Removing Underdrive Brake Accumulator Piston

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Fig. 14: Measuring Input Shaft End Play

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Fig. 15: Removing & Installing Transaxle Housing Bolts

10. Remove 7 oil pump bolts and oil pump. Remove thrust bearing and bearing race from underdrive
planetary gear assembly. Remove differential assembly. See Fig. 18. Remove 2 apply gaskets from front
of transaxle case. See Fig. 16. Remove forward clutch from transaxle case. Remove multiple clutch hub
and needle roller bearing from transaxle case. See Fig. 17.
11. Remove one bolt and parking lock pawl clamp. See Fig. 18. Remove parking lock pawl shaft. Push
parking lock pawl toward transaxle case to prevent interference during underdrive planetary gear
assembly removal. See Fig. 19. Using both hands, remove underdrive planetary gear assembly. DO NOT
allow planetary gear assembly to separate.
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Fig. 16: Removing 2 Apply Gaskets

12. Remove spring, pawl pin and parking lock pawl. Remove underdrive clutch assembly. See Fig. 18.
Remove thrust bearing and bearing race. Using a screwdriver, remove No. 2 one-way clutch snap ring.
Remove No. 2 one-way clutch from transaxle case. Note position of index marks on No. 2 one-way clutch
for reassembly reference. See Fig. 87. Note position of outer race retainer on No. 2 one-way clutch for
reassembly reference. See Fig. 20. Remove outer race retainer from No. 2 one-way clutch.
13. Using a screwdriver, remove underdrive brake snap ring. Remove flange, 3 discs and 3 plates from
transaxle case. Note location of components during removal for reassembly reference. Using appropriate
press, compress underdrive brake piston return spring. Using snap ring expander, remove snap ring from
underdrive brake. Remove piston return spring. See Fig. 18.
14. Remove 11 bolts and transaxle rear cover. If necessary, tap on circumference of rear cover with plastic
hammer to remove cover. Remove 2 oil seal rings from rear cover. Using appropriate puller, remove
needle roller bearing, if necessary. See Fig. 17. Remove bolt, clamp and 2 brake apply pipes. Using a
screwdriver, remove 2 apply gaskets from rear of transaxle case. See Fig. 18.
15. Remove direct clutch with thrust bearing from transaxle case. Remove bearing race from direct clutch
(shaft side). Remove rear planetary sun gear assembly from transaxle case. Remove thrust bearing from
rear planetary sun gear. Remove thrust washer No. 1 from rear planetary sun gear.
16. Remove No. 1 one-way clutch and thrust bearing from transaxle case. Remove inner race from one-way
clutch. Remove one-way clutch outer sleeve from transaxle case. Note direction of components for
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reassembly reference. Using a screwdriver, remove 2nd brake snap ring. Remove flange, 3 discs and 3
plates from transaxle case. Note location of components during removal for reassembly reference. See
Fig. 17.
17. Using a screwdriver, remove rear planetary gear snap ring. Remove rear planetary gear from transaxle
case. Remove thrust washer No. 2 from rear planetary gear. Remove 2 bearing races, thrust bearings and
front planetary sun gear from transaxle case. See Fig. 17.
18. Using a hammer and chisel, unstake washer located on counter drive gear. See Fig. 17. Ensure all claws
on washer are pushed down to allow socket to fit securely on nut. Using holding tool and socket, remove
nut. See Fig. 21. Using appropriate adapter and press, remove front planetary gear from counter drive
gear. See Fig. 22.
19. Using a screwdriver, remove 2nd brake assembly snap ring. Remove brake hub with 2nd brake assembly.
Remove brake hub from 2nd brake assembly. See Fig. 17. Using a screwdriver, remove snap ring and
front planetary ring gear from brake hub. Remove 1st/reverse brake flange, 5 discs and 5 plates from
transaxle case. Note location of components during removal for reassembly reference.
excessively.
20. Using appropriate press, compress 1st/reverse brake piston return spring. Using snap ring expander,
remove snap ring from underdrive brake. Remove piston return spring. Using 57 psi (4 kg/cm2 ) of
compressed air applied to transaxle case, remove 1st/reverse brake piston from case. See Fig. 23. Cover
piston with shop towel during removal.
21. Using appropriate adapter and press, remove counter drive gear from transaxle case. Install and tighten 2
bolts opposite each other evenly on counter drive gear. Ensure clearance between counter drive gear and
bearing race is about .79" (20.0 mm). Using bearing puller, remove rear tapered roller bearing from
counter drive gear. See Fig. 17.
22. Using a brass drift and hammer, remove bearing inner and outer races. Remove snap ring at underdrive
brake piston from transaxle case. Using 57 psi (4 kg/cm2 ) of compressed air applied to transaxle case,
remove underdrive brake piston from case. See Fig. 24. Cover piston with shop towel during removal.
23. Using appropriate puller, remove needle roller bearing from transaxle case. Remove 2 oil seal rings from
transaxle case. See Fig. 26. Using appropriate puller, remove cylindrical roller bearing from transaxle
case.
24. Remove oil seal ring from transaxle housing. See Fig. 25. Remove bolt, clamp and apply pipe from
transaxle case. Remove 3 bolts and oil deflector (if equipped) from transaxle case. See Fig. 7.
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Fig. 19: Pushing Parking Lock Pawl Toward Case

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Fig. 20: Removing & Installing Outer Race Retainer

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Fig. 21: Removing & Installing Counter Drive Gear Nut

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Fig. 22: Removing Front Planetary Gear From Counter Drive Gear
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Fig. 23: Removing 1st/Reverse Brake Piston

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Fig. 24: Removing Underdrive Brake Piston

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Fig. 25: Removing & Installing Transaxle Housing Oil Seal Ring
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Fig. 26: Removing Underdrive Clutch Oil Seal Rings

COMPONENT DISASSEMBLY & REASSEMBLY

OIL PUMP ASSEMBLY
Disassembly
Using 2 screwdrivers, turn drive gear and check for smooth rotation. Remove 2 oil seal rings. Using T30 Torx
socket, remove 11 bolts attaching oil pump body and stator shaft. Remove "O" ring from oil pump body. See
Fig. 27. Note direction and location of drive and driven gears. Leave gears in oil pump body for inspection.
Inspection
1. Check body clearance of driven gear. Push driven gear to one side of body. Using a feeler gauge, measure
clearance. See Fig. 28. Body clearance should be .0039-.0067" (.100-.170 mm). Maximum body
clearance is .0067" (.170 mm). If body clearance exceeds specification, replace oil pump body.
2. Using a feeler gauge, check tip clearance of driven gear. Measure between gear teeth and crescent-shaped
part of oil pump body. See Fig. 29. Tip clearance is .0028-.0059" (.070-.150 mm). Maximum tip
clearance is .0059" (.150 mm). If tip clearance exceeds specification, replace oil pump body.
3. Check side clearance of both gears. Use a steel straightedge and feeler gauge to measure side clearance of
both gears. See Fig. 30. Clearance is .0008-.0020" (.020-.050 mm). Maximum side clearance
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is .0020" (.050 mm). Replace gears as necessary. If side clearance is not within specification after gear
replacement, replace oil pump body.
4. Using a dial indicator, measure inside diameter of oil pump body bushing. See Fig. 31. Maximum inside
diameter is 1.503" (38.18 mm). If inside diameter exceeds specification, replace oil pump body.
5. Using a dial indicator, measure inside diameter of stator shaft bushing. See Fig. 32. Maximum inside
diameter is .849" (21.57 mm). If inside diameter exceeds specification, replace stator shaft.
6. Inspect front oil seal for cracks, damage or wear. Replace oil seal (if necessary). Remove oil seal with
slide hammer. Install a NEW oil seal. Seal is properly installed when it is flush with outer edge of pump
body.
Reassembly
1. Install front oil seal. Install driven gear and drive gear. Ensure top of gears are facing upward. Install
stator shaft on oil pump body. Align bolt holes. Install 11 stator shaft-to-oil pump body bolts. Tighten
bolts in crisscross pattern to 87 INCH lbs. (9.8 N.m).
2. Install 2 oil seal rings on oil pump. DO NOT expand ring ends excessively. Turn drive gear with
screwdrivers to ensure a smooth rotation. DO NOT damage oil seal lip.
Fig. 27: Exploded View Of Oil Pump Assembly

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Fig. 28: Checking Oil Pump Driven Gear Clearance

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Fig. 29: Checking Oil Pump Driven Gear Tip Clearance

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Fig. 30: Checking Oil Pump Gear Side Clearance

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Fig. 31: Checking Oil Pump Body Bushing Diameter

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Fig. 32: Checking Stator Shaft Bushing Diameter

DIRECT CLUTCH
Disassembly
1. Prior to disassembly, measure piston stroke of direct clutch. Install direct clutch and needle roller bearing
on transaxle rear cover. Using a dial indicator, measure direct clutch piston stroke by applying and
releasing 57 psi (4 kg/cm2 ) of compressed air to transaxle rear cover. See Fig. 33. Piston stroke should
be .024-.033" (.61-.83 mm). If piston stroke is not within specification, inspect each component during
disassembly.
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excessively.
2. Remove direct clutch from transaxle rear cover. Using a screwdriver, remove snap ring from direct clutch
drum. Remove flange, 3 discs and 3 plates. Note location of components during removal for reassembly
reference. Position clutch balancer on a press. Compress piston return springs and remove snap ring. See
Fig. 34.
3. Remove clutch balancer and piston return springs from clutch drum. Install direct clutch on transaxle rear
cover. While holding direct clutch piston, apply 57 psi (4 kg/cm2 ) of compressed air to transaxle rear
cover to remove direct clutch piston. See Fig. 33.
Fig. 33: Measuring Direct Clutch Piston Stroke

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Fig. 34: Exploded View Of Direct Clutch Assembly

Inspection
components.
2. Using vernier calipers, measure direct clutch piston return spring free length with spring mounted to
NOTE: New discs must be soaked in ATF at least 15 minutes prior to reassembly.
Reassembly
1. Coat piston with ATF. Using hand pressure, press piston into direct clutch drum. Ensure piston lip seal is
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not damaged. Install piston return springs and clutch balancer onto direct clutch drum. Set snap ring in
position.
excessively.
expander, install snap ring in direct clutch drum groove. Ensure end gap of spring is not aligned with gaps
in clutch balancer hub.
Fig. 34. Install snap ring. Ensure end gap of snap ring is not aligned with cutouts of direct clutch drum.
4. If disc, plate or flange have been replaced, check piston stroke. Install direct clutch and needle roller
bearing on transaxle rear cover. Using a dial indicator, measure direct clutch piston stroke by applying
and releasing 57 psi (4 kg/cm2 ) of compressed air to transaxle rear cover. See Fig. 33.
5. Piston stroke should be .024-.033" (.61-.83 mm). If piston stroke is not within specification, disassemble
and reassemble direct clutch components.
available in 6 thicknesses, from .118" (3.00 mm) to .138" (3.50 mm) in increments of .004" (.10 mm).
7. Check direct clutch operation. Insert rear planetary sun gear into direct clutch. Ensure rear planetary sun
gear rotates in both directions. See Fig. 35. If sun gear does not rotate as described, disassemble and
inspect direct clutch.
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Fig. 35: Checking Direct Clutch Operation

FORWARD CLUTCH
Disassembly
1. Prior to disassembly, measure piston stroke of forward clutch. Install forward clutch on oil pump
piston stroke is not within specification, inspect each component during disassembly.
2. Remove forward clutch from oil pump assembly. Using a screwdriver, remove snap ring from forward
clutch drum. Remove flange, 4 discs and 4 plates. Note location of components during removal for
reassembly reference. Using appropriate press, compress piston return springs. Using snap ring expander,
remove snap ring. See Fig. 37.
3. Remove press and piston return springs. Install forward clutch on oil pump assembly. While holding
forward clutch piston, apply 57 psi (4 kg/cm2 ) of compressed air to oil pump to remove forward clutch
piston. See Fig. 36. Opening in oil pump is large. To prevent air from discharging, surround air nozzle
with shop towel.
4. If piston cannot be removed using compressed air, wrap needle nose pliers tips with vinyl tape and
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remove piston using pliers. Remove 2 "O" rings from piston.
Fig. 36: Measuring Forward Clutch Piston Stroke

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Fig. 37: Exploded View Of Forward Clutch Assembly With Multiple Clutch Hub
Inspection
1. Clean all parts (except discs) with solvent. Dry parts using compressed air. Ensure check ball is free in
piston. Apply low air pressure to small hole in piston to check for air leakage around piston valve. Inspect
discs and plates for wear or burnt areas. If disc lining is peeled or discolored, replace discs as necessary.
Replace all damaged components.
2. Using vernier calipers, measure forward clutch piston return spring free length with spring mounted to
spring seat. Free length should be 1.111" (28.23 mm). Replace springs as necessary.
3. Using a dial indicator, measure inside diameter of multiple clutch hub bushing. See Fig. 38. Maximum
inside diameter is .909" (23.09 mm). If inside diameter exceeds specification, replace multiple clutch hub.
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Fig. 38: Measuring Multiple Clutch Hub Bushing Inside Diameter

NOTE: New discs must be soaked in ATF for 15 minutes prior to reassembly.
Reassembly
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1. Coat NEW piston "O" rings with ATF. Install "O" rings on forward clutch piston. Using hand pressure,
press piston into forward clutch drum. Ensure "O" rings are not damaged. Set piston return springs in
position.
excessively.
2. Position spring seat on a press. Compress piston return springs. Using snap ring expander, install snap
ring in forward clutch drum groove. Ensure end gap of spring is not aligned with gap in spring retainer
hub.
Fig. 37. Install snap ring. Ensure end gap of snap ring is not aligned with cutouts of forward clutch drum.
4. If disc, plate or flange have been replaced, check piston stroke. Install forward clutch on oil pump
piston stroke is not within specification, disassemble and reassemble forward clutch components.
available in 5 thicknesses from .118" (3.00 mm) to .142" (3.60 mm) in increments of .006" (.15 mm).
Coat thrust bearings with ATF and install.
6. Check forward clutch operation. Insert multiple clutch hub into forward clutch. Ensure forward clutch
rotates in both directions. See Fig. 39. If forward clutch does not rotate as described, disassemble and
inspect forward clutch.
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Fig. 39: Checking Forward Clutch Operation

2ND BRAKE
Disassembly & Reassembly
1. Using appropriate press, position press on piston return springs and compress springs. Using a
screwdriver, remove snap ring. Remove press and piston return springs. See Fig. 40. While holding 2nd
brake piston, apply 57 psi (4 kg/cm2 ) of compressed air to 2nd brake cylinder to remove piston. See Fig.
41. Remove 2 "O" rings from piston.
2. Using vernier calipers, measure 2nd brake piston return spring free length with spring mounted to spring
seat. Free length should be .654" (16.61 mm). Replace springs as necessary. Coat NEW "O" rings with
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ATF and install on piston.

3. Carefully press 2nd brake piston by hand into 2nd brake cylinder. See Fig. 40. Using appropriate press,
compress piston return springs and install snap ring. Ensure end gap of snap ring is not aligned with gap
in piston return spring hub.
Fig. 40: Exploded View Of 2nd Brake Assembly

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Fig. 41: Removing 2nd Brake Piston

UNDERDRIVE PLANETARY GEAR
Disassembly
1. Using gear stand, lock nut socket, adapter and INCH-lb. torque wrench with a fulcrum length of
6.30" (160.0 mm), measure underdrive input shaft starting torque for reference. See Fig. 42. Starting
torque should be 7.0-51.3 INCH lbs. (.8-5.8 N.m).
2. Using pin punch and hammer, loosen staked part of lock nut. Clamp underdrive planetary gear in a soft-
jawed vise. Use care not to damage differential drive pinion. Using appropriate socket, remove lock nut.
Remove gear from vise. Using appropriate puller, remove cylindrical roller bearing inner race. See Fig.
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43.
3. Using gear stand and appropriate press, remove differential drive pinion, parking lock gear, counter
driven gear with underdrive planetary ring gear and front tapered roller bearing. See Fig. 43.
4. Clamp underdrive planetary gear in soft-jawed vise. Using appropriate puller, remove rear tapered roller
bearing from underdrive planetary gear. Using snap ring pliers, remove snap ring. Remove underdrive
planetary ring gear from counter driven gear.
Fig. 42: Measuring Underdrive Planetary Gear Input Shaft Starting Torque
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Fig. 43: Exploded View Of Underdrive Planetary Gear Assembly

Reassembly
1. Install underdrive planetary ring gear into counter driven gear. Install snap ring. Using appropriate press,
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install rear tapered roller bearing onto underdrive planetary gear. Press bearing until it becomes flat at the
bottom.
2. Install counter driven gear with underdrive planetary ring gear onto underdrive planetary gear. Using
appropriate press, install front tapered roller bearing onto underdrive planetary gear while rotating counter
driven gear.
3. Using appropriate press, install parking lock gear while rotating counter driven gear. Using press, install
differential drive pinion, then install cylindrical roller bearing inner race while rotating counter driven
gear.
4. Clamp underdrive planetary gear in a soft-jawed vise. Use care not to damage differential drive pinion.
Using appropriate socket, install NEW lock nut and tighten to 207 ft. lbs. (280 N.m). Remove gear from
vise. Using gear stand, lock nut socket, adapter and INCH-lb. torque wrench with a fulcrum length of
6.30" (160.0 mm), ensure underdrive input shaft starting torque is 7.0-51.3 INCH lbs. (.8-5.8 N.m). See
Fig. 42. Using pin punch and hammer, stake lock nut. Ensure lock nut is not cracked.
UNDERDRIVE CLUTCH
Disassembly
1. Prior to disassembly, check piston stroke of underdrive clutch. Install underdrive clutch into transaxle
case. DO NOT damage oil seal rings. Install dial indicator onto underdrive clutch flange. See Fig. 44.
Apply and release 57 psi (4 kg/cm2 ) of compressed air to transaxle case. See Fig. 45.
2. Piston stroke should be .059-.075" (1.51-1.90 mm). If piston stroke is not within specification, inspect
discs and plates during disassembly. Using a screwdriver, remove drum snap ring. Remove flange, 3 discs
and 3 plates from underdrive clutch drum. Note location of components during removal for reassembly
excessively.
3. Using appropriate press placed on clutch balancer, compress piston return springs. Using snap ring
expander, remove snap ring. Remove press, clutch balancer and piston return springs.
4. Install underdrive clutch into transaxle case. DO NOT damage oil seal rings. While holding underdrive
clutch piston, apply 57 psi (4 kg/cm2 ) of compressed air to transaxle case to remove underdrive clutch
piston. See Fig. 45. Remove "O" ring from underdrive clutch drum.
Inspection
components.
2. Using vernier calipers, measure underdrive clutch piston return spring free length with spring mounted to
3. Using a dial indicator, measure inside diameter of underdrive clutch drum bushing. See Fig. 46.
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Maximum inside diameter is 1.462" (37.13 mm). If inside diameter exceeds specification, replace
underdrive clutch drum.
Reassembly
1. Coat NEW "O" ring with ATF and install on underdrive clutch drum. Coat underdrive clutch piston with
ATF. Using hand pressure, install piston into underdrive clutch drum. Use care not to damage "O" ring.
Install piston return springs and clutch balancer to underdrive clutch drum. Set snap ring in position.
excessively.
expander, install snap ring in underdrive clutch drum groove. Ensure end gap of spring is not aligned with
gap in clutch balancer hub.
Fig. 47. Install snap ring. Ensure end gap of snap ring is not aligned with cutouts of underdrive clutch
drum.
4. Check piston stroke of underdrive clutch. Install underdrive clutch into transaxle case. DO NOT damage
oil seal rings. Install dial indicator onto underdrive clutch flange. See Fig. 44. Apply and release 57 psi (4
kg/cm2 ) of compressed air to transaxle case. See Fig. 45.
5. Piston stroke should be .059-.075" (1.51-1.90 mm). If piston stroke is not within specification, replace
flange. Flange is available in thicknesses of .118" (3.00 mm), .126" (3.20 mm) and .134" (3.40 mm).
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Fig. 44: Installing Dial Indicator Onto Underdrive Clutch Flange

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Fig. 45: Measuring Underdrive Clutch Piston Stroke

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Fig. 46: Checking Underdrive Clutch Drum Bushing

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Fig. 47: Exploded View Of Underdrive Clutch Assembly

VALVE BODY ASSEMBLY
NOTE: All valve body components must be installed in original location. Lay all
components in sequence during removal for reassembly reference. Primary
regulator valve position controls line pressure. Note location of primary
regulator valve sleeve, plug and pin prior to disassembly. See Fig. 50.
Disassembly
1. Remove 5 bolts and 5 shift solenoids. See Fig. 48 and Fig. 51 . Using snap ring pliers, remove 2 snap
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rings securing accumulator assemblies. Remove 2 washers, 4 springs and 2 pistons from upper valve
body. See Fig. 49.
2. Remove 8 upper valve body bolts. See Fig. 52. Remove 7 upper valve body cover bolts. See Fig. 53.
Remove bolt, cover and 2 pressure relief check balls. See Fig. 54.
3. Remove 7 lower valve body bolts. See Fig. 55. Hold plate against lower valve body and carefully remove
lower valve body from upper valve body. Remove plate from lower valve body. DO NOT lose check
balls. Note location of check balls, keys, plugs and pins in valve body. See Fig. 56-Fig. 59 .
Fig. 48: Exploded View Of Valve Body Assembly

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Fig. 49: Locating Upper Valve Body Accumulator Pistons, Check Balls & Bolts
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Fig. 50: Identifying Primary Regulator Valve Position

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Fig. 51: Identifying Shift Solenoid Locations

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Fig. 52: Removing & Installing 8 Upper Valve Body Bolts

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Fig. 53: Removing & Installing Upper Valve Body Cover Bolts
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Fig. 54: Locating Pressure Relief Check Balls

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Fig. 55: Removing & Installing 7 Lower Valve Body Bolts

Inspection
1. Clean all parts with solvent. Dry parts with compressed air. Ensure all valve body oil passages are clear.
Inspect valves for scoring or roughness. See Fig. 56 and Fig. 57 . Inspect valve springs for damage,
squareness, rust and collapsed coils. Measure spring free length and outer diameter.
2. Replace spring if not within specification. See appropriate VALVE BODY SPRING SPECIFICATIONS
table. Ensure valve body springs correspond with appropriate valve. Ensure keys are installed in
appropriate locations. See appropriate VALVE BODY KEY SPECIFICATIONS table.
UPPER VALVE BODY SPRING SPECIFICATIONS

Clutch Apply Control Valve .354 (9.00) 1.586 (40.29)
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(Purple)
Direct Clutch Exhaust Valve .291 (7.40) 1.585 (40.27)
(Orange)
Direct Clutch Lock Valve .291 (7.40) 1.325 (33.65)
(Yellow)
Lock-Up Control Valve (None) .213 (5.40) .944 (23.98)
Lock-Up Relay Valve (None) .382 (9.70) 1.152 (29.27)
Secondary Regulator Valve (Blue) .343 (8.70) 2.297 (58.35)
Solenoid Modulator Valve (Red) .386 (9.80) 2.457 (62.40)
Underdrive Brake Orifice Control .307 (7.80) 2.467 (62.65)
Valve (Gray)
2nd Brake Lock Valve (White) .386 (9.80) 1.472 (37.40)
(1) Refer to illustration for spring locations. See Fig. 56.
LOWER VALVE BODY SPRING SPECIFICATIONS

Direct Clutch Control Valve .390 (9.90) 1.346 (34.20)
(Brown)
Primary Regulator Valve (Orange) .783 (19.90) 2.266 (57.55)
1st/Reverse Brake Control Valve .386 (9.80) 2.246 (57.05)
(Pink)
2nd Brake Control Valve (Light .386 (9.80) 1.911 (48.55)
Green)
3-4 Shift Valve (None) .382 (9.70) 1.152 (29.25)
(1) Refer to illustration for spring locations. See Fig. 57.
UPPER VALVE BODY KEY SPECIFICATIONS

Key I. D. Letter (1) (2) Height - In. (mm)
A, B & D .394 (10.00)

F .728 (18.50)
All Other Keys .315 (8.00)
(1) Refer to illustration for key locations. See Fig. 58.
(2) Thickness for key "F" is .091" (2.30 mm). Width is not available. For all other keys, width
is .197" (5.00 mm). Thickness is .126" (3.20 mm).
LOWER VALVE BODY KEY SPECIFICATIONS

Key I. D. Letter (1) (2) Height - In. (mm)
A 1.004 (25.50)
B, C & D .571 (14.50)
Refer to illustration for key locations. See Fig. 59.
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(1)
(2) Thickness for key "A" is .091" (2.30 mm). Width is not available. For keys "B", "C" and "D", key
width is .197" (5.00 mm). Thickness is .126" (3.20 mm).
Fig. 56: Exploded View Of Upper Valve Body

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Fig. 57: Exploded View Of Lower Valve Body

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Fig. 58: Identifying Upper Valve Body Check Ball & Key Locations
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Fig. 59: Identifying Lower Valve Body Check Ball & Key Locations
Reassembly
1. Install check balls in upper and lower valve bodies. Ensure check balls are installed in correct locations.
See Fig. 58 and Fig. 59 . Install plate to lower valve body. Install lower valve body with plate to upper
valve body. Install 7 lower valve body bolts and tighten to 97 INCH lbs. (11 N.m). Bolts are
1.614" (41.00 mm) in length.
2. Install accumulator pistons, springs, washers and snap rings. Ensure spring free length and outer diameter
are within specification. For spring specifications, see ACCUMULATOR VALVE SPRING
SPECIFICATIONS table. Ensure components are installed in correct locations. Install pressure relief
check balls, retainer and bolt. Tighten bolt to 97 INCH lbs. (11 N.m). See Fig. 54.
3. Turn valve body over. Install 7 upper valve body cover bolts. Tighten bolts to 58 INCH lbs. (6.6 N.m).
Install 8 upper valve body bolts. Tighten bolts to 97 INCH lbs. (11 N.m). Ensure bolts are installed in
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correct locations. For bolt identification, see UPPER VALVE BODY BOLT IDENTIFICATION table.
4. Install 5 shift solenoids and bolts. Tighten shift solenoid SLT and SL1 bolts to 58 INCH lbs. (6.6 N.m).
Bolt length is .47" (12.0 mm). Tighten all other shift solenoid bolts to 97 INCH lbs. (11 N.m). Bolt length
is 1.77" (45.0 mm). See Fig. 51. Ensure primary regulator valve is installed in correct position. See Fig.
50.
ACCUMULATOR VALVE SPRING SPECIFICATIONS

Outer Diameter - In.
Application (Color) Free Length - In. (mm) (mm)
Direct Clutch Accumulator
Inner Spring (Brown) 1.873 (47.58) .441 (11.20)
Outer Spring (Brown) 1.874 (47.61) .472 (12.00)
2nd Brake Accumulator
Inner Spring (Purple) 1.728 (43.88) .433 (11.00)
Outer Spring (White) 1.776 (45.12) .465 (11.80)
UPPER VALVE BODY BOLT IDENTIFICATION

Cover Bolt (1)
Bolt A .551 (14.00)
Bolt B .394 (10.00)
Upper Valve Body Bolt (2)
Bolt A 1.614 (41.00)
Bolt B 1.181 (30.00)
(1) Refer to illustration for cover bolt locations. See Fig. 53.
(2) Refer to illustration for upper valve body bolt locations. See Fig. 52.
DIFFERENTIAL ASSEMBLY
Disassembly
1. Mark ring gear and differential case for reassembly reference. Remove 16 bolts. Using a plastic hammer,
tap on ring gear to remove it from differential case. Remove left side differential case from differential
right side case. Remove front differential case from left side differential case. See Fig. 60.
2. Remove front differential side gear, front differential side gear thrust washer, conical washer and center
differential side gear thrust washer No. 2 from left side differential case. Using snap ring expander,
remove snap ring from front differential case. See Fig. 61. Remove spacer from front differential case.
Remove 3 pinion shafts from front differential case. See Fig. 60.
3. Remove 4 front differential pinion gears, thrust washers, pinion shaft holder, side gear and thrust washer
from front differential case. Using appropriate puller, remove tapered roller bearing from left side
differential case. See Fig. 60.
4. Using snap ring expander, remove snap ring from right side differential case. See Fig. 62. Slide spacer
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down to remove 4 center differential pinion shafts. Remove 4 center differential pinion shafts, differential
pinions, thrust washers, pinion shaft holder, side gear, conical washer and center differential side gear
thrust washer No. 1 from right side differential case. See Fig. 63. Remove the spacer. See Fig. 60.
5. Using appropriate puller, remove tapered roller bearing from right side differential case. Remove
transaxle housing bearing race. Remove transaxle housing oil seal. Remove transaxle case bearing race
and plate washer. Remove transaxle case oil seal. See Fig. 60.
Fig. 60: Exploded View Of Differential Assembly

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Fig. 61: Removing Snap Ring From Front Differential Case

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Fig. 62: Removing Snap Ring From Right Side Differential Case
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Fig. 63: Removing Right Side Differential Case Components

Cleaning & Inspection
Clean all parts with solvent. Dry with compressed air. Check bearings, races and gears for wear or damage.
Replace as necessary.
Reassembly
NOTE: Coat all sliding and rotating surfaces with ATF prior to reassembly.
1. Using appropriate race installer and a hammer, install transaxle housing bearing race. Install plate washer
of lesser thickness than washer removed during disassembly into transaxle case. Using appropriate race
installer and a hammer, install transaxle case bearing race. See Fig. 60.
2. Coat front differential side gear thrust washer, front differential side gear, front differential pinion shaft
holder, 4 front differential pinion thrust washers and 4 front differential pinion gears with ATF, and
install components into front differential case. Install 3 pinion shafts into front differential case. See Fig.
60.
3. Mount front differential case in soft-jawed vise. DO NOT damage surface of front differential case which
contacts vise. Using a dial indicator, measure front differential pinion gear backlash while holding front
differential side gear toward front differential case. See Fig. 64.
4. Backlash should be .002-.008" (.05-.20 mm). If backlash is not within specification, select appropriate
thrust washer to ensure backlash is within specification. Thrust washers are marked in alphabetical order
from "B" to "G", and are available in thicknesses from .039" (1.00 mm) to .049" (1.25 mm) in increments
of .002"(.05 mm).
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Fig. 64: Measuring Front Differential Pinion Gear Backlash

5. Engage side gear to front differential case. Install left side differential case to front differential case.
Ensure side gear is centered. Once side gear is centered, remove left side differential case.
6. Using a straightedge and feeler gauge, measure clearance between front differential case and side gear.
See Fig. 65. Use the following formula to determine correct thrust washer thickness for specified
clearance: thrust washer thickness equals clearance (feeler gauge thickness) minus .006-.011" (.16-.27
mm).
7. Thrust washers are marked in alphabetical order from "A" to "K" (except "I"), and are available in
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thicknesses from .037" (.95 mm) to .055" (1.40 mm) in increments of .002" (.05 mm). If clearance is not
as specified, ensure components were assembled correctly.
Fig. 65: Measuring Front Differential Case-To-Side Gear Clearance

8. Install spacer to front differential case. Wrap vinyl tape around case prior to snap ring installation to avoid
damaging front differential case. Install snap ring on front differential case as shown. See Fig. 66. Install
spacer to right side differential case. Slide down spacer to install 4 center differential pinion shafts.
9. Install center differential side gear thrust washer No. 1, conical washer, center differential side gear,
pinion shaft holder, differential pinion gears, thrust washers and pinion shafts to right side differential
case. Ensure conical washer is installed correctly into right side differential case. See Fig. 63. Mount right
side differential case in soft-jawed vise. Using dial indicator, measure center differential pinion gear
backlash, while holding center differential side gear toward case. See Fig. 67.
10. Backlash should be .002-.008" (.05-.20 mm). If backlash is not within specification, select appropriate
thrust washer to ensure backlash is within specification. Thrust washers are marked in alphabetical order
from "MA" to "MN" (except "MI"), and are available in thicknesses from .032" (.80 mm) to .055" (1.40
mm) in increments of .002" (.05 mm).
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Fig. 66: Installing Snap Ring To Front Differential Case

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Fig. 67: Measuring Center Differential Pinion Gear Backlash

NOTE: In the following step, the .039" (1.00 mm) thick center differential side gear
thrust washer No. 2 is used for reference when checking backlash.
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Fig. 68: Installing Components Into Right Side Differential Case

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11. Temporarily install front differential case, front differential side gear, front differential side gear thrust
washer, a .039" (1.00 mm) thick center differential side gear thrust washer No. 2 (temporarily) and center
differential side gear thrust washer No. 2 to right side differential case. See Fig. 68. Engage front
differential side gear and pinion gear of right side differential case.
12. Clean contact surface of center differential side gear thrust washer No. 2 and left side differential case.
Apply Plastigage on center differential side gear thrust washer No. 2 as shown in Fig. 69, in 4 positions
directly above pinion shafts in right side differential case.
13. Install left side differential case downward. Align match marks on right side differential case and left side
differential case. See Fig. 70. Temporarily install right side differential case and 4 service bolts to left
side differential case. See Fig. 71. Tighten bolts to 24 ft. lbs. (33 N.m). Remove 4 bolts and left side
differential case.
14. Measure Plastigage at its widest point. See Fig. 72. Standard clearance should be .006-.010" (.16-.25
mm). If standard clearance is not as specified, select appropriate thrust washer No. 2 to ensure backlash is
within specification. Try to select a thrust washer of the same size. Thrust washers are marked in numeric
and alphabetic order and are available in thicknesses from 032" (.80 mm), marked with a zero,
to .049" (1.25 mm), marked with the number "9", and from .051" (1.30 mm), marked with the letter "A",
to .055" (1.40 mm), marked with the letter "C". Thrust washers increase in increments of .002" (.05 mm).
Fig. 69: Installing Plastigage On Center Differential Side Gear Thrust Washer No. 2
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Fig. 70: Aligning Differential Cases

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Fig. 71: Installing 4 Service Bolts To Differential Cases

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Fig. 72: Measuring Plastigage At Its Widest Point

15. Remove left side differential case, center differential side gear thrust washer No. 2 and
temporary .039" (1.00 mm) thick center differential side gear thrust washer No. 2. Install conical washer
and center differential side gear thrust washer No. 2 (previously selected) from differential case. Ensure
conical washer is installed correctly. See Fig. 73.
16. Install left side differential case onto right side differential case and align match marks. See Fig. 70.
Temporarily install right side differential case and 4 service bolts to left side differential case. See Fig.
71. Tighten service bolts to 24 ft. lbs. (33 N.m).
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Fig. 73: Installing Conical Washer

17. Using appropriate adapter and press, install differential case tapered roller bearings. Remove any material
from transaxle housing and transaxle case mating surfaces. DO NOT allow oil to contact surfaces. Install
differential assembly into transaxle case. Install transaxle housing onto transaxle case. Install 5 lower
bolts inside transaxle housing and tighten to 16 ft. lbs. (22 N.m). Install all other bolts and tighten to 21 ft.
lbs. (29 N.m). Ensure bolts are in correct locations. Longest bolts go inside transaxle housing. See Fig.
15.
18. Temporarily install transfer assembly intermediate shaft. See Fig. 74. Turn intermediate shaft right and
left several times to allow bearings to seat. Remove intermediate shaft. Using appropriate adapter and
INCH-lb. torque wrench, measure differential preload. See Fig. 75. Preload should be 1.8-6.1 INCH lbs.
(.20-.69 N.m) for NEW bearings and .9-3.1 INCH lbs. (.10-.35 N.m) for used bearings.
19. If preload is not within specification, remove 16 transaxle housing bolts. Using a plastic hammer, remove
transaxle housing from transaxle case. Remove differential assembly from transaxle case and replace
plate washer behind transaxle case bearing race. See Fig. 60.
20. Plate washers are marked in numeric and alphabetic order and are available in thicknesses
from .079" (2.00 mm), marked with a zero, to .096" (2.45 mm), marked with the number "9", and
from .098" (2.50 mm), marked with the letter "A", to .112" (2.85 mm), marked with the letter "H".
Washers increase in increments of .002" (.05 mm). Recheck preload after washer replacement.
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Fig. 74: Installing Transfer Assembly Intermediate Shaft

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Fig. 75: Measuring Differential Preload

21. Clean contact surface of differential case and ring gear using cleaning solvent. Heat ring gear to 212°F
(100°C) in water. DO NOT heat ring gear above 230°F (110 °C).
22. Carefully remove ring gear from water and quickly align match marks made during disassembly. Install
ring gear on differential case. Install but DO NOT tighten 8 ring gear bolts, in pairs of 2, in a crisscross
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pattern. Ensure ring gear is properly seated and aligned. Remove 4 service bolts previously installed. See
Fig. 71. Install remaining 8 ring gear bolts and tighten all bolts to 70 ft. lbs. (95 N.m). Install NEW oil
seal in transaxle case. Coat oil seal lip with lubricant.
23. For transaxle housing oil seal, wrap vinyl tape around seal installer at a position .236" (6.00 mm) above
bottom end of installer, until thickness of tape is about .197" (5.00 mm). Coat NEW oil seal lip with
lubricant. Install oil seal until wound vinyl tape contacts transaxle housing. Oil seal installed depth should
be .22-.26" (5.5-6.5 mm).
TRANSAXLE REASSEMBLY
NOTE: Coat all oil seal rings, clutch discs, clutch plates, rotating parts and sliding
surfaces with ATF prior to reassembly. All gaskets and rubber "O" rings should
be replaced. Ensure ends of snap rings are not aligned with cutouts of drum.
Check thrust bearings and races for wear or damage. Use petroleum jelly to
secure parts in place. Clutch discs should be soaked in ATF for at least 15
minutes before installation.
NOTE: Refer to illustration for thrust bearing and race locations. See Fig. 94. For
component dimensions, see THRUST BEARING & RACE SPECIFICATIONS
table.
1. Install oil deflector (if equipped) with 3 bolts to transaxle housing. Install apply pipe and clamp. See Fig.
7. Install bolt and tighten to 87 INCH lbs. (9.8 N.m). Ensure pipe is installed to stopper. Install oil seal
ring to transaxle housing. See Fig. 25. Using appropriate adapter and press, install underdrive cylindrical
roller bearing into transaxle housing. DO NOT apply excessive pressure to bearing.
2. Using vernier calipers, measure underdrive brake piston return spring free length with spring mounted to
spring seat. Free length should be .553" (14.04 mm). Replace springs as necessary. Install 2 oil seal rings
to transaxle case. See Fig. 26.
3. For needle roller bearing installation, wrap vinyl tape around bearing installer at a position .157" (4.00
mm) above bottom end of installer, until thickness of tape is about .197" (5.00 mm). Using bearing
installer and press, install needle roller bearing to transaxle case until wound vinyl tape contacts transaxle
case.
4. Coat 2 NEW "O" rings with ATF and install on underdrive brake piston. See Fig. 18. Using hand
pressure, install piston into transaxle case. Using appropriate adapter and press, compress underdrive
brake piston return springs into transaxle case and install snap ring. DO NOT apply excessive force.
5. Install snap ring into transaxle case. Using appropriate bearing race adapter and press, install 2 bearing
outer races into transaxle case. Press each outer race into transaxle case until race contacts snap ring. See
Fig. 17. Using appropriate adapter and press, install tapered roller bearing to counter drive gear until
bearing contacts gear. DO NOT apply excessive force.
6. Using appropriate adapter and press, install counter drive gear and bearing into transaxle case. DO NOT
apply excessive pressure. Using vernier calipers, measure 1st/reverse brake piston return spring free
length with spring mounted to spring seat. Free length should be .611" (15.51 mm). Replace springs as
necessary.
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excessively.
7. Coat 2 NEW "O" rings with ATF and install on 1st/reverse brake piston. Using hand pressure, install
piston into transaxle case. See Fig. 17. Using appropriate adapter and press, compress 1st/reverse brake
piston return springs into transaxle case and install snap ring. DO NOT apply excessive force.
8. Install front planetary ring gear and snap ring to brake hub. Install front planetary gear to brake hub.
Using appropriate adapter and press, install brake hub with front planetary gear into transaxle case. See
Fig. 76. Install washer on counter drive gear in correct direction. See Fig. 77.
9. Using holding tool, socket and torque wrench, install nut and tighten to 207 ft. lbs. (280 N.m). Using
socket, adapter and INCH-lb. torque wrench, measure counter drive gear tapered roller bearing starting
torque. Starting torque should be 4.4-8.8 INCH lbs. (.5-1.0 N.m). See Fig. 78. If starting torque is not
within specification, gradually tighten nut until starting torque is within specification.
10. Install 2 thrust bearings, bearing race and front planetary sun gear to front planetary gear. Coat bearing
race with ATF and install race to rear planetary gear. Install thrust washer No. 2. Install rear planetary
gear into transaxle case. Install snap ring.
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Fig. 76: Installing Front Planetary Gear With Brake Hub Into Transaxle Case
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Fig. 77: Installing Counter Drive Gear Washer

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Fig. 78: Measuring Counter Drive Gear Bearing Starting Torque

11. Install 1st/reverse brake. Install 5 plates and 5 discs, starting with a plate and alternating with a disc. DO
NOT install flange. Measure 1st/reverse brake piston stroke. Using vernier calipers, measure distance
between disc surface and contact surface of 2nd brake assembly at transaxle case. See Fig. 79.
within specification. Flanges are marked in numeric order and are available in thicknesses
from .071" (1.80 mm), marked with the number "1", to .098" (2.50 mm), marked with the number "8", in
increments of .004" (.10 mm). Recheck piston stroke after flange is installed.
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Fig. 79: Measuring 1st/Reverse Brake Piston Stroke

13. Install 2nd brake assembly into transaxle case. Install snap ring and measure inside diameter. Snap ring
inside diameter should be more than 6.57" (167.0 mm). Snap ring has a specific tapered installation
direction. If inside diameter is not within specification, ensure snap ring is installed in correct direction. If
snap ring is installed correctly, replace snap ring.
14. Install one-way clutch outer sleeve to 2nd brake assembly. Ensure sleeve is positioned correctly. Install
one-way clutch inner race to No. 1 one-way clutch. Ensure inner race is installed correctly. Check No. 1
one-way clutch operating direction. One-way clutch should rotate in counterclockwise direction and lock
in clockwise direction. See Fig. 80.
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Fig. 80: Checking No. 1 One-Way Clutch Rotation

15. Install No. 1 one-way clutch and thrust bearing into outer sleeve. See Fig. 81. Ensure Black race on thrust
bearing is visible upon installation. Coat thrust washer No. 1 with petroleum jelly and install on rear
planetary sun gear. Coat thrust bearing with petroleum jelly and install on rear planetary sun gear. Install
rear planetary sun gear onto rear planetary gear.
16. Install 2nd brake. Install 3 discs and 3 plates, starting with a plate and alternating with a disc. DO NOT
install flange at this time. Temporarily install snap ring. Using vernier calipers, measure 2nd brake piston
stroke between disc surface and snap ring surface. See Fig. 82. Piston stroke should be .024-.036" (.62-
.91 mm).
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Fig. 81: Installing No. 1 One-Way Clutch & Bearing

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Fig. 82: Measuring 2nd Brake Piston Stroke

17. Select appropriate flange to ensure piston stroke is within specification. Use the following formula to
determine flange thickness: measured distance, minus flange thickness, minus snap ring thickness
of .063" (1.60 mm). Flanges are available in thicknesses from .118" (3.00 mm) to .142" (3.60 mm) in
increments of .004" (.10 mm), and are marked in numeric order from "1" to "7". Remove snap ring, install
appropriate flange and reinstall snap ring. Ensure snap ring end gap is visible through groove in transaxle
case.
18. Install bearing race over shaft and onto direct clutch. Install direct clutch assembly and thrust bearing onto
rear planetary sun gear assembly. See Fig. 17. Ensure discs in direct clutch completely mate with rear
planetary sun gear to ensure rear cover can be installed correctly.
19. Ensure transaxle case and rear cover mating surfaces are clean. Place a straightedge onto direct clutch
drum. Using vernier calipers, measure distance between bottom of straightedge and transaxle case
(dimension "B"). See Fig. 83.
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Fig. 83: Measuring Direct Clutch End Play (Dimension "B")

20. Measure dimension No. 1 and dimension No. 2 of rear cover in 2 places. See Fig. 84. Subtract dimension
No. 2 from dimension No. 1. This total equals dimension "C". Calculate direct clutch end play by
subtracting dimension "B" from dimension "C". End play should be .008-.037" (.20-.94 mm).
21. Select a thrust bearing to ensure end play is within specification. Thrust bearings are available in 2
thicknesses of .140" (3.55 mm) with an outside diameter of 2.74" (69.6 mm), and .152" (3.85 mm) with
an outside diameter of 2.76" (70.18 mm). Inside diameter of both thrust bearings is 2.11" (53.6 mm).
During installation, ensure Black race side of thrust bearing is facing transaxle rear cover.
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Fig. 84: Measuring Distance Between Rear Cover Surfaces (Dimensions No. 1 & 2)
22. Install 2 NEW apply gaskets to transaxle case. Install clamp to apply pipes prior to installing pipes to
transaxle case. This will prevent apply pipes from being deformed or damaged. Install 2 apply pipes,
clamp and bolt. See Fig. 18. Ensure pipes are securely inserted into transaxle case until they reach the
pipe stopper on pipe. Tighten bolt to 48 INCH lbs. (5.4 N.m).
23. Install needle roller bearing onto transaxle rear cover with inscribed mark on bearing facing up. Using
appropriate adapter and press, install needle roller bearing to transaxle rear cover. Press bearing in to a
depth of .474-.502" (12.05-12.75 mm). Install transaxle rear cover plate and 2 screws. Apply thread
sealant to screw threads and tighten screws to 66 INCH lbs. (7.5 N.m). Coat 2 oil seal rings with ATF and
install on transaxle rear cover. See Fig. 17.
24. Install underdrive brake. Install 3 discs and 3 plates, starting with a plate and alternating with a disc. DO
NOT install flange at this time. Temporarily install snap ring. Using a dial indicator, measure underdrive
brake piston stroke by applying and releasing 57 psi (4 kg/cm2 ) of compressed air to transaxle case. See
Fig. 24 and Fig. 85 .
within specification. Flanges are available in 3 thicknesses of .118" (3.00 mm), .126" (3.20 mm)
and .134" (3.40 mm), and are marked in numeric order from "1" to "3". Remove snap ring, install
appropriate flange and reinstall snap ring.
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Fig. 85: Measuring Underdrive Brake Piston Stroke

26. Ensure transaxle case and rear cover surfaces are clean. DO NOT allow oil to contact surfaces. Coat
needle roller bearing with ATF. Apply Three Bond (1281) or equivalent gasket sealant to rear cover
around inside edges of bolt holes. Install rear cover onto transaxle case. Install 11 rear cover bolts. Install
thread sealant to 3 bolts at bottom of rear cover and tighten bolts to 14 ft. lbs. (18 N.m). Tighten all other
bolts to 18 ft. lbs. (24 N.m).
27. Install outer race retainer to No. 2 one-way clutch, ensuring long finger of retainer is facing up. See Fig.
20. Install underdrive clutch to No. 2 one-way clutch. Rotate underdrive clutch to ensure correct
installation. Underdrive clutch should rotate in a counterclockwise direction, and lock in a clockwise
direction. See Fig. 86.
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Fig. 86: Checking Underdrive Clutch Assembly Rotation

28. Install No. 2 one-way clutch into transaxle case. Note position of index marks on No. 2 one-way clutch.
Ensure marks are facing up. See Fig. 87. Install snap ring into transaxle case. Coat thrust bearing and
bearing race with petroleum jelly and install onto underdrive clutch. Install underdrive clutch into
transaxle case.
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Fig. 87: Installing No. 2 One-Way Clutch & Retainer

29. Install pawl pin and spring to parking lock pawl. Temporarily install parking lock pawl, shaft and spring
to transaxle case. See Fig. 18. Install underdrive planetary gear assembly into transaxle case. Engage all
clutch discs and hub spline of planetary gear assembly firmly and securely. Install parking lock pawl
shaft. Install lock pawl clamp and bolt. Tighten bolt to 87 INCH lbs. (9.8 N.m).
30. Using vernier calipers and a straightedge, measure gap between top of differential drive pinion in
underdrive planetary gear, and contact surface of transaxle case. See Fig. 88. Record measurement as
dimension "D".
31. Measure dimension No. 1 and dimension No. 2 of transaxle housing in 2 places. See Fig. 89. Subtract
dimension No. 2 from dimension No. 1. Record measurement as dimension "E". Install bearing race onto
counter drive gear in correct direction. See Fig. 17.
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Fig. 88: Measuring Gap Between Top Of Differential Drive Pinion & Transaxle Case (Dimension
"D")
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Fig. 89: Measuring Distance Between Transaxle Housing Surfaces (Dimensions No. 1 & 2)
32. Coat needle roller bearing with petroleum jelly and install onto multiple clutch hub (shaft side). Install
multiple clutch hub into transaxle case. Install thrust bearing onto multiple clutch hub (forward clutch
side). Install forward clutch onto multiple clutch hub. See Fig. 17. Align splines of all discs of forward
clutch with multiple clutch hub. Install thrust bearing onto forward clutch. Ensure Black side of thrust
bearing is visible.
33. Install 2 NEW apply gaskets to front of transaxle case. See Fig. 17. Install differential assembly.
Calculate transaxle housing-to-underdrive planetary gear assembly end play using the following formula:
subtract dimension "D" from dimension "E", performed in steps 30 and 31 , minus thrust bearing
thickness of .129" (3.28 mm), equals bearing race thickness. End play should be .020-.039" (.50-.99 mm).
34. Select a bearing race to ensure end play is within specification. If dimension "E" minus dimension "D" is
less than .292" (7.42 mm), bearing race thickness should be .138" (3.50 mm). If dimension "E" minus
dimension "D" is .292" (7.42 mm) or more, bearing race thickness should be .150" (3.80 mm).
35. Install appropriate bearing race onto underdrive planetary gear assembly to ensure end play is within
specification. Bearing race outside diameter is 3.268" (83.00 mm). Bearing race inside diameter is
2.220" (56.40 mm). Install appropriate thrust bearing onto bearing race. Thrust bearing outside diameter
is 3.345" (84.96 mm). Thrust bearing inside diameter is 2.252" (57.20 mm).
36. Coat oil pump "O" ring with ATF. Install oil pump and 7 bolts. Tighten bolts to 16 ft. lbs. (22 N.m).
Ensure transaxle case and transaxle housing surfaces are clean. DO NOT allow oil to contact surfaces.
Apply Three Bond (1281) or equivalent gasket sealant about .047" (1.20 mm) wide, to transaxle case
around inside edges of bolt holes. Install transaxle housing to transaxle case.
37. Install 16 transaxle housing bolts. Apply thread sealant to 5 lower bolts inside transaxle housing, and
tighten these bolts to 16 ft. lbs. (22 N.m) within 10 minutes of installation. Tighten all other bolts to 21 ft.
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lbs. (29 N.m). Ensure bolts are in correct locations. Longest bolts go inside transaxle housing. See Fig.
15.
38. Inspect input shaft end play. Using a dial indicator, measure input shaft end play. See Fig. 14. End play
should be .010-.049" (.26-1.25 mm). Recheck differential preload. Using appropriate adapter and INCH-
lb. torque wrench, measure differential preload. See Fig. 75. Preload should be 1.8-6.1 INCH lbs. (.20-.69
N.m) for new bearings and .9-3.1 INCH lbs. (.10-.35 N.m) for used bearings.
39. If preload is not within specification, remove differential assembly from transaxle case and replace shim
or plate washer behind transaxle case bearing race. See Fig. 60.
40. Place transaxle on 2 blocks of wood, with oil pan surface facing outward. Coat NEW manual valve lever
shaft oil seal with ATF. Install oil seal into transaxle case. Install parking lock pawl rod to manual valve
lever. Install NEW spacer and manual valve lever shaft into transaxle case. See Fig. 7.
41. Using a pin punch and hammer, drive in NEW roll pin. Turn spacer and lever shaft to align small hole for
locating staking position in spacer with position mark on lever shaft. See Fig. 90. Using a pin punch and
hammer, stake spacer through small hole. Ensure spacer does not turn.
Fig. 90: Staking Spacer To Manual Valve Lever Shaft

42. Using needle nose pliers, install retainer spring. Install parking lock pawl bracket. Install bolts and tighten
to 15 ft. lbs. (20 N.m). Install cover, manual detent spring and 2 bolts. Ensure cover and detent spring are
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installed correctly. See Fig. 7.

43. Tighten 1.063" (27.00 mm) bottom bolt to 15 ft. lbs. (20 N.m). Tighten .630" (16.00 mm) top bolt to 106
INCH lbs. (12 N.m). Coat NEW "O" rings with ATF and install them onto accumulator pistons. Coat 4
springs and 3 accumulator pistons with ATF, and install components into transaxle case holes. See Fig.
91. See ACCUMULATOR SPRING FREE LENGTH SPECIFICATIONS table for spring
specifications and identification.
Fig. 91: Identifying Accumulator Piston & Spring Locations

ACCUMULATOR SPRING FREE LENGTH SPECIFICATIONS

(Color) (mm)
Forward 3.210 (81.53) .728 (18.50)
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Clutch
(Pink)
Underdrive Brake
Inner 2.372 (60.24) .626 (15.90)
(Green)
Outer 2.859 (72.61) .657 (16.70)
(Blue)
Underdrive 3.563 (90.49) .756 (19.20)
Clutch
(White)
44. Install check ball body and spring. See Fig. 10. Coat NEW "O" ring with ATF and install on transaxle
solenoid connector. Install connector into transaxle case, above park/neutral position switch, and tighten
bolt to 48 INCH lbs. (5.4 N.m). Coat NEW apply gaskets with ATF and install them into transaxle case,
below valve body assembly. See Fig. 10. Install brake drum gasket, located near 3 apply gaskets. See Fig.
7.
45. Align groove in manual valve with pin in manual valve lever. Push valve body assembly against
accumulator piston springs and check ball body to assist in installation. Install valve body bolts. Hand
tighten 2 bolts temporarily. See Fig. 92. These bolts are positioning bolts.
46. Ensure valve body is aligned. Ensure bolts are installed in correct locations. For bolt length, see VALVE
BODY BOLT IDENTIFICATION table. Tighten bolts to 97 INCH lbs. (11 N.m). Install NEW gasket
on oil strainer. Install oil strainer and tighten bolts to specification. See TORQUE SPECIFICATIONS.
VALVE BODY BOLT IDENTIFICATION

Bolt Identification Length - In. (mm)
A .98 (25)
B 1.61 (41)
C 1.77 (45)
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Fig. 92: Identifying Valve Body Bolt Locations

47. Connect 5 shift solenoid connectors. Install fluid temperature sensor, clamps and bolt. Tighten bolt to 58
INCH lbs. (6.6 N.m). See Fig. 9. Install 3 magnets into oil pan in original locations. Apply Three Bond
(2430) or equivalent to 18 oil pan bolt threads. Install NEW oil pan gasket, oil pan and bolts. Tighten
bolts to 67 INCH lbs. (7.6 N.m) within 10 minutes of installation.
48. Coat NEW "O" rings with ATF and install on speed sensors. Install input turbine and counter gear speed
sensors into top of transaxle case. Tighten bolts to 97 INCH lbs. (11 N.m). Install NEW "O" rings on oil
line union and elbow. Install oil line union and elbow into transaxle case. Tighten to 20 ft. lbs. (27 N.m).
See Fig. 6.
49. Coat NEW "O" ring with ATF and install on transaxle test plug. Install transaxle test plug into transaxle
case. See Fig. 8. Install park/neutral position switch onto manual valve lever shaft and temporarily install
2 adjusting bolts. See Fig. 7.
50. Install NEW lock tab and nut. Tighten nut to 61 INCH lbs. (6.9 N.m). Temporarily install control shift
lever. Turn lever counterclockwise until it stops, then turn it clockwise 2 notches. Remove control shift
lever. Align groove in park/neutral position switch to neutral basic line. Tighten 2 adjusting bolts to 48
INCH lbs. (5.4 N.m). Stake lock tab onto nut. Install control shift lever, washer and nut. Tighten nut to 10
ft. lbs. (13 N.m).
51. Remove any debris between transfer case and transaxle case contact surfaces. DO NOT allow oil to
contact surfaces. Coat NEW round gasket with petroleum jelly and install onto transfer case.
52. Install intermediate shaft into transfer case assembly. Apply Three Bond (1281) or equivalent gasket
sealant about .047" (1.20 mm) wide, to transfer case contact surface. Install transfer case by pushing
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straight up and into transaxle. Use care not to damage oil seal lip when installing transfer case. Install 2
bolts and 6 nuts and tighten to 51 ft. lbs. (69 N.m).
measuring distance from edge of transaxle housing. See Fig. 93. Distance should be .510" (12.95 mm) for
all models.
Fig. 93: Measuring Torque Converter Depth

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Fig. 94: Identifying Thrust Bearing & Race Locations

THRUST BEARING & RACE SPECIFICATIONS (1)

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Application Inner Diameter - In. (mm) Outer Diameter - In.

(mm)
A
Bearing 2.252 (57.20) 3.345 (84.96)
Rear 2.220 (56.40) 3.268 (83.00)
Race
B
Bearing 1.485 (37.73) 2.283 (58.00)
Rear 1.177 (29.90) 2.185 (55.50)
Race
C
Bearing 1.333 (33.85) 2.055 (52.20)
D
Bearing .925 (23.50) 1.732 (44.00)
E
Bearing 1.429 (36.30) 2.055 (52.20)
Rear 1.358 (34.50) 1.909 (48.50)
Race
F
Bearing 1.362 (34.60) 2.055 (52.20)
G
Front 1.587 (40.30) 2.283 (58.00)
Race
Bearing 1.520 (38.60) 2.362 (60.00)
Rear 1.520 (38.60) 2.283 (58.00)
Race
H
Bearing 2.110 (53.60) 2.740 (69.60)
I
Bearing 1.327 (33.70) 1.898 (48.20)
Rear 1.193 (30.30) 1.811 (46.00)
Race
J
Bearing 2.110 (53.60) 2.740 (69.60) Or 2.763
(70.18)
(1) Refer to illustration for component locations. See Fig. 94.
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Control Shift Lever Lock Tab Nut 10 (13)

Converter-To-Drive Plate Bolt 30 (41)
Counter Drive Gear Nut 207 (280)
Differential Ring Gear Bolt 70 (95)
Drive Plate Bolt 72 (98)
Elbow 20 (27)
Manual Detent Spring Bottom Bolt 15 (20)
Oil Pan Drain Plug 35 (47)
Oil Pump Bolt 16 (22)
Parking Lock Pawl Bracket Bolt 15 (20)
Transaxle Housing-To-Transaxle Case Bolt
Transaxle Rear Cover Bolt
Transfer Case-To-Transaxle Bolt/Nut 51 (69)
Underdrive Planetary Gear Lock Nut 207 (280)
Union 18 (25)
INCH Lbs. (N.m)
Apply Pipe Clamp Bolt
Transaxle Case 48 (5.4)
Transaxle Housing 87 (9.8)
Manual Detent Spring Top Bolt 89 (10)
Oil Deflector Bolt 87 (9.8)
Oil Pan Bolt 67 (7.6)
Oil Strainer Bolt 97 (11)
Parking Lock Pawl Clamp Bolt 87 (9.8)
Park/Neutral Position Switch
Nut 61 (6.9)
Bolt 48 (5.4)
Pressure Relief Check Ball Retainer Bolt 97 (11)
Rear Cover Plate Screws 66 (7.5)
Shift Solenoids
SLT & SL1 Solenoid Bolt 58 (6.6)
All Other Solenoid Bolts 97 (11)
Solenoid Connector Bolt 48 (5.4)
Speed Sensor Bolt 97 (11)
Stator Shaft-To-Oil Pump Bolt 87 (9.8)
Temperature Sensor Clamp Bolt 58 (6.6)
Transaxle Case Plug 65 (7.4)
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58 (6.6)
Upper & Lower Valve Body Bolt 97 (11)
Valve Body Bolt 97 (11)
Bushing Inside Diameter (Maximum)
Multiple Clutch Hub .909 (23.09)
Oil Pump Body 1.503 (38.18)
Oil Pump Stator Shaft .849 (21.57)
Underdrive Clutch Drum 1.462 (37.13)
Direct Clutch End Play .008-.037 (.20-.94)
Input Shaft End Play .010-.049 (.26-1.25)
Underdrive Planetary Gear Assembly End Play .020-.039 (.50-.99)
Oil Pump
Driven Gear-To-Body Clearance .0039-.0067 (.100-.170)
Driven Gear Tip-To-Cresent Clearance 0028-.0059 (.070-.150)
Gear Side Clearance .0008-.0020 (.020-.050)
Piston Stroke
Direct Clutch .024-.033 (.61-.83)
Forward Clutch .056-.069 (1.41-1.75)
Underdrive Brake .071-.087 (1.81-2.20)
Underdrive Clutch .059-.075 (1.51-1.90)
1st/Reverse Brake .040-.048 (1.02-1.21)
2nd Brake .024-.036 (.62-.91)
Side Gear Backlash .002-.008 (.05-.20)
Torque Converter Runout (Maximum)
Drive Plate .008 (.20)
Sleeve .012 (.30)
Torque Converter Installed Depth .510 (12.95)
CLUTCH DISC & PLATE QUANTITY

Component Discs Plates
Direct Clutch 3 3
Forward Clutch 4 4
Underdrive Brake 3 3
Underdrive Clutch 3 3
1st/Reverse Brake 5 5
2nd Brake 3 3
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2004 Toyota RAV4
2004 BRAKES Disc & Drum - RAV4
2004 BRAKES
Disc & Drum - RAV4
WARNING: For warnings and procedures regarding vehicles equipped with Anti-Lock
Brake Systems (ABS), see appropriate ANTI-LOCK article.
Hydraulic brake system uses a tandem master cylinder with a vacuum power assist servo. RAV4 is equipped
with front disc brakes standard. Rear disc brakes are standard equipment on US. models, and a set option with
VSC (Vehicle Skid Control) on Canadian models. VSC is standard equipment on US models, and optional
equipment on the Canadian models. A vehicle equipped with VSC comes with the following functions:
 ABS with EBD (Electronic Brake Force Distribution)

 Brake Assist
 TRAC (Traction Control) systems
Rear disc brakes are optional. Rear drum brakes are self-adjusting.
Parking brake lever mechanically activates rear brakes, and a cable applies rear shoes.
BLEEDING BRAKE SYSTEM

BRAKE BLEEDING SEQUENCE
For correct bleeding sequence, see BRAKELINE BLEEDING SEQUENCE table.
BRAKELINE BLEEDING SEQUENCE

Application Sequence
All Models Right Rear, Left Rear, Right Front, Left Front
BLEEDING PROCEDURES
CAUTION: DO NOT allow reservoir to run dry during brake bleeding procedure. Use
only clean brake fluid. Ensure no dirt or other foreign matter contaminates
brake fluid. DO NOT mix different types of brake fluid, as they may not be
compatible. DO NOT spill brake fluid on vehicle, as it may damage paint. If
brake fluid contacts paint, immediately wash with water.
1. If master cylinder is rebuilt or reservoir is empty, bleed master cylinder first. Bleed wheels in sequence.
Start on wheel with longest hydraulic line, and work toward wheel with shortest hydraulic line. See
BRAKE BLEEDING SEQUENCE table.
2. Raise and support vehicle. Ensure brake fluid reservoir is at least half full during bleeding procedure.
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2004 Toyota RAV4
Connect one end of transparent vinyl tube to bleeder screw. Submerge other end of tube in a container
half filled with clean brake fluid.
3. Have an assistant depress brake pedal several times and hold in depressed position. Loosen bleeder screw,
and drain fluid into container. Tighten bleeder screw.
NOTE: Ensure brake pedal remains depressed until bleeder screw is tightened.
4. Refill brake fluid reservoir as necessary. Repeat step 3 until air is no longer discharged. Tighten front
bleeder screw to 70 INCH lbs (8.0 N.m), and tighten rear bleeder screw to 74 INCH lbs. (8.3 N.m).
Ensure fluid leakage is not present. Add fluid to reservoir. Repeat procedure for remaining wheels.
ADJUSTMENTS
BRAKE PEDAL HEIGHT
1. Brake pedal height is measured from face of pedal pad to asphalt sheet under carpet. To adjust clearance,
loosen stoplight switch and lock nut on brake push rod. See Fig. 1.
2. Adjust pedal height by turning push rod. See BRAKE PEDAL SPECIFICATIONS table. After setting
pedal height, tighten lock nut on push rod. Adjust stoplight switch and tighten switch lock nut. See
STOPLIGHT SWITCH.
Fig. 1: Measuring Brake Pedal Height & Free Play

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2004 Toyota RAV4
BRAKE PEDAL SPECIFICATIONS

Application Free Play - In. (mm) Pedal Height - In. (mm)
RAV4 .04-.24 (1-6) 6.69-7.09 (170-180)
BRAKE PEDAL FREE PLAY
1. Brake pedal free play is distance brake pedal travels before feeling resistance with engine stopped. To
check pedal free play, depress brake pedal several times to exhaust vacuum from booster.
2. Depress pedal and measure travel until initial resistance is felt. See BRAKE PEDAL
SPECIFICATIONS table. If free play is not within specification, adjust by turning push rod. See Fig. 1.
BRAKE PEDAL RESERVE DISTANCE
1. Pedal reserve distance is measured from face of pedal pad to asphalt sheet under carpet with brakes
applied. Measure reserve distance with engine running and weight of 110 lbs. (50 kg) applied against
pedal.
2. If measured reserve distance is less than specification, inspect brake system. See BRAKE PEDAL
MINIMUM RESERVE DISTANCE SPECIFICATIONS table.
BRAKE PEDAL MINIMUM RESERVE DISTANCE SPECIFICATIONS

RAV4 4.65 (118)
PARKING BRAKE
NOTE: Rear brakes must be correctly adjusted before adjusting parking brake. For
RAV4 with rear drum brakes, see REAR BRAKE DRUM under REMOVAL &
INSTALLATION. For RAV4 with rear disc brakes, see PARKING BRAKE (REAR
DISC SYSTEM) under REMOVAL & INSTALLATION.
Lever Stroke Adjustment
1. To check parking brake adjustment, depress parking brake pedal with specified weight. Count number of
notches (clicks) until parking brake is fully applied. See PARKING BRAKE LEVER STROKE
SPECIFICATIONS table. Adjust parking brake if travel is not within specification.
PARKING BRAKE LEVER STROKE SPECIFICATIONS

Application Notches Weight Applied Lbs. (Kg)
RAV4 6-8 44 (20)
2. Remove rear console box. Loosen lock nut and turn adjusting nut until lever travel is correct. Tighten
lock nut. Install rear console box.
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2004 Toyota RAV4
POWER BRAKE UNIT PUSH ROD
For procedure, see Fig. 2.
Fig. 2: Adjusting Brake Booster Push Rod

REAR DRUM BRAKE SHOES
NOTE: All rear drum brakes have a self-adjuster which is activated when brake pedal is
applied with vehicle traveling in reverse.
To set initial lining-to-drum clearance, raise and support rear of vehicle. Release parking brake. Remove rear
wheels and brake drums. Measure brake drum inside diameter and brake lining diameter. Measured clearance
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between linings and braking surface of drum should be .024 in. (.60 mm). Turn brake adjuster to obtain
specified clearance. Install brake drum and wheel and adjust brakes (if necessary).
STOPLIGHT SWITCH
Remove lower instrument panel and air duct (if necessary). Loosen lock nuts. Turn switch until clearance
between threaded end of switch and pedal stop is .02-.09 in. (.5-2.4 mm). See Fig. 1. Check brake pedal height
and brake light operation.
TESTING
POWER BRAKE UNIT
Operational Check
Depress brake pedal several times with engine off. There should be no change in pedal reserve distance.
Depress brake pedal and start engine. If pedal goes down slightly, operation is normal.
Air Tightness Check
1. Start engine and run for 1-2 minutes, then turn engine off. Depress brake pedal several times slowly. If
pedal goes down farthest on first time, but gradually rises after second or third time, power brake unit is
airtight.
2. With engine stopped, depress brake pedal several times using normal pressure. Pedal should be low when
first depressed. On consecutive applications, pedal height should gradually rise. If pedal height does not
increase, check for air leaks.
PROPORTIONING VALVE (REAR DRUM BRAKE SYSTEM ONLY)
Attach and bleed pressure gauge set. Raise master cylinder pressure and check rear wheel pressure. See
PROPORTIONING VALVE PRESSURE SPECIFICATIONS table. When inspecting fluid pressure, check
left front and right rear together, then check right front and left rear together. If rear cylinder pressure is
incorrect, replace proportioning valve. Remove pressure gauge set. Bleed brake system and check for leaks.
PROPORTIONING VALVE PRESSURE SPECIFICATIONS

Application Master Cylinder Pressure - Rear Wheel Cylinder
psi (kg/cm2) Pressure - psi (kg/cm2)
Low Pressure Reading 497 (35) 497 (2-35)
High Pressure Reading 1138 (80) 749 (52)
TROUBLESHOOTING
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
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Fig. 3: Brakes Troubleshooting Table (1 Of 2)

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Fig. 4: Brakes Troubleshooting Table (2 Of 2)

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REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS
NOTE: Pushing piston into caliper bore will force fluid back into master cylinder
reservoir. Remove reservoir cap when compressing caliper piston.
1. Raise and support vehicle. Remove front wheel. Hold sliding pin on bottom and loosen installation bolt.
Remove installation bolt and rotate caliper upward. Suspend caliper aside with wire.
2. Remove pads, 4 anti-squeal shims, pad support plates and wear indicator See Fig. 5.
3. Seat pistons using a hammer handle or equivalent. Slide NEW pads and anti-rattle shims into caliper.
Check reservoir fluid level. To install, reverse removal procedure. Tighten lower caliper bolt to
specification. See TORQUE SPECIFICATIONS
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Fig. 5: Exploded View Of Front Brake Caliper Assembly

FRONT BRAKE CALIPER

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1. Raise vehicle and remove wheels. Disconnect flexible brake hose from caliper. Plug hose to prevent fluid
spillage. Remove caliper mounting bolts or slide pins as necessary.
2. Pivot caliper up to clear edge of disc. Slide caliper off main pin. To install, reverse removal procedure.
Install boot end in groove of main pin.
FRONT BRAKE DISC
Remove caliper. See FRONT BRAKE CALIPER. Remove 2 bolts securing torque plate. See Fig. 5. Remove
brake disc. To install, reverse removal procedure. Tighten bolts and nut to specifications. See TORQUE
SPECIFICATIONS.
PARKING BRAKE (REAR DISC SYSTEM)
Disassembly
For disassembly procedure, see Fig. 6 and Fig. 7 . For component view, see Fig. 8.
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Fig. 6: Rear Disc Brake Parking Brake Removal Procedure (1 Of 2)

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Fig. 7: Rear Disc Brake Parking Brake Removal Procedure (2 Of 2)

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Fig. 8: Rear Disc Brake System Parking Brake Components

Inspection
For inspection procedure, see Fig. 9.
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Fig. 9: Rear Disc Brake Parking Brake Inspection Procedure

Installation
For installation procedure, see Fig. 10. For parking brake lever adjustment procedure, see PARKING BRAKE.
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Fig. 10: Rear Disc Brake Parking Brake Reassembly Procedure

REAR BRAKE DRUM
Removal
Ensure parking brake is released. Raise and support vehicle. Remove wheel. Remove set screws from brake
drum (if equipped). Pull drum from axle flange. It may be necessary to loosen brake shoe adjuster before
removing drum.
Installation
Measure inside diameter of brake drum and diameter of brake shoes. Turn brake adjuster until difference
between diameters is .024 in. (.60 mm). Install brake drum and adjust brakes, if necessary.
REAR BRAKE SHOES
1. Remove brake drum. See REAR BRAKE DRUM. Disconnect return spring from both shoes. Remove
hold-down spring, cups and pin from front shoe. Disconnect anchor spring, and remove front shoe.
Remove anchor spring from rear shoe.
2. Remove rear shoe hold-down spring, cups and pin. Disconnect parking brake cable from brake lever.
Remove rear shoe with adjuster. See Fig. 11.
3. To install, reverse removal procedure. Apply lithium soap-base glycol grease and high-temperature grease
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to moving parts (DO NOT get grease on brake shoe linings or drum).
4. Check operation of automatic adjuster by moving parking brake lever of rear shoe back and forth, and
ensure that adjuster turns. Adjust parking brake-to-drum clearance to .024 in. (.60 mm). Bleed system and
check for leaks.
Fig. 11: Exploded View Of Rear Drum Brake Assembly

REAR WHEEL CYLINDER
With brake drum and shoes removed, disconnect hydraulic line from wheel cylinder. Remove 2 mounting bolts
and remove wheel cylinder. To install, reverse removal procedure. Adjust brakes and bleed system. See
BLEEDING BRAKE SYSTEM.
MASTER CYLINDER
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1. Disconnect fluid level warning switch connector. Remove fluid from master cylinder with syringe.
2. Disconnect brake lines and 3-way line connector from master cylinder. If equipped with M/T, disconnect
clutch reservoir hose. On all models, remove 2 bolts and master cylinder.
3. Prior to installation, adjust length of brake booster push rod if necessary. See POWER BRAKE UNIT
PUSH ROD under ADJUSTMENTS. If adjusting booster push rod, install new gasket before checking
adjustment.
4. Install master cylinder in reverse of removal procedure. Use NEW gasket. Fill and bleed system. Check
for leaks and adjust pedal, if needed. Bleed clutch system, if equipped.
POWER BRAKE UNIT
1. Remove master cylinder. See MASTER CYLINDER. Disconnect vacuum hose. Remove brake pedal
return spring, clip and clevis pin. Remove 4 nuts, clevis pin, brake booster and gasket.
2. Install power brake unit. Install NEW gasket to power brake unit. Install clevis to operating rod. Attach
clevis pin, clip and return spring. Adjust push rod length. See POWER BRAKE UNIT PUSH ROD
under ADJUSTMENTS.
3. Install master cylinder with NEW gasket. Connect vacuum hose. Fill master cylinder. Bleed system and
check for leaks. See BLEEDING BRAKE SYSTEM. Adjust brake pedal, if necessary.
REAR BRAKE DISC
1. Remove caliper assembly with brakeline connected, and support securely aside ensuring flexible brake
hose is not stressed. See REAR BRAKE CALIPER. Remove torque plate from backing plate.
2. Mark disc and hub for installation reference. Slide disc off hub assembly. Turn parking brake shoe
adjuster to release shoes from disc (as necessary) to remove disk. To install, reverse removal procedure.
Tighten bolts to specification. See TORQUE SPECIFICATIONS.
REAR BRAKE PADS
For procedure, see Fig. 12 and Fig. 13 . For component view, see Fig. 14.
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Fig. 12: Rear Disc Brake Pad Replacement Procedure (1 Of 2)

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Fig. 13: Rear Disc Brake Pad Replacement Procedure (2 Of 2)

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Fig. 14: Exploded View Of Rear Disc Brake Pad Components

REAR BRAKE CALIPER
For removal procedure, see Fig. 15. Install caliper in reverse of removal procedure. Fill and bleed system. See
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Fig. 15: Rear Disc Brake Caliper Removal Procedure

OVERHAUL
NOTE: When overhauling caliper, if piston bores are pitted or scored beyond repair
after light honing, replace entire assembly.
FRONT BRAKE CALIPER
NOTE: For overhaul of front brake calipers, see Fig. 5 and Fig. 16 . Install caliper
components in reverse of removal procedure. Fill and bleed system. See
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Fig. 16: Front Brake Caliper Overhaul Procedure

REAR BRAKE CALIPER
NOTE: For overhaul of rear brake calipers, see Fig. 17 and Fig. 18 . Install caliper
components in reverse of removal procedure. Fill and bleed system. See
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Fig. 17: Rear Brake Caliper Overhaul Procedure

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Fig. 18: Locating Rear Brake Caliper Components

REAR WHEEL CYLINDERS
NOTE: For overhaul of rear wheel cylinders, see Fig. 11 and Fig. 19 . Install wheel
cylinder components in reverse of removal procedure. Fill and bleed system.
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See BLEEDING BRAKE SYSTEM.
Fig. 19: Rear Wheel Cylinder Overhaul Procedure

MASTER CYLINDER
NOTE: For overhaul of master cylinder assembly, see Fig. 20-Fig. 23 . Install master
cylinder components in reverse of removal procedure. Fill and bleed system.
See BLEEDING BRAKE SYSTEM.
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Fig. 20: Exploded View Of Master Cylinder Assembly Except ABS Or VSC
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Fig. 21: Exploded View Of Brake Master Cylinder With ABS

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Fig. 22: Exploded View Of Brake Master Cylinder With VSC

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Fig. 23: Master Cylinder Overhaul Procedure

Application Ft. Lbs. (N.m.)
Front Brake Caliper Bolt 19 (26)
Front Brake Caliper Torque Plate Bolt 78 (106)
Front Brake Hose-To-Brake Caliper Bolt 22 (30)
Brake Pedal Pivot Bolt/Nut 29 (39)
Brake Pedal Push Rod Lock Nut 19 (26)
Brakeline-To-Master Cylinder Nut 11 (15)
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Brakeline-To-Wheel Cylinder Nut 11 (15)

Brakeline-To-Three-Union Nut 11 (15)
Rear Axle Hub Nut (4WD) 159 (216)
Rear Brake Caliper Mounting Bolt 33 (44)
Wheel Lug Nut 76 (103)
INCH Lbs. (N.m)
Bleeder Screw
Front Brake Caliper 71 (8)
Wheel Cylinder 73 (8.2)
Brake Booster Retaining Nut 115 (13)
Master Cylinder Mounting Nut 115 (13)
Master Cylinder Piston Stopper Bolt 89 (10.1)
Parking Brake Adjustment Lock Nut 48 (5.4)
Rear Speed Sensor Installation Bolt 71 (8)
Reservoir-To-Master Cylinder Set Screw 16 (1.8)
Wheel Cylinder Bolt 89 (10.1)
DISC & DRUM BRAKE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS
Front Disc
Original Disc Thickness .984 (25)
Minimum Refinish Thickness .906 (23)
Maximum Disc Runout .002 (.05)
Brake Pad Thickness
Standard Thickness .472 (12)
Minimum Thickness .039 (1.0)
Rear Disc
Original Disc Thickness .354 (9)
Minimum Refinish Thickness .317 (8)
Maximum Disc Runout .039 (1.0)
Brake Pad Thickness
Standard Thickness .394 (10)
Parking Brake Shoe Lining Thickness (1)
Standard Thickness .098 (2.5)
Rear Brake Drum Inside Diameter (2)
Standard 9.00 (228.6)
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Maximum 9.08 (230.6)

(1) This is brake lining for the parking brake on the inside of the rear disc.
(2) This is the drum for the parking brake on the inside of the rear disc.
DRUM BRAKE SPECIFICATIONS (1)

Rear Brake Drum
Brake Shoe-To-Drum Clearance .024 (.61)
Drum Diameter
Original Diameter 9.000 (228.60)
Maximum Diameter 9.080 (230.63)
Rear Brake Shoe Lining Thickness
Standard Thickness .197 (5.55)
Minimum .039 (1.00)
(1) With rear drum brakes.
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2004 TRANSMISSION Clutch -RAV4
2004 TRANSMISSION
Clutch -RAV4
TROUBLESHOOTING
Use Fig. 1 to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the
problem. Check each part in order. If necessary, replace these parts.
Fig. 1: Problem Symptoms Chart

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2004 Toyota RAV4
CLUTCH PEDAL
INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from dash panel:
169.0 to 179.0 mm (6.653 to 7.047 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT

a. Loosen the lock nut and turn the stopper bolt until the height becomes correct.
b. Tighten the lock nut.
3. CHECK PEDAL FREE PLAY AND PUSH ROD PLAY
a. Depress the pedal until clutch resistance begins to be felt.
Pedal free play: 5.0 to 15.0 mm (0.197 to 0.591 in.)
b. Gently push on the pedal until the resistance begins to increase a little.
Push rod play at pedal top:
1.0 to 5.0 mm (0.039 to 0.197 in.)
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Fig. 2: Adjusting Clutch Pedal Play

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4. IF NECESSARY, ADJUST PEDAL FREE PLAY AND PUSH ROD PLAY

a. Loosen the lock nut and turn the push rod until the free play and push rod play becomes correct.
b. Tighten the lock nut.
c. After adjusting the pedal free play, check the pedal height.
5. CHECK CLUTCH RELEASE POINT
a. Pull the parking brake lever and install the wheel stopper.
b. Start and idle the engine.
c. Without depressing the clutch pedal, slowly shift the shift lever into reverse position until the gears
contact.
d. Gradually depress the clutch pedal and measure the stroke distance from the point the gear noise
stops (release point) to the pedal stroke end position.
Standard distance: 25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
Fig. 3: Checking Clutch Pedal Release Point

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If the distance is not as specified, perform the following operations:
Inspect pedal height.


 Inspect push rod play and pedal free play.
 Bleed the clutch line.
 Inspect the clutch cover and disc.
6. CHECK CLUTCH START SYSTEM

a. Check that the engine does not start when the clutch pedal is released.
b. Check that the engine starts when the clutch pedal is fully depressed.
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Fig. 4: Checking Clutch Start System

If necessary, replace the clutch start switch.

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7. INSPECT CLUTCH START SWITCH CONTINUITY
Check the resistance between terminals when the switch is ON and OFF.
Fig. 5: Checking Resistance Of Clutch Start Switch

START SWITCH CONTINUITY

Switch position Condition
ON (pushed) Below 1 ohm
OFF (free) 10 kohm or higher
CLUTCH MASTER CYLINDER

COMPONENTS
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Fig. 6: Exploded View Of Clutch Master Cylinder Components (1 Of 2)

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Fig. 7: Exploded View Of Clutch Master Cylinder Components (2 Of 2)

REMOVAL
1. REMOVE WIPER ASSEMBLY (See REMOVAL )

2. DISCONNECT RESERVOIR HOSE
a. Using pliers, disconnect the clip.
b. Disconnect the reservoir hose from the inlet union.
c. Use a container to catch the fluid.
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Fig. 8: Disconnecting Clip And Reservoir Hose

3. DISCONNECT CLUTCH LINE

a. Using SST, disconnect the clutch line.
SST 09023-00100
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Fig. 9: Disconnecting Clutch Line

b. Use a container to catch the fluid.

4. REMOVE CLIP AND PIN
Using needle-nose pliers, remove the clip and pin.
5. REMOVE CLUTCH MASTER CYLINDER

a. Remove the 2 nuts.
b. Pull out the master cylinder.
c. Remove the gasket, pedal stay bracket and master cylinder bracket from the master cylinder.
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Fig. 10: Removing 2 Nuts & Master Cylinder

DISASSEMBLY
1. REMOVE INLET UNION

a. Using a pin punch and a hammer, tap out the slotted spring pin.
b. Remove the inlet union.
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Fig. 11: Removing Inlet Union

c. Remove the grommet from the inlet union.

2. REMOVE CLEVIS
Loosen the lock nut, and remove the clevis and lock nut.
3. REMOVE PUSH ROD

a. Remove the boot.
b. Using snap ring pliers, remove the snap ring while pushing the push rod.
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Fig. 12: Removing Push Rod Using Snap Ring Pliers

c. Pull out the push rod and washer.

4. REMOVE PISTON WITH SPRING FROM CYLINDER
REASSEMBLY
1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN
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Fig. 13: Coating Parts With Lithium Soap Base Glycol Grease
2. INSERT PISTON WITH SPRING INTO CYLINDER

3. INSTALL PUSH ROD
a. Install the washer to the push rod.
b. Push the push rod into the piston.
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Fig. 14: Installing Push Rod

c. Using snap ring pliers, install the snap ring.

4. INSTALL BOOT TO CYLINDER
5. TEMPORARILY INSTALL LOCK NUT AND CLEVIS
6. INSTALL INLET UNION
a. Install a new grommet and inlet union to the cylinder body.
b. Using a pin punch and a hammer, tap in the slotted spring pin.
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Fig. 15: Installing Slotted Spring Pin

INSTALLATION
1. INSTALL CLUTCH MASTER CYLINDER

a. Install the gasket, pedal stay bracket and master cylinder bracket to the master cylinder.
b. Install the master cylinder with the 2 nuts.
Torque: 12 N.m (120 kgf.cm, 9 ft.lbf)
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Fig. 16: Installing Master Cylinder With 2 Nuts

c. Connect the push rod to the clutch pedal with the pin and pin clip.
2. CONNECT CLUTCH LINE
Using SST, connect the clutch line.
SST 09023-00100
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Fig. 17: Connecting Clutch Line

Torque:
15 N.m (155 kgf.cm, 11 ft.lbf)
14 N.m (143 kgf.cm, 10 ft.lbf) for use with SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
3. CONNECT RESERVOIR HOSE

a. Connect the reservoir hose to the inlet union.
NOTE: Facing the mark upwards.

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b. Using pliers, connect the clip.
Fig. 18: Connecting Reservoir Hose And Clip

4. INSTALL WIPER ASSEMBLY (See INSTALLATION )

5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEM (See
BLEEDING BRAKE SYSTEM )
6. ADJUST CLUTCH PEDAL (See INSPECTION )
7. CHECK FOR LEAKS
CLUTCH RELEASE CYLINDER

COMPONENTS
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Fig. 19: Exploded View Of Clutch Release Cylinder Components

REMOVAL
1. DISCONNECT CLUTCH LINE FROM RELEASE CYLINDER

a. Remove the 2 bolts and release cylinder heat insulator.
b. Using SST, disconnect the clutch line from the release cylinder.
SST 09023-00100
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Fig. 20: Disconnecting Clutch Line Using SST

c. Use a container to catch the fluid.

2. REMOVE RELEASE CYLINDER
Remove the 2 bolts and release cylinder.
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Fig. 21: Removing Release Cylinder With 2 Bolts

DISASSEMBLY
1. REMOVE BOOT AND PUSH ROD

a. Pull out the boot with the push rod.
b. Remove the boot from the push rod.
2. REMOVE PISTON AND SPRING
Using compressed air, remove the piston with the spring from the cylinder.
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Fig. 22: Removing Piston And Spring Using Compressed Air

NOTE:  Blowing off the air may cause the piston's jump-out. When removing
the piston, hold it with your hand using a waste cloth.
 Take care not to splash brake fluid when air-blowing.
REASSEMBLY
1. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN
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Fig. 23: Coating Piston With Lithium Soap Base Glycol Grease
2. INSTALL PISTON AND SPRING INTO CYLINDER

3. INSTALL BOOT AND PUSH ROD
a. Install the push rod to the boot.
b. Install the boot with the push rod to the cylinder.
INSTALLATION
1. INSTALL RELEASE CYLINDER

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Install the release cylinder with the 2 bolts.
Fig. 24: Installing Release Cylinder With 2 Bolts

2. CONNECT CLUTCH LINE TO RELEASE CYLINDER

a. Using SST, connect the clutch line to the release cylinder.
SST 09023-00100
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Fig. 25: Connecting Clutch Line To Release Cylinder Using SST

Torque:
14 N.m (143 kgf.cm, 10 ft.lbf) for use with SST
15 N.m (155 kgf.cm, 11 ft.lbf)
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
b. Install the 2 bolts and release cylinder heat insulator.
3. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEM (See
BLEEDING BRAKE SYSTEM )
4. CHECK FOR LEAKS
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CLUTCH UNIT
COMPONENTS
Fig. 26: Exploded View Of Clutch Unit Components

REMOVAL
1. REMOVE TRANSAXLE FROM ENGINE
2WD: See REMOVAL
4WD: See REMOVAL
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2. REMOVE CLUTCH COVER AND DISC

a. Align the matchmarks on the clutch cover with the one on the flywheel.
Fig. 27: Aligning Matchmark On Clutch Cover With One On Flywheel

b. Loosen each set bolt one turn at a time until spring tension is released.
c. Remove the set bolts, and pull off the clutch cover with the clutch disc.
NOTE: Do not drop the clutch disc.
3. REMOVE RELEASE BEARING AND FORK FROM TRANSAXLE
Remove the release bearing with the fork together and then separate them.
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Fig. 28: Removing Release Bearing And Fork

4. REMOVE RELEASE FORK SUPPORT AND BOOT
INSPECTION
1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using vernier calipers, measure the rivet head depth.
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Fig. 29: Measuring Rivet Head Depth With Using Vernier Caliper
Minimum rivet depth: 0.3 mm (0.012 in.)
If necessary, replace the clutch disc.
2. INSPECT CLUTCH DISC RUNOUT
Using a dial indicator, check the disc runout.
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Fig. 30: Checking Disc Runout Using Dial Indicator

Maximum runout: 0.8 mm (0.031 in.)
If necessary, replace the clutch disc.
3. INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout.
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2004 Toyota RAV4
Fig. 31: Checking Flywheel Runout Using Dial Indicator

If necessary, replace the flywheel.
Install the 8 mounting bolts in several passes, in the sequence shown.
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Fig. 32: Tightening 8 Mounting Bolts In Sequence

Torque: 130 N.m (1,325 kgf.cm, 96 ft.lbf)
4. INSPECT DIAPHRAGM SPRING FOR WEAR
Using vernier calipers, measure the diaphragm spring for depth and width of wear.
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Fig. 33: Inspecting Diaphragm Spring Using Vernier Caliper

Maximum:
Depth (A): 0.5 mm (0.020 in.)
Width (B): 6.0 mm (0.236 in.)
If necessary, replace the clutch cover.
5. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direction.
HINT:
The bearing is permanently lubricated and requires no cleaning or lubrication.
If necessary, replace the release bearing.
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2004 Toyota RAV4
Fig. 34: Inspecting Release Bearing

INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON FLYWHEEL

a. Insert SST in the clutch disc, then insert them in the flywheel.
SST 09301-00210
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2004 Toyota RAV4
Fig. 35: Inserting SST In Clutch Disc & Insert In Flywheel

HINT:
Take care not to insert clutch disc in the wrong direction.
b. Align the matchmarks on the clutch cover and flywheel.

c. Following the procedures shown in Fig. 36 , tighten the 6 bolts in the order starting the bolt
locating near the knock pin on the top.
HINT:
 Following the order in Fig. 36 , tighten the bolts at a time evenly.
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Fig. 36: Tightening Bolts

Move SST up and down, right and left lightly, after checking that the disc is in the center, tighten

the bolts.
2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the diaphragm spring tip alignment.
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2004 Toyota RAV4
Fig. 37: Checking Diaphragm Spring Tip Alignment Using Dial Indicator
Maximum non-alignment: 0.5 mm (0.020 in.)
If alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.
SST 09333-00013
3. INSTALL BOOT AND RELEASE FORK SUPPORT TO TRANSAXLE
4. APPLY RELEASE HUB GREASE
Apply release hub grease to the release fork and hub contact, release fork and push rod contact and
release fork pivot points.
Sealant:
Part No. 08887-01806, RELEASE HUB GREASE or equivalent

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2004 Toyota RAV4
5. APPLY CLUTCH SPRING GREASE
Apply clutch spline grease to the input shaft spline.
Sealant:
Part No. 08887-01706, CLUTCH SPLINE GREASE or equivalent
Fig. 38: Applying Grease To Release Hub & Clutch Spring

6. INSTALL RELEASE BEARING AND FORK TO TRANSAXLE
Install the bearing to the release fork, and then install them to the transaxle.
7. INSTALL TRANSAXLE TO ENGINE
2WD: See INSTALLATION
4WD: See INSTALLATION
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2004 ENGINE Cooling - RAV4
2004 ENGINE
Cooling - RAV4
COOLANT
INSPECTION
1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR
The engine coolant level should be between the "LOW" and "FULL" lines, when the engine is cold. If
low, check for leaks and add "Toyota Super Long Life Coolant" or similar high quality ethylene glycol
based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid
technology up to the "FULL" line. Do not use plain water alone.
2. CHECK ENGINE COOLANT QUALITY

a. Remove the radiator cap from the water outlet.
CAUTION: To avoid the danger of being burned, do not remove the radiator
cap while the engine and radiator are still hot, as fluid and
steam can be blown out under pressure.
b. There should not be any excessive deposits of rust or scale around the radiator cap or water outlet
filler hole, and the coolant should be free from oil.
If excessively dirty, clean the coolant passages and replace the coolant.
c. Reinstall the radiator cap.
REPLACEMENT
CAUTION: To avoid the danger of being burned, do not remove the radiator cap while
the engine and radiator are still hot, as fluid and steam can be blown out
under pressure.
1. DRAIN ENGINE COOLANT

a. Remove the radiator cap.
b. Loosen the radiator drain plug (on the left side of the radiator lower tank) and engine drain plug,
and drain the coolant.
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Fig. 1: Locating Radiator Drain Plug And Engine Drain Plug

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2004 Toyota RAV4
c. Close the drain plugs.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf) for engine
2. FILL ENGINE COOLANT

a. Slowly fill the system with coolant.
 Use of improper coolants may damage engine cooling system.
 Only use "Toyota Super Long Life Coolant" or similar high quality ethylene gltcol based
non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic
acid technology.
 New Toyota vehicles are filled with Toyota Super Long Life Coolant. When replacing the
coolant, Toyota Super Long Life Coolant is recommended.
 Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses
several times by hand. If the coolant level goes down, add the coolant.
NOTE:  Do not use an alcohol type coolant or plain water alone.

 The coolant should be mixed with plain water (preferably
demineralized water or distilled water).
Capacity (W/ Heater):
COOLANT CAPACITY
M/T 6.6 liters (7.0 US qts, 5.8 lmp. qts)
A/T 6.8 liters (7.2 US qts, 6.0 lmp. qts)
b. Reinstall the radiator cap.

c. Start the engine, and bleed the cooling system.
d. Refill the radiator reservoir with coolant until it reaches the "FULL" line.
3. CHECK ENGINE COOLANT FOR LEAKS
4. CHECK ENGINE COOLANT SPECIFIC GRAVITY CORRECTLY
WATER PUMP
ON-VEHICLE INSPECTION
NOTE: Be sure to do checking when the engine coolant is charged.
INSPECT WATER PUMP
a. Remove the drive belt (See ON-VEHICLE TESTING ).

b. Turn the pulley, and check that the water pump bearing moves smoothly and quietly.
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Fig. 2: Turning Water Pump Pulley

If necessary, replace the water pump.
c. Remove the water pump pulley (see REMOVAL ).

d. Visually check the inlet hole and drain hole for coolant leakage.
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2004 Toyota RAV4
Fig. 3: Inspecting Inlet Hole And Drain Hole For Coolant Leakage
If leakage is found, replace the water pump.
e. Reinstall the water pump pulley (see INSTALLATION ).

f. Reinstall the drive belt (See ON-VEHICLE TESTING ).
COMPONENTS
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Fig. 4: Identifying Water Pump Components

REMOVAL
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1. DRAIN ENGINE COOLANT (See REPLACEMENT )

2. REMOVE DRIVE BELT (See ON-VEHICLE TESTING )
3. REMOVE WATER PUMP
a. Using SST, remove the 4 bolts and pump pulley.
SST 09960-10010 (09962-01000, 09963-00600)
Fig. 5: Removing Water Pump Pulley & Bolts

b. Disconnect the crankshaft position sensor wire clamp from the water pump.
c. Disconnect the crankshaft position sensor wire from the clamp on the water pump.
d. Remove the 4 bolts, 2 nuts, wire clamp and water pump.
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Fig. 6: Removing Water Pump, Bolts And Nuts

e. Using a screwdriver, pry between the water pump and cylinder block, and remove the water pump.
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Fig. 7: Inserting Screwdriver Between Water Pump And Cylinder Block

NOTE: Be careful not to damage the contact surface of the water pump and
cylinder block.
INSTALLATION
1. INSTALL WATER PUMP

a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contacting
surfaces of the water pump and cylinder block.
 Using a razor blade and gasket scraper, remove all the old packing (FIPG) materials from the
gasket surfaces and sealing grooves.
 Thoroughly clean all components to remove all the loose material.
 Using a non-residue solvent, clean both sealing surfaces.
b. Apply seal packing to the water pump as shown in Fig. 8 .
Seal packing: Part No. 08826-00100 or equivalent
 Install a nozzle that has been cut to a 2.2 to 2.5 mm (0.09 to 0.10 in.) opening.
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2004 Toyota RAV4
 Parts must be assembled within 5 minutes of application. Otherwise the material must be
removed and reapplied.
 Immediately remove nozzle from the tube and reinstall cap.
Fig. 8: Applying Seal Packing To Water Pump

c. Install the water pump and wire clamp with the 4 bolts and 2 nuts.
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Fig. 9: Installing Water Pump & Wire Clamp With 4 Bolts & 2 Nuts
Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
d. Install the crankshaft position sensor wire harness clamp to the water pump.
e. Install the crankshaft position sensor wire to the wire clamp on the water pump.
f. Using SST, install the pump pulley with the 4 bolts.
SST 09960-10010 (09962-01000, 09963-00600)
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Fig. 10: Installing Water Pump Pulley & Bolts

2. INSTALL DRIVE BELT (See ON-VEHICLE TESTING )

3. FILL WITH ENGINE COOLANT
4. START ENGINE AND CHECK FOR COOLANT LEAKS
5. RECHECK ENGINE COOLANT LEVEL
THERMOSTAT
COMPONENTS
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2004 Toyota RAV4
Fig. 11: Thermostat Components

REMOVAL
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2004 Toyota RAV4
HINT:
Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not
remove the thermostat, even if the engine tends to overheat.

2. REMOVE DRIVE BELT (See ON-VEHICLE TESTING )
3. REMOVE GENERATOR (See GENERATOR )
4. REMOVE WATER INLET AND THERMOSTAT
a. Remove the 2 nuts and water inlet.
b. Remove the thermostat.
c. Remove the gasket from the thermostat.
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Fig. 12: Removing Water Inlet And Thermostat

INSPECTION
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INSPECT THERMOSTAT
HINT:
The thermostat is numbered with the valve opening temperature.
Fig. 13: Identifying Thermostat Opening Temperature Number

a. Immerse the thermostat in water and gradually heat the water.
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2004 Toyota RAV4
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2004 Toyota RAV4
Fig. 14: Immersing Thermostat In Water

b. Check the valve opening temperature.
Valve opening temperature: 80 to 84°C (176 to 183.2°F)
If the valve opening temperature is not as specified, replace the thermostat.
c. Check the valve lift.
Valve lift: 10 mm (0.39 in.) or more at 95°C (203°F)
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Fig. 15: Inspecting Valve Lift

If the valve lift is not as specified, replace the thermostat.
d. Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)).
If not closed, replace the thermostat.
INSTALLATION
1. PLACE THERMOSTAT IN CYLINDER BLOCK

a. Install a new gasket to the thermostat.
b. Install the thermostat with the jiggle valve upward.
HINT:
The jiggle valve may be set within 10° of either side of the prescribed position.
Fig. 16: Installing Thermostat With Jiggle Valve Upward

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2004 Toyota RAV4
2. INSTALL WATER INLET
Install the water inlet with the 2 nuts.
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2004 Toyota RAV4
Fig. 17: Installing Water Inlet

3. INSTALL GENERATOR (See GENERATOR )

4. INSTALL DRIVE BELT (See ON-VEHICLE TESTING )
5. FILL WITH ENGINE COOLANT (See REPLACEMENT )
6. START ENGINE AND CHECK FOR LEAKS
7. RECHECK ENGINE COOLANT LEVEL
RADIATOR
ON-VEHICLE CLEANING
INSPECT FINS FOR BLOCKAGE
If fins are clogged, wash them with water or a steam cleaner and dry with compressed air.
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Fig. 18: Inspecting Radiator Fins For Blockage

NOTE:  If the distance between the steam cleaner and the core is too close, there
is a possibility of damaging the fin, so keep the following injection
distance.
INJECTION PRESSURE AND DISTANCE SPECIFICATIONS

Injection Pressure Injection Distance
2
2,942 to 4,903 kPa (30 to 80 kgf.cm , 300 mm (11.811 in.)
427 to 711 psi)
4,903 to 7,845 kPa (50 to 80 kgf.cm2 , 500 mm (19.685 in.)
711 to 1,138 psi)
 If the fins are bent, straighten them with a screwdriver or pliers.

 Never apply water directly onto the electronic components.
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1. REMOVE RADIATOR CAP
CAUTION: To avoid the danger of being burned, do not remove the radiator cap
while the engine and radiator are still hot, as fluid and steam can be
blown out under pressure.
2. INSPECT RADIATOR CAP
NOTE:  If the radiator cap has contaminations, always rinse it with water.
 Before using a radiator cap tester, wet the relief valve and pressure
valve with engine coolant or water.
 When performing steps (a) and (b) below, keep the radiator cap tester
at an angle of over 30° above the horizontal.
a. Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum
valve.
Pump speed: 1 push/ (3 seconds or more)
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Fig. 19: Testing Radiator Cap

NOTE: Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator cap.
b. Pump the tester and measure the relief valve opening pressure.
Pump speed: 1 push within 1 second
NOTE: This pump speed is for the first pump only (in order to close the
vacuum valve). After this, the pump speed can be reduced.
Standard opening pressure:
93 to 123 kPa (0.95 to 1.25 kgf/cm2 ,13.5 to 17.8 psi)
Minimum opening pressure:
78 kPa (0.8 kgf/cm2 ,11.4 psi)
HINT:
Use the tester's maximum reading as the opening pressure. If the opening pressure is less than
minimum, replace the radiator cap.
3. INSPECT COOLING SYSTEM FOR LEAKS

a. Fill the radiator with coolant and attach a radiator cap tester.
b. Warm up the engine.
c. Pump it to 118 kPa (1.2 kgf/cm2 ,17.1 psi), and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are
found, check the heater core, cylinder block and head.
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Fig. 20: Inspecting Cooling System For Leaks

4. REINSTALL RADIATOR CAP
COMPONENTS
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Fig. 21: Radiator Components (1 Of 2)

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Fig. 22: Radiator Components (2 Of 2)

REMOVAL

2. REMOVE RADIATOR GRILLE
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2004 Toyota RAV4
Remove the 4 screws, 2 clips and radiator grille.
Fig. 23: Removing Radiator Grille

3. REMOVE FRONT END PANEL
Remove the 4 screws and front end panel.
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Fig. 24: Removing Front End Panel

4. DISCONNECT HOOD LOCK

a. Remove the 3 bolts, and disconnect the hood lock.
b. Disconnect the wire from the clamp.
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Fig. 25: Disconnecting Hood Lock

5. DISCONNECT UPPER RADIATOR HOSE

6. REMOVE UPPER RADIATOR SUPPORT
Remove the 5 bolts and radiator support.
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Fig. 26: Removing Upper Radiator Support

7. REMOVE LH ENGINE UNDER COVER

8. REMOVE RADIATOR RESERVOIR
9. REMOVE NO. 1 AND NO. 2 COOLING FANS (See ELECTRIC COOLING FANS )
10. A/T: DISCONNECT OIL 2 HOSES
Disconnect the 2 oil cooler hoses from the radiator.
11. DISCONNECT LOWER RADIATOR HOSE

12. REMOVE RADIATOR
13. REMOVE UPPER AND LOWER RADIATOR SUPPORTS FROM RADIATOR
DISASSEMBLY
1. REMOVE DRAIN PLUG

a. Remove the drain plug.
b. Remove the O-ring.
2. ASSEMBLE SST
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SST 09230-01010
a. Install the claw to the overhaul handle, inserting it in the hole in part "A" as shown in Fig. 27 .
Fig. 27: Installing Claw To Overhaul Handle

b. While gripping the handle, adjust the stopper bolt so that dimension "B" is as shown in Fig. 27 .
Dimension: 0.2 to 0.3 mm (0.008 to 0.012 in.)
NOTE: If the stopper bolt is not adjusted, the claw may be damaged.
3. UNCAULK LOCK PLATES
Using SST to release the caulking, grip the handle until stopped by the stopper bolt.
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Fig. 28: Releasing Caulking

SST 09230-01010
4. REMOVE TANKS AND O-RINGS

a. Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a soft-faced hammer,
and remove the tank.
b. Remove the O-ring.
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Fig. 29: Removing Tanks And O-Rings

5. A/T: REMOVE OIL COOLER PIPES FROM LOWER TANK

a. Remove the 2 cooler pipes
b. Loosen the 2 nuts, and remove the 2 pipes.
c. Remove the 2 nuts.
d. Remove the 2 O-rings from the oil cooler.
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2004 Toyota RAV4
Fig. 30: Removing Oil Cooler Pipes From Lower Tank

REASSEMBLY
1. A/T: INSTALL OIL COOLER PIPES TO LOWER TANK

a. Install 2 new O-rings to the oil cooler.
b. Install the 2 nuts.
c. Install the LH cooler pipe in the direction indicated in Fig. 31 .
Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf)
d. Install the RH cooler pipe.
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Fig. 31: Installing Oil Cooler Pipes To Lower Tank

2. INSPECT LOCK PLATE FOR DAMAGE
HINT:
 If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible.
Therefore, first correct any deformation with pliers or similar object.
 Water leakage will result if the bottom of the lock plate groove is damaged or dented. Repair or
replace if necessary.
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Fig. 32: Inspecting Lock Plate For Damage

NOTE: The radiator can only be recaulked 2 times. After the 2nd time, the
radiator core must be replaced.
3. INSTALL NEW O-RINGS AND TANKS

a. After checking that there are no foreign objects in the lock plate groove, install a new O-ring
without twisting it.
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Fig. 33: Identifying O-Ring Conditions

HINT:
When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.
b. Install the tank without damaging the O-ring.

c. Tap the lock plate with a soft-faced hammer so that there is no gap between the lock plate and the
tank.
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Fig. 34: Correct Way Of Tank Installation

4. ASSEMBLE SST
SST 09230-01010, 09231-14010
a. Install the punch assembly to the overhaul handle, inserting it in the hole in part "A" as shown in
Fig. 35 .
b. While gripping the handle, adjust the stopper bolt so that dimension "B" is as shown in Fig. 35 .
Dimension: 8.4 mm (0.331 in)
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2004 Toyota RAV4
Fig. 35: Installing Punch Assembly To Overhaul Handle

5. CAULK LOCK PLATE

a. Lightly press SST against the lock plate in the order shown in Fig. 36 . After repeating this a few
times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate.
SST 09230-01010
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Fig. 36: Pressing Order Of Lock Plate

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HINT:
 Do not tap the areas protruding around the pipes, brackets or tank ribs.
Fig. 37: Avoiding Tapping Areas Protruding Around Pipes, Brackets Or Tank Ribs
 The points shown in Fig. 38 and oil cooler near here (A/T) cannot be tapped with the SST.
Use pliers or similar objects and be careful not to damage the core plates.
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Fig. 38: Avoiding Tapping Points With SST

b. Check the lock plate height (H) after completing the caulking.
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Fig. 39: Checking Lock Plate Height

Plate height (H): 8.45 to 8.85 mm (0.3327 to 0.3484 in.)
If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
6. INSTALL DRAIN PLUG

a. Install a new O-ring to the drain plug.
b. Install the drain plug.
7. INSPECT FOR WATER LEAKS
a. Tighten the drain plug.
b. Plug the inlet and outlet pipes of the radiator with SST.
SST 09230-01010
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Fig. 40: Plugging Inlet & Outlet Pipes Of Radiator With SST
c. Using a radiator cap tester, apply pressure to the radiator.
Test pressure: 177 kPa (1.8 kgf/cm2 , 26 psi)
d. Submerge the radiator in water.

e. Inspect for leaks.
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Fig. 41: Identifying Air Leaks Between Tank And Lock Plate
HINT:
On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute
amount of air will remain, giving the appearance of an air leak when the radiator is submerged in
water. Therefore, before doing the water leak test, first swish the radiator around in the water until
all air bubbles disappear.
INSTALLATION
1. INSTALL UPPER AND LOWER RADIATOR SUPPORTS TO RADIATOR

2. INSTALL RADIATOR
3. CONNECT LOWER RADIATOR HOSE
4. A/T: CONNECT 2 HOSES
Connect the 2 oil cooler hoses to the radiator.
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5. INSTALL NO. 1 AND NO. 2 COOLING FANS (See ELECTRIC COOLING FANS )
6. INSTALL RADIATOR RESERVOIR
7. INSTALL RH ENGINE UNDER COVER
8. INSTALL UPPER RADIATOR SUPPORT
Install the radiator upper support with the 5 bolts.
Fig. 42: Installing Upper Radiator Support

9. CONNECT UPPER RADIATOR HOSE

10. CONNECT HOOD LOCK
a. Install the hood lock with the 3 bolts.
b. Install the wire from the clamps.
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Fig. 43: Installing Hood Lock

11. INSTALL FRONT END PANEL
Install the front end panel with the 4 screws.
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Fig. 44: Installing Front End Panel

12. INSTALL RADIATOR GRILLE
Install the radiator grille with the 4 screws and 2 clips.
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Fig. 45: Installing Radiator Grille


14. START ENGINE AND CHECK FOR COOLANT LEAKS
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2004 TOYOTA
RAV4
BUZZERS, RELAYS & TIMERS

BUZZERS, RELAYS & TIMERS LOCATION
Component Location
ABS MTR CUT Relay In ABS R/B. See Fig. 20 .
ABS MTR Relay In ABS R/B. See Fig. 20 .
C/OPN Relay In engine room J/B. See Fig. 21 .
DEF Relay In driver side J/B. See Fig. 22 .
EDU Relay In engine room J/B. See Fig. 21 .
EFI MAIN Relay In engine room J/B. See Fig. 21 .
FAN NO. 1 Relay In engine room J/B. See Fig. 21 .
FR FOG Relay In driver side J/B. See Fig. 22 .
H-LP Relay In engine room R/B. See Fig. 19 .
HORN Relay In driver side J/B. See Fig. 22 .
HTR Relay In engine room J/B. See Fig. 21 .
IG2 Relay In engine room J/B. See Fig. 21 .
Moon Roof Control SW & Relay At center front of roof. See Fig. 18 .
POWER Relay In driver side J/B. See Fig. 22 .
PWR OUTLET Relay In driver side J/B. See Fig. 22 .
Rear Wiper Motor & Relay On back door. See Fig. 18 .
ST Relay In engine room R/B. See Fig. 19 .
Taillight Relay Behind left side of dash. See Fig. 17 .
Turn Signal Flasher Relay Behind left side of dash. See Fig. 17 .
VSC Warning Buzzer Behind left end of dash. See Fig. 4 .
Wireless Door Lock Buzzer At left front of engine compartment. See Fig. 2 .
CIRCUIT PROTECTION DEVICES

CIRCUIT PROTECTION DEVICES LOCATION
Component Location
ABS R/B At left side of engine compartment. See Fig. 16 .
Driver Side J/B Behind left side of dash. See Fig. 17 .
Engine Room J/B At left side of engine compartment. See Fig. 16 .
Engine Room R/B At left side of engine compartment. See Fig. 16 .
In engine compartment, on right side of firewall.
Fusible Link Block
See Fig. 16 .
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2004 TOYOTA RAV4
Passenger Side J/B Behind right side of dash. See Fig. 17 .
CONTROL UNITS
CONTROL UNITS LOCATION
Component Location
ABS Actuator & ECU At right side of engine compartment. See Fig. 16 .
Center Air Bag Sensor Assembly Below front of center floor console. See Fig. 3 .
Engine Control Module Behind right side of dash. See Fig. 17 .
Passenger Side J/B ECU On passenger side J/B. See Fig. 17 .
Below center floor console, near base of shift lever.
Shift Lock ECU
See Fig. 17 .
Skid Control With Actuator At right side of engine compartment. See Fig. 16 .
Wireless Door Control Receiver At left rear side of cargo area. See Fig. 18 .
MOTORS
MOTORS LOCATION
Component Location
A/C Condenser Fan Motor Behind left side of radiator. See Fig. 1 .
Air Inlet Control Servo Motor Behind right side of dash. See Fig. 3 .
Back Door Lock Motor At lower left side of back door. See Fig. 5 .
Blower Motor Behind right side of dash. See Fig. 3 .
Door Lock Motor (Left Front) At rear of left front door. See Fig. 5 .
Door Lock Motor Rear LH At rear of left rear door. See Fig. 5 .
Door Lock Motor Rear RH At rear of right rear door. See Fig. 5 .
Door Lock Motor (Right Front) At rear of right front door. See Fig. 5 .
At right front corner of engine compartment. See
Front Washer Motor
Fig. 1 .
Front Wiper Motor On left side of firewall. See Fig. 1 .
Fuel Pump & Sender Under center rear of vehicle. See Fig. 5 .
Moon Roof Motor & Limit SW At center front of roof. See Fig. 5 .
Power Window Motor Front LH At center of left front door. See Fig. 6 .
Power Window Motor Front RH At center of right front door. See Fig. 6 .
Power Window Motor Rear LH At center of left rear door. See Fig. 6 .
Power Window Motor Rear RH At center of right rear door. See Fig. 6 .
Radiator Fan Motor Behind left side of radiator. See Fig. 2 .
Rear Washer Motor
Fig. 2 .
Rear Wiper Motor & Relay At center of back door. See Fig. 6 .
Remote Control Mirror LH At mirror. See Fig. 6 .
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2004 TOYOTA RAV4
Remote Control Mirror RH At mirror. See Fig. 6 .

Starter At left rear of engine. See Fig. 2 .
SENDING UNITS & SENSORS

SENDING UNITS & SENSORS LOCATION
Component Location
ABS Deceleration Sensor Below rear of center floor console. See Fig. 3 .
Mounted on hub assembly of left front wheel. See
ABS Speed Sensor Front LH
Fig. 1 .
Mounted on hub assembly of right front wheel. See
ABS Speed Sensor Front RH
Fig. 1 .
Mounted on hub assembly of left rear wheel. See
ABS Speed Sensor Rear LH
Fig. 5 .
Mounted on hub assembly of right rear wheel. See
ABS Speed Sensor Rear RH
Fig. 5 .
Accelerator Pedal Position Sensor Below left side of dash. See Fig. 3 .
A/C Thermistor Behind center of dash. See Fig. 3 .
Air Fuel Ratio Sensor (Bank 1 Sensor 1) At rear of engine. See Fig. 1 .
Ambient Temp. Sensor Behind left side of front grille. See Fig. 1 .
Camshaft Position Sensor On rear of engine. See Fig. 1 .
Center Air Bag Sensor Assembly Behind lower center of dash. See Fig. 17 .
Counter Gear Speed Sensor At left side of engine compartment. See Fig. 1 .
Crankshaft Position Sensor On front of engine. See Fig. 1 .
Engine Coolant Temp. Sensor On rear of engine. See Fig. 1 .
At left front corner of engine compartment. See Fig.
Front Air Bag Sensor LH
1.
Front Air Bag Sensor RH
Fig. 1 .
Fuel Pump & Sender Under center rear of vehicle. See Fig. 5 .
Fuel Sender (Sub) Under center rear of vehicle. See Fig. 5 .
Heated Oxygen Sensor (Bank 1 Sensor 2) In exhaust system. See Fig. 4 .
Knock Sensor On top center of engine. See Fig. 2 .
Mass Air Flow Meter At right rear of engine. See Fig. 2 .
Seat Belt Warning Occupant Detection Sensor Under right front seat. See Fig. 5 .
Seat Position Airbag Sensor LH Under left front seat. See Fig. 5 .
Side Airbag Squib Sensor Front LH At base of left "B" pillar. See Fig. 6 .
Side Airbag Squib Sensor Front RH At base of right "B" pillar. See Fig. 6 .
Side Airbag Squib Sensor Rear LH Forward of left rear wheelwell. See Fig. 6 .
Side Airbag Squib Sensor Rear RH Forward of right wheelwell. See Fig. 6 .
Steering Angle Sensor In steering column. See Fig. 4 .
Throttle Position Sensor & Motor On top right rear of engine. See Fig. 2 .
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Turbine Speed Sensor At left front of engine compartment. See Fig. 2 .

Vapor Pressure Sensor Under rear of vehicle. See Fig. 6 .
Vehicle Speed Sensor (Combination Meter) At left front of engine compartment. See Fig. 2 .
Washer Level Warning Sensor
Fig. 2 .
Yaw Rate Sensor Under rear of center console. See Fig. 4 .
SOLENOIDS & SOLENOID VALVES

SOLENOIDS & SOLENOID VALVES LOCATION
Component Location
ABS Actuator & ECU At right side of engine compartment. See Fig. 1 .
A/C Magnetic Clutch & Lock Sensor At left front of engine compartment. See Fig. 1 .
Camshaft Timing Oil Control Valve At front of engine. See Fig. 1 .
Electronically Controlled Transmission Solenoid At left front of engine compartment. See Fig. 1 .
Injector No. 1 Top of engine. See Fig. 2 .
VSV (Canister Closed Valve) Near right rear of engine. See Fig. 2 .
VSV (EVAP) Near right rear of engine. See Fig. 2 .
VSV (Pressure Switching Valve) Under center of vehicle. See Fig. 6 .
SWITCHES
SWITCHES LOCATION
Component Location
At right front corner of engine compartment,
A/C Dual Pressure SW
integral to A/C triple pressure switch. See Fig. 1 .
At right front corner of engine compartment,
A/C Single Pressure SW
integral to A/C triple pressure switch. See Fig. 1 .
A/C Triple Pressure SW
Fig. 1 .
At left front of engine compartment, integral to
A/T Indicator Light SW
park/neutral position switch. See Fig. 2 .
Back Door Courtesy SW At lower left side of back door. See Fig. 5 .
Back-Up Light SW At left side of engine compartment. See Fig. 1 .
At left rear corner of engine compartment. See Fig.
Brake Fluid Level Warning SW
1.
Buckle SW LH In driver seat belt buckle assembly. See Fig. 5 .
In front passenger seat belt buckle assembly. See
Buckle SW RH
Fig. 5 .
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Clutch Start SW Behind left side of dash. See Fig. 2 .

Cruise Control Clutch SW Behind left side of dash. See Fig. 3 .
Door Courtesy SW Front LH Near base of left "B" pillar. See Fig. 5 .
Door Courtesy SW Front RH Near base of "B" pillar. See Fig. 5 .
Door Courtesy SW Rear LH Forward of left rear wheelwell. See Fig. 5 .
Door Courtesy SW Rear RH Forward of right rear wheelwell. See Fig. 5 .
Door Unlock Detection SW Front LH At rear of left front door. See Fig. 5 .
Door Unlock Detection SW Front RH At rear of right front door. See Fig. 5 .
Moon Roof Control SW & Relay At center front of roof. See Fig. 5 .
Moon Roof Motor & Limit SW At center front of roof. See Fig. 5 .
O/D Main SW Under front of center console. See Fig. 4 .
Oil Pressure SW On rear of engine. See Fig. 2 .
Parking Brake SW Below center floor console. See Fig. 4 .
Park/Neutral Position SW At left front of engine compartment. See Fig. 2 .
Power Steering Oil Pressure SW Near front of engine. See Fig. 2 .
Stop Light SW Behind left side of dash. See Fig. 4 .
Unlock Warning SW At top of steering column. See Fig. 4 .
MISCELLANEOUS
MISCELLANEOUS LOCATION
Component Location
A/C Amplifier Behind center of dash. See Fig. 17 .
Airbag Squib (Front Passenger's Airbag Assembly) Behind right side of dash. See Fig. 3 .
Airbag Squib (Steering Wheel Pad) Under steering wheel pad. See Fig. 3 .
Blower Resistor Behind lower right side of dash. See Fig. 3 .
Curtain Shield Airbag Squib LH At top of left "B" pillar. See Fig. 5 .
Curtain Shield Airbag Squib RH At top of right "B" pillar. See Fig. 5 .
Data Link Connector 3 Behind left side of dash. See Fig. 3 .
Diode (Fan) Behind right side of dash. See Fig. 3 .
Diode (Idle-Up) On driver side J/B. See Fig. 22 .
Diode (Seat Heater) Behind center of dash. See Fig. 3 .
Generator At left front of engine. See Fig. 1 .
At center right front of engine compartment. See
Horn (High)
Fig. 1 .
At center left front of engine compartment. See Fig.
Horn (Low)
1.
Ignition Coil & Igniter No. 1 Top of engine. See Fig. 2 .
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Junction Connector No. 9 At right rear side of cargo area. See Fig. 5 .
Junction Connectors No. 1, 2,3 10, 11, 12 & 13 Behind left side of dash. See Fig. 4 .
Junction Connectors No. 4, 5, 14, 15, 16 & 17 Behind center of dash. See Fig. 4 .
Junction Connectors No. 6, 7 & 8 Behind right side of dash. See Fig. 4 .
Noise Filter (Ignition) Near rear of engine. See Fig. 2 .
Noise Filter (LH) Behind left rear quarterpanel. See Fig. 6 .
Noise Filter (RH) Behind right rear quarterpanel. See Fig. 6 .
Option Connector (Siren) At center rear of engine compartment. See Fig. 2 .
Option Connector (TVSS ECU) Behind lower right side of dash. See Fig. 4 .
Pretensioner LH Near base of left "B" pillar. See Fig. 6 .
Pretensioner RH Near base of right "B" pillar. See Fig. 6 .
Seat Heater LH Under left front seat. See Fig. 6 .
Seat Heater RH Under right front seat. See Fig. 6 .
Short Connector (Light) Behind top center of dash. See Fig. 4 .
Short Connector (SRS) Behind top center of dash. See Fig. 4 .
Side Airbag Squib LH At left "B" pillar. See Fig. 6 .
Side Airbag Squib RH At right "B" pillar. See Fig. 6 .
Stereo Component Amplifier At left rear corner of vehicle. See Fig. 18 .
Transponder Key Amplifier On top of steering column. See Fig. 17 .
Transponder Key Computer Behind left side of dash. See Fig. 17 .
CONNECTORS
CONNECTORS LOCATION
Component Location
BA1 (White, 12 Pin) At left "B" pillar. See Fig. 11 .
BB1 (White, 12 Pin) At right "B" pillar. See Fig. 11 .
BC1 (White, 13 Pin) At right side of back door. See Fig. 11 .
BD1 (White, 2 Pin) At front center of roof. See Fig. 11 .
EA1 (White, 12 Pin) Under engine room J/B. See Fig. 7 .
IA1 (Gray/White, 43 Pin) At left kick panel. See Fig. 8 .
IA2 (Yellow, 2 Pin) At left kick panel. See Fig. 8 .
IA3 (White, 12 Pin) At left kick panel. See Fig. 8 .
IB1 (White, 5 Pin) At left kick panel. See Fig. 8 .
IC1 (White, 13 Pin) At left kick panel. See Fig. 8 .
ID1 (White, 9 Pin) Near driver side J/B. See Fig. 8 .
IE1 (White, 14 Pin) Near passenger side J/B. See Fig. 9 .
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IE2 (White, 13 Pin) Near passenger side J/B. See Fig. 9 .

IF1 (Yellow, 2 Pin) At right kick panel. See Fig. 9 .
IF2 (Gray/White, 43 Pin) At right kick panel. See Fig. 9 .
IG1 (White, 12 Pin) At right kick panel. See Fig. 9 .
IH1 (White, 13 Pin) At right kick panel. See Fig. 9 .
II1 (White, 16 Pin) At right kick panel. See Fig. 9 .
II2 (White, 2 Pin) At right kick panel. See Fig. 9 .
IJ1 (White, 1 Pin) Behind left end of dash. See Fig. 10 .
IJ2 (White, 2 Pin) Behind left side of dash. See Fig. 10 .
IL1 (White, 4 Pin) Behind upper center of dash. See Fig. 10 .
IL2 (White, 3 Pin) Behind upper center of dash. See Fig. 10 .
IM1 (White, 4 Pin) Behind right side of dash. See Fig. 10 .
IN1 (White, 5 Pin) Behind right end of dash. See Fig. 10 .
IO1 (White, 4 Pin) Behind upper right end of dash. See Fig. 10 .
IO2 (White, 2 Pin) Behind right end of dash. See Fig. 10 .
IO3 (White, 1 Pin) Behind right end of dash. See Fig. 10 .
IP1 (White, 2 Pin) At right kick panel. See Fig. 10 .
GROUNDS
GROUNDS LOCATION
Component Location
BJ At front of headliner. See Fig. 11 .
BK At rear of left quarterpanel. See Fig. 11 .
BL At center of back door. See Fig. 11 .
BM At rear of right quarterpanel. See Fig. 11 .
EA At front of right front fender. See Fig. 7 .
EB At left rear of cylinder block. See Fig. 7 .
EC At left rear of cylinder head. See Fig. 7 .
ED At front of left front fender. See Fig. 7 .
IE At left kick panel. See Fig. 13 .
Below center of dash, at left dash brace. See Fig.
IF
13 .
Below center of dash, at right dash brace. See Fig.
IG
13 .
IH Below right side of dash. See Fig. 13 .
II At right kick panel. See Fig. 13 .
SPLICES
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2004 TOYOTA RAV4
SPLICES LOCATION
Component Location
B1 In body harness, at left front door. See Fig. 15 .
In body harness, above left rear wheelwell. See Fig.
B2
15 .
In body harness, at center of back door. See Fig.
B3 15 .
In body harness, above right rear wheelwell. See
B4 Fig. 15 .
In body harness, behind left rear quarterpanel. See
B5
Fig. 15 .
In roof harness, at right front corner of roof. See
B6
Fig. 15 .
In engine compartment harness, at right side of
E1
engine compartment. See Fig. 12 .
In engine compartment harness, at top of engine.
E2
See Fig. 12 .
In engine compartment harness, at rear of engine.
E3
See Fig. 12 .
In engine compartment harness, at rear of engine.
E4
See Fig. 12 .
In engine compartment harness, at left side of
E5
engine compartment. See Fig. 12 .
In dash harness, behind right side of dash. See Fig.
I1
14 .
I2
14 .
I3
14 .
COMPONENT LOCATION GRAPHICS
NOTE: Figures may show multiple component locations. Refer to appropriate table for
proper figure references.
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Fig. 1: Engine Compartment

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Fig. 2: Engine
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Fig. 3: Dash & Center Console

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Fig. 5: Vehicle Overview

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Fig. 8: Dash
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Fig. 9: Dash
Fig. 10: Dash

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Fig. 13: Dash

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Fig. 14: Dash

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Fig. 19: Engine R/B

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Fig. 20: ABS R/B

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Fig. 21: Engine Room J/B

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Fig. 22: Driver Side J/B

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2004 ENGINE Emission Control - RAV4
2004 ENGINE
Emission Control - RAV4
EMISSION CONTROL SYSTEM

PURPOSE
The emission control systems are installed to reduce the amount of CO, HC and NOx exhausted from the engine
(3 and 4). They prevent blow-by gas containing HC from being released into the air (1) and evaporated fuel
containing HC from being released from the fuel tank (2).
The functions of each system are shown in Fig. 1 below:
Fig. 1: Emission Control System Function Description

PARTS LAYOUT AND SCHEMATIC DRAWING

LOCATION
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2004 Toyota RAV4
Fig. 2: Emission Control System Parts Layout

DRAWING
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Fig. 3: Emission Control System Drawing

POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM

INSPECTION
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1. INSPECT PCV VALVE

a. Disconnect the PCV hose from the PCV valve.
b. Remove the PCV valve.
Fig. 4: Disconnecting PCV Hose From PCV Valve

c. Connect a clean hose to the PCV valve.

d. Inspect the PCV valve operation.
1. Blow air from the cylinder head side, and check that air passes through smoothly.
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Fig. 5: Inspecting PCV Valve Operation For Blowing Air From Cylinder Head Side
CAUTION: Do not suck air through the valve. Petroleum substances

inside the valve are harmful.
2. Blow air from the intake manifold side, and check that air passes through with difficulty.
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Fig. 6: Inspecting PCV Valve Operation For Blowing Air From Intake Manifold Side
If operation is not as specified, replace the PCV valve.
e. Disconnect the clean hose from the PCV valve.

f. Reinstall the PCV valve.
1. Apply adhesive to 2 or 3 threads.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent
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Fig. 7: Applying Adhesive To Threads

2. Reinstall the PCV valve.
2. INSPECT PCV HOSES AND CONNECTIONS
Visually check for cracks, leaks or damage.
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Fig. 8: Inspecting PCV Hoses And Connections

If the PCV valve and connections are damaged, repair or replace it.
EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM

COMPONENTS
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Fig. 9: Identifying Evaporative Emission (EVAP) Control System Components

INSPECTION
1. INSPECT LINES AND CONNECTORS

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Visually check hoses for loose connections, bends or damage. If necessary, repair or replace the hoses.
2. INSPECT FUEL TANK FILLER PIPE
Visually check the fuel tank filler pipe for deformation, cracks or fuel leak.
If necessary, repair or replace the fuel tank filler pipe.
3. INSPECT FUEL TANK CAP
Visually check if the cap and/or gasket are deformed or damaged.
Fig. 10: Checking If Cap And Gasket Are Deformed Or Damaged

If necessary, repair or replace the cap and/or gasket.
4. INSPECT EVAP SYSTEM LINE

a. Warm up the engine to the normal operating temperature, then stop the engine.
b. Install a vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service
port on the purge line.
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Fig. 11: Installing Vacuum Gauge To EVAP Service Port On Purge Line
c. When using the hand-held tester:
Forced driving of the VSV for the EVAP.
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Fig. 12: Connecting Hand-Held Tester To DLC3


3. Push the hand-held tester main switch ON.
4. Use the hand-held tester ACTIVE TEST to operate the VSV for EVAP.
d. When not using the hand-held tester:
Forced driving of the VSV for the EVAP.
1. Disconnect the VSV connector for the EVAP.

2. Connect the battery's positive (+) and negative (-) to the VSV terminals for the EVAP.
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Fig. 13: Connecting Battery Positive And Negative To VSV Terminals For EVAP

e. Check the vacuum at idle.
Vacuum:
0.368 to 3.678 in.Hg (5 to 50 in.Aq) should be maintained for more than 5 seconds
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Fig. 14: Checking Vacuum At Idle

HINT:
If the vacuum does not change, there is a possibility that the hose connecting the VSV to the
service port may be loose or blocked, or the VSV may have a malfunction.
f. When using the hand-held tester:
Forced driving of the VSV for EVAP.
1. Stop the engine.

2. Disconnect the hand-held tester from the DLC3.
g. When not using the hand-held tester:
Forced driving of the VSV for EVAP.
1. Stop the engine.
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2. Disconnect the battery's positive (+) and negative (-) leads from the VSV terminals for the
EVAP.
3. Connect the VSV connector for the EVAP.
h. Disconnect the vacuum gauge from the EVAP service port on the purge line.
i. Connect a pressure gauge to the EVAP service port on the purge line.
j. Check the pressure.
1. Using a hose clipper or similar instrument, pinch the air drain hose at the position shown in
Fig. 15 to close the hose.
Fig. 15: Pinching Air Drain Hose Using Hose Clipper

HINT:
Insert the hose clipper through the clearance of the front engine under cover and pinch the
yellow marked portion of the air drain hose.
2. Apply pressure (13.5 to 15.5 in.Aq) from the EVAP service port.
Pressure:
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2 minutes after the pressure is applied, the gauge should be over 7.7 to 8.8 in.Aq.
Fig. 16: Applying Pressure From EVAP Service Port

HINT:
If no more pressure can be applied, the hose connecting among the VSV, canister and fuel
tank may be slipped off or the VSV may be open.
3. Check if the pressure decreases when the fuel tank cap is removed while applying pressure.
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Fig. 17: Checking If Pressure Decreases When Fuel Tank Cap Is Removed While
Applying Pressure
HINT:
If the pressure does not decrease when the fuel tank cap is removed, there is a possibility that
the hose connecting the service port to the fuel tank may be blocked.
k. Disconnect the pressure gauge from the EVAP service port on the purge line.
5. CHECK AIRTIGHTNESS IN FUEL TANK AND FILLER PIPE
a. Disconnect the EVAP line hose from the charcoal canister.
1. Pinch portion A.
2. Pull the connector out.
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Fig. 18: Disconnecting EVAP Line Hose From Charcoal Canister

b. Pressurize the internal fuel tank at 4 kPa (41 gf/cm2 , 0.58 psi).
c. Check that the internal pressure of the fuel tank can be maintained for 1 minute.
d. Check the connections of the hoses and pipes.
e. Check the installed parts on the fuel tank.
If there is abnormality, replace the fuel tank and filler pipe.
f. Reconnect the EVAP line hose to the charcoal canister.

6. INSPECT FUEL CUTOFF VALVE AND FILL CHECK VALVE
a. Disconnect the purge line hose and EVAP line hose from the charcoal canister.
b. Disconnect the drain hose from the charcoal canister and plug the drain port with a cap.
Fig. 19: Locating Purge Line Hose, EVAP Line Hose & Cap
c. Pressurize the purge port at 4 kPa (41 gf/cm2 , 0.58 psi) and check that it is ventilated through the
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EVAP line hose.
HINT:
It is necessary to check the amount of fuel in the fuel tank. When the fuel tank is full, the float
valve of the fill check valve is closed and no air can pass through.
1. If air can flow freely from the purge port through to the EVAP line hose, the fuel cutoff valve
and fill check valve are operating normally. Go to step c .
2. If air cannot flow freely from the purge port through to the EVAP line hose, disconnect the
vent line hose and EVAP line hose and check if they are clogged or not. If clogged, replace
as necessary.
3. If the vent line hose and EVAP line hose are operating normally and air still cannot flow
freely from the purge port through to the EVAP line hose, replace the fuel cutoff valve and
fill check valve.
d. Reconnect the purge line hose and EVAP line hose to the charcoal canister.
7. CHECK AIR INLET LINE HOSE
a. Disconnect the air inlet line hose from the charcoal canister.
b. Check that there is ventilation in the air inlet line.
If the air inlet line is clogged, repair or replace the hose.
c. Reconnect the air inlet line hose to the charcoal canister.
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Fig. 20: Checking Air Inlet Line Hose

8. REMOVE CHARCOAL CANISTER ASSEMBLY

a. Remove the bolt, 3 nuts and protector from the body.
b. Disconnect the VSV connector.
c. Disconnect the purge line hose, EVAP line hose and air inlet line hose from the charcoal canister.
d. Disconnect the vent line hose from the charcoal canister.
1. Push the connector deeply.
2. Pinch portion A.
3. Pull out the connector.
e. Remove the 2 bolts and charcoal canister assembly.
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Fig. 21: Removing Charcoal Canister Assembly

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9. INSPECT CHARCOAL CANISTER

a. Visually check the charcoal canister for cracks or damage.
Fig. 22: Checking Charcoal Canister For Cracks Or Damage

HINT:
Be sure to check the areas indicated by the arrow marks.
These areas are especially prone to cracking.
b. Inspect the charcoal canister operation.

1. Plug the vent port with a cap.
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Fig. 23: Plugging Vent Port With Cap

2. While holding the purge port closed, blow air (1.76 kPa, 18 gf/cm2 , 0.26 psi) into the EVAP
port and check that air flows from the air drain port.
3. While holding the purge port and the air drain port closed, blow air (1.76 kPa, 18 gf/cm2 ,
0.26 psi) into the EVAP port and check that air does not flow from the air inlet port.
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Fig. 24: Checking Air Does Not Flow From Air Inlet Port
4. Apply vacuum (3.43 kPa, 25.7 mmHg, 1.01 in.Hg) to the purge port and check that the
vacuum does not decrease when the air inlet port is closed. Then check that the vacuum
decreases when the air inlet port is released.
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Fig. 25: Checking Vacuum Decreases When Air Inlet Port Is Released
5. With the air inlet port closed, apply vacuum (3.43 kPa, 25.7 mmHg, 1.01 in.Hg) to the EVAP
port and check that air flows into the purge port.
If there is a problem, replace the charcoal canister.
6. Remove the cap from the vent port.
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Fig. 26: Removing Cap From Vent Port

10. INSPECT VSV FOR EVAP (See INSPECTION )

11. INSPECT VSV FOR CCV (See INSPECTION )
12. INSPECT VSV FOR PRESSURE SWITCHING VALVE (See INSPECTION )
13. INSPECT VAPOR PRESSURE SENSOR (See INSPECTION )
14. REINSTALL CHARCOAL CANISTER ASSEMBLY
15. REINSTALL PROTECTOR
THREE-WAY CATALYTIC CONVERTER (TWC) SYSTEM

1. INSPECT EXHAUST PIPE ASSEMBLY

a. Check the connections for looseness or damage.
If the exhaust pipe is loose, tighten it.
If damaged, replace it.

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b. Check the clamps for wear, cracks or damage.

2. INSPECT TWC
Check for dents or damage.
If any part of the protector is damaged or dented for example, the protector comes in contact with the
TWC, repair or replace it.
3. INSPECT HEAT INSULATOR

a. Check the heat insulator for damage.
If the heat insulator is damaged, repair or replace it.
b. Check that there is adequate clearance between the catalytic converter and heat insulator.
If there is no clearance, repair or replace the heat insulator.
COMPONENTS
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Fig. 27: Exploded View Of Three-Way Catalytic Converter Components

REPLACEMENT
NOTE: Check if an old gasket still remains on the pipe. If so, remove it. Also, check if
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any bolts or nuts are rusted. If so, replace them.
1. REMOVE FRONT EXHAUST PIPE

a. Remove the 2 bolts and 2 compression springs.
b. Remove the 2 bolts and exhaust pipe.
c. Remove the exhaust pipe's gasket and exhaust manifold's gasket.
2. REMOVE CENTER EXHAUST PIPE
a. Remove the heated oxygen sensor (bank 1 sensor 2).
b. Remove the 2 bolts from the exhaust pipe.
c. Remove the exhaust pipe from the 2 rings.
d. Remove the gasket from the exhaust pipe.
3. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
a. Disconnect the A/F sensor connector (bank 1 sensor 1).
b. Remove the 3 bolts, nut and No. 1 exhaust manifold heat insulator.
c. Remove the A/F sensor (bank 1 sensor 1) from the exhaust manifold.
4. REMOVE EXHAUST MANIFOLD (w/TWC)
a. Remove the 2 bolts, 2 nuts and 2 exhaust manifold stays.
b. Remove the 5 nuts and exhaust manifold,
c. Remove the gasket from the cylinder head,
5. INSPECT EXHAUST MANIFOLD (w/ TWC)
Using a precision straight edge and feeler gauge, measure the manifold surface contacting the cylinder
head for warpage.
Maximum warpage: 0.70 mm (0.0276 in.)
If the warpage is greater than the maximum, replace the manifold.
6. REMOVE HEAT INSULATORS

a. Remove the 3 bolts and No. 1 manifold converter heat insulator.
b. Remove the 2 bolts and No. 2 manifold converter heat insulator.
c. Remove the 2 bolts and No. 2 exhaust manifold heat insulator.
7. INSTALL HEAT INSULATORS
a. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.
b. Install the No. 2 exhaust converter heat insulator with the 2 bolts.
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c. Install the No. 1 manifold converter heat insulator with the 3 bolts.
8. INSTALL EXHAUST MANIFOLD (w/ TWC)

a. Install a new gasket to the cylinder head.
b. Install the exhaust manifold with the 5 nuts. Uniformly tighten the 5 nuts in the order.
c. Install the 2 exhaust manifold stays with the 2 bolts and 2 nuts.
9. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

a. Install the A/F sensor (bank 1 sensor 1) to the exhaust manifold.
b. Install the No. 1 exhaust manifold heat insulator with the 3 bolts and nut.
c. Connect the A/F sensor connector (bank 1 sensor 1).

10. INSTALL CENTER EXHAUST PIPE
a. Install a new gasket to the exhaust pipe.
NOTE:  Do not reuse the gasket.

 The gasket must be installed to the exhaust pipe before the pipe
is installed to the tailpipe. Do not indirectly use the tailpipe to
force the gasket onto the exhaust pipe.
b. Install the exhaust pipe to the 2 rings.

c. Install the 2 bolts to the exhaust pipe.
d. Install the heated oxygen sensor (bank 1 sensor 2).
HINT:
 Before installing the heated oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 turns.
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After installing the heated oxygen sensor, check that the sensor wire is not twisted. If it is twisted,

remove the heated oxygen sensor and reinstall it.
11. INSTALL FRONT EXHAUST PIPE
a. Using a vernier caliper, measure the free length of the compression spring.
Fig. 28: Measuring Free Length Of Compression Spring Using Vernier Caliper
Minimum length: 40 mm (1.57 in.)
If the free length is less than the minimum, replace the compression spring.
b. Install a new gasket to the front exhaust pipe.
NOTE:  Do not reuse the gasket.

 The gasket must be installed to the front exhaust pipe before
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the pipe is installed to the center exhaust pipe. Do not indirectly

use the center exhaust pipe to force the gasket onto the front
exhaust pipe.
c. Install a new gasket to the exhaust manifold.
Fig. 29: Installing Gasket To Exhaust Manifold

NOTE:  Using a plastic faced hammer, uniformly strike the gasket so

that the gasket and exhaust manifold are properly fit.
 Be careful with the installation direction of the gasket.
 Do not reuse the gasket.
 The gasket must be installed to the exhaust manifold before the
manifold is installed to the exhaust pipe. Do not indirectly use
the exhaust pipe to force the gasket onto the exhaust manifold.
d. Temporarily install the 2 compression springs and 2 bolts holding the exhaust manifold to the front
exhaust manifold pipe.
e. Install the front exhaust pipe to the center exhaust pipe with the 2 bolts.
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f. Tighten the 2 compression springs and 2 bolts.
12. CHECK FOR EXHAUST GAS LEAKS
If gas is leaking, tighten the areas necessary to stop the leak.
Replace damaged parts as necessary.
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2004 ENGINE Engine Mechanical - RAV4
2004 ENGINE
Engine Mechanical - RAV4
CO/HC
INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/HC complies with specifications.
1. INITIAL CONDITIONS
a. Engine at normal operating temperature
b. Air cleaner installed
c. Air pipes and hoses of air induction system connected
d. All accessories switched OFF
e. All vacuum lines properly connected
f. SFI system wiring connectors fully plugged
g. Ignition timing check correctly
h. Transmission in neutral position
i. Tachometer and CO/HC meter calibrated by hand
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE
DURING IDLING
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2004 Toyota RAV4
Fig. 1: Inserting CO/HC Meter Testing Probe Into Tailpipe

5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM
Complete the measuring within 3 minutes.
HINT:
When performing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the
applicable local regulations.
If the CO/HC concentration does not conform to specifications, perform troubleshooting in the order
given below.
1. Check the A/F sensor operation (see DTC P2195: OXYGEN (A/F) SENSOR SIGNAL STUCK
LEAN (BANK 1 SENSOR 1), DTC P2196: OXYGEN (A/F) SENSOR SIGNAL STUCK
RICH (BANK 1 SENSOR 1) ).
2. See Fig. 2 for possible causes, and then inspect and correct the applicable causes if necessary.
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Fig. 2: CO/HC Problems Causes Table

COMPRESSION
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE IGNITION COILS (See IGNITION COIL )

3. REMOVE SPARK PLUGS
4. INSPECT CYLINDER COMPRESSION PRESSURE
a. Insert a compression gauge into the spark plug hole.
b. Fully open the throttle.
c. While cranking the engine, measure the compression pressure.
HINT:
Always use a fully charged battery to obtain engine speed of 250 rpm or more.
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Fig. 3: Measuring Compression Pressure

d. Repeat steps () through (b) for each cylinder.
NOTE: This measurement must be done in as short a time as possible.
Compression pressure: 1.300 kPa (13.8 kgf/cm2 , 196 psi)

Minimum pressure: 1.00 MPa (10 kgf/cm2 , 142 psi)
Difference between each cylinder: 100 kPa (1.0 kgf/cm2 , 14 psi)
e. If the cylinder compression in one more cylinders is low, pour a small amount of engine oil into the
cylinder through the spark plug hole and repeat steps ) through (b) for cylinders with low
compression.
 If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or
damaged.
 If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage
through the gasket.
5. REINSTALL SPARK PLUGS
6. REINSTALL IGNITION COILS (See IGNITION COIL )
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VALVE CLEARANCE
ADJUSTMENT
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. REMOVE RH ENGINE UNDER COVER

2. REMOVE AIR CLEANER ASSEMBLY
3. REMOVE CYLINDER HEAD COVER
4. SET NO. 1 CYLINDER TO TDC/COMPRESSION
a. Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover.
Fig. 4: Aligning Groove With Timing Mark Turning Crankshaft Pulley

b. Check that the timing marks of the camshaft timing sprocket and VVT timing sprocket are aligned
with the timing marks of the No. 1 and No. 2 bearing caps as shown in Fig. 5 .
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If not, turn the crankshaft 1 revolution (360°) and align the marks as above.
Fig. 5: Checking Timing Marks & VVT Timing Sprocket Are Aligned With Bearing Caps
5. INSPECT VALVE CLEARANCE

a. Check only the valves indicated.
1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
2. Record the out-of-specification valve clearance measurements. They will be used later to
determine the required replacement adjusting valve lifter.
Valve clearance (Cold):
VALVE CLEARANCE (COLD) SPECIFICATIONS

Intake 0.19 to 0.29 mm (0.008 to 0.011 in.)
Exhaust 0.30 to 0.40 mm (0.012 to 0.016 in.)
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Fig. 6: Checking Valves

b. Turn the crankshaft 1 revolution (360°) and align the mark as above (see step 4).
c. Check only the valves indicated as shown in Fig. 7. Measure the valve clearance (see step ).
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Fig. 7: Checking Valves Indicated

6. ADJUST VALVE CLEARANCE

a. Set the No. 1 cylinder to the TDC/compression (See step 4).
b. Place matchmarks on the timing chain and camshaft timing sprockets.
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Fig. 8: Placing Match Marks Of Timing Chain & Camshaft Timing Sprockets
c. Remove the 2 nuts, gasket and chain tensioner.

d. Hold the hexagonal head portion of the camshaft with a wrench, and loosen the camshaft timing
sprocket bolt.
NOTE: Be careful not to damage the cylinder head and valve lifter with the
wrench.
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Fig. 9: Holding Hexagonal Head Portion Of Camshaft

e. Uniformly loosen and remove the 10 camshaft bearing cap bolts in several passes, in the sequence
shown in Fig. 10.
f. Remove the 5 camshaft bearing caps.
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Fig. 10: Removing Camshaft Bearing Cap Bolts In Sequence

g. Raising the camshaft, remove the camshaft timing sprocket bolt.
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Fig. 11: Removing Camshaft Timing Sprocket Bolt

h. Disconnect the camshaft timing sprocket together with the timing chain from the exhaust camshaft.
i. Remove the camshaft timing sprocket from the timing chain.
j. Uniformly loosen and remove the 10 camshaft bearing cap bolts in several passes, in the sequence
shown in Fig. 12.
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Fig. 12: Removing Camshaft Bearing Cap Bolts In Sequence

k. Remove the 5 camshaft bearing caps.

l. Disconnect the timing chain from the VVT timing sprocket, and remove the intake camshaft with
the VVT timing sprocket.
m. Tie the timing chain as shown in Fig. 13 .
NOTE:  Be careful not to drop anything inside the timing chain cover.
 Do not allow the chain to come into contact with water or dust.
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Fig. 13: Tying Timing Chain

n. Remove the valve lifter.

o. Determine the replacement valve lifter size according to these Formula or Charts:
 Using a micrometer, measure the thickness of the removed lifter.
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Fig. 14: Measuring Valve Lifter Thickness

 Calculate the thickness of a new lifter so the valve clearance comes within the specified
value.
T ......... Thickness of used lifter
A ......... Measured valve clearance
N ......... Thickness of new lifter
VALVE LIFTER SIZE FORMULA CHART

Intake N = T + (A - 0.24 mm (0.009 in.))
Exhaust N = T + (A - 0.35 mm (0.014 in.))
 Select a new lifter with a thickness as close as possible to the calculated values.
HINT:
 Valve lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060
mm (0.1992 in.) to 5.740 mm (0.2260 in.).
 Identification number inside the valve lifter shows the value of the 2 decimal places (In Fig.
15 shows 5.380 mm (0.2118 in.).
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Fig. 15: Locating Valve Lifter Identification Number

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Fig. 16: Valve Lifter Selection Chart (Intake)

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Fig. 17: Valve Lifter Selection Chart (Exhaust)

p. Apply a light coat engine oil to new valve lifter.

q. Reinstall the valve lifter.
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Fig. 18: Installing Valve Lifter

r. Align the crankshaft pulley groove with timing mark 0 of the timing chain cover.
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Fig. 19: Aligning Crankshaft Pulley Groove With Timing Mark

s. Hold the timing chain.

7. REINSTALL INTAKE CAMSHAFT
a. Align the matchmarks on the timing chain and VVT timing sprocket (See step a), and place the
intake camshaft on the cylinder head.
b. Apply a light coat engine oil on the threads and under the camshaft bearing cap bolts.
c. Install the 5 intake camshaft bearing caps in their proper locations (see INSTALLATION ).
d. Uniformly tighten the 10 bearing cap bolts in several passes, in the sequence shown in Fig. 20.
Torque:
30 N.m (301 kgf.cm, 22 ft.lbf) for bolt A

9.0 N.m (92 kgf.cm, 80 in.lbf) for others
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Fig. 20: Tightening Bearing Cap Bolts In Sequence

e. Align the matchmarks on the timing chain and camshaft timing sprocket (See step a), and install
them.
8. REINSTALL EXAHUST CAMSHAFT
a. Temporarily install the camshaft timing sprocket with the timing chain to the exhaust camshaft with
the bolt.
b. Place the exhaust camshaft on the cylinder head.
c. Apply a light coat engine oil on the threads and under the camshaft bearing cap bolts.
d. Install the 5 exhaust camshaft bearing caps in their proper locations (see INSTALLATION ).
e. Uniformly tighten the 10 bearing cap bolts in several passes, in the sequence shown in Fig. 21.
Torque:

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f. Hold the hexagon head portion of the exhaust camshaft with a wrench, and tighten the bolt.
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Fig. 22: Tightening Bolt Holding Hexagon Portion Of Exhaust Camshaft

g. Check that the each sprocket aligned with the match-marks as shown in Fig. 23 .
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Fig. 23: Checking Matchmarks Are Aligned With Sprocket

h. Install the chain tensioner (see INSTALLATION ).

i. Recheck the valve clearance (see step 5).
j. Check the valve timing (see INSTALLATION ).
9. REINSTALL CYLINDER HEAD COVER (See INSTALLATION )
10. REINSTALL AIR CLEANER ASSEMBLY (See REMOVAL )
11. REINSTALL RH ENGINE UNDER COVER
IGNITION TIMING
INSPECTION
1. WARM UP ENGINE
2. CHECK IDLE SPEED (See INSPECTION )
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3. CONNECT TIMING LIGHT
Connect the tester probe of a timing light to the black-white service wire of the engine wire as shown in
Fig. 24.
Fig. 24: Connecting Timing Light

4. INSPECT IGNITION TIMING

a. Using SST, connect terminals to TC and CG of the DLC3.
SST 09843-18040
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Fig. 25: Connecting Terminals To TC & CG Of DLC3

HINT:
After engine rpm is kept at 900 - 1,500 rpm for 5 seconds, check that it returns to idle speed.
b. Using a timing light, check the ignition timing.
Ignition timing: 8 to 12° BTDC @ idle
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Fig. 26: Checking Ignition Timing

c. Remove the SST from the DLC3.

5. FURTHER CHECK IGNITION TIMING
Ignition timing: 5 to 15° BTDC @ idle
HINT:
The timing mark moves in a range between 5 and 15°.
6. DISCONNECT TIMING LIGHT
IDLE SPEED
INSPECTION
1. INITIAL CONDITIONS
a. Engine at normal operating temperature
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b. Air cleaner installed

c. All pipes and hoses of air induction system connected
d. All vacuum lines properly connected
e. SFI system wiring connectors fully plugged
f. All operating accessories switched OFF
g. Ignition timing check correctly
h. Transmission in neutral range
i. A/C switched OFF
2. CONNECT HAND-HELD TESTER OR OBD II SCAN TOOL
a. Connect the hand-held tester or OBD II scan tool to the DLC3.
Fig. 27: Connecting Hand Held Tester To DLC3

b. Please refer to the hand-held tester or OBD II scan tool operator's for further details.
3. INSPECT IDLE SPEED
a. Race the engine at 2,500 RPM for approx. 90 seconds.
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b. Check the idle speed.
Idle speed W/Cooling fan OFF):
IDLE SPEED (W/COOLING FAN OFF) SPECIFICATIONS

AT 610 to 710 RPM
MT 610 +/- 710 RPM
If the idle speed is not as specified, check the air intake system.
4. DISCONNECT HAND-HELD TESTER OR OBD II SCAN TOOL
TIMING CHAIN
COMPONENTS
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Fig. 28: Identifying Timing Chain Components (1 Of 2)

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Fig. 29: Identifying Timing Chain Components (2 Of 2)

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REMOVAL
NOTE: Under the condition with the timing chain cover removed, in case of rotating the
camshafts, make the position of the crankshaft rotated clockwise by about 45°
from TDC/compression of No. 1 cylinder.
Fig. 30: Rotating Crankshaft Clockwise By About 45°

1. DRAIN ENGINE OIL

3. REMOVE PS VANE PUMP (See REMOVAL )
4. REMOVE ABS ACTUATOR (See REMOVAL & INSTALLATION )
5. REMOVE RH ENGINE MOUNTING INSULATOR (See REMOVAL )
6. REMOVE DRIVE BELT (See REMOVAL & INSTALLATION )
7. REMOVE GENERATOR (See REMOVAL & INSTALLATION )
8. REMOVE AIR CLEANER ASSEMBLY (See REMOVAL )
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10. REMOVE CYLINDER HEAD COVER

a. Disconnect the 2 PCV hoses from the cylinder head cover.
b. Remove the 8 bolts, 2 nuts, cylinder head cover and gasket.
Fig. 31: Removing Cylinder Head Cover


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Fig. 32: Aligning Crankshaft Pulley Groove With Timing Mark 0 Of Timing Chain Cover
b. Check that the timing marks of the camshaft timing sprocket and VVT timing sprocket aligned with
the timing marks of the No. 1 and No. 2 bearing caps as shown in Fig. 33 .
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Fig. 33: Checking Timing Marks & VVT Timing Sprocket Are Aligned
12. REMOVE CRANKSHAFT PULLEY

a. Using SST, loosen the pulley bolt.
SST 09213-54015, 09330-00021
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Fig. 34: Removing Crankshaft Pulley Bolt

b. Remove the pulley bolt and crankshaft pulley.
HINT:
If necessary, remove the pulley with SST.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021), 09950-40011

(09957-04010)
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Fig. 35: Removing Pulley With SST

13. REMOVE CHAIN TENSIONER
Remove the 2 nuts, chain tensioner and gasket.
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Fig. 36: Removing Chain Tensioner

14. REMOVE DRIVE BELT TENSIONER
Remove the bolt, nut and drive belt tensioner.
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Fig. 37: Removing Drive Belt Tensioner

15. REMOVE CRANKSHAFT POSITION SENSOR (See )

16. REMOVE OIL PAN (See REMOVAL )
17. REMOVE TIMING CHAIN COVER
a. Using a torx socket wrench (E10), remove the stud bolt for the drive belt tensioner.
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Fig. 38: Removing Stud Bolt

b. Remove the 14 bolts and 2nuts.
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Fig. 39: Removing Timing Chain Cover Bolts/Nuts

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c. Using a screwdriver, pry between the timing chain cover and cylinder head or cylinder block.
d. Remove the timing chain cover.
NOTE: Be careful not to damage the contact surfaces of the timing chain
cover, cylinder head and cylinder block.
18. REMOVE CRANK ANGLE SENSOR PLATE

19. REMOVE CHAIN TENSIONER SLIPPER
Remove the bolt and slipper.
20. REMOVE CHAIN VIBRATION DAMPER
Remove the 2 bolts and damper.
21. REMOVE TIMING CHAIN GUIDE
Remove the bolt and chain guide.
Fig. 40: Removing Timing Chain Guide Bolt

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22. REMOVE TIMING CHAIN

23. REMOVE CRANKSHAFT TIMING SPROCKET
24. REMOVE CAMSHAFT TIMING SPROCKET AND VVT TIMING SPROCKET
a. Hold the hexagonal head wrench portion of the camshaft with a wrench, and loosen the sprocket
bolts.
Fig. 41: Loosening Sprocket Bolts Holding Hexagonal Head Wrench

NOTE: Be careful not to damage the cylinder head and valve lifter by a
wrench.
b. Remove the bolt and exhaust camshaft timing sprocket.

c. Remove the bolt and VVT timing sprocket.
NOTE: Do not disassemble the VVT timing sprocket.
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INSPECTION
1. INSPECT TIMING CHAIN AND TIMING SPROCKETS

a. Using vernier calipers, measure the length of the 16 links with the chain fully stretched.
Maximum chain elongation: 122.6 mm (4.827 in.)
If the elongation is greater than maximum, replace the chain.
HINT:
Make the same pulling measurements at 3 or more places selected at random.
Fig. 42: Measuring Length Of Links

b. Wrap the chain around the timing sprocket.

c. Using vernier calipers, measure the timing sprocket diameter with the chain.
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Fig. 43: Measuring Timing Sprocket Diameter With Chain

NOTE: Vernier calipers must contact the chain rollers for measuring.
Minimum sprocket diameter (w/ Chain):
MINIMUM SPROCKET DIAMETER (W/CHAIN) SPECIFICATIONS

Camshaft 97.3 mm (3.831 in.)
Crankshaft 51.6 mm (2.031 in.)
If the diameter is less than the minimum, replace the chain and sprockets.
2. INSPECT CHAIN TENSIONER SLIPPER AND VIBRATION DAMPER
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Measure the chain tensioner slipper and vibration damper wears.
Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than the maximum, replace the slipper and/or damper.
Fig. 44: Inspecting Chain Tensioner Slipper & Vibration Damper Wear
3. INSPECT CHAIN TENSIONER

a. Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.
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Fig. 45: Checking Plunger Moves Smoothly

b. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does
not move when pushed with your finger.
4. INSPECT DRIVE BELT TENSIONER
Check the oil leakage and crack.
If necessary, replace the drive belt tensioner.
REPLACEMENT
REPLACE CRANKSHAFT FRONT OIL SEAL
HINT:
There are 2 methods (() and (a)) to replace the oil seal.
a. If the timing chain cover is removed from the cylinder head and block.
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1. Using a screwdriver and a hammer, tap out the oil seal.
Fig. 46: Tapping Out Oil Seal

2. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover
edge.
SST 09309-37010
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Fig. 47: Tapping In Oil Seal

3. Apply MP grease to the oil seal lip.

b. If the timing chain cover is installed to the cylinder head and block.
1. Using SST, remove the oil seal.
SST 09308-10010, 09950-60010 (09951-00200)
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Fig. 48: Removing Oil Seal

2. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover
edge.
SST 09309-37010
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INSTALLATION
1. INSTALL CAMSHAFT TIMING SPROCKET AND VVT TIMING SPROCKET

a. Install the camshaft timing sprocket.
1. Face the timing mark of the sprocket outward.
2. Align the camshaft knock pin with the knock pin groove on the sprocket side with the timing
mark, and slide on the timing sprocket.
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Fig. 50: Aligning Camshaft Knock Pin With Knock Pin Groove On Sprocket Side
3. Temporarily install the timing sprocket set bolt.

4. Hold the hexagon wrench head portion of the exhaust camshaft with a wrench, and tighten
the bolt.
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Fig. 51: Tightening Bolt Holding Hexagon Wrench Head Portion

b. Install the VVT timing sprocket.

1. Holding the timing sprocket in the position where the timing sprocket pin groove is slightly
to right of the camshaft pin looking from the front side, install the timing sprocket to the
camshaft, lightly pressing and turning it counterclockwise. Check that there is virtually no
clearance between the timing sprocket and camshaft flange.
NOTE: Be careful not to turn the timing sprocket clockwise when

installing it.
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Fig. 52: Installing Timing Sprocket To Camshaft

2. Temporarily install the timing sprocket set bolt.

3. Hold the hexagon wrench head portion of the intake camshaft with a wrench.
4. Take care to install the timing sprocket with the bolt
5. Check that the valve timing controller turns clockwise and that it is locked securely when the
lock pin in hole is at the locking point.
a. Turn the hexagonal wrench head portion of the camshafts, and align the timing marks of the
camshaft timing sprocket and VVT timing sprocket with the timing marks of No 1 and No. 2
bearing caps as shown in Fig. 53 .
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Fig. 53: Aligning Timing Marks & VVT Timing Sprocket With Timing Marks
b. Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
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Fig. 54: Setting Key On Crankshaft Upward

3. INSTALL CHAIN VIBRATION DAMPER
Install the damper with the 2 bolts.
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Fig. 55: Installing Chain Vibration Damper

4. INSTALL CRANKSHAFT TIMING SPROCKET
Align the sprocket set key with the key groove of the sprocket, slide on the sprocket.
5. INSTALL TIMING CHAIN

a. Install the timing chain on the crankshaft timing sprocket with the blue or orange mark link aligned
with the timing mark on the crankshaft timing sprocket.
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Fig. 56: Installing Timing Chain On Crankshaft Timing Sprocket

b. Install the timing chain on the camshaft timing sprocket and VVT timing sprocket with the gold or
yellow mark links aligned with the timing marks on the camshaft timing sprocket and VVT timing
sprocket.
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Fig. 57: Installing Timing Chain On Camshaft Timing Sprocket & VVT Timing Sprocket
6. INSTALL TIMING CHAIN GUIDE
Install the timing chain guide with the bolt.
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Fig. 58: Installing Timing Chain Guide

7. INSTALL CHAIN TENSIONER SLIPPER

a. Install the slipper with the bolt.
b. Check that the slipper is hold on the cylinder block stopper.
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Fig. 59: Installing Chain Tensioner Slipper

8. INSTALL CRANK ANGLE SENSOR PLATE
Install the plate with the F mark facing forward.
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Fig. 60: Installing Crank Angle Sensor Plate

9. INSTALL TIMING CHAIN COVER

a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces
of the timing chain cover and cylinder head/block/crank case.
 Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from
the gasket surfaces and sealing grooves.
b. Apply seal packing to the timing chain cover as shown in Fig. 61 .
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Fig. 61: Applying Seal Packing To Timing Chain Cover

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 Install a nozzle that has been cut to a 3 to 4 mm (0.12 to 0.16 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.
Parts must be assembled within 3 minutes of application. Otherwise the material must be
c. Apply seal packing to 2 locations as shown in Fig. 62 .
Fig. 62: Applying Seal Packing

 Install a nozzle that has been cut to a 2 mm (0.08 in.) opening.
HINT:
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d. Install the timing chain cover with the 14 bolts and 2 nuts. Uniformly tighten the bolts and nuts in
several passes.
Torque:
9.0 N.m (92 kgf.cm, 80 in.lbf) for bolt A

21 N.m (214 kgf.cm, 15 ft.lbf) for bolt B
43 N.m (439 kgf.cm, 32 ft.lbf) for bolt C
43 N.m (439 kgf.cm, 32 ft.lbf) for bolt D
9.0 N.m (92 kgf.cm, 80 ft.lbf) for nut
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Fig. 63: Tightening Timing Chain Cover Bolts

HINT:
Bolt length:
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BOLT LENGTH REFERENCE

Bolt A 30 mm (1.18 in) length for 10 mm head
Bolt B 30 mm (1.18 in) length for 12 mm head
Bolt C 40 mm (1.57 in) length for 14 mm head
Bolt D 65 mm (2.56 in) length for 14 mm head
e. Using a torx socket wrench (E10), install the stud bolt for the drive belt tensioner.
Torque: 21.5 N.m (219 kgf.cm, 15.8 in.lbf)
Fig. 64: Installing Drive Belt Tensioner Stud Bolt

10. INSTALL DRIVE BELT TENSIONER
Install the drive belt tensioner with the bolt and nut.
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Fig. 65: Installing Drive Belt Tensioner

NOTE: As the drive belt tensioner should be torqued together with the timing
chain cover, so be sure install it with in 15 minutes after the timing chain
cover is installed.
11. INSTALL CRANKSHAFT POSITION SENSOR (See INSTALLATION )

12. INSTALL OIL PAN (See INSTALLATION )
13. INSTALL CRANKSHAFT PULLEY
a. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
b. Using SST, install the pulley bolt.
SST 09213-54015, 09330-00021
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Fig. 66: Installing Crankshaft Pulley

14. INSTALL CHAIN TENSIONER

a. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger
cannot spring out.
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Fig. 67: Pushing Plunger

b. Place a new gasket on the timing chain cover with portion A facing as shown in Fig. 68 .
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Fig. 68: Placing Gasket On Timing Chain Cover With Portion A

c. Push the chain tensioner into the timing chain cover, and install the 2 nuts.
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Fig. 69: Installing Chain Tensioner Into Timing Chain Cover

15. SET CHAIN TENSION

a. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
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Fig. 70: Disconnecting Plunger Knock Pin From Hook

b. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
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Fig. 71: Checking Slipper Is Pushed By Plunger

16. CHECK VALVE TIMING

NOTE: Always turn the crankshaft clockwise.
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Fig. 72: Aligning Groove With Timing Mark Turning Crankshaft Pulley
b. Check that the timing marks of the camshaft timing sprocket and VVT timing sprocket are aligned
with the timing marks of the No. 1 and No. 2 bearing caps as shown in Fig. 73 .
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Fig. 73: Checking Camshaft Timing Sprocket & VVT Timing Sprocket Are Aligned With
Bearing Caps
17. INSTALL CYLINDER HEAD COVER

a. Remove any old packing (FIPG) material.
b. Apply seal packing to 2 locations as shown in Fig. 74 .
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Fig. 74: Applying Seal Packing

c. Install the gasket to the cylinder head cover. If the gasket has damage, replace a new one.
HINT:
Part must be assembled within 3 minutes of application. Otherwise the material must be removed
and reapplied.
d. Install the cylinder head cover with the 8 bolts and 2 nuts.
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Fig. 75: Installing Cylinder Head Cover

e. Connect the 2 PCV hoses to the cylinder head cover.

18. INSTALL IGNITION COILS (See IGNITION COIL )
19. INSTALL VANE PUMP (See INSTALLATION )
20. INSTALL GENERATOR (See REMOVAL & INSTALLATION )
21. INSTALL RH ENGINE MOUNTING INSULATOR (See INSTALLATION )
22. INSTALL DRIVE BELT (See REMOVAL & INSTALLATION )
23. INSTALL ABS ACTUATOR (See BRAKE ACTUATOR ASSEMBLY )
24. INSTALL AIR CLEANER ASSEMBLY (See INSTALLATION )
25. INSTALL ENGINE UNDER COVER
26. FILL WITH ENGINE OIL (See REPLACEMENT )
27. START ENGINE AND CHECK FOR LEAK
28. RECHECK ENGINE OIL LEVEL
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CYLINDER HEAD
COMPONENTS
Fig. 76: Identifying Cylinder Head Components (1 Of 4)

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REMOVAL

3. DRAIN ENGINE OIL (See REPLACEMENT )
a. Disconnect the MAF meter connector.
b. Disconnect the 2 EVAP hoses from the VSV.
c. Disconnect VSV connector for EVAP.
d. Disconnect the CCV hose from the air cleaner.
e. Disconnect the PCV hose from the cylinder head cover.
Fig. 80: Removing Air Cleaner Assembly

5. REMOVE DRIVE BELT (See )

6. REMOVE GENERATOR (See REMOVAL & INSTALLATION )
7. REMOVE PS VANE PUMP (See REMOVAL )
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9. REMOVE SPARK PLUGS (See ON-VEHICLE INSPECTION )
10. REMOVE INJECTORS (See REMOVAL )
11. REMOVE EXHAUST MANIFOLD ASSEMBLY
a. Disconnect the A/F sensor connector.
b. Remove the 3 bolts, nut and exhaust manifold heat insulator No. 1.
c. Remove the 2 bolts holding the exhaust manifold stays and crank case.
d. Remove the 5 nuts, 2 bolts, 2 compression springs, the exhaust manifold assembly and 2 gaskets.
e. Remove the 2 nuts, No. 1 and No. 2 exhaust manifold stays.
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Fig. 81: Removing Exhaust Manifold Assy

12. REMOVE OIL FILLER CAP

13. REMOVE PCV HOSES AND VALVE
a. Remove the 2 PCV hoses.
b. Remove the PCV valve and grommet.
14. REMOVE INTAKE MANIFOLD AND THROTTLE BODY ASSEMBLY
a. Disconnect the throttle position sensor connector.
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b. Disconnect the 2 water hoses from the throttle body.

c. Disconnect the 2 vacuum hoses from the intake manifold.
d. Disconnect the engine wire harness from the clamp.
e. Remove the 5 bolts, 2 nuts, the intake manifold and throttle body assembly, and gasket.
f. Remove the intake manifold insulator.
Fig. 82: Removing Intake Manifold & Throttle Body Assy

15. DISCONNECT ENGINE WIRE

a. Disconnect the OCV connector.
b. Disconnect the crankshaft position sensor connector.
c. Disconnect the oil pressure switch connector and wire.
d. Disconnect the camshaft position sensor connector.
e. Disconnect the ECT sensor connector.
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f. Disconnect the noise filter.

16. REMOVE CAMSHAFT TIMING CHAIN (See REMOVAL )
17. REMOVE TIMING SPROCKET AND VVT SPROCKET (See REMOVAL )
18. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE (OCV) (See CAMSHAFT TIMING
OIL CONTROL VALVE )
19. REMOVE CAMSHAFTS
a. Uniformly loosen and remove the 20 bearing cap bolts in several passes, in the sequence shown in
Fig. 83.
Fig. 83: Removing Bearing Cap Bolts In Sequence

b. Remove the 10 bearing caps, intake camshaft and exhaust camshaft.

c. Remove the camshaft bearings from the No. 1 camshaft bearing cap and intake camshaft No. 1
journal part of the cylinder head.
20. REMOVE CYLINDER HEAD
a. Using a 10 mm bi-hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts in
several passes, in the sequence shown in Fig. 84.
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NOTE: Head warpage or cracking could result from removing bolts in an

incorrect order.
Fig. 84: Removing Cylinder Head Bolts In Sequence

b. Remove the 10 plate washers.

c. Using a screwdriver, pry between the cylinder head and cylinder block, and remove the cylinder
head.
NOTE: Be careful not to damage the contact surfaces of the cylinder head
and cylinder block.
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Fig. 85: Prying Between Cylinder Head & Cylinder Block

DISASSEMBLY
1. REMOVE OIL PRESSURE SWITCH
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Fig. 86: Removing Oil Pressure Switch

2. REMOVE ECT SENSOR

3. REMOVE CAMSHAFT POSITION SENSOR
Remove the bolt, camshaft position sensor and O-ring.
4. REMOVE VALVE LIFTERS
HINT:
Arrange the valve lifters in the correct order.
5. REMOVE VALVES
a. Using SST, compress the valve spring and remove the 2 keepers.
SST 09202-00020, 09202-70020
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Fig. 87: Removing Spring Retainer, Valve Spring & Valve

b. Remove the spring retainer, valve spring and valve.

c. Using needle-nose pliers, remove the oil seal.
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Fig. 88: Removing Oil Seal

d. Using compressed air and a magnetic finger, remove the spring seat by blowing air.
HINT:
Arrange the valves, valve springs, spring seats and spring retainers in the correct order.
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Fig. 89: Removing Spring Seat By Blowing Air

INSPECTION
1. CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK

a. Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper,
remove all the carbon from the piston surface.
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Fig. 90: Removing All Carbon From Piston Surface

b. Using a gasket scraper, remove all the gasket material from the cylinder block surface.
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Fig. 91: Removing All Gasket Material From Cylinder Block Surface
c. Using compressed air, blow carbon and oil from the bolt holes.
CAUTION: Protect your eyes when using high pressure compressed air.
NOTE: Be careful not to scratch the cylinder head contact surface.
2. INSPECT CYLINDER BLOCK FOR FLATNESS (See INSPECTION )

3. CLEAN CYLINDER HEAD
a. Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.
NOTE: Be careful not to scratch the cylinder block contact surface.
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Fig. 92: Removing All Gasket Material From Cylinder Block Contact Surface
b. Using a wire brush, remove all the carbon from the combustion chambers.
NOTE: Be careful not to scratch the cylinder block contact surface.
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Fig. 93: Removing All Carbon From Combustion Chambers

c. Using a soft brush and solvent, thoroughly clean the cylinder head.
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Fig. 94: Cleaning Cylinder Head

d. Using a valve guide bushing brush and solvent, clean all the guide bushings.
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Fig. 95: Cleaning All Guide Bushings

4. INSPECT CYLINDER HEAD

a. Inspect for flatness.
Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder
block and the manifolds for warpage.
If warpage is greater than the maximum, replace the cylinder head.
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Fig. 96: Measuring Surface Contacting Cylinder Block & Manifolds For Warpage
b. Inspect for cracks.
Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder
block surface for cracks.
If cracked, replace the cylinder head.
Fig. 97: Inspecting For Cracks

5. CLEAN VALVES
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a. Using a gasket scraper, chip off any carbon from the valve head.
b. Using a wire brush, thoroughly clean the valve.
Fig. 98: Cleaning Valve

6. INSPECT VALVE STEMS AND GUIDE BUSHINGS

a. Using a caliper gauge, measure the inside diameter of the guide bushing.
Bushing inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.)
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Fig. 99: Measuring Inside Diameter Of Guide Bushing

b. Using a micrometer, measure the diameter of valve stem.
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Fig. 100: Measuring Diameter Of Valve Stem

Valve stem diameter:
VALVE STEM DIAMETER REFERENCE

Intake 5.470 to 5.485 mm (0.2154 to 0.2159 in.)
c. Subtract the valve stem diameter measurement from the guide bushing inside diameter
measurement.
Standard oil clearance:
STANDARD OIL CLEARANCE REFERENCE

Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.)
Maximum oil clearance:

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MAXIMUM OIL CLEARANCE REFERENCE

Intake 0.08 mm (0.0031 in.)
Exhaust 0.10 mm (0.0039 in.)
If the clearance is greater than the maximum, replace the valve and guide bushing (see page
REPLACEMENT ).
7. INSPECT VALVES
a. Check the valve is ground to the correct valve face angle.
Valve face angle: 44.5°
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Fig. 101: Checking Valve Face Angle

b. Check that the surface of the valve for wear.
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If the valve face is worn, replace the valve.
c. Check the valve head margin thickness.

Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.5 mm (0.028 in.)
If the margin thickness is less than the minimum, replace the valve.
Fig. 102: Checking Valve Head Margin Thickness

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d. Check the valve overall length.
Fig. 103: Checking Valve Overall Length

Standard overall length:
STANDARD OVERALL LENGTH REFERENCE

Intake 101.71 mm (4.0043 in.)
Exhaust 101.15 mm (3.9823 in.)
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Minimum overall length:
MINIMUM OVERALL LENGTH REFERENCE

Intake 101.21 mm (3.9846 in.)
Exhaust 100.70 mm (3.9646 in.)
If the overall length is less than the minimum, replace the valve.
e. Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
8. INSPECT AND CLEAN VALVE SEATS

a. Using a 45° carbide cutter, resurface the valve seats.
Fig. 104: Resurfacing Valve Seats

b. Remove only enough metal to clean the seats.

c. Check the valve seating position.
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Apply a light coat of Prussian blue (or white lead) to the valve face. Lightly press the valve against
the seat. Do not rotate valve.
Fig. 105: Checking Valve Seating Position

d. Check the valve face and seat for the following:

 If blue appears 360° around the face, the valve is concentric. If not, replace the valve.
 If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface
the seat.
 Check that the valve seat contact is in the middle of the valve face with the width between
1.0 to 1.4 mm (0.039 to 0.055 in.).
If not, correct the valve seats as follows:
1. If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.
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Fig. 106: Correcting Valve Seats (Too High)

2. If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat.
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Fig. 107: Correcting Valve Seats (Too Low)

e. Hand-lap the valve and valve seat with an abrasive compound.
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Fig. 108: Hand-Lap Valve & Valve Seat

f. After hand-lapping, clean the valve and valve seat.

9. INSPECT VALVE SPRINGS
a. Using a steel square, measure the deviation of the valve spring.
Maximum deviation: 1.6 mm (0.063 in.)
Maximum angle (Reference): 2°
If the deviation is greater than the maximum, replace the valve spring.
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Fig. 109: Measuring Deviation Of Valve Spring

b. Using vernier calipers, measure the free length of the valve spring.
Free length: 45.7 mm (1.799 in.)
If the free length is not as specified, replace the valve spring.
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Fig. 110: Measuring Free Length Of Valve Spring

c. Using a spring tester, measure the tension of the valve spring at the specified installed length.
Installed tension:
184.3 to 203.7 N (18.8 to 20.8 kgf, 41.4 to 45.9 lbf) at 34.0 mm (1.339 in.)
Maximum working tension:
344.8 to 381.2 N (35.2 to 38.9 kgf, 77.4 to 85.8 lbf) at 24.6 mm (0.968 in.)
If the tension is not as specified, replace the valve spring.
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Fig. 111: Measuring Tension Of Valve Spring

10. INSPECT CAMSHAFTS

a. Inspect for runout.
1. Place the camshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.03 mm (0.0012 in.)
If the circle runout is greater than the maximum, replace the camshaft.
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Fig. 112: Measuring Circle Runout At Center Journal

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b. Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.
Fig. 113: Measuring Cam Lobe Height

Standard cam lobe height:
STANDARD CAM LOBE HEIGHT

Intake 46.495 to 46.595 mm (1.8305 to 1.8345 in.)
Minimum cam lobe height:
MINIMUM CAM LOBE HEIGHT
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Intake 46.385 mm (1.8262 in.)

Exhaust 45.873 mm (1.8060 in.)
If the lobe height is less than the minimum, replace the camshaft.
c. Inspect the camshaft journals.
Using a micrometer, measure the journal diameter.
Fig. 114: Measuring Journal Diameter

Journal diameter:
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JOURNAL DIAMETER REFERENCE

No. 1 35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Others 22.959 to 22.975 mm (0.9040 to 0.9045 in.)
If the journal diameter is not as specified, check the oil clearance.
d. Inspect the journal clearance.

1. Clean the bearings, bearing caps and camshaft journals.
2. Install the bearings (see step 7).
3. Place the camshafts on the cylinder head.
4. Lay a strip of Plastigage across each of the camshaft journal.
Fig. 115: Measuring Plastigage At Widest Point

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Fig. 116: Laying Strip Of Plastigage Across Each Of Camshaft Journal

5. Install the bearing caps (see INSTALLATION ).

6. Remove the bearing caps.
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Fig. 117: Removing/Installing Bearing Caps

7. Measure the Plastigage at its widest point.
Standard oil clearance:
STANDARD OIL CLEARANCE REFERENCE

Intake No. 1 0.007 to 0.038 mm (0.0003 to 0.0015 in.)
Intake Others 0.025 to 0.062 mm (0.0010 to 0.0024 in.)
Exhaust No. 1 0.040 to 0.079 mm (0.0015 to 0.0031 in.)
Exhaust Others 0.025 to 0.062 mm (0.0010 to 0.0024 in.)
Maximum oil clearance:
MAXIMUM OIL CLEARANCE REFERENCE

Intake No. 1 0.07 mm (0.0028 in.)
Others 0.10 mm (0.0039 in.)
If the oil clearance is greater than the maximum, replace the bearing and/or camshaft. If
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necessary, replace the bearing caps and cylinder head as a set.
HINT:
If using a standard bearing, replace it with one have the same number.
Fig. 118: Replacing With Same Number

Reference
Cylinder head journal bore diameter:
CYLINDER HEAD JOURNAL BORE DIAMETER

Mark 1 40.000 to 40.008 mm (1.5748 to 1.5751 in.)
Mark 2 40.009 to 40.017 mm (1.5752 to 1.5755 in.)
Mark 3 40.018 to 40.025 mm (1.5755 to 1.5758 in.)
Standard bearing center wall thickness:
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STANDARD BEARING CENTER WALL THICKNESS

Mark 1 2.000 to 2.004 mm (0.0787 to 0.0789 in.)
Mark 2 2.005 to 2.008 mm (0.0789 to 0.0791 in.)
Mark 3 2.009 to 2.012 mm (0.0791 to 0.0792 in.)
Camshaft journal diameter: 35.971 to 35.985 mm (1.4165 to 1.4167 in.)
8. Remove the Plastigage completely.

9. Remove the camshafts.
10. Remove the bearings.
e. Inspect the thrust clearance.
1. Install the bearings.
2. Install the camshafts (see INSTALLATION ).
3. Using a dial indicator, measure the thrust clearance while moving the camshaft back and
forth.
Fig. 119: Measuring Thrust Clearance

Standard thrust clearance:

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STANDARD THRUST CLEARANCE

Intake 0.040 to 0.095 mm (0.0016 to 0.0037 in.)
Maximum thrust clearance:
MAXIMUM THRUST CLEARANCE

Intake 0.11 mm (0.0043 in.)
Exhaust 0.15 mm (0.0059 in.)
If the thrust clearance is greater than the maximum, replace the camshaft. If necessary,
replace the bearing caps and cylinder head as a set.
4. Remove the bearings.

5. Remove the camshafts.
11. INSPECT VVT TIMING SPROCKET (VALVE TIMING CONTROLLER ASSEMBLY)
a. Apply vinyl tape to all the ports except the one.
Fig. 120: Applying Vinyl Tape To All Ports

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b. Install the VVT timing sprocket.
torque: 54 N.m (550 kgf.cm, 40 ft.lbf)
NOTE: Do not push VVT timing sprocket to the camshaft forcibly when
installing it.
c. Check that the VVT timing sprocket will not turn.

d. Wind tape around the tip of the air gun and apply air of approx. 100 kPa (1 kgf/cm2 , 14 psi) to the
port of the camshaft.
NOTE: When the oil splashes, wipe it off with a shop rag and the likes.
HINT:
Perform this in order to release the lock pin for the maximum delay angle locking.
e. Under the condition of (d), turn the VVT timing sprocket to the advance angel side (the arrow
marked direction in the illustration) with your hand.
Standard: Must turn
HINT:
Depending on the air pressure, the VVT timing sprocket will turn to the advance angle side without
applying force by hand. Also, under the condition that the pressure can be hardly applied because
of the air leakage from the port, there may be the case that the lock pin could be hardly released.
f. Except the position where the lock pin meets at the maximum delay angle, let the VVT timing
sprocket turn back and forth and check the movable range and that there is no disturbance.
Standard: Movable smoothly in the range about 30°
g. Turn the VVT timing sprocket with your hand and lock it at the maximum delay angel position.
12. INSPECT VALVE LIFTERS AND LIFTER BORES
a. Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
Lifter bore diameter: 31.009 to 31.025 mm (1.2208 to 1.2215 in.)
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Fig. 121: Measuring Lifter Bore Diameter Of Cylinder Head

b. Using a micrometer, measure the lifter diameter.
Lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.)
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Fig. 122: Measuring Lifter Diameter

c. Subtract the lifter diameter measurement from the lifter bore diameter measurement.
Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.)
Maximum oil clearance: 0.079 mm (0.0031 in.)
If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder
head.
13. INSPECT EXHAUST MANIFOLD
Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder head for
warpage.
If warpage is greater than the maximum, replace the exhaust manifold.
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Fig. 123: Inspecting Exhaust Manifold

14. INSPECT CYLINDER HEAD BOLTS

Standard length: 161.3 the 162.7 mm (6.350 the 6.405 in.)
Maximum length: 164.2 mm (6.4646 in.)
If the length is greater than the maximum, replace the bolt.
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Fig. 124: Inspecting Cylinder Head Bolts

REPLACEMENT
REPLACE VALVE GUIDE BUSHINGS
a. Gradually heat the cylinder head to 80 to 100°C (176 to 212°F).
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Fig. 125: Heating Cylinder Head

b. Using SST and a hammer, tap out the guide bushing.
SST 09201-01055, 09950-70010 (09951-07100)
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Fig. 126: Tapping Out Guide Bushing

c. Using a caliper gauge, measure the bushing bore diameter of the cylinder head.
Diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
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Fig. 127: Measuring Bushing Bore Diameter Of Cylinder Head

d. Install the standard bushing if the diameter is within specified diameter.
Standard: 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
e. Gradually heat the cylinder head to 80 to 100°C (176 to 212°F).

f. Using SST and a hammer, tap in a new guide bushing to the specified protrusion height.
SST 09201-01055, 09950-70010 (09951-07100)
Protrusion height (H): 9.6 to 10.0 mm (0.380 to 0.394 in.)
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Fig. 128: Tapping Guide Bushing To Specified Protrusion Height

g. Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance (see
INSPECTION ) between the guide bushing and valve stem.
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Fig. 129: Reaming Guide Bushing

REASSEMBLY
HINT:
 Thoroughly clean all parts to be assembled.

 Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
 Replace oil seals with new ones.
1. INSTALL VALVES
a. Using SST, push in a new oil seal.
SST 09201-41020
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Fig. 130: Pushing In New Oil Seal

HINT:
The intake valve oil seal is gray and the exhaust valve oil seal is black.
NOTE: Pay much attention to assemble the oil seal for intake and exhaust.
Assembling the wrong one may cause a failure.
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Fig. 131: Identifying Intake Valve & Exhaust Valve Oil Seal
b. Install the valve (1), spring seat (2), valve spring (3) and spring retainer (4).
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Fig. 132: Identifying Valve

c. Using SST, compress the valve spring and place the 2 keepers around the valve stem.
SST 09202-00020, 09202-70020
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Fig. 133: Compressing Valve Spring Using SST

d. Using a plastic-faced hammer and the valve stem (not in use) tip wound with vinyl tape, lightly tap
the valve stem tip to ensure a proper fit.
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Fig. 134: Tapping Valve Stem Tip

NOTE: Be careful not to damage the valve stem tip.
2. INSTALL VALVE LIFTERS

a. Install the valve lifter.
b. Check that the valve lifter rotates smoothly by hand.
3. INSTALL CAMSHAFT POSITION SENSOR
Install the camshaft position sensor with the bolt.
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Fig. 135: Installing Camshaft Position Sensor

4. INSTALL ECT SENSOR
Install a new gasket and the ECT sensor.
5. INSTALL OIL PRESSURE SWITCH

a. Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent.
b. Install the oil pressure switch.
INSTALLATION
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HINT:

 Replace all gaskets and oil seals with new ones.
1. INSTALL CYLINDER HEAD

a. Place a new cylinder head gasket on the cylinder block surface with the lot No. upward.
NOTE: Be careful of the installation direction.
Fig. 136: Identifying Lot No.

b. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.
c. Install the cylinder head bolts.
HINT:
 The cylinder head bolts are tightened in 2 steps (steps 2 and 4 ).

 If any cylinder head bolt is broken or deformed, replace it.
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1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head
bolts.
2. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head
bolts and plate washers in several passes, in the sequence shown.
If any one of the cylinder head bolts does not meet the torque specification, replace the
cylinder head bolt.
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Fig. 137: Installing Cylinder Head Bolts In Sequence

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3. Mark the front of the cylinder head bolt with paint.

4. Retighten the cylinder head bolts 90° in the numerical order shown in Fig. 138.
Fig. 138: Retightening Cylinder Head Bolts

5. Check that the painted mark is now at a 90° angle to the front.
2. INSTALL CAMSHAFTS
a. Install the lower camshaft bearing to the cylinder head.
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Fig. 139: Installing Lower Camshaft Bearing To Cylinder Head

b. Align the bearing claw with the claw groove of No. 1 bearing cap, and push in the upper camshaft
bearing.
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Fig. 140: Aligning Bearing Claw With The Claw Groove Of No. 1 Bearing Cap
c. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown in Fig. 141 .
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Fig. 141: Placing Camshafts On Cylinder Head With No. 1 Cam Lobes
d. Install the bearing caps in their proper locations.
HINT:
 Each of No. 3 camshaft bearing cap has a number and front mark.
 The No. 1 and No. 2 bearing caps has a front marks.
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Fig. 142: Installing Bearing Caps In Their Proper Locations

e. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
f. Install and uniformly tighten the 20 bearing cap bolts in several passes, in the sequence shown in
Fig. 143.
Torque:
29.5 N.m (301 kgf.cm, 22 ft.lbf) for No. 1 and No. 2

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3. CHECK AND ADJUST VALVE CLEARANCE (See ADJUSTMENT )
NOTE: Under the condition with the timing chain cover removed, in case of
rotating the camshafts, make the position of the crankshaft rotated
clockwise by about 45° from TDC/compression of No. 1 cylinder.
Turn the camshafts and position the cam lobe upward, and check and adjust the valve clearance.
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Fig. 144: Checking & Adjusting Valve Clearance

4. INSTALL CAMSHAFT TIMING SPROCKET AND VVT TIMING SPROCKET (See

INSTALLATION )
5. INSTALL TIMING CHAIN (See INSTALLATION )
6. INSTALL CAMSHAFT POSITION SENSOR (See CAMSHAFT POSITION SENSOR )
7. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE (OCV) (See CAMSHAFT TIMING
OIL CONTROL VALVE )
8. INSTALL OIL FILLER CAP
9. INSTALL INTAKE MANIFOLD AND THROTTLE BODY ASSEMBLY
a. Install a new gasket to the intake manifold.
b. Install intake manifold insulator.
c. Install the intake manifold and throttle body assembly with the 5 bolts and 2 nuts. Uniformly
tighten the bolts and nuts in several passes.
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Fig. 145: Installing Intake Manifold & Throttle Body Assembly

d. Connect the engine wire harness to the clamp.

e. Connect the 2 vacuum hoses to the intake manifold.
f. Connect the 2 water hoses to the throttle body.
g. Connect the throttle position sensor connector.
10. INSTALL PCV VALVE AND HOSES
a. Install the PCV valve with the grommet.
b. Install the PCV hoses.
11. CONNECT ENGINE WIRE
a. Connect the noise filter.
b. Connect the ETC sensor connector.
c. Connect the camshaft position sensor connector.
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d. Connect the oil pressure switch connector and wire.

e. Connect the crankshaft position sensor.
f. Connect the OCV connector.
g. Install the engine wire with the 2 bolts.
12. INSTALL EXHAUST MANIFOLD ASSEMBLY
a. Temporary install the No. 1 and No. 2 exhaust manifold stays to the exhaust manifold with the 2
nuts.
b. Install a new gasket and the exhaust manifold with the 5 nuts.
c. Install the 2 exhaust manifold stays with the 2 bolts.
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Fig. 146: Installing Exhaust Manifold Stays

d. Tighten the 2 nuts holding the exhaust manifold stays to crank case.
e. Install the 2 compression springs and 2 bolts holding the exhaust manifold and front exhaust pipe.
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f. Install the exhaust manifold heat insulator No. 1 with the 4 bolts.
g. Connect the A/F sensor connector.

13. INSTALL INJECTORS (See INJECTOR )
14. INSTALL SPARK PLUGS (See ON-VEHICLE INSPECTION )
15. INSTALL IGNITION COILS (See IGNITION COIL )
16. INSTALL PS VANE PUMP (See INSTALLATION )
17. INSTALL GENERATOR (See REMOVAL & INSTALLATION )
18. INSTALL DRIVE BELT (See BELT TENSION )
19. INSTALL AIR CLEANER ASSEMBLY
a. Connect the PCV hose to the cylinder head cover.
b. Connect the CCV hose to the air cleaner.
c. Connect the VSV connect for EVAP.
d. Connect the 2 EVAP hoses to the VSV.
e. Connect the MAF meter connector.
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Fig. 147: Installing Air Cleaner Assy

20. FILL WITH ENGINE OIL (See REPLACEMENT )

22. START ENGINE AND CHECK FOR LEAK
23. RECHECK ENGINE OIL AND COOLANT LEVEL
24. INSTALL RH ENGINE UNDER COVER
ENGINE UNIT
COMPONENTS
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Fig. 148: Identifying Engine Unit Components (1 Of 6)

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REMOVAL
1. REMOVE ENGINE UNDER COVERS

2. DRAIN TRANSAXLE OIL
3. DRAIN TRANSFER OIL
4. DRAIN ENGINE OIL
6. REMOVE HOOD
7. REMOVE RADIATOR RESERVOIR
8. REMOVE BATTERY AND TRAY
a. Remove the cowl top ventilation louver (see REMOVAL ).
b. Remove the hold-down clamp, battery and tray.
c. Remove the 5 bolts and battery bracket.
Fig. 154: Removing Battery & Tray


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b. Disconnect the 2 EVAP hoses from the VSV.

c. Disconnect VSV connector for EVAP.
d. Disconnect the CCV hose from the air cleaner.
e. Disconnect the PCV hose from the cylinder head cover.
f. Disconnect the air cleaner hose from the throttle body, and remove the 3 bolts and the air cleaner
assembly.
Fig. 155: Removing Air Cleaner Assy

10. REMOVE ENGINE ROOM J/B

a. Remove the engine room J/B cover.
b. Loosen the bolt.
c. Remove the engine room J/B.
d. Pull out the engine wire connector.
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Fig. 156: Removing Engine Wire Connector

e. Disconnect the connector.

f. Disconnect the engine wire clamp.
11. DISCONNECT ENGINE WIRE FROM CABIN
a. Remove the 2 screws and glove compartment door.
b. Disconnect the 6 engine wire connectors from the ECM and instrument panel wire.
c. Pull out the engine wire from the cabin.
12. DISCONNECT TUBES, HOSES, CONNECTOR, CABLE AND WIRE
a. Disconnect the accelerator cable.
b. Disconnect the ground wire from the cylinder head.
c. Disconnect the discharge and liquid tubes from the compressor, and remove the 2 O-rings (see
REMOVAL ).
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Fig. 157: Disconnecting Discharge & Liquid Tubes

d. Disconnect the suction hose, pressure feed tube and gasket from the PS vane pump.
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Fig. 158: Disconnecting Suction Hose

e. Disconnect the upper radiator hose.

f. Disconnect the lower radiator hose.
g. Disconnect the fuel tube connector (see PRECAUTION ).
h. Disconnect the 2 heater hoses.
i. Disconnect the connector from the fusible link block.
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Fig. 159: Disconnecting Connector From Fusible Link Block

13. M/T:
DISCONNECT SHIFT CONTROL CABLES FROM TRANSAXLE
a. Remove the 2 clips and 2 washers.

b. Remove the 2 clips, and disconnect the 2 control cables.
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Fig. 160: Disconnecting Shift Control Cables From Transaxle

14. REMOVE STARTER

a. A/T:
Disconnect the hose from the dipstick guide.
b. Disconnect the connector.

c. Remove the 2 bolts, and disconnect the starter.
d. Remove the nut, and disconnect the starter cable.
e. Remove the starter.
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Fig. 161: Removing Starter

15. M/T: DISCONNECT CLUTCH RELEASE CYLINDER AND LINE FROM TRANSAXLE
a. Remove the 2 bolts and heat insulator.
b. Remove the 5 bolts, and disconnect the release cylinder.
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Fig. 162: Disconnecting Clutch Release Cylinder & Line From Transaxle (M/T)
16. A/T: DISCONNECT SHIFT CONTROL CABLE FROM TRANSAXLE

a. Remove the nut holding the control shift lever to the control cable.
b. Remove the clip, and disconnect the control cable.
c. Disconnect the control cable from the cable clamp.
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Fig. 163: Disconnecting Shift Control Cable From Transaxle (A/T)

17. A/T: DISCONNECT OIL COOLER HOSES
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Fig. 164: Disconnecting Oil Cooler Hose

18. DISCONNECT GROUND CABLE FROM TRANSAXLE

19. 4WD: REMOVE PROPELLER SHAFT (See REMOVAL )
20. REMOVE FRONT DRIVE SHAFTS (See REMOVAL )
Remove the 4 bolts, 2 compression rings, 2 gaskets and exhaust pipe.
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Fig. 165: Removing Front Exhaust Pipe

22. DISCONNECT STABILIZER BAR LINKS
Remove the 2 nuts, and disconnect the LH and RH stabilizer links.
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Fig. 166: Disconnecting Stabilizer Bar Links

23. DISCONNECT PS GEAR ASSEMBLY
Remove the 2 bolts of the PS gear assembly.
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Fig. 167: Disconnecting PS Gear Assembly

24. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS

a. Install No. 1 and No. 2 engine hangers in the correct direction.
ENGINE HANGERS PART NO.

Item Part No.
No. 1 and No. 2 engine hangars 12281-28010, 12281-28020 or 12281-28030
bolt 91512-61020 x 2
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Fig. 168: Installing No. 1 & No. 2 Engine Hangers

b. Attach the sling device to the engine hangers.
CAUTION: Do not attempt to hang the engine by hooking the chain to any
other part.
25. REMOVE ENGINE, TRANSAXLE, FRONT SUSPENSION CROSSMEMBER AND CENTER

ENGINE MOUNTING MEMBER ASSEMBLY
a. Remove the 2 nuts and bolt holding the RH engine mounting insulator to the timing chain cover.
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Fig. 169: Removing Nuts/Bolt Holding RH Engine Mounting Insulator

b. Remove the bolt holding the LH engine mounting insulator to the mounting bracket.
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Fig. 170: Removing Bolt Holding LH Engine Mounting Insulator

c. Support the suspension crossmember with a jack.

d. Remove the 6 bolts holding the suspension crossmember engine mounting member to the body.
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Fig. 171: Removing Suspension Crossmember Engine Mounting Member Bolts

e. Lower the engine out of the vehicle slowly and carefully.
NOTE: Make sure the engine is clear of all wiring, hoses and cables.
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Fig. 172: Lowering Engine Out Of Vehicle

26. REMOVE ENGINE AND TRANSAXLE ASSEMBLY FROM FRONT SUSPENSION

CROSSMEMBER AND CENTER ENGINE MOUNTING MEMBER
a. Remove the bolt holding the front engine mounting bracket to the mounting insulator.
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Fig. 173: Removing Front Engine Mounting Bracket Holding Bolt

b. Remove the bolt holding the rear engine mounting bracket to the mounting insulator.
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Fig. 174: Removing Rear Engine Mounting Bracket Holding Bolt

c. Separate the engine and transaxle assembly from the suspension crossmember and engine mounting
member.
27. 4WD: REMOVE STIFFENER PLATE
Remove the 5 bolts and stiffener plate.
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Fig. 175: Removing Stiffener Plate (4WD)

28. 2WD: REMOVE CENTER BEARING BRACKET
Remove the 3 bolts and bearing bracket.
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Fig. 176: Removing Center Bearing Bracket (2WD)

29. A/T: REMOVE TORQUE CONVERTER CLUTCH BOLTS

a. Remove the hole plug.
b. Turn the crankshaft to gain access to each bolt.
c. Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts.
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Fig. 177: Removing Torque Converter Clutch Bolts (A/T)


a. Remove the 4 lower bolts holding the engine to the transaxle.
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Fig. 178: Removing Transaxle Bolts

b. M/T:
Disconnect the connectors.
1. Disconnect the vehicle speed sensor connector.

2. Disconnect the back-up light switch connector.
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Fig. 179: Disconnecting Connectors (M/T)

c. A/T:
Disconnect the connectors and clamps.
1. Disconnect the park/neutral position switch connector.
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Fig. 180: Disconnecting Park/Neutral Position Switch Connector (A/T)

2. Disconnect the solenoid wire connector.

3. Disconnect the input turbine speed sensor connector.
4. Disconnect the counter gear speed sensor connector.
5. Disconnect the vehicle speed sensor.
6. Disconnect the wire clamp from the bracket.
7. Disconnect the wire clamp from the engine mounting bracket.
d. Remove the 6 upper bolts holding the transaxle to the engine.
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Fig. 181: Removing Transaxle Bolts

e. Remove the transaxle together with the torque converter clutch (A/T) from the engine.
31. REMOVE DRIVE BELT (See REMOVAL & INSTALLATION )
32. M/T: REMOVE CLUTCH COVER, DISC AND FLYWHEEL
33. A/T: REMOVE DRIVE PLATE
34. REMOVE A/C COMPRESSOR
a. Disconnect the magnetic clutch and lock sensor connector from the compressor.
b. Remove the 3 bolts, nut and compressor.
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Fig. 182: Removing A/C Compressor

35. REMOVE PS VANE PUMP

a. Disconnect the oil pressure switch connector.
b. Remove the 2 bolts and vane pump.
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Fig. 183: Removing PS Vane Pump

36. REMOVE GENERATOR

a. Remove the terminal cover and nut, and disconnect the generator wire.
b. Disconnect the generator connector.
c. Disconnect the A/C wire.
d. Remove the 2 bolts and generator.
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Fig. 184: Removing Generator

INSTALLATION
1. INSTALL GENERATOR
a. Install the generator with the 2 bolts.
Torque:

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Fig. 185: Installing Generator

b. Connect the A/C wire.

c. Connect the generator connector.
d. Connect the generator wire with the nut, and install the cover.
2. INSTALL PS VANE PUMP

a. Install the vane pump with the 2 bolts.
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Fig. 186: Installing PS Vane Pump

b. Connect the oil pressure switch connector.

3. INSTALL A/C COMPRESSOR
1. Install the compressor with the 3 bolts and nut.
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Fig. 187: Installing A/C Compressor

2. Connect the magnetic clutch and lock sensor connector.

4. INSTALL DRIVE BELT (See REMOVAL & INSTALLATION )
5. A/T: INSTALL DRIVE PLATE
a. Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
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Fig. 188: Applying Adhesive To Threads Of Bolt End

b. Align the pin of the front spacer with the pin hole of the crankshaft, and install the front spacer.
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Fig. 189: Aligning Pin Of Front Spacer With Pin Hole Of Crankshaft
c. Install the drive plate and rear spacer as shown in Fig. 190 .
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Fig. 190: Installing Drive Plate & Rear Spacer

d. Install and uniformly tighten the 8 bolts in several passes, in the sequence shown.
6. M/T: INSTALL FLYWHEEL (See procedure in step 5)
7. MT: INSTALL CLUTCH DISC AND COVER (See INSTALLATION )
Fig. 191: Tightening Sequence Of Flywheel Drive Plate And Rear Spacer Bolts
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8. INSTALL ENGINE TO TRANSAXLE

a. Install the 6 upper bolts holding the transaxle to the engine.
Torque:

Fig. 192: Installing Transaxle Bolts

b. A/T:
Connect the connectors and clamps.
1. Connect the park/neutral position switch connector.

2. Connect the solenoid wire connector.
3. Connect the input turbine speed sensor connector.
4. Connect the counter gear speed sensor connector.
5. Connect the vehicle speed sensor.
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6. Connect the wire clamp from the bracket.

7. Connect the wire clamp to the mounting bracket.
Fig. 193: Connecting Connectors & Clamps (A/T)

c. M/T:
Connect the connectors.
1. Connect the vehicle speed sensor connector.

2. Connect the back-up light switch connector.
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Fig. 194: Connecting Connectors (M/T)

d. Install the 4 lower bolts holding the engine to the transaxle.
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Fig. 195: Installing Lower Bolts Holding Engine To Transaxle

9. A/T: INSTALL TORQUE CONVERTER CLUTCH BOLTS

a. Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
b. Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly.
HINT:
First tighten the green colored bolt, install the other bolts.
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Fig. 196: Tightening Green Colored Bolt

10. 2WD: INSTALL CENTER BEARING BRACKET
Install the bearing bracket with the 3 bolts.
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Fig. 197: Installing Center Bearing Bracket

11. 4WD: INSTALL STIFFENER PLATE
Install the stiffener plate with the 5 bolts.
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Fig. 198: Installing Stiffener Plate

12. INSTALL ENGINE AND TRANSAXLE ASSEMBLY TO FRONT SUSPENSION

CROSSMEMBER AND CENTER ENGINE MOUNTING MEMBER
a. Attach the engine and transaxle assembly to the suspension crossmember and engine mounting
member.
b. Install the bolt holding the rear engine mounting bracket to the mounting insulator.
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Fig. 199: Installing Bolt Holding Rear Engine Mounting Bracket To Mounting Insulator
c. Install the bolt holding the front engine mounting bracket to the mounting insulator.
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Fig. 200: Installing Bolt Holding Front Engine Mounting Bracket To Mounting Insulator
13. INSTALL ENGINE, TRANSAXLE, FRONT SUSPENSION CROSSMEMBER AND CENTER

ENGINE MOUNTING MEMBER ASSEMBLY IN VEHICLE
a. Attach the engine sling device to the engine hangers.
b. Lift the engine into the engine compartment.
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Fig. 201: Lifting Engine Into Engine Compartment

c. Install the bolt and 2 nuts holding the RH engine mounting insulator to the timing chain cover.
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Fig. 202: Installing Bolt And Nuts Holding RH Engine Mounting Insulator To Timing Chain
Cover
d. Install the bolt holding the LH engine mounting bracket to the mounting insulator.
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Fig. 203: Installing LH Engine Mounting Bracket Bolt

e. Support the suspension crossmember with a jack.

f. Install the 6 bolts holding the suspension crossmember engine mounting member to the body.
Torque:

113 N.m (1,153 kgf.cm, 83 ft.lbf) for bolt B
157 N.m (1,601 kgf.cm, 116 ft.lbf) for bolt C
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Fig. 204: Installing Suspension Crossmember Engine Mounting Member Bolts

14. INSTALL PS GEAR ASSEMBLY
Install the PS gear assembly with the 2 bolts.
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Fig. 205: Installing PS Gear Assembly

15. REMOVE NO. 1 AND NO. 2 ENGINE HANGERS

16. CONNECT STABILIZER BAR LINKS
Connect the LH and RH stabilizer links with the 2 nuts.
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Fig. 206: Connecting Stabilizer Bar Links

Install 2 new gaskets and the exhaust pipe, with the 2 compression rings and 4 bolts.
Torque:

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Fig. 207: Installing Front Exhaust Pipe

18. INSTALL LH AND RH FRONT DRIVE SHAFTS (See INSTALLATION )

19. 4WD: INSTALL PROPELLER SHAFT (See INSTALLATION )
20. CONNECT GROUND CABLE TO TRANSAXLE
21. A/T: CONNECT OIL COOLER HOSES
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Fig. 208: Connecting Oil Cooler Hoses (A/T)

22. A/T: CONNECT SHIFT CONTROL CABLE TO TRANSAXLE

a. Connect the control cable with the nut.
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Fig. 209: Connecting Control Cable Nut

b. Connect the control cable with the clip.

c. Connect the control cable to the cable clamp.
23. M/T: INSTALL CLUTCH RELEASE CYLINDER AND TUBE
a. Install the release cylinder with the 5 bolts.
Torque:

5.0 N.m (51 kgf.cm, 44 in.lbf) for bolt C
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Fig. 210: Installing Release Cylinder (M/T)

b. Install the heat insulator with the 2 bolts.
24. INSTALL STARTER

a. Install the starter.
b. Connect the starter cable with the nut.
c. Install the starter with the 2 bolts.
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Fig. 211: Installing Starter

d. Connect the connector.

e. Connect the hose to the dipstick guide.
25. M/T: CONNECT SHIFT CONTROL CABLES TO TRANSAXLE
a. Connect the 2 control cables with the 2 clips.
b. Install the 2 washers and 2 clips.
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Fig. 212: Connecting Shift Control Cables To Transaxle

26. DISCONNECT TUBES, HOSES, CONNECTOR, CABLE AND WIRE

a. Install 2 new O-rings, and connect the discharge and liquid tubes to the compressor (see
REMOVAL ).
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Fig. 213: Connecting Discharge & Liquid Tubes To Compressor

b. Connect the accelerator cable.

c. Connect the ground wire to the cylinder head.
d. Install a new gasket, and connect the suction hose and pressure feed tube to the PS vane pump.
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Fig. 214: Connecting Suction Hose & Pressure Feed Tube

e. Connect the upper radiator hose.

f. Connect the lower radiator hose.
g. Connect the fuel tube connector (see PRECAUTION ).
h. Connect the 2 heater hoses.
i. Connect the connector to the fusible link block.
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Fig. 215: Connecting Connector To Fusible Link Block

27. CONNECT ENGINE WIRE TO CABIN

a. Push in engine wire through the cabin.
b. Connect the 6 engine wire connectors to the ECM and instrument panel wire.
c. Install the glove compartment door with the 2 screws.
28. INSTALL ENGINE ROOM J/B
a. Connect the engine wire clamp.
b. Connect the connector.
c. Push into the engine wire connector.
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Fig. 216: Pushing Into Engine Wire Connector

d. Install the engine room J/B, and tighten the bolt until it fails to catch.
e. Install the engine room J/B cover.
29. INSTALL AIR CLEANER ASSEMBLY
a. Connect the air cleaner hose to the throttle body, and install the air cleaner assembly with the 3
bolts.
b. Connect the MAF meter connector.
c. Connect the 2 EVAP hoses to the VSV.
d. Connect the VSV connector for EVAP.
e. Connect the CCV hose to the air cleaner.
f. Connect the PCV hose to the cylinder head cover.
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Fig. 217: Installing Air Cleaner Assembly

30. INSTALL BATTERY AND TRAY

a. Install the battery bracket with the 5 bolts.
b. Install the battery tray and battery with the hold-down clamp.
c. Install the cowl top ventilation louver (see INSTALLATION ).
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Fig. 218: Installing Battery & Tray

31. INSTALL RADIATOR RESERVOIR TANK

32. INSTALL HOOD (See ADJUSTMENT )
34. FILL WITH ENGINE OIL
35. FILL WITH TRANSFER OIL
36. FILL WITH TRANSAXLE OIL
38. BLEED POWER STEERING SYSTEM (See BLEEDING )
39. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
40. RECHECK ENGINE COOLANT AND OIL LEVELS

41. INSTALL ENGINE UNDER COVERS
CYLINDER BLOCK
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COMPONENTS
Fig. 219: Identifying Cylinder Block Components (1 Of 2)

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Fig. 220: Identifying Cylinder Block Components (2 Of 2)

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DISASSEMBLY
1. Install Engine To Engine Stand For Disassembly

2. Remove Timing Chain (See REMOVAL ).
3. Remove Cylinder Head See REMOVAL .
4. Remove Knock Sensor See KNOCK SENSOR .
5. Remove Engine Wire Clamps
6. Remove Plug
7. Remove OCV Filter
Using a 12 mm hexagon wrench, remove the plug, gasket and OCV filter.
Fig. 221: Removing Plug, Gasket & OCV Filter

8. Remove Water Pump See REMOVAL .

9. Remove Thermostat See REMOVAL .
10. Remove Engine Coolant Drain Union
11. Remove Oil Dipstick & Guide
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a. Remove the bolt, oil dipstick and guide.

b. Remove the O-ring from the oil dipstick.
Fig. 222: Removing Oil Dipstick & Guide

12. Remove Water Bypass Pipe
Remove the 2 nuts, bolt, water bypass pipe and gasket.
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Fig. 223: Removing Water Bypass Pipe

13. Remove Oil Pump See REMOVAL .

14. Remove Oil Filter See REPLACEMENT .
15. Remove Oil Filter Union
Using a 12 mm hexagon wrench, remove the oil filter union.
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Fig. 224: Removing Oil Filter Union

16. Check Balance Shaft Thrust Clearance
Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
Standard Thrust Clearance: 0.050-0.090 mm (0.00197-0.00354 in.)

Maximum Thrust Clearance: 0.090 mm (0.00354 in.)
If the thrust clearance is greater than maximum, replace the balance shaft housing and bearings. If
necessary, replace the balance shaft.
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17. Remove Balance Shaft Housing & Check Oil Clearance

a. Uniformly loosen and remove the 8 bolts in several passes, in the sequence shown in Fig. 226.
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Fig. 226: Removing Balance Shaft Housing Bolts

If the balance shaft housing is difficult to lift up, pry between the balance shaft housing and crank
case with a screwdriver.
NOTE: Be careful not to damage the contact surfaces of the balance shaft
housing and crank case.
HINT: Keep the lower bearing and balance shaft housing together.
b. Lift out the No. 1 and No. 2 balance shafts.
HINT: Keep the upper bearing with the crank case.
c. Clean each bearing and journal.

d. Check each bearing and journal for pitting and scratches.
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If the bearing or journal is damaged, replace the bearings. If necessary, replace the balance shaft.
e. Place the No. 1 and No. 2 balance shafts on the crank case.
f. Lay a strip of Plastigage across each journal.
Fig. 227: Laying Strip Of Plastigage Across Each Journal

g. Install the balance shaft housing. See REASSEMBLY .
NOTE: Do not turn the balance shaft.
h. Remove the balance shaft housing. See step above.

i. Measure the Plastigage at its widest point.
Standard Clearance: 0.004-0.049 mm (0.00016-0.00192 in.)
If the oil clearance is greater than standard, replace the bearings.
If necessary, replace the balance shaft.
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HINT: If using a standard bearing, replace it with one having the same number.
Balance Shaft Housing Journal Diameter

Mark 1 26.000-26.006 mm (1.02362-
1.02386 in.)
Mark 2 26.007-26.012 mm (1.02390-
1.02409 in.)
Mark 3 26.013-26.018 mm (1.02413-
1.02433 in.)
Balance Shaft Journal Diameter: 22.985-23.000 mm (0.90492-0.90551 in.)
Standard Bearing Center Wall Thickness

Mark 1 1.486-1.489 mm (0.05850-
0.05862 in.)
Mark 2 1.490-1.492 mm (0.05866 to
0.05874 in.)
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Mark 3 1.493-1.495 mm (0.05877 to

0.05885 in.)
Fig. 229: Replacing Balance Shaft

18. Remove Balance Shaft

a. Lift out the balance shaft.
b. Remove the 4 upper bearings from the crank case.
HINT: Arrange the bearings in the correct order.
19. Remove Crank Case

a. Uniformly loosen and remove the 11 bolts in several passes, in the sequence shown in Fig. 230.
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Fig. 230: Removing Crank Case Bolts

b. Using a screwdriver, remove the crank case by prying the portions between the crank case and
cylinder block.
NOTE: Be careful not to damage the contact surfaces of the crank case and
cylinder block.
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Fig. 231: Removing Crank Case By Prying

c. Remove the O-ring.

20. Remove Crankshaft Rear Oil Seal
21. Check Connecting Rod Thrust Clearance
Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

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If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary,
replace the crankshaft.
Connecting Rod Thickness: 19.788-19.840 mm (0.7791-0.7811 in.)
22. Remove Connecting Rod Caps & Check Oil Clearance

a. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
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Fig. 233: Checking Matchmarks On Connecting Rod & Cap Are Aligned
b. Remove the 2 connecting rod cap bolts.

c. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by
wiggling the connecting rod cap right and left.
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Fig. 234: Removing Connecting Rod Cap

HINT: Keep the lower bearing inserted with the connecting rod cap.
d. Clean the crank pin and bearing.

e. Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
f. Lay a strip of Plastigage on the crank pin.
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Fig. 235: Laying Strip Of Plastigage On Crank Pin

g. Install the connecting rod cap. See REASSEMBLY.
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Fig. 236: Installing Connecting Rod Cap Bolt

NOTE: Do not turn the crankshaft.
h. Remove the connecting rod cap. See steps a and b above.

i. Measure the Plastigage at its widest point.
Standard Oil Clearance: 0.024-0.048 mm (0.0009-0.0019 in.)
Maximum Oil Clearance: 0.08 mm (0.0031 in.)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the
crankshaft.
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Fig. 237: Measuring Plastigage At Its Widest Point

HINT: If replacing a bearing, replace it with one having the same number as marked on the
connecting rod. There are 3 sizes of standard bearings, marked 1, 2 and 3 accordingly.
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Fig. 238: Locating Mark On Bearing & Bearing Cap

Reference:
STANDARD BEARING CENTER WALL THICKNESS

Mark 1 1.485-1.488 mm (0.0585-
0.0586 in.)
Mark 2 1.489-1.491 mm (0.0586-
0.0587 in.)
Mark 3 1.492-1.494 mm (0.0586-
0.0587 in.)
j. Completely remove the Plastigage.

23. Remove Piston & Connecting Rod Assemblies
a. Using a ridge reamer, remove all the carbon from the top of the cylinder.
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Fig. 239: Removing Carbon From Top Of Cylinder

b. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
HINT:
 Keep the bearings, connecting rod and cap together.
 Arrange the piston and connecting rod assemblies in the correct order.
24. Check Crankshaft Thrust Clearance
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a
screwdriver.

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If the thrust clearance is greater than the maximum, replace the thrust washers as a set.
Thrust Washer Thickness: 1.930-1.980 mm (0.0760-0.0780 in.)
25. Remove Main Bearing Caps & Check Oil Clearance

a. Uniformly loosen and remove the 10 main bearing cap bolts in several passes, in the sequence
shown. See Fig. 241.
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Fig. 241: Removing Main Bearing Bolts In Sequence

b. Using the 2 removed main bearing cap bolts, remove the 5 main bearing caps and 5 lower bearings.
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Fig. 242: Removing Main Bearing Caps

NOTE: Be careful not to damage the cylinder block.
HINT:
 Keep the lower bearing and main bearing cap together.
 Arrange the main bearing caps in the correct order.
c. Lift out the crankshaft.
HINT: Keep the main bearings and thrust washers together with the cylinder block.
d. Clean each main journal and bearing.

e. Check each main journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
f. Place the crankshaft on the cylinder block.

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g. Lay a strip of Plastigage across each journal.
Fig. 243: Laying Strip Of Plastigage Across Each Journal

h. Install the main bearing caps. See REASSEMBLY .
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Fig. 244: Installing Main Bearing Caps

NOTE: Do not turn the crankshaft.
i. Remove the main bearing cap. See procedure and a above.

j. Measure the Plastigage at its widest point.
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the
crankshaft.
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k. If using a standard bearing, replace it with one having the same number. If the number of the
bearing cannot be determined, select the correct bearing by adding together the numbers imprinted
on the cylinder block and crankshaft, then selecting the bearing with the same number as the total.
There are 4 sizes of standard bearings, marked 1, 2, 3 and 4 accordingly.
EXAMPLE: Cylinder Block "4" + Crankshaft "3" = Total Number 7 (Use Bearing "3")
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Fig. 246: Bearing Number Reference Table

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Fig. 247: Locating Number Markings On Crankshaft, Bearing & Cylinder Block
Fig. 248: Main Bearing Reference Specifications Table

l. Completely remove the Plastigage.

26. Remove Crankshaft
a. Lift out the crankshaft.
b. Remove the 5 upper main bearings and 2 thrust washers from the cylinder block.
HINT: Arrange the main bearings and thrust washers in the correct order.
27. Check Fit Between Piston & Piston Pin
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and
pin as a set.
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Fig. 249: Checking Fit Between Piston & Piston Pin

28. Remove Piston Rings

a. Using a piston ring expander, remove the 2 compression rings.
b. Remove the 2 side rails and oil ring by hand.
HINT: Arrange the piston rings in the correct order only.
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Fig. 250: Removing Piston Rings

29. Disconnect Connecting Rod From Piston

a. Using a small screwdriver, pry out the 2 snap rings.
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Fig. 251: Prying Out Snap Rings

b. Gradually heat the piston to 80-90°C (176-194°F).
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Fig. 252: Heating Piston

c. Using a plastic-faced hammer and a brass bar, lightly tap out the piston pin and remove the
connecting rod.
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Fig. 253: Tapping Out Piston Pin & Removing Connecting Rod
HINT:
 The piston and pin are a matched set.

 Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
INSPECTION
1. Clean Cylinder Block

a. Remove the gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
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Fig. 254: Removing Gasket Material

b. Clean the cylinder block.
Using a soft brush and solvent, thoroughly clean the cylinder block.
NOTE: If the cylinder is washed at high temperatures, the cylinder liner sticks out
beyond the cylinder block, so always wash the cylinder block at a
temperature of 45°C (133°F) or less.
2. Inspect Cylinder Block

a. Inspect for flatness.
Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder head
gasket for warpage.
Maximum Warpage: 0.05 mm (0.0020 in.)
If warpage is greater than the maximum, replace the cylinder block.
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Fig. 255: Measuring Surface Contacting Cylinder Head Gasket For Warpage
b. Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder
block.
Fig. 256: Checking Cylinder For Vertical Scratches

c. Inspect the cylinder bore diameter.
Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust
and axial directions.
Specified Diameter: 88.500-88.513 mm (3.4843-3.4847 in.)

Maximum Diameter: 88.633 mm (3.4894 in.)
If the diameter is greater than the maximum, replace the cylinder block.
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Fig. 257: Measuring Cylinder Bore Diameter

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3. Remove Cylinder Ridge
If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.
Fig. 258: Grinding Top Of Cylinder Using Ridge Reamer

4. Inspect Crankshaft Bearing Cap Bolts
Using vernier calipers, measure the tension portion diameter of the bolt.
Standard Diameter: 7.5-7.6 mm (0.2953-0.2992 in.)

Minimum Diameter: 7.2 mm (0.284 in.)
If the diameter is less than the minimum, replace the bolt.
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Fig. 259: Measuring Tension Portion Diameter

5. Clean Piston
a. Using a gasket scraper, remove the carbon from the piston top.
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Fig. 260: Removing Carbon From Piston Top

b. Using a groove cleaning tool or a broken ring, clean the piston ring grooves.
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Fig. 261: Cleaning Piston Ring Grooves

c. Using a brush and solvent, thoroughly clean the piston.
NOTE: Do not use a wire brush.
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Fig. 262: Cleaning Piston Using Brush & Solvent

6. Inspect Piston
a. Inspect the piston oil clearance.
1. Using a micrometer, measure the piston diameter at right angles to the piston pin center line,
30.4 mm (1.1967 in.) from the piston head.
Piston Diameter: 88.439-88.449 mm (3.4818-3.4822 in.)
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Fig. 263: Measuring Piston Diameter At Right Angles

2. Measure the cylinder bore diameter in the thrust directions. See step 2.
3. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
If the oil clearance is greater than the maximum, replace all the 4 pistons. If necessary,
replace the cylinder block.
b. Inspect the piston ring groove clearance.
Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring
groove. See RING GROOVE CLEARANCE REFERENCE table.
Ring Groove Clearance Reference

No. 1 0.170-0.220 mm (0.0066-
0.0086 in.)
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No. 2 0.170-0.210 mm (0.0066-

0.0082 in.)
Oil (Side rail) 0.210-0.290 mm (0.0082-
0.0114 in.)
If the clearance is not as specified, replace the piston.
Fig. 264: Measuring Clearance Between Piston Ring & Wall Of Ring Groove
c. Inspect the piston ring end gap.

1. Insert the piston ring into the cylinder bore.
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Fig. 265: Inserting Piston Ring Into Cylinder Bore

2. Using the piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm
(4.33 in.) from the top of the cylinder block.
3. Using a feeler gauge, measure the end gap. See STANDARD END GAP REFERENCE
and MAXIMUM END GAP REFERENCE tables.
Standard End Gap Reference

No. 1 0.22-0.32 mm (0.0087-0.0126
in.)
No. 2 0.50-0.60 mm (0.0197-0.0236
in.)
Oil (Side Rail) 0.10-0.35 mm (0.0039-0.0138
in.)
Maximum End Gap Reference

No. 1 0.89 mm (0.0350 in.)
No. 2 1.35 mm (0.0531 in.)
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Oil (Side Rail) 0.73 mm (0.0287 in.)
If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater
than maximum, even with a new piston ring, replace the cylinder block.
Fig. 266: Measuring End Gap Of Piston Ring

d. Inspect the piston pin fit.
At 80-90°C (176-194°F), you should be able to push the piston pin into the piston pin hole with
your thumb.
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Fig. 267: Inspecting Piston Pin Fit

7. Inspect Connecting Rod

a. Using a rod aligner and a feeler gauge, check the connecting rod alignment.
1. Check for out-of-alignment.
Maximum Out-Of-Alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If out-of-alignment is greater than the maximum, replace the connecting rod assembly.
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Fig. 268: Checking For Out-Of-Alignment

2. Check for twist.
Maximum Twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than the maximum, replace the connecting rod assembly.
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Fig. 269: Checking For Twist

b. Inspect the piston pin oil clearance.

1. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing Inside Diameter: 22.005-22.014 mm (0.8663-0.8667 in.)
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Fig. 270: Measuring Inside Diameter

2. Using a micrometer, measure the piston pin diameter.
Piston Pin Diameter: 21.997-22.006 mm (0.8660-0.8664 in.)
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Fig. 271: Measuring Piston Pin Diameter

3. Subtract the piston pin diameter measurement from the bushing inside diameter
measurement.
If the oil clearance is greater than the maximum, replace the bushing. See
REPLACEMENT . If necessary, replace the piston and piston pin as a set.
8. Inspect Connecting Rod Bolts
Using vernier calipers, measure the tension portion diameter of the bolt.
Standard Diameter: 7.2-7.3 mm (0.283-0.287 in.)

Minimum Diameter: 7.0 mm (0.275 in.)
If the diameter is less than the minimum, replace the bolt.
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Fig. 272: Measuring Tension Portion Diameter

9. Inspect Crankshaft
a. Inspect for circle runout.
1. Place the crankshaft on V-blocks.
2. Using a dial indicator, measure the circle runout, as shown in Fig. 273.
Maximum Circle Runout: 0.03 mm (0.0012 in.)
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Fig. 273: Measuring Circle Runout Crankshaft

If the circle runout is greater than the maximum, replace the crankshaft.
b. Inspect the main journals and crank pins.

1. Using a micrometer, measure the diameter of each main journal and crank pin. See
DIAMETER REFERENCE table.
Diameter Reference
Main Journal 54.988-55.000 mm (2.1649-
2.1654 in.)
Crank Pin 47.990-48.000 mm (1.8894-
1.8898 in.)
If the diameter is not as specified, check the oil clearance. See DISASSEMBLY . If
necessary, replace the crankshaft.
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2. Check each main journal and crank pin for taper and out-of-round as shown in Fig. 274.
Maximum Taper & Out-Of-Round: 0.003 mm (0.0001 in.)
If the taper and out-of-round is greater than the maximum, replace the crankshaft.
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Fig. 274: Checking Each Journal & Crank Pin

REPLACEMENT
1. Replace Connecting Rod Bushings

a. Using SST and a press, press out the bushing.
SST 09222-30010
Fig. 275: Pressing Out Bushing

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b. Align the oil holes of a new bushing and the connecting rod.
Fig. 276: Aligning Oil Holes Of Bushing & Connecting Rod

c. Using SST and a press, press in the bushing.
SST 09222-30010
d. Using a pin hole grinder, hone the bushing to obtain the standard specified clearance between the
bushing and piston pin. See INSPECTION .
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Fig. 277: Honing Connecting Rod

e. Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push
it into the connecting rod with your thumb.
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Fig. 278: Pushing Piston Pin Into Connecting Rod

2. Replace Crankshaft Rear Oil Seal
If the rear oil seal is installed to the cylinder block.
1. Using a knife, cut off the oil seal lip.
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Fig. 279: Cutting Off Oil Seal Lip

2. Using a screwdriver, pry out the oil seal.
NOTE: Be careful not to damage the crankshaft. Tape the screwdriver tip.
3. Apply MP grease to a new oil seal lip.

4. Using SST and a hammer, tap in the oil seal until its surface is flush with the oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)
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REASSEMBLY
HINT:

 Replace all gaskets, O-rings and oil seals with new parts.
1. Assemble Piston & Connecting Rod

a. Using a small screwdriver, install a new snap ring at one end of the piston pin hole.
NOTE: Be sure that end gap of the snap ring is not aligned with the pin hole
cutout portion of the piston.
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Fig. 281: Installing Snap Ring

b. Gradually heat the piston to 80-90°C (176-194°F).
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Fig. 282: Heating Piston

c. Coat the piston pin with engine oil.

d. Align the front marks on the piston and connecting rod, and push in the piston with your thumb.
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Fig. 283: Aligning Front Marks On Piston & Connecting Rod

e. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.
NOTE: Be sure that end gap of the snap ring is not as aligned with the pin
hole cutout portion of the piston.
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2. Install Piston Rings

a. Install the oil ring expander and 2 side rails by hand.
b. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
See CODE MARK table.
Code Mark
Piston Ring Code
No. 1 None
No. 2 2N
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Fig. 285: Installing Compression Rings

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c. Position the piston rings so that the ring ends are as shown in Fig. 286.
NOTE: Do not align the ring ends.
Fig. 286: Positioning Piston Rings

3. Install Connecting Rod Bearings

a. Align the bearing claw with the groove of the connecting rod or connecting cap.
b. Install the bearings in the connecting rod and connecting rod cap.
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Fig. 287: Installing Connecting Rod Bearings

4. Install Main Bearings
HINT: Upper bearings have an oil groove and oil holes; Lower bearings do not.
a. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper
bearings.
NOTE:  Install the bearing with the oil hole in the cylinder block.
 Clean the backside of the bearing and the bearing surface of the
bearing cap and do not let the oils and fats stick.
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Fig. 288: Aligning Bearing Claw With Claw Groove Of Cylinder Block
b. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower
bearings.
NOTE: Clean the backside of the bearing and the bearing surface of the
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Fig. 289: Aligning Bearing Claw With Claw Groove Of Main Bearing Cap
5. Install Thrust Washers
Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves
facing outward.
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Fig. 290: Installing Thrust Washers

6. Place Crankshaft On Cylinder Block

7. Install Main Bearing Caps
a. Install the 5 main bearing caps in their proper locations.
HINT: A number is marked on each main bearing cap to indicate the installation position.
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Fig. 291: Installing Main Bearing Caps In Proper Locations

b. Install the main bearing cap bolts.
HINT:
 The main bearing cap bolts are tightened in 2 progressive steps in steps 2, 3 and 5 below.
 If any one of the main bearing cap bolts is broken or deformed, replace it.
1. Apply a light coat of engine oil on the threads and under the main bearing cap bolts.
2. Install and uniformly tighten the 10 main bearing cap bolts in several passes, in the sequence
shown in Fig. 292.
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Fig. 292: Tightening Main Bearing Cap Bolts In Sequence

3. Retighten the 10 main bearing cap bolts in several passes, in the sequence shown in Fig. 292
If any one of the main bearing cap bolts does not meet the torque specification, replace the
main bearing cap bolt.
4. Mark the front of the main bearing cap bolt with paint.
5. Retighten the main bearing cap bolts by 90° in the numerical order shown in Fig. 293.
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Fig. 293: Retightening Main Bearing Cap Bolts

c. Check that the crankshaft turns smoothly.
8. Check Crankshaft Thrust Clearance See DISASSEMBLY .
9. Install Piston & Connecting Rod Assembles
Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into
each cylinder with the front mark of the piston facing forward.
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Fig. 294: Installing Piston & Connecting Rod Assembly

10. Install Connecting Rod Cap

a. Place the connecting rod cap on the connecting rod.
1. Match the numbered connecting rod cap with the connecting rod.
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Fig. 295: Matching Numbered Connecting Rod Cap With Connecting Rod
2. Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and
install on the connecting rod.
NOTE: Clean the backside of the bearing and the bearing surface of the
3. Check that the protrusion of the connecting rod cap is facing in the correct direction.
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Fig. 296: Checking Protrusion Of Connecting Rod Cap

b. Install the connecting rod cap bolts.
HINT:
 The connecting rod cap bolts are tightened in 2 steps. See steps 3 and 4 .
 If any of the connecting rod cap bolts is broken or deformed, replace it.
1. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap
bolts.
2. Install and alternately tighten the 2 connecting rod cap bolts in several passes.
If any of the connecting rod cap bolts does not meet the torque specification, replace the
connecting rod cap bolts.
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Fig. 297: Tightening Connecting Rod Cap Bolts Alternately

3. Mark the front of the connecting cap bolts with paint.

4. Retighten the cap bolts by 90° as shown in Fig. 298.
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Fig. 298: Retightening Cap Bolts By 90°

c. Check that the crankshaft turns smoothly.
11. Check Connecting Rod Thrust Clearance See INSPECTION .
12. Install Rear Crankshaft Oil Seal See REPLACEMENT .
HINT: Wipe seal packing away from the contact surface of the cylinder block assembly and oil seal.
13. Install Crank Case

of the crank case and cylinder block.
 Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the
gasket surfaces and sealing groove.
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b. Apply seal packing to the crank case or cylinder block as shown in Fig. 299.
Seal Packing: Part No. 08826-00080 or equivalent
 Install a nozzle that has been cut to a 2.5-3.0 mm (0.10-0.12 in.) opening.
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Fig. 299: Applying Seal Packing To Crank Case Or Cylinder Block

c. Install a new O-ring to the cylinder block.

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Fig. 300: Installing O-Ring To Cylinder Block

d. Temporarily install the crank case with the 11 bolts.
HINT:
Bolt length:
 112 mm (4.41 in.) for A of 12 mm head
 35 mm (1.38 in.) for B of 12 mm head
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Fig. 301: Installing Crank Case Bolts

e. Uniformly tighten the bolts, stud bolts and nuts in several passes.
14. Install Balance Shaft

a. Align the bearing claw with the claw groove, and push in the 8 bearings.
b. Apply a light coat of engine oil on the bearings.
c. Align the timing marks of the No. 1 and No. 2 balance shafts as shown in Fig. 302.
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Fig. 302: Aligning Timing Marks Of No. 1 & No. 2 Balance Shafts
d. Place the No. 1 and No. 2 balance shaft on the crank case.
15. Install Balance Shaft Housing
16. Install Balance Shaft Housing Bolts
HINT:
The balance shaft housing bolts are tightened in 2 progressive steps. See steps a and c .

 If any of the balance shaft housing bolts is broken or deformed, replace it.
a. Apply a light coat of engine oil on the threads and under the heads of the balance shaft housing
bolts.
b. Install and uniformly tighten the 8 bolts, several passes, in the sequence shown in Fig. 303.
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Fig. 303: Installing Balance Shaft Housing Bolts In Sequence

c. Mark the front of the balance shaft housing bolts with paint.
d. Retighten the bolts by 90° as shown in Fig. 304.
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Fig. 304: Retightening Bolts Additional 90°

e. Check that the painted mark is now at a 90° angle to the front.
f. Check that the balance shafts turns smoothly.
g. Turn the balance shafts, and check that the timing marks of No. 1 and No. 2 balance shafts are in a
straight line with line on the crank case surface as shown in Fig. 302.
17. Install Oil Filter Union
Using a 12 mm hexagon wrench, install the oil filter union.
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Fig. 305: Installing Oil Filter Union

18. Install Oil Filter See REPLACEMENT .

19. Install Oil Pump See INSTALLATION .
20. Install Water By-Pass Pipe
Install a new gasket, the water bypass pipe with the 2 nuts.
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Fig. 306: Installing Water By-Pass Pipe

21. Install Oil Dipstick & Guide

a. Install a new O-ring to the dipstick guide.
b. Apply soapy water to the O-ring.
c. Push in the dipstick guide end into the guide hole of the No. 1 oil pan.
d. Install the dipstick guide with the bolt.
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Fig. 307: Installing Dipstick Guide

e. Install the dipstick.

22. Install Engine Coolant Drain Union
a. Apply adhesive to 2 or 3 threads.
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Fig. 308: Applying Adhesive To Threads

b. Install the drain union.
Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) or more
HINT: After applying the specified torque, rotate the drain union clockwise until its drain port is
facing downward.
23. Install Thermostat See INSTALLATION .

24. Install Plug
25. Install Wire Clamps
26. Install Knock Sensor See KNOCK SENSOR .
27. Install Water Pump See INSTALLATION .
28. Install OCV Filter
Using a 12 mm hexagon wrench, install the OCV filter with a new gasket and the plug.
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Fig. 309: Installing OCV Filter

29. Install Cylinder Head See INSTALLATION .

30. Install Timing Chain See INSTALLATION .
31. Remove Engine Stand
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2004 ENGINE PERFORMANCE Engine - Diagnostics - RAV4
2004 ENGINE PERFORMANCE
Engine - Diagnostics - RAV4
HOW TO PROCEED WITH TROUBLESHOOTING

Troubleshoot in accordance with the following procedure.
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2004 Toyota RAV4
Fig. 1: Troubleshooting Flowchart

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CUSTOMER PROBLEM ANALYSIS CHECK
Fig. 2: Analysis Check Sheet

PRE-CHECK
1. DIAGNOSIS SYSTEM
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Description
 When troubleshooting On-Board Diagnostic (OBD II) vehicles, the vehicle must be connected to
the OBD II scan tool (in compliance with SAE J1978) or the hand-held tester. Various data output
from the vehicle's ECM can then be read.
 OBD II regulations require that the vehicle's on-board computer illuminates the Malfunction
Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in: 1) the
emission control system/components, or 2) the powertrain control components (which affect
vehicle emissions), or 3) the computer. In addition, the applicable Diagnostic Trouble Codes
(DTCs) prescribed by SAE J2012 are recorded in the ECM memory (see DIAGNOSTIC
TROUBLE CODE CHART ).
Fig. 3: Identifying Malfunction Indicator Lamp

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2004 Toyota RAV4
If the malfunction does not reoccur in 3 consecutive trips, the MIL turns off automatically but the DTCs
remain recorded in the ECM memory.
 To check the DTC, connect the hand-held tester or OBD II scan tool to the Data Link Connector 3
(DLC3) on the vehicle. The hand-held tester or OBD II scan tool also enables you to erase the DTC
and check the freeze frame data and various forms of engine data (for operating instructions, see the
OBD II scan tool's instruction book). The DTC includes SAE controlled codes and manufacturer
controlled codes. SAE controlled codes must be set as prescribed by the SAE, while manufacturer
controlled codes can be set freely by a manufacturer within the prescribed limits (see
DIAGNOSTIC TROUBLE CODE CHART ).
 The diagnosis system operates in "normal mode" during normal vehicle use. In "normal mode", 2
trip detection logic* is used to ensure accurate detection of malfunctions. A "check mode" is also
available to technicians as an option. In "check mode", 1 trip detection logic is used for simulating
malfunction symptoms and increasing the system's ability to detect malfunctions, including
intermittent malfunctions (hand-held tester only) (see step 5 ).
Fig. 4: Connecting Hand Held Tester To DLC3 Connector

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 *2 trip detection logic:
When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory
(1st trip). If the ignition switch is turned OFF and then ON again, and the same malfunction is
detected again, the MIL will illuminate (2nd trip).
 Freeze frame data:
The freeze frame data records the engine conditions (fuel system, calculated load, engine coolant
temperature, fuel trim, engine speed, vehicle speed, etc.) when a malfunction is detected. When
troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the
engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the
malfunction occurred.
Priorities for troubleshooting:
When multiple DTCs occur, find out the order in which the DTCs should be inspected by checking the
component's DTC chart. If no instructions are written in the DTC chart, check DTCs in the following
order of priority:
1. DTCs other than fuel trim malfunction (DTC P0171, P0172) and misfire (DTC P0300 - P0304).
2. Fuel trim malfunction (DTC P0171, P0172).
3. Misfire (DTC P0300 - P0304).
2. CHECK DLC3
The vehicle's ECM uses the ISO 9141-2 for communication protocol. The terminal arrangement of the
DLC3 complies with SAE J1962 and matches the ISO 9141-2 format.
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Fig. 5: Identifying DLC3 Connector Terminals

TESTER CONNECTION SPECIFIED CONDITION

Tester Connection Condition Specified Condition
7 (Bus + line) - 5 (Signal ground) During communication Pulse generation
4 (Chassis ground) - Body ground Constant Below 1 ohm
5 (Signal ground) - Body ground Constant Below 1 ohm
16 (B+) - Body ground Constant 9 to 14 V
HINT:
Connect the cable of the hand-held tester or the OBD II scan tool to the DLC3, turn the ignition switch
ON and attempt to use the hand-held tester or the OBD II scan tool. If the screen displays UNABLE TO
CONNECT TO VEHICLE, a problem exists in the vehicle side or the tester side.
 If the communication is normal when the tool is connected to another vehicle, inspect the DLC3 on
the original vehicle.
 If communication is still impossible when the tool is connected to another vehicle, the problem is
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probably in the tool itself, so consult the Service Department listed in the tool's instruction manual.
3. INSPECT BATTERY VOLTAGE
Battery voltage: 11 to 14 V
If the voltage is below 11 V, recharge the battery before proceeding.
4. CHECK MIL
a. The MIL turns on when the ignition switch is turned ON and the engine is not running.
HINT:
If the MIL is not illuminated, troubleshoot the MIL circuit (see MIL CIRCUIT
MALFUNCTION ).
b. When the engine is started, the MIL should turn off. If the lamp remains on, it means that the
diagnosis system has detected a malfunction or abnormality in the system.
5. DTC CHECK (Normal Mode)
NOTE:  If there is no DTC in the normal mode, check the pending fault code
using the Continuous Test Results function (Mode 7 for SAE J1979)
on the OBD II scan tool or the hand-held tester.
 Hand-held tester only:
When the diagnosis system is switched from the normal mode to the
check mode, all the DTCs and freeze frame data recorded in the
normal mode will be erased. So before switching modes, always
check the DTCs and freeze frame data, and then write them down.
a. Checking DTCs using the hand-held tester or OBD II scan tool.

1. Connect the hand-held tester or the OBD II scan tool to DLC3.
3. Use the hand-held tester or the OBD II scan tool to check the DTCs and freeze frame data
and then write them down.
For the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II /
DTC INFO / CURRENT CODES. For the OBD II scan tool, see its instruction manual.
4. See DIAGNOSTIC TROUBLE CODE CHART to confirm the details of the DTCs.
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Fig. 6: Connecting Hand-Held Tester To DLC3 Connector

NOTE: When simulating a symptom with the OBD II scan tool (excluding
hand-held tester) to check for DTCs, use the normal mode. For DTCs
subject to "2 trip detection logic", perform either of the following
actions.
 Turn the ignition switch OFF after the symptom is simulated

once. Then repeat the simulation process again. When the
problem has been simulated twice, the MIL lights up and the
DTCs are recorded in the ECM.
 Check the pending fault code using the Continuous Test
Results function (Mode 7 for SAE J1979) on the OBD II scan
tool.
b. Clearing the DTCs using the hand-held tester or the OBD II scan tool.
1. Connect the hand-held tester or the OBD II scan tool to the DLC3.
3. Erase DTCs and freeze frame data using the hand-held tester or the OBD II scan tool
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(complying with SAE J1978).
For the hand-held tester: 1) enter the following menus: DIAGNOSIS / ENHANCED OBD
II / DTC INFO / CLEAR CODES; and 2) press YES. For the OBD II scan tool, see its
instruction manual.
c. Clearing the DTCs without using the hand-held tester or the OBD II scan tool.
1. Remove the EFI1 fuse from the engine room J/B and ETCS fuse from the engine room R/B
for more than 60 seconds. Or, disconnect the battery terminal for more than 60 seconds.
After disconnecting the battery terminal, perform the "INITIALIZE" procedure (see PRE-
CHECK in Automatic Transaxle Diagnostics article).
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Fig. 7: Locating Engine Room J/B EFI1 Fuse And Engine Room R/B ETCS Fuse
6. DTC CHECK (Check Mode)

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HINT:
Hand-held tester only:
Check mode has a higher sensitivity to detect malfunctions and can detect malfunctions that normal mode
cannot detect.
Check mode can also detect all the malfunctions that normal mode can detect.
a. Procedure for Check Mode using the hand-held tester.

1. Make sure that the items below are true:
 Battery positive voltage 11 V or more.
 Throttle valve fully closed.
 Transmission in the P or N position.
 A/C switched OFF.

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Fig. 8: Connecting Hand Held Tester To DLC3 Connector

5. Change the ECM to check mode with the hand-held tester. Enter the following menus:
DIAGNOSIS / ENHANCED OBD II / CHECK MODE. Make sure the MIL flashes as
shown in the illustration.
NOTE: All DTCs and freeze frame data recorded will be erased if: 1) the
hand-held tester is used to change the ECM from normal mode
to check mode or vice-versa; or 2) during check mode, the
ignition switch is turned from ON to ACC or OFF.
Fig. 9: Identifying MIL Flashes

6. Start the engine. The MIL should turn off after the engine starts.
7. Simulate the conditions of the malfunction described by the customer.
8. After simulating the malfunction conditions, use the hand-held tester diagnosis selector to
check the DTC, freeze frame data and other data.
 After checking the DTC, inspect the applicable circuit.
b. Clearing the DTCs using the hand-held tester or the OBD II scan tool.
1. Connect the hand-held tester or the OBD II scan tool to the DLC3.
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3. Erase DTCs and freeze frame data with the hand-held tester or the OBD II scan tool
(complying with SAE J1978)
For the hand-held tester: 1) enter the following menus: DIAGNOSIS / ENHANCED OBD
II / DTC INFO / CLEAR CODES; and 2) press YES. For the OBD II scan tool, see its
instruction manual.
c. Clearing the DTCs not using the hand-held tester or the OBD II scan tool.
1. Remove the EFI1 fuse from the engine room J/B and ETCS fuse from the engine room R/B
for more than 60 seconds. Or, disconnect the battery terminal for more than 60 seconds. After
disconnecting the battery terminal, perform the "INITIALIZE" procedure (see PRE-CHECK
in Automatic Transaxle Diagnostics article).
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Fig. 10: Locating Engine Room J/B EFI1 Fuse And Engine Room R/B ETCS Fuse
7. FAIL-SAFE CHART
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If any of the following codes are recorded, the ECM enters the fail-safe mode.
Fig. 11: DTC Fail Safe Chart

8. CHECK FOR INTERMITTENT PROBLEMS

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Inspect the vehicle's ECM using check mode. Intermittent problems are easier to detect when the ECM is
in check mode with the hand-held tester. In check mode, the ECM uses 1 trip detection logic, which has a
higher sensitivity to malfunctions than normal mode (default), which uses 2 trip detection logic.
a. Clear the DTCs (see step 5 ).

b. Set the check mode (see step 6 ).
c. Perform a simulation test (see SYMPTOM SIMULATION under HOW TO PROCEED WITH
TROUBLESHOOTING in INTRODUCTION article).
d. Check the connector and terminal (see HOW TO USE THE DIAGNOSTIC CHART AND
INSPECTION PROCEDURE in INTRODUCTION article).
e. Wiggle the harness and connector (see HOW TO USE THE DIAGNOSTIC CHART AND
9. BASIC INSPECTION
When the malfunction is not confirmed in the DTC check, troubleshooting should be carried out in all the
possible circuits considered as causes of the problem. In many cases, by carrying out the basic engine
check shown in the following flow chart, the location causing the problem can be found quickly and
efficiently. Therefore, using this check is essential in the engine troubleshooting.
1. Is battery positive voltage 11 V or more when engine stopped?

NO : Charge or replace battery.
YES : Go to next step.
2. Is engine cranked?
NO : Proceed to STARTERS article and continue to troubleshoot.
3. Does engine start?
NO : Go to step 6 .
4. Check air filter.
PREPARATION:
Remove the air filter.
CHECK:
Visually check if air filter is contaminated with dirty or oily.
NG : Repair or replace.
OK : Go to next step.
5. Check idle speed.
PREPARATION:
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a. Warm up the engine to the normal operating temperature.

b. Switch off all the accessories.
c. Switch off the A/C.
d. Shift the transmission into the N position.
e. Connect the hand-held tester or OBD II scan tool to the DLC3 of the vehicle.
CHECK:
Use CURRENT DATA to check the idle speed.
OK:
Idle speed:
M/T: 650 to 750 RPM
A/T: 550 to 750 RPM
NG : Proceed to PROBLEM SYMPTOMS TABLE .

6. Check fuel pressure (see ON-VEHICLE INSPECTION ).
NG : Proceed to Check fuel pressure (see ON-VEHICLE INSPECTION and continue to
troubleshoot.
7. Check for spark.
PREPARATION:
a. Disconnect the ignition coil.

b. Remove the spark plug.
c. Install the spark plug to the ignition coil assembly.
d. Disconnect the injector connector.
e. Ground the spark plug.
CHECK:
Check if spark occurs while the engine is being cranked.
NOTE:  Do not crash the electrode gap.

 To prevent the injectors from injecting excess fuel during this test,
do not crank the engine for more than 5 seconds at one time.
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NG : Proceed to ON-VEHICLE INSPECTION in IGNITION article and continue to

troubleshoot.
OK : Proceed to PROBLEM SYMPTOMS TABLE .
8. DATA LIST
HINT:
Using the hand-held tester DATA LIST allows switch, sensor, actuator and other item values to be read
without removing any parts. Reading the DATA LIST early in troubleshooting is one way to shorten
labor time.
NOTE: In the table below, the values listed under "Normal Condition" are
reference values. Do not depend solely on the these reference values
when deciding whether a part is faulty or not.
a. Warm up the engine.

c. Connect the hand-held tester or the OBD II scan tool to the DLC3.
d. Turn the ignition switch ON.
e. Push the "ON" button of the hand-held tester or the OBD II scan tool.
f. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST.
g. According to the display on tester, read the "DATA LIST".
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Fig. 12: Hand Held Tester Display Data List (1 Of 3)

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9. ACTIVE TEST
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HINT:
Performing the hand-held tester ACTIVE TEST allows relay, VSV, actuator and other items to be
operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way
to shorten labor time. The DATA LIST can be displayed during the ACTIVE TEST.
a. Warm up the engine.

e. Turn ON the hand-held tester or the OBD II scan tool.
f. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST.
g. According to the display on tester, perform the ACTIVE TEST.
Fig. 15: Hand Held Tester Display Active Test

10. DEFINITION OF TERMS

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Fig. 16: Terms Definition Table

11. TOYOTA/LEXUS PART AND SYSTEM NAME LIST
This reference list indicates the part names used in this manual along with their definitions.
TOYOTA/LEXUS PART AND SYSTEM NAME LIST

TOYOTA/LEXUS Name Definition
Toyota HCAC system, Hydro-carbon Adsorptive HC adsorptive three-way catalytic converter
Catalyst (HCAC) system, HC adsorptive three-way
catalyst
Variable valve timing sensor, VVT sensor Camshaft position sensor
Variable valve timing system, VVT system Camshaft timing control system
Camshaft timing oil control valve, Oil control Camshaft timing oil control valve
valve, OCV, VVT, VSV
Variable timing and lift, VVTL Camshaft timing and lift control
Crankshaft position sensor "A" Crankshaft position sensor
Engine speed sensor Crankshaft position sensor
THA Intake air temperature
Knock control module Engine knock control module
Knock sensor Engine knock sensor
Mass or volume air flow circuit Mass air flow sensor circuit
Vacuum sensor Manifold air pressure sensor
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Internal control module, Control module, Engine Power train control module
control ECU, PCM
FC idle Deceleration fuel cut
Idle air control valve Idle speed control
CCV, Canister close valve VSV for canister control Evaporative emissions canister vent valve
EVAP VSV, Vacuum switching valve assembly No. Evaporative emissions canister purge valve
1, EVAP VSV, Purge VSV
Pressure switching valve, Bypass VSV Evaporative emission pressure switching valve
Vapor pressure sensor, EVAP pressure sensor, Fuel tank pressure sensor
Evaporative emission control system pressure
sensor
Charcoal canister Evaporative emissions canister
ORVR system On-board refueling vapor recovery system
Intake manifold runner control Intake manifold tuning system
Intake manifold runner valve, IMRV, IACV (runner Intake manifold tuning valve
valve)
Intake control VSV Intake manifold tuning solenoid valve
AFS Air fuel ratio sensor
O2 sensor Heater oxygen sensor
Oxygen sensor pumping current circuit Oxygen sensor output signal
Oxygen sensor reference ground circuit Oxygen sensor signal ground
Accel position sensor Accelerator pedal position sensor
Throttle actuator control motor, Actuator control Electronic throttle actuator
motor, Electronic throttle motor, Throttle control
motor
Electronic throttle control system, Throttle actuator Electronic throttle control system
control system
Throttle/pedal position sensor, Throttle/pedal Throttle position sensor
position switch, Throttle position sensor/switch
Turbo press sensor Turbocharger pressure sensor
Turbo VSV Turbocharger pressure control solenoid valve
P/S pressure switch Power-steering pressure switch
VSV for ACM Active control engine mount
12. List of Disable a Monitor
HINT:
This table indicates ECM monitoring status for the items in the upper columns if the DTCs in each line on
the left are being set.
As for the "X" make, when the DTC on the left is stored detection of the DTC in the upper column is not
performed.
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Fig. 17: Monitor Disabling Chart (1 Of 6)

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13. O2S TEST RESULT

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a. INTRODUCTION
The O2S TEST RESULT refers to the results of the engine control module (ECM) when it
monitors the oxygen sensor (O2S), and it can be read using the hand-held tester or the generic
OBDII scantool. Based on this, you can find the O2S's conditions.
The ECM monitors the O2S in the various items. You can read the monitor result (TEST DATA) of
each monitor item using the O2S TEST RESULT. However, the output value of the TEST DATA
is the latest "snapshot" value that is taken after monitoring and therefore it is not dynamic.
In this repair manual, the description of the O2S TEST RESULT (for O2S related DTCs) are
written in a table. This table consists of 5 items:
1. TEST ID (a code applied to each TEST DATA)

2. Description of TEST DATA
3. Conversion Factor (When Conversion Factor has a value written in the table, multiply the
TEST DATA value appearing on the scantool by the Conversion Factor value. The result will
be the required value.)
4. Unit
5. Standard Value
If the TEST DATA value appearing on the scan tool is out of the standard value, the O2S is
malfunctioning. If it is within the standard value, the O2S is functioning normally. However, if the
value is on the borderline of the standard value, the O2S may malfunction very soon.
b. HOW TO READ O2S TEST RESULT USING HAND-HELD TESTER

2. On the tester screen, select the following menus: DIAGNOSIS / CARB OBDII / O2S TEST
RESULT. A list of the O2S equipped on the vehicle will be displayed.
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Fig. 23: O2S Test Result Screen

3. Select the desired O2S and press ENTER. The following screen will appear.
c. Example
1. The hand-held tester displays "17" as a value of the "TIME $81" (see the illustration on the
left).
2. Find the Conversion Factor value of "TIME $81" in the O2S TEST RESULT chart below.
0.3906 is specified for $81 in this chart.
3. Multiply "17" in step (1) by 0.3906 (Conversion Factor) in the step (2).
17 x 0.3906 = 6.6 %
4. If the answer is within the standard value, the "TIME $81" can be confirmed to be normal.
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Fig. 24: Test Data Screen

O2S TEST RESULT Chart
O2S TEST RESULT CHART

Description of
TEST ID TEST DATA Conversion Factor Unit Standard Value
$81 Percentage of Multiply 0.3906 % Within 60 %
monitoring time
when the O2S
voltage is less than
0.05 V
14. CHECKING MONITOR STATUS
NOTE: The Monitor Status is not applicable to the heated oxygen sensor (HO2S).
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The HO2S status can be checked with O2S TEST RESULT.
a. INTRODUCTION
The purpose of the monitor result (mode 6) is to allow access to the results for on-board diagnostic
monitoring tests of specific components/systems that are not continuously monitored. Examples are
catalyst, EVAP and thermostat.
The monitor result allows the OBD scan tool to display the monitor status, test value and test limit.
The monitor status indicates whether the component is functioning normally or not (PASS or
FAIL). The test value is the value that was used to determine the monitor status. When the test
value is inside the test limit, the ECM determines the component is functioning normally (PASS).
If the test value is outside the test limit, the ECM determines the component is malfunctioning
(FAIL).
A problem in these components/systems can be found by comparing the test value and test limit.
The monitor result information is included under "MONITOR RESULT" in the DTC sections.
b. PROCEDURE
NOTE: The monitor result and test value are cleared when the ignition switch is
turned OFF.

3. Clear the DTCs.
4. Run the vehicle in accordance with the applicable drive pattern described in READINESS
MONITOR DRIVE PATTERN ).
5. Select from the tester menus: DIAGNOSIS, ENHANCED OBD II, MONITOR INFO and
MONITOR RESULT. The monitor result appears after the component name.
INCMP: The component has not been monitored yet.
PASS: The component is functioning normally.
FAIL: The component is malfunctioning.
6. Confirm that the component is set to either PASS or FAIL.
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Fig. 25: Monitor Result Screen

7. Select the component (Label) and press ENTER.
The accuracy test value appears when the monitor result is either PASS or FAIL.
VAL The test value
LMT: The test limit

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TLT: The test limit type. Either 0 or 1 is displayed.
8. If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If
TLT is 1, the component is malfunctioning when the test value is lower than the test limit.
9. Compare the test value with the test limit. The test value is usually significantly higher or lower
than the test limit. If the test value is on the borderline of the test limit, there is a potential
malfunction in the component.
Fig. 26: Thermostat Malfunction Screen

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HINT:
The monitor result might on rare occasions be PASS even if the MIL is illuminated. This indicates the system
malfunctioned on a previous driving cycle. This might be caused by an intermittent problem.
READINESS MONITOR DRIVE PATTERN

1. PURPOSE OF READINESS TESTS
 The On-Board Diagnostic (OBD II) system is designed to monitor the performance of emission-
related components, and report any detected abnormalities with Diagnostic Trouble Codes (DTCs).
Since various components need to be monitored during different driving conditions, the OBD II
system runs separate monitoring programs called readiness monitors.
 The hand-held tester's software must be version 9.0 or newer to view the readiness monitor status.
From the "Enhanced OBD II Menu", select "Monitor Status" to view the readiness monitor status.
 A generic OBD II scan tool can also be used to view the readiness monitor status.
 When the readiness monitor status reads "complete", the necessary conditions have been met for
running performance tests for that readiness monitor.
HINT:
Many state Inspection and Maintenance (I/M) programs require a vehicle's readiness monitor status to
show "complete".
 The Readiness Monitor will be reset to "incomplete" if:

 The ECM has lost battery power or blown a fuse
 DTCs have been cleared.
 The conditions for running the Readiness Monitor have not been met.
 If the readiness monitor status shows "incomplete", follow the appropriate readiness monitor drive
pattern to change the status to "complete".
CAUTION: Strictly observe posted speed limits, traffic laws, and road conditions
when performing these drive patterns.
NOTE: The following drive patterns are the fastest method of completing all the
requirements necessary for making the readiness monitor status read
"complete".
If forced to momentarily stop a drive pattern due to traffic or other factors,
the drive pattern can be resumed. Upon completion of the drive pattern, in
most cases, the readiness monitor status will change to "complete".
Sudden changes in vehicle load and speed, such as driving up and down
hills and / or sudden acceleration, hinder readiness monitor completion.
2. CATALYST MONITOR (A/F sensor TYPE)
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Fig. 27: Catalyst Monitoring (A/F Sensor Type) Graph

a. Preconditions
The monitor will not run unless:
 The MIL is OFF.

 Engine Coolant Temperature (ECT) is 75°C (167°F) or greater.
 Intake Air Temperature (IAT) is -10°C (14°F) or greater*
NOTE: The readiness test can be completed in cold ambient conditions (less
than -10°C/14°F) and / or high altitudes (more than 2,450 m / 8,000
feet). Finish the drive pattern, turn the ignition switch OFF and then
on again, and repeat the drive pattern a second time.
b. Drive Pattern
1. Connect the OBD II scan tool to the DLC3 to check monitor status and preconditions (refer
to step " ").
2. Drive the vehicle at 64 to 88 km/h (40 to 55 mph) for approximately 4 minutes.
NOTE: Drive with smooth throttle operation and avoid sudden

acceleration.
If IAT is less than 10°C (50°F) when the engine was started,
drive the vehicle at 64 to 88 km/h (40 to 55 mph) for an
additional 4 minutes.
3. Drive the vehicle allowing speed to fluctuate between 64 to 80 km/h (40 to 50 mph) for about
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16 minutes.
NOTE: Drive with smooth throttle operation and avoid sudden closure
of the throttle.
4. Check the status of the readiness monitor on the scan tool display. If the readiness monitor
status did not switch to "complete", ensure preconditions are met, turn the ignition switch
OFF, and then repeat steps 2 and 3 .
3. EVAP MONITOR (VACUUM PRESSURE MONITOR)
NOTE: A cold soak must be performed prior to conducting the drive pattern to
complete the Internal Pressure Readiness Monitor.
a. Cold Soak Preconditions
 The MIL is OFF

 Fuel level is approximately 1/2 to 3/4 fuel.
 Altitude is 2,450 m (8,000 feet) or less.
b. Cold Soak Procedure
Let vehicle cold soak for 8 hours or until "IAT - ECT" must be -7°C (-13°F) to 11.1°C (20°F).
HINT:
Examples:
 Scenario 1
ECT = 24°C (75°F)
IAT = 16°C (60°F)
Difference between ECT and IAT is 8°C (15°F)
--> The monitor will not run because "IAT - ECT" is less than -7°C (-13°F).
 Scenario 2
ECT = 21°C (70°F)
IAT = 20°C (68°F)

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--> The monitor will run because "IAT - ECT" is -7°C (-13°F) and 11.1°C (20°F).
Fig. 28: EVAP Monitoring (Vacuum Pressure Monitor) Graph

c. Preconditions
 The MIL is OFF

 Fuel level is approximately 1/2 to 3/4 fuel.
 The altitude is 2,450 m (8,000 feet) or less*
 Engine Coolant Temperature (ECT) is between 4.4°C and 35°C (40°F and 95°F)
 Intake Air Temperature (IAT) is between 4.4°C and 35°C (40°F and 95°F)*
 The cold Soak Procedure has been completed
 Before starting the engine, the difference between ECT and IAT must be less than 7°C (13°
F)
HINT:
Examples:
 Scenario 1
ECT = 24°C (75°F)
IAT = 16°C (60°F)
--> The monitor will not run because difference between ECT and IAT is higher than 7°C
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(13°F)
 Scenario 2
ECT = 21°C (70°F)
IAT = 20°C (68°F)
--> The monitor will run because difference between ECT and IAT is less than 7°C (13°F)
NOTE: The readiness test can be completed in cold ambient conditions

(less than 4.4°C / 40°F) and / or high altitudes (more than 2,450
m / 8,000 feet). Finish the drive pattern, turn the ignition switch
OFF and then on again, and repeat the drive pattern a second
time.
d. Drive Pattern
to step " ").
2. Release pressure in fuel tank by removing the fuel tank cap and then reinstalling it.
3. Start the engine and allow to idle until ECT is 75°C (167°F) or more.
4. Run the engine at 3,000 RPM for about 10 seconds.
5. With the engine idling, turn the A/C ON to create slight electrical load. Wait 15 to 50
minutes.
NOTE: If the vehicle is not equipped with A/C, put a slight load on the engine
by doing the following:
 Set the parking brake securely.

 Use wheel chocks to secure the tires.
 Move the shift lever to drive (position D) and allow the engine to
idle for 15 to 50 minutes.
Check the readiness monitor status.
4. OXYGEN / AIR FUEL RATIO SENSOR MONITOR (FRONT A/F SENSOR AND REAR O2S
SYSTEM)
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Fig. 29: Oxygen/Air Fuel Ratio Sensor Monitoring (Front A/F Sensor And Rear O2S System)
Graph
a. Preconditions
The MIL is OFF
b. Drive Pattern
to step " ").
2. Start the engine and allow it to idle for 2 minutes or more.
3. Drive the vehicle at 64 to 112 km/h (40 to 70 mph) for at least 150 seconds.
4. Stop the vehicle and allow the engine to idle for 10 seconds or more.
5. Drive the vehicle at 40 to 64 km/h (25 to 40 mph) for at least 40 seconds.
6. Stop the vehicle and allow the engine to idle for 10 seconds or more
7. Perform steps 5 and 6 10 times.
8. Check the readiness monitor status. If the readiness monitor status did not change to
"complete", check the preconditions, turn the ignition switch OFF, and repeat steps 1 to 6 .
5. OXYGEN / A/F SENSOR HEATER MONITOR
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Fig. 30: Oxygen/A/F Sensor Heater Monitoring Graph

a. Preconditions
The MIL is OFF
b. Drive Pattern
to step " ").
2. Start the engine and allow it to idle for 500 seconds or more.
3. Drive the vehicle at 40 km/h (25 mph) or more at least 2 minutes.
4. Check the readiness monitor status. If the readiness monitor status did not change to
"complete", check preconditions, turn the ignition switch OFF, and repeat steps 2 and 3 .
DIAGNOSTIC TROUBLE CODE CHART

HINT:
Parameters listed in the chart may not be exactly the same as your readings due to the type of instrument or
other factors.
If a malfunction code is displayed during the DTC check in check mode, check the circuit for the code listed in
the table below. For details of each code, refer to the respective "DTC No." in the DTC chart.
DIAGNOSTIC TROUBLE CODES

DTC Description
DTC P0010 Camshaft Position "A" Actuator Circuit (Bank 1)
DTC P0011 Camshaft Position "A" -Timing Over-Advanced or
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System Performance (Bank 1)

DTC P0012 Camshaft Position "A" -Timing Over-Retarded
(Bank 1)
DTC P0016 Crankshaft Position - Camshaft Position Correlation
(Bank 1 Sensor A)
DTC P0031 Oxygen (A/F) Sensor Heater Control Circuit Low
(Bank 1 Sensor 1)
DTC P0032 Oxygen (A/F) Sensor Heater Control Circuit High
(Bank 1 Sensor 1)
DTC P0037 Oxygen Sensor Heater Control Circuit Low (Bank 1
Sensor 2)
DTC P0038 Oxygen Sensor Heater Control Circuit High (Bank 1
Sensor 2)
DTC P0100 Mass or Volume Air Flow Circuit Malfunction
DTC P0101 Mass or Volume Air Flow Circuit
Range/Performance Problem
DTC P0102 Mass or Volume Air Flow Circuit Low Input
DTC P0103 Mass or Volume Air Flow Circuit High Input
DTC P0110 Intake Air Temperature Circuit
DTC P0112 Intake Air Temperature Circuit Low Input
DTC P0113 Intake Air Temperature Circuit High Input
DTC P0115 Engine Coolant Temperature Circuit
DTC P0116 Engine Coolant Temperature Circuit
DTC P0117 Engine Coolant Temperature Circuit Low Input
DTC P0118 Engine Coolant Temperature Circuit High Input
DTC P0120 Throttle/Pedal Position Sensor/Switch "A" Circuit
Malfunction
Low Input
High Input
DTC P0125 Insufficient Coolant Temperature for Closed Loop
Fuel Control
DTC P0128 Coolant Thermostat (Coolant Temperature Below
Thermostat Regulating Temperature)
DTC P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor
2)
DTC P0171 System too Lean (Bank 1)
DTC P0172 System too Rich (Bank 1)
DTC P0220 Throttle/Pedal Position Sensor/Switch "B" Circuit
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Malfunction
Low Input
High Input
DTC P0300 Random/Multiple Cylinder Misfire Detected
DTC P0301 Cylinder 1 Misfire Detected
DTC P0325 Knock Sensor 1 Circuit (Bank 1 or Single Sensor)
DTC P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or
Single Sensor)
DTC P0328 Knock Sensor 1 Circuit High Input (Bank 1 or
Single Sensor)
DTC P0335 Crankshaft Position Sensor "A" Circuit Malfunction
DTC P0339 Crankshaft Position Sensor "A" Circuit Intermittent
DTC P0340 Camshaft Position Sensor "A" Circuit
DTC P0341 Camshaft Position Sensor "A" Circuit
Range/Performance (Bank 1 or Single Sensor)
DTC P0351 Ignition Coil "A" Primary/Secondary Circuit
DTC P0352 Ignition Coil "B" Primary/Secondary Circuit
DTC P0353 Ignition Coil "C" Primary/Secondary Circuit
DTC P0354 Ignition Coil "D" Primary/Secondary Circuit
DTC P0420 Catalyst System Efficiency Below Threshold (Bank
1)
DTC P0441 Evaporative Emission Control System Incorrect
Purge Flow
DTC P0442 Evaporative Emission Control System Leak
Detected (Small Leak)
DTC P0446 Evaporative Emission Control System Vent Control
Circuit
DTC P0451 Evaporative Emission Control System Pressure
Sensor/Switch Range/Performance
Sensor/Switch Low Input
Sensor/Switch High Input
Detected (Gross Leak)
Detected (Very Small Leak)
DTC P0500 Vehicle Speed Sensor Malfunction
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DTC P0504 Brake Switch "A"/"B" Correlation

DTC P0505 Idle Air Control System
DTC P0560 System Voltage
DTC P0604 Internal Control Module Random Access Memory
(RAM) Error
DTC P0606 ECM/PCM Processor
DTC P0607 Control Module Performance
DTC P0617 Starter Relay Circuit High
DTC P0657 Actuator Supply Voltage Circuit / Open
DTC P0705 Transmission Range Sensor Circuit Malfunction
(PRNDL Input)
DTC P2102 Throttle Actuator Control Motor Circuit Low
DTC P2103 Throttle Actuator Control Motor Circuit High
DTC P2111 Throttle Actuator Control System - Stuck Open
DTC P2112 Throttle Actuator Control System - Stuck Closed
DTC P2118 Throttle Actuator Control Motor Current
Range/Performance
DTC P2119 Throttle Actuator Control Throttle Body Range
Performance
DTC P2120 Throttle/Pedal Position Sensor/Switch "D" Circuit
Range/Performance
Low Input
High Input
DTC P2125 Throttle/Pedal Position Sensor/Switch "E" Circuit
Low Input
High Input
DTC P2135 Throttle/Pedal Position Sensor/Switch "A"/"B"
Voltage Correction
DTC P2138 Throttle/Pedal Position Sensor/Switch "D"/"E"
Voltage Correlation
DTC P2195 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1
Sensor 1)
DTC P2196 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1
Sensor 1)
DTC P2238 Oxygen Sensor Pumping Current Circuit Low (for
A/F sensor) (Bank 1 Sensor 1)
DTC P2239 Oxygen Sensor Pumping Current Circuit High (for
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DTC P2252 Oxygen Sensor Pumping Ground Circuit Low (for

DTC P2253 Oxygen Sensor Pumping Ground Circuit High (for
DTC P2418 Evaporative Emission System Valve Control
Circuit/Open
DTC P2A00 A/F Sensor Circuit Slow Response (Bank 1 Sensor
1)
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Fig. 31: Diagnostic Trouble Code Chart (1 Of 7)

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PARTS LOCATION
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Fig. 38: Locating Parts

TERMINALS OF ECM
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Fig. 39: Identifying ECM Terminals

HINT:
Each ECM terminal's standard voltage is shown in the table below.
In the table, first follow the information under "Condition". Next look under "Symbols (Terminal No.)" for the
terminals to be inspected. The standard voltage between the terminals is shown under "Specified Condition".
Use the illustration above as a reference for the ECM terminals.
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Fig. 40: Terminal Specified Condition Table (1 Of 2)

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Fig. 41: Terminal Specified Condition Table (2 Of 2)

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CIRCUIT INSPECTION
DTC P0010: CAMSHAFT POSITION "A" ACTUATOR CIRCUIT (BANK 1)
CIRCUIT DESCRIPTION
The Variable Valve Timing (VVT) system includes the ECM, the Oil Control Valve (OCV) and the VVT
controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal, applied to the
OCV, regulates the oil pressure supplied to the VVT controller. Camshaft timing control is performed based on
engine operation conditions such as intake air volume, throttle position and engine coolant temperature.
The ECM controls the OCV based on the signals output from several sensors. The VVT controller regulates the
intake camshaft angle using oil pressure through the OCV. As result, the relative position between the camshaft
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and the crankshaft is optimized. Also, the engine torque improves, fuel economy improves, and exhaust
emissions decrease. The ECM detects the actual valve timing using signals from the camshaft position sensor
and the crankshaft position sensor. The ECM performs feedback control and verifies target valve timing.
Fig. 43: Camshaft Position "A" Actuator Circuit Description

Fig. 44: DTC (P0010) Diagnosis Table

MONITOR DESCRIPTION
After the ECM sends the "target" duty-cycle signal to the OCV, the ECM monitors the OCV current to establish
an "actual" duty-cycle. When the actual duty-cycle ratio varies from the target duty-cycle ratio, the ECM sets a
DTC.
MONITOR STRATEGY
STRATEGY MONITORING
Related DTCs P0010: VVT OCV range check
Required sensors/ components (Main) VVT OCV
Required sensors/ components (Related) -
Frequency of operation Continuous
Duration 1 sec.
MIL operation Immediate
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Sequence of operation None
TYPICAL ENABLING CONDITIONS

The monitor will run whenever the following DTCs None
are not present
Battery voltage 11 to 13 V
Target duty ratio for the OCV 70 % or less
Starter OFF
Current cut status for the OCV Not cut
TYPICAL MALFUNCTION THRESHOLDS
MALFUNCTION THRESHOLDS
Either of the following condition is set:
OCV duty ratio 100 % (always ON) despite the target duty ratio is
less than 70 %
OCV duty ratio when ECM supplies current to OCV 3 % or less despite the ECM supplying the current
to the OCV
COMPONENT OPERATING RANGE

VVT OCV duty ratio 3 to 100 %
WIRING DIAGRAM
Fig. 45: C2 OCV Wiring Diagram

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HINT:
Read freeze frame data using the hand-held tester or the OBD II scan tool. Freeze frame data records the engine
conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the
vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and
other data from the time the malfunction occurred.
Hand-held tester:
1. Check operation of VVT system.
PREPARATION:

b. Start the engine and warm it up.
c. Turn ON the ignition switch. Push the hand-held tester main switch.
d. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL
B1.
CHECK:
Check the engine speed when operating the OCV by using the hand-held tester.
OK:
VVT system is OFF (OCV is OFF): Normal engine speed
VVT system is ON (OCV is ON): Rough idle or engine stalled
OK : Check for intermittent problems (see PRE-CHECK ).

NG : Go to next step.
2. Check operation of OCV.
PREPARATION:
a. Start the engine and warm it up.

b. Disconnect the OCV connector.
c. Apply battery positive voltage to the terminals of the OCV.
CHECK:
Check the engine speed.
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OK:
Rough idle or engine stalled
Fig. 46: Checking OCV Connector Operation

NG : Replace OCV.
3. Check voltage between terminals OC1+ and OC1- of ECM connector.
Reference: INSPECTION USING OSCILLOSCOPE
During idling, check the waveform between terminals OC1+ and OC1- of the ECM connector.
HINT:
The correct waveform is as shown in the illustration.
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Fig. 47: Locating OC1+ And OC1- Connector Terminals Of ECM And Inspecting OCV Signal
Waveform
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NG : Replace ECM (see COMPONENTS ).

4. Check for open and short in wire harness between OCV and ECM (see DTC P0011: CAMSHAFT
POSITION "A" -TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), DTC
P0012: CAMSHAFT POSITION "A" -TIMING OVER-RETARDED (BANK 1) ).
OBD II scan tool (excluding hand-held tester):
PREPARATION:
a. Start the engine and warm it up.

b. Disconnect the OCV connector.
c. Apply battery positive voltage to the terminals of the OCV.
CHECK:
Check the engine speed.
OK:
Rough idle or engine stalled
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NG : Replace OCV.
During idling, check the waveform between terminals OC1+ and OC1- of the ECM connector.
HINT:
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Waveform
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3. Check for open and short in wire harness between OCV and ECM (see DTC P0011: CAMSHAFT
POSITION "A" -TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), DTC
P0012: CAMSHAFT POSITION "A" -TIMING OVER-RETARDED (BANK 1) ).
NG : Repair or replace harness and connector.
DTC P0011: CAMSHAFT POSITION "A" -TIMING OVER-ADVANCED OR SYSTEM

PERFORMANCE (BANK 1), DTC P0012: CAMSHAFT POSITION "A" -TIMING OVER-RETARDED
(BANK 1)
CIRCUIT DESCRIPTION
Fig. 50: DTC (P0011, P0012) Diagnosis Table

MONITOR DESCRIPTION
The ECM optimizes the valve timing using the Variable Valve Timing (VVT) system to control the intake valve
camshaft. The VVT system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. The ECM
sends a target "duty-cycle" control signal to the OCV. This control signal, applied to the OCV, regulates the oil
pressure supplied to the VVT controller. The VVT controller can advance or retard the intake valve camshaft.
Example:
A DTC will set if: 1) the difference between the target and actual valve timing is more than 5 degrees of the
camshaft angle (CA) and the condition continues for more than 4.5 seconds; or 2) the OCV is forcibly activated
63 times or more.
Advanced cam DTCs are subject to "1 trip" detection logic.
Retarded cam DTCs are subject to "2 trip" detection logic.
VVT System: P0011 and P0012

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VVT SYSTEM
Related DTCs P0011: Advanced camshaft timing
Related DTCs P0012: Retarded camshaft timing
Required sensors/ components (Main) VVT OCV and VVT actuator
Required sensors/ components (Related) CKP, CMP and ECT sensors
Frequency of operation Once per driving cycle
Duration Within 10 sec.
MIL operation P0011: Immediate
MIL operation P0012: 2 driving cycles

The monitor will run whenever the following DTCs See PRE-CHECK
are not present
Battery voltage 11 V or more
Engine RPM 550 to 4,000 RPM
ECT 75 to 100°C (167 to 212°F)
Response of valve timing 1 second /°CA or more
Difference between "target" and "actual" camshaft More than 5°CA (Crankshaft Angle)
timing
Camshaft timing change for 5 sec. Within 5°CA
If the difference between "target" and "actual" camshaft timing is larger than the specified value, the ECM
operates the VVT actuator. Then, the ECM monitors the camshaft timing change for 5 seconds.
WIRING DIAGRAM
Refer to WIRING DIAGRAM under DTC P0010.
HINT:
 If DTC P0011 or P0012 is displayed, check the VVT system circuit.

 Read freeze frame data using the hand-held tester or the OBD II scan tool. Freeze frame data records the
engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help
determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio
was lean or rich, and other data from the time the malfunction occurred.
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Hand-held tester:
1. Check valve timing (check for loose or jumped tooth of timing chain) (see INSTALLATION ).
NG : Adjust valve timing.
PREPARATION:

c. Turn ON the ignition switch. Push the hand-held tester main switch.
d. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL
B1
CHECK:
Check the engine speed when operating the OCV using the hand-held tester.
OK:
OCV is OFF: Normal engine speed
OCV is ON: Rough idle or engine stall
OK : Go to step 4
3. Check if DTC outputs reoccur.
PREPARATION:
a. Erase the DTC(s) using one of the following methods: 1) use the hand-held tester, 2) disconnect the
battery terminals for more than 60 seconds, or 3) remove the EFI1 and ETCS fuses for more than
60 seconds.
HINT:
After disconnecting the battery terminals, perform the "INITIALIZE" procedure (see PRE-

c. Drive the vehicle around for 10 minutes or more.
CHECK:
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Read output DTC using the hand-held tester.
OK:
DTC P0011 or P0012 is not stored.
OK : VVT system is OK.*
HINT:
*: DTCs P0011 and P0012 are output when a foreign object in the engine oil enters the system.
These codes will stay even if the system returns to normal after a short time.
Foreign objects are filtered out by the oil filter.
During idling. Check the waveform between terminals OC1+ and OC1- of the ECM connector.
HINT:
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Waveform
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5. Check OCV filter (see DISASSEMBLY . ).
NG : Replace OCV filter.
6. Check OCV (see INSPECTION ).
OK : Go to step 8 .
7. Replace OCV (see COMPONENTS ).
GO: Go to next step.
8. Check VVT controller assembly (see INSPECTION ).
OK : Go to step 10 .
9. Replace VVT controller assembly.
10. Check blockage of OCV and oil hole.
11. Check whether or not DTC P0011 or P0012 is stored.
PREPARATION:
60 seconds.
HINT:
b. Perform the simulation test (see SYMPTOM SIMULATION under HOW TO PROCEED WITH
CHECK:
Check whether or not DTC P0011 or P0012 is stored (see PRE-CHECK ).
OK:
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HINT:
PREPARATION:
Start the engine.
CHECK:
a. Check the engine speed when disconnecting the OCV connector.

b. Check the engine speed when applying the positive battery voltage between the terminals of the
OCV.
RESULT:
Fig. 52: OCV Operation Check Result Table

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2 : Go to step 4 .
1
PREPARATION:
60 seconds.
HINT:

c. Drive the vehicle around for 10 minutes or more.
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CHECK:
Read output DTC using the hand-held tester.
OK:
HINT:
Turn the ignition switch ON, and check the waveform between terminals OC1+ and OC1- of the ECM
connector.
HINT:
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Waveform
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5. Check OCV filter (see INSPECTION ).
NG : Replace OCV filter.
6. Check OCV (see INSPECTION ).
NG : Replace OCV, and then go to step 7.
7. Check VVT controller assembly (see INSPECTION ).
NG : Replace VVT controller assembly, and then go to step 8.
8. Check blockage of OCV and oil hole.
9. Check whether or not DTC P0011 or P0012 is stored.
PREPARATION:
a. Erase the DTC (s) using one of the following methods: 1) use the hand-held tester, 2) disconnect
the battery terminals for more than 60 seconds, or 3) remove the EFI1 and ETCS fuses for more
than 60 seconds.
HINT:
b. Perform the simulation test (see SYMPTOM SIMULATION under HOW TO PROCEED WITH
CHECK:
Check whether or not DTC P0011 or P0012 is stored (see PRE-CHECK ).
OK:
HINT:
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DTC P0016: CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK 1

SENSOR A)
CIRCUIT DESCRIPTION
Refer to DTC CIRCUIT DESCRIPTION under DTC P0335: CRANKSHAFT POSITION SENSOR "A"
CIRCUIT MALFUNCTION, DTC P0339: CRANKSHAFT POSITION SENSOR "A" CIRCUIT
INTERMITTENT.

MONITOR DESCRIPTION
The ECM optimizes the valve timing using the Variable Valve Timing (VVT) system to control the intake valve
camshaft. The VVT system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. The ECM
sends a target duty-cycle control signal to the OCV. This control signal, applied to the OCV, regulates the oil
pressure supplied to the VVT controller. The VVT controller can advance or retard the intake valve camshaft.
The ECM calibrates the valve timing of the VVT system by setting the camshaft to the maximum retard angle
when the engine speed is idling. The ECM closes the OCV to retard the cam. The ECM stores this valve as
VVT learned value. When the difference between the target valve timing and the actual valve timing is 5
degrees or less, the ECM stores this in its memory.
If the learned value meets both of the following conditions ("a" and "b"), the ECM interprets this as a defect in
the VVT system and set a DTC.
a. VVT learning value is less than 27°CA or more than 49°CA.

b. Above condition continues for more than 18 seconds.
VVT System: P0016
VVT SYSTEM (P0016)

Related DTCs P0016: Camshaft timing misalignment at Idling
Required sensors/ components (Main) VVT actuator
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Required sensors/ components (Related) CMP and CKP sensors

Frequency of operation Once per driving cycles
MIL operation 2 driving cycles

are not present
Camshaft timing Maximum retarded
Difference between "target" and "actual" camshaft 5°CA or more within 0.5 sec.
timing
"Actual" camshaft timing change per 360 °CA 1.875 °CA or less
Engine RPM 550 to 1,400 RPM
Either of the following conditions is met: -
"VVT learning value" Less than 27°CA
"VVT learning value" More than 49°CA
WIRING DIAGRAM
Refer to WIRING DIAGRAM under DTC P0335: CRANKSHAFT POSITION SENSOR "A" CIRCUIT
MALFUNCTION, DTC P0339: CRANKSHAFT POSITION SENSOR "A" CIRCUIT INTERMITTENT.
HINT:
OK : Replace ECM (see COMPONENTS ).
DTC P0031: OXYGEN (A/F) SENSOR HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1),
DTC P0032: OXYGEN (A/F) SENSOR HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)
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HINT:
Although the title (DTC description) says "oxygen sensor", this DTC is related to the "A/F sensor".
CIRCUIT DESCRIPTION
Refer to CIRCUIT DESCRIPTION under DTC P2195: OXYGEN (A/F) SENSOR SIGNAL STUCK LEAN
(BANK 1 SENSOR 1), DTC P2196: OXYGEN (A/F) SENSOR SIGNAL STUCK RICH (BANK 1 SENSOR
1).
HINT:
The ECM provides a pulse width modulated control circuit to adjust current through the heater. The A/F sensor
heater circuit uses a relay on the +B side of the circuit.
Fig. 56: A/F Sensor Circuit Diagram


MONITOR DESCRIPTION
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The ECM uses A/F sensor information to keep the air/fuel ratio close to the stoichiometric ratio. This
maximizes the catalytic converter's ability to purify exhaust gases. The sensor detects oxygen levels in the
exhaust gas and sends this signal to the ECM.
The inner surface of the sensor element is exposed to outside air. The outer surface of the sensor element is
exposed to exhaust gas. The sensor element is made of platinum coated zirconia and includes an integrated
heating element. The zirconia element generates a small voltage when there is a large difference in the oxygen
concentrations of the exhaust and the outside air. The platinum coating amplifies the voltage generation. When
heated, the sensor becomes very efficient. If the temperature of the exhaust is low, the sensor will not generate
useful voltage signals without supplemental heating. The ECM regulates the supplemental heating using a duty-
cycle approach to regulate the average current in the heater element. If the heater current is out of the normal
range, the sensor's output signals will be inaccurate and the ECM cannot regulate the A/F ratio properly.
When the heater current is out of the normal operating range, the ECM interprets this as a malfunction and sets
a DTC.
MONITOR STRATEGY
STRATEGY MONITORING
Related DTCs P0031: A/F sensor heater range check (Low
Current)
Related DTCs P0032: A/F sensor heater range check (High
Current)
Required sensors/ components (Main) A/F sensor heater
Duration 10 sec.

are not present
Battery voltage Less than 10.5 V
Time after engine start 10 sec. or more
P0031: A/F sensor heater duty ratio 50 % or more
P0031:
A/F sensor heater current Less than 0.8 A
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P0032:
A/F sensor heater current More than 10 A

A/F sensor heater current 1.8 to 3.4 A at 20°C (68°F)
MONITOR RESULT
The detailed information is described in "CHECKING MONITOR STATUS" (see PRE-CHECK ).
 TID (Test Identification) is assigned to each emission-related component.

 TLT (Test Limit Type):
If TLT is 0, the component is malfunctioning when the test value is higher than the test limit.
If TLT is 1, the component is malfunctioning when the test value is lower than the test limit.
 CID (Component Identification) is assigned to each test value.

 Unit Conversion is used to calculate the test value indicated on generic OBD scan tools.
TID $07: A/F Sensor Heater
A/F SENSOR HEATER TEST LIMIT DESCRIPTION

Description of Test Description of Test
TLT CID Unit Conversion Value Limit
1 $01 Multiply by 0.00017 Maximum A/F Malfunction
(A) sensor heater current criterion
(bank 1)
WIRING DIAGRAM
Refer to WIRING DIAGRAM under DTC P2195: OXYGEN (A/F) SENSOR SIGNAL STUCK LEAN
1).
HINT:
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1. Check resistance of A/F sensor heater (see INSPECTION ).

NG : Replace A/F sensor.
2. Check EFI main relay.
PREPARATION:
Remove the EFI main relay from the engine room J/B.
CHECK:
Inspect the EFI main relay.
OK:

3-5 10 kohm or higher
3-5 Below 1 ohm (when battery voltage is applied to
terminals 1 and 2)
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Fig. 58: Identifying EFI Main Relay

NG : Replace EFI main relay.

3. Check voltage between terminal HA1A of ECM connector and body ground.
PREPARATION:

CHECK:
Measure the voltage between terminal HA1A of the ECM connector and body ground.
OK:
Voltage: 9 to 14 V

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Fig. 59: Locating HA1A (+) Connector Terminal Of ECM

4. Check for open and short in wire harness between EFI main relay and A/F sensor, and A/F sensor
and ECM (see HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE in
INTRODUCTION article).
DTC P0037: OXYGEN SENSOR HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2), DTC
P0038: OXYGEN SENSOR HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)
CIRCUIT DESCRIPTION
Refer to CIRCUIT DESCRIPTION under DTC P0136: OXYGEN SENSOR CIRCUIT MALFUNCTION
(BANK 1 SENSOR 2).
HINT:
The ECM provides a pulse width modulated control circuit to adjust current through the heater. The heated
oxygen sensor heater uses a relay on the +B side of the circuit.
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Fig. 60: Heated Oxygen Sensor Circuit Diagram


HINT:
Sensor 2 refers to the farther sensor from the engine body.
MONITOR DESCRIPTION
The sensing portion of the heated oxygen sensor has a zirconia element which is used to detect oxygen
concentration in the exhaust. If the zirconia element is at the proper temperature and difference of the oxygen
concentration between the inside and outside surface of sensor is large, the zirconia element will generate
voltage signals. In order to increase the oxygen concentration detecting capacity in the zirconia element, the
ECM supplements the heat from the exhaust with heat from a heating element inside the sensor. When current
in the sensor is out of the standard operating range, the ECM interprets this as a fault in the heated oxygen
sensor and sets a DTC.
MONITOR STRATEGY
STRATEGY MONITORING
Related DTCs P0037: Rear HO2S heater range check (Low
Current)
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Related DTCs P0038: Rear HO2S heater range check (High

Current)
Required sensors/ components (Main) HO2S heater
Duration P0037: 2 sec.
Duration P0038: 0.3 sec.
P0037:

are not present
Either of the following conditions A and B are met
Condition A
Time after engine start 250 to 500 sec.
Vehicle speed Within 90 km/h (56 mph)
Battery voltage 10.5 V or more
Pass or Fail detection in this driving cycle None
Condition B
Vehicle speed 40 km/h (25 mph) or more
Pass or Fail detection in this driving cycle None
P0038:

Combined heater current for 0.3 second or more 2.2 A or more
P0037:
HO2S heater current when HO2S heater OFF Less than 0.25 A (when battery voltage is 11.5 V)
P0038:
HO2S heater current when HO2S heater ON More than 2 A
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HO2S heater current 0.4 to 1 A (at idle, warmed-up engine and +B: 11 to
14 V)
MONITOR RESULT


TID $04: HO2S Heater
HO2S HEATER TEST LIMIT DESCRIPTION

1 $02 Multiply by Maximum HO2S Malfunction
0.000076 (A) heater current (bank criterion
1 sensor 2)
WIRING DIAGRAM
Refer to WIRING DIAGRAM under DTC P0136: OXYGEN SENSOR CIRCUIT MALFUNCTION (BANK
1 SENSOR 2).
HINT:
1. Check resistance of heated oxygen sensor heater (see INSPECTION ).

NG : Replace heated oxygen sensor.
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PREPARATION:
CHECK:
OK:

terminals 1 and 2)


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3. Check voltage between terminals HT1B of ECM connector and body ground.
PREPARATION:

CHECK:
Measure the voltage between terminal HT1B of the ECM connector and body ground.
HINT:
Connect terminal HT1B to bank 1 sensor 2.
OK:
Voltage: 9 to 14 V

Fig. 63: Locating HT1B (+) Connector Terminal Of ECM

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4. Check for open and short in wire harness between EFI main relay and heated oxygen sensor, and
heated oxygen sensor and ECM (see HOW TO USE THE DIAGNOSTIC CHART AND
DTC P0100: MASS OR VOLUME AIR FLOW CIRCUIT MALFUNCTION, DTC P0102: MASS OR
VOLUME AIR FLOW CIRCUIT LOW INPUT, DTC P0103: MASS OR VOLUME AIR FLOW
CIRCUIT HIGH INPUT
CIRCUIT DESCRIPTION
The Mass Air Flow (MAF) meter measures the amount of air flowing through the throttle valve. The ECM uses
this information to determine the fuel injection time and provide a proper air fuel ratio. Inside the MAF meter,
there is a heated platinum wire exposed to the flow of intake air.
By applying a specific current to the wire, the ECM heats this wire to a given temperature. The flow of
incoming air cools the wire and an internal thermistor, affecting their resistance. To maintain a constant current
value, the ECM varies the voltage applied to these components in the MAF meter. The voltage level is
proportional to the airflow through the sensor. The ECM interprets this voltage as the intake air amount.
The circuit is constructed so that the platinum hot wire and temperature sensor provide a bridge circuit, with the
power transistor controlled so that the potential of A and B remains equal to maintain the set temperature.
Fig. 64: Mass Air Flow (MAF) Sensor Circuit Description

The circuit is constructed so that the platinum hot wire and temperature sensor provide a bridge circuit with the
power transistor, and the potential of A and B remains equal to maintain the set temperature.
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Fig. 65: DTC (P0100, P0102, P0103) Diagnosis Table

HINT:
After confirming DTC P0100, P0102 or P0103, use the hand-held tester or the OBD II scan tool to confirm the
MAF ratio from the ALL menu (to reach the ALL menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST /
ALL.
Fig. 66: Air Flow Value Table

MONITOR DESCRIPTION
If there is a defect in the sensor or an open or short circuit, the voltage level will deviate outside the normal
operating range. The ECM interprets this deviation as a defect in the MAF meter and sets a DTC
Example:
When the sensor voltage output is less than 0.2 V, or more than 4.9 V, and if either the condition continues for
more than 3 seconds.
MONITOR STRATEGY
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Fig. 67: Strategy Monitoring Table


are not present
P0100:
MAF meter voltage Less than 0.2 V or more than 4.9 V
P0102:
MAF meter voltage Less than 0.2 V
P0103:
MAF meter voltage More than 4.9 V

MAF meter voltage Between 0.4 and 2.2 V
WIRING DIAGRAM
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Fig. 68: Mass Air Flow Wiring Diagram

HINT:
1. Connect hand-held tester or OBD II scan tool and read value of air flow rate.
PREPARATION:

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b. Start the engine.

c. Push the hand-held tester or the OBD II scan tool main switch ON.
d. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS /
ENHANCED OBD II / DATA LIST / ALL / MAF.
CHECK:
Read the mass air flow rate on the OBD II scan tool or the hand-held tester.
RESULT:
MASS AIR FLOW RATE CHECK RESULT

Air Flow Rate (gm/s) Proceed to
0.0 Type I
271.0 or more Type II
Between 1 and 270.0 (1) Type III
(1) The value must be changed when the throttle valve is opened or closed.
Type II : Go to step 5 .
Type III : Check for intermittent problems (see PRE-CHECK ).
Type I: Go to next step.
2. Check voltage of MAF meter power source.
PREPARATION:

CHECK:
Measure the voltage between terminal 1 of the MAF meter connector and body ground.
OK:
Voltage: 9 to 14 V
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Fig. 69: Locating MAF Meter Power Source Connector +B (+) Terminal
NG : Check for open in harness and connector between EFI main relay and MAF meter (see
HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE in
3. Check voltage between terminal VG and EVG of ECM connector.
PREPARATION:

CHECK:
Measure the voltage between terminal VG and EVG of the ECM connector while the engine is idling.
OK:
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Voltage:
0.5 to 3.0 V (Neutral position and A/C switch OFF)
Fig. 70: Locating VG (+) And EVG (-) Connector Terminals Of ECM

4. Check for open and short in wire harness between MAF meter and ECM, and between the MAF
meter and EFI main relay (see HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION
PROCEDURE in INTRODUCTION article).
OK : Replace MAF meter.
5. Check resistance between terminal EVG of ECM connector and body ground.
PREPARATION:
Remove the glove compartment (see COMPONENTS ).
CHECK:
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2004 Toyota RAV4
Check the resistance between terminal EVG of the ECM connector and body ground.
OK:
Fig. 71: Locating EVG (-) Connector Terminal Of ECM


6. Check for open in wire harness between MAF meter and ECM (see HOW TO USE THE
DIAGNOSTIC CHART AND INSPECTION PROCEDURE in INTRODUCTION article).
DTC P0101: MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE PROBLEM
CIRCUIT DESCRIPTION
Refer to CIRCUIT DESCRIPTION under DTC P0100: MASS OR VOLUME AIR FLOW CIRCUIT
MALFUNCTION, DTC P0102: MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT, DTC P0103:
MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT.
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MONITOR DESCRIPTION
The Mass Air Flow (MAF) meter helps the ECM calculate the amount of air flowing through the throttle valve.
The ECM uses this information to determine the fuel injection time and provide a proper air fuel ratio. Inside
the MAF meter, there is a heated platinum wire exposed to the flow of intake air. By applying a specific current
to the wire, the ECM heats this wire to a given temperature. The flow of incoming air cools the wire and an
internal thermistor, affecting their resistance. To maintain a constant current value, the ECM varies the voltage
applied to these components in the MAF meter. The voltage level is proportional to the air flow through the
sensor. The ECM interprets this voltage as the intake air amount. If there is a defect in the sensor or an open or
short circuit, the voltage level will deviate from the normal operating range. The ECM interprets this deviation
as a defect in the MAF meter and sets a DTC.
Example: If the voltage is more than 2.2 V at idle or less than 0.4 V at idle off, the ECM interprets this as a
defect in the MAF meter and sets a DTC.
MONITOR STRATEGY
STRATEGY MONITORING
Related DTCs P0101: MAF meter rationality (Low voltage)
Related DTCs P0101: MAF meter rationality (High voltage)
Required sensors/ components (Main) MAF meter
Required sensors/ components (Related) CKP sensor, ECT sensor, TP sensor
Duration 10 sec.

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are not present
MAF Meter Rationality (Low voltage):
MAF METER RATIONALITY (LOW VOLTAGE)

Engine RPM Less than 900 RPM
Idle ON
ECT 70°C (158°F) or more
MAF Meter Rationality (High voltage):
MAF METER RATIONALITY (HIGH VOLTAGE)

RPM 0 RPM or more
TP voltage 0.1 V or more
MAF Meter Rationality (Low voltage):
MAF METER RATIONALITY (LOW VOLTAGE)

MAF meter voltage Less than 0.4 V
MAF Meter Rationality (High voltage):
MAF METER RATIONALITY (HIGH VOLTAGE)

MAF meter voltage More than 2.2 V
WIRING DIAGRAM
Refer to WIRING DIAGRAM under DTC P0100: MASS OR VOLUME AIR FLOW CIRCUIT
MALFUNCTION, DTC P0102: MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT, DTC P0103:
MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT.
HINT:
1. Are there any other codes (besides DTC P0101) being output?
NO : Replace MAF meter.
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YES : Go to relevant DTC chart (see DIAGNOSTIC TROUBLE CODE CHART ).
DTC P0110: INTAKE AIR TEMPERATURE CIRCUIT, DTC P0112: INTAKE AIR TEMPERATURE
CIRCUIT LOW INPUT, DTC P0113: INTAKE AIR TEMPERATURE CIRCUIT HIGH INPUT
CIRCUIT DESCRIPTION
The Intake Air Temperature (IAT) sensor, mounted on the Mass Air Flow (MAF) meter, monitors the intake air
temperature. The IAT sensor has a thermistor that varies its resistance depending on the temperature of the
intake air. When the air temperature is low, the resistance in the thermistor increases. When the temperature is
high, the resistance drops. The variations in resistance are reflected as voltage changes to the ECM terminal (see
Fig. 1).
The IAT sensor is connected to the ECM (see below). The 5 V power source voltage in the ECM is applied to
the IAT sensor from terminal THA (THAR) via resistor R.
That is, the resistor R and the IAT sensor are connected in series. When the resistance value of the IAT sensor
changes in accordance with changes in the IAT, the voltage at terminal THA (THAR) also changes. Based on
this signal, the ECM increases the fuel injection volume to improve the driveability during cold engine
operation.
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Fig. 73: Resistance/Temperature Graph

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HINT:
After confirming DTC P0110, P0112 or P0113, use the hand-held tester to confirm the intake air temperature
from the "DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL".
TEMPERATURE DISPLAYING
Temperature Displayed Malfunction
-40 °C (-40°F) Open circuit
140°C (284°F) or more Short circuit
MONITOR DESCRIPTION
The ECM monitors the sensor voltage and uses this value to calculate the intake air temperature (IAT). When
the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the IAT
Example:
When the sensor voltage output equal to less than -40°C (-40°F), or more than 140°C (284°F), and either
condition continue 0.5 second or more.
MONITOR STRATEGY

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TYPICAL ENABLING CONDITION

are not present
P0110:
IAT sensor resistance Less than 98.5 ohm or more than 156 kohm
P0112:
IAT sensor resistance [IAT] Less than 98.5 ohm [More than 140°C (284°F)]
P0113:
IAT sensor resistance [IAT] More than 156 kohm [Less than -40°C (-40°F)]

IAT sensor resistance [IAT] 98.5 ohm to 156 kohm [-40 to 140°C (-40 to 284°
F)]
WIRING DIAGRAM
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Fig. 76: MAF Meter Wiring Diagram

HINT:
 If different DTCs that are related to different systems are output simultaneously while terminal E2 is used
as a ground terminal, terminal E2 may be open.
was lean or rich, and other data from the time the malfunction occurred
1. Connect hand-held tester or OBD II scan tool, and read value of intake air temperature.
PREPARATION:
a. Connect the hand-held tester or the OBD II scan tool to the DLC3.
b. Turn the ignition switch ON. Push the hand-held tester or OBD II scan tool main switch ON.
c. On the hand-held tester or OBD II scan tool, enter the following menus: DIAGNOSIS /
ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR.
CHECK:
Read the temperature value on the hand-held tester or the OBD II scan tool.
OK:
Same value as the actual air intake temperature.
HINT:
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2004 Toyota RAV4
If there is open circuit, hand-held tester or OBD II scan tool indicates -40°C (-40°F).

 If there is short circuit, hand-held tester or OBD II scan tool indicates 140°C (284°F) or more.
NG :
-40°C (-40°F) ..... Go to step 2.
140°C (284°F) or more ..... Go to step 4 .
2. Check for open in harness or ECM.
PREPARATION:

b. Connect the terminals THA and E2 of the MAF meter wire harness side connector.
e. Push the hand-held tester or OBD II scan tool main switch ON.
Fig. 77: Checking For Open Harness Or ECM

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f. On the hand-held tester or OBD II scan tool, enter the following menus: DIAGNOSIS /
CHECK:
OK:
Temperature value: 140°C (284°F) or more
OK : Confirm good connection at sensor. If OK, replace MAF meter.

PREPARATION:

b. Connect terminals THA and E2 of the ECM connector.
HINT:
Before checking, do a visual and contact pressure check for the ECU connector.
CHECK:
OK:
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Fig. 78: Checking For Open Harness Or ECM And Locating THA And E2 Connector Terminals Of
ECM
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OK : Open in harness between terminals E2 or THA, repair or replace harness.

NG : Confirm good connection at ECM. If OK, replace ECM (see COMPONENTS ).
4. Check for short in harness and ECM.
PREPARATION:

b. Connect the hand-held tester or the OBD II scan tool to the DLC3.
d. Push the hand-held tester or OBD II scan tool main switch ON.
e. On the hand-held tester or OBD II scan tool, enter the following menus: DIAGNOSIS /
Fig. 79: Checking For Short In Harness And ECM

CHECK:
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OK:
Temperature value: -40°C (-40°F)

5. Check for short in harness or ECM.
PREPARATION:
a. Disconnect the E6 ECM connector.

b. Connect the hand-held tester or the OBD II scan tool to the DLC3.
HINT:
The MAF meter connector is disconnected.

CHECK:
OK:
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2004 Toyota RAV4
Fig. 80: Checking For Short In Harness Or ECM And Locating E6 Connector Of ECM
OK : Repair or replace harness and connector.

DTC P0115: ENGINE COOLANT TEMPERATURE CIRCUIT, DTC P0117: ENGINE COOLANT
TEMPERATURE CIRCUIT LOW INPUT, DTC P0118: ENGINE COOLANT TEMPERATURE
CIRCUIT HIGH INPUT
CIRCUIT DESCRIPTION
A thermistor is built in the Engine Coolant Temperature (ECT) sensor and changes the resistance value
according to the engine coolant temperature.
The structure of the sensor and connection to the ECM is the same as those of the Intake Air Temperature (IAT)
sensor.
HINT:
If the ECM detects the DTC "P0115, P0117 or P0118", it operates the fail-safe function in which the ECT is
assumed to be 80°C (176°F).

HINT:
After confirming DTC "P0115, P0117 or P0118", use the hand-held tester or the OBD II scan tool to confirm
the engine coolant temperature from the DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL.
TEMPERATURE DISPLAY
Temperature Displayed Malfunction
-40°C (-40°F) Open circuit
140°C (284°F) or more Short circuit
MONITOR DESCRIPTION
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2004 Toyota RAV4
The ECT sensor is used to monitor the engine coolant temperature. The ECT sensor has a thermistor that varies
its resistance depending on the temperature of the engine coolant. When the coolant temperature is low, the
resistance in the thermistor increases. When the temperature is high, the resistance drops. The variations in
resistance are reflected in the voltage output from the sensor.
The ECM monitors the sensor voltage and uses this value to calculate the engine coolant temperature. When the
sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the ECT
Example:
When the ECM calculates that the ECT is less than -40°C (-40°F), or more than 140°C (284°F), and if either the
condition continues for 0.5 seconds or more, the ECM will set a DTC.
MONITOR STRATEGY


are not present
P0115:
ECT sensor resistance Less than 79 ohm or more than 156 kohm
P0117:
ECT sensor resistance [ECT] Less than 79 ohm [More than 140°C (284°F)]
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2004 Toyota RAV4
P0118:
ECT sensor resistance [ECT] More than 156 kohm [Less than -40°C (-40°F)]

ECT sensor resistance [ECT] 79 ohm to 156 kohm [-40 to 140°C (-40 to 284°F)]
WIRING DIAGRAM
Fig. 83: E2 ECT Sensor Wiring Diagram

HINT:
1. Connect hand-held tester or OBD II scan tool and read value of engine coolant temperature.
PREPARATION:
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c. Push the hand-held tester or OBD II scan tool main switch ON.
d. On the hand-held tester or OBD II scan tool, enter the following menus: DIAGNOSIS /
ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP.
CHECK:
OK:
Same value as the actual engine coolant temperature.
HINT:
If there is open circuit, hand-held tester or OBD II scan tool indicates -40°C (-40°F).

 If there is short circuit, hand-held tester or OBD II scan tool indicates 140°C (284°F) or more.
NG :
-40°C (-40°F) ..... Go to step 2.
140°C (284°F) or more ..... Go to step 4 .
PREPARATION:
a. Disconnect the ECT sensor connector.

b. Connect terminals 1 and 2 of the ECT sensor wire harness side connector.
c. Connect the hand-held tester or OBD II scan tool to the DLC3.
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Fig. 84: Checking For Open In Harness Or ECM

CHECK:
OK:
OK : Confirm good connection at sensor. If OK, replace engine coolant temperature sensor.
PREPARATION:

b. Connect terminals THW and E2 of the ECM connector.
HINT:
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2004 Toyota RAV4
Before checking, perform a visual and contact pressure check for the ECU connector.
c. Connect the hand-held tester or OBD II scan tool to the DLC3.

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Fig. 85: Checking Open In Harness Or ECM And Locating THW And E2 Connector
Terminals Of ECM
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CHECK:
OK:
OK : Open in harness between terminals E2 or THW, repair or replace harness.

NG : Confirm good connection at ECM. If OK, replace ECM (see COMPONENTS ).
4. Check for short in harness and ECM.
PREPARATION:

b. Connect the hand-held tester or OBD II scan tool to the DLC3.
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Fig. 86: Checking For Short In Harness And ECM

CHECK:
OK:
OK : Replace ECT sensor.

5. Check for short in harness or ECM.
PREPARATION:
a. Disconnect the E6 ECM connector.

b. Connect the hand-held tester or OBD II scan tool to the DLC3.
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Fig. 87: Checking For Short In Harness Or ECM And Locating E6 Connector Of ECM
CHECK:
OK:

DTC P0116: ENGINE COOLANT TEMPERATURE CIRCUIT RANGE/PERFORMANCE PROBLEM
CIRCUIT DESCRIPTION
Refer to CIRCUIT DESCRIPTION under DTC P0115: ENGINE COOLANT TEMPERATURE CIRCUIT,
DTC P0117: ENGINE COOLANT TEMPERATURE CIRCUIT LOW INPUT, DTC P0118: ENGINE
COOLANT TEMPERATURE CIRCUIT HIGH INPUT.

MONITOR DESCRIPTION
The Engine Coolant Temperature (ECT) sensor is used to monitor the engine coolant temperature. The ECT
sensor has a thermistor that varies its resistance depending on the temperature of the engine coolant. When the
coolant temperature is low, the resistance in the thermistor increases. When the temperature is high, the
resistance drops. The variations in resistance are reflected in the voltage output from the sensor. The ECM
monitors the sensor voltage and uses this value to calculate the engine coolant temperature. When the sensor
output voltage deviates from the normal operating range, the ECM interprets this as a fault in the ECT sensor
and sets a DTC.
Examples:
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1. Upon starting the engine, the ECT is between 35°C (95°F) and 60°C (140°F). If after driving for 250
seconds, the ECT still remains within 3°C (5.4°F) of the starting temperature, a DTC will be set (2 trip
detection logic).
2. Upon starting the engine, the ECT is over 60°C (140°F). If, after driving for 250 seconds, the ECT still
remains within 1°C (1.8°F) of the starting temperature, a DTC will be set (6 trip detection logic).
MONITOR STRATEGY
STRATEGY MONITORING
Related DTCs P0116: ECT sensor stuck at Low ECT
Related DTCs P0116: ECT sensor stuck at High ECT
Required sensors/ components (Main) ECT sensor
Required sensors/ components (Related) CKP sensor, IAT sensor, MAF meter
Duration 250 sec. or more
MIL operation 2 driving cycles: ECT sensor stuck at Low ECT
MIL operation 6 driving cycles: ECT sensor stuck at High ECT

The monitor will run whenever the following DTCs P0100 to P0103: MAF meter
are not present
ECT Sensor Stuck at Low ECT:
ECT SENSOR STUCK AT LOW ECT

Cumulative idle off period 250 sec. or more
Speed increase by 30 km/h (19 mph) or more 10 times or more
ECT 35 to 60°C (95 to 140°F)
IAT -6.7°C (20°F) or more
ECT Sensor Stuck at High ECT:
ECT SENSOR STUCK AT HIGH ECT

IAT -6.7°C (20°F) or more
"Stop and go" (1) Once or more
"Steady driving and stop" (2) Once or more
(1) Vehicle is stopped for 20 seconds or more and accelerated to more than 70 km/h (44 mph) within 40
seconds.
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(2) Vehicle is driven by 65 km/h (40 mph) or more for 30 sec or more and the vehicle speed reaches 70
km/h (44 mph). The vehicle is decelerated from 65 km/h (40 mph) to 3 km/h (2 mph) or less within
35 seconds and stopped for 10 seconds.
ECT Sensor Stuck at Low ECT:
ECT SENSOR STUCK AT LOW ECT MALFUNCTION THRESHOLDS

ECT change Less than 3°C (5.4°F)
ECT Sensor Stuck at High ECT:
ECT SENSOR STUCK AT HIGH ECT MALFUNCTION THRESHOLDS

ECT change 1°C (1.8°F) or less

ECT Varies with actual ECT
HINT:
 If DTCs P0115, P0116, P0117, P0118 and P0125 are output simultaneously, the ECT sensor circuit may
be open or shorted. Perform the troubleshooting of DTC P0115, P0117 or P0118 first.
engine conditions when the malfunction is detected. When troubleshooting, freeze frame data can help
Replace ECT sensor.
DTC P0120: THROTTLE/PEDAL POSITION SENSOR/SWITCH "A" CIRCUIT MALFUNCTION,

DTC P0122: THROTTLE/PEDAL POSITION SENSOR/SWITCH "A" CIRCUIT LOW INPUT, DTC
P0123: THROTTLE/PEDAL POSITION SENSOR/SWITCH "A" CIRCUIT HIGH INPUT, DTC
P0220: THROTTLE/PEDAL POSITION SENSOR/SWITCH "B" CIRCUIT MALFUNCTION, DTC
P0222: THROTTLE/PEDAL POSITION SENSOR/SWITCH "B" CIRCUIT LOW INPUT, DTC P0223:
THROTTLE/PEDAL POSITION SENSOR/SWITCH "B" CIRCUIT HIGH INPUT, DTC P2135:
THROTTLE/PEDAL POSITION SENSOR/SWITCH "A"/"B" VOLTAGE CORRECTION
HINT:
This is the purpose of the "throttle position sensor".
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CIRCUIT DESCRIPTION
HINT:
 This Electronic Throttle Control System (ETCS) does not use a throttle cable.
 This throttle position sensor is non-contact type.
The throttle position sensor is mounted on the throttle body and it detects the opening angle of the throttle valve.
This sensor is electronically controlled and uses Hall-effect elements, so that accurate control and reliability can
be obtained. The throttle position sensor has 2 sensor elements/single outputs: VTA1 and VTA2. VTA1 is used
to detect the throttle opening angle and VTA2 is used to detect malfunctions in VTA1. Voltage applied to
VTA1 and VTA2 change between 0 V and 5 V in proportion to the opening angle of the throttle valve. This
sensor includes 2 signals, VTA1 and VTA2. VTA1 is used to detect the throttle opening angle and VTA2 is
used to detect malfunctions in VTA1. There are several checks that the ECM performs to confirm proper
operation of the throttle position sensor and VTA1.
The ECM judges the current opening angle of the throttle valve from these signals input from terminals VTA1
and VTA2, and the ECM controls the throttle motor to make the throttle valve angle properly in response to
driver inputs.
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Fig. 89: Electronic Throttle Control System Circuit Description

Fig. 90: DTC (P0120, P0122, P0123, P0220, P0222, P0223, P2135) Diagnosis Table
NOTE: When a malfunction is detected, the throttle valve is locked at a certain opening
angle. Also, all electronic throttle operations are inoperable until the system
returns to normal or the ignition switch is turned OFF
HINT:
 After confirming DTCs, use the hand-held tester or the OBD II scan tool to confirm the throttle valve
opening percentage and closed throttle position switch condition.
 THROTTLE POS is a VTA1 signal and the THROTTLE POS #2 is a VTA2 signal.
Reference (Normal condition):
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NORMAL CONDITION REFERENCE

Accelerator pedal fully
Tester display Accelerator pedal fully released depressed
THROTTLE POS 10 to 24 % 64 to 96 %
THROTTLE POS #2 2.1 to 3.1 V 4.5 to 5.5 V
MONITOR DESCRIPTION
The ECM uses the throttle position sensor to monitor the throttle valve opening angle.
a. There is a specific voltage difference expected between VTA1 and VTA2 for each throttle opening angle.
 If the difference between VTA1 and VTA2 is incorrect, the ECM interprets this as a fault and will
set a DTC.
b. VTA1 and VTA2 each have a specific voltage operating range.
 If VTA1 or VTA2 is out of the normal operating range, the ECM interprets this as a fault and will
set a DTC.
c. VTA1 and VTA2 should never be close to the same voltage levels.
 If VTA1 is within 0.02 V of VTA2, the ECM interprets this as a short circuit in the throttle position
sensor system and will set a DTC.
FAIL-SAFE
If the Electronic Throttle Control System (ETCS) has a malfunction, the ECM cuts off current to the throttle
control motor. The throttle control valve returns to a predetermined opening angle (approximately 16°) by the
force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent
fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to
continue at a minimal speed.
If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly.
If a "pass" condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and
the system will return to normal condition.
MONITOR STRATEGY
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are not present
Ignition switch and electronic throttle motor power ON
P0120:
VTA1 voltage 0.2 V or less or 4.8 V or more
P0122:
VTA1 voltage 0.2 V or less
P0123:
VTA2 voltage 4.8 V or more
P0220:
VTA2 voltage 0.5 V or less or 4.8 V or more
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P0222:
P0223:
VTA2 voltage when the VTA1 is 0.2 to 1.8 V 4.8 V or more
P2135:
Both of the following condition(s) is met: Condition A or B
Condition A
Difference between VTA1 and VTA2 voltage 0.02 V or less
Condition B
Both of the following condition is met (a) and (b)
(a) VTA1 voltage 0.2 V or less
(b) VTA2 voltage 0.5 V or less

VTA1 voltage 0.6 to 3.96 V
VTA2 voltage 2.25 to 4.8 V
WIRING DIAGRAM
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Fig. 92: T1 Throttle Position Sensor Wiring Diagram

HINT:
Hand-held tester:
1. Connect hand-held tester and read voltage for throttle position sensor data.
PREPARATION:
a. Connect the hand-held tester to DLC3.

b. Turn ON the ignition switch. Push the hand-held tester main switch ON.
c. On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA
LIST / ETCS / THROTTLE POS and THROTTLE POS #2.
CHECK:
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Read the voltage for the accelerator pedal position sensor data.
RESULT:
Fig. 93: Accelerator Pedal Position Sensor Data Table

B : Go to step 2 .
A : Go to next step.
2. Check for open and short in wire harness in VC, VTA1, VTA2 and E2 circuits between ECM and
throttle position sensor (see HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION
3. Check voltage between terminals VC and E2 of ECM connector.
PREPARATION:

c. Disconnect the throttle position sensor connector.
CHECK:
Measure the voltage between terminals VC and E2 of the ECM connector.
OK:
Voltage: 4.5 to 5.5 V
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Fig. 94: Locating VC (+) And E2 (-) Connector Terminals Of ECM


4. Replace throttle body (see REMOVAL ).
5. Check if DTC output reoccur.
PREPARATION:

c. Drive the engine at idle for 15 seconds or more.
CHECK:
Read the DTC output.
OK:
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No DTC output.
OK : System is OK.
1. Check for open and short in wire harness in VC, VTA and E2 circuits between ECM and throttle
position sensor (see HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION
2. Check voltage between terminal VC and E2 of ECM connector.
PREPARATION:

c. Disconnect the throttle position sensor connector.
CHECK:
OK:
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Fig. 95: Locating VC (+) And E2 (-) Connector Terminals Of ECM

NG : Check for open and short in harness and connector between ECM and throttle position
sensor (VTA or E2 line) (see HOW TO USE THE DIAGNOSTIC CHART AND
3. Replace throttle body (see REMOVAL ).
PREPARATION:

c. Run the engine at idle for 15 seconds or more.
CHECK:
Check whether or not DTC P0120, P0122, P0123, P0220, P0222, P0223 and/or P2135 are stored.
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NG : System is OK.
DTC P0121: THROTTLE/PEDAL POSITION SENSOR/SWITCH "A" CIRCUIT

RANGE/PERFORMANCE PROBLEM
HINT:
This is the purpose of the "throttle position sensor".
CIRCUIT DESCRIPTION
Refer to CIRCUIT DESCRIPTION under DTC P0120: THROTTLE/PEDAL POSITION SENSOR/SWITCH

"A" CIRCUIT MALFUNCTION, DTC P0122: THROTTLE/PEDAL POSITION SENSOR/SWITCH "A"
CIRCUIT LOW INPUT, DTC P0123: THROTTLE/PEDAL POSITION SENSOR/SWITCH "A" CIRCUIT
HIGH INPUT, DTC P0220: THROTTLE/PEDAL POSITION SENSOR/SWITCH "B" CIRCUIT
MALFUNCTION, DTC P0222: THROTTLE/PEDAL POSITION SENSOR/SWITCH "B" CIRCUIT LOW
INPUT, DTC P0223: THROTTLE/PEDAL POSITION SENSOR/SWITCH "B" CIRCUIT HIGH INPUT, DTC
P2135: THROTTLE/PEDAL POSITION SENSOR/SWITCH "A"/"B" VOLTAGE CORRECTION.
DTC (P0121) DIAGNOSIS

DTC No. Detection Item Trouble Area
P0121 Condition (a) continues for 2.0 Throttle position sensor
seconds: (a) Difference between
VTA1 and VTA2 deviates from
threshold
MONITOR DESCRIPTION
The ECM uses the throttle position sensor to monitor the throttle valve opening angle.
This sensor includes 2 signals: VTA1 and VTA2. VTA1 is used to detect the throttle opening angle and VTA2
is used to detect malfunctions in VTA1. There are several checks that the ECM performs to confirm proper
operation of the throttle position sensor and VTA1.
There is a specific voltage difference expected between VTA1 and VTA2 for each throttle opening angle. If the
voltage output difference of the VTA1 and VTA2 deviates from the normal operating range, the ECM interprets
this as a malfunction of the throttle position sensor. The ECM will turn on the MIL and a DTC is set.
FAIL-SAFE
If the Electronic Throttle Control System (ETCS) has a malfunction, the ECM cuts off current to the throttle
control motor. The throttle control valve returns to a predetermined opening angle (approximately 16°) by the
force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent
fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to
continue at a minimal speed.
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If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly.
MONITOR STRATEGY
STRATEGY MONITORING
Related DTCs P0121: TP sensor rationality
Required sensors/ components (Main) TP sensor
Duration 2 sec.

are not present
Either of the following conditions is met:
Difference in voltage between "VTA1 - opener Less than 0.8 V or more than 1.6V
angle (sensor 1)" and "VTA2 x 0.8 opener angle
(sensor 2)"
HINT:
Replace throttle body (see REMOVAL )
DTC P0125: INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL
CIRCUIT DESCRIPTION
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Refer to CIRCUIT DESCRIPTION under DTC P0115: ENGINE COOLANT TEMPERATURE CIRCUIT,
DTC P0117: ENGINE COOLANT TEMPERATURE CIRCUIT LOW INPUT, DTC P0118: ENGINE
COOLANT TEMPERATURE CIRCUIT HIGH INPUT.

MONITOR DESCRIPTION
The engine coolant temperature (ECT) sensor is used to monitor the temperature of the engine coolant. The
resistance of the sensor varies with the actual coolant temperature. The ECM applies a voltage to the sensor and
the varying resistance of the sensor causes the signal voltage to vary. The ECM monitors the ECT signal
voltage after engine start-up. If, after sufficient time has passed, the sensor still reports that the engine is not
warm enough for closed-loop fuel control, the ECM interprets this as a fault in the sensor or cooling system and
sets a DTC.
Example:
The ECT is 0°C (32°F) at engine start. After 5 minutes running time, the ECT sensor still indicates that the
engine is not warm enough to begin active feedback control of the air-fuel ratio. The ECM interprets this as a
fault in the sensor or cooling system and will set a DTC.
MONITOR STRATEGY
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are not present
Fuel cut OFF
Engine Running
Fig. 98: Malfunction Thresholds Table

HINT:
 If DTCs P0115, P0116, P0117, P0118 and P0125 are output simultaneously, engine coolant temperature
sensor circuit may be open or short. Perform the troubleshooting of DTC P0115, P0117 or P0118 first.
1. Are there any other codes (besides DTC P0125) being out put ?
a. Read the DTCs using the hand-held tester or the OBD II scan tool.
RESULT:
DTC OUTPUT DISPLAY

Display (DTC output) Proceed to
Only "P0125" are output A
"P0125" and other DTCs are output B
HINT:
If any other codes besides "P0125" is output, perform the troubleshooting for those codes first.
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B : Go to relevant DTC chart (see DIAGNOSTIC TROUBLE CODE CHART ).

2. Inspect thermostat (see INSPECTION ).
CHECK:
Check the valve opening temperature of the thermostat.
HINT:
Also check that the valve is completely closed under opening temperature as above.
NG : Replace (see REMOVAL ).

3. Check cooling system.
CHECK:
Check that there is a defect in the cooling system which causes overcool, such as abnormal radiator fan
operation or modified cooling system.
NG : Repair or replace cooling system.

OK : Replace ECT sensor.
DTC P0128: COOLANT THERMOSTAT (COOLANT TEMPERATURE BELOW THERMOSTAT

REGULATING TEMPERATURE)
HINT:
This is the procedure of thermostat malfunction detection.
CIRCUIT DESCRIPTION
If the engine coolant temperature (ECT) does not reach 75°C (167°F) despite sufficient warm-up time has
elapsed.

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MONITOR DESCRIPTION
Fig. 100: Engine Coolant Temperature Warm-up Elapsed Time Graph

The ECM estimates the coolant temperature based on starting temperature, engine loads, and engine speeds.
The ECM then compares the estimated temperature with the actual ECT. When the estimated coolant
temperature reaches 75°C (167°F), the ECM checks the actual ECT. If the actual ECT is less than 75°C (167°
F), the ECM will interpret this as a fault in the thermostat or the engine cooling system and set a DTC.
MONITOR STRATEGY
STRATEGY MONITORING
Related DTCs P0128: Coolant thermostat
Required sensors/ components (Main) Thermostat
Required sensors/ components (Related) ECT sensor, IAT sensor, VSS
Frequency of operation Once per drive cycle
Duration 900 sec.
MIL operation 2 drive cycles

are not present
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Engine start IAT -10 to 35°C (14 to 95°F)

Engine start ECT -10 to 35°C (14 to 95°F)
Difference between engine start ECT and engine -15 to 7°C (-27 to 12.6°F)
start IAT
Accumulated time with vehicle speed 80 mph (128 20 sec. or more
km/h) or more
Time that both of the following conditions are met: 5 sec. or more
Estimated ECT 75°C (167°F) or more
Actual ECT Less than 75°C (167°F)
MONITOR RESULT


TID $08: Thermostat
THERMOSTAT TEST LIMIT DESCRIPTION

1 $01 Multiply by 0.625 ECT sensor output Malfunction
and subtract 40 (°C) when estimated ECT criterion
reaches malfunction
criterion
HINT:
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1. Check cooling system.
CHECK:
Check that there is a defect in the cooling system which causes overcool, such as abnormal radiator fan
operation or modified cooling system.
NG : Repair or replace cooling system.

2. Check thermostat (see INSPECTION ).
CHECK:
Check the valve opening temperature of the thermostat.
HINT:
Also check that the valve is completely closed under opening temperature as above.
NG : Replace thermostat (see REMOVAL ).

YES : Replace ECM (see COMPONENTS ).
DTC P0136: OXYGEN SENSOR CIRCUIT MALFUNCTION (BANK 1 SENSOR 2)
CIRCUIT DESCRIPTION
The heated oxygen sensor (HO2S) is used to monitor oxygen in the exhaust gas. For optimum catalyst
operation, the air fuel mixture (air-fuel ratio) must be maintained near the ideal "stoichiometric" ratio. The
HO2S output voltage changes suddenly in the vicinity of the stoichiometric ratio. The ECM adjusts the fuel
injection time so that the air-fuel ratio is nearly stoichiometric.
The HO2S generates a voltage between 0 and 1 volt in response to oxygen in the exhaust gas. If the oxygen in
the exhaust gas increases, the air-fuel ratio becomes "Lean". The ECM determines Lean when the HO2S
voltage is below 0.45 volts. If the oxygen in the exhaust gas increases, the air-fuel ratio becomes "Rich". The
ECM determines Rich when the HO2S voltage is above 0.45 volts.
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Fig. 101: Identifying Heated Oxygen Sensor


MONITOR DESCRIPTION
The ECM monitors the rear heated oxygen sensor (HO2S) in the following 3 items:
1. The HO2S voltage changes between Rich (more than 4.5 volts) and Lean (less than 4.5 volts) while the
vehicle is running (repeating acceleration and deceleration) for 8 minutes. If not, the ECM interprets this
as a malfunction, illuminates the MIL, and then sets DTC.
2. The HO2S voltage does not remain at less than 0.05 volts for a long time while the vehicle is running
(60% of the time in the 220 second-monitor, the sensor output is less than 0.05V). If it does, the ECM
interprets this as a malfunction, illuminates the MIL, and then sets a DTC.
3. The sensor's voltage drops to below 0.2 volts (extremely Lean status) immediately when the vehicle
decelerates and the fuel cut is working for 7 seconds. if not, the ECM interprets this to mean the sensor's
response feature has deteriorated, illuminates the MIL, and then sets DTC.
MONITOR STRATEGY
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All:

are not present
Rear HO2S Voltage:

Engine Running
Either of the following condition is set -
Cumulative time while rear HO2S heater is ON 22 sec.
Rear HO2S voltage 0.7 V or more
Rear HO2S Slow Response:

Rear HO2S voltage before the fuel cut 0.2 V or more
Estimated catalyst temperature 400 to 850 °C (752 to 1,562°F)
Fuel cut Operating
Rear HO2S Low Voltage:

Vehicle speed 1 mph (3 km/h) or more
Idle OFF
Fuel cut OFF (for 5 sec. or more)
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Intake air amount 0.32 g/rev or more

Time while rear HO2S heater is ON 80 sec. or more
Rear HO2S Voltage:
One of the following conditions is set:
Number of Lean/Rich switching None
Minimum rear HO2S voltage 0.45 V or more
Maximum rear HO2S voltage Less than 0.6 V
Switching time from Lean to Rich 3 sec. or more
Switching time from Rich to Lean 3 sec. or more
Time until the rear HO2S voltage drops to below 0.2 7 sec. or more
V after fuel-cut starting
Percentage of time when the sensor voltage was 60 % or more
smaller than 0.05 V
Percentage of time when the sensor voltage was Within 20 %
higher than 0.7 V
Time when the sensor voltage was higher than 0.45 Within 20 sec.
V
Percentage of time when the sensor voltage was Less than 40 %
higher than 0.45 V

Rear HO2S voltage Varies between 0.1 and 0.9 V
O2S TEST RESULT
Refer to PRE-CHECK for detailed information.
Rear HO2S Voltage:
If the value is out of the standard value, the ECM interprets this as a malfunction and sets DTC.
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REAR HO2S VOLTAGE TEST DATA

Description of
$07 Minimum rear N/A V Below 0.45 V
HO2S voltage
$08 Maximum rear N/A V 0.6 V or more
HO2S voltage
$31 Time that rear N/A sec. Below 3 sec.
HO2S output
changes Lean to
Rich
$32 Time that rear N/A sec. Below 3 sec.
HO2S output
changes Rich to
Lean
If the time is out of the standard value, the ECM interprets this as a malfunction and sets DTC.
REAR HO2S SLOW RESPONSE TEST DATA

Description of
$37 Time until rear N/A sec. Below 7 sec.
HO2S voltage drops
to below 0.2 V after
fuel-cut starting
If all the values ($81, $84, $85 and $87) are out of the standard values, the ECM interprets this as a malfunction
and sets DTC.
REAR HO2S LOW VOLTAGE TEST DATA

Description of
$81 Percentage in Multiply 0.3906 % Within 60 %
monitor time where
rear HO2S voltage
is below 0.05 V
$84 Percentage in Multiply 0.3906 % 20 % or more
monitor time where
rear HO2S voltage
is 0.7 V or more
$85 Continuous time that Multiply 0.2621 sec. 20 sec. or more
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rear HO2S voltage

is 0.45 V or more
$87 Percentage in Multiply 0.3906 % 40 % or more
monitor time where
rear HO2S voltage
is 0.45 V or more
WIRING DIAGRAM
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Fig. 104: Heated Oxygen Sensor Wiring Diagram

CONFIRMATION DRIVING PATTERN
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Fig. 105: Confirmation Driving Pattern Graph


b. Switch the hand-held tester from normal mode to check (test) mode (see PRE-CHECK ).
c. Start the engine and warm it up until the engine coolant temperature becomes more than 75°C.
d. Drive the vehicle at 60 km/h (38 mph) or more for 40 seconds or more.
e. Let the engine idle for 10 seconds or more.
f. Perform steps c and d 12 times.
HINT:
If a malfunction exists, the CHK ENG will be illuminated on the multi-information display during step (f).
NOTE: If the steps in this test are not followed exactly, detecting a malfunction will be
difficult. If you do not have a hand-held tester, turn the ignition switch OFF after
performing steps from b to e , then perform steps from b to e again.
HINT:
It is possible the malfunctioning area can be found using the ACTIVE TEST A/F CONTROL operation. The
A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other potential trouble
areas are malfunctioning or not.
a. Perform the ACTIVE TEST / A/F CONTROL operation.
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HINT:
The A/F CONTROL operation lowers the injection volume 12.5% or increases the injection volume 25%.
1. Connect the hand-held tester to the DLC3 on the vehicle.

3. Warm up the engine by running the engine at 2,500 RPM for approximately 90 seconds.
4. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F
CONTROL.
5. Perform A/F CONTROL with the engine in an idle condition (press the right or left button).
Result:
A/F sensor reacts in accordance with increase and decrease of injection volume:
+25 % --> Rich output: less than 3.0 V
-12.5 % --> Lean output: more than 3.35 V
Heated oxygen sensor reacts in accordance with increase and decrease of injection volume:
+25 % --> Rich output: more than 0.55 V
-12.5 % --> Lean output: less than 0.4 V
NOTE: The A/F sensor output has a few seconds of delay and the heated oxygen
sensor output has about 20 seconds of delay.
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Fig. 106: A/F Sensor Output Display Graph

The following A/F CONTROL procedure enables a technician to check and graph the voltage outputs of both
the A/F sensor and the heated oxygen sensor.
For displaying the graph, enter "ACTIVE TEST / A/F CONTROL / USER DATA", select "AFS B1S1 and O2S
B1S2" by pressing "YES" and push "ENTER". Then, press "F4".
HINT:
HINT:
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If any other codes besides P0136 is output, perform the troubleshooting for those DTCs first.

2. Check output voltage of heated oxygen sensor.
PREPARATION:

b. After warm up the engine, race the engine at 2,500 RPM for 3 minutes.
CHECK:
Read the output voltage of the heated oxygen sensor when the engine is suddenly raced.
HINT:
Quickly accelerate the engine to 4,000 RPM 3 times by using the accelerator pedal.
OK:
Heated oxygen sensor output voltage: Alternates from 0.4 V or less to 0.5 V or more.
OK : Go to step 6 .
3. Check heated oxygen sensor (heater resistance) (see INSPECTION ).
PREPARATION:
CHECK:
OK:

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terminals 1 and 2)


5. Check for open and short in wire harness between ECM and heated oxygen sensor (see HOW TO
USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE in INTRODUCTION
article).
Reference: Bank 1 Sensor 2 System Drawing
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OK : Replace heated oxygen sensor.
6. Perform confirmation driving pattern.
HINT:
Clear all DTCs prior to perform the confirmation driving pattern.

7. Is there DTC P0136 being output again?
NO : Check for intermittent problems.
YES : Replace heated oxygen sensor.
DTC P0171: SYSTEM TOO LEAN (BANK 1), DTC P0172: SYSTEM TOO RICH (BANK 1)
CIRCUIT DESCRIPTION
The fuel trim is related to the feedback compensation value, not to the basic injection time. The fuel trim
includes the short-term fuel trim and the long-term fuel trim.
The short-term fuel trim is the short-term fuel compensation used to maintain the ideal stoichiometric air-fuel
ratio. The signal from the A/F sensor indicates whether the air-fuel ratio is RICH or LEAN compared to the
stoichiometric air-fuel ratio. This variance triggers a reduction in the fuel volume if the air-fuel ratio is RICH,
and an increase in the fuel volume if it is LEAN.
The short-term fuel trim varies from the central value due to individual engine differences, wear over time and
changes in the operating environment. The long-term fuel trim is the overall fuel compensation for the short-
term fuel trim variation from the central value.
If both the short-term fuel trim and the long-term fuel trim are LEAN or RICH beyond a certain value, it is
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detected as a malfunction, the MIL is illuminated and a DTC is set.

HINT:
 When DTC P0171 is recorded, the actual air-fuel ratio is on the LEAN side. When DTC P0172 is
recorded, the actual air-fuel ratio is on the RICH side.
 If the vehicle runs out of fuel, the air-fuel ratio is LEAN and DTC P0171 is recorded. The MIL then
illuminates.
MONITOR DESCRIPTION
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Fig. 110: Fuel Compensation Amount Graph

Under closed-loop fuel control, fuel injection amounts that deviate from the ECM's estimated fuel amount will
cause a change in the long-term fuel trim compensation value. This long-term fuel trim is adjusted when there
are persistent deviations in the short-term fuel trim values. And, the deviation from the simulated fuel injection
amount by the ECM affects the smoothed fuel trim learning value. The smoothed fuel trim learning value is the
combination of smoothed short-term fuel trim (fuel feedback compensation value) and smoothed long-term fuel
trim (learning value of the air-fuel ratio). When the smoothed fuel trim learning value exceeds the DTC
threshold, the ECM interprets this as a fault in the fuel system and sets a DTC.
Example:
The smoothed fuel trim leaning value is more than +38 % or less than -32 %. The ECM interprets this as a fault
in the fuel system.
MONITOR STRATEGY
STRATEGY MONITORING
Related DTCs P0171: Fuel trim lean
Related DTCs P0172: Fuel trim rich
Required sensors / components (Main) Fuel system
Required sensors / components (Related) A/F sensor, MAF meter, CKP sensor
Duration 10 sec.
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are not present
Fuel system Closed Loop (for 13 sec. or more)
Warm-up condition to enable air fuel ratio learning The conditions are met
control
Either of the following conditions is met: -
Engine RPM Less than 1,100 RPM
Intake air amount per revolution 0.22 g/rev or more
Fuel Trim Lean:
Smoothed fuel trim learning value 38 % (1) or more at ECT: 80°C (176°F)
(1) The threshold value varies with the ECT.
Fuel Trim Rich:
Smoothed fuel trim learning value -32 % (1) or more at ECT: 80°C (176°F)
(1) The threshold value varies with the ECT.
WIRING DIAGRAM
Refer to WIRING DIAGRAM under DTC P2195: OXYGEN (A/F) SENSOR SIGNAL STUCK LEAN
1).
HINT:
a. Perform the ACTIVE TEST A/F CONTROL operation.
HINT:
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The A/F CONTROL operation lowers the injection volume 12.5 % or increases the injection volume
25%.

4. Enter the following menus: DIAGNOSIS / ENHANCED OBD II/ACTIVE TEST / A/F
CONTROL.
5. Perform "A/F CONTROL" with the engine in an idle condition (press the right or left button).
Result:
+25 % --> Rich output: Less than 3.0 V
-12.5 % --> Lean output: More than 3.35 V
+25 % --> Rich output: More than 0.55 V
-12.5 % --> Lean output: Less than 0.4 V
sensor output has about 20 seconds of delay at maximum.
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Fig. 111: A/F Sensor Output Display Graph

HINT:
 A high A/F sensor voltage could be caused by a rich air fuel mixture. Check the conditions that might
cause the engine to run with a rich air fuel mixture.
 A low A/F sensor voltage could be caused by a lean air fuel mixture. Check the conditions that might
cause the engine to run with a lean air fuel mixture.
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1. Check air induction system (see SFI SYSTEM ).
CHECK:
Check for vacuum leaks in the air induction system.
NG : Repair or replace air induction system.

2. Check connection of PCV hose.
NG : Repair or replace PCV hose.
3. Check injector injection (Injection and volume). Check fuel pressure (see INSPECTION ).
NG : Replace injector.
4. Check MAF meter (see INSPECTION ) and ECT sensor (see INSPECTION ).
5. Check for sparks and ignition (see ON-VEHICLE INSPECTION in IGNITION article)
6. Check fuel pressure (see Check fuel pressure (see ON-VEHICLE INSPECTION ).
CHECK:
Check the fuel pressure (high or low pressure).
NG : Check and repair fuel pump, pressure regulator, fuel pipe line and filter.
7. Check gas leaks in exhaust system.
8. Connect hand-held tester or OBD II scan tool and read value for voltage output of A/F sensor.
PREPARATION:
a. Connect the hand-held tester or OBD II scan tool to the DLC 3.

b. Warm up the A/F sensor with the engine at 2,500 RPM for approximately 90 seconds.
c. Read A/F sensor voltage on the hand-held tester or OBD II scan tool.
CHECK:
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a. Hand-held tester only:
On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II /
SNAPSHOT / MANUAL SNAPSHOT / USER DATA. Read the values.
b. Select "AFS B1 S1/ENGINE SPD" and press button "YES".

c. Monitor the A/F sensor voltage carefully.
d. Check the A/F sensor voltage under the condition as follows.
1. Allow the engine to idle for 30 seconds.
2. Engine is racing at Approx. 2,500 RPM (when engine revolution is not suddenly changed).
3. Raise the engine speed to 4,000 RPM and release the accelerator pedal fully closed quickly.
OK:
Standard:
Conditions (1) and (2)
Voltage changes a little in the vicinity of 3.3 V (0.66 V)* (between approximately 3.1 to 3.5 V) as
Condition (3)
A/F sensor voltage increase to 3.8 V (0.76 V)* or more during engine deceleration (when fuel cut) as
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Fig. 112: A/F Sensor Condition Graph

HINT:
 Whenever the output voltage of the A/F sensor remains at approximately 3.3 V (0.660 V)* (see
dwg. 2) under any conditions as well as the above conditions, the A/F sensor may have an open-
circuit. (This will happen also when the A/F sensor heater has an open-circuit.)
 Whenever the output voltage of the A/F sensor remains at a certain value of approximately 3.8 V
(0.76 V)* or more, or 2.8 V (0.56 V)* or less (see dwg. 2) under any conditions as well as the
above conditions, the A/F sensor may have a short-circuit.
 The ECM will stop fuel injection (fuel cut) during engine deceleration. This will cause a lean
condition and should result in a momentary increase in A/F ratio sensor voltage.
 The ECM must establish a closed throttle position learned value to perform fuel cut. If the battery
terminal has been disconnected, the vehicle must be driven over 16 km/h (10 mph) to allow the
ECM to relearn the closed throttle position.
 When the vehicle is driven:
In the case that the output voltage of the A/F sensor is below 2.8 V (0.76 V)* during fuel
enrichment (for example, when the vehicle tries to overtake another vehicle on a highway, the
vehicle speed is suddenly increased with the accelerator pedal fully depressed), the A/F sensor are
functioning normally.
 The A/F sensor is a current output element, and therefore the current is converted into voltage
inside the ECM. If measuring voltage at connectors of the A/F ratio sensor or ECM, you can obtain
a constant voltage.
*: Voltage when using the OBD II scan tool.
9. Check A/F sensor heater (see INSPECTION ).
PREPARATION:
CHECK:
OK:
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terminals 1 and 2)


11. Check for open and short in wire harness between ECM and A/F sensor (bank 1 sensor 1) (see
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12. Replace A/F sensor (see COMPONENTS ).
13. Perform confirmation driving pattern (see CONFIRMATION DRIVING PATTERN under DTC
P2195: OXYGEN (A/F) SENSOR SIGNAL STUCK LEAN (BANK 1 SENSOR 1), DTC P2196:
OXYGEN (A/F) SENSOR SIGNAL STUCK RICH (BANK 1 SENSOR 1).
HINT:
Clear all DTCs prior to performing the confirmation driving pattern.

14. Are there DTCs P0171 and/or P0172 being output again?
YES : Replace ECM (see COMPONENTS ) and perform confirmation driving pattern (see
CONFIRMATION DRIVING PATTERN under DTC P2195: OXYGEN (A/F) SENSOR
SIGNAL STUCK LEAN (BANK 1 SENSOR 1), DTC P2196: OXYGEN (A/F) SENSOR
SIGNAL STUCK RICH (BANK 1 SENSOR 1).
15. Did vehicle run out of fuel in past?
NO : Check for intermittent problems (see PRE-CHECK ).
YES : DTC P0171 or P0172 is caused by running out of fuel.
OXYGEN (A/F) SENSOR SIGNAL STUCK RICH (BANK 1 SENSOR 1.
HINT:
Clear all DTCs prior to performing the confirmation driving pattern (refer to step 13 ).
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NO : Go to step 21 .
18. Replace A/F sensor.
OXYGEN (A/F) SENSOR SIGNAL STUCK RICH (BANK 1 SENSOR 1.
HINT:
Clear all DTCs prior to performing the confirmation driving pattern (refer to step 13 ).

YES : Replace ECM (see COMPONENTS ) and perform confirmation driving pattern
(seeCONFIRMATION DRIVING PATTERN under DTC P2195: OXYGEN (A/F) SENSOR
SIGNAL STUCK LEAN (BANK 1 SENSOR 1), DTC P2196: OXYGEN (A/F) SENSOR
SIGNAL STUCK RICH (BANK 1 SENSOR 1.
YES : DTC P0171 or P0172 is caused by running out of fuel.
DTC P0300: RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED, DTC P0301: CYLINDER 1

MISFIRE DETECTED, DTC P0302: CYLINDER 2 MISFIRE DETECTED, DTC P0303: CYLINDER 3
MISFIRE DETECTED, DTC P0304: CYLINDER 4 MISFIRE DETECTED
CIRCUIT DESCRIPTION
When a misfire occurs in the engine, hydrocarbons (HC) enter the exhaust in high concentrations. If this HC
concentration is high enough, there could be an increase in exhaust emissions levels. High concentrations of HC
can also cause the temperature of the catalyst to increase, possibly damaging the catalyst. To prevent increases
in emissions and limit the possibility of thermal damage, the ECM monitors the misfire rate. When the
temperature of the catalyst reaches a point of thermal degradation, the ECM will blink the MIL. For monitoring
a misfire, the ECM uses both the camshaft position sensor and the crankshaft position sensor. The camshaft
position sensor is used to identify misfiring cylinders and the crankshaft position sensor is used to measure
variations in the crankshaft rotation speed. The misfire is counted when crankshaft rotation speed variations
exceed threshold values.
If the misfiring rate exceeds the threshold value and could cause emissions deterioration, the ECM illuminates
the MIL.
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Fig. 115: DTC (P0300, P0301, P0302, P0303, P0304) Diagnosis Table
HINT:
When codes for a misfiring cylinder are recorded repeatedly but no random misfire code is recorded, it indicates
that the misfires have been detected and recorded at different times.
Reference: Inspection using an oscilloscope.
With the engine idling, check the waveform between terminals #10 to #40 and E01 of the ECM connectors.
MONITOR DESCRIPTION
Fig. 116: Camshaft And Crankshaft Position Sensor Monitor Description

The ECM illuminates the MIL (2 trip detection logic) if:
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 The misfiring rate exceeds a threshold value and could cause emissions deterioration.
 During the first 1,000 engine revolutions after the engine starts, an excessive misfire rate (approximately
20 to 50 misfire per 1,000 engine revolutions) occurs once.
 After the first 1,000 engine revolutions after the engine starts, an excessive misfire rate (approximately 20
to 50 misfire per 1,000 engine revolutions) occurs 4 times.
The ECM blinks the MIL (MIL blinks immediately) if:
 Within 200 engine revolutions at a high RPM, the threshold for "percent of misfire causing catalyst
damage" is reached once.
 Within 200 engine revolutions at a normal RPM, the threshold for "percent of misfire causing catalyst
damage" is reached 3 times (for the 2nd trip, reaching the threshold once will cause the MIL to flash).
MONITOR STRATEGY


are not preset
VVT system No active test by scan tool
Engine RPM 400 RPM to 6,200 RPM
ECT -10 °C (14 °F) or more
Either of (a) or (b) is met (a) IAT is -10°C (14°F) or more
Either of (a) or (b) is met (b) ECT is 75°C (167°F) or more
MAF Varies with ECT and RPM
TP Not changing rapidly (when engine RPM is more
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than 3,000 RPM)
P0301 to P0304:
Misfire count on each cylinder 6 or more per 1,000 revolutions
Emission-related-misfire:
Misfire rate when engine start at cold 1.5 % or more
Catalyst-damage-misfire (MIL flashes immediately):
Either of the following conditions is set:
Misfire counts 101 or more (1) per 200 revolutions (at intake air
amount: 0.4 g/rev and engine RPM: 1,600 RPM)
Misfire counts of paired cylinder 150 per 200 revolutions
(1) The threshold value varies with the intake air amount and the engine RPM.
WIRING DIAGRAM
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Fig. 118: Fuel Injector Wiring Diagram


b. Record the DTCs, freeze frame data and misfire counter data.
c. Use the hand-held tester to set the check mode (see PRE-CHECK ).
d. Read the value on the misfire counter for each cylinder while idling the engine. If the value is displayed
on the misfire counter, skip step (e).
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e. Drive the vehicle several times with the engine speed, load and its surrounding range shown with
ENGINE SPD, CALC LOAD in the freeze frame data or MISFIRE RPM, MISFIRE LOAD in the DATA
LIST.
If you have no hand-held tester, turn the ignition switch OFF after the symptom is simulated once. Then
repeat the simulation process again.
HINT:
In order to memorize the misfire DTC, it is necessary to drive with MISFIRE RPM, MISFIRE LOAD in
the DATA LIST for the period of time in the chart below. Take care not to turn the ignition switch OFF.
Turning the ignition switch OFF switches the diagnosis system from check mode to normal mode and all
DTCs, freeze frame data and other data are erased.
ENGINE SPEED TIME

Engine Speed Time
Idling 3 minutes 30 seconds or more
1,000 RPM 3 minutes or more
2,000 RPM 1 minute 30 seconds or more
3,000 RPM 1 minute or more
f. Check if there is misfire or not by monitoring DTC and the freeze frame data. Record the data.
g. Turn the ignition switch OFF and wait for at least 5 seconds.
HINT:
 If DTCs besides misfire DTCs are memorized simultaneously, troubleshoot the non-misfire DTCs first.
 If the misfire does not occur when the vehicle is brought to the workshop, the misfire can be confirmed
by reproducing the condition of the freeze frame data. Also, after finishing the repair, confirm that there is
no misfire (see confirmation driving pattern).
 On 6 and 8 cylinder engines, misfiring cylinder identification is disabled at high engine speed and only a
general misfire fault code P0300 is stored instead of a cylinder specific misfire fault code (P0301 to
P0308). If the misfire starts in a high engine speed area or the misfire occurs only in a high engine speed
area, only code P0300 will be stored.
 Erase the general misfire fault code from the hand-held tester or OBD II scan tool.
 Start the engine and drive the confirmation pattern.
 Read the value of the misfire ratio for each cylinder. Or read the DTC.
 Perform repairs on the cylinder that has a high misfire ratio. Or repair the cylinder indicated by the DTC.
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 After finishing repairs, drive the confirmation pattern again and confirm that no misfire occurs.
 When either of SHORT FT #1, LONG FT #1 in the freeze frame data is over the range of +/-20 %, there
is a possibility that the air-fuel ratio is becoming to RICH (-20 % or less) or LEAN (+20 % or more).
 When COOLANT TEMP in the freeze frame data is less than 80°C (176°F), there is a possibility of
misfire only during engine warm-up.
 If the misfire cannot be reproduced, the following reasons may apply: 1) the vehicle has low fuel, 2)
improper fuel is being used, and 3) the ignition plug is contaminated.
 Be sure to check the value on the misfire counter after the repair.
1. Are there any other codes (besides DTC P0300, P0301, P0302, P0303 or P0304) being output?
NG : Go to relevant DTC chart (see DIAGNOSTIC TROUBLE CODE CHART ).
2. Check wire harness and vacuum hose in engine room.
CHECK:
a. Check the connection conditions of the wire harness and connector.

b. Check the piping of the vacuum hose.
NG : Repair or replace, then confirm that there is no misfire (see confirmation driving
pattern).
3. Check connection of PCV piping.
NG : Repair or replace PCV piping.
4. Connect hand-held tester or OBD II scan tool and read number of misfire.
PREPARATION:
b. Turn ON the ignition switch and push the hand-held tester or the OBD II scan tool main switch
ON.
c. Start the engine.
d. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / CYL#1 -
CYL#4.
CHECK:
Read the number of misfire on the hand-held tester or the OBD II scan tool.
HINT:
When a misfire is not reproduced, be sure to branch below based on the stored DTC.
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RESULT:
CYLINDER MISFIRE REFERENCE

High Misfire Rate Cylinder Proceed to
1 or 2 cylinders Type I
More than 3 cylinders Type II
5. Check spark plug and spark of misfiring cylinder.
PREPARATION:
a. Disconnect the ignition coil.

CHECK:
a. Check the spark plug type.

b. Check the electrode for carbon deposits.
c. Check the electrode gap.
OK:
a. Recommended spark plug:
SPARK PLUG REFERENCE

DENSO made SK20R11
NGK made IFR6A11
b. No large carbon deposit present. Not wet with gasoline or oil.

c. Maximum electrode gap for used spark plug: 1.3 mm (0.051 in.)
Correct electrode gap for new spark plug: 1.0 to 1.1 mm (0.039 to 0.043 in.)
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Fig. 119: Checking Spark Plug Gap And Spark Of Misfiring Cylinder
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PREPARATION:
a. Disconnect the ignition coil with igniter connector, and disconnect the ignition coil with igniter.
c. Install the spark plug to the ignition coil with igniter, and connect the ignition coil with igniter
connector.
CHECK:
Check if sparks occur while the engine is being cranked.
NOTE: To prevent excess fuel from being injected from the injectors during this
test, do not crank the engine for more than 2 seconds at a time.
OK:
Spark jumps across electrode gap.
OK : Go to step 8 .
6. Change normal spark plug and check spark of misfiring cylinder.
PREPARATION:
a. Disconnect the spark plug.

b. Change the normal spark plug.
c. Install the spark plug to the ignition coil with igniter.
CHECK:
OK:
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OK : Replace spark plug.

7. Change normal ignition coil with igniter and check spark of misfiring cylinder.
PREPARATION:
a. Disconnect the ignition coil with igniter connector, and disconnect the ignition coil with igniter.
c. Change normal ignition coil with igniter.
d. Install the spark plug to the ignition coil with igniter, and connect the ignition coil with igniter
connector.
e. Disconnect the injector connector.
f. Ground the spark plug.
CHECK:
OK:
OK : Replace ignition coil with igniter, then confirm that there is no misfire.
8. Check for open and short in wire harness between ignition coil and ECM of misfiring cylinder (see
OK : Replace ignition coil with igniter.
9. Check voltage of ECM terminal for injector of failed cylinder.
PREPARATION:

CHECK:
Measure the voltage between applicable terminal of the ECM connector and body ground.
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OK:
Voltage: 9 to 14 V
Fig. 120: Checking Voltage Of ECM Terminal For Injector Of Failed Cylinder
With the engine idling, check the waveform between terminals #1 - #4 and E01/E02 of the ECM
connector.
HINT:
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Fig. 121: Injector Signal Waveform (Engine Idling)

10. Check resistance of injector of misfiring cylinder (see ON-VEHICLE INSPECTION ).
11. Check for open and short in wire harness between ignition switch and injector, and injector and
ECM of misfiring cylinder (see HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION
12. Check injector injection and volume of misfiring cylinder (see INSPECTION ).
13. Check compression pressure of misfiring cylinder (see INSPECTION ).
14. Check valve clearance of misfiring cylinder (see ADJUSTMENT ).
NG : Adjust valve clearance.
15. Switch step by number of misfire cylinders (refer to result of step 4).
HINT:
 If the result of step 4 is "1 or 2 cylinders", proceed to A.

 If the result of step 4 is "more than 3 cylinders", proceed to B.
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B : Check for intermittent problems (see PRE-CHECK ).

16. Check valve timing (Check for loose and jumped tooth of timing chain) (see INSPECTION ).
NG : Adjust valve timing (Replace timing chain).
NG : Check and repair fuel pump, pressure regulator, fuel pipe line and filter (see PRE-
CHECK ).
18. Read value of hand-held tester or OBD II scan tool (intake air temperature and mass air flow rate).
PREPARATION:
CHECK:
a. Check the intake air temperature.
Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE
AIR and read its value displayed on the hand-held tester or the OBD II scan tool.
Temperature: Equivalent to ambient temperature
b. Check the mass air flow rate.
Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / MAF and read
its value displayed on the hand-held tester or the OBD II scan tool.
OK:
AIR FLOW RATE CONDITION

Condition Air Flow Rate (gm/s)
Ignition switch ON (do not start engine) 0
Idling 0.5 to 5
Running without load (2,500 RPM) 3 to 10
Idling to quickly accelerating Air flow rate fluctuates
NG : Replace MAF meter.

19. Check ECT sensor (see INSPECTION ).
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NG : Replace ECT sensor.

20. Switch step by number of misfire cylinders (refer result of step).
RESULT:
CYLINDER MISFIRE HIGH RATE RESILIENCE

High misfire rate cylinder Proceed to
1 or 2 cylinders A
more than 3 cylinders B
B : Go to step 5 .
A : Check for intermittent problems (see PRE-CHECK ).
DTC P0325: KNOCK SENSOR 1 CIRCUIT (BANK 1 OR SINGLE SENSOR), DTC P0327: KNOCK
SENSOR 1 CIRCUIT LOW INPUT (BANK 1 OR SINGLE SENSOR), DTC P0328: KNOCK SENSOR 1
CIRCUIT HIGH INPUT (BANK 1 OR SINGLE SENSOR)
CIRCUIT DESCRIPTION
A flat type knock sensor (non-resonant type) has the structure that can detect vibration in a wider band of
frequency from approximately 6 kHz to 15 kHz and has the following features.
Knock sensor is fitted on the left side of the cylinder block to detect engine knocking.
Each sensor contains a piezoelectric element which generates a voltage when it becomes deformed. This occurs
when the cylinder block vibrates due to knocking. If engine knocking occurs, the ignition timing is retarded to
suppress it.

MONITOR DESCRIPTION
The knock sensor, located on the cylinder block, detects spark knock.
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When spark knock occurs, the sensor pick-up vibrates in a specific frequency range. When the ECM detects
voltage in this frequency range, it retards the ignition timing to suppress the spark knock,
The ECM also senses background engine noise with the knock sensor and uses this noise to check for faults in
the sensor. If the knock sensor signal level is too low for more than 10 seconds, or if the knock sensor output
voltage is out of normal range, the ECM interprets this as a fault in the knock sensor and sets a DTC.
MONITOR STRATEGY


are not preset
Knock Sensor Rationality:

Idle OFF
Spark cut OFF
Intake air amount 0.3 g/rev
RPM 3,000 to 5,000 RPM
Knock Sensor Range Check:

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Knock Sensor Rationality (P0325):
Knock sensor signal Signal level is low
Knock Sensor Range Check (Fluttering) (P0325):
Knock sensor signal Less than 0.5 V or more than 4.5 V
Knock Sensor Range Check (Low voltage) (P0327):
Knock sensor signal Less than 0.5 V
Knock Sensor Range Check (High voltage) (P0328):
Knock sensor signal More than 4.5 V
WIRING DIAGRAM
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Fig. 124: Knock Sensor Wiring Diagram

HINT:
1. Check DTC.
PREPARATION:
ON.
c. Warm up the engine.
d. Run the engine at 3,000 RPM for 10 seconds or more.
e. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT
CODES.
CHECK:
Read the DTC.
OK:
DTC OUTPUT DISPLAY

Only P0325 is output again Type I
P0325, P0327 and/or P0328 are output again Type II
No DTCs are output again Type III
Type III : Check for intermittent problems, (see PRE-CHECK ).
2. Inspect knock sensor installation.
CHECK:
Check the knock sensor installation.

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Fig. 125: Locating Knock Sensor

NG : Tighten knock sensor.

OK : Replace knock sensor.
3. Check for open and short in wire harness between ECM and knock sensor (see HOW TO USE
THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE in INTRODUCTION article).
NG : Go to step 5 .
4. Check voltage between terminal KNK1 and EKNK of ECM connector.
PREPARATION:
CHECK:
Measure the voltage between terminals KNK1 and EKNK of the ECU connector.
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OK:
Fig. 126: Locating KNK1 (+) And EKNK (-) Connector Terminals Of ECU
HINT:
ITEM CONTENTS
Item Contents
Terminal KNK1 - EKNK
Equipment Set 0.01 to 10V/DIV.
Equipment Set 0.01 to 10 msec./DIV.
Condition After warming up the engine, keep engine speed
4,000 RPM
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Fig. 127: KNK Signal Waveform


OK : Check for intermittent problems (see HOW TO USE THE DIAGNOSTIC CHART
AND INSPECTION PROCEDURE in INTRODUCTION article).
NOTE: Fault may be intermittent. Check the harness and connectors carefully.
5. Check knock sensor.
PREPARATION:
Disconnect the sensor connector.
CHECK:
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Check the resistance between terminals 1 and 2 of the sensor.
OK:
Resistance: 120 to 280 kohm
Fig. 128: Identifying Knock Sensor Connector Terminals

NG : Replace knock sensor.

OK : Check and replace harness and connector.
DTC P0335: CRANKSHAFT POSITION SENSOR "A" CIRCUIT MALFUNCTION, DTC P0339:
CRANKSHAFT POSITION SENSOR "A" CIRCUIT INTERMITTENT
CIRCUIT DESCRIPTION
The crankshaft position sensor (CKP) system consists of a crankshaft position sensor plate and a pickup coil.
The sensor plate has 34 teeth and is installed on the crankshaft. The pickup coil is made of an iron core and
magnet. The sensor plate rotates and as each tooth passes through the pickup coil, a pulse signal is created. The
pickup coil generates 34 signals for each engine revolution. Based on these signals, the ECM calculates the
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crankshaft position and engine RPM. Using these calculations, the fuel injection time and ignition timing are
controlled.

MONITOR DESCRIPTION
If there is no signal from the crankshaft sensor even though the engine is revolving, the ECM interprets this as a
malfunction of the sensor.
MONITOR STRATEGY
P0335
STRATEGY MONITORING
Related DTCs P0335: CKP sensor range check during cranking
Related DTCs P0335: CKP sensor range check during engine
running
Required sensors / components (Main) CKP sensor
Required sensors / components (Related) -
Duration 4.7 sec.: CKP sensor range check during cranking
Duration 0.5 sec.: CKP sensor range check during engine
running
P0335

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are not present
CKP Sensor Range Check during Cracking:

Starter ON
Minimal battery voltage while starter ON Less than 11 V
CKP Sensor Range Check during Engine Running:

Engine RPM 600 RPM or more
Starter OFF
Time after starter ON to OFF 3 sec. or more
P0335
CKP signal No signal

CKP signal CKP sensor voltage fluctuates when the crankshaft
rotates 34 CKP signals per 1 revolution crankshaft
WIRING DIAGRAM
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Fig. 130: Crankshaft Position Sensor Wiring Diagram

HINT:
 Read value of hand-held tester or OBD II scan tool

b. Start the engine and push the hand-held tester or the OBD II scan tool main switch ON.
c. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / ENGINE
SPD.
 The engine speed can be confirmed in DATA LIST using the hand-held tester or OBD II scan tool. If
there is no NE signals from the crankshaft position sensor despite the engine revolving, the engine speed
will be indicated as zero. If voltage output of the crankshaft position sensor is insufficient, the engine
speed will be indicated as lower PRM (than the actual RPM).
1. Check resistance of crankshaft position sensor.
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CHECK:
Measure the resistance between the terminals of the crankshaft position sensor.
HINT:
In the above section, 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).
OK:
Fig. 131: Identifying C4 Crankshaft Position Sensor Connector Terminals

Resistance:
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985 to 1,600 ohm at cold
1,265 to 1,890 ohm at hot
During cranking or idling, check the waveform between the terminals of the ECM connector.
ITEM CONTENTS
Item Contents
Terminal CH1: G2+ - NE-
Terminal CH2: NE+ - NE-
Equipment Set 5 V/DIV, 20 ms/DIV
Condition During Cranking or idling
HINT:
The correct waveforms are as shown in the illustration.
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Fig. 132: Locating NE+ (+) NE- (-) And G2+ (+) Connector Terminals Of ECM And Checking
Signal Waveform
NG : Replace crankshaft position sensor.

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2. Check for open and short in wire harness between ECM and crankshaft position sensor (see HOW
TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE in INTRODUCTION
article).
3. Check crankshaft position sensor installation (see HOW TO USE THE DIAGNOSTIC CHART
CHECK:
Check the crankshaft position sensor installation.
NG : Tighten sensor.
4. Inspect crankshaft position sensor plate No. 1 (Teeth of signal plate).
PREPARATION:
Remove the crankshaft position sensor plate No. 1 (see REMOVAL ).
CHECK:
Check the teeth of the sensor plate.
NG : Replace crank shaft position sensor plate No. 1.

DTC P0340: CAMSHAFT POSITION SENSOR "A" CIRCUIT, DTC P0341: CAMSHAFT POSITION
SENSOR "A" CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR)
CIRCUIT DESCRIPTION
The camshaft position (CMP) sensor, like the Crankshaft Position (CKP) sensor, consists of a magnet and an
iron core wrapped in copper wire. The camshaft has 3 teeth and the CMP sensor is installed so that it can detect
these teeth passing by. When the camshaft rotates and the teeth pass by the CMP sensor, the magnet on the
CMP sensor creates a magnetic field and voltage is generated in the copper wire. When the crankshaft makes 2
rotation, voltage will be generated in the CMP sensor 3 times. The CKP sensor is roughly the same. When the
crankshaft makes 1 rotation, its 34 teeth pass by the CKP sensor and voltage is generated 34 times. The
camshaft rotates at half the speed of the crankshaft. Therefore, the CMP sensor generates voltage 3 times in the
time the crankshaft takes to make 2 rotations.
The Engine Control Module (ECM) detects generation of these voltages to locate the camshaft position, which
are used to indicate the cylinder.
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MONITOR DESCRIPTION
If there is no signal from the camshaft position sensor even though the engine is revolving, or if the rotation of
the camshaft and the crankshaft is not synchronized, the ECM interprets this as a malfunction of the sensor.
MONITOR STRATEGY


are not present
CMP Sensor Range Check (P0340):

Starter ON
Minimal battery voltage while starter ON Less than 11 V
CMP/CKP Misalignment and CMP Sensor Malfunction (P0340):
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Starter OFF
CMP Sensor Range Check (P0340):
CMP signal No signal
CMP/CKP Sensor Malfunction (P0340):
CMP and CKP phase Misaligned
CMP Sensor Malfunction (P0341):
CMP and CKP phase Misaligned
CMP signal per 2 revolutions crankshaft 12 CMP signals or more
Fig. 135: Component Operating Range Table

WIRING DIAGRAM
Refer to WIRING DIAGRAM under DTC P0335: CRANKSHAFT POSITION SENSOR "A" CIRCUIT
MALFUNCTION, DTC P0339: CRANKSHAFT POSITION SENSOR "A" CIRCUIT INTERMITTENT.
HINT:
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1. Check resistance of camshaft position sensor.
CHECK:
Measure the resistance between the terminals of the camshaft position sensor.
HINT:
In the above section, 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).
OK:
Fig. 136: Identifying C1 Camshaft Position Sensor Connector Terminals

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Resistance:
835 to 1,400 ohm at cold
1,060 to 1,645 ohm at hot
During cranking or idling, check the waveform between the terminals of the ECM connector.
ITEM CONTENTS
Item Contents
Terminal CH1: G2+ - NE-
Terminal CH2: NE+ - NE-
Equipment Set 5V/DIV, 20ms/DIV
Condition During Cranking or idling
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Fig. 137: Locating NE+ (+), NE- (-) And G2+ (+) Connector Terminals Of ECM And Inspecting
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Signal Waveform
HINT:
The correct waveforms are as shown in the left.
NG : Replace camshaft position sensor.

2. Check for open and short in wire harness between ECM and camshaft position sensor (see HOW
TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE in INTRODUCTION
article).
3. Check camshaft position sensor installation.
Inspect the camshaft position sensor installation.
NG : Tighten sensor.
4. Inspect camshaft.
PREPARATION:
Remove the camshaft (see REMOVAL ).
CHECK:
Check the camshaft lobes.
NG : Replace camshaft.
DTC P0351: IGNITION COIL "A" PRIMARY/SECONDARY CIRCUIT, DTC P0352: IGNITION
COIL "B" PRIMARY/SECONDARY CIRCUIT, DTC P0353: IGNITION COIL "C"
PRIMARY/SECONDARY CIRCUIT, DTC P0354: IGNITION COIL "D" PRIMARY/SECONDARY
CIRCUIT
HINT:
 These DTCs indicate a malfunction related to primary circuit.

 If DTC P0351 is displayed, check No. 1 ignition coil with igniter circuit.
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CIRCUIT DESCRIPTION
A Direct Ignition System (DIS) is used on this vehicle.
The DIS is a 1-cylinder ignition system which ignites one cylinder with one ignition coil. In the 1-cylinder
ignition system, one spark plug is connected to the end of the secondary winding. High-voltage is generated in
the secondary winding and is applied directly to the spark plug. The spark of the spark plug passes from the
center electrode to the ground electrode.
The ECM determines the ignition timing and outputs the ignition signals (IGTs) for each cylinder. Using the
IGT, the ECM turns on and off the power transistor inside the igniter, which switches on and off current to the
primary coil. When current to the primary coil is cut off, high-voltage is generated in the secondary coil and this
voltage is applied to the spark plugs to create sparks inside the cylinders. As the ECM cuts the current to the
primary coil, the igniter sends back the ignition confirmation signal (IGF) for each cylinder ignition to the
ECM.
Fig. 138: Ignition Coil Circuit Diagram

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Fig. 139: DTC (DTC P0351, P0352, P0353, P0354) Diagnosis Table
MONITOR DESCRIPTION
Fig. 140: Ignition Coil Monitor Description

If the ECM does not receive the ignition confirmation signal (IGF) after sending the ignition signal (IGT), it
interprets this as a fault in the igniter and sets a DTC.
MONITOR STRATEGY
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are not present
Starter OFF or Engine RPM 1,500 RPM or more
Ignition signal fail count More than 2
Ignition fail count is as follows When IGF should have returned despite sending
IGT

IGF signal Igniter outputs IGF signal when it receives IGT
signal from ECM
WIRING DIAGRAM
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Fig. 142: Ignition Coil Wiring Diagram

HINT:
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1. Check spark plug and spark of misfiring cylinder (see ON-VEHICLE INSPECTION in IGNITION
article).
NG : Go to step 4 .
2. Check for open and short in wire harness in IGF and IGT signal circuit between ECM and ignition
coil with igniter (see HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION
NG : Replace harness and connector.
3. Disconnect ignition coil with igniter connector and check voltage between terminal IGF1 of ECM
connector and body ground.
PREPARATION:

b. Disconnect the ignition coil with igniter connector.
CHECK:
Measure the voltage between terminal IGF1 of the ECM connector and body ground.
OK:
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Fig. 143: Locating IGF1 (+) Connector Terminal Of ECM


4. Check for open and short in wire harness in IGT signal circuit between ECM and ignition coil with
igniter (see HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE in
5. Check voltage between terminals IGT1 to IGT4 of ECM connector and body ground.
PREPARATION:
CHECK:
Measure the voltage between terminals IGT1 to IGT4 of the ECM connector and the body ground when
the engine is cranked.
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OK:
Voltage: More than 0.1 V and less than 4.5 V
Fig. 144: Locating IGT1, IGT2, IGT3, IGT4 Connector Terminals Of ECM And Body Ground
During cranking or idling, check the waveform between terminals IGT1 to IGT4 and E1, and IGF1 and
E1 of the ECM connector.
HINT:
The correct waveforms are as shown in the illustration.
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Fig. 145: Inspecting Signal Waveform


6. Disconnect ignition coil with igniter connector and check voltage between terminals IGT1 to IGT4
of ECM connector and body ground.
PREPARATION:

b. Disconnect the ignition coil with igniter connector.
CHECK:
Measure the voltage between terminals IGT1 to IGT4 of the ECM connector and the body ground when
the engine is cranked.
OK:
Voltage: More than 0.1 V and less than 4.5 V

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Fig. 146: Locating IGT1, IGT2, IGT3, IGT4 Connector Terminals Of ECM And Body Ground

7. Check ignition coil with igniter power source circuit.
PREPARATION:
Disconnect the ignition coil with igniter connector.
CHECK:
Measure the voltage between terminal 1 of the ignition coil with igniter connector and the body ground
when the ignition switch is turned the to ON or START position.
OK:
Voltage: 9 to 14 V
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Fig. 147: Identifying Ignition Coil Igniter Power Source Circuit Connector Terminal 1 (+)
NG : Repair ignition coil with igniter power source circuit.

8. Check for open and short in are wire harness between ignition switch and ignition coil with igniter
(see HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE in
DTC P0420: CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)
MONITOR DESCRIPTION
The ECM uses sensors mounted before and after the three-way catalyst (TWC) to monitor its' efficiency. The
first sensor, an air fuel ratio sensor (A/F sensor), sends pre-catalyst A/F ratio information to the ECM. The
second sensor, a heated oxygen sensor (O2S), sends post-catalyst information to the ECM. The ECM compares
these two signals to judge the efficiency of the catalyst and the catalyst's ability to store oxygen. During normal
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operation, the TWC stores and releases oxygen as needed. The capacity to store oxygen results in a low
variation in the post-TWC exhaust stream as shown below.
If the catalyst is functioning normally, the waveform of the heated oxygen sensor slowly switches between
RICH and LEAN.
If the catalyst is deteriorated, the waveform will alternate frequently between RICH and LEAN. As the catalyst
efficiency degrades, its ability to store oxygen is reduced and the catalyst output becomes more variable. When
running the monitor, the ECM compares sensor 1 signals (A/F sensor) over a specific amount of time to
determine catalyst efficiency. The ECM begins by calculating the signal length for both sensors (for the rear
oxygen sensor, the ECM uses the output voltage signal length).
If the oxygen sensor output voltage signal length is greater than the threshold (threshold is calculated based on
the A/F sensor signal length), the ECM concludes that the catalyst is malfunctioning. The ECM will turn on the
MIL and a DTC will be set.
Fig. 148: Waveform Signals Of Normal And Deteriorated Catalysts

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Fig. 149: Identifying Heated Oxygen Sensor Signal Length


MONITOR STRATEGY
MONITOR STRATEGY
Related DTCs P0420: Catalyst deterioration
Required sensors / components (Main) Catalyst
Required sensors / components (Related) AF sensor, Rear HO2S, IAT sensor, MAF meter,
CKP sensor, ECT sensor
Duration 150 sec. (30 sec. x 5)
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ENGINE ENABLING CONDITION

are not present
Accumulated time that the following conditions are 30 sec.
met
IAT -10 °C (14°F) or more
Idle OFF
MAF 8 to 35 g/sec.
RPM Less than 4,500 RPM
ECT 75° C (167°F) or more
Estimated catalyst temperature Up stream catalyst: 550 to 900°C (1,022 to 1,652°F)
Estimated catalyst temperature Down stream catalyst: 550 to 900°C (1,022 to
1,652°F)
Fuel system status Closed Loop
AF sensor voltage 3 to 3.5 V
Fig. 151: Malfunction Thresholds Table

MONITOR RESULT


TID $01: Catalyst - Using A/F Sensor and HO2S
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Fig. 152: A/F Sensor And HO2S Table

CONFIRMATION ENGINE RACING PATTERN
Fig. 153: Confirmation Engine Racing Pattern Graph


b. Start the engine and warm it up with all the accessories switched OFF until the engine coolant
temperature is stable.
c. Race the engine at 2,500 to 3,000 RPM for about 3 minutes.
d. When racing the engine at 3,000 RPM for 2 seconds and 2,000 RPM for 2 seconds alternately, check the
waveform of the heated oxygen sensor (bank 1 sensor 2).
HINT:
1. Are there any other codes (besides P0420) being output?
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HINT:
If any other codes besides P0420 are output, perform the troubleshooting for those DTCs first.

2. Check gas leakage in exhaust system.
3. Check A/F sensor (bank 1 sensor 1) (see INSPECTION ).
4. Check heated oxygen sensor (bank 1 sensor 2) (see INSPECTION ).
Replace the front and rear three-way catalytic converter in bank malfunction is detected.
HINT:
The following procedure enables a technician to identify a trouble area if there is a malfunction in both front
A/F sensor or rear heated oxygen sensor other than the catalyst converter, or the malfunction that indicates the
actual air-fuel ratio extremely RICH or LEAN.
Perform ACTIVE TEST A/F CONTROL operation.
HINT:
The A/F CONTROL operation lowers the injection volume 12.5 % or increases the injection volume 25 %.

3. Warm up the engine with the engine speed at 2,500 RPM for approximately 90 seconds.
4. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL.
5. Perform the A/F CONTROL operation with the engine idle (press the right or left button).
Result:
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Heated oxygen sensor reacts in accordance with increase and decrease of injection volume +25 % --
> rich output: More than 0.5 V - 12.5 % --> lean output: Less than 0.4 V
NOTE: However, there is a few second delay in the sensor 1 (front sensor) output. And
there is about 20 seconds delay in the sensor 2 (rear sensor).
Fig. 154: Heated Oxygen Sensor (Sensor 1 And 2) Output Display Graphic
The following A/F CONTROL procedure enables a technician to check and graph the voltage output of the
heated oxygen sensors (sensor 1 and 2).
For displaying the graph indication, enter "ACTIVE TEST/ A/F CONTROL / USER DATA" then select "AFS
B1S1 and O2S B1S2" by pressing "YES" button and push "ENTER" button before pressing "F4" button.
DTC P0441: EVAPORATIVE EMISSION CONTROL SYSTEM INCORRECT PURGE FLOW, DTC
P0446: EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT, DTC P2418:
EVAPORATIVE EMISSION SYSTEM VALVE CONTROL CIRCUIT/OPEN
CIRCUIT DESCRIPTION
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The vapor pressure sensor, Canister Closed Valve (CCV), pressure switching valve are used to detect
abnormalities in the evaporative emission control system.
The ECM decides whether there is an abnormality in the evaporative emission control system based on the
vapor pressure sensor signal.
DTCs P0441, P0446 and P2418 are recorded in the ECM when evaporative emissions leak from the
components within the dotted line in Fig. Fig. 155 below, or when there is a malfunction in both the EVAP
VSV and pressure switching valve, or in the vapor pressure sensor itself.
Fig. 155: Identifying Evaporative Emission Control System (1 Of 2)

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HINT:
Typical DTC output of each trouble is shown below.
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Fig. 158: DTC Output Table

MONITOR DESCRIPTION
P0441
a. The ECM checks the EVAP VSV "stuck closed" by commanding the EVAP VSV to open with the CCV
closed. If a high negative pressure is not developed in the fuel tank, the ECM determines that the EVAP
VSV remains closed. The ECM will turn on the MIL and set a DTC.
b. The ECM checks the EVAP VSV "stuck open" by commanding both the valves (EVAP VSV and CCV)
to close when the fuel tank is at atmospheric pressure. If the fuel tank develops a high negative pressure at
the early stage of this test, the ECM determines that the EVAP VSV is stuck open.
The ECM will turn on the MIL and set a DTC.
P0446
a. The ECM checks the CCV malfunction by commanding the CCV to open after the EVAP leak test. If the
fuel tank pressure does not rise (lose vacuum), the ECM determines that the CCV is malfunctioning. The
ECM will turn on the MIL and set a DTC.
b. If the EVAP VSV "stuck closed" is detected, DTC P2418 is set.
P2418
a. Bypass VSV (VSV for pressure switching valve) stuck open: The ECM checks the bypass VSV (VSV for
pressure switching valve) "stuck open" by commanding the bypass VSV to close after the EVAP leak
test. If the fuel tank pressure does not change, the ECM determines that the bypass VSV is
malfunctioning. The ECM will turn on the MIL and set a DTC.
b. If the EVAP VSV "stuck closed" is detected, DTC P2418 is set.
MONITOR STRATEGY
MONITOR STRATEGY
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Related DTCs P0441: EVAP VSV stuck closed

Related DTCs P0441: EVAP VSV stuck open
Related DTCs P0442: EVAP leak (0.04 inch)
Related DTCs P0446: CCV stuck closed
Related DTCs P0446: CCV stuck open
Related DTCs P0455: EVAP gross leak
Related DTCs P2418: Bypass VSV malfunction
Required sensors / components EVAP VSV, Bypass VSV, CCV, EVAP canister,
EVAP hose, Fuel cap, Fuel tank and Vapor pressure
sensor

are not present
Battery voltage 11 V
Altitude 7,870 ft. (2,400 m) or less
IAT 10 °C (50°F) or more
IAT at engine start 10 to 32°C (50 to 90°F)
ECT at engine start 10 to 32°C (50 to 90°F)
Difference between engine start IAT and engine -7 to 11.1°C (-13 to 20°F)
start ECT
Purge VSV, CCV and bypass VSV No active test by scan tool
Time after engine start 5 sec. to 50 min.
Vehicle speed Minimal change
Fuel slosh No sloshing, i.e. fairly smooth road
MAF No great change
FTP change Minimal change
FTP Less than -19.5 mmHg (-2.6 kPa)
Fuel tank level Less than 90 %
Number of "negative pressure introduction" in this Within 8 times
driving cycles
EVAP VSV Stuck Closed (P0441):
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EVAP VSV STUCK CLOSED

FTP change during "negative pressure introduction" Less than 7 mmHg (0.933 kPa)
EVAP VSV Stuck Open (P0441):
EVAP VSV STUCK OPEN

FTP 14 sec. after leak check -28 mmHg (-3.73 kPa)
CCV Stuck Closed (P0446):
CCV STUCK CLOSED

FTP change when CCV is commanded to open after -4.5 to 4.5 mmHg (-0.6 to 0.6 kPa)
EVAP leak check
CCV Stuck Open (P0446):
CCV STUCK OPEN

EVAP VSV stuck closed Detected
Bypass VSV Malfunction (P2418):
VSV MALFUNCTION
Either of the following conditions is met
FTP change when bypass VSV is commanded to -4.5 to 4.5 mmHg (-0.6 to 0.6 kPa)
close after EVAP leak check
EVAP Leak (0.04 inch) (P0442):
EVAP LEAK
All of the following conditions are met:
FTP increase for 5 sec. from -20 mmHg (-2.67 kPa) More than 1.5 mmHg (0.2 kPa)
[740 mmHg]
FTP increase for 5 sec. from -15 mmHg (-2 kPa) More than 1.5 mmHg (0.2 kPa)
[745 mmHg]
Minimum FTP after "negative pressure Less than -18 mmHg (-2.4 kPa)
introduction"
EVAP LEAK
[740 mmHg]
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[745 mmHg]
EVAP Gross Leak (P0455):
EVAP GROSS LEAK

FTP increase for 5 sec from -15 mmHg (-2 kPa) More than 1.5 mmHg (0.2 kPa)
[745 mmHg]
MONITOR RESULT


TID $02: EVAP - Vacuum Monitor
EVAP - VACUUM MONITOR

1 $01 Multiply by 0.0916 Test value of EVAP Malfunction
(mmHg) VSV: Determined criterion
by fuel tank pressure
change during
vacuum introduction
1 $02 Multiply by 0.0458 Test value of bypass Malfunction
and subtract 2.93 VSV (pressure criterion
(mmHg) switching valve):
Determined by fuel
tank pressure change
at switching over
bypass VSV
0 $03 Multiply by 0.0458 Test value of 0.04 Malfunction
(mmHg) inch leak: criterion
Determined by fuel
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Determined by fuel
1 $05 Multiply by 0.0458 Test value of CCV: Malfunction
and subtract 2.93 Determined by fuel criterion
(mmHg) tank pressure change
at switching over
CCV
WIRING DIAGRAM
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Fig. 159: EVAP System Wiring Diagram

HINT:
 If DTC P0441 (Purge Flow), P0446 (CCV), P2418 (Pressure Switching Valve) or P0451 (Evaporative
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Pressure Sensor) is output with DTC P0442, P0455 or P0456, first troubleshoot DTC P0441, P0446 or
P0451. If no malfunction is detected, troubleshoot DTC P0442, P0455 or P0456 next.
 When the ENGINE RUN TIME in the freeze frame data is less than 200 seconds, carefully check the
vapor pressure sensor.
Hand-held tester:
1. Check that fuel tank cap meets OEM specification.

NG : Replace it with a cap that meets OEM specification.
2. Check that fuel tank cap is correctly installed
NG : Correctly install fuel tank cap.
3. Check fuel tank cap (see INSPECTION ).
NG : Replace fuel tank cap.
4. Check filler neck for damage.
PREPARATION:
Remove the fuel tank cap.
CHECK:
Visually check the filler neck for damage.
Reinstall the fuel tank cap.
NG : Replace filler pipe.

5. Check purge flow.
PREPARATION:

b. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST mode on the
hand-held tester.
c. Disconnect the EVAP VSV vacuum hose from the charcoal canister.
d. Start the engine
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e. Select the item EVAP VSV (ALON) / ALL in the ACTIVE TEST and operate the EVAP VSV
(press the right or left button).
Fig. 160: Checking Purge Flow

CHECK:
When the EVAP VSV is operated by the hand-held tester, check whether the disconnected hose applies
suction to your finger.
OK:
VSV is ON:
Disconnected hose applies suction to your finger.
VSV is OFF:
Disconnected hose applies no suction to your finger.
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OK : Go to step 9 .
6. Check vacuum hose between intake manifold and EVAP VSV, and EVAP VSV and charcoal
canister.
CHECK:
a. Check that the vacuum hose is connected correctly.

b. Check the vacuum hose for looseness and disconnection.
c. Check the vacuum hose for cracks, puncture, damage and blockage.
NG : Repair or replace vacuum hose.
7. Check operation of EVAP VSV (see INSPECTION ).
NG : Replace EVAP VSV.
8. Check for open and short in wire harness between EFI main relay and EVAP VSV, and EVAP
VSV and ECM (see HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION
9. Check CCV.
PREPARATION:
a. Disconnect the CCV vacuum hose from the charcoal canister.

b. Turn ON the ignition switch. Push the hand-held tester main switch.
c. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST mode on the
hand-held tester.
d. Select the item CAN CTRL VSV / ALL in the ACTIVE TEST and operate the CAN CTRL VSV
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Fig. 161: Checking CCV

CHECK:
When the VSV is operated by the hand-held tester, check whether or not air flows from port E to F.
OK:
VSV is ON:
Air does not flow from port E to port F.
VSV is OFF:
Air from port E flows out through port F.
10. Check vacuum hose between CCV and charcoal canister.
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CHECK:

11. Check operation of CCV (see INSPECTION ).
NG : Replace CCV.
12. Check for open and short in wire harness between EFI main relay and CCV, and CCV and ECM
13. Check pressure switching valve.
PREPARATION:
a. Turn ON the ignition switch. Push the hand-held tester main switch.
hand-held tester.
c. Select the item TANK BYPASS VSV / ALL in the ACTIVE TEST and operate the TANK
BYPASS VSV (press the right or left button).
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Fig. 162: Checking Pressure Switching Valve

CHECK:
OK:
VSV is ON:
VSV is OFF:
14. Check operation of pressure switching valve (see INSPECTION ).
NG : Replace pressure switching valve.
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15. Check for open and short in wire harness between EFI main relay and pressure switching valve,
and pressure switching valve and ECM (see HOW TO USE THE DIAGNOSTIC CHART AND
16. Check whether hose close to fuel tank has been modified, and whether there are signs of any
accident near fuel tank.
CHECK:
Check the following parts for cracks, deformation and loose connection:
 Fuel tank
 Fuel tank filler pipe
 Hoses and tubes around fuel tank
Fig. 163: Checking Fuel Tank, Filler Pipe, Hoses And Tubes For Cracks, Deformation And
Loose Connection
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NG : Repair or replace evaporative emission leak part.

17. Check vacuum hoses between vapor pressure sensor and fuel tank, and charcoal canister and VSV
for pressure switching valve.
CHECK:

c. Check the vacuum hose for cracks, puncture and damage.
18. Check hose and tube between fuel tank and charcoal canister.
CHECK:
a. Check the connection between the fuel tank and fuel EVAP pipe, fuel EVAP pipe and under-floor
fuel tube, and under-floor fuel tube and charcoal canister.
b. Check the hose and tube for cracks, puncture and damage.
NG : Repair or replace hose and tube.
CHECK:

CHECK:
OK:
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Fig. 164: Checking Voltage Between Terminals VC (+) And E2 (-) Of ECM Connector

20. Check voltage between terminals PTNK and E2 of ECM connectors.
PREPARATION:

CHECK:
Measure the voltage between terminals PTNK and E2 of the ECM connectors.
1. Disconnect the vacuum hose from the vapor pressure sensor.

2. Using the MITYVAC (hand-held vacuum pump), apply a vacuum of 4.0 kPa (30 mmHg, 1.18
in.Hg) to the vapor pressure sensor.
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NOTE: The vacuum applied to the vapor pressure sensor must be less than 66.7
kPa (500 mmHg, 19.7 in.Hg).
OK:
1. Voltage: 2.9 to 3.7 V

2. Voltage: 0.5 V or less
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Fig. 165: Checking Voltage Between Terminals PTNK (+) And E2 (-) Of ECM Connector
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21. Check for open and short in wire harness between vapor pressure sensor and ECM (see HOW TO
article).
22. Check fuel tank over fill check valve.
NG : Replace fuel tank over fill check valve.
23. Check fuel tank.
NG : Replace fuel tank.
24. Check charcoal canister for cracks and damage.
NG : Replace charcoal canister.

2. Check that fuel tank cap is correctly installed.
PREPARATION:
CHECK:
Visually check the filler neck for damage.

accident near fuel tank or charcoal canister.
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CHECK:
 Fuel tank
 Charcoal canister
 Hoses and tubes around fuel tank and charcoal canister
Fig. 166: Checking Fuel Tank, Filler Pipe, Hoses And Tubes For Cracks, Deformation And
Loose Connection
NG : Repair or replace evaporative emissions leak part.

6. Check vacuum hoses between vapor pressure sensor and fuel tank, charcoal canister and pressure
switching valve, and pressure switching valve and charcoal canister.
CHECK:
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CHECK:
a. Check the connection between the fuel tank and fuel EVAP pipe fuel EVAP pipe and under-floor
fuel tube and under-floor fuel tube and charcoal canister.
b. Check the hose and tube for cracks, hole and damage.
8. Check vacuum hoses ((5), (6), (7), (8) and (9) in Fig. 155 in CIRCUIT DESCRIPTION).
CHECK:

c. Check the vacuum hose for cracks, puncture, damage, and blockage.
9. Check EVAP VSV connector, CCV connector, pressure switching valve connector and vapor
pressure sensor connector for looseness and disconnection.
NG : Repair or connect VSV or sensor connector.
10. Check charcoal canister (cracks, puncture and damage).
NG : Check and replace charcoal canister.
CHECK:

CHECK:
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OK:

PREPARATION:

CHECK:

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OK:

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Fig. 168: Checking Voltage Between Terminals E2 (-) And PTNK (+) Of ECM Connector
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13. Check for open and short in wire harness between vapor pressure sensor and ECM (See HOW TO
article).
OK : Replace vapor pressure sensor.
14. Check EVAP VSV.
PREPARATION:

CHECK:
Check the VSV function.
1. Connect terminal PRG of the ECM connector and body ground (ON).
2. Disconnect terminal PRG from the body ground (OFF).
OK:
1. VSV is ON:
2. VSV is OFF:
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Fig. 169: Checking VSV Function

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17. Check CCV.
PREPARATION:

CHECK:
1. Connect terminal CCV of the ECM connector and body ground (ON).
2. Disconnect terminal CCV from the body ground (OFF).
OK:
VSV is ON:
VSV is OFF:
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2004 Toyota RAV4
NG : Replace CCV.
PREPARATION:

CHECK:
1. Connect terminal TBP of the ECM connector and body ground (ON).
2. Disconnect terminal TBP from the body ground (OFF).
OK:
1. VSV is ON:
2. VSV is OFF:
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NG : Go to step 24 .
22. Check for open and short in harness and connector between EFI main relay and pressure switching
valve, and pressure switching valve and ECM (see HOW TO USE THE DIAGNOSTIC CHART
NG : Repair or replace harness or connector.
23. Check the fuel tank over fill check valve (see INSPECTION ).
NG : Replace fuel tank over fill check valve or fuel tank.
24. Check fuel tank (see INSPECTION ).
OK : It is likely that vehicle user did not properly close fuel tank cap.
DTC P0442: EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK),
DTC P0455: EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (GROSS LEAK),
DTC P0456: EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL
LEAK)
CIRCUIT DESCRIPTION
The vapor pressure sensor, CCV and Pressure switching valve are used to detect abnormalities in the
evaporative emission control system.
DTC P0442, P0455 or P0456 is recorded in the ECM when evaporative emissions leak from the components
within the dotted line in Fig. 172 below, or when the vapor pressure sensor malfunctions.
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HINT:
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2004 Toyota RAV4
Refer to DTCs P0441, P0446 and P2418. See DTC P0441: EVAPORATIVE EMISSION CONTROL
SYSTEM INCORRECT PURGE FLOW, DTC P0446: EVAPORATIVE EMISSION CONTROL
SYSTEM VENT CONTROL CIRCUIT, DTC P2418: EVAPORATIVE EMISSION SYSTEM VALVE
CONTROL CIRCUIT/OPEN .

HINT:
Typical DTC output of each trouble is shown below.
Fig. 175: DTC Output Table

MONITOR DESCRIPTION
A leak in the evaporative emission system directs the ECM to set DTC P0442, P0455 or P0456.
The ECM checks for leaks in the system by introducing a high negative pressure (vacuum) from the intake
manifold by commanding the EVAP VSV to open while the CCV (vent) is closed. After sufficient time has
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elapsed, the fuel tank should have developed a high negative pressure (vacuum) and the EVAP VSV should be
closed. The ECM then monitors the pressure-rise (loss of vacuum) in the fuel tank. If the pressure rises too
rapidly, the ECM concludes that the system has a leak. The ECM will turn on the MIL and set a DTC.
The ECM sets the following DTCs for small and large leaks:
1. DTC P0442 is set when the internal fuel tank pressure has a large increase and the EVAP system has a
small leak.
2. DTC P0455 is set when the EVAP system has a very large leak. Even though the ECM sends a signal to
the EVAP VSV (when CCV is closed) to create a vacuum, the internal fuel tank pressure does not
decrease beyond a specified level.
3. DTC P0456 is set when the internal fuel tank pressure increases slightly and the EVAP system has a
small leak.
MONITOR STRATEGY
MONITOR STRATEGY
Related DTCs P0441: EVAP VSV stuck open
Related DTCs P0441: EVAP VSV stuck close
Related DTCs P0446: CCV stuck open
Related DTCs P0446: CCV stuck close
Related DTCs P0455: EVAP gross leak
Related DTCs P2418: Bypass VSV malfunction
Required sensors / components (Main) Bypass VSV, CCV, EVAP canister, EVAP hose,
Fuel cap, Fuel tank and EVAP VSV
Required sensors / components (Related) ECT, FTP, IAT, MAF and VSS (Vehicle Speed
Sensor)

are not present
IAT 10 °C (50°F) or more
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Difference between engine start IAT and engine -7 to 11.1°C (-13 to 20°F)
start ECT
Purge VSV, CCV and bypass VSV No active test by scan tool
Time after engine start 5 sec. to 50 min.
Vehicle speed Minimal change
Fuel slosh No sloshing, i.e. fairly smooth road
MAF No great change
FTP change Minimal change
FTP Less than -19.5 mmHg (-2.6 kPa) [Less than 740.5
mmHg]
FUEL TANK LEVEL

Fuel tank level Less than 90 %
Number of "negative pressure introduction" in this Within 8 times
driving cycles
EVAP VSV Stuck Closed (P0441):
EVAP VSV STUCK CLOSED

FTP change during "negative pressure introduction" Less than 7 mmHg (0.933 kPa)
EVAP VSV Stuck Open (P0441):
EVAP VSV STUCK OPEN

FTP 14 sec. after leak check -28 mmHg (-3.73 kPa)
CCV Stuck Closed (P0446):
CCV STUCK CLOSED

FTP change when CCV is commanded to open after -4.5 to 4.5 mmHg (-0.6 to 0.6 kPa)
EVAP leak check
CCV Stuck Open (P0446):
CCV STUCK OPEN

Bypass VSV Malfunction (P2418):
BYPASS VSV MALFUNCTION

Either of the following conditions is met
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FTP change when bypass VSV is commanded to -4.5 to 4.5 mmHg (-0.6 to 0.6 kPa)
close after EVAP leak check
EVAP LEAK
[740 mmHg]
[745 mmHg]
Minimum FTP after "negative pressure Less than -18 mmHg (-2.4 kPa)
introduction"
EVAP LEAK
[740 mmHg]
[745 mmHg]
EVAP Gross Leak (P0455):
EVAP GROSS LEAK

FTP increase for 5 sec from -15 mmHg (-2 kPa) More than 1.5 mmHg (0.2 kPa)
[745 mmHg]
MONITOR RESULT


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TID $02: EVAP - Vacuum Monitor
EVAP - VACUUM MONITOR

1 $01 Multiply by 0.0916 Test value of EVAP Malfunction
(mmHg) VSV: Determined criterion
by fuel tank pressure
change during
vacuum introduction
1 $02 Multiply by 0.0458 Test value of bypass Malfunction
and subtract 2.93 VSV (pressure criterion
(mmHg) switching valve):
Determined by fuel
at switching over
bypass VSV
Determined by fuel
Determined by fuel
1 $05 Multiply by 0.0458 Test value of CCV: Malfunction
and subtract 2.93 Determined by fuel criterion
(mmHg) tank pressure change
at switching over
CCV
WIRING DIAGRAM
Refer to DTC P0441. See DTC P0441: EVAPORATIVE EMISSION CONTROL SYSTEM INCORRECT
PURGE FLOW, DTC P0446: EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL
CIRCUIT, DTC P2418: EVAPORATIVE EMISSION SYSTEM VALVE CONTROL CIRCUIT/OPEN .
CONFIRMATION READINESS TEST
First Trip Procedure
a. The vehicle must be cold, and ambient temperature is between approximately 10°C (50°F) and 35°C (95°
F).
b. Intake Air Temperature (IAT) and Engine Coolant Temperature (ECT) sensors indicate almost the same
value.
c. Clear DTCs.
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Disconnect the battery terminals or EFI fuse for more than 60 seconds.

 READINESS TESTS will show INCMPL (incomplete).
d. Drive the vehicle on a freeway. Write down the state of READINESS TESTS. They will change to
COMPL as the evaluation monitors operate and if the system passes. This procedure may take
approximately 20 minutes or more.
NOTE: Do not shut off the engine - the results will be invalid.
Fig. 176: Readiness Test Confirmation - First Trip Procedure (1 Of 3)

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2004 Toyota RAV4
Pass Condition - No Problem Found by the ECM
If the EVAP evaluation monitor shows COMPL, go to the NON-CONTINUOUS TESTS screen.
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2004 Toyota RAV4
 To get there, go to Advanced OBD II, Onboard Tests, NON-CONTINUOUS TESTS.

 If all of the tests in the time $02 category Tests show "Pass", the evaluation monitor has operated and no
problem was detected.

Fail Condition - Problem Detected in the ECM

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If the EVAP evaluation monitor shows INCMPL, go to the NON-CONTINUOUS TESTS screen.
Fig. 179: Readiness Test Confirmation - Fail Condition (1 Of 3)

1. If all tests show "Pass", the following may have occurred.

 The EVAP evaluation monitor did not operate.
 The EVAP evaluation monitor did not finish.
 The ECM withheld judgement.
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2. If one or more tests in the time $02 category show "Fail", the EVAP evaluation monitor did operate and
the ECM detected a problem.

3. Go to CONTINUOUS TESTS screen. This is the only place where first trip DTC's are listed.
NOTE: The listed DTCs may not be valid. A second trip is needed to confirm the
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DTCs.

Second Trip Procedure
a. The vehicle must be cold, and the ambient temperature is between approximately 10°C (50°F) and 35°C
(95°F).
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2004 Toyota RAV4
b. Go to READINESS TESTS screen.

c. Drive the vehicle on a freeway. Write down the state of the EVAP evaluation monitor. This procedure
may take approximately 20 minutes or more.
Fig. 182: Readiness Test Confirmation - Second Trip Procedure (1 Of 2)

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If READINESS TESTS changes to COMPL, the EVAP evaluation monitor has operated. Check for any stored
DTCs.
 If a DTC Is stored, the problem has been detected and confirmed by the ECM.
 If no DTC Is found, the EVAP monitor has operated but no problem Is detected.
Fig. 183: Readiness Test Confirmation - Second Trip Procedure (2 Of 2)

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HINT:
 If DTC P0441 (Purge Flow), P0446 (CCV or Pressure switching valve) or P0451 (evaporative pressure
sensor) is output with DTC P0442 or P0456, first troubleshoot DTC P0441, P0446 or P0451. If no
malfunction is detected, troubleshoot DTC P0442 or P0456 next.
 Ask the customer whether, after the MIL is turned on, the customer found the fuel tank cap loose and
tightened it. Also ask the customer whether the fuel tank cap was loose when refuelling. If the fuel tank
cap was loose, it was the cause of the DTC. If the fuel tank cap was not loose or if the customer was not
sure if it was loose, troubleshoot according to the following procedure.
vapor pressure sensor.
Hand-held tester:

PREPARATION:
CHECK:
a. Visually check the filler neck for damage.

b. Reinstall the fuel tank cap.
5. Check purge flow.
PREPARATION:
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hand-held tester.
c. Disconnect the EVAP VSV vacuum hose from the charcoal canister.
d. Start the engine
e. Select the item EVAP VSV (ALON) / ALL in the ACTIVE TEST and operate the EVAP VSV
Fig. 184: Checking Purge Flow

CHECK:
When the EVAP VSV is operated by the hand-held tester, check whether the disconnected hose applies
suction to your finger.
OK:
VSV is ON:
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Disconnected hose applies suction to your finger.
VSV is OFF:
Disconnected hose applies no suction to your finger.
OK : Go to step 9 .
6. Check vacuum hose between intake manifold and EVAP VSV, and EVAP VSV and charcoal
canister.
CHECK:

9. Check CCV.
PREPARATION:
a. Disconnect the CCV vacuum hose from the charcoal canister.

c. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST mode on the
hand-held tester.
d. Select the item CAN CTRL VSV / ALL in the ACTIVE TEST and operate the CAN CTRL VSV
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Fig. 185: Checking CCV

CHECK:
OK:
VSV is ON:
VSV is OFF:
10. Check vacuum hose between CCV and charcoal canister.
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CHECK:

c. Check the vacuum hose for cracks, hole damage, and blockage.
11. Check CCV operation (see INSPECTION ).
NG : Replace CCV.
PREPARATION:
a. Turn ON the ignition switch. Push the hand-held tester main switch.
hand-held tester.
c. Select the item TANK BYPASS VSV / ALL in the ACTIVE TEST and operate the TANK
BYPASS VSV (press the right or left button).
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Fig. 186: Checking Pressure Switching Valve

CHECK:
OK:
VSV is ON:
VSV is OFF:
14. Check pressure switching valve operation (see INSPECTION ).
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accident near fuel tank or charcoal canister
CHECK:
 Fuel tank
Fig. 187: Checking Fuel Tank, Charcoal Canister, Filler Pipe, Hoses And Tubes For Cracks,
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Deformation And Loose Connection

NG : Repair or replace evaporative emissions leak part.

17. Check vacuum hoses between vapor pressure sensor and fuel tank, and charcoal canister and
pressure switching valve.
CHECK:

NG : Repair or replace vacuum hose and tube.
CHECK:
a. Check the connection between the fuel tank and fuel EVAP pipe, fuel EVAP pipe and under-floor
fuel tube and under-floor fuel tube and charcoal canister.
b. Check the hose and tube for cracks, hole and damage.
CHECK:

CHECK:
OK:
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PREPARATION:

CHECK:

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OK:
1. Voltage: 2.9 to 3.7V

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article).
24. Check charcoal canister for crack, puncture and damage.

PREPARATION:
CHECK:
a. Visually inspect the filler neck for damage.

b. Reinstall the fuel tank cap.
5. Check whether hose close to fuel tank have been modified, and whether there are signs of any
accident near fuel tank or charcoal canister.
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CHECK:
Check for cracks, deformation and loose connection of the following parts:
 Fuel tank
Fig. 190: Checking Fuel Tank, Charcoal Canister, Filler Pipe, Hoses And Tubes For Cracks,
Deformation And Loose Connection
NG : Repair or replace evaporative emission leak part.

6. Check vacuum hoses between vapor pressure sensor and fuel tank, charcoal canister and pressure
switching valve. and pressure switching valve and charcoal canister.
CHECK:
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2004 Toyota RAV4

CHECK:
a. Check for proper connection of the fuel tank and fuel EVAP pipe, fuel EVAP pipe and fuel tube
under the floor, fuel tube under the floor and charcoal canister (see INSPECTION ).
b. Check the hose and tube for cracks, puncture and damage.
8. Check vacuum hoses ((5), (6), (7) (8) and (9) in Fig. 1 in circuit description).
CHECK:

9. Check VSV connector for EVAP, VSV connector for CCV, VSV connector for pressure switching
valve and vapor pressure sensor connector for looseness and disconnection.
NG : Repair or connect VSV and sensor connector.
NG : Check and replace charcoal canister.
CHECK:
a. Remove the grove compartment (see COMPONENTS ).

CHECK:
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OK:

PREPARATION:

CHECK:

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OK:

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article).
14. Check EVAP VSV.
PREPARATION:

CHECK:
1. Connect between terminal PRG of the ECM connector and body ground (ON).
2. Disconnect between terminal PRG of the ECM connector and body ground (OFF).
OK:
1. VSV is ON:
2. VSV is OFF:
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Fig. 193: Checking EVAP VSV

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17. Check CCV.
PREPARATION:

CHECK:
1. Connect between terminal CCV of the ECM connector and body ground (ON).
2. Disconnect between terminal CCV of the ECM connector and body ground (OFF).
OK:
VSV is ON:
VSV is OFF:
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2004 Toyota RAV4

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NG : Replace CCV.
PREPARATION:

CHECK:
1. Connect between terminal TBP of the ECM connector and body ground (ON).
2. Disconnect between terminal TBP of the ECM connector and body ground (OFF).
OK:
1. VSV is ON:
2. VSV is OFF:
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2004 Toyota RAV4
OK : It is likely that vehicle user did not properly close fuel tank cap.
DTC P0451: EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR/SWITCH

RANGE/PERFORMANCE, DTC P0452: EVAPORATIVE EMISSION CONTROL SYSTEM
PRESSURE SENSOR/SWITCH LOW INPUT, DTC P0453: EVAPORATIVE EMISSION CONTROL
SYSTEM PRESSURE SENSOR/SWITCH HIGH INPUT
CIRCUIT DESCRIPTION
The vapor pressure sensor, CCV and pressure switching valve are used to detect abnormalities in the
evaporative emission control system.
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Fig. 196: Identifying Evaporative Emission Control Sensor/Switch Circuit

MONITOR DESCRIPTION
DTC "P0451, P0452 or P0453" is recorded by the ECM when the vapor pressure sensor malfunctions.
P0451
The ECM senses pressure in the fuel tank using the vapor pressure sensor. The ECM supplies the sensor with a
regulated 5 V reference-voltage and the sensor returns a signal voltage between 0.5 V and 4.5 V according to
the pressure level in the fuel tank.
When the pressure in the fuel tank is low, the output voltage of the vapor pressure sensor is low. When it is
high, the output voltage is high.
For this DTC P0451, the ECM checks for a "noisy" sensor or a "stuck" sensor.
The ECM checks for a "noisy" sensor by monitoring the fuel tank pressures when the vehicle is stationary and
there should be little variation in the tank pressure. If the indicated pressure varies beyond specified limits, the
ECM will illuminate the MIL (2-trip detection logic) and a DTC is set.
The ECM checks for a "stuck" sensor by monitoring the fuel tank pressure for an extended time period. If the
indicated pressure does not change over this period, the ECM will conclude that the fuel tank pressure sensor is
malfunctioning, the ECM will illuminate the MIL and a DTC is set.
P0452 and P0453
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The ECM senses pressure in the fuel tank using the vapor pressure sensor. The ECM supplies the sensor with a
regulated 5 V reference-voltage and the sensor returns a signal voltage between 0.5 V and 4.5 V according to
the pressure level in the fuel tank.
When the pressure in the fuel tank is low, the output voltage of the vapor pressure sensor is low. When it is
high, the output voltage is high.
If the output voltage of the vapor pressure sensor is out of the normal range, the ECM will determine that there
is a malfunction in the sensor or sensor circuit.
When pressure indicated by the vapor pressure sensor deviates below -3.999 kPa (-30 mmHg) or above 1.999
kPa (15 mmHg), the ECM interprets this as a malfunction in the vapor pressure sensor. The ECM will turn on
the MIL and a DTC will be set.

MONITOR STRATEGY
MONITOR STRATEGY
Related DTCs P0451: FTP sensor noise
Related DTCs P0451: FTP sensor stuck
Related DTCs P0452: FTP sensor range check (Low voltage)
Related DTCs P0453: FTP sensor range check (High voltage)
Required sensors / components (Main) FTP sensor
Required sensors / components (Related) ECT sensor, IAT sensor
Duration 7 sec.: FTP sensor range check
Duration 10 sec.: FTP sensor noise (P0451)
Duration 5 min.: FTP sensor stuck
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All:

are not present
FTP Sensor Noise and FTP Sensor Stuck (P0451):
FTP SENSOR NOISE AND FTP SENSOR STUCK

IAT at engine start 4.4 to 35°C (40 to 95°F)
ECT at engine start 4.4 to 35°C (40 to 95°F)
Difference between engine start IAT and engine -7 to 11.1°C (-12.6 to 20°F)
start ECT
FTP Sensor Range Check (P0452: Low voltage) (P0453: High voltage):
FTP SENSOR RANGE CHECK

Difference between engine start ECT and engine 12°C (21.6°F) or less
start IAT
Engine condition Running
FTP Sensor Noise (P0451):
FTP SENSOR NOISE

Number that the following condition is set 5 times from 5 to 15 sec. after idling start
FTP change (during 5 to 15 sec after idling start) 5 mmHg (0.667 kPa) or more
FTP Sensor Stuck (P0451):
FTP SENSOR STUCK

FTP change for 5 min Less than 0.135 mmHg (0.018 kPa)
FTP Sensor Range Check (Low voltage) (P0452):
FTP SENSOR RANGE CHECK

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FTP Less than -30 mmHg (-4 kPa) [Less than 730
mmHg]
FTP Sensor Range Check (High voltage):
FTP SENSOR RANGE (HIGH VOLTAGE)

FTP 15 mmHg (2 kPa) or more [775 mmHg or more]

FTP -26 to 11 mmHg (-3.5 to 1.5 kPa) [734 to 771
mmHg]
WIRING DIAGRAM
Refer to DTC P0441 DTC P0441: EVAPORATIVE EMISSION CONTROL SYSTEM INCORRECT
PURGE FLOW, DTC P0446: EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL
CIRCUIT, DTC P2418: EVAPORATIVE EMISSION SYSTEM VALVE CONTROL CIRCUIT/OPEN
HINT:
 If DTC P0441 (purge flow), P0446 (CCV), P2418 (pressure switching valve), P0451 (evaporative
pressure sensor), P0452 (evaporative pressure sensor low input), or P0453 (evaporative pressure sensor
low input) is output after DTC P0442 or P0456, first troubleshoot DTC P0441, P0446, P2418, P0451,
P0452 or P0453. If no malfunction is detected, troubleshoot DTC P0442 or P0456 next.
 If different DTCs related to different systems that have terminal E2 as the ground terminal are output
simultaneously, terminal E2 may be open.
EVAP VSV, charcoal canister and vapor pressure sensor.
PREPARATION:

CHECK:
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2004 Toyota RAV4
OK:

PREPARATION:

CHECK:
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2004 Toyota RAV4

OK:

3. A consecutive waveform presents.
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2004 Toyota RAV4

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article).
OK : Replace vapor pressure sensor.
DTC P0500: VEHICLE SPEED SENSOR MALFUNCTION
CIRCUIT DESCRIPTION
The No. 1 vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated
by the transmission output shaft via the driven gear. After this signal is converted into a more precise
rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to
the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals.
Fig. 200: Describing Vehicle Speed Sensor Circuit


MONITOR DESCRIPTION
The ECM assumes that the vehicle is driven when the park/neutral position switch is OFF and it has been over 4
seconds since the actual vehicle speed was 9 km/h (6 mph) or more.
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If there is no signal from the vehicle speed sensor with these conditions satisfied, the ECM concludes that there
is a fault in the vehicle speed sensor. The ECM will turn on the MIL and a DTC is set.
MONITOR STRATEGY
MONITOR STRATEGY
Related DTCs P0500: VSS circuit
Required sensors / components (Main) VSS, Combination meter, ABS ECU
Required sensors / components (Related) PNP switch, ECT sensor
Duration 1 sec.: Automatic transmission
Duration 8 sec.: Manual transmission
MIL operation Immediate: Automatic transmission 2 driving
cycles: Manual transmission

are not present
Automatic Transmission:
AUTOMATIC TRANSMISSION
Countergear speed 300 RPM or more
Either of the following conditions A and B is met:
Conditions A:
Time after PNP switch ON to OFF 2 sec. or more
ECT and ECT sensor ECT is 20°C (68°F) or more and ECT sensor does
not malfunction (P0115 or P0116)
Conditions B:
Time after PNP switch ON to OFF 30 sec. or more
ECT and ECT sensor ECT is less than 20°C (68°F) or ECT sensor
malfunction (P0115 or P0116)
Time after ignition switch ON 3 sec. or more
Manual Transmission:
MANUAL TRANSMISSION
Engine RPM 2,000 to 5,000 RPM
Intake air amount per revolution 0.55 g/rev or more
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VSS signal No pulse input
WIRING DIAGRAM
Fig. 202: Vehicle Speed Sensor Wiring Diagram

HINT:
1. Check operation of speedometer.
CHECK:
Drive the vehicle and check if operation of the speedometer in the combination meter is normal.
HINT:
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2004 Toyota RAV4
The vehicle speed sensor is operating normally if the speedometer display is normal.
NG : Check speedometer circuit.

2. Check for short in wire harness between terminal SPD of ECM connector and body ground.
PREPARATION:

b. Disconnect the E7 connector from the ECM.
CHECK:
Check the resistance between terminal SPD of the ECM connector and body ground.
OK:
Resistance: 10 kohm or higher
Fig. 203: Checking Resistance Between Body Ground and Terminal SPD Of ECM E7 Connector
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NG : Repair of replace harness and connector.

3. Check voltage between terminal SPD of ECM connector and body ground.
PREPARATION:

b. Shift the shift lever to neutral.
c. Jack up the vehicle.
CHECK:
Measure the voltage between terminal SPD of the ECM connector and the body ground when the wheel is
turned slowly.
Fig. 204: Checking Voltage Between Body Ground Terminal SPD Of ECM Connector
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OK:
Voltage is generated intermittently.
HINT:
The output voltage should fluctuate up and down similarly to the diagram on the left when the wheel is
turned slowly.
Fig. 205: Identifying Voltage Fluctuation

NG : Check and repair harness and connector between combination meter and ECM.
DTC P0504: BRAKE SWITCH "A"/"B" CORRELATION
CIRCUIT DESCRIPTION
In addition to turning on the stop light, the stop light switch signals are used for a variety of engine,
transmission, and suspension functions as well as being an input for diagnostic checks. It is important that the
switch operates properly, therefore this switch is designed with two complementary signal outputs: STP and
ST1-. The ECM analyzes these signal outputs to detect malfunctions in the stop light switch.
HINT:
Normal condition is as shown in the table

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BRAKE PEDAL
Signal Brake Pedal Released In Transition Brake Pedal Depressed
STP OFF ON ON
ST1- ON ON OFF

WIRING DIAGRAM
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Fig. 207: Brake Switch System Wiring Diagram

HINT:
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Hand-held tester:
1. Check operation of stop light
CHECK:
Check if the stop lights turn ON and OFF normally when the brake pedal is depressed and released.
NG : Check and repair stop light circuit.

2. Check stop light switch (see INSPECTION ).
NG : Replace stop light switch.
3. Check STP and ST1- voltage.
PREPARATION:

c. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STOP
LIGHT SW.
CHECK:
a. Read the STP signal on the hand-held tester.

b. Check the voltage between terminal STP and ST1- of the ECM connector and body ground.
OK:
BRAKE PEDAL
Brake Pedal STP Signal ST1- Terminal Voltage
Depressed ON Below 1.5 V
Released OFF 7.5 to 14 V
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Fig. 208: Checking Voltage Between Terminals STP (+) And ST1 (-) Of ECM Connector
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4. Check for wire harness between ECM and stop light switch (see HOW TO USE THE
1. Check operation of stop light.
CHECK:
Check if the stop lights turn ON and OFF normally when the brake pedal is depressed and released.
NG : Repair stop light circuit.

2. Check stop light switch (see INSPECTION in STOPLIGHT SYSTEM article).
NG : Replace stop light switch.
3. Check STP and ST1- voltage.
PREPARATION:
CHECK:
a. Check the voltage between terminal STP and ST1- of the ECM connector and body ground
OK:
STPV TERMINAL VOLTAGE

Brake Pedal STP Terminal Voltage ST1- Terminal Voltage
Depressed 7.5 to 14 V Below 1.5 V
Released Below 1.5 V 7.5 to 14 V
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Fig. 209: Checking Voltage Between Terminals STP (+) And ST1 (-) Of ECM Connector
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4. Check for wire harness between ECM and stop light switch (see HOW TO USE THE
DTC P0505: IDLE AIR CONTROL SYSTEM
MONITOR DESCRIPTION
The idle speed is controlled by the Electronic Throttle Control System (ETCS).
The ETCS is composed of the throttle actuator which operates the throttle valve, and the throttle position sensor
which detects the opening angle of the throttle valve.
The ECM controls the throttle actuator to provide the proper throttle valve opening angle to obtain the target
idle speed.
The ECM regulates the idle speed by opening and closing the throttle valve using the ETCS. The ECM
concludes that the idle speed control ECM function is malfunctioning if: 1) the actual idle RPM varies more
than the specified amount 5 times or more during a drive cycle, or 2) a learned value of the idle speed control
remains at the maximum or minimum 5 times or more during a drive cycle. The ECM will turn on the MIL and
set a DTC.
Example:
If the actual idle RPM varies from the target idle RPM by more than 200 (*1) RPM 5 times during a drive
cycle, the ECM will turn on the MIL and a DTC is set.
HINT:
*1: RPM threshold varies with engine load.
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Fig. 210: Idle Engine RPM Graph


MONITOR STRATEGY
MONITOR STRATEGY
Related DTCs P0505: IAC functional check
Related DTCs P0505: IAC range check
Required sensors / components (Main) ETCS
Required sensors / components (Related) CKP sensor, ECT sensor and VSS
Duration 10 min: IAC functional check 10 sec.: IAC range
check
MIL operation 2 driving cycles: IAC functional check Immediate:
IAC range check

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are not present
IAC Functional Check:
IAC FUNCTION CHECK

ECT 75°C (167°F)
Idle ON
Vehicle speed Within 2 mph (3 km/h)
IAC Range Check:
IAC RANGE CHECK

IAC output duty ratio 10 to 90%
Battery voltage 10V
IAC Functional Check:
IAC FUNCTIONS CHECK

Both of the conditions 1 and 2 are met -
1. Either of the conditions A or B is met -
Condition A Both of the following conditions (a) and (b) are met
(a) Engine RPM - Target engine RPM Less than -100 RPM
(b) IAC flow rate learning value 2.78 L/sec. (A/C: ON)
(b) IAC flow rate learning value 2.08 L/sec. (A/C: OFF)
Condition B Both of the following conditions (c) and (d) are met
(c) Engine RPM - Target engine RPM More than 150 RPM (shift position: N and A/C:
ON)
(c) Engine RPM - Target engine RPM More than 200 RPM (shift position: D and A/C:
OFF)
(d) IAC flow rate learning value 0.55 L/sec. (shift position: N and A/C: ON) -0.17
L/sec. (shift position: D and A/C: OFF)
2. Either of the conditions C or D is met -
Condition C -
IAC flow rate learning value for 0.5 sec. Below 1.3 L/sec. or above 4.51 L/sec.
Condition D Both of the following conditions (e) and (f) are met
(e) Number of the following condition is met 5 times
(f) IAC flow rate learning value gE "Value when fail is judged first" +1.55 L/sec. lE
"Value when fail is judged first" -2.4 L/sec.
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IAC Range Check:
IAC RANGE CHECK

IAC duty ratio change None
HINT:
1. Are there any other codes (besides P0505) being output?
HINT:
If any other codes besides P0505 are output, perform the troubleshooting for those DTCs first.

CHECK:
Check for vacuum leaks in air induction system.
NG : Repair or replace
OK : Check ETCS (see ON-VEHICLE INSPECTION ).
DTC P0560: SYSTEM VOLTAGE
MONITOR DESCRIPTION
The battery supplies electricity to the ECM even when the ignition switch is OFF. This electricity allows the
ECM to store data such as DTC history, freeze frame data, fuel trim values and other data. If the battery voltage
falls below a minimum level, the ECM will conclude that there is a fault in the power supply circuit. The next
time the engine starts, the ECM will turn on the MIL and a DTC will be set.
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HINT:
If DTC P0560 appears, the ECM does not store any other DTCs.
MONITOR STRATEGY
MONITOR STRATEGY
Related DTCs P0560: ECM system voltage
Required sensors / components (Main) ECM
Duration 3 sec.
MIL operation Immediate (MIL will illuminate after the next
engine start)
VOLTAGE ENABLING CONDITION

are not present
ECM power source Less than 3.5 V
WIRING DIAGRAM
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Fig. 213: ECM System Voltage Wiring Diagram

HINT:
1. Check EFI1 and EFI2 fuse.
PREPARATION:
Remove the EFI1 and 2 fuses from the engine room J/B.
CHECK:
Check the resistance of the EFI1 and 2 fuses.
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OK:
Fig. 214: Identifying EFI1 And EFI2 Fuses

NG : Replace fuse.
2. Check voltage between terminal BATT of ECM connector and body ground.
PREPARATION:
CHECK:
Measure the voltage between terminal BATT of the ECM connector and body ground.
OK:
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Voltage: 9 to 14 V
Fig. 215: Checking Voltage Between Body Ground And Terminal BATT (+) Of ECM Connector

3. Check for open in wire harness between ECM and battery.
OK : Check and replace engine room J/B.
DTC P0604: INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR, DTC
P0606: ECM/PCM PROCESSOR, DTC P0607: CONTROL MODULE PERFORMANCE, DTC P0657:
ACTUATOR SUPPLY VOLTAGE CIRCUIT / OPEN
MONITOR DESCRIPTION
The ECM continuously monitors it's internal memory status, internal circuits, and output signals to the throttle
actuator. This self-check insures that the ECM is functioning properly. If any malfunction is detected, the ECM
will set the appropriate DTC and illuminate the MIL.
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The ECM memory status is diagnosed by internal "mirroring" of the main CPU and the sub CPU to detect
random access memory (RAM) errors. The two CPUs also perform continuous mutual monitoring. The ECM
sets a DTC if: 1) outputs from the 2 CPUs are different and deviate from the standards, 2) the signals to the
throttle actuator deviate from the standards, 3) a malfunction is found in the throttle actuator supply voltage, and
4) any other ECM malfunction is found.
Fig. 216: DTC (DTC P0604, P0606, P0607, P0657) Diagnosis Table
MONITOR STRATEGY
MONITOR STRATEGY
Related DTCs P0604: RAM error
Related DTCs P0606: CPU malfunction
Related DTCs P0657: ETCS power supply
Required sensors / components (Main) ECM
ENABLING CONDITION
are not present
RAM Error (P0604):
RAM ERROR
Difference between main and sub CPU output Larger than the specified range
CPU Malfunction (P0606):
CPU MALFUNCTION
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Either of the following condition is met:

Difference between TP of main CPU and TP of sub 0.3 V or more
CPU
Difference between APP of main CPU and APP of 0.3 V or more
sub CPU
ETCS Power Supply (P0657):
ETCS POWER SUPPLY

ETCS power supply when ignition switch OFF to 7 V or more
ON
HINT:
Replace ECM (see COMPONENTS ).
DTC P0617: STARTER RELAY CIRCUIT HIGH
MONITOR DESCRIPTION
While the engine is being cranked, the positive battery voltage is applied to terminal STA of the ECM. If the
vehicle is being driven and the ECM detects the starter control signal (STA), the ECM concludes that the starter
control circuit is malfunctioning. The ECM will turn on the MIL and a DTC is set.

MONITOR STRATEGY
MONITOR STRATEGY
Related DTCs P0617: Starter signal
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Required sensors / components (Main) Starter relay and PNP switch

Required sensors / components (Related) CKP sensor and vehicle speed sensor
Duration 20 sec.
ENABLING CONDITION
are not present
Vehicle speed 12 mph (20 km/h) or more
Engine RPM 1,000 RPM or more
Starter signal ON
WIRING DIAGRAM
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Fig. 218: Starter Relay Wiring Diagram

HINT:
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Hand-held tester:
1. Connect hand-held tester and check STA signal.
PREPARATION:

LIST / ALL / STARTER SIG.
CHECK:
Read the STA signal on the hand-held tester while the starter operates.
OK:
STA SIGNAL
Ignition Switch Position ON START
STA signal OFF ON

2. Check PNP switch (A/T) (see DTC P0705: TRANSMISSION RANGE SENSOR CIRCUIT
MALFUNCTION (PRNDL INPUT) ) or clutch start switch (M/T) (see CHECK CLUTCH START
SYSTEM under INSPECTION in CLUTCH article).
NG : Replace PNP switch or clutch start switch.
PREPARATION:

CHECK:
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2004 Toyota RAV4
OK:
STA SIGNAL
STA signal OFF ON
OK : System OK.
4. Check ignition switch (see INSPECTION in IGNITION SWITCH & KEY UNLOCK WARNING
SYSTEM ARTICLE).
NG : Replace ignition switch.
PREPARATION:

b. Turn ON the ignition switch. Push the hand-held tester main switch ON.
CHECK:
OK:
STA SIGNAL
STA signal OFF ON
OK : System OK.
1. Check voltage between terminal STA of ECM connector and body ground.
PREPARATION:

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CHECK:
Measure the voltage between terminal STA of the ECM connector and the body ground, during the
engine cranking (ignition switch START position) and does not engine cranking (ignition switch position
ON).
Fig. 219: Checking Voltage Between Body Ground and Terminal STA (+) Of ECM Connector
OK:
Voltage:
6 V or more (ignition switch START position)
0 V (ignition switch ON position)

2. Check PNP switch (A/T) (see DTC P0705: TRANSMISSION RANGE SENSOR CIRCUIT
MALFUNCTION (PRNDL INPUT) ) or clutch start switch (M/T) (see CHECK CLUTCH START
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SYSTEM under INSPECTION in CLUTCH article).

NG : Replace PNP switch or clutch start switch.
PREPARATION:

CHECK:
ON).
Fig. 220: Checking Voltage Between Body Ground and Terminal STA (+) Of ECM Connector
OK:
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Voltage:

SYSTEM ARTICLE).
PREPARATION:

CHECK:
ON).
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Fig. 221: Checking Voltage Between Body Ground And Terminal STA (+) Of ECM
OK:
Voltage:

6. Check for open in wire harness between ECM and PNP switch (A/T) (see DTC P0705:
TRANSMISSION RANGE SENSOR CIRCUIT MALFUNCTION (PRNDL INPUT) ) or clutch
start switch (M/T) (see CHECK CLUTCH START SYSTEM under INSPECTION in CLUTCH
article).
DTC P0705: TRANSMISSION RANGE SENSOR CIRCUIT MALFUNCTION (PRNDL INPUT)

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CIRCUIT DESCRIPTION
When the shift lever is in the N or P position: 1) the PNP switch turns on, and 2) ECM terminal NSW is
grounded to the body ground via the starter relay and voltage becomes 0 V. When the shift lever is in the D, 2,
L or R position: 1) the PNP switch turns off, and 2) ECM terminal NSW receives current and becomes the
voltage of the ECM internal power source.
If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction
and for idle speed control (estimated control).

HINT:
After confirming DTC P0705, use the hand-held tester to confirm the PNP switch signal in the ALL menu (to
reach the ALL menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL).
WIRING DIAGRAM
Refer to DTC P0705 (see WIRING DIAGRAM under DTC: P0705 TRANSMISSION RANGE SENSOR
CIRCUIT MALFUNCTION (PRNDL INPUT) in AUTOMATIC TRANSAXLE DIAGNOSTICS article).
Refer to DTC P0705 (see INSPECTION PROCEDURE under DTC: P0705 TRANSMISSION RANGE
SENSOR CIRCUIT MALFUNCTION (PRNDL INPUT) in AUTOMATIC TRANSAXLE DIAGNOSTICS
article).
HINT:
DTC P2102: THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW, DTC P2103:
THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH
CIRCUIT DESCRIPTION
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The throttle actuator is operated by the ECM and it opens and closes the throttle valve.
The opening angle of the throttle valve is detected by the throttle position sensor which is mounted on the
throttle body. The throttle position sensor provides feedback to the ECM. This feedback allows the ECM to
control the throttle actuator and monitor the throttle opening angle as the ECM responds to driver inputs.
HINT:
This Electronic Throttle Control System (ETCS) does not use a throttle cable.

MONITOR DESCRIPTION
The ECM monitors the flow of electrical current through the electronic throttle actuator, and detects
malfunctions or open circuits in the throttle actuator based on the value of the electrical current. When the
current deviates from the standard, the ECM concludes that there is a fault in the throttle actuator.
Or, if the throttle valve is not functioning properly (for example, stuck on), the ECM concludes that there is a
fault and turns on the MIL and a DTC is set.
Example:
When the current is more than 10 A. Or the current is less than 0.5 A when the actuator driving duty ratio is
more than 80 %. The ECM concludes that the current is out of the normal range, turns on the MIL and a DTC is
set.
FAIL-SAFE
If the ETCS has a malfunction, the ECM cuts off current to the throttle actuator. The throttle control valve
returns to a predetermined opening angle (approximately 16°) by the force of the return spring. The ECM then
adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in
accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed. If the
accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly.
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MONITOR STRATEGY
MONITOR STRATEGY
Related DTCs P2102: Throttle actuator current (low current)
Related DTCs P2103: Throttle actuator current (high current)
Required sensors / components (Main) Throttle actuator
Duration 2 sec.
ENABLING CONDITION
are not present
P2102:
P2102
Electronic throttle actuator ON
Throttle actuator duty ratio 80 % or more
Throttle actuator power supply 8 V or more
P2103:
P2103
Electronic throttle actuator ON
Throttle actuator power supply 8 V or more
P2102:
DTC 2102
Throttle actuator current Less than 0.5 A
P2103:
DTC 2103
Either of the following conditions is set: -
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Hybrid IC diagnosis signal Fail (for 0.1 sec.)

Hybrid IC current limiter port Fail (for 0.6 sec.)
WIRING DIAGRAM
Fig. 224: Throttle Actuator Control Motor Wiring Diagram

HINT:
1. Check throttle body (throttle actuator) (see ON-VEHICLE INSPECTION ).

NG : Replace throttle body.
2. Check for open and short in wire harness between throttle actuator and ECM (see HOW TO USE
THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE in INTRODUCTION article).
3. Inspect throttle body (Visually check throttle valve).
CHECK:
a. Check for foreign objects between the throttle valve and the housing.
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b. Also, check if the valve can open and close smoothly.

NG : Remove foreign objects and clean throttle body.
DTC P2111: THROTTLE ACTUATOR CONTROL SYSTEM - STUCK OPEN, DTC P2112:
THROTTLE ACTUATOR CONTROL SYSTEM - STUCK CLOSED
CIRCUIT DESCRIPTION
The throttle actuator is operated by the ECM and it opens and closes the throttle valve using gears. The opening
angle of the throttle valve is detected by the throttle position sensor, which is mounted on the throttle body. The
throttle position sensor provides feedback to the ECM to control the throttle actuator and set the throttle valve
angle in response to driver inputs.
HINT:
This Electronic Throttle Control System (ETCS) dose not use a throttle cable.

MONITOR DESCRIPTION
The ECM concludes that there is a malfunction of the ETCS when the throttle valve remains at a fixed angle
despite high drive current from the ECM. The ECM will turn on the MIL and a DTC is set.
FAIL-SAFE
If the ETCS has a malfunction, the ECM cuts off current to the throttle control actuator. The throttle control
valve returns to a predetermined opening angle (approximately 16°) by the force of the return spring. The ECM
then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in
MONITOR STRATEGY
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MONITOR STRATEGY
Related DTCs P2111: Throttle actuator stuck open
Related DTCs P2112: Throttle actuator stuck close
Duration 0.5 sec.
ENABLING CONDITIONS
are not present
Throttle actuator stuck open (P2111):
THROTTLE ACTUATOR STUCK OPEN

System guard ON
Throttle actuator current 2 A or more
Throttle actuator close duty ratio 80 % or more
Throttle actuator stuck close (P2112):
THROTTLE ACTUATOR STUCK CLOSED

System guard ON
Throttle actuator current 2 A or more
Throttle actuator open duty ratio 80 % or more
MALFUNCTION THRESHOLD
TP sensor voltage change Less than 0.1 A
WIRING DIAGRAM
Refer to DTC P2102. See DTC P2102: THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW,
DTC P2103: THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH .
HINT:
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1. Is there DTC P2111 or P2112 being output.

NG : Go to relevant DTC chart (see DIAGNOSTIC TROUBLE CODE CHART ).
2. Visually check throttle valve.
PREPARATION:
Remove the intake air duct.
CHECK:
Check for contamination between the throttle valve and the housing. If necessary, clean the throttle body.
And check that the throttle valve moves smoothly.
OK:
The throttle valve is not contaminated with foreign objects and can move smoothly

3. Check DTC output.
PREPARATION:
a. Start the engine, and depress and release the accelerator pedal quickly (fully open and fully close).
b. Clear the DTC.
CHECK:
Read the DTC.
RESULT:
DTC CHECK
No DTC A
P2111 and/or P2112 B
B : Replace ECM (see COMPONENTS ).
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A : Check for intermittent problems (see PRE-CHECK ).
DTC P2118: THROTTLE ACTUATOR CONTROL MOTOR CURRENT RANGE/PERFORMANCE
CIRCUIT DESCRIPTION
The Electronic Throttle Control System (ETCS) has a dedicated power supply circuit. The voltage (+BM) is
monitored and when the voltage is low (less than 4 V), the ECM concludes that the ETCS has a fault and
current to the throttle actuator is cut.
When the voltage becomes unstable, the ETCS control condition itself becomes unstable. For this reason, when
the voltage is low, the current to the actuator is cut. If repairs are made and the system has returned to normal
and then the ignition switch is turned OFF, the ECM will be able to restart the actuator.
HINT:
This ETCS does not use a throttle cable.
Fig. 226: Throttle Actuator Wiring Diagram


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MONITOR DESCRIPTION
The ECM monitors the battery supply voltage applied to the electronic throttle actuator. When the power supply
voltage drops below the threshold, the ECM concludes that the power supply circuit has an open circuit. A DTC
is set and the MIL is turned on.
FAIL-SAFE
If a "pass" condition is detected and the ignition switch is turned OFF, the fail-safe operation will stop and the
system will return to normal.
MONITOR STRATEGY
MONITOR STRATEGY
Related DTCs P2118: Throttle actuator power supply
Required sensors / components (Main) Throttle actuator, Throttle valve, ETCS fuse
Duration 0.8 sec.
ENABLING CONDITION
are not present
Throttle actuator power ON
Battery voltage More than 8 V
Throttle actuator power supply voltage Less than 4 V

Throttle actuator power supply voltage 9 to 14 V
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WIRING DIAGRAM
Fig. 228: Throttle Actuator Wiring Diagram

HINT:
1. Check ETCS fuse.
PREPARATION:
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Remove the ETCS fuse from the engine room R/B.
CHECK:
Check the resistance of the ETCS fuse.
OK:
Resistance : Below 1 ohm
Fig. 229: Locating ETCS Fuse

NG : Replace ETCS fuse.

2. Check voltage between terminal +BM of ECM connector and body ground.
PREPARATION:
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CHECK:
Measure the voltage between terminal +BM of the ECM connector and body ground.
OK:
Voltage: 9 to 14 V
Fig. 230: Checking Voltage Between Body Ground And Terminal +BM (+) Of ECM Connector

3. Check for open in wire harness between battery and ETCS fuse, and ETCS fuse and ECM (see
OK : Check and repair engine room R/B.
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DTC P2119: THROTTLE ACTUATOR CONTROL THROTTLE BODY RANGE PERFORMANCE
CIRCUIT DESCRIPTION
The Electronic Throttle Control System (ETCS) is composed of a throttle actuator that operates the throttle
valve, a throttle position sensor that detects the opening angle of the throttle valve, an accelerator pedal position
sensor that detects the accelerator pedal position, and the ECM that controls the ETCS system. The ECM
operates the throttle actuator to position the throttle valve for proper response to driver inputs. The throttle
position sensor, mounted on the throttle body, detects the opening angle of the throttle valve and provides this
signal to the ECM so that the ECM can regulate the throttle actuator.

MONITOR DESCRIPTION
The ECM determines the "actual" throttle angle based on the throttle position sensor signal. The "actual"
throttle position is compared to the "target" throttle position commanded by the ECM. If the difference of these
two values exceeds a specified limit, the ECM interprets this as a fault in the ETCS system. The ECM turns on
the MIL and a DTC is set.
FAIL-SAFE
MONITOR STRATEGY
MONITOR STRATEGY
Related DTCs P2119: ETCS malfunction
Duration 1 sec.
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ENABLING CONDITION
are not present
Difference between "target TP" and "actual TP" 0.3 V or more
WIRING DIAGRAM
Refer to DTC P2102. see DTC P2102: THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW,
DTC P2103: THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH .
HINT:
PREPARATION:
ON.
c. On the hand-held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DTC
INFO / CURRENT CODES.
CHECK:
Read the DTC using the hand-held tester or the OBD II scan tool.
RESULT:
DTC
Display (DTC Output) Proceed to
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Only P2119 is output A

P2119 and other DTC B
HINT:
If any codes other than P2119 are output, perform the troubleshooting for those DTCs first.
B : Go to relevant DTC chart (see DIAGNOSTIC TROUBLE CODE CHART ).

2. Check DTC output (Check if DTC outputs reoccur).
PREPARATION:
a. Clear the DTC (See PRE-CHECK ).

b. Allow the engine to idle for 15 seconds.
c. Pull the hand brake and shift the gear to D.
d. Depress the brake pedal securely and the accelerator pedal fully for 5 seconds.
CHECK:
Read the output DTC.
HINT:
Accelerator pedal position (TP) sensor voltage can be confirmed using the hand-held tester (DATA
LIST / ALL / THROTTLE POS #1).
OK:
No DTC is output.
OK : System is OK.
DTC P2120: THROTTLE/PEDAL POSITION SENSOR/SWITCH "D" CIRCUIT, DTC P2122:

THROTTLE/PEDAL POSITION SENSOR/SWITCH "D" CIRCUIT LOW INPUT, DTC P2123:
THROTTLE/PEDAL POSITION SENSOR/SWITCH "D" CIRCUIT HIGH INPUT, DTC P2125:
THROTTLE/PEDAL POSITION SENSOR/SWITCH "E" CIRCUIT, DTC P2127: THROTTLE/PEDAL
POSITION SENSOR/SWITCH "E" CIRCUIT LOW INPUT, DTC P2128: THROTTLE/PEDAL
POSITION SENSOR/SWITCH "E" CIRCUIT HIGH INPUT, DTC P2138: THROTTLE/PEDAL
POSITION SENSOR/SWITCH "D"/"E" VOLTAGE CORRELATION
HINT:
This is the repair procedure for the "accelerator pedal position sensor".
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CIRCUIT DESCRIPTION
HINT:
 This Electronic Throttle Control System (ETCS) does not use a throttle cable.
The accelerator pedal position sensor is mounted on the accelerator pedal bracket. The accelerator pedal
position sensor has 2 sensor elements/signal outputs: VPA1 and VPA2. VPA1 is used to detect the actual
accelerator pedal angle (used for engine control) and VPA2 is used to detect malfunctions in VPA1.
Voltage applied to VPA1 and VPA2 changes between 0 V and 5 V depending on the accelerator pedal
angle.
The ECM monitors the accelerator pedal angle from VPA1 and VPA2 signal output, and controls the
throttle motor based on these signals.
Fig. 232: Identifying Accelerator Pedal Position Sensor Ranges And Output Voltage
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HINT:
After confirming DTCs P2120, P2122, P2123, P2125, P2127, P2128 and P2138, use the hand-held tester to
confirm the throttle valve opening percentage.
Fig. 234: Accelerator Pedal Voltage Table

MONITOR DESCRIPTION
When VPA or VPA2 deviates from the standard, or the difference between the voltage outputs of the 2 sensors
is less than the threshold, the ECM concludes that there is a defect in the accelerator pedal position sensor. The
ECM turns on the MIL and a DTC is set.
Example:
When the voltage output of the VPA is below 0.2 V or exceeds 4.8 V.
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FAIL-SAFE
The accelerator pedal position sensor has 2 (main and sub) sensor circuits. If a malfunction occurs in either of
the sensor circuits, the ECM detects the abnormal signal voltage difference between the 2 sensor circuits and
switches to fail-safe mode. In fail-safe mode, the remaining circuit is used to calculate the accelerator pedal
opening to allow the vehicle to continue driving.
If both circuits malfunction, the ECM regards the opening angle of the accelerator pedal to be fully closed. In
this case, the throttle valve will remain closed as if the engine is idling.
MONITOR STRATEGY
MONITOR STRATEGY
Related DTCs P2120: APP sensor 1 range check (Fluttering)
Related DTCs P2122: APP sensor 1 range check (low voltage)
Related DTCs P2123: APP sensor 1 range check (high voltage)
Related DTCs P2125: APP sensor 2 range check (Fluttering)
Related DTCs P2127: APP sensor 2 range check (low voltage)
Related DTCs P2128: APP sensor 2 range check (high voltage)
Related DTCs P2138: APP sensor 2 range check (correlation)
Required sensors / components (Main) TP sensor
Duration 0.5 sec.: P2120, P2122, P2125 and P2127
Duration 2 sec.: P2123, P2128 and P2138
ENABLING CONDITION
are not present
ETCS power ON
P2120:
P2120
VPA1 voltage 0.2 V or less or 4.8 V or more
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2004 Toyota RAV4
P2122:
P2122
VPA1 voltage when VPA2 is 0.97° or more 0.2 V or less
P2123:
P2123
VPA1 voltage 4.8 V or more
P2125:
P2125
VPA2 voltage 0.5 V or less or 4.8 V or more
P2127:
P2127
VPA2 voltage when VPA1 is 0.97° or more 0.5 V or less
P2128:
P2128
VPA2 voltage when the VPA1 is 0.2 to 3.45 V 4.8 V or more
P2138:
DTC 2138
Either of the following conditions is met: Condition A or B
Conditions A:
Difference between VPA1 and VPA2 voltage 0.02 V or less
Conditions B (following condition are met):
VPA1 voltage 0.2 V or less
VPA2 voltage 0.5 V or less
COMPONENTS OPERATING
VPA1 voltage 0.5 to 4.5 V
VPA2 voltage 1.2 to 4.8 V
WIRING DIAGRAM
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Fig. 235: Accelerator Pedal Position Sensor Wiring Diagram

HINT:
Hand-held tester:
1. Connect hand-held tester and read voltage for accelerator pedal position sensor data.
PREPARATION:

LIST / ETCS / ACCEL POS #1 and ACCEL POS #2.
CHECK:
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Fig. 236: Identifying Brake Pedal Positions

OK:
ACCELERATOR PEDAL
Accelerator Pedal ACCEL POS #1 ACCEL POS #2
Released 0.5 to 1.1 V 1.2 to 2.0 V
Depressed 2.6 to 4.5 V 3.4 to 5.3 V
OK : Go to step 6 .
2. Check accelerator pedal position sensor (see INSPECTION ).
NG : Replace accelerator pedal assembly.
3. Check voltage between terminals VCPA and EPA, and VCP2 and EPA2 of ECM connector.
PREPARATION:

CHECK:
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Measure the voltage between terminals VCPA and EPA, and VCP2 and EPA2 of the ECM connector.
OK:
Fig. 237: Checking Voltage Between Terminals VCPA (+) And EPA (-), And VCP2 (+) And EPA2
(-)

4. Check voltage between terminals VPA and EPA, and VPA2 and EPA2 of ECM connector.
PREPARATION:

CHECK:
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Measure the voltage between terminals VPA and EPA, and VPA2 and EPA2 of the ECM connector.
OK:
ACCELERATOR PEDAL VOLTAGE

Accelerator Pedal Voltage
Accelerator Pedal VPA - EPA VPA2 - EPA2
Fig. 238: Checking Voltage Between Terminals VPA (+) And EPA (-), And VPA2 (+) And EPA2 (-)

5. Check for open and short in wire harness in VCPA, VCP2, VPA, VPA2, EPA and EPA2 circuits
between ECM and accelerator pedal position sensor (see HOW TO USE THE DIAGNOSTIC
CHART AND INSPECTION PROCEDURE in INTRODUCTION article).
OK : Repair or replace.
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6. Read output DTC (see DIAGNOSTIC TROUBLE CODE CHART ).

OK : System is OK.
1. Check accelerator pedal assembly (accelerator pedal position sensor) (see INSPECTION ).
2. Check voltage between terminals VCPA and EPA, and VCP2 and EPA2 of ECM connector.
PREPARATION:

CHECK:
Measure the voltage between terminals VCPA and EPA, and VCP2 and EPA2 of the ECM connector.
OK:
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Fig. 239: Checking Voltage Between Terminals VCPA (+) And EPA (-), And VCPA2 (+) And EPA2
(-)

PREPARATION:

CHECK:
OK:
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Fig. 240: Checking Voltage Between Terminals VPA (+) And EPA, And VPA2 (+) And EPA2 (-)

5. Read output DTC (see DIAGNOSTIC TROUBLE CODE CHART ).
OK : System is OK.
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DTC P2121: THROTTLE/PEDAL POSITION SENSOR/SWITCH "D" CIRCUIT

RANGE/PERFORMANCE
HINT:
This is repair procedure for the "accelerator pedal position sensor".
CIRCUIT DESCRIPTION
Refer to DTC P2120. See DTC P2120: THROTTLE/PEDAL POSITION SENSOR/SWITCH "D"
CIRCUIT, DTC P2122: THROTTLE/PEDAL POSITION SENSOR/SWITCH "D" CIRCUIT LOW
INPUT, DTC P2123: THROTTLE/PEDAL POSITION SENSOR/SWITCH "D" CIRCUIT HIGH
INPUT, DTC P2125: THROTTLE/PEDAL POSITION SENSOR/SWITCH "E" CIRCUIT, DTC P2127:
THROTTLE/PEDAL POSITION SENSOR/SWITCH "E" CIRCUIT LOW INPUT, DTC P2128:
THROTTLE/PEDAL POSITION SENSOR/SWITCH "E" CIRCUIT HIGH INPUT, DTC P2138:
THROTTLE/PEDAL POSITION SENSOR/SWITCH "D"/"E" VOLTAGE CORRELATION .

MONITOR DESCRIPTION
The accelerator pedal position sensor is mounted on the accelerator pedal bracket. The accelerator pedal
position sensor has 2 sensor elements/signal outputs: VPA1 and VPA2. VPA1 is used to detect the actual
accelerator pedal angle (used for engine control) and VPA2 is used to detect malfunctions in VPA1. When the
difference between the voltage outputs of VPA and VPA2 deviate from the standard, the ECM concludes the
accelerator pedal position sensor has a malfunction. The ECM turns on the MIL and a DTC is set.
FAIL-SAFE
The accelerator pedal position sensor has 2 (main and sub) sensor circuits. If a malfunction occurs in either of
the sensor circuits, the ECM detects the abnormal signal voltage difference between the 2 sensor circuits and
switches to fail-safe mode. In fail-safe mode, the remaining circuit is used to calculate the accelerator pedal
opening to allow the vehicle to continue driving.
If both circuits malfunction, the ECM regards the opening angle of the accelerator pedal to be fully closed. In
this case, the throttle valve will remain closed as if the engine is idling.
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MONITOR STRATEGY
MONITOR STRATEGY
Related DTCs P2121: TP sensor malfunction
Required sensors / components (Main) TP sensor
Duration 0.5 sec.
TYPICAL ENABLING CONDITION

are not present
ETCS power ON
Difference in voltage between "VAT1 - basic Less than 0.4 V, or more than 1.2 V
voltage learned value (sensor 1)" and "VPA2 - basic
voltage learned value (sensor 2)"
WIRING DIAGRAM
Refer to DTC P2120. See DTC P2120: THROTTLE/PEDAL POSITION SENSOR/SWITCH "D"
CIRCUIT, DTC P2122: THROTTLE/PEDAL POSITION SENSOR/SWITCH "D" CIRCUIT LOW
INPUT, DTC P2123: THROTTLE/PEDAL POSITION SENSOR/SWITCH "D" CIRCUIT HIGH
INPUT, DTC P2125: THROTTLE/PEDAL POSITION SENSOR/SWITCH "E" CIRCUIT, DTC P2127:
THROTTLE/PEDAL POSITION SENSOR/SWITCH "E" CIRCUIT LOW INPUT, DTC P2128:
THROTTLE/PEDAL POSITION SENSOR/SWITCH "E" CIRCUIT HIGH INPUT, DTC P2138:
THROTTLE/PEDAL POSITION SENSOR/SWITCH "D"/"E" VOLTAGE CORRELATION .
HINT:
Hand-held tester:
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1. Connect hand-held tester and read voltage for accelerator pedal position sensor data.
PREPARATION:

LIST / ETCS / ACCEL POS #1 and ACCEL POS #2.
CHECK:
Fig. 242: Identifying Brake Pedal Position

OK:

Accelerator Pedal ACCEL POS #1 ACCEL POS #2
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2004 Toyota RAV4

2. Check accelerator pedal assembly (accelerator pedal position sensor) (see INSPECTION ).
PREPARATION:

CHECK:
OK:
VOLTAGE
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2004 Toyota RAV4

NG : Replace accelerator pedal assembly (see COMPONENTS ).
OBD II scan tool (excluding hand held tester):
PREPARATION:

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2004 Toyota RAV4
CHECK:
OK:


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2004 Toyota RAV4
NG : Replace accelerator pedal assembly (see SFI article).
DTC P2195: OXYGEN (A/F) SENSOR SIGNAL STUCK LEAN (BANK 1 SENSOR 1), DTC P2196:
OXYGEN (A/F) SENSOR SIGNAL STUCK RICH (BANK 1 SENSOR 1)
HINT:
CIRCUIT DESCRIPTION
The A/F sensor provides output voltage* approximately equal to the existing air-fuel ratio. The A/F sensor
output voltage is used to provide feedback for the ECM to control the air-fuel ratio.
With the A/F sensor output, the ECM can determine deviation from the stoichiometric air-fuel ratio and control
proper injection time. If the A/F sensor is malfunctioning, the ECM is unable to accurately control air-fuel ratio.
The A/F sensor is equipped with a heater which heats the zirconia element. The heater is also controlled by the
ECM. When the intake air volume is low (the temperature of the exhaust gas is low), current flows to the heater
witch heats the sensor to facilitate detection of accurate oxygen concentration.
The A/F sensor is a planar type. Compared to a conventional type, the sensor and heater portions are narrower.
Because the heat of the heater is conducted through the alumina to zirconia (of the sensor portion), sensor
activation is accelerated.
To obtain a high purification rate of the CO, HC and NOx components of the exhaust gas, a three-way catalytic
converter is used. The converter is most efficient when the air-fuel ratio is maintained near the stoichiometric
air-fuel ratio.
*: The voltage value changes in the inside of the ECM only.
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2004 Toyota RAV4
Fig. 245: Identifying A/F Sensor


HINT:
 DTCs P2195 and P2196 indicate a malfunction related to bank 1 of the A/F sensor circuit.
 Sensor 1 refers to the sensor closest to the engine assembly.
 After confirming DTCs P2195 and P2196, use the hand-held tester or the OBD II scan tool to confirm
A/F sensor output voltage (AFS B1S1) from the All menu (to reach the ALL menu: DIAGNOSIS /
ENHANCED OBD II / DATA LIST / ALL).
 The A/F sensor's output voltage and the short-term fuel trim value can be read using the OBD II scan tool
or the hand-held tester.
 The ECM controls the voltage of the A1A+ and A1A- terminals of the ECM to a fixed voltage. Therefore,
it is impossible to confirm the A/F sensor output voltage without the OBD II scan tool or the handheld
tester.
 The OBD II scan tool (excluding hand-held tester) displays one fifth of the A/F sensor output voltage
which is displayed on the hand-held tester.
MONITOR DESCRIPTION
Under the air-fuel ratio feedback control, if the voltage output of the A/F sensor indicates RICH or LEAN for a
certain period of time or more, the ECM concludes that there is a fault in the A/F sensor system. The ECM will
turn on the MIL and a DTC is set.
Example:
If the A/F sensor voltage output is less than 2.8 V (very RICH) for 10 seconds even though voltage output of the
heated oxygen sensor output voltage is less than 0.85 V, the ECM sets DTC P2196 or DTC P2198. If the heated
oxygen sensor output voltage is 0.15 V or more but the A/F sensor voltage output is more than 3.8 V (very
LEAN) for 10 seconds, DTC P2195 is set.
MONITOR STRATEGY
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2004 Toyota RAV4
MONITOR STRATEGY
Related DTCs P2195: A/F sensor signal (Bank 1) stuck lean
Related DTCs P2196: A/F sensor signal (Bank 1) stuck rich
Required sensors / components (Main) A/F sensor
Duration 10 sec.
ENABLING CONDITION
are not present
A/F sensor status Activated
A/F admittance 0.014 1/ohm or more
Sub-feedback status Executing
Rear oxygen sensor heater malfunction Not detected
Malfunction Rich side (P2195):
MALFUNCTION RICH SIDE

A/F sensor voltage More than 3.8 V
Malfunction Lean side (P2196):
MALFUNCTION LEAN SIDE

A/F sensor voltage Less than 2.8 V
WIRING DIAGRAM
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2004 Toyota RAV4
Fig. 247: Oxygen (A/F) Sensor Wiring Diagram

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2004 Toyota RAV4
Fig. 248: Confirmation Driving Pattern


b. Switch the hand-held tester from normal mode to check mode (see PRE-CHECK ).
c. Start the engine and warm it up for 2 minutes with all the accessory switched OFF.
d. Drive the vehicle at 60 to 120 km/h (38 to 75 mph) and engine speed at 1,400 to 3,200 RPM for 3 to 5
minutes.
HINT:
If a malfunction exists, the MIL will light up during step (d).
NOTE:  If the conditions in this test are not strictly followed, detecting the
malfunction will not be possible.
 If you do not have a hand-held tester, turn the ignition switch OFF after
performing steps (c) and (d), then perform steps (c) and (d) again.
HINT:
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2004 Toyota RAV4
HINT:
The A/F CONTROL operation lowers the injection volume 12.5 % or increases the injection volume 25%.

4. Select the item DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL.
5. Perform A/F CONTROL with the engine idle (press the right or left button).
Result:
-12.5 % --> Lean output: less than 0.4 V
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2004 Toyota RAV4
Fig. 249: A/F Sensor Output Diagram

For displaying the graph, enter "ACTIVE TEST / A/F CONTROL / USER DATA", select AFS B1S1 and O2S
HINT:
 A low A/F sensor voltage could be caused by a rich air fuel mixture. Check for conditions that might
cause the engine to run with a rich air fuel mixture.
 A high A/F sensor voltage could be caused by a lean air fuel mixture. Check for conditions that might
cause the engine to run with a lean air fuel mixture.
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2004 Toyota RAV4
1. Are there any other codes (besides DTC P2195 and/or P2196) being output?
HINT:
If any other codes besides P2195 and/or P2196 are output, perform the troubleshooting for those DTCs
first.

2. Connect hand-held tester or OBD II scan tool, and read value for voltage output of A/F sensor.
PREPARATION:
a. Connect the hand-held or the OBD II scan tool to the DLC3.

b. Warm up the A/F sensor with the engine at 2,500 RPM for approximately 90 seconds.
c. Read A/F sensor voltage on the hand-held tester or OBD II scan tool.
CHECK:

1. Allow engine to idle for 30 seconds.
2. Engine is racing at approximately 2,500 RPM (when engine revolution is not suddenly
changed).
3. Raise the engine speed to 4,000 RPM and release the accelerator pedal fully quickly.
OK:
Standard:
Voltage changes a little in the vicinity of 3.3 V (between Approx. 3.1 - 3.5 V) as shown in the
illustration.
Condition (3)
A/F ratio sensor voltage increases to 3.8 V or more during engine deceleration (when fuel cut) as
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2004 Toyota RAV4

HINT:
 Whenever the output voltage of the A/F sensor remains at approximately 3.3 V (0.660 V)* (see
dwg. 2) under any conditions as well as the above conditions, the A/F sensor may have an open-
circuit. (This will happen also when the A/F sensor heater has an open-circuit.)
 Whenever the output voltage of the A/F sensor remains at a certain value of approximately 3.8 V
(0.76 V)* or more, or 2.8 V (0.56 V)* or less (see dwg. 2) under any conditions as well as the
above conditions, the A/F sensor may have a short-circuit.
 The ECM will stop fuel injection (fuel cut) during engine deceleration. This will cause a lean
condition and should result in a momentary increase in the A/F ratio sensor voltage.
In the case that the output voltage of the A/F sensor is below 2.8 V (0.76 V)* during fuel
enrichment (for example, when the vehicle tries to overtake another vehicle on a highway, the
vehicle speed is suddenly increased with the accelerator pedal fully depressed), the A/F sensor are
functioning normally.
inside the ECM. If measuring voltage at connectors of A/F ratio sensor or ECM, you can obtain a
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2004 Toyota RAV4
constant voltage.
*: When using the OBD II scan tool (excluding hand-held tester).
PREPARATION:
CHECK:
OK:
EFI MAIN RELAY

terminals 1 and 2)
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2004 Toyota RAV4
Fig. 251: Identifying EPI Main Relay


5. Check for open and short in wire harness between ECM and A/F sensor (see HOW TO USE THE
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2004 Toyota RAV4
Fig. 252: A/F Sensor Wiring Diagram


CHECK:
CHECK:
Check fuel pressure (high or low pressure).
NG : Check and repair fuel pump, fuel pipe line and filter.
8. Check injector injection (see INSPECTION ).
CHECK:
Check injector injection (high or low injection quantity or poor injection pattern).
GO : Go to next step.
HINT:
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2004 Toyota RAV4
YES : A/F sensor circuit DTCs are caused by shortage of fuel.

HINT:
HINT:
17. Are there A/F sensor circuit DTC codes being output again?
YES : Replace ECM (see COMPONENTS and perform confirmation driving pattern.
YES : A/F sensor circuit DTCs are caused by shortage of fuel.
DTC P2238: OXYGEN SENSOR PUMPING CURRENT CIRCUIT LOW (FOR A/F SENSOR) (BANK
1 SENSOR 1), DTC P2239: OXYGEN SENSOR PUMPING CURRENT CIRCUIT HIGH (FOR A/F
SENSOR) (BANK 1 SENSOR 1), DTC P2252: OXYGEN SENSOR PUMPING GROUND CIRCUIT
LOW (FOR A/F SENSOR) (BANK 1 SENSOR 1), DTC P2253: OXYGEN SENSOR PUMPING
GROUND CIRCUIT HIGH (FOR A/F SENSOR) (BANK 1 SENSOR 1)
HINT:
CIRCUIT DESCRIPTION
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Fig. 253: DTC (P2238, P2239, P2252, P2253) Diagnosis Table

MONITOR DESCRIPTION
The air-fuel ratio (A/F) sensor varies its voltage output in proportion to the air-fuel ratio. If impedance
(alternating current resistance) or voltage output of the sensor deviates greatly from the standard, the ECM
determines if an open or short malfunction is in the A/F sensor circuit.
MONITOR STRATEGY
MONITOR STRATEGY
Related DTCs P2238: A/F sensor (bank 1) open circuit between
AF+ and AF-
Related DTCs P2238: A/F sensor (bank 1) short circuit between
AF+ and AF-
AF+ and GND
AF+ and +B
AF+ and GND
AF- +B
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Required sensors / components (Main) A/F sensor

Required sensors / components (Related) ECT sensor, CKP sensor
Duration 20 sec.
ENABLING CONDITION
are not present
A/F sensor open circuit between AF+ and AF- (P2238):
A/F SENSOR OPEN CIRCUIT

Time after A/F sensor heating 20 sec. or more
Others:
BATTERY VOLTAGE
Time after ignition switch is OFF to ON 5 sec. or more
A/F sensor open circuit between AF+ and AF- (P2238):
A/F SENSOR OPEN CIRCUIT

A/F sensor admittance Less than 0.022 1/ohm
A/F sensor short circuit between AF+ and AF- (P2238):
A/F SENSOR SHORT CIRCUIT

Difference between AF+ and AF- voltage Less than 0.1 V
A/F sensor short circuit between AF+ and GND (P2238):
AF AND GND
AF+ voltage Less than 0.5 V
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A/F sensor short circuit between AF+ and +B (P2239):
AF+ AND +B P2252

AF+ voltage 4.5 V or more
A/F sensor short circuit between AF- and GND (P2252):
AF- AND GND

AF- voltage Less than 0.5 V
A/F sensor short circuit between AF- and +B (P2253):
AF- AND +B
AF- voltage 4.5 V or more
WIRING DIAGRAM
Refer to DTC P2195. See DTC P2195: OXYGEN (A/F) SENSOR SIGNAL STUCK LEAN (BANK 1
SENSOR 1), DTC P2196: OXYGEN (A/F) SENSOR SIGNAL STUCK RICH (BANK 1 SENSOR 1) .
HINT:
HINT:
The A/F CONTROL operation lowers the injection volume 12.5% or increases the injection volume 25%.

4. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F
CONTROL.
Result:
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2004 Toyota RAV4
-12.5 % -> Lean output: less than 0.4 V

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2004 Toyota RAV4
B1S2" by pressing "YES" and push "ENTER". Then press "F4".
HINT:
 If DTC P2238, P2239, P2252 or P2253 is displayed, check the bank 1 sensor 1 circuit.

PREPARATION:
CHECK:
OK:
EFI RELAY
terminals 1 and 2)
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2004 Toyota RAV4


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2004 Toyota RAV4


DTC P2A00: A/F SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)
CIRCUIT DESCRIPTION
Fig. 257: DTC (P2A00) Diagnosis Table

MONITOR DESCRIPTION
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Fig. 258: A/F Output (V) Graph

The air-fuel ratio (A/F) sensor varies its output voltage in proportion to the air-fuel ratio. Based on the output
voltage, the ECM determines if the air-fuel ratio is RICH or LEAN and adjusts the stoichiometric air-fuel ratio.
The ECM also checks the fuel injection volume compensation value to check if the A/F sensor is deteriorating
or not. A/F sensor response deterioration is determined by the ratio of the A/F sensor output voltage variation
and fuel trim variation
MONITOR STRATEGY
MONITOR STRATEGY
Related DTCs P2A00: A/F sensor slow response
Required sensors/ components (Main) A/F sensor
Required sensors/ components (Related) VSS, CKP sensor
Duration 60 sec.
MIL operation 2 drive cycles

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ENABLING CONDITION
are not present
A/F sensor status Activated
Idle OFF
Time after idle OFF 20 sec. or more
Engine RPM 1,400 to 3,200 RPM
Vehicle speed 37 to 74 mph (60 to 120 km/h)
Fuel cut OFF
Time after fuel cut is OFF 20 sec. or more
Driving record for 20 sec. or more 25 mph (40 km/h) or more and 900 RPM or more
MONITOR RESULT


TID $06: A/F Sensor
A/F SENSOR
0 $01 Multiply by Parameter for Malfunction
0.000244 (No identify A/F sensor criterion
dimension) response rate (bank
1)
WIRING DIAGRAM
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2004 Toyota RAV4
HINT:
Perform the ACTIVE TEST A/F CONTROL operation.
HINT:
A/F CONTROL operation lowers the injection volume 12.5% or increases the injection volume 25%.

3. Warm up the engine with the engine speed at 2,500 RPM for approximately 90 seconds.
4. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL.
Result:
A/F sensor reacts in synchronizing with increase and decrease of injection volume
+25 % --> rich output: Less than 3.0 V
-12.5 % --> lean output: More than 3.35 V
Heated oxygen sensor reacts in synchronizing with increase and decrease of injection volume
+25 % --> rich output: More than 0.55 V
-12.5 % --> lean output: Less than 0.4 V
NOTE: However, there is a few second delay in the A/F sensor output. And there is
about 20 seconds delay in the heated oxygen sensor.
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2004 Toyota RAV4

B1S2" by pressing "YES" and push "ENTER". Then press "F4".
HINT:
 DTC P2A00 may be also detected, when the air fuel ratio is stuck rich or lean.
 A low A/F sensor voltage could be caused by a rich air fuel mixture. Check for conditions that would
cause the engine to run rich.
 A high A/F sensor voltage could be caused by a lean air fuel mixture. Check for conditions that would
cause the engine to run lean.
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2004 Toyota RAV4
1. Are there any other codes (besides DTC P2A00) being output?
2. Connect hand-held tester or OBD II scan tool, and read value for voltage output of A/F sensor.
PREPARATION:
a. Connect the hand-held tester or the OBD II scan tool to the DLC 3.
b. Warm up the A/F sensor (bank 1 sensor 1) with the engine at 2,500 RPM for approximately 90
seconds.
c. Read the A/F sensor voltage on the hand-held tester or OBD II scan tool.
CHECK:

1. Allow the engine to idle for 30 seconds.
2. Engine is racing at approximately 2,500 RPM (when engine revolution is not suddenly
changed).
3. Raise the engine speed to 4,000 RPM and release the accelerator pedal fully quickly.
OK:
Standard:
Voltage changes a little in the vicinity of 3.3 V (0.66 V)* (between approximately 3.1 to 3.5 V) as
Condition (3)
A/F ratio sensor voltage increases to 3.8 V (0.76 V)* or more during engine deceleration (when fuel
cut) as shown in the illustration.
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2004 Toyota RAV4

HINT:
 Whenever the A/F sensor output voltage remains at approximately 3.3 V (0.660 V)* (see
"Malfunction Condition" graphic) under any condition as well as the above conditions, the A/F
sensor may have an open-circuit. This will happen also when the A/F sensor heater has an open-
circuit.
 Whenever the A/F sensor output voltage remains at a certain value of approximately 3.8 V (0.76 V)
* or more, or 2.8 V (0.56 V)* or less (see "Malfunction Condition" graphic) under any condition as
well as the above conditions, the A/F sensor may have a short-circuit.
 The ECM will stop fuel injection (fuel is cut) during engine deceleration. This will cause a LEAN
condition and should result in a momentary increase in the A/F sensor output voltage.
The output voltage of the A/F sensor may be below 2.8 V (0.76 V)* during fuel enrichment. For the
vehicle, this translates to a sudden increase in speed with the accelerator pedal fully depressed
when trying to overtake another vehicle. The A/F sensor is functioning normally.
inside the ECM. If measuring voltage at connectors of the A/F sensor or ECM, you will observe a
constant voltage.
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2004 Toyota RAV4
*: Voltage when using the OBD II scan tool.
PREPARATION:
CHECK:
OK:
EFI RELAY
terminals 1 and 2)
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2004 Toyota RAV4


References: Bank 1 Sensor 1 System Drawing

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2004 Toyota RAV4

CHECK:
CHECK:
Check fuel pressure (high or low fuel pressure)
NG : Check and repair fuel pump, fuel pipe line and filter.
9. Check injector injection (see INSPECTION ).
CHECK:
Check injector injection (high or low fuel injection quantity or poor injection pattern).
HINT:
12. Is there DTC P2A00 being output again?
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2004 Toyota RAV4
YES : Replace ECM (see COMPONENTS ) and perform confirmation driving pattern.
13. Confirm if vehicle has run out of fuel in past?
YES : DTC P2A00 is caused by running out of fuel.
HINT:
HINT:
19. Confirm if vehicle has run out of fuel in past?
YES : DTC P2A00 is caused by running out of fuel.
ECM POWER SOURCE CIRCUIT
CIRCUIT DESCRIPTION
When the ignition switch is turned ON, battery voltage is applied to terminal IGSW of the ECM. The ECM
"MREL" output signal causes current to flow to the coil, closing the contacts of the EFI main relay and
supplying power to terminal +B of the ECM.
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2004 Toyota RAV4
If the ignition switch is turned OFF, the ECM holds the EFI main relay ON for a maximum of 2 seconds to
allow for the initial setting of the throttle valve.
WIRING DIAGRAM
Fig. 263: ECM Power Source Wiring Diagram

1. Check voltage between terminals +B and E1 or ECM connectors.
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2004 Toyota RAV4
PREPARATION:

CHECK:
Measure the voltage between terminals +B and E1 of the ECM connectors.
OK:
Voltage: 9 to 14V
Fig. 264: Checking Voltage Between Terminals +B (+) And E1 (-)

OK : Proceed to next circuit inspection shown on problem symptoms table (see PROBLEM
SYMPTOMS TABLE ).
2. Check for open in wire harness between terminal E1 of ECM connector and body ground (see
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2004 Toyota RAV4
3. Check voltage between terminal IGSW of ECM connector and body ground.
PREPARATION:

CHECK:
Measure the voltage between terminal IGSW of the ECM connector and the body ground.
OK:
Voltage: 9 to 14V
Fig. 265: Checking Voltage Between body Ground And Terminal Locating IGSW (+)
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2004 Toyota RAV4
OK : Go to step 6 .
4. Check IGN fuse.
PREPARATION:
Remove the IGN fuse from the engine room J/B.
CHECK:
Check the resistance of the IGN fuse.
OK:
Fig. 266: Locating IGN Fuse

NG : Replace IGN fuse.
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2004 Toyota RAV4
SYSTEM ARTICLE).
OK : Check and repair harness and connector between battery and ignition switch, and
ignition switch and ECM.
6. Check voltage between terminal MREL of ECM connector and body ground.
PREPARATION:

CHECK:
Measure the voltage between terminal MREL of the ECM connector and body ground.
OK:
Voltage: 9 to 14V
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Fig. 267: Checking Voltage Between Body Ground And Terminal MREL (+)

7. Check EFI1 fuse.
PREPARATION:
Remove the EFI1 fuse from the engine room J/B.
CHECK:
Check the resistance of the EFI1 fuse.
OK:
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2004 Toyota RAV4
Fig. 268: Locating EFI1 Fuse

NG : Replace EFI1 fuse.

PREPARATION:
CHECK:
OK:
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2004 Toyota RAV4
EFI RELAY
terminals 1 and 2)


9. Check for open and short in wire harness between terminal MREL of ECM and body ground (see
OK : Check and repair harness and connector between EFI1 fuse and battery.
FUEL PUMP CONTROL CIRCUIT
CIRCUIT DESCRIPTION
When the engine is cranked, current flows from the ignition switch terminal ST1 to the starter relay coil
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2004 Toyota RAV4
(Marking: ST), and current flows to terminal STA of the ECM (STA signal).
When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to coil of the circuit
opening relay (Marking: C/OPN), the relay switches ON, power is supplied to the fuel pump and the fuel pump
operates.
While the NE signal is generated and the engine is running, the ECM keeps Tr ON (C/OPN relay ON) and the
fuel pump also keeps operating.
Fig. 270: Fuel Pump Control Circuit

WIRING DIAGRAM
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2004 Toyota RAV4
Fig. 271: Fuel Pump Control Wiring Diagram

Hand-held tester:
1. Connect hand-held tester and check operation of fuel pump.
PREPARATION:

c. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP /
SPD.
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2004 Toyota RAV4
CHECK:
Check that operating noise is heard from the relay while operating it using the hand-held tester.
OK:
Operating noise can be heard from the relay.
OK : Go to step 5 .
2. Check circuit opening relay (Marking: C/OPN).
PREPARATION:
Remove the circuit opening relay from the engine room J/B.
CHECK:
Measure the circuit opening relay.
OK:
EFI RELAY
terminals 1 and 2)
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2004 Toyota RAV4
Fig. 272: Identifying C/OPN Relay

NG : Replace circuit opening relay.

3. Check voltage between terminal FC of ECM connector and body ground.
PREPARATION:

CHECK:
Measure the voltage between terminal FC of the ECM connector and body ground.
OK:
Voltage: 9 to 14V
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Fig. 273: Checking Voltage Between Body Ground And Terminal FC (+)
OK : Go to step 5 .
4. Check for open in wire harness between EFI main relay and circuit opening relay (Marking:
C/OPN), and circuit opening relay and ECM (see HOW TO USE THE DIAGNOSTIC CHART
5. Check fuel pump (see Check fuel pressure (see ON-VEHICLE INSPECTION ).
NG : Repair or replace fuel pump.
6. Check for open in wire harness between circuit opening relay (Marking: C/OPN) and fuel pump,
and fuel pump and body ground (see HOW TO USE THE DIAGNOSTIC CHART AND

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2004 Toyota RAV4
1. Check fuel pump operation (see Check fuel pressure (see ON-VEHICLE INSPECTION ).
CHECK:
Check if there is pressure in the fuel inlet hose.
HINT:
The pipe has fuel pressure if the sound of flowing fuel can be heard.
NG : Proceed to next circuit inspection shown on problem symptoms table (see PROBLEM
SYMPTOMS TABLE ).
2. Check operation circuit opening relay (Marking: C/OPN).
PREPARATION:
Connect between terminal FC of the ECM connector and the body ground.
CHECK:
Check the relay operation.
OK:
Noise can be heard from the circuit opening relay.
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2004 Toyota RAV4
Fig. 274: Checking Voltage Between Body Ground And Terminal FC (+)
NG : Go to step 6 .
3. Check circuit opening relay (Marking: C/OPN).
PREPARATION:
Remove the circuit opening relay from the engine room J/B.
CHECK:
Measure the circuit opening relay.
OK:
EFI RELAY
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2004 Toyota RAV4
terminals 1 and 2)
Fig. 275: Identifying C/OPN Relay

NG : Replace circuit opening relay.

4. Check voltage between terminal FC of ECM connector and body ground.
PREPARATION:

CHECK:
Measure the voltage between terminal FC of the ECM connector and body ground.
OK:
Voltage: 9 to 14V
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2004 Toyota RAV4
Fig. 276: Checking Voltage Between Body Ground and Terminal FC (+)

6. Check fuel pump (see Check fuel pressure (see ON-VEHICLE INSPECTION ).
NG : Repair or replace fuel pump.
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2004 Toyota RAV4
MIL CIRCUIT MALFUNCTION
CIRCUIT DESCRIPTION
The MIL is used to indicate the ECM's detection of a vehicle malfunction.
The instrument panel IG2 fuse provides circuit power and the ECM provides the circuit ground that illuminates
the MIL.
MIL operations should be checked visually:
The MIL should be illuminated when the ignition is first turned ON. If the MIL is always ON or OFF, use the
hand-held tester or OBD II scan tool and follow the procedures to determine the cause of problem.
WIRING DIAGRAM
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2004 Toyota RAV4
Fig. 277: MIL Circuit Wiring Diagram

HINT:
Troubleshoot in accordance with the chart below for each trouble symptom.
Troubleshooting Table
MIL is not illuminated Start inspection from step 1 in case of using hand-
held tester and start from step 2 in case of not using
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2004 Toyota RAV4
hand-held tester
MIL remains on After inspection of step 3, start inspection from step
4 in case of using hand-held tester and start from
step 5 in case of not using hand-held tester
1. Check operation of MIL.
PREPARATION:

ON.
c. Switch the hand-held tester or the OBD II scan tool from the normal mode to the check mode.
CHECK:
Check if the MIL blinks.
OK:
The MIL blinks.

2. Check bulb of MIL.
See combination meter troubleshooting.
NG : Repair or replace bulb or combination meter assembly.

3. Check that ECM connectors are securely connected to ECM.
NG : Connect connector to ECM.
OK : Check for open circuit in wire harness between combination meter and ECM (see HOW
TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE in
4. Check operation of MIL (see step 1 ).
5. Is DTC output?
CHECK:
Check the DTC. See DIAGNOSTIC TROUBLE CODE CHART .

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2004 Toyota RAV4
OK : Repair circuit indicated by output code.

NG : Check for short circuit in wire harness between DLC3 and ECM (see HOW TO USE
THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE in INTRODUCTION
article).
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2004 Toyota RAV4
2004 ENGINE Engine Mechanical (Service Specifications) - RAV4
2004 ENGINE
Engine Mechanical (Service Specifications) - RAV4
SERVICE DATA
Fig. 1: Engine Mechanical Service Specifications (1 Of 4)

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2004 Toyota RAV4
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2004 Toyota RAV4


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TORQUE SPECIFICATION
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2004 Toyota RAV4
Fig. 5: Engine Mechanical Torque Specifications (1 Of 2)

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2004 Toyota RAV4
Fig. 6: Engine Mechanical Torque Specifications (2 Of 2)

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2004 Toyota RAV4
2004 ENGINE Ignition -RAV4
2004 ENGINE
Ignition -RAV4
IGNITION SYSTEM
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils
themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C
(122°F) to 100°C (212°F).
1. INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST
Check that the spark occurs.
1. Remove the ignition coils (see COMPONENTS ).

2. Remove the spark plugs.
3. Install the spark plugs to each ignition coil and connect the ignition coil connector.
4. Disconnect the 4 injector connectors.
5. Ground the spark plug.
6. Check if the spark occurs while the engine is being cranked.
NOTE: To prevent gasoline from being injected from injectors during this
test, crank the engine for no more than 5 - 10 seconds at one time.
If the spark does not occur, do the test as follows:
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2004 Toyota RAV4
Fig. 1: Spark Testing Chart

7. Using a 16 mm plug wrench, reinstall the spark plugs.
8. Reinstall the ignition coils (see COMPONENTS ).

2. INSPECT SPARK PLUGS
NOTE:  Never use a wire brush for cleaning.

 Never attempt to adjust the electrode gap on used spark plug.
a. Remove the air cleaner assembly.

b. Remove the ignition coils (see COMPONENTS ).
c. Check the electrode.
 Using a megger (insulation resistance meter), measure the insulation resistance.
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Fig. 2: Measuring Insulation Resistance

Correct insulation resistance: 10 Mohm or more
If the resistance is less than the specified value, proceed to step (d).
HINT:
If a megger is not available, the following simple method of inspection provides fairly
accurate results.
 Simple Method:
 Quickly race the engine to 4,000 rpm 5 times.
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 Remove the spark plug (see step (d)).

 Visually check the spark plug.
Fig. 3: Visually Checking Spark Plug Electrode

If the electrode is dry ... OK.
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2004 Toyota RAV4
If the electrode is wet... Proceed to step f .
Reinstall the spark plug (see step g ).

d. Using a 16 mm plug wrench, remove the spark plugs.
Fig. 4: Removing Spark Plugs

e. Check the spark plug for thread damage and insulator damage.
If abnormal, replace the spark plug.
Recommended spark plug:
SPARK PLUG REFERENCE

DENSO made SK20R11
NGK made IFR6A11
f. Check the spark plug electrode gap.
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Fig. 5: Checking Spark Plug Electrode Gap

Maximum electrode gap for used spark plug:
1.3 mm (0.047 in.)
If the gap is greater than maximum, replace the spark plug.
Correct electrode gap for new spark plug:
1.0 to 1.1 mm (0.039 to 0.043 in.)
NOTE: When adjusting the gap of a new spark plug, bend only the base of
the ground electrode. Do not touch the tip. Never attempt to adjust
the gap on a used plug.
g. Clean the spark plugs.
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Fig. 6: Cleaning Spark Plugs

If the electrode has traces of wet carbon, make it dry and then clean it with a spark plug cleaner.
Air pressure: Below 588 kPa (6 kgf/cm2 , 85 psi)
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Duration: 20 seconds or less
HINT:
If there are traces of oil, wipe them off with gasoline before using the spark plug cleaner.
h. Using a 16 mm plug wrench, install the spark plugs.
i. Reinstall the ignition coils (see COMPONENTS ).

j. Reinstall the air cleaner assembly.
3. INSPECT CAMSHAFT POSITION SENSOR
a. Remove the sensor connector (see CAMSHAFT POSITION SENSOR ).
b. Using an ohmmeter, measure the resistance between terminals.
Fig. 7: Measuring Resistance Between Camshaft Position Sensor Connector Terminals

Resistance:
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CAMSHAFT RESISTANCE
Cold 835 to 1,400 ohm
Hot 1,060 to 1,645 ohm
If the result is not as specified, replace the sensor (see CAMSHAFT POSITION SENSOR ).
c. Reconnect the sensor connector.

4. INSPECT CRANKSHAFT POSITION SENSOR
a. Disconnect the sensor connector.
b. Using an ohmmeter, measure the resistance between the terminals.
Fig. 8: Measuring Resistance Between Crankshaft Position Sensor Connector Terminals

Resistance:
CRANKSHAFT RESISTANCE
Cold 985 to 1,600 ohm
Hot 1,265 to 1,890 ohm
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If the result is not as specified, replace the sensor (see CRANKSHAFT POSITION SENSOR ).
IGNITION COIL
COMPONENTS
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Fig. 9: Identifying Ignition Coil Components

CAMSHAFT POSITION SENSOR

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COMPONENTS
Fig. 10: Identifying Camshaft Position Sensor Components

CRANKSHAFT POSITION SENSOR
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COMPONENTS
Fig. 11: Identifying Crankshaft Position Sensor Components

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IGNITION RELAY (NO. 2)

INSPECTION
1. REMOVE IGNITION RELAY (Marking: IG2)
Fig. 12: Removing Ignition Relay (IG2)

2. INSPECT IGNITION RELAY

a. Check the resistance of the IG relay.
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Fig. 13: Checking Resistance Of IG Relay

Standard:
IG RELAY CONNECTOR TERMINALS SPECIFIED CONDITION

Tester Condition Specified Condition
terminals 1 and 2)
If the result is not as specified, replace the relay.
3. REINSTALL IGNITION RELAY
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2004 ACCESSORIES & EQUIPMENT Instrument Panel - RAV4
2004 ACCESSORIES & EQUIPMENT
Instrument Panel - RAV4
COMPONENTS
Fig. 1: Locating Instrument Panel Components (1 Of 3)

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HINT:
Screw shapes and sizes are indicated in the table below. The codes (A to M) correspond to those indicated in
Fig. 1 , Fig. 2 and Fig. 3 .
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Fig. 4: Identifying Nuts And Bolts Size Chart

REMOVAL
CAUTION: Work must be started at least 90 seconds after the ignition switch is
turned into the LOCK position and the negative (-) terminal cable is
disconnected from the battery. The SRS is equipped with a back-up power
source. If work is started within 90 seconds from disconnecting the
negative (-) terminal cable of the battery, the SRS may be deployed.
HINT:
A bolt without a torque specification is shown in the standard bolt chart. (See SPECIFIED TORQUE FOR
STANDARD BOLTS )
1. REMOVE STEERING WHEEL PAD AND STEERING WHEEL (See REMOVAL )

2. REMOVE DOOR SCUFF PLATE
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2004 Toyota RAV4
3. REMOVE COWL SIDE TRIM

4. REMOVE NO. 1 SWITCH HOLE BASE
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL
a. Remove the 3 screws and disconnect the connector.
b. Using a screwdriver, pry out the lower finish panel.
Fig. 5: Removing Lower Instrument Panel Finish Panel & Screws

HINT:
Tape the screwdriver tip before use.
6. REMOVE LOWER PANEL INSERT
Remove the 4 bolts and panel.
7. REMOVE COLUMN COVERS (See REMOVAL )

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8. REMOVE SPIRAL CABLE (See REMOVAL )

9. REMOVE WIPER AND WASHER SWITCH AND LIGHT CONTROL SWITCH AND
HEADLIGHT DIMMER SWITCH (See REMOVAL )
10. REMOVE CLUSTER FINISH PANEL
Using a screwdriver, pry out the finish panel.
HINT:
11. REMOVE COMBINATION METER

a. Push out the connector by loosening the 2 bolts.
NOTE: Operation is completed when the bolt failed to catch.
b. Check that the red-colored indicator goes back as shown in Fig. 6 .

c. Remove the 4 screws.
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Fig. 6: Removing Screws & Combination Meter

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12. REMOVE INSTRUMENT CLUSTER FINISH PANEL CENTER NO. 1 AND NO. 2
a. Using a screwdriver, pry out the 2 cluster finish panel centers.
Fig. 7: Removing Instrument Cluster Finish Panel Center No. 1 & No. 2
HINT:
13. REMOVE INSTRUMENT CLUSTER FINISH PANEL

a. Remove the 2 screws.
b. Using a screwdriver, pry out the finish panel.
HINT:
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c. w/o Radio:
Remove the 4 bolts and stereo opening cover.
d. w/Radio:
Remove the 4 bolts and radio, then disconnect the connectors.
Fig. 8: Removing Instrument Cluster Finish Panel, Screws & Bolts

14. REMOVE HEATER CONTROL ASSEMBLY (See REMOVAL )

15. REMOVE INSTRUMENT PANEL CLUSTER FINISH CENTER PANEL
a. Remove the 2 screws.
b. Using a screwdriver, pry out the finish panel then disconnect the connector.
HINT:
 After removing the screws, if you remove the clips shown by the arrow marks with a resin spatula,
the panel can be removed smoothly.
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 Tape the screwdriver tip before use.
Fig. 9: Removing Instrument Panel Cluster Finish Center Panel & Screws
16. REMOVE UPPER CONSOLE PANEL

a. M/T only:
Remove the shift lever knob.
b. Using a screwdriver, pry out the console panel.
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Fig. 10: Removing Upper Console Panel

HINT:
17. REMOVE REAR CONSOLE BOX
Remove the 2 bolts, 2 screws and console box, then disconnect the connector.
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Fig. 11: Removing Rear Console Box, Bolts & Screws

18. REMOVE FRONT CONSOLE BOX

a. Remove the 6 screws and console box.
b. Using a screwdriver, pry out the console box in the direction indicated by the arrow mark.
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Fig. 12: Removing Front Console Box & Screws

HINT:
19. REMOVE NO. 1 AND NO. 2 INSTRUMENT PANEL UNDER COVERS

20. REMOVE GLOVE COMPARTMENT BOX
21. REMOVE INSTRUMENT SIDE PANEL
22. REMOVE STEERING COLUMN (See REMOVAL )
23. REMOVE FRONT PILLAR GARNISH LH
a. Using a screwdriver, disengage the 2 clips.
HINT:
b. Remove the pillar garnish.

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1. Pull the pillar garnish until the clip marked A in Fig. 13 stitches.
2. Turn the clip marked A in Fig. 13 90 degrees and remove the pillar garnish.
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Fig. 13: Removing Front Pillar Garnish LH & Clips

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c. w/Curtain shield airbag:
Protect the curtain shield airbag LH.
1. Cover the airbag with cloth or a piece of nylon approximately 700 mm (27.56 in.) x 120 mm
(4.72 in.) in size. Fix the ends of the cover with tape as shown in Fig. 14 .
NOTE: Cover the curtain shield airbag with the protective cover as soon as
the front pillar garnish is removed.
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Fig. 14: Protecting Curtain Shield Air Bag LH

24. REMOVE FRONT PILLAR GARNISH RH
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HINT:
Use the same procedures described for the LH side.
25. REMOVE INSTRUMENT PANEL

a. Disconnect the connectors as shown in Fig. 15 .
b. Disengage the wire harness clamps as shown in Fig. 15 .
c. Remove the 4 screws, 2 nuts, 8 bolts and instrument panel.
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Fig. 15: Removing Instrument Panel, Screws, Nuts And Bolts

26. REMOVE NO. 1 AND NO. 2 BRACES
Remove the 3 bolts, 3 nuts, and the No. 1 and No. 2 braces.
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Fig. 16: Removing No. 1 & No. 2 Braces, Bolts & Nuts
27. REMOVE REINFORCEMENT

a. Remove the brake pedal spring.
b. Remove the 5 bolts, nut and reinforcement.
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Fig. 17: Removing Reinforcement, Bolts And Nut

DISASSEMBLY
1. REMOVE DEFROSTER NOZZLE WITH NO. 1 AND NO. 2 DEFROSTER DUCTS
2. REMOVE NO. 1 HEATER TO REGISTER DUCT
5. REMOVE NO. 1 RESISTER
6. REMOVE NO. 2 RESISTER
7. REMOVE INSTRUMENT PANEL REGISTER BEZEL
8. REMOVE INSTRUMENT PANEL WIRE
9. REMOVE PASSENGER AIRBAG
REASSEMBLY
The reassembly procedures are the disassembly procedures in reverse order (see DISASSEMBLY ).
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INSTALLATION
The installation procedures are the removal procedures in reverse order (see REMOVAL ).
NOTE:  The combination meter assembly has equipped with the inclination sensor
to control the fuel gauge. When replacing the inclination sensor or
combination meter assembly, please reset the vehicle in a horizontal
condition according to the following procedure.
 If you do not reset the vehicle in a horizontal condition, the fuel gauge fails
to display the accurate value.
RESET INCLINATION SENSOR INSIDE COMBINATION METER
a. After replacing the part, install the combination meter to the vehicle.
b. Park the vehicle in a flat area (A surface with an angle of inclination no greater than +/-0.5°)
c. With the ignition switch OFF, press the trip switch.
d. While pressing the trip switch, turn the ignition switch to the ON position.
e. Within 5 seconds after the ignition switch is turned ON, release the trip switch and press the trip switch
again 3 times, but hold the switch for 5 seconds on the third press. (A buzzer of 800 Hz will sound for 1
second.)
f. After the buzzer stops, release the trip switch.
g. Within 30 seconds after buzzer stops, press the trip switch one more time and hold it for 5 seconds. (Once
more, a buzzer of 800 Hz will sound for 1 second.)
h. The horizontal setting is now completed.
HINT:
If a buzzer higher than that of step (e) sounds continually at step (g), turn the ignition switch OFF and perform
the setting procedure from step (c) again.
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2004 ENGINE Lubrication - RAV4
2004 ENGINE
Lubrication - RAV4
OIL AND FILTER

INSPECTION
1. CHECK ENGINE OIL QUALITY
Check the oil for deterioration, entry of water, discoloring or thinning.
If the quality is visibly poor, replace the oil.
Oil grade:
API grade SL, Energy-Conserving or ILSAC multi-grade engine oil. SAE 5W-30 is the best choice
for your vehicle, for good fuel economy, and good starting in cold weather.
Fig. 1: Identifying Recommended Viscosity (SAE) Graph

2. CHECK ENGINE OIL LEVEL

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After warming up the engine and then 5 minutes after the engine stop, oil level should be between the
upper and lower marks on the dipstick.
If low, check for leakage and add oil up to the upper dot mark.
NOTE: Do not fill with engine oil above the upper dot mark.
3. REMOVE OIL PRESSURE SWITCH AND INSTALL OIL PRESSURE GAUGE

a. Remove the oil pressure switch.
Fig. 2: Removing Oil Pressure Switch

b. Install the oil pressure gauge.
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Fig. 3: Installing Oil Pressure Gauge

4. WARM UP ENGINE
5. CHECK OIL PRESSURE
Oil pressure:
ENGINE RPM AND OIL PRESSURE SPECIFICATION

Idle 29 kPa (0.3 kgf/cm2 , 4.3 psi) or more
3,000 RPM 245 to 539 kPa (2.5 to 5.5 kgf/cm2 , 36 to 78 psi)
6. REMOVE OIL PRESSURE GAUGE AND REINSTALL OIL PRESSURE SWITCH

a. Remove the oil pressure gauge.
b. Apply adhesive to 2 or 3 threads of the oil pressure switch.
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Fig. 4: Applying Adhesive To Oil Pressure Switch Threads

Adhesive:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Install the oil pressure switch.
7. START ENGINE AND CHECK FOR OIL LEAKS
REPLACEMENT
CAUTION:  Prolonged and repeated contact with mineral oil will result in the
removal of natural fats from the skin, leading to dryness, irritation
and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer.
 Exercise caution in order to minimize the length and frequency of
contact of your skin to used oil. Wear protective clothing and gloves.
Wash your skin thoroughly with soap and water, or use water-less
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hand cleaner, to remove any used engine oil. Do not use gasoline,
thinners, or solvents.
 In order to preserve the environment, used oil and used oil filter must
be disposed of only at designated disposal sites.
1. REMOVE ENGINE UNDER COVER

2. DRAIN ENGINE OIL
a. Remove the oil filter cap.
b. Remove the oil drain plug, and drain the oil into a container.
3. REPLACE OIL FILTER
a. Using SST, remove the oil filter.
SST 09228-06501
Fig. 5: Removing Oil Filter Using SST

b. Check and clean the oil filter installation surface.

c. Check the part number of the new oil filter is as same as old one.
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d. Apply clean engine oil to the gasket of a new oil filter.

e. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
Fig. 6: Screwing Oil Filter Into Place

f. Using SST, tighten it an additional 3/4 turn.
SST 09228-06501
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Fig. 7: Tightening Oil Filter Additional 3/4 Turn Using SST

4. REFILL WITH ENGINE OIL

a. Clean and install the oil drain plug with a new gasket.
b. Fill with fresh engine oil.
Capacity:
ENGINE OIL CAPACITY SPECIFICATION

Drain and refill w/Oil filter change 3.8 liters (4.0 US qts, 3.3 Imp. qts)
Drain and refill w/o Oil filter change 3.6 liters (3.8 US qts, 3.2 Imp. qts)
Dry fill 4.3 liters (4.5 US qts, 3.8 Imp. qts)
c. Install the oil filter cap.

5. START ENGINE AND CHECK FOR OIL LEAKS
6. INSTALL CENTER ENGINE UNDER COVER
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OIL PUMP
COMPONENTS
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Fig. 8: Oil Pump Components (1 Of 3)

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REMOVAL
1. DRAIN ENGINE OIL

Remove 4 bolts, 2 compression springs, 2 gaskets and front exhaust pipe.
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Fig. 11: Removing Front Exhaust Pipe & Bolts


4. REMOVE OIL PAN
a. Remove the 12 bolts and 2 nuts.
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Fig. 12: Removing Bolts & Nuts From Oil Pan

b. Insert the blade of SST between the crank case and oil pan, and timing chain cover and oil pan, cut
off applied sealer and remove the oil pan.
SST 09032-00100
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Fig. 13: Inserting Blade Of SST Between Crank Case & Oil Pan, Timing Chain Cover & Oil
Pan
NOTE: Be careful not to damage the contact surface of the timing chain
cover, crank case and oil pan.
5. REMOVE AIR CLEANER ASSEMBLY (See REMOVAL )

6. REMOVE ABS ACTUATOR (See REMOVAL )
7. REMOVE RH ENGINE MOUNTING INSULATOR (See REMOVAL )
8. REMOVE TIMING CHAIN AND CRANKSHAFT TIMING SPROCKET (See REMOVAL )
9. REMOVE OIL PUMP DRIVE CHAIN AND SPROCKETS
a. Set the crankshaft key into the left horizontal position.
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Fig. 14: Setting Crankshaft Key Into Left Horizontal Position

b. Remove the bolt, chain tensioner plate and spring.

c. Using a screwdriver, hold the oil pump drive shaft sprocket as shown in Fig. 15 .
d. Remove the nut, 2 sprockets and drive chain.
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Fig. 15: Removing Oil Pump Drive Chain And Sprockets

10. REMOVE OIL PUMP
Remove the 3 bolts, oil pump and gasket.
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Fig. 16: Removing Oil Pump & Bolts

DISASSEMBLY
1. REMOVE OIL PUMP STRAINER SET
Remove the 2 nuts and oil pump strainer.
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Fig. 17: Removing Oil Pump Strainer & Nuts

2. REMOVE RELIEF VALVE

a. Using a socket wrench (27 mm), remove the plug.
b. Remove the valve spring and relief valve.
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Fig. 18: Removing Valve Spring & Relief Valve

3. REMOVE OIL PUMP BODY COVER
Remove the 5 bolts and oil pump body cover.
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Fig. 19: Removing Oil Pump Body Cover & Bolts

INSPECTION
1. INSPECT OIL JET
Check the oil jet for damage or clogging. If necessary, replace the cylinder block.
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Fig. 20: Inspecting Oil Jet

2. INSPECT RELIEF VALVE
Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight.
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Fig. 21: Inspecting Relief Valve

If it does not, replace the relief valve. If necessary, replace the oil pump assembly.
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3. INSPECT DRIVE AND DRIVEN ROTORS

a. Place the drive and driven rotors into the oil pump body (see REASSEMBLY ).
b. Inspect for the tip clearance.
Using a feeler gauge, measure the clearance between the drive and driven rotor tips.
Fig. 22: Inspecting Drive And Driven Rotor (Tip Clearance)

Standard tip clearance:
0.080 to 0.160 mm (0.0031 to 0.0063 in.)
Maximum tip clearance: 0.35 mm (0.0138 in.)

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If the tip clearance is greater than the maximum, replace the rotors as a set.
c. Inspect for the side clearance.
Using a feeler gauge and precision straight edge, measure the clearance between the rotors and
precision straight edge.
Fig. 23: Inspecting Drive And Driven Rotors (Side Clearance)

Standard side clearance:
0.030 to 0.085 mm (0.0012 to 0.0033 in.)
Maximum side clearance: 0.16mm (0.0063 in.)
If the side clearance is greater than the maximum, replace the rotors as a set. If necessary, replace
the oil pump assembly.
d. Inspect for the body clearance.
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Using a feeler gauge, measure the clearance between the driven rotor and body.
Fig. 24: Inspecting Drive And Driven Rotors (Body Clearance)

Standard body clearance:
0.100 to 0.170 mm (0.0039 to 0.067 in.)
Maximum body clearance: 0.325 mm (0.0128 in.)
If the body clearance is greater than the maximum, replace the rotors as a set. If necessary, replace
the oil pump assembly.
4. INSPECT OIL PUMP DRIVE CHAIN AND OIL PUMP SPROCKETS
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a. Using vernier calipers, measure the length of the 8 links with the chain dully stretched.
Maximum chain elongation: 52.4 mm (2.063 in.)
If the elongation is greater than the maximum, replace the chain.
HINT:
Make the same measurements pulling at 3 or more places selected at random.
Fig. 25: Measuring Links Length With Chain Dully Stretched

b. Wrap the chain around the oil pump sprocket.

c. Using vernier calipers, measure the sprocket diameter with the chain.
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Fig. 26: Measuring Sprocket Diameter With Chain

NOTE: Vernier calipers must contact the chain rollers for measuring.
Minimum sprockets diameter (w/chain):
48.2 mm (1.898 in.)
If the diameter is less than the minimum, replace the chain and 2 sprockets.
5. INSPECT CHAIN TENSIONER PLATE
Measure the chain tensioner plate wear.
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Fig. 27: Measuring Chain Tensioner Plate Wear

Maximum wear: 0.5 mm (0.020 in.)
If the wear is greater than the maximum, replace the chain tensioner plate.
REASSEMBLY
1. INSTALL OIL PUMP BODY COVER
Install the pump body cover with the 5 bolts.
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Fig. 28: Installing Oil Pump Body Cover With Bolts

2. INSTALL RELIEF VALVE

a. Coat the relief valve with engine oil.
b. Insert the relief valve and spring into the pump body hole.
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Fig. 29: Installing Relief Valve & Spring

c. Using a socket wrench (27 mm), install the plug.
3. INSTALL OIL PUMP STRAINER SET

a. Place a new gasket on the oil pump.
b. Install the oil strainer with the 2 nuts.
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Fig. 30: Installing Oil Pump Strainer & Nuts

INSTALLATION
1. INSTALL OIL PUMP
Install a new gasket and the oil pump with the 3 bolts.
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Fig. 31: Installing Oil Pump With Bolts

2. INSTALL DRIVE CHAIN AND SPROCKETS

a. Set the crankshaft key into the left horizontal position and turn the cutout of the drive shaft to the
top.
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Fig. 32: Setting Crankshaft Key Into Left Horizontal Position

b. Set the chain on the 2 sprockets as shown in Fig. 33 .
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Fig. 33: Setting Chain On Sprockets

HINT:
 Set the mark on the oil pump drive sprocket at the colored link in the chain.
 Set the mark on the oil pump drive shaft sprocket at the colored link.
c. Install the chain and 2 sprockets with the nut.
3. INSTALL CHAIN TENSIONER
Install the spring and plate with the bolt.
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Fig. 34: Installing Chain Tensioner

4. INSTALL OIL PAN

of the timing chain/crank case and oil pan.
 Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the
gasket surfaces and sealing grooves.
NOTE: Do not use a solvent which will affect the painted surfaces.
b. Apply seal packing to the oil pan as shown in Fig. 35 .
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Fig. 35: Identifying Seal Width

 Install a nozzle that has been cut to a 4.0 to 4.5 mm (0.16 to 0.18 in.) opening.
HINT:
c. Install the oil pan with the 12 bolts and 2 nuts.
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Fig. 36: Installing Oil Pan, Bolts & Nuts

5. INSTALL CRANKSHAFT TIMING SPROCKET AND TIMING CHAIN (See INSTALLATION )

6. INSTALL RH ENGINE MOUNTING INSULATOR (See INSTALLATION )
7. INSTALL ABS ACTUATOR (See INSTALLATION )
8. INSTALL AIR CLEANER ASSEMBLY (See INSTALLATION )
Install 2 new gaskets and front exhaust pipe with the 2 compression springs and 4 bolts.
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Fig. 37: Installing Front Exhaust Pipe, Gaskets, Compression Springs & Bolts
Torque:
10. INSTALL ENGINE UNDER COVER

11. FILL ENGINE WITH OIL
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2004 TRANSMISSION Manual Transaxle - RAV4
2004 TRANSMISSION
Manual Transaxle - RAV4
TROUBLESHOOTING
Use Fig. 1 to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the
problem. Check each part in order. If necessary, replace parts.

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MANUAL TRANSAXLE UNIT (2WD)

ON-VEHICLE REPAIR
REPLACE TRANSAXLE OIL
a. Loosen the filler plug.

b. Remove the drain plug.
HINT:
Use a container to catch the transaxle oil.
c. Remove the filler plug.

d. Reinstall the drain plug.
e. Refill new transaxle oil as shown in Fig. 2 .
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Fig. 2: Replacing Transaxle Oil

Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 2.5 liters (2.6 US qts, 2.2 lmp.qts)
f. Reinstall the filler plug.
COMPONENTS
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Fig. 3: Locating Manual Transaxle Unit 2WD Components (1 Of 2)

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Fig. 4: Locating Manual Transaxle Unit 2WD Components (2 Of 2)

REMOVAL
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1. REMOVE HOOD
Remove the 4 bolts and hood.
Torque: 13 N.m (133 kgf.cm, 9.6 ft.lbf)
HINT:
At the time of installation, please refer to the following item.
Adjust the hood (See ADJUSTMENT ).
2. REMOVE AIR CLEANER ASSEMBLE WITH AIR HOSE

3. REMOVE ENGINE COOLANT RESERVOIR TANK
4. DISCONNECT CONTROL CABLES FROM TRANSAXLE
b. Remove the 2 clips and disconnect the 2 control cables.
Fig. 5: Removing Clips & Washers & Disconnecting Control Cable

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5. DISCONNECT VEHICLE SPEED SENSOR AND BACK-UP LIGHT SWITCH CONNECTORS

6. DISCONNECT GROUND CABLE FROM TRANSAXLE
Remove the bolt and disconnect the ground cable.
Fig. 6: Removing Bolt & Disconnecting Transaxle Ground Cable

7. REMOVE STARTER
a. Disconnect the starter connector.
b. Remove the nut and disconnect the starter cable.
c. Remove the 2 bolts and starter.
8. DISCONNECT CLUTCH RELEASE CYLINDER AND LINE

a. Remove the 3 bolts.
Torque:
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5 N.m (51 kgf.cm, 44 in.lbf) for bolt C
b. Remove the 2 bolts and heat insulator.
c. Remove the 2 bolts and disconnect the release cylinder and line.
Fig. 7: Disconnecting Clutch Release Cylinder And Line

9. REMOVE 5 MOUNTING BOLTS OF TRANSAXLE UPPER SIDE
Torque:
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Fig. 8: Removing Mounting Bolts Of Transaxle Upper Side

10. ATTACH ENGINE SUPPORT FIXTURE

a. Install the No. 2 engine hanger in the correct direction.
Parts No.:
No. 2 engine hanger: 12281-28010
Bolt: 91512-61020
b. Using an engine sling device, attach the engine support fixture to the engine hangers.
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Fig. 9: Attaching Engine Support Fixture

11. DISCONNECT LEFT ENGINE MOUNTING INSULATOR FROM TRANSAXLE
Remove the through bolt and nut.
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Fig. 10: Removing Through Bolt & Nut

12. REMOVE LH AND RH ENGINE UNDER COVERS

13. DRAIN TRANSAXLE OIL (See ON-VEHICLE REPAIR )
a. Remove the 2 bolts and springs from the exhaust manifold.
b. Remove the 2 bolts and 2 gaskets with pipe.
HINT:
At the time of installation, using the new gasket.
15. REMOVE LH AND RH FRONT DRIVE SHAFTS (See REMOVAL )

16. DISCONNECT 2 STABILIZER BAR LINKS
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Remove the 2 nuts and disconnect the LH and RH stabilizer bar links.
Fig. 11: Disconnecting Stabilizer Bar Links

17. REMOVE FRONT SUSPENSION CROSSMEMBER ASSEMBLY WITH STABILIZER BAR

a. Support the front suspension crossmember with a jack.
b. Remove the 2 set bolts of the PS gear assembly.
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Fig. 12: Removing PS Gear Assembly Set Bolts

c. Remove the 2 nuts, 5 bolts and front suspension crossmember assembly with the stabilizer bar.
Torque:
Bolt A: 113 N.m (1,150 kgf.cm, 82 ft.lbf)
Bolt B: 157 N.m (1,600 kgf.cm, 115 ft.lbf)
Bolt C: 72 N.m (734 kgf.cm, 53 ft.lbf)
Nut D: 72 N.m (734 kgf.cm, 53 ft.lbf)
18. REMOVE ENGINE MOUNTING CENTER MEMBER
Remove the 4 bolts and center member.
Torque:
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Bolt E: 80 N.m (820 kgf.cm, 59 ft.lbf)
Bolt F: 39 N.m (400 kgf.cm, 28 ft.lbf)
Fig. 13: Removing Nut, Bolts & Front Suspension Crossmember Assembly
19. JACK UP TRANSAXLE SLIGHTLY
Using a transmission jack, support the transaxle.
20. REMOVE 4 MOUNTING BOLTS OF TRANSAXLE LOWER SIDE
Torque:
21. REMOVE TRANSAXLE
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Lower the engine left side, then slowly and carefully remove the transaxle from the engine.
Fig. 14: Removing Bolts & Transaxle From Engine

HINT:
At the time of installation, please refer to the following items.
 Align the input shaft with the clutch disc and install the transaxle to the engine.
 Temporarily tighten the transaxle mounting bolts.
INSTALLATION
Installation is in the reverse order of removal (See REMOVAL ).
HINT:
After installation, check and inspect items as follows.

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 Check the front wheel alignment (See INSPECTION ).

 Do the road test.
MANUAL TRANSAXLE UNIT (4WD)

ON-VEHICLE REPAIR
REPLACE TRANSAXLE OIL

HINT:
Use a container to catch the transaxle oil.

e. Refill new transaxle oil as shown in Fig. 15 .
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Fig. 15: Replacing Transaxle Oil

Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
COMPONENTS
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Fig. 16: Locating Manual Transaxle Unit (4WD) Components

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REMOVAL
1. REMOVE TRANSAXLE WITH ENGINE (See REMOVAL )

2. REMOVE TRANSAXLE CASE PROTECTOR
Remove the 2 bolts and transaxle case protector.
3. DISCONNECT BACK-UP LIGHT SWITCH AND VEHICLE SPEED SENSOR CONNECTORS

4. REMOVE TRANSFER STIFFENER PLATE
Remove the 5 bolts and stiffener plate.
Fig. 17: Removing Stiffener Plate & Bolts

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Remove the 10 bolts, separate the engine and transaxle.
Fig. 18: Separating Transaxle From Engine & Removing Bolts

Torque:
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44 N.m (440 kgf.cm, 32 ft.lbf) for bolt C
HINT:
At the time of installation, please refer to the following items.
 Align the input shaft with the clutch disc and install the transaxle to the engine.
 Temporarily tighten the transaxle mounting bolts.
INSTALLATION
HINT:
After installation, check and inspect items as follows.
 Check the front wheel alignment (See INSPECTION ).

 Do the road test.
MANUAL TRANSAXLE ASSEMBLY

COMPONENTS
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Fig. 19: Identifying Manual Transaxle Assembly Components (1 Of 5)

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DISASSEMBLY
1. REMOVE CLUTCH RELEASE FORK AND BEARING
HINT:
At the time of reassembly, please refer to the following item.
Apply molybdenum disulphide lithium base grease (See INSTALLATION ).
2. 4WD: REMOVE TRANSFER ASSEMBLY

Sealant:
b. Remove the 6 nuts.
Torque:
78.4 N.m (800 kgf.cm, 58 ft.lbf) for 17 mm nut
29.4 N.m (300 kgf.cm, 22 ft.lbf) for 14 mm nut
c. Using a plastic hammer, remove the transfer assembly from the transaxle.
HINT:
 Shift into the 4th gear, and install the transfer assembly while turning the input shaft of the
transaxle.
 It is possible to apply FIPG either transaxle side or transfer side. In addition, be sure to apply it on
the center of the seal.
FIPG:
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Fig. 24: Applying FIPG To Transaxle Side Or Transfer Side

3. 4WD: REMOVE DIFFERENTIAL SIDE GEAR INTERMEDIATE SHAFT

4. REMOVE FILLER PLUG AND DRAIN PLUG WITH 2 GASKETS
5. REMOVE BACK-UP LIGHT SWITCH WITH GASKET
6. REMOVE BOLT AND VEHICLE SPEED SENSOR
7. REMOVE CONTROL CABLE BRACKET
Remove the 3 bolts and control cable bracket.

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8. REMOVE CLUTCH TUBE BRACKET
Remove the bolt and tube bracket.
9. REMOVE SELECTING BELLCRANK ASSEMBLY
Remove the 2 bolts and the selecting bellcrank assembly.
Fig. 25: Removing Selecting Bellcrank Assembly

10. REMOVE CONTROL SHIFT LEVER AND DUST BOOT

a. Remove the nut and wave washer.
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Fig. 26: Removing Nut & Wave Washer

b. Using a pin punch and a hammer, tap out the lever lock pin.
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Fig. 27: Tapping Out Lever Lock Pin

NOTE: At the time of reassembly, please refer to the following item.
When fixing the lever lock pin, properly position the shaft groove.
c. Remove the control shift lever and dust boot.
NOTE: At the time of reassembly, please refer to the following items.
 Install the dust boot into a groove in the control shift lever.
 Be sure to install the dust boot in the correct direction, as
shown in Fig. 27 .
11. REMOVE LOCK BALL ASSEMBLY AND SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a. Remove the lock ball assembly.
Sealant:
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b. Remove the 4 bolts, shift and select lever shaft assembly and gasket.
Fig. 28: Removing Lock Ball Assembly & Shift And Select Lever Shaft Assembly
Sealant:
12. REMOVE CONTROL SHAFT COVER
Remove the control shaft cover from the shift and select lever shaft assembly.
NOTE: At the time of reassembly, please refer to the following item.

Set the claws of the shift interlock plate into the shift head part of the gear
shift fork shaft securely.
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13. REMOVE TRANSMISSION CASE COVER
Remove the 10 bolts and transmission case cover.
Fig. 29: Removing Transmission Case Cover & Bolts

FIPG:
Part No. 08826-00100, THREE BOND 1282B or equivalent

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14. REMOVE BREATHER PLUG WITH GASKET
15. REMOVE OUTPUT SHAFT LOCK NUT

a. Unstake the lock nut.
b. Engage the gear double meshing.
c. Remove the lock nut.
d. Disengage the gear double meshing.
Fig. 30: Removing Output Shaft Lock Nut

16. REMOVE NO. 3 HUB SLEEVE AND NO. 3 SHIFT FORK

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a. Remove the No. 3 shift fork set bolt.
b. Remove the No. 3 hub sleeve and No. 3 shift fork.

17. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03030)
Fig. 31: Removing 5th Driven Gear

18. MEASURE 5TH GEAR THRUST CLEARANCE AND RADIAL CLEARANCE

a. Using a dial indicator, measure the thrust clearance.
Maximum clearance:
0.65 mm (0.0256 in.)
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b. Using a dial indicator, measure the radial clearance.
Maximum clearance:
0.050 mm (0.0020 in.)
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Fig. 33: Measuring Radial Clearance

19. REMOVE NO. 3 CLUTCH HUB AND 5TH GEAR

a. Using 2 screwdrivers and a hammer, tap out the snap ring.
HINT:
At the time of the reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
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Fig. 34: Selecting Snap Ring Allowing Minimum Axial Play

SNAP RING THICKNESS

Mark Thickness mm (in.)
a 1.75 (0.0689)
b 1.80 (0.0709)
c 1.85 (0.0729)
d 1.90 (0.0748)
e 1.95 (0.0768)
f 2.00 (0.0787)
g 2.05 (0.0807)
h 2.10 (0.0827)
j 2.15 (0.0847)
b. Using SST, remove the No. 3 clutch hub with the synchronizer ring and 5th gear.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010)
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Fig. 35: Removing No. 3 Clutch Hub With Synchronizer Ring & 5th Gear
20. REMOVE NEEDLE ROLLER BEARINGS

21. REMOVE REAR BEARING RETAINER
Using a torx socket wrench (T45), remove the 7 torx screws and rear bearing retainer.
Sealant:
22. REMOVE SNAP RING

a. Using a snap ring expander, remove the input shaft rear bearing snap ring.
b. Using 2 screwdrivers and a hammer, remove the 2 snap rings.
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Fig. 36: Removing Snap Ring

23. REMOVE STRAIGHT SCREW PLUG
Using a hexagon wrench (6 mm), remove the plug.
Sealant:
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Fig. 37: Removing Straight Screw Plug

24. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND WASHER
Sealant:
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Fig. 38: Removing Reverse Idler Gear Shaft Lock Bolt And Washer
25. REMOVE TRANSMISSION CASE

a. Transaxle case side:
Remove the 3 bolts.
b. Transmission case side:
Remove the 14 bolts and tap out the case with a plastic hammer.
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Fig. 39: Removing Transmission Case Bolts

FIPG:
Part No. 08826-00100, THREE BOND 1282B or equivalent
Torque:
29 N.m (300 kgf.cm, 21 ft.lbf) for transaxle case side
30 N.m (306 kgf.cm, 22 ft.lbf) for transmission case side
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Fig. 40: Locating FIPG

26. REMOVE SHIM
HINT:
At the time of reassembly, please refer to the following item. Install the previously selected shim by
adjusting output shaft preload (See REASSEMBLY ).
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Fig. 41: Removing Shim

27. REMOVE OUTPUT SHAFT REAR BEARING OUTER RACE
Using SST and a hammer, remove the output shaft rear bearing outer race.
SST 09316-6001 1 (09316-00011)
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Fig. 42: Removing Output Shaft Rear Rearing Outer Race

28. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
Remove the 2 bolts and pull off the reverse shift arm and bracket.
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Fig. 43: Removing Reverse Shift Arm Bracket Assembly

29. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft, remove the reverse idler gear and thrust washer.
HINT:
Align the matchmarks, as shown in Fig. 44 .
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Fig. 44: Aligning Matchmarks

30. REMOVE STRAIGHT SCREW PLUGS
Using a hexagon wrench (6 mm), remove the 2 plugs.
Sealant:
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Fig. 45: Removing Straight Screw Plugs

31. REMOVE 3 SHIFT FORK SET BOLTS
32. REMOVE NO. 1 SHIFT FORK SHAFT
Pull up the No. 3 shift fork shaft, remove the No. 1 shift fork shaft.
HINT:
At the time of reassembly, please refer to the following item. When it is difficult to push the fork shaft
through the reverse shift fork, pull up the No. 3 shift fork shaft.
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Fig. 46: Pulling Up No. 3 Shift Fork Shaft

33. REMOVE INTERLOCK ROLLER
Using a magnetic finger, remove the interlock roller from the reverse shift fork.
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Fig. 47: Removing Interlock Roller

34. REMOVE NO. 2 SHIFT FORK SHAFT, SHIFT HEAD AND NO. 1 SHIFT FORK
a. Pull out the No. 2 shift fork shaft.
b. Remove the shift head and No. 1 shift fork.
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Fig. 48: Removing No. 2 Shift Fork Shaft Shift Head & No. 1 Shift Fork
35. REMOVE NO. 3 SHIFT FORK SHAFT WITH REVERSE SHIFT FORK AND NO. 2 SHIFT
FORK
a. Pull out the No. 3 shift fork shaft with the reverse shift fork.
b. Remove the No. 2 shift fork.
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Fig. 49: Removing No.3 Shift Fork Shaft With Reverse Shift Fork & No. 2 Shift Fork
36. REMOVE SNAP RING

a. Using 2 screwdrivers and a hammer, remove the snap ring and reverse shift fork from the No. 3
shift fork shaft.
b. Using 2 screwdrivers and a hammer, remove the snap rings from the No. 1, No. 2 and No. 3 shift
fork shafts.
37. REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY
a. Leaning the output shaft to the differential side, remove the input shaft assembly.
b. Lift up the differential case assembly, remove the output shaft assembly.
38. REMOVE DIFFERENTIAL CASE ASSEMBLY
39. REMOVE MAGNET FROM TRANSAXLE CASE
40. REMOVE 2 BOLTS, NO. 1 AND NO. 2 OIL RECEIVER PIPES
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41. REMOVE STRAIGHT SCREW PLUG FROM TRANSAXLE CASE
Sealant:
42. REMOVE NO. 5 SYNCHRONIZER RING WITH KEY SPRING FROM NO. 3 CLUTCH HUB
a. Remove the No. 5 synchronizer ring with the key spring from the No. 3 clutch hub.
Fig. 50: Removing No.5 Synchronizer Ring with Key Spring from No.3 Clutch Hub
b. Using a screwdriver, remove the snap ring.
HINT:
Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring.
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c. Remove the synchronizer rings.
INSPECTION
1. INSPECT NO. 5 SYNCHRONIZER RING

a. Check for wear or damage.
Fig. 51: Checking No. 5 Synchronizer Ring For Wear Or Damage

b. Check the braking effect of the synchronizer ring.

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Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring
locks.
If the braking effect is insufficient, apply a small amount of the fine lapping compound between the
synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.
NOTE: Ensure the fine lapping compound is completely washed off after
rubbing.
c. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline
end.
Fig. 52: Measuring Clearance Between Synchronizer Ring Back & Gear Spline End
Minimum clearance: 0.7 mm (0.028 in.)
If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount
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of the fine lapping compound on gear cone.
rubbing.
2. INSPECT NO. 3 SHIFT FORK AND HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 0.35 mm (0.014 in.)
If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
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Fig. 53: Inspecting No. 3 Shift Fork & Hub Sleeve Clearance
REPLACEMENT
1. REPLACE INPUT SHAFT FRONT BEARING AND OIL SEAL

a. Remove the 3 bolts and transaxle case receiver.
b. Using SST, pull out the bearing.
SST 09612-65014 (09612-01040, 09612-01050)
Fig. 54: Pulling Out Bearing

c. Using a screwdriver, remove the oil seal.

d. Using SST, drive in a new oil seal.
SST 09608-00081, 09950-70010 (09951-07150)
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Fig. 55: Driving In New Oil Seal

e. Coat the lip of seal with MP grease.

f. Using SST, drive in a new bearing.
SST 09950-60010 (09951-00580), 09950-70010 (09951-07150)
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Fig. 56: Driving In New Bearing

g. Install the transaxle case receiver.

h. Install and torque the 3 bolts.
2. REPLACE OUTPUT SHAFT FRONT BEARING OUTER RACE AND OUTPUT SHAFT FRONT
COVER
a. Using SST, pull out the output shaft front bearing outer race.
SST 09308-00010
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Fig. 57: Removing Output Shaft Front Bearing Outer Race

b. Remove the output shaft cover.

c. Install a new output shaft cover.
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Fig. 58: Installing New Output Shaft Cover

HINT:
Install the output shaft cover projection into the case side groove.
d. Using SST and a hammer, drive in a new output shaft front bearing outer race.
SST 09316-6001 1 (09316-00011, 09316-00021)
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Fig. 59: Installing New Output Shaft Front Bearing Outer Race
3. REPLACE REVERSE RESTRICT PIN

a. Using a hexagon wrench (6 mm), remove the screw plug.
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Fig. 60: Removing Screw Plug

b. Using a pin punch (5 mm) and hammer, drive out the slotted spring pin.
c. Replace the reverse restrict pin.
d. Using a pin punch (5 mm) and hammer, drive in the slotted spring pin.
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Fig. 61: Driving In Slotted Spring Pin

e. Apply sealant to the screw plug threads.
Sealant:
f. Using a hexagon wrench (6 mm), install and torque the screw plug.
4. REPLACE CONTROL SHAFT COVER OIL SEAL AND BUSHING

a. Using a screwdriver, pry out the oil seal.
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Fig. 62: Prying Out Oil Seal

b. Using SST and a press, press out the bushing.
SST 09950-60010 (09951-00200, 09951-00210), 09950-70010 (09951-07150)
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Fig. 63: Pressing Out Bushing

c. Using SST and a press, press in a new bushing.
SST 09950-60010 (09951-00200), 09950-70010 (09951-07150)
Depth: 0.65 +/- 0.25 mm (0.0256 +/- 0.0098 in.)
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Fig. 64: Pressing In New Bushing

d. Using SST and a plastic-faced hammer, carefully tap in a new oil seal.
SST 09950-60010 (09951-00270), 09950-70010 (09951-07150)
Depth: 0.70 +/- 0.50 mm (0.0276 +/- 0.0197 in.)
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Fig. 65: Tapping In New Oil Seal

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REASSEMBLY
Reassembly is in the reverse order of disassembly (See DISASSEMBLY ).
NOTE: When working with FIPG material, you must observe the following items.
 Using a razor blade and gasket scraper, remove all the old FIPG material
from the gasket surfaces.
 Clean both sealing surfaces with a non-residue solvent.
 Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing
surface.
 Parts must be assembled within 10 minutes of application. Otherwise, the
FIPG material must be removed and reapplied.
HINT:
 Before reassembly, select a shim by adjusting output shaft preload.

 Coat all of the sliding and rotating surfaces with gear oil before reassembly.
ADJUST OUTPUT SHAFT PRELOAD
a. Install the output shaft assembly to the transaxle case.

b. Install the transmission case to the transaxle case.
HINT:
If necessary, tap on the case with a plastic hammer.
c. Install and torque the 17 bolts.
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Fig. 66: Installing & Torquing Bolts

Torque:
d. Install the output shaft rear taper roller bearing outer race.
e. Install the adjusting shim.
HINT:
When reusing the output shaft bearing, first install a shim of the same thickness as before. If installing a
new taper roller bearing, first select and install a shim of lesser thickness than before.
f. Install the rear bearing retainer.

g. Using a torx wrench (T45), install and torque the 7 torx screws.
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h. Install a new lock nut to the output shaft.

i. Turn the output shaft right and left 2 or 3 times to allow the bearing to settle.
j. Using a torque wrench, measure the preload.
Fig. 67: Measuring Preload Using Torque Wrench

Preload (at starting):
New bearing
0.8 to 1.6 N.m (8 to 16 kgf.cm, 6.9 to 13.9 in.lbf)
Reused bearing

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If the preload is not within the specification, select an appropriate adjusting shim.
PRELOAD THICKNESS SPECIFICATION

0 1.30 (0.0512)
1 1.35 (0.0531)
2 1.40 (0.0551)
3 1.45 (0.0571)
4 1.50 (0.0591)
5 1.55 (0.0610)
6 1.60 (0.0630)
7 1.65 (0.0650)
8 1.70 (0.0669)
9 1.75 (0.0689)
A 1.80 (0.0709)
B 1.85 (0.0728)
C 1.90 (0.0748)
D 1.95 (0.0768)
E 2.00 (0.0787)
F 2.05 (0.0807)
G 2.10 (0.0827)
H 2.15 (0.0846)
J 2.20 (0.0866)
K 2.25 (0.0886)
L 2.30 (0.0906)
M 2.35 (0.0925)
N 2.40 (0.0945)
P 2.45 (0.0965)
Q 2.50 (0.0984)
k. Remove the lock nut.

l. Remove the 5 parts. Removal is in the reverse order of installation.
1. Remove the rear bearing retainer.
2. Remove the shim.
3. Remove the transmission case.
4. Remove the output shaft assembly.
5. Remove the output shaft rear bearing outer race.
INPUT SHAFT
COMPONENTS
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Fig. 68: Exploded View Of Input Shaft Components

DISASSEMBLY
1. MEASURE 3RD AND 4TH GEARS THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.
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Maximum clearance:
3rd gear: 0.35 mm (0.0138 in.)
4th gear: 0.57 mm (0.0224 in.)
2. CHECK 3RD AND 4TH GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between the gear and shaft.
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Fig. 70: Measuring Radial Clearance Between Gear & Shaft

Maximum clearance:
3rd gear: 0.053 mm (0.0021 in.)
4th gear: 0.051 mm (0.0020 in.)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
3. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.
4. REMOVE REAR BEARING AND 4TH GEAR
Using SST and a press, remove the rear bearing and 4th gear.
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SST 09950-00020
Fig. 71: Removing Rear Bearing & 4th Gear

5. REMOVE 2 NEEDLE ROLLER BEARINGS, SPACER AND SYNCHRONIZER RING

6. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.
7. REMOVE NO. 2 HUB SLEEVE ASSEMBLY, SYNCHRONIZER RING AND 3RD GEAR
Using a press, remove the No. 2 hub sleeve assembly, synchronizer ring and 3rd gear.
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Fig. 72: Removing No. 2 Hub Sleeve Assembly, Synchronizer Ring & 3rd Gear
8. REMOVE 2 NEEDLE ROLLER BEARINGS

9. DISASSEMBLY NO. 2 HUB SLEEVE ASSEMBLY
a. Remove the No. 2 hub sleeve from the No. 2 clutch hub.
b. Remove the 3 shifting keys and springs from the No. 2 clutch hub.
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Fig. 73: Removing No. 2 Hub Sleeve From No. 2 Clutch Hub
10. REMOVE INPUT SHAFT FRONT BEARING INNER RACE
Using a screwdriver and hammer, remove the input shaft front bearing inner race.
INSPECTION
1. INSPECT GEAR SYNCHRONIZER RING

b. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while
pushing it to the gear cone. Check that the ring locks.
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Fig. 74: Turning Synchronizer Ring

If the braking effect is insufficient, apply a small amount of the fine lapping compound between the
synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.
rubbing.
c. Check again the braking effect of the synchronizer ring.

d. Using a feeler gauge, measure the clearance between the synchronizer ring back and spline end.
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Fig. 75: Measuring Clearance Between Synchronizer Ring Back And Spline End
Minimum clearance:
3rd gear: 0.65 mm (0.0256 in.)
4th gear: 0.75 mm (0.0295 in.)
If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount
of the fine lapping compound on gear cone.
rubbing.
2. MEASURE NO. 2 SHIFT FORK AND HUB SLEEVE CLEARANCE
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Fig. 76: Measuring Clearance Between Hub Sleeve And Shift Fork
3. INSPECT INPUT SHAFT

a. Check the input shaft for wear or damage.
b. Using a micrometer, measure the outer diameter of the input shaft journal surface.
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2004 Toyota RAV4
Fig. 77: Measuring Outer Diameter Of Input Shaft Journal Surface

Minimum outer diameter:
Part A: 27.957 mm (1.1007 in.)
Part B: 35.984 mm (1.4167 in.)
c. Using a dial indicator, check the shaft runout.
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Fig. 78: Checking Shaft Runout

REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before reassembly.
1. INSTALL INPUT SHAFT FRONT BEARING INNER RACE
Using SST and a press, install a new input shaft front bearing inner race.
SST 09608-00071
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Fig. 79: Installing Input Shaft Front Bearing Inner Race

2. INSTALL NO. 2 CLUTCH HUB INTO NO. 2 HUB SLEEVE

a. Install the 3 springs and shifting keys to the clutch hub.
b. Install the hub sleeve to the clutch hub.
NOTE: Assembly the hub sleeve and clutch hub in the direction shown in
Fig. 80 .
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2004 Toyota RAV4
Fig. 80: Installing Springs And Shifting Keys To Clutch Hub

3. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR, SYNCHRONIZER RING AND NO. 2
HUB SLEEVE ASSEMBLY TO INPUT SHAFT
a. Apply MP grease to the needle roller bearing and install it.
b. Install the 3rd gear.
c. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
d. Using SST and a press, install the No. 2 hub sleeve assembly.
SST 09506-35010
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Fig. 81: Installing No. 2 Hub Sleeve Assembly

4. INSTALL SNAP RING

a. Select a snap ring that allows the minimum axial play.
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Fig. 82: Selecting Snap Ring

SNAP RING THICKNESS SPECIFICATION CHART

Mark Thickness mm (in.) Mark Thickness mm (in.)
H 2.30 (0.0906) M 2.50 (0.0984)
J 2.35 (0.0925) N 2.55 (0.1004)
K 2.40 (0.0945) P 2.60 (0.1024)
L 2.45 (0.0965) - -
b. Using a screwdriver and hammer, tap in the snap ring.

5. MEASURE 3RD GEAR THRUST CLEARANCE (See DISASSEMBLY )
6. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, 4TH GEAR AND
REAR BEARING
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2004 Toyota RAV4
a. Install the spacer.

b. Apply MP grease to the 2 needle roller bearings and install it.
c. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
d. Install the 4th gear.
e. Using SST and a press, install the rear bearing.
SST 09309-36010
Fig. 83: Installing Rear Bearing


a. Select a snap ring that allows the minimum axial play.
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2004 Toyota RAV4
Fig. 84: Selecting Snap Ring

SNAP RING THICKNESS SPECIFICATION CHART

1 2.35 (0.0925) 5 2.55 (0.1004)
2 2.40 (0.0945) 6 2.60 (0.1024)
3 2.45 (0.0965) 7 2.65 (0.1043)
4 2.50 (0.0984) 8 2.70 (0.1063)
b. Using a screwdriver and hammer, tap in the snap ring.

8. MEASURE 4TH GEAR THRUST CLEARANCE (See DISASSEMBLY )
OUTPUT SHAFT
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2004 Toyota RAV4
COMPONENTS
Fig. 85: Exploded View Of Output Shaft Components

DISASSEMBLY
1. MEASURE 1ST AND 2ND GEARS THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.
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2004 Toyota RAV4

Maximum clearance:
1st gear: 0.40 mm (0.0157 in.)
2nd gear: 0.35 mm (0.0138 in.)
2. CHECK 1ST AND 2ND GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between the gear and shaft.
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Fig. 87: Measuring Radial Clearance Between Gear And Shaft

Maximum clearance:
1st and 2nd gears: 0.053 mm (0.0021 in.)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
3. REMOVE OUTPUT SHAFT REAR BEARING, 4TH DRIVEN GEAR AND SPACER
a. Using a press, remove the bearing and 4th driven gear.
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Fig. 88: Removing Bearing And 4th Driven Gear

b. Remove the spacer.

4. REMOVE 3RD DRIVEN GEAR AND 2ND GEAR
Using a press, remove the 3rd driven gear and 2nd gear.
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Fig. 89: Removing 3rd Driven Gear And 2nd Gear

5. REMOVE NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RINGS

6. REMOVE INNER RACE AND BALL FROM OUTPUT SHAFT
7. REMOVE NO. 1 HUB SLEEVE ASSEMBLY AND 1ST GEAR
Using a press, remove the No. 1 hub sleeve and 1st gear.
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Fig. 90: Removing No. 1 Hub Sleeve & 1st Gear

8. REMOVE SYNCHRONIZER RINGS AND NEEDLE ROLLER BEARING

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9. REMOVE 1ST GEAR BEARING INNER RACE
Using SST and a press, remove the 1st gear bearing inner race.
SST 09950-00020
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Fig. 91: Removing 1st Gear Bearing Inner Race

10. DISASSEMBLY NO. 1 HUB SLEEVE ASSEMBLY

a. Remove the No. 1 hub sleeve from the No. 1 clutch hub.
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b. Remove the 3 shifting keys and springs from the No. 1 clutch hub.
Fig. 92: Removing Shifting Keys And Springs From No. 1 Clutch Hub
11. REMOVE OUTPUT SHAFT FRONT BEARING
Using SST, remove the output shaft front bearing.
SST 09950-00020,09950-00030
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Fig. 93: Removing Output Shaft Front Bearing

INSPECTION
1. INSPECT GEAR SYNCHRONIZER RINGS

b. Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring
locks.
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2004 Toyota RAV4
Fig. 94: Turning Synchronizer Ring

If it does not lock, replace the synchronizer ring.
c. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline
end.
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Fig. 95: Measuring Clearance Between Synchronizer Ring Back And Gear Spline End
Minimum clearance: 0.7 mm (0.028 in.)
If the clearance is less than the minimum, replace the synchronizer ring.
2. MEASURE NO. 1 SHIFT FORK AND HUB SLEEVE CLEARANCE
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Fig. 96: Measuring Clearance Between Hub Sleeve And Shift Fork
3. INSPECT OUTPUT SHAFT

a. Check the output shaft for wear or damage.
b. Using a micrometer, measure the outer diameter of the output shaft journal surface.
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Fig. 97: Measuring Outer Diameter Of Output Shaft Journal Surface

Minimum outer diameter:
Part A: 37.610 mm (1.4807 in.)
Part B: 34.502 mm (1.3583 in.)
c. Using a dial indicator, check the shaft runout.
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Fig. 98: Checking Shaft Runout

REASSEMBLY
HINT:
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2004 Toyota RAV4
1. INSTALL NO. 1 CLUTCH HUB INTO NO. 1 HUB SLEEVE

a. Install the 3 springs and shifting keys to the clutch hub.
Fig. 99: Installing Springs And Shifting Keys To Clutch Hub

b. Install the hub sleeve to the clutch hub.
NOTE: Assemble the clutch hub and hub sleeve in the direction shown in
Fig. 99 .
2. INSTALL 1ST GEAR BEARING INNER RACE
Using SST and a press, install the 1st gear bearing inner race.
SST 09506-35010
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Fig. 100: Installing 1st Gear Bearing Inner Race

HINT:
Align the hole of the output shaft and inner race.
3. INSTALL NEEDLE ROLLER BEARING, 1ST GEAR, SYNCHRONIZER RINGS AND NO. 1
HUB SLEEVE TO OUTPUT SHAFT
a. Apply MP grease to the needle roller bearing and install it.
b. Place the synchronizer rings on the 1st gear.
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Fig. 101: Placing Synchronizer Rings On 1st Gear

c. Install the 1st gear.

d. Using SST and a press, install the 1st gear and No. 1 hub sleeve.
SST 09316-60011 (09316-00041)
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Fig. 102: Installing 1st Gear And No. 1 Hub Sleeve

4. MEASURE 1ST GEAR THRUST CLEARANCE (See DISASSEMBLY )

5. INSTALL BALL AND INNER RACE TO OUTPUT SHAFT
HINT:
Align the groove of the inner race and ball.
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Fig. 103: Aligning Groove Of Inner Race And Ball

6. INSTALL SPACER, NEEDLE ROLLER BEARING, SYNCHRONIZER RINGS, 2ND GEAR

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AND 3RD DRIVEN GEAR

b. Apply MP grease to the needle roller bearing.
c. Place the synchronizer rings on the 2nd gear.
Fig. 104: Placing Synchronizer Rings On 2nd Gear

d. Install the 2nd gear.

e. Using a press, install the 3rd driven gear.
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Fig. 105: Installing 3rd Driven Gear

NOTE: Align the clutch hub grooves with the projections on the
synchronizer ring.
7. MEASURE 2ND GEAR THRUST CLEARANCE (See DISASSEMBLY )

8. INSTALL SPACER AND 4TH DRIVEN GEAR
b. Using a press, install the 4th driven gear.
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Fig. 106: Installing 4th Driven Gear

9. INSTALL OUTPUT SHAFT REAR BEARING

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Using SST and a press, install a new bearing.
SST 09506-30012
Fig. 107: Installing New Bearing

10. INSTALL OUTPUT SHAFT FRONT BEARING
Using SST and a press, install a new output shaft front bearing.
SST 09316-60011 (09316-00071)
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Fig. 108: Installing New Output Shaft Front Bearing

OIL PUMP (4WD)

COMPONENTS
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Fig. 109: Exploded View Of Oil Pump Components (4WD)

INSPECTION
1. CHECK ROTOR BODY CLEARANCE

a. Install the oil pump drive gear to the drive rotor.
b. Using a feeler gauge, measure the body clearance between the drive rotor and oil pump case.
Standard clearance:
0.10 to 0.16 mm (0.0039 to 0.0063 in.)
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Fig. 110: Measuring Body Clearance Between Drive Rotor And Oil Pump Case
2. CHECK ROTOR TIP CLEARANCE

a. Install the oil pump drive gear to the drive rotor.
b. Using a feeler gauge, measure the tip clearance between the drive and driven rotors.
Standard clearance:
0.08 to 0.15 mm (0.0031 to 0.0059 in.)
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Fig. 111: Measuring Tip Clearance Between Drive And Driven Rotors
3. CHECK SIDE CLEARANCE
Using a precision straight edge and feeler gauge, measure the side clearance of both rotors.
Standard clearance:
0.03 to 0.08 mm (0.0012 to 0.0031 in.)
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Fig. 112: Measuring Side Clearance Of Both Rotors

SHIFT AND SELECT LEVER SHAFT

COMPONENTS
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Fig. 113: Exploded View Of Shift And Select Lever Shaft Components
DIFFERENTIAL CASE (2WD)

COMPONENTS
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Fig. 114: Exploded View Of Differential Case Components (2WD)

DISASSEMBLY
1. Vehicle Speed sensor drive gear side:

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REMOVE TAPERED ROLLER BEARING FROM DIFFERENTIAL CASE
a. Using SST, remove the tapered roller bearing.
SST 09950-00020, 09950-00030,09950-40011 (09957-04010), 09950-60010 (09951-00530)
Fig. 115: Removing Tapered Roller Bearing

HINT:
Set the claw of SST to the bearing inner race securely.
b. Remove the vehicle speed sensor drive gear.

2. REMOVE RING GEAR
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a. Place matchmarks on the ring gear and differential case.

b. Remove the 16 bolts.
c. Using a copper hammer, tap on the ring gear to remove it from the differential case.
Fig. 116: Removing Bolts & Ring Gear

3. Ring gear side:
REMOVE TAPERED ROLLER BEARING FROM DIFFERENTIAL CASE
Using SST, remove the tapered roller bearing.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00450)
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2004 Toyota RAV4

HINT:
Set the claw of SST to the bearing inner race at the position where the differential case is indented.
4. INSPECT SIDE GEAR BACKLASH
Using a dial indicator, measure the backlash of one side gear while holding one pinion toward the
differential case.
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Fig. 118: Measuring Backlash Of One Side Gear While Holding One Pinion Toward Differential
Case
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)
If the backlash is not within the specification, install the correct thrust washer to the side gears.
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5. DISASSEMBLE DIFFERENTIAL CASE

a. Using a pin punch and hammer, drive out the straight pin.
b. Remove the pinion shaft from the differential case.
c. Remove the 2 pinions and side gears with the 4 thrust washers from each gear.
REPLACEMENT
1. Transmission Case Side:
REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE
a. Using a screwdriver and a hammer, remove the oil seal.

b. Using a brass bar and hammer, drive out the tapered roller bearing outer race lightly and evenly.
Fig. 119: Removing Tapered Roller Bearing Outer Race

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c. Remove the shim.

d. Install the shim.
HINT:
First select and install a shim of lesser thickness than before.
e. Using SST and a press, install a new tapered roller bearing outer race.
SST 09316-60011 (09316-00011, 09316-00041)
Fig. 120: Installing Tapered Roller Bearing Outer Race

NOTE: When replacing the tapered roller bearing outer race, replace the
tapered roller bearing along with it.
f. Using SST and a hammer, drive in a new oil seal.
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SST 09316-60010 (09316-00011, 09316-00031)
Fig. 121: Using SST And A Hammer To Drive In New Oil Seal
Drive in depth: 3.5 +/- 0.5 mm (0.138 +/- 0.020 in.)
g. Coat the lip of oil seal with MP grease.

2. Transaxle Case Side:
a. Using a screwdriver and hammer, drive out the oil seal from the transaxle case.
b. Using SST, remove the tapered roller bearing outer race.
SST 09316-60011 (09316-00011, 09316-00021)
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2004 Toyota RAV4

c. Remove the oil baffle.

d. Install the oil baffle.
HINT:
Install the oil baffle projection into the case side cutout.
SST 09950-60020 (09951-00890), 09950-70010 (09951-00150)
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2004 Toyota RAV4

SST 09316-60011 (09316-00011, 09316-00041)
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Fig. 124: Using SST And Hammer To Drive In New Oil Seal
Drive in depth: 0 +/- 0.5 mm (0 +/- 0.020 in.)
g. Coat the oil seal lip with MP grease.
REASSEMBLY
HINT:
1. ASSEMBLE DIFFERENTIAL CASE

a. Install the correct thrust washers and side gears.
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Fig. 125: Installing Correct Thrust Washers And Side Gears

Refer to THRUST WASHERS THICKNESS SPECIFICATION CHART , select thrust

washers which will ensure that the backlash is within the specification. Try to select washers of the
same size for both sides.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)
THRUST WASHERS THICKNESS SPECIFICATION CHART

Thickness mm (in.) Thickness mm (in.)
1.00 (0.0394) 1.20 (0.0472)
1.10 (0.0433) 1.30 (0.0512)
b. Install the thrust washers and side gears in the differential case.
c. Install the pinion shaft.
d. Using a dial indicator, check the side gear backlash.
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2004 Toyota RAV4

Measure the side gear backlash while holding one pinion toward the differential case.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)
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If the backlash is not within the specification, install a thrust washer of different thickness.
e. Using a pin punch and hammer, drive in the straight pin through the differential case and hole in
the pinion shaft.
f. Using a chisel and hammer, caulk the pin holes around the circumference of the differential case.
2. INSTALL RING GEAR ON DIFFERENTIAL CASE
a. Clean the contact surface of the differential case.
b. Heat the ring gear in boiling water.
c. Carefully take the ring gear out of the water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the
differential case.
HINT:
Align the matchmarks on the differential case and contact the ring gear.
e. Temporarily install the 16 set bolts.
CAUTION: The ring gear set bolts should not be tightened until the ring
gear has cooled sufficiently.
f. After the ring gear has cooled sufficiently, torque the ring gear set bolts uniformly at a time.
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Fig. 127: Installing Ring Gear On Differential Case

3. Ring gear side:
INSTALL TAPERED ROLLER BEARING
Using SST and a press, install a new tapered roller bearing.
SST 09316-60011 (09316-00011)
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Fig. 128: Installing Tapered Roller Bearing

NOTE: When replacing the tapered roller bearing outer race, replace the tapered
roller bearing along with it.
HINT:
Set SST to the bearing inner race securely.
4. Vehicle Speed sensor drive gear side:
a. Place the vehicle speed sensor drive gear in position to stop it turning and install the vehicle speed
sensor drive gear.
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Fig. 129: Placing Vehicle Speed Sensor Drive Gear In Position

NOTE: Be sure to install the vehicle speed sensor drive gear in the correct
direction, as shown in Fig. 129 .
b. Using SST, a steel plate and press, install a new tapered roller bearing.
SST 09316-20011, 09316-60011 (09316-00011)
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2004 Toyota RAV4

HINT:
Set SST to the bearing inner race securely.
5. INSPECT DIFFERENTIAL TAPERED ROLLER BEARING PRELOAD
NOTE: Perform this only when replacing the tapered roller bearing and outer race
of the differential case.
a. Install the differential case assembly to the transaxle case.
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Fig. 131: Installing Differential Case Assembly To Transaxle Case

b. Install the transmission case to the transaxle case with the 17 bolts.
c. Using SST and a torque wrench, turn the differential case assembly right and left 2 or 3 times to
allow the bearings to settle.
SST 09564-32011
d. Using SST and a torque wrench, measure the preload.
SST 09564-32011
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Fig. 132: Measuring Preload

New bearing
Reused bearing
If the preload is not within the specification, remove the transmission case side outer race of the
tapered roller bearing with SST (See DISASSEMBLY ). Select an appropriate shim.
SHIM THICKNESS SPECIFICATION CHART

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2004 Toyota RAV4
0 2.00 (0.0787) 9 2.45 (0.0965)

1 2.05 (0.0807) A 2.50 (0.0984)
2 2.10 (0.0827) B 2.55 (0.1004)
3 2.15 (0.0846) C 2.60 (0.1024)
4 2.20 (0.0866) D 2.65 (0.1043)
5 2.25 (0.0886) E 2.70 (0.1063)
6 2.30 (0.0906) F 2.75 (0.1083)
7 2.35 (0.0925) G 2.80 (0.1102)
8 2.40 (0.0945) H 2.85 (0.1122)
e. Remove the 17 bolts and transmission case.

f. Remove the differential case assembly.
DIFFERENTIAL CASE (4WD)

COMPONENTS
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Fig. 133: Exploded View Of Differential Case Components (4WD)

DISASSEMBLY
1. REMOVE NO.2 DIFFERENTIAL CASE

b. Remove the No. 2 differential case upward.
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2. REMOVE DIFFERENTIAL RING GEAR

a. Place matchmarks on both the differential case and ring gear.
Fig. 134: Placing Matchmarks On Both Differential Case And Ring Gear
b. Using a plastic hammer, tap out the ring gear.
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Fig. 135: Using Plastic Hammer To Tap Out Ring Gear

3. REMOVE NO.2 DIFFERENTIAL SIDE GEAR THRUST WASHER AND CONICAL SPRING
WASHER
4. REMOVE FRONT DIFFERENTIAL CASE ASSEMBLY
5. DISASSEMBLE FRONT DIFFERENTIAL CASE
a. Remove the front differential side gear together with the thrust washer from the front differential
case.
b. Remove the front differential side gear thrust washer from the side gear.
c. Using a snap ring expander, remove the snap ring and spacer.
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Fig. 136: Removing Snap Ring And Spacer

HINT:
Before removing the shaft snap ring, wrap vinyl tape around the case to prevent from damage.
d. Remove the parts from the front differential case.

1. Remove the 2 front differential pinion shafts.
2. Remove the No. 2 front differential pinion shaft.
3. Remove the front differential pinion shaft holder.
4. Remove the 4 differential pinions.
5. Remove the 4 differential pinion thrust washers.
6. Remove the front differential side gear.
7. Remove the front differential side gear thrust washer.
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Fig. 137: Exploded View Of Front Differential Case

6. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR

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a. Using a snap ring expander, remove the snap ring.

b. Remove the spacer and vehicle speed sensor drive gear.
7. DISASSEMBLE NO. 1 DIFFERENTIAL CASE
Remove the parts from the No. 1 differential case.
1. Remove the 4 differential pinion shafts.

2. Remove the pinion shaft holder.
3. Remove the 4 differential pinions.
4. Remove the 4 differential pinion thrust washers.
5. Remove the differential side gear subassembly.
6. Remove the conical spring washer.
7. Remove the No. 2 differential side gear thrust washer.
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2004 Toyota RAV4
Fig. 138: Exploded View Of No. 1 Differential Case

8. No. 2 Differential Case Side:
REMOVE TAPERED ROLLER BEARING
SST 09950-00020, 09950-00030, 09950-60010 (09951-00520)

REMOVE TAPERED ROLLER BEARING
SST 09950-00020, 09950-00030, 09950-60010 (09951-00450)
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2004 Toyota RAV4

INSPECTION
1. MEASURE NO.1 AND NO.2 DIFFERENTIAL CASES
Using a cylinder gauge, measure the inner diameter of the No. 1 and No. 2 differential cases bushing.
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Fig. 141: Measuring Inner Diameter Of Differential Cases Bushing

Standard diameter:
A: 104.000 to 104.035 mm (4.0945 to 4.0959 in.)
B: 97.000 to 97.035 mm (3.8189 to 3.8203 in.)
Maximum diameter:
A: 104.060 mm (4.0969 in.)
B: 97.060 mm (3.8213 in.)
2. MEASURE FRONT DIFFERENTIAL CASE
Using a micrometer, measure the outer diameter of the front differential case.
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Fig. 142: Measuring Outer Diameter Of Front Differential Case

Standard diameter:
A: 103.929 to 103.964 mm (4.0917 to 4.0931 in.)
B: 96.929 to 96.964 mm (3.8161 to 3.8175 in.)
Minimum diameter:
A: 103.850 mm (4.0887 in.)
B: 96.850 mm (3.8130 in.)

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3. MEASURE CONICAL SPRING WASHER
Using calipers, measure the height of the conical spring washer.
Fig. 143: Measuring Height Of Conical Spring Washer

Standard height:
No. 2 differential case side
2.60 to 2.80 mm (0.102 to 0.110 in.)
1.55 to 1.75 mm (0.061 to 0.069 in.)
Minimum height:

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2.50 mm (0.098 in.)
1.60 mm (0.063 in.)
REPLACEMENT
1. Transmission Case Side:
a. Using a screwdriver and a hammer, remove the oil seal.

b. Using a brass bar and hammer, drive out the tapered roller bearing outer race lightly and evenly.
Fig. 144: Using Brass Bar And Hammer To Drive Out Tapered Roller Bearing Outer Race
c. Remove the shim.

d. Install the shim.
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HINT:
First select and install a shim of lesser thickness than before.
SST 09316-60011 (09316-00011, 09316-00041)

SST 09316-60010 (09316-00011, 09316-00031)
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Drive in depth: 0 +/- 0.5 mm (0 +/- 0.020 in.)
g. Coat the lip of oil seal with MP grease.

2. Transaxle Case Side:
a. Using a screwdriver and hammer, drive out the oil seal from the transaxle case.
b. Using SST, remove the tapered roller bearing outer race.
SST 09316-60011 (09316-00011, 09316-00021)
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c. Remove the oil baffle.

d. Install the oil baffle.
HINT:
Install the oil baffle projection into the case side cutout.
e. Using SST and a press, install the tapered roller bearing outer race.
SST 09316-60011 (09316-00011, 09316-00041).
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SST 09316-60011 (09316-00011, 09316-00041)
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Drive in depth: 6.9 +/- 0.5 mm (0.272 +/- 0.020 in.)
g. Coat the oil seal lip with MP grease.
REASSEMBLY
HINT:

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2004 Toyota RAV4
Using SST, install a new tapered roller bearing.
SST 09316-20011

Using SST, install a new tapered roller bearing.
SST 09316-20011
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2004 Toyota RAV4

3. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE GEAR BACKLASH (DIFFERENTIAL

SIDE GEAR SUB-ASSEMBLY SIDE)
a. Install the parts to the No. 1 differential case.
1. Install the No. 2 differential side gear thrust washer.
2. Temporarily install a 1.0 mm (0.039 in.) thick thrust washer.
3. Install the differential side gear subassembly.
4. Install the pinion shaft holder.
5. Install the 4 differential pinions.
6. Install the 4 differential pinion thrust washers.
7. Install the 4 differential pinion shafts.
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Fig. 152: Installing Parts Of No. 1 Differential Case

b. Using a dial indicator, measure the backlash of one pinion gear while holding the differential side
gear sub assembly toward the case.
Fig. 153: Measuring Backlash Of One Pinion Gear

Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)
HINT:
Push the pinion gear of the right side of the differential case.
If the backlash is out of the specification, refer to THRUST WASHER THICKNESS

SPECIFICATION CHART and select a thrust washer which will ensure that the backlash is
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2004 Toyota RAV4
within the specification.
Thrust washer thickness: mm (in.)
THRUST WASHER THICKNESS SPECIFICATION CHART

MA 0.80 (0.0315) MH 1.15 (0.0453)
MB 0.85 (0.0335) MI 1.20 (0.0472)
MC 0.90 (0.0354) MJ 1.25 (0.0492)
MD 0.95 (0.0374) MK 1.30 (0.0512)
ME 1.00 (0.0394) ML 1.35 (0.0531)
MF 1.05 (0.0413) MN 1.40 (0.0551)
MG 1.10 (0.0433) - -
c. Disassemble the No. 1 differential case.

4. ASSEMBLE NO. 1 DIFFERENTIAL CASE
Install the parts to the No. 1 differential case.
1. Install the No. 2 side gear thrust washer (previously selected).

2. Install the conical spring washer.
3. Install the differential side gear subassembly.
4. Install the pinion shaft holder.
7. Install the 4 differential pinion shafts.
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Microsoft
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HINT:
Ensure that the conical spring washer is installed correctly.
5. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR

a. Install the vehicle speed sensor drive gear and spacer.
b. Using a snap ring expander, install the snap ring.

6. CHECK AND ADJUST FRONT SIDE GEAR BACKLASH (FRONT DIFFERENTIAL CASE
SIDE)
a. Install the parts to the front differential case.
1. Install the front differential side gear thrust washer.
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2. Install the front differential side gear.

3. Install the front differential pinion shaft holder.
6. Install the No. 2 front differential pinion shaft.
7. Install the 2 front differential pinion shafts.
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Fig. 156: Installing Parts Of Front Differential Case

b. Using a dial indicator, measure the backlash of one pinion gear while holding the front differential
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side gear toward the case.
Fig. 157: Measuring Backlash Of One Pinion Gear

Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)
NOTE: Do not mount the surface of front differential case which contacts
with bushing in a vise.
If the backlash is out of the specification, refer to THRUST WASHER THICKNESS

SPECIFICATION CHART and select a thrust washer which will ensure that the backlash is
within the specification.
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B 1.00 (0.0394)
C 1.05 (0.0413)
D 1.10 (0.0433)
E 1.15 (0.0453)
F 1.20 (0.0472)
G 1.25 (0.0492)
7. CHECK AND ADJUST FRONT DIFFERENTIAL SIDE GEAR THRUST CLEARANCE (NO. 2
DIFFERENTIAL CASE SIDE)
a. Engage the side gear to the above mentioned front differential case.
b. Install the differential case LH to the front differential case and measure its center.
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Fig. 158: Installing Differential Case LH To Front Differential Case

c. After that, remove the differential case LH.

d. Using a straight edge and feeler gauge, measure the clearance between the front differential case
and the side gear.
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Fig. 159: Measuring Clearance Between Front Differential Case And Side Gear
t= Thrust washer thickness
L= Clearance
t= L - 0.16 to 0.27 mm (0.0063 to 0.0106 in.)
HINT:
Refer to THRUST WASHER THICKNESS SPECIFICATION CHART and select a thrust

washer which will ensure that the clearance is within the specification.

Mark Thickness Mark Thickness.
A 0.95 (0.0373) F 1.20 (0.0472)
B 1.00 (0.0393) G 1.25 (0.0492)
C 1.05 (0.0413) H 1.30 (0.0512)
D 1.10 (0.0433) J 1.35 (0.0532)
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E 1.15 (0.0453) K 1.40 (0.0552)
If the clearance is not within the specified value, parts may have been assembled incorrectly, so
check and reassemble it.

b. Using a snap ring expander, install the shaft snap ring, as shown in Fig. 160 .
Fig. 160: Installing Shaft Snap Ring

HINT:
Before installing the shaft snap ring, wrap vinyl tape around the case to avoid damaging the case.
9. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE GEAR THRUST CLEARANCE

(FRONT DIFFERENTIAL CASE SIDE)
a. Install the parts to the No. 2 differential case.
1. Install the front differential case assembly.
2. Install the front differential side gear.
3. Install the front differential side gear thrust washer.
4. Temporarily install a 1.0 mm (0.039 in.) thick No. 2 differential side gear thrust washer.
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5. Install the No. 2 differential side gear thrust washer.
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Microsoft
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HINT:
Engage the front differential side gear and pinion gear of the No. 1 differential case.
 The temporarily installed a 1.0 mm (0.039 in.) thick No. 2 side gear thrust washer is
used for reference when checking backlash.
b. Clean the contact surface of the No. 2 side gear thrust washer and No. 2 differential case.
c. Apply plastigage on the No. 2 side gear thrust washer, as shown in Fig. 162 .
HINT:
Apply the plastigage on the No. 2 side gear thrust washer in the 4 positions directly above the
pinion shafts in the No. 1 differential case's position.
Fig. 162: Applying Plastigage On No. 2 Side Gear Thrust Washer

d. Install the ring gear.
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1. Clean the contact surface of the differential left case.

2. Heat the ring gear to about 100°C (212°F) in boiling water.
3. Carefully take the ring gear out of the water.
4. Clean the contact surface of the ring gear with cleaning solvent.
5. Quickly install the ring gear on the differential case.
Fig. 163: Installing Ring Gear

HINT:
Align the matchmarks on the No. 2 differential case and connect the ring gear.
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Fig. 164: Aligning Matchmarks On No. 2 Differential Case

e. Install the No. 2 differential case downward.
HINT:
Align the matchmarks on the No. 1 differential case and contact the No. 2 differential case.
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Fig. 165: Aligning Matchmarks On No. 1 Differential Case And Contact No. 2 Differential
Case
f. Temporarily install the 4 service bolts.
Parts No:
Service bolt: 90105-08055
g. Remove the 4 service bolts and No. 2 differential case upward.

h. Measure the Plastigage at its widest point.
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Fig. 166: Measuring Plastigage

Standard clearance: 0.16 to 0.25 mm (0.006 to 0.010 in.)
Refer to THRUST WASHER THICKNESS SPECIFICATION CHART , select the No. 2 thrust
washer which will ensure that the backlash is within the specification. Try to select a washer of the
same size.

0 0.80 (0.0315) 7 1.15 (0.0453)
1 0.85 (0.0335) 8 1.20 (0.0472)
2 0.90 (0.0354) 9 1.25 (0.0492)
3 0.95 (0.0374) A 1.30 (0.0512)
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4 1.00 (0.0394) B 1.35 (0.0531)

5 1.05 (0.0413) C 1.40 (0.0551)
6 1.10 (0.0433) - -
i. Remove the No. 2 differential case, No. 2 side gear thrust washer and (temporarily install) a 1.0
mm (0.039 in.) thick No. 2 side gear thrust washer.
10. ASSEMBLE NO.2 DIFFERENTIAL CASE
a. Install the No. 2 side gear thrust washer (previously selected) and conical spring washer to the front
differential case.
Fig. 167: Installing No. 2 Side Gear Thrust Washer And Conical Spring Washer To Front
Differential Case
HINT:
Be careful not to mistake the direction of the conical spring washer.
b. Install the No. 2 differential case to the No. 1 differential case.

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HINT:
Align the matchmarks on the No. 2 differential case and connect the No. 1 differential case.
Fig. 168: Aligning Matchmarks On No. 2 Differential Case And Connect No. 1 Differential
Case
c. Temporarily install the 4 service bolts.
Parts No:
Service bolt: 90105-08055
11. ADJUST DIFFERENTIAL CASE SIDE BEARING PRELOAD

a. Install the differential case assembly to the transaxle case.
b. Install the transmission case.
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HINT:
If necessary, tap on the transmission case with a plastic hammer.
c. Install and torque the 17 bolts.
Torque:
Fig. 169: Installing & Torquing Bolts

d. Temporarily install the intermediate shaft.

e. Turn the intermediate shaft right and left 2 or 3 times to allow the bearing settle.
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Fig. 170: Turning Intermediate Shaft

f. Remove the intermediate shaft.

g. Using SST and a torque wrench, measure the differential preload.
SST 09564-32011
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Fig. 171: Measuring Differential Preload

Preload (at starting)
New bearing:
0.8 to 1.6 N.m (8.0 to 16.3 kgf.cm, 7.1 to 14.2 in.lbf)

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Reused bearing:
0.5 to 1.0 N.m (5.1 to 10.2 kgf.cm, 4.4 to 8.6 in.lbf)
If the preload is not within the specification, select an appropriate adjusting shim.
HINT:
The total preload will change about 5.1 N (0.5 kgf, 1.1 lbf) for every 0.05 mm change in adjusting
shim thickness.

0 2.00 (0.0787) 9 2.45 (0.0965)
1 2.05 (0.0807) A 2.50 (0.0984)
2 2.10 (0.0827) B 2.55 (0.1004)
3 2.15 (0.0846) C 2.60 (0.1024)
4 2.20 (0.0866) D 2.65 (0.1043)
5 2.25 (0.0886) E 2.70 (0.1063)
6 2.30 (0.0906) F 2.75 (0.1083)
7 2.35 (0.0925) G 2.80 (0.1102)
8 2.40 (0.0945) H 2.85 (0.1122)
h. Remove the 17 bolts, tap the transmission case with a plastic hammer and remove it.
i. Remove the differential case assembly.
SHIFT LEVER AND CONTROL CABLE

COMPONENTS
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Fig. 172: Exploded View Of Shift Lever And Control Cable (1 Of 2)

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Fig. 173: Exploded View Of Shift Lever And Control Cable (2 Of 2)

REMOVAL
1. DISCONNECT CONTROL CABLES FROM TRANSAXLE

b. Remove the 2 clips and disconnect the 2 control cables.
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Fig. 174: Removing Clips & Washers & Disconnecting Control Cables From Transaxle
2. REMOVE SHIFT AND SELECT CONTROL CABLES

a. Remove the front console box (See REMOVAL ).
b. Remove the No. 1 and No. 2 instrument panel under cover (See REMOVAL ).
c. Remove the 6 bolts and the shift lever and control cables assembly.
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Fig. 175: Removing Bolts, Shift Lever And Control Cables Assembly
Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) for bolt A
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf) for bolt B
d. Remove the shift and select control cables from the shift lever assembly.
INSTALLATION
NOTE: When installing the 2 control cables, you must observe the following items.
 When handling the cable, do not bend the cable less than R130°.
 Pay thorough attention not to damage the boots.
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 When installing, do not apply force but install it gently.

 After finishing the installation, check the cable for twist. If there is any
irregularity, adjust it.
 Never reuse the board-type clip to fix the control cable.
TRANSFER (4WD)
ON-VEHICLE REPAIR
REPLACE TRANSFER OIL

HINT:
Use a container to catch the transfer oil.

e. Refill new transfer oil as shown in Fig. 176 .
Oil grade: API GL-5
Viscosity: SAE 90
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Fig. 176: Refilling New Transfer Oil & Reinstalling Filler Plug
COMPONENTS
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Fig. 177: Exploded View Of Transfer Components (4WD)

DISASSEMBLY
1. REMOVE GASKET
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Fig. 178: Removing Gasket

2. REMOVE NO.2 INTERMEDIATE DIFFERENTIAL SIDE GEAR
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Fig. 179: Removing No. 2 Intermediate Differential Side Gear

3. REMOVE NO.1 CASE COVER

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Fig. 180: Removing Bolts Of No. 1 Case Cover

b. Using a brass bar and hammer, remove the No. 1 case cover.
NOTE: Be careful not to damage the transfer case and case cover No. 1.
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Fig. 181: Removing No. 1 Case Cover

c. Remove the bolt and breather oil deflector from the case cover No. 1.
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Fig. 182: Removing Bolt & Breather Oil Deflector From Case Cover No. 1
4. REMOVE PIN
5. REMOVE STUD BOLT
6. INSTALL TRANSFER ON OVERHAUL ATTACHMENT
7. REMOVE EXTENSION HOUSING
a. Using a plastic hammer, remove the dust deflector from the extension housing.
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Fig. 183: Removing Dust Deflector From Extension Housing

b. Using SST, remove the oil seal from the extension housing.
SST 09308-00010
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Fig. 184: Removing Oil Seal From Extension Housing

NOTE: Be careful not to damage the extension housing.
c. Remove the 4 bolts.
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Fig. 185: Removing Bolts

d. Using a plastic hammer, remove the extension housing.
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Fig. 186: Removing Extension Housing

8. CHECK PRELOAD
a. Using SST and a torque wrench, measure the driven pinion preload of the backlash between the
driven pinion and ring gear.
SST 09326-20011
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Fig. 187: Measuring Driven Pinion Preload Of Backlash Between Driven Pinion And Ring
Gear
0.9 to 1.3 N.m (9 to 13 kgf.cm, 7.8 to 12 in.lbf)
HINT:
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Using a torque wrench with a fulcrum length of 160 mm (6.3 in.).

 This torque value is effective in case that SST is parallel to a torque wrench.
b. Using SST and the torque wrench, measure the total preload.
SST 09326-20011
Total preload (at starting):
1.0 to 1.6 N.m (10 to 16 kgf.cm, 8.9 to 14 in.lbf)
HINT:
Using a torque wrench with a fulcrum length of 160 mm (6.3 in.).


 This torque value is effective in case that SST is parallel to a torque wrench.
9. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash.
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Fig. 188: Measuring Ring Gear Backlash

Backlash: 0.10 to 0.15 mm
10. CHECK TOOTH CONTACT
(See REASSEMBLY )
11. REMOVE CENTER DIFFERENTIAL LOCK SLEEVE

a. Using a snap ring pliers, remove the shaft snap ring.
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Fig. 189: Removing Shaft Snap Ring

b. Using SST, remove the center differential lock sleeve.
SST 09308-00010
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Fig. 190: Removing Center Differential Lock Sleeve

NOTE: Be careful not to damage the center differential lock sleeve.
c. Using a screwdriver, remove the O-ring from the center differential lock sleeve.
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Fig. 191: Removing O-Ring From Center Differential Lock Sleeve

NOTE: Be careful not to damage the center differential lock sleeve.
12. REMOVE OIL SEAL
Using SST, remove the oil seal from the transfer case.
SST 09308-00010
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Fig. 192: Removing Oil Seal From Transfer Case

NOTE: Be careful not to damage the transfer case.
13. REMOVE BEARING RETAINER RH

a. Using SST, remove the oil seal from the bearing retainer RH.
SST 09308-00010
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Fig. 193: Removing Oil Seal From Bearing Retainer RH

NOTE: Be careful not to damage the bearing retainer.
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Fig. 194: Removing Bolts

c. Using a screwdriver and a hammer, make clearance by hitting between the bearing retainer RH and
the transfer case.
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Fig. 195: Using Screwdriver And Hammer To Make Clearance By Hitting Between Bearing
Retainer RH And Transfer Case
d. Using SST, remove the bearing retainer RH from the transfer case.
SST 09520-10021
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Fig. 196: Removing Bearing Retainer RH From Transfer Case

e. Using a screwdriver, remove 2 O-rings from the bearing retainer RH.
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Fig. 197: Removing O-Rings From Bearing Retainer RH

NOTE: Be careful not to damage the bearing retainer RH.
f. Using soft jaws, hold the bearing retainer RH in a vise.

g. Using SST, remove the outer race, washer and oil seal from the bearing retainer RH.
SST 09308-00010
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Fig. 198: Removing Outer Race, Washer & Oil Seal From Bearing Retainer RH
NOTE: Be careful not to damage the bearing retainer RH.
h. Using snap ring pliers, remove the snap ring.
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Fig. 199: Removing Snap Ring

i. Remove the side gear shaft holder bearing from the bearing retainer RH.
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14. REMOVE CENTER DIFFERENTIAL CONTROL COUPLING ASSEMBLY
Fig. 200: Removing Center Differential Control Coupling Assembly

15. REMOVE TAPERED ROLLER BEARING LH AND RH
Using SST, remove the tapered roller bearing inner race LH and RH.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00360)
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Fig. 201: Removing Tapered Roller Bearing Inner Race LH And RH

16. CHECK RING GEAR RUNOUT
Using a dial indicator, check the ring gear runout.
Fig. 202: Checking Ring Gear Runout

17. REMOVE RING GEAR

a. Place matchmarks on both the ring gear and the center differential control coupling.
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Fig. 203: Placing Matchmarks On Both Ring Gear And Center Differential Control Coupling

c. Using a plastic hammer, remove the ring gear.
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Fig. 204: Removing Ring Gear

18. CHECK CENTER DIFFERENTIAL CONTROL COUPLING RUNOUT
Using a dial indicator, check the center differential control coupling runout.
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Fig. 205: Checking Center Differential Control Coupling Runout

19. REMOVE DRIVEN PINION

a. Using SST and a hammer, unstake the lock nut.
SST 09930-00010 (09931-00010, 09931-00020)
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Fig. 206: Using SST And Hammer To Unstake Lock Nut

b. Using SST, remove the lock nut.
SST 09326-20011, 09556-16030
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Fig. 207: Removing Lock Nut

c. Using a press, remove the driven pinion, the rear bearing inner race and the spacer.
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Fig. 208: Removing Driven Pinion, Rear Bearing Inner Race & Spacer
NOTE:  Place a waste cloth inside the case to prevent the driven pinion
from dropping.
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 Keep the case level using a wood plate.
d. Using SST and a press, remove the front bearing inner race from the driven pinion.
SST 09950-00020
Fig. 209: Removing Front Bearing Inner Race From Driven Pinion
20. REMOVE BEARING OUTER RACE LH
Using a brass bar and a hammer, remove the outer race and the washer.
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Fig. 210: Removing Bearing Outer Race LH And Washer

21. REMOVE FRONT BEARING OUTER RACE
Using a brass bar and a hammer, remove outer race and washer.
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Fig. 211: Removing Front Bearing Outer Race And Washer

22. REMOVE REAR BEARING OUTER RACE
Using a brass bar and a hammer, remove outer race.
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Fig. 212: Removing Rear Bearing Outer Race

REASSEMBLY
1. INSTALL REAR BEARING OUTER RACE
Using SST and a press, install the outer race.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
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Fig. 213: Installing Rear Bearing Outer Race

2. INSTALL FRONT BEARING OUTER RACE

a. Install the washer to the transfer case.
HINT:
First install a washer of the same thickness as before.
b. Using SST, bolt and nut, install outer race to the transfer case.
SST 09950-60010 (09951-00610, 09951-00620), 09950-60020 (09951-00790, 09951-00810)
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Fig. 214: Installing Front Bearing Outer Race To Transfer Case

3. INSTALL BEARING OUTER RACE LH

a. Install the washer to the transfer case.
HINT:
First install a washer of the same thickness as before.
b. Using SST and a press, install outer race to the transfer case.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07200)
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Fig. 215: Installing Bearing Outer Race LH To Transfer Case

4. INSTALL DRIVEN PINION

a. Using SST and a press, install the front bearing inner race to the driven pinion.
SST 09316-60011 (09316-00041)
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Fig. 216: Installing Front Bearing Inner Race To Driven Pinion

b. Install the driven pinion to the transfer case.
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Fig. 217: Installing Driven Pinion To Transfer Case

c. Install the new spacer and the rear bearing inner race to the driven pinion.
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Fig. 218: Installing Spacer And Rear Bearing Inner Race To Driven Pinion
d. Coat gear oil (LSD type) to the thread of a new lock nut.
e. Using SST, install the lock nut.
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SST 09326-20011, 09556-16030
Fig. 219: Installing Lock Nut

Torque:
308 N.m (3,142 kgf.cm, 227 ft.lbf) for use with SST
349 N.m (3,560 kgf.cm, 257 ft.lbf)
HINT:
 Using a torque wrench with a fulcrum length of 380 mm (15.03 in.).

 This torque value is effective in case the SST is parallel to torque wrench.
NOTE: Do not tighten the nut until the final adjustment of the preload,
tooth contact and backlash is completed.
5. CHECK DRIVEN PINION PRELOAD

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Using SST and a torque wrench, measure the driven pinion preload.
SST 09326-2001
Fig. 220: Measuring Driven Pinion Preload

New bearing:
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Reused bearing:
HINT:


 This torque value is effective in case that SST is parallel to torque wrench.
 If the preload is not sufficient, adjust the driven pinion by tightening the lock nut by 5° to 10° and
measuring the preload until the preload is within the standard value.
 If the preload is more than the standard value, replace the spacer with a new one.
 If the tightening torque for a driven pinion nut is more than the standard value, and the preload is
not sufficient, loosen the lock nut, apply gear oil on the thread and bearing surface and adjust it as
described above. When the tightening torque is less than the standard value, replace the spacer with
a new one.
6. ASSEMBLE CENTER DIFFERENTIAL CONTROL COUPLING
a. Clean the contact surface of the ring gear and center differential control coupling.
b. Heat the ring gear in water and boil for 10 minutes.
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Fig. 221: Heating Ring Gear In Boiling Water

c. Carefully remove the ring gear from the water.

center differential control coupling.
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Fig. 222: Installing Ring Gear To Center Differential Control Coupling

e. Install the 12 bolts.
f. Using SST and a press, install the center differential case tapered roller bearing inner race LH and
RH.
SST 09223-00010, 09506-35010, 09950-60010 (09951-00420)
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Fig. 223: Installing Center Differential Case Tapered Roller Bearing Inner Race LH And RH
7. INSTALL CENTER DIFFERENTIAL CONTROL COUPLING ASSEMBLY
Fig. 224: Installing Center Differential Control Coupling Assembly

8. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING OUTER RACE

RH
a. Install the washer to the bearing retainer RH.
b. Using SST and a press, install the outer race to the bearing retainer RH.
SST 09550-60010 (09951-00620), 09950-70010 (09951-07150)
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Fig. 225: Installing Outer Race To Bearing Retainer RH

9. INSTALL BEARING RETAINER RH

a. Place the transfer with the installation surface for the retainer upward.
b. Do centering of the center differential control coupling assembly and the case.
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Fig. 226: Centering Center Differential Control Coupling Assembly & Case
c. Insert the SST into the retainer.
SST 09387-00090
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Fig. 227: Inserting SST Into Retainer

NOTE: Insert the SST straight down without making its tip interfered the lip
of the oil seal.
d. Insert the retainer and the SST into the case together as a unit.
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Fig. 228: Inserting Retainer And SST Into Case Together As Unit
NOTE:  Do not make the transfer case, bearing retainer RH and SST
interfere with the center differential control coupling.
 Do not damage the retainer O-ring only after adjusting the
backlash, tooth contact and total pre-loading.
HINT:
When the retainer cannot be inserted in the case, give a slight blow with a plastic hammer and
insert it.
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e. After inserting the retainer in the case, remove the SST.
Fig. 229: Removing SST

f. Install the 7 bolts.
10. INSPECT BACKLASH
Using a dial indicator, measure the backlash of the ring gear at 3 positions at least.
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Fig. 230: Measuring Backlash Of Ring Gear

Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 in.)
HINT:
The measure values should be used as reference when selecting washer, so take a note of the values.
If the backlash is not within the specification replace the washer on the ring gear side with one of a
different thickness using the following procedure.
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Fig. 231: Identifying Washer For Backlash Adjusting

Washer thickness: mm (in.)
WASHER THICKNESS SPECIFICATION CHART

Mark Thickness Mark Thickness
AA 2.07 (0.0815) FB 2.55 (0.1004)
AB 2.10 (0.0827) FC 2.58 (0.1016)
AC 2.13 (0.0839) GA 2.61 (0.1028)
BA 2.16 (0.0850) GB 2.64 (0.1039)
BB 2.19 (0.0862) GC 2.67 (0.1051)
BC 2.22 (0.0874) HA 2.70 (0.1063)
CA 2.25 (0.0886) HB 2.73 (0.1075)
CB 2.28 (0.0898) HC 2.76 (0.1087)
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CD 2.31 (0.0909) JA 2.79 (0.1098)

DA 2.34 (0.0921) JB 2.82 (0.1110)
DB 2.37 (0.0933) JC 2.85 (0.1122)
DC 2.40 (0.0945) KA 2.88 (0.1134)
EA 2.43 (0.0957) KB 2.91 (0.1146)
EB 2.46 (0.0969) KC 2.94 (0.1157)
EC 2.49 (0.0980) LA 2.97 (0.1169)
FA 2.52 (0.0992) LB 3.00 (0.1181)
11. INSPECT TOOTH CONTACT PATTERN

a. Coat 3 or 4 teeth at the 4 different positions on the ring gear with red lead.
Fig. 232: Coating Teeth On Ring Gear With Red Lead

b. Rotate the ring gear, inspect the teeth pattern.
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2004 Toyota RAV4
Fig. 233: Inspecting Teeth Pattern

c. If the teeth are not contacting properly, select the proper washer again.
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2004 Toyota RAV4
Fig. 234: Identifying Washer Tooth Contact Adjusting


AA 1.20 (0.0472) HC 1.43 (0.0563)
AB 1.21 (0.0476) JA 1.44 (0.0567)
AC 1.22 (0.0480) JB 1.45 (0.0571)
BA 1.23 (0.0484) JC 1.46 (0.0575)
BB 1.24 (0.0488) KA 1.47 (0.0579)
BC 1.25 (0.0492) KB 1.48 (0.0583)
CA 1.26 (0.0496) KC 1.49 (0.0587)
CB 1.27 (0.0500) LA 1.50 (0.0591)
CC 1.28 (0.0504) LB 1.51 (0.0594)
DA 1.29 (0.0508) LC 1.52 (0.0598)
DB 1.30 (0.0512) MA 1.53 (0.0602)
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2004 Toyota RAV4
DC 1.31 (0.0516) MB 1.54 (0.0606)

EA 1.32 (0.0520) MC 1.55 (0.0610)
EB 1.33 (0.0524) NA 1.56 (0.0614)
EC 1.34 (0.0528) NB 1.57 (0.0618)
FA 1.35 (0.0531) NC 1.58 (0.0622)
FB 1.36 (0.0535) PA 1.59 (0.0626)
FC 1.37 (0.0539) PB 1.60 (0.0630)
GA 1.38 (0.0543) PC 1.61 (0.0634)
GB 1.39 (0.0547) QA 1.62 (0.0638)
GC 1.40 (0.0551) QB 1.63 (0.0642)
HA 1.41 (0.0555) QC 1.64 (0.0646)
HB 1.42 (0.0559) RA 1.65 (0.0650)
12. ADJUST TOTAL PRELOAD
Using SST and a torque wrench, measure the total preload.
SST 09326-20011
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2004 Toyota RAV4

Total preload:
New bearing:
Driven pinion preload + 0.2 to 0.4 N.m (2 to 4 kgf.cm, 1.8 to 3.5 in.lbf)
Reused bearing:
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2004 Toyota RAV4
Driven pinion preload + 0.1 to 0.3 N.m (1 to 3 kgf.cm, 0.9 to 2.6 in.lbf)
HINT:
HINT:
Turn the driven pinion counterclockwise and clockwise several times.
If the preload is not as specified, select a proper washer again.
Fig. 236: Identifying Washer Preload Adjusting

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2004 Toyota RAV4

AA 1.47 (0.0579) GB 2.04 (0.0803)
AB 1.50 (0.0591) GC 2.07 (0.0815)
AC 1.53 (0.0602) HA 2.10 (0.0827)
BA 1.56 (0.0614) HB 2.13 (0.0839)
BB 1.59 (0.0626) HC 2.16 (0.0850)
BC 1.62 (0.0638) JA 2.19 (0.0862)
CA 1.65 (0.0650) JB 2.22 (0.0874)
CB 1.68 (0.0661) JC 2.25 (0.0886)
CC 1.71 (0.0673) KA 2.28 (0.0898)
DA 1.74 (0.0685) KB 2.31 (0.0909)
DB 1.77 (0.0697) KC 2.34 (0.0921)
DC 1.80 (0.0709) LA 2.37 (0.0933)
EA 1.83 (0.0720) LB 2.40 (0.0945)
EB 1.86 (0.0734) LC 2.43 (0.0957)
EC 1.89 (0.0744) MA 2.46 (0.0969)
FA 1.92 (0.0756) MB 2.49 (0.0980)
FB 1.95 (0.0768) MC 2.52 (0.0992)
FC 1.98 (0.0780) NA 2.55 (0.1004)
GA 2.01 (0.0791) NB 2.58 (0.1016)
13. REMOVE BEARING RETAINER RH

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2004 Toyota RAV4
Fig. 237: Removing Bolts Of Bearing Retainer RH

b. Using a screwdriver and a hammer, make clearance by hitting between the bearing retainer RH and
the transfer case.
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2004 Toyota RAV4
Fig. 238: Using Screwdriver And Hammer To Make Clearance By Hitting Between Bearing
Retainer RH And Transfer Case
c. Using SST, remove the bearing retainer RH from the transfer case.
SST 09520-10021
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Fig. 239: Removing Bearing Retainer RH From Transfer Case

d. Using SST, remove the outer race and washer from the bearing retainer RH.
SST 09308-00010
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Fig. 240: Removing Outer Race And Washer From Bearing Retainer RH
14. ASSEMBLE BEARING RETAINER RH

a. Install the side gear shaft holder bearing to the bearing retainer RH.
b. Using snap ring pliers, install the snap ring.
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2004 Toyota RAV4

c. Coat the oil seal lip with MP grease.

d. Using SST and a press, install the oil seal to the bearing retainer RH.
SST 09950-60010 (09951-00370, 09951-00540, 09952-06010), 09950-70010 (09951-07150)
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Fig. 242: Installing Oil Seal To Bearing Retainer RH

e. Install the washer.

f. Using SST and a press, install the outer race to the bearing retainer RH
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
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Fig. 243: Installing Outer Race To Bearing Retainer RH

g. Coat new 2 O-rings with gear oil, and install them to the bearing retainer RH.
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Fig. 244: Installing O-Rings To Bearing Retainer RH

15. INSTALL BEARING RETAINER RH

a. Place the transfer with the installation surface for the retainer upward.
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2004 Toyota RAV4
Fig. 245: Placing Transfer With Installation Surface For Retainer Upward
b. Do centering of the center differential control coupling assembly and the case.
c. Insert the SST into the retainer.
SST 09387-00090
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Fig. 246: Inserting SST Into Retainer

NOTE: Insert the SST straight down without making its tip interfered the lip
of the oil seal.
d. Insert the retainer and the SST into the case together as a unit.
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2004 Toyota RAV4
Fig. 247: Inserting Retainer & SST Into Case As Unit

NOTE:  Do not strongly make the case and retainer interfered. Neither
the SST or the center differential control coupling.
 Pay attention to the scratches and the curving up of the retainer
O-ring only after adjusting the backlash, tooth contact and total
pre-loading.
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Fig. 248: Identifying Oil Seal & O-Ring

HINT:
When the retainer cannot be inserted in the case, give a slight blow with a plastic hammer and
insert it.
e. After inserting the retainer in the case, remove the SST.

f. Install the 7 bolts.
NOTICE:
16. RECHECK TOTAL PRELOAD (See step 12 )

17. INSTALL OIL SEAL
a. Coat the oil seal lip with MP grease.
b. Using SST, install the oil seal to the bearing retainer RH.
SST 09223-46011
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Fig. 249: Installing Oil Seal To Bearing Retainer RH

c. Coat the oil seal lip with MP grease.

d. Using SST, install the oil seal to the transfer case.
SST 09387-00010, 09950-70010 (09951-07150)
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Fig. 250: Installing Oil Seal To Transfer Case

18. INSTALL CENTER DIFFERENTIAL LOCK SLEEVE

a. Coat new O-ring with gear oil, install it to the center differential lock sleeve.
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Fig. 251: Installing O-Ring To Center Differential Lock Sleeve

b. Using SST, install the center differential lock sleeve to the transfer case.
SST 09950-60010 (09951-00600), 09950-70010 (09951-07150)
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Fig. 252: Installing Center Differential Lock Sleeve To Transfer Case

c. Using snap ring pliers, install the snap ring.
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2004 Toyota RAV4

19. STAKE LOCK NUT
Using a chisel and a hammer, stake the lock nut.
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Fig. 254: Using Chisel And Hammer To Stake Lock Nut

20. INSTALL EXTENSION HOUSING

a. Coat the oil seal lip with MP grease.
b. Using SST, install the oil seal to the extension housing.
SST 09950-60010 (09951-00380, 09951-00590, 09952-06010) 09950-70010 (09951-07150)
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Fig. 255: Installing Oil Seal To Extension Housing

c. Using SST and a press, install the dust deflector to the extension housing.
SST 09950-60010 (09951-00640), 09950-70010 (09951-07150)
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Fig. 256: Installing Dust Deflector To Extension Housing

d. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the
extension housing and the transfer case.
e. Apply FIPG to the extension housing.
FIPG:
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2004 Toyota RAV4
Part No.08826-00100, THREE BOND 1281 or equivalent
Fig. 257: Identifying Seal Bend Width

f. Install the extension housing with 4 bolts.
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Fig. 258: Installing Bolts & Extension Housing

21. INSTALL STUD BOLT
Install the 4 new stud bolts to the transfer case.
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2004 Toyota RAV4
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2004 Toyota RAV4
Fig. 259: Installing Stud Bolts To Transfer Case

HINT:
From the bottom side of the stud bolt shown in Fig. 259 it should be installed to the case.

 Install the stud bolt to the transfer case which has sealer applied on it.
22. INSTALL PIN
Using a plastic hammer, install the 4 pins.
Fig. 260: Installing Pins

23. REMOVE TRANSFER FROM OVERHAUL ATTACHMENT

24. INSTALL CASE COVER
a. Install the oil deflector with a bolt to the case cover.
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2004 Toyota RAV4
Fig. 261: Installing Bolt & Oil Deflector

NOTE: Pay due attention to the direction of deflector bending.
b. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the case
cover and the transfer case.
c. Apply FIPG to the case cover.
FIPG:
Part No.08826-00100, THREE BOND 1281 or equivalent
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2004 Toyota RAV4
Fig. 262: Identifying Seal Bend Width

d. Install the No. 1 case cover with 2 new seal bolts and 6 bolts.
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Fig. 263: Installing No. 1 Case Cover With Seal Bolts & Bolts
25. INSTALL INTERMEDIATE SHAFT

26. INSTALL GASKET
Coat new gasket with ATF, install it to the transfer case.
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Fig. 264: Installing Gasket To Transfer Case

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2004 Toyota RAV4
2004 STEERING Power Steering Gear - RAV4
2004 STEERING
Power Steering Gear - RAV4
COMPONENTS
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Tuesday, July 21, 2009 4:33:39
2004 Toyota RAV4
Fig. 1: Identifying Power Steering Gear Components (1 Of 3)


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2004 Toyota RAV4
Microsoft
2004 Toyota RAV4

REMOVAL
NOTE: Remove the steering wheel assembly before the steering gear removal, because
there is possibility of breaking of the spiral cable.
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

2. REMOVE STEERING WHEEL PAD (See REMOVAL )
3. REMOVE STEERING WHEEL (See REMOVAL )
4. DISCONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY (See REMOVAL )
5. DISCONNECT STEERING COLUMN HOLE COVER
a. Loosen the clamp of the steering column hole cover.
b. Disconnect the steering column hole cover from the dash panel.
6. DISCONNECT RH AND LH TIE ROD ENDS (See REMOVAL )
7. DISCONNECT STABILIZER BAR
Remove the 4 bolts and disconnect the stabilizer bar.
HINT:
Do not remove the stabilizer bar.
8. DISCONNECT PRESSURE FEED AND RETURN TUBES

a. Using SST, disconnect the pressure feed and return tubes from the P/S gear.
SST 09023-12700
b. Remove the 2 bolts and disconnect the pressure feed and return tube from the P/S gear.
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2004 Toyota RAV4
Fig. 4: Disconnecting Pressure Feed And Return Tubes Using SST

9. REMOVE P/S GEAR ASSEMBLY

a. Remove the 2 P/S gear assembly mounting bolts.
b. Remove the steering column hole cover and clamp.
c. Place matchmarks on the steering intermediate extension and control valve shaft.
d. Remove bolt and steering intermediate extension.
e. Remove the P/S gear assembly.
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2004 Toyota RAV4
Fig. 5: Removing P/S Gear Assembly

NOTE: Do not damage the turn pressure tubes.
DISASSEMBLY
NOTE: When using a vise, do not overtighten it.
1. REMOVE TURN PRESSURE TUBES
Using SST, remove the 2 turn pressure tubes. SST 09023-38200
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2004 Toyota RAV4
Fig. 6: Removing Turn Pressure Tube Using SST

2. SECURE P/S GEAR ASSEMBLY IN VISE
Using SST, secure the P/S gear assembly in a vise. SST 09612-00012
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2004 Toyota RAV4
Fig. 7: Securing P/S Gear Assembly In Vise Using SST

3. REMOVE RH AND LH TIE ROD ENDS AND LOCK NUTS

a. Place matchmarks on the tie rod end and rack end.
b. Loosen the lock nut, and remove the tie rod end and lock nut.
c. Employ the same manner described above to the other side.
HINT:
Mark the RH and LH tie rod ends and lock nuts.
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2004 Toyota RAV4
Fig. 8: Marking RH & LH Tie Rod Ends & Lock Nuts

4. REMOVE RH AND LH CLIPS, CLAMPS AND RACK BOOTS

a. Loosen the clamp screw.
b. Remove the clip, clamp and rack boot.
NOTE: Be careful not to damage the boot.
HINT:
Mark the RH and LH rack boots.
5. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS

a. Using a screwdriver and a hammer, unstake the claw washer.
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2004 Toyota RAV4
Fig. 9: Unstaking Claw Washer

NOTE: Avoid any impact on the steering rack.
b. Using SST and spanner (22 mm), remove the power steering rack and claw washer.
SST 09922-10010
HINT:
Using spanner, hold the steering rack to remove the rack end and claw washer.
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2004 Toyota RAV4
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2004 Toyota RAV4
Fig. 10: Removing Power Steering Rack And Claw Washer Using SST & Spanner
NOTE: Use SST 09922-10010 in the direction shown in Fig. 10 .
HINT:
Mark the RH and LH rack ends.
c. Using 2 SST, remove the other rack end.
HINT:
Using SST, hold the power steering rack to remove the rack end and claw washer.
6. REMOVE RACK GUIDE

a. Using a straight hexagon wrench 24, remove the rack guide spring cap.
b. Remove the rack guide spring and rack guide.
7. REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Place matchmarks on the control valve housing and rack housing.
c. Pull out the control valve housing with control assembly.
d. Remove the gasket
SST 09616-00011
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2004 Toyota RAV4
Fig. 11: Placing Matchmarks And Removing Control Valve And Rack Housing
8. REMOVE CONTROL VALVE ASSEMBLY, UPPER OIL SEAL AND UPPER BEARING
a. Wind vinyl tape on the control valve shaft.
b. Press out the control valve assembly.
SST 09613-12010
NOTE:  Be careful not to damage the oil seal lip.

 Place a shop rag between the valve housing and the blocks.
 Be careful not to drop the valve assembly.
c. Remove the oil seal and bearing from the control valve assembly.
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2004 Toyota RAV4
Fig. 12: Removing Control Valve Assembly, Upper Oil Seal And Upper Bearing
9. REMOVE CYLINDER END STOPPER

a. Place rack housing in vise.
NOTE: Hold the arrow part in Fig. 13 in a vice.
b. Using SST, remove the cylinder end stopper from the rack housing.
SST 09631-20120
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2004 Toyota RAV4
Fig. 13: Removing Cylinder End Stopper From Rack Housing

c. Using a screwdriver, remove the O-ring from the cylinder end stopper.
NOTE: Do not damage the cylinder end stopper.
d. Using a screwdriver, remove the rack guide bush from the cylinder end stopper.
NOTE: Do not damage the cylinder end stopper.
10. REMOVE POWER STEERING RACK

a. Using a service bolt and press, remove the steering rack from the steering rack housing.
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2004 Toyota RAV4
Fig. 14: Removing Steering Rack From Steering Rack Housing Using Service Bolt & Press
Recommended service bolt:
RECOMMENDED SERVICE BOLT IDENTIFICATION

Thread diameter 14 mm (0.55 in.)
Thread pitch 1.5 mm (0.059 in.)
b. Using a screwdriver, remove the power piston oil seal and power piston O-ring from the steering
rack.
NOTE: Do not damage the steering rack ring groove.
c. Remove the cylinder end stopper oil seal from the steering rack.
11. REMOVE POWER STEERING CYLINDER TUBE OIL SEAL
a. Using needle nose pliers, remove the bush from the rack housing.
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2004 Toyota RAV4
Fig. 15: Removing Bush From Rack Housing

b. Install SST (09612-07130) on SST (09612-07210). SST 09612-70100 (09612-07130, 09612-

07210)
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2004 Toyota RAV4
Fig. 16: Installing SST

NOTE:  Before using them, apply a small dab of grease to the inside
wall of SST (09612-07210, 09612-07130).
 To prevent the inside of the housing from being damaged
securely install SST (09612-07130) on SST (09612-07210).
c. Diagonally insert SST (09612-07210) into the housing until it contacts with the oil seal, and then,
further insert the SST (09612-07210) until the tip of SST (09612-07220) contacts with SST (09612-
07130).
SST 09612-70100 (09612-07130, 09612-07210, 09612-07220)
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2004 Toyota RAV4
Fig. 17: Inserting SST Into Housing

NOTE: Do not damage the inside of the housing.
d. Secure SST (09612-07220), and pull SST (09612-07210) to place SST (09612-07130) in the
housing.
SST 09612-70100 (09612-07130, 09612-07210, 09612-07220)
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2004 Toyota RAV4
Fig. 18: Securing SST (09612-07220), Pulling SST (09612-07210) To Place SST (09612-07130)
In Housing
HINT:
Place SST on the chamfering position between the oil seal and rack housing.
e. Remove the SST (09612-07210, 09612-07220). SST 09612-07100 (09612-07210, 09612-07220)

f. After installing SST (09612-07240) on SST (09612-07210), insert the tip of SST (09612-07230) in
the service hole of SST (09612-07130).
SST 09612-70100 (09612-07130, 09612-07230, 09612-07240)
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2004 Toyota RAV4
Fig. 19: Inserting Tip Of SST (09612-07230) In Service Hole Of SST (09612-07130)
NOTE:  Before using them, apply a small dab of grease to the tip of SST
(09612-07130).
 To prevent SST (09612-07130) from being damaged, be sure to
install SST (09612-07240).
 Do not damage the inside of the rack housing.
g. Install SST (09951-07100) on SST (09612-07230) and remove the oil seal using a press.
SST 09612-70100 (09612-07130, 09612-07230, 09612-07240), 09950-70010 (09951-07100)
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2004 Toyota RAV4
Fig. 20: Installing SST (09951-07100) On SST (09612-07230) And Removing Oil Seal
NOTE: Do not damage the rack housing.
HINT:
Replace SST (09951-07100) with SST that is different in length in the set, if necessary.
INSPECTION
1. INSPECT STEERING RACK

a. Using a dial indicator, check the rack for runout, teeth wear and damage.
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2004 Toyota RAV4
Fig. 21: Inspecting Steering Rack For Runout, Teeth Wear And Damage Using Dial Indicator
b. Check the back surface for wear and damage.
If necessary, replace the steering rack.
REPLACEMENT
1. IF NECESSARY, REPLACE OIL SEAL AND BEARING

a. Using SST, press out the bearing and oil seal from the control valve housing.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)
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2004 Toyota RAV4
Fig. 22: Pressing Out Bearing And Oil Seal From Control Valve Housing Using SST
b. Coat a new oil seal lip with power steering fluid.

c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00180, 09951-00330, 09952-06010), 09950-70010 (09951-07150)
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Fig. 23: Pressing In Oil Seal Using SST

NOTE: Make sure that the oil seal is installed facing in the correct direction.
d. Coat a new bearing with molybdenum disulfide lithium base grease.

e. Using SST, press in the bearing.
SST 09950-60100 (09951-00350), 09950-70010 (09951-07150)
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2004 Toyota RAV4
Fig. 24: Pressing In Bearing Using SST

2. IF NECESSARY, REPLACE OIL SEAL

a. Using SST, remove the oil seal from the bushing.
SST 09612-24014 (09613-22011)
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2004 Toyota RAV4
Fig. 25: Removing Oil Seal From Bushing Using SST

NOTE: Be careful not to damage the bushing.
HINT:
As shown in Fig. 25 , from the opposite side of SST confirm that its claws are firmly caught on the
oil seal.
b. Coat a new oil seal lip with power steering fluid.

c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00210, 09951-00340, 09952-06010), 09950-70010 (09951-07100)
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2004 Toyota RAV4
Fig. 26: Pressing In Oil Seal Using SST

NOTE: Make sure that the oil seal is installed facing in the correct direction.
3. IF NECESSARY, REPLACE 2 UNION SEATS

a. Using a screw extractor, remove the union seat from the control valve housing.
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2004 Toyota RAV4
Fig. 27: Removing Union Seat From Control Valve Housing Using Screw Extractor
b. Using a plastic hammer and an extension bar, lightly tap in a new union seat.
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2004 Toyota RAV4
Fig. 28: Tapping In New Union Seat Using Plastic Hammer & Extension Bar
4. IF NECESSARY, REPLACE TEFLON RING AND O-RING

a. Using a screwdriver, remove the teflon ring and O-ring from the steering rack.
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2004 Toyota RAV4
Fig. 29: Removing Teflon Ring And O-Ring From Steering Rack
NOTE: Be careful not to damage the groove for the teflon ring.
b. Coat a new O-ring with power steering fluid and install it to the steering rack.
c. Expand a new teflon ring with your fingers.
NOTE: Be careful not to overexpand the Teflon ring.
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2004 Toyota RAV4
Fig. 30: Expanding New Teflon Ring With Fingers

d. Coat the teflon ring with power steering fluid.

e. Install the teflon ring to the steering rack and settle it down with your fingers.
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2004 Toyota RAV4
Fig. 31: Installing Teflon Ring To Steering Rack And Settle It Down With Fingers
5. IF NECESSARY, REPLACE 4 TEFLON RINGS

a. Using a screwdriver, remove the 4 teflon rings from the control valve assembly.
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2004 Toyota RAV4
Fig. 32: Removing Teflon Rings From Control Valve Assembly

HINT:
NOTE: Be careful not to damage the grooves for the teflon rings.
b. Expand 4 new teflon rings with your fingers.
NOTE: Be careful not to overexpand the teflon ring.
c. Coat the teflon rings with power steering fluid.

d. Install the teflon rings to the control valve assembly and settle them down with your fingers.
e. Carefully slide the tapered end of SST over the teflon rings until they fit to the control valve
assembly.
SST 09631-20081
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2004 Toyota RAV4
Fig. 33: Sliding Tapered End Of SST Over Teflon Rings

NOTE: Be careful not to damage the teflon rings.
REASSEMBLY
1. INSTALL POWER STEERING CYLINDER TUBE OIL SEAL
a. Apply power steering fluid to a new oil seal, and install the oil seal on the rack housing at an angle.
NOTE: Install the oil seal in the correct direction.
HINT:
Install the oil seal so that the port faces downward with approx. 15 degrees.
b. Using SST, push in the oil seal by hand until it passes through the 2 ports.
SST 09631-00180, 09950-70010 (09951-07360)
NOTE: Do not turn SST when inserting the oil seal.

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2004 Toyota RAV4
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2004 Toyota RAV4
Fig. 34: Installing Power Steering Cylinder Tube Oil Seal

c. After the oil seal has passed through the ports, push in the oil seal by hand until it becomes level,
using SST.
SST 09950-60010 (09951-00490), 09950-70010 (09951-07360)
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2004 Toyota RAV4
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2004 Toyota RAV4
Fig. 35: Pushing Oil Seal By Hand Until It Becomes Level

NOTE: When SST is set, do not damage the inside surface of the rack
housing.
d. After the oil seal has become level, using SST and press, install the oil seal.
SST 09950-60010 (09951-00490), 09950-70010 (09951-07360)
e. Coat new oil seal lip with power steering fluid.

f. Using needle nose pliers, install the bush to the rack housing.
Fig. 36: Installing Bush To Rack Housing

2. INSTALL POWER STEERING RACK

a. Coat a new power piston O-ring with power steering fluid and install it to the steering rack.
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2004 Toyota RAV4
b. Coat a new power piston oil seal with power steering fluid.
c. Expand the power piston oil seal with your fingers.
NOTE: Be careful not to over expand the power piston oil seal.
Fig. 37: Expanding Power Piston Oil Seal With Fingers

d. Install the power piston oil seal to the steering rack, and settle it down with your fingers.
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2004 Toyota RAV4
Fig. 38: Installing Power Piston Oil Seal To Steering Rack

e. Install SST to the steering rack.
SST 09631-20102
HINT:
If necessary, scrape the burrs off the steering rack teeth end and burnish.
f. Coat the SST with power steering fluid.

g. Install the steering rack into the rack housing.
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2004 Toyota RAV4
Fig. 39: Installing Steering Rack Into Rack Housing

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2004 Toyota RAV4
h. Remove the SST.
SST 09631-20102
3. INSTALL CYLINDER END STOPPER

a. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering
fluid.
b. Coat a new cylinder end stopper oil seal lip with power steering fluid.
c. Install the cylinder end stopper oil seal by pushing it into the rack housing without tilting.
Fig. 40: Installing Cylinder End Stopper Oil Seal

NOTE:  Make sure that the oil seal is installed facing in the correct
direction.
 Be careful not to damage the oil seal lip.
d. Coat a new O-ring with power steering fluid.
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2004 Toyota RAV4
e. Install the O-ring to the cylinder end stopper.

f. Install a new rack guide bush to the cylinder end stopper.
g. Apply molybdenum disulfide lithium base grease to the inside of the bush.
Fig. 41: Applying Grease To Inside Of Bush

h. Place rack housing in vise.
NOTE: Hold the arrow part in Fig. 42 in a vise.
i. Using SST, install the cylinder end stopper to rack housing.
SST 09631-20120

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2004 Toyota RAV4
Fig. 42: Installing Cylinder End Stopper To Rack Housing Using SST
4. INSPECT RACK & PINION POWER STEERING GEAR ASSEMBLY

a. Install SST to the rack housing.
SST 09631-12071 (09633-00010)
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2004 Toyota RAV4
Fig. 43: Installing SST To Rack Housing

b. Apply vacuum of 53 kPa (400 mmHg, 15.75 in. Hg) for about 30 seconds.
c. Check that there is no change in the vacuum.
If there is a change in the vacuum, check the installation of the oil seals.
5. INSTALL CONTROL VALVE ASSEMBLY

a. Coat the teflon rings and oil seal lip with power steering fluid.
b. Coat the bearing with molybdenum disulfide lithium base grease.
c. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
d. Using SST, press the control valve assembly into the control valve housing.
SST 09612-22011
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Fig. 44: Installing Control Valve Assembly Using SST

NOTE: Be careful not to damage the teflon rings and oil seal lips.
6. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY

a. Install a new gasket.
b. Align the matchmarks on the control valve housing and rack housing.
c. Push into the control valve housing with control valve assembly.
d. Install the 2 bolts.
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2004 Toyota RAV4
Fig. 45: Aligning Matchmarks On Control Valve Housing And Rack Housing, Installing Bolts
7. INSTALL RACK GUIDE SUB-ASSEMBLY

a. Apply molybdenum lithium base grease to the contact surface of the power steering rack and of the
rack guide.
b. Install the rack guide and compression spring to the rack housing.
c. Apply sealant to 2 or 3 threads of the rack guide spring cap.
Sealant:
d. Temporarily install the rack guide spring cap.

8. ADJUST TOTAL PRELOAD
a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH
rack ends.
b. Using a hexagon wrench (24 mm), torque the rack guide spring cap.

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2004 Toyota RAV4
c. Using a hexagon wrench (19 mm), return the rack guide spring cap 12°
d. Using SST, turn the control valve shaft right and left 1 or 2 times.
e. Using a hexagon wrench (19 mm), loosen the rack guide spring cap until the rack guide spring is
not functioning.
f. Using SST, a torque wrench hexagon wrench (19 mm), tighten the rack guide spring cap until the
preload is within the specification.
SST 09616-00010
Preload (turning):
1.0 to 1.6 N.m (10 to 17 kgf.cm, 9 to 15 in.lbf)
9. INSTALL STEERING RACK END SUB-ASSEMBLY

a. Install 2 new claw washers, and temporally install the rack ends.
HINT:
Align the claws of the claw washer with the steering rack grooves.
b. Apply MP grease to the rack end ball joint.

c. Using 2 SST, install the rack end sub-assy (RH side).
SST 09922-10010
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2004 Toyota RAV4
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2004 Toyota RAV4
Fig. 46: Installing Steering Rack End Sub Assembly Using SST
HINT:
Using SST, hold the rack and install the rack end sub-assy.
 Use a torque wrench with a fulcrum length of 425 mm (16.73 in.).
d. Using SST and a spanner (22 mm), tighten the rack end (LH side).
HINT:
Using SST, hold the rack and install the rack end.
 Use a torque wrench with a fulcrum length of 425 mm (16.73 in.).
e. Using a brass bar and a hammer, stake the 2 claw washers.
NOTE: Avoid any impact to the steering rack.
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Fig. 47: Staking Claw Washers Using Brass Bar And Hammer
f. Ensure that the steering rack hole is not clogged with grease.
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Fig. 48: Ensuring Steering Rack Hole Is Not Clogged With Grease
HINT:
If the hole is clogged, the pressure inside the boot will change after it is assembled and steering
wheel is turned.
10. INSTALL STEERING RACK BOOT NO. 2

a. Apply silicon grease to the inside small caliber of steering rack boots No. 2
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Fig. 49: Identifying Steering Rack Boot

b. Install the steering rack boots No. 2 to the groove on the rack housing.
11. INSTALL STEERING RACK BOOT NO. 1
HINT:
Install the rack boot No. 1 by the same procedures with rack boot No. 2.
12. INSTALL STEERING RACK BOOT NO. 2 CLAMP

a. Using pliers and a screwdriver, install a new rack boot No. 2 clamp.
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Fig. 50: Installing New Steering Rack Boot No. 2 Clamp

NOTE: Be careful not to damage or twist the rack boot.
13. INSTALL STEERING RACK BOOT NO. 1 CLAMP
HINT:
Install the rack boot No. 1 clamp by the same procedures with rack boot No. 2 clamp.
14. INSTALL STEERING RACK BOOT CLIP

a. Using pliers, install the 2 boot clips.
b. Using SST, turn the control valve, and check that the rack boots expand and contract smoothly.
SST 09616-00011
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Fig. 51: Checking Expanding And Contracting Of Rack Boots

15. INSTALL TIE ROD END SUB-ASSEMBLY LH

a. Screw the lock nut and tie rod end sub-assy LH onto the rack end until the matchmarks are aligned.
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Fig. 52: Installing Tie Rod End Sub-Assembly LH

HINT:
After adjusting toe-in, torque the lock nut.
16. INSTALL TIE ROD END SUB-ASSEMBLY RH
HINT:
Install the RH side by the same procedures with LH side.
INSTALLATION
1. INSTALL P/S GEAR ASSEMBLY
a. Place the P/S gear assembly in installation position.
NOTE: Do not damage the turn pressure tubes.
b. Align the matchmarks on the steering intermediate extension and control valve shaft.
c. Install the bolt.
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Fig. 53: Aligning Matchmarks On Steering Intermediate Extension And Control Valve Shaft,
Installing Bolt
d. Place the steering column hole cover clamp and cover on the control valve shaft.
e. Install the P/S gear assembly with the 2 bolts.
2. CONNECT PRESSURE FEED AND RETURN TUBES

a. Connect the pressure feed and return tubes to the P/S gear with the 2 bolts.
b. Using SST, connect the pressure feed and return tubes.
SST 09023-12700
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Fig. 54: Connecting Pressure Feed And Return Tubes Using SST
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
3. CONNECT STABILIZER BAR
Connect the stabilizer bar with the 4 bolts.
4. CONNECT RH AND LH TIE ROD ENDS (See INSTALLATION )

5. CONNECT STEERING COLUMN HOLE COVER
a. Connect the steering column hole cover to the dash panel.
b. Tighten the clamp of the steering column hole cover.
6. CONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY (See INSTALLATION )
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2004 Toyota RAV4
7. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
HINT:
Do it with the front of the vehicle jacked up.
8. CENTER SPIRAL CABLE (See INSTALLATION )

9. INSTALL STEERING WHEEL
a. Align the matchmarks on the steering wheel and steering column main shaft.
b. Temporarily tighten the steering wheel set nut.
10. BLEED POWER STEERING SYSTEM (See BLEEDING )
11. CHECK STEERING WHEEL CENTER POINT
12. TORQUE STEERING WHEEL SET NUT
13. INSTALL STEERING WHEEL PAD (See INSTALLATION )

14. CHECK FRONT WHEEL ALIGNMENT (See INSPECTION )
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2004 DRIVELINE/AXLES Rear Differential Carrier (4WD) - RAV4
2004 DRIVELINE/AXLES
Rear Differential Carrier (4WD) - RAV4
ON-VEHICLE REPAIR
REPLACE REAR DIFFERENTIAL OIL
a. Remove the filler plug and gasket.

b. Remove the drain plug and gasket, and drain the oil.
c. Reinstall the drain plug with a new gasket.
d. Fill new differential oil as shown in Fig. 1 .
Fig. 1: Identifying Differential Oil Level

Capacity: 0.9 liter (1.0 US qts, 0.8 Imp. qts)

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Tuesday, July 21, 2009 4:07:14
2004 Toyota RAV4
Oil grade: Hypoid gear oil API GL-5
Recommended oil viscosity:
OIL VISCOSITY IDENTIFICATION

Above - 18°C (0°F) SAE 90
Below -18°C (0°F) SAE 80W or 80W-90
e. Reinstall the filler plug with a new gasket.
COMPONENTS
Fig. 2: Identifying Rear Differential Carrier Assembly (1 Of 2)

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Fig. 3: Identifying Rear Differential Carrier Assembly (2 Of 2)

REMOVAL
1. REMOVE DRIVE SHAFTS (See REMOVAL )
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2004 Toyota RAV4
HINT:
Support the drive shafts securely.
2. REMOVE PROPELLER SHAFT (See COMPONENTS )
HINT:
Support the propeller shaft securely.
3. DRAIN DIFFERENTIAL OIL
4. REMOVE DIFFERENTIAL
a. Support the differential with a jack.
b. Remove the 2 rear mounting bolts.
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Fig. 4: Removing Rear Mounting Bolts

c. Remove the 2 front mounting bolts and differential.
d. Remove the 2 bolts and differential rear mount cushion from the differential.
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Fig. 5: Removing Differential Rear Mount Cushion & Bolts

DISASSEMBLY
1. REMOVE DIFFERENTIAL CARRIER COVER
a. Remove the 8 bolts from the carrier cover.
b. Using a brass bar and a hammer, separate the cover from the carrier.
c. Remove the breather plug from the differential carrier cover.
d. Torque sensing LSD:
Remove the bolt and oil deflector from the differential.
2. CHECK RUNOUT OF COMPANION FLANGE

a. Using a dial indicator, measure the runout of the companion flange vertically.
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Fig. 6: Measuring Runout Of Companion Flange Vertically

b. Place a dial indicator on the place 30 mm (1.181 in.) apart from the center of the companion flange.
c. Measure the runout of the companion flange horizontally.
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Fig. 7: Measuring Runout Of Companion Flange Horizontally

3. CHECK RING GEAR

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a. Check the runout.
Using a dial indicator, check the runout of the ring gear.
If the runout is greater than the maximum value, replace it with a new ring gear.
Fig. 8: Measuring Runout Of Ring Gear

b. Check the backlash.
Using a dial indicator, check the backlash of the ring gear.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
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Fig. 9: Checking Backlash Of Ring Gear

If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.
4. CHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See
REASSEMBLY )
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2004 Toyota RAV4
5. 2 pinion differential: CHECK BACKLASH OF SIDE GEAR
Using a dial indicator, check the backlash of the side gear with holding 1 pinion gear toward the
differential case.
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Fig. 10: Checking Backlash Of Side Gear

If the backlash is not within the specification, install the 2 side gear thrust washers of different thickness
(See REASSEMBLY ).
6. MEASURE DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
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Fig. 11: Measuring Drive Pinion Preload

0.6 - 0.9 N.m (6 - 9 kgf.cm, 5.3 - 8.0 in.lbf)
7. CHECK TOTAL PRELOAD
Using a torque wrench, measure the preload.
Drive pinion preload plus
0.3 - 0.5 N.m (3 - 5 kgf.cm, 2.6 - 4.3 in.lbf)
If necessary, disassemble and inspect the differential.
8. REMOVE COMPANION FLANGE

a. Using a chisel and a hammer, unstake the staked part of the nut.
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2004 Toyota RAV4
b. Using SST to hold the flange, remove the nut.
SST 09330-00021
Fig. 12: Removing Companion Flange Nut

c. Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03020)
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Fig. 13: Removing Companion Flange

9. REMOVE FRONT OIL SEAL AND OIL SLINGER

a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
b. Remove the oil slinger.
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2004 Toyota RAV4
Fig. 14: Removing Oil Seal & Slinger

10. REMOVE FRONT BEARING AND BEARING SPACER

a. Using SST, remove the front bearing from the drive pinion.
SST 09556-22010
b. Remove the bearing spacer.
Fig. 15: Removing Front Bearing & Bearing Spacer

11. Torque sensing LSD: REMOVE SIDE GEAR SHAFTS

a. Using SST, remove the 2 side gear shafts from the differential carrier.
SST 09520-24010 (09520-04010, 09520-32040)
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b. Using a screwdriver, remove the 2 snap rings from the 2 side gear shafts.
Fig. 16: Removing Side Gear Shaft (Torque Sensing LSD)

12. 2 pinion differential: REMOVE SIDE GEAR SHAFTS

a. Using needle nose pliers, remove the 2 snap rings from the 2 side gear shafts.
b. Remove the 2 side gear shafts.
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Fig. 17: Removing Side Gear Shaft (2 Pinion Differential)

13. REMOVE SIDE GEAR SHAFT OIL SEALS
Using SST, remove the 2 oil seals from the housing.
SST 09308-10010
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Fig. 18: Removing Side Gear Shaft Oil Seals

14. REMOVE DIFFERENTIAL CASE

a. Place matchmarks on the bearing cap and differential carrier.
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Fig. 19: Locating Matchmarks

b. Remove the 4 bolts and 2 bearing caps.

c. Using SST and a hammer, remove the 2 plate washers.
SST 09504-22012
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Fig. 20: Removing Plate Washers

HINT:
Measure the plate washer and note down the thickness.
d. Remove the differential case and 2 bearing outer races from the carrier.
HINT:
Tag the 2 bearing outer races to show the location of reassembling.
15. REMOVE DRIVE PINION FROM DIFFERENTIAL CARRIER

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16. REMOVE DRIVE PINION REAR BEARING

a. Using SST and a press, remove the bearing from the drive pinion.
SST 09950-00020
Fig. 21: Removing Drive Pinion Rear Bearing

HINT:
If the drive pinion and ring gear are damaged, replace them as a set.
b. Remove the plate washer.

17. REMOVE FRONT AND REAR BEARING OUTER RACES
Using a brass bar and a hammer, remove the 2 outer races from the carrier.
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Fig. 22: Removing Front & Rear Bearing Outer Races

18. REMOVE RING GEAR

a. Place matchmarks on the ring gear and differential case.
b. Using a screwdriver and a hammer, unstake the 4 lock plates.
c. Remove the 8 ring gear set bolts and 4 lock plates.
d. Using a plastic hammer, tap the ring gear to separate it from the differential case.
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Fig. 23: Removing Ring Gear & Locating Match Mark

19. REMOVE SIDE BEARINGS
Using SST and a press, remove the 2 side bearings from the differential case.
SST 09950-00020
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Fig. 24: Removing Side Bearings

NOTE: Be careful not to drop the differential case.
20. 2 pinion differential: DISASSEMBLE DIFFERENTIAL CASE
NOTE: If equipped with torque sensing LSD, do not disassemble the differential
case.
a. Using a pin punch and a hammer, remove the straight pin.
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Fig. 25: Removing Straight Pin Using Pin Punch & Hammer
b. Remove the pinion shaft, 2 pinion gears, 2 pinion gear thrust washers, 2 side gears and 2 side gear
thrust washers.
REPLACEMENT
1. REPLACE SIDE GEAR SHAFT DUST COVER
a. Using a screwdriver and a hammer, remove the side gear shaft dust cover.
b. Using a steel plate and a press, install a new dust cover to the side gear shaft.
NOTE: Be careful not to damage the dust cover.
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Fig. 26: Installing Dust Cover To Side Gear Shaft

2. REPLACE COMPANION FLANGE DUST DEFLECTOR

a. Using SST and a press, remove the dust deflector.
SST 09950-00020
b. Using a press, install a new dust deflector.
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Fig. 27: Replacing Companion Flange Dust Deflector

REASSEMBLY
1. 2 pinion differential: REASSEMBLE DIFFERENTIAL CASE
a. Install the 2 proper thrust washers on the 2 side gears.
b. Install the 2 side gears, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft in the
differential case.
HINT:
Align the holes of the differential case and pinion shaft.
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Fig. 28: Installing Thrust Washers & Side Gears

c. Measure the side gear backlash.

1. Install the 2 side gear shafts.
2. Measure the side gear backlash with holding 1 pinion gear toward the differential case.
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
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If the backlash is not within the specification, install the 2 side gear thrust washers with
different thicknesses.
HINT:
Refer to THRUST WASHER THICKNESS IDENTIFICATION and select 2 thrust

washers which ensures that the backlash is within the specification.
Thrust washer thickness [mm (in.)]
THRUST WASHER THICKNESS IDENTIFICATION [mm (in.)]

0.93 - 0.97 (0.0366 - 0.0382) 1.18 - 1.22 (0.0465 - 0.0480)
0.98 - 1.02 (0.0386 - 0.0402) 1.23 - 1.27 (0.0484 - 0.0500)
1.03 - 1.07 (0.0406 - 0.0421) 1.28 - 1.32 (0.0503 - 0.0520)
1.08 - 1.12 (0.0425 - 0.0441) 1.33 - 1.37 (0.0523 - 0.0539)
1.13 - 1.17 (0.0445 - 0.0461) 1.38 - 1.42 (0.0543 - 0.0559)
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2004 Toyota RAV4
3. Remove the 2 side gear shafts.

d. Using a pin punch and a hammer, install the straight pin through the differential case and hole of
the pinion shaft.
Fig. 30: Installing Straight Pin Using Pin Pinch & Hammer
e. Using a chisel and a hammer, stake the outside of the differential case pin hole.
2. INSTALL RING GEAR ON DIFFERENTIAL CASE
a. Clean the contact surfaces of the differential case and ring gear.
b. Heat the ring gear in boiling water.
c. Carefully remove the ring gear from the boiling water.
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Fig. 31: Heating Ring Gear In Boiling Water

differential case.
e. Align the matchmarks on the ring gear and differential case.
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Fig. 32: Aligning Matchmarks On Ring Gear & Differential Case

f. Temporarily install 4 new lock plates and the 8 bolts.

g. After the ring gear cools down enough, torque the 8 bolts uniformly at a time.
h. Using a chisel and a hammer, raise up claws of the 4 lock plates.
HINT:
Bend one of the claws which touches the flat surface of the bolt so that the claw can contact

the surface firmly.
 If one of the claws is divided into two due the protruding portion of the bolt, make the claw
contact firmly with the tightening side of the bolt.
3. INSTALL SIDE BEARINGS
Using SST and a press, install the 2 side bearings into the differential case.
SST 09710-22021 (09710-01031)
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Fig. 33: Installing Side Bearings

4. INSPECT RING GEAR RUNOUT

a. Install the differential case on the carrier, and install the 2 plate washers so that there is no play in
the bearing.
b. Install the bearing caps.
c. Using a dial indicator, measure the runout of the ring gear.
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Fig. 34: Measuring Runout Of Ring Gear

d. Remove the 2 bearing caps, 2 plate washers and differential carrier.

5. INSTALL FRONT AND REAR BEARING OUTER RACES
a. Front side:
Using SST and a press, install the outer race to the carrier.
SST 09950-60020 (09951-00790), 09950-70010 (09951-07150)
b. Rear side:
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2004 Toyota RAV4
Using SST and a press, install the 2 outer races to the carrier.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)
Fig. 35: Installing Front & Rear Bearing Outer Race

6. INSTALL DRIVE PINION REAR BEARING

a. Install the removed plate washer on the drive pinion.
b. Using SST and a press, install the rear bearing onto the drive pinion.
SST 09506-30012
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Fig. 36: Installing Rear Bearing Into Drive Pinion

7. TEMPORARILY ADJUST DRIVE PINION PRELOAD

a. Install the drive pinion and front bearing.
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Fig. 37: Installing Drive Pinion & Front Bearing

HINT:
Assemble the spacer, oil slinger and oil seal after adjusting the gear contact pattern.
b. Using SST, install the companion flange.
Fig. 38: Installing Companion Flange

SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03020)
c. Coat the threads of the nut with MP grease.

d. Adjusting the drive pinion preload by tightening the companion flange nut.
Using SST to hold the flange, tighten the nut.
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Fig. 39: Tightening Flange Nut

Torque:
108 - 235 N.m (1,100 - 2,400 kgf.cm, 80 - 173 ft.lbf)
SST 09330-00021
NOTE: Without a spacer, torque a little at a time, being careful not to over
tighten it.
e. Using a torque wrench, measure the preload.
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PRELOAD BEARING SPECIFICATION

New bearing 1.1 - 1.7 N.m (11 - 17 kgf.cm, 9.5 - 14.7 in.lbf)
Reused bearing 0.6 - 0.9 N.m (6 - 9 kgf.cm, 5.2 - 7.8 in.lbf)
8. INSTALL DIFFERENTIAL CASE IN CARRIER

a. Place the 2 bearing outer races on their respective bearings. Make sure the left and right races are
not interchanged.
b. Install the differential case in the carrier.
9. ADJUST RING GEAR BACKLASH
a. Install only the plate washer on the ring gear back side.
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Fig. 41: Installing Plate Washer

b. Make the washer and bearing fit by tapping the ring gear with a plastic hammer.
c. Using a dial indicator, hold the companion flange and measure the ring gear backlash.
Backlash (reference):
0.13 - 0.18 mm (0.0051 - 0.0071 in.)
d. Select a ring gear back side plate washer so that the backlash becomes 0.13 - 0.18 mm (0.0051 -
0.0071 in.).
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Fig. 42: Measuring Ring Gear Back Lash

e. Select a ring gear teeth side washer so that there is no clearance between the outer race and case.
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f. Remove the plate washer and differential case.

g. Install the plate washer into the ring gear back side.
Fig. 43: Installing Plate Washer Into Ring Gear Back Side
h. Place the outer plate washer on the differential case together with the outer race, and install the
differential case with the outer race into the carrier.
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Fig. 44: Installing Differential Case To Carrier

i. Using a plastic hammer, make the washer fit and bearing by tapping the ring gear.
j. Using a dial indicator, measure the ring gear backlash during holding the companion flange.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
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2004 Toyota RAV4

If the value is not within the specification, adjust it by either increasing or decreasing the thickness
of the washers on both sides by an equal amount.
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2004 Toyota RAV4
HINT:
There should be clearance between the plate washer and case. Ensure that there is the ring gear
backlash.
10. ADJUST SIDE BEARING PRELOAD

a. After adjusting the ring gear backlash as reference, remove the teeth side plate washer.
b. Using a micrometer, measure the thickness of the removed plate washer.
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Fig. 46: Measuring Plate Washer Thickness Using Micrometer

c. Install a new washer of 0.06 - 0.09 mm (0.0024 - 0.0035 in.) thicker than the removed washer.
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HINT:
Select a washer which can be pressed in 2/3 of the way by finger.
d. Using a brass bar and a hammer, tap the plate washer.
Fig. 47: Tapping Plate Washer Using Brass Bar & Hammer
e. Align the matchmarks on the cap and carrier, and install the 2 bearing caps with the 4 bolts.
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Fig. 48: Aligning Match Mark On Cap & Carrier

f. Recheck the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
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2004 Toyota RAV4

If the value is not within the specification, adjust it by either increasing or decreasing the washers
thickness on both sides by equal amount.
HINT:
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2004 Toyota RAV4
The backlash will change by about 0.02 mm (0.0008 in.) corresponding to 0.03 mm (0.0012 in.)
change in the plate washer thickness.
Washer thickness:
WASHER THICKNESS SPECIFICATIONS

Thickness mm (in.) Thickness mm (in.) Thickness mm (in.)
2.21 - 2.23 (0.0870 - 0.0878) 2.57 - 2.59 (0.1012 - 0.1020) 2.93 - 2.95 (0.1154 - 0.1161)
2.24 - 2.26 (0.0882 - 0.0890) 2.60 - 2.62 (0.1024 - 0.1031) 2.96 - 2.98 (0.1165 - 0.1173)
2.27 - 2.29 (0.0894 - 0.0902) 2.63 - 2.65 (0.1035 - 0.1043) 2.99 - 3.01 (0.1177 - 0.1185)
2.30 - 2.32 (0.0906 - 0.0913) 2.66 - 2.68 (0.1047 - 0.1055) 3.02 - 3.04 (0.1189 - 0.1197)
2.33 - 2.35 (0.0917 - 0.0925) 2.69 - 2.71 (0.1059 - 0.1067) 3.05 - 3.07 (0.1201 - 0.1209)
2.36 - 2.38 (0.0929 - 0.0937) 2.72 - 2.74 (0.1071 - 0.1079) 3.08 - 3.10 (0.1213 - 0.1220)
2.39 - 2.41 (0.0941 - 0.0949) 2.75 - 2.77 (0.1083 - 0.1091) 3.11 - 3.13 (0.1224 - 0.1232)
2.42 - 2.44 (0.0953 - 0.0961) 2.78 - 2.80 (0.1094 - 0.1102) 3.14 - 3.16 (0.1236 - 0.1244)
2.45 - 2.47 (0.0965 - 0.0972) 2.81 - 2.83 (0.1106 - 0.1114) 3.17 - 3.19 (0.1248 - 0.1256)
2.48 - 2.50 (0.0976 - 0.0984) 2.84 - 2.86 (0.1118 - 0.1126) 3.20 - 3.22 (0.1260 - 0.1268)
2.51 - 2.53 (0.0988 - 0.0996) 2.87 - 2.89 (0.1130 - 0.1138) -
2.54 - 2.56 (0.1000 - 0.1008) 2.90 - 2.92 (0.1142 - 0.1150) -
11. MEASURE TOTAL PRELOAD
Using a torque wrench, measure the preload.
Drive pinion preload plus 0.3 - 0.5 N.m (3 - 5 kgf.cm, 2.6 - 4.3 in.lbf)
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2004 Toyota RAV4

12. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
a. Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.
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2004 Toyota RAV4
Fig. 51: Coating Teeth On Ring Gear With Red Lead Primer
b. Hold the companion flange firmly and rotate the ring gear in both directions.
c. Inspect the tooth contact pattern.
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2004 Toyota RAV4
Fig. 52: Identifying Types Of Gear Contact

If the teeth are not contacting properly, use WASHER THICKNESS IDENTIFICATION to
select a proper washer for correction.
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2004 Toyota RAV4
Fig. 53: Identifying Plate Washer

Washer thickness:
WASHER THICKNESS IDENTIFICATION

Thickness mm (in.) Thickness mm (in.) Thickness mm (in.)
2.26 - 2.28 (0.0890 - 0.0898) 2.41 - 2.43 (0.0949 - 0.0957) 2.56 - 2.58 (0.1008 - 0.1016)
2.29 - 2.31 (0.0902 - 0.0909) 2.44 - 2.46 (0.0961 - 0.0969) 2.59 - 2.61 (0.1020 - 0.1028)
2.32 - 2.34 (0.0913 - 0.0921) 2.47 - 2.49 (0.0972 - 0.0980) 2.62 - 2.64 (0.1031 - 0.1039)
2.35 - 2.37 (0.0925 - 0.0933) 2.50 - 2.52 (0.0984 - 0.0992) 2.65 - 2.67 (0.1043 - 0.1051)
2.38 - 2.40 (0.0937 - 0.0945) 2.53 - 2.55 (0.0996 - 0.1004) 2.68 - 2.70 (0.1055 - 0.1063)
13. REMOVE COMPANION FLANGE (See REPLACEMENT )

14. REMOVE FRONT BEARING (See DISASSEMBLY )
15. INSTALL NEW BEARING SPACER AND FRONT BEARING
Install a new bearing spacer and the front bearing on the drive pinion.
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2004 Toyota RAV4
Fig. 54: Installing Spacer, Front Bearing & Drive Pinion

16. INSTALL OIL SLINGER

17. INSTALL NEW FRONT OIL SEAL
a. Using SST and a hammer, install a new oil seal.
SST 09554-22010
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2004 Toyota RAV4
Fig. 55: Installing Front Oil Seal

Oil seal drive in depth: 2.0 mm (0.079 in.)
b. Apply MP grease to the oil seal lip.

18. INSTALL COMPANION FLANGE
a. Using SST, install the companion flange on the drive pinion.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03020)
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2004 Toyota RAV4
Fig. 56: Installing Companion Flange

b. Coat the threads of a new nut with hypoid gear oil.

c. Using SST to hold the flange, torque the nut.
SST 09330-00021
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2004 Toyota RAV4
Fig. 57: Holding Flange & Torquing Nut

19. CHECK DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
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2004 Toyota RAV4
Fig. 58: Checking Drive Pinion Preload

PRELOAD SPECIFICATIONS
New bearing 1.1 - 1.7 N.m (11 - 17 kgf.cm, 9.5 - 14.7 in.lbf)
Reused bearing 0.6 - 0.9 N.m (6 - 9 kgf.cm, 5.2 - 7.8 in.lbf)
If the preload is larger than the specification, replace the bearing spacer.
If the preload is less than the specification, retighten the nut 13 N.m (130 kgf.cm, 9 ft.lbf) of torque at a
time until reaching the specified value.
Torque: 235 N.m (2,400 kgf.cm, 174 ft.lbf) or less
If the torque exceeds the maximum value while retighten the nut, replace the bearing spacer and repeat
the preload procedure. Do not loosen the pinion nut to reduce the preload.
20. RECHECK TOTAL PRELOAD (See DISASSEMBLY )

21. RECHECK RING GEAR BACKLASH (See DISASSEMBLY )
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2004 Toyota RAV4
22. RECHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See
REASSEMBLY )
23. CHECK COMPANION FLANGE RUNOUT (See DISASSEMBLY )
24. STAKE DRIVE PINION NUT
25. INSTALL SIDE GEAR SHAFT OIL SEALS
a. Using SST and a hammer, install 2 oil seals until they are flush with the carrier end surface.
SST 09550-00032, 09950-70010 (09951-07150)
Fig. 59: Installing Side Gear Shaft Oil Seals

b. Coat the oil seal lip with MP grease.

26. Torque sensing LSD: INSTALL SIDE GEAR SHAFTS
a. Install 2 new snap rings to the side gear shafts.
b. Using SST, install the 2 side gear shafts until they contacts the pinion shaft.
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2004 Toyota RAV4
SST 09520-24010 (09520-04010, 09520-32040)
Fig. 60: Installing Side Gear Shafts (Torque Sensing LSD)

HINT:
Check that the shaft is fully inserted by the noise being made when it is tapped.
27. 2 pinion differential: INSTALL SIDE GEAR SHAFTS

a. Install the 2 side gear shafts to the differential case.
b. Using needle nose pliers, install 2 new snap rings to the 2 side gear shafts.
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2004 Toyota RAV4
Fig. 61: Installing Side Gear Shafts (2 Pinion Differential)

28. INSTALL DIFFERENTIAL CARRIER COVER

a. Torque sensing LSD:
Install the oil deflector and bolt to the carrier cover.
b. Install the breather plug to the carrier cover.
c. Clean contacting surfaces of any residual FIPG material by using gasoline or alcohol.
d. Apply FIPG to the carrier.
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2004 Toyota RAV4
Fig. 62: Installing Differential Carrier Cover

FIPG:
HINT:
Install the carrier cover within 3 minutes after applying FIPG.
e. Torque the 8 bolts.

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2004 Toyota RAV4
INSTALLATION
Installation is in the reverse order of removal procedure (See REMOVAL ).
HINT:
After installation, fill the differential with differential oil (See REPLACE REAR DIFFERENTIAL OIL ).
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2004 Toyota RAV4
2004 DRIVELINE/AXLES Rear Differential Front Oil Seal (4WD) - RAV4
2004 DRIVELINE/AXLES
Rear Differential Front Oil Seal (4WD) - RAV4
COMPONENTS
Fig. 1: Identifying Rear Differential Front Oil Seal Components

REPLACEMENT
1. DRAIN DIFFERENTIAL OIL
2. REMOVE PROPELLER SHAFT (See REMOVAL )
3. REMOVE COMPANION FLANGE
a. Using a chisel and a hammer, unstake the staked part of the nut.
b. Using SST to hold the flange, remove the nut.
SST 09330-00021
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2004 Toyota RAV4
Fig. 2: Removing Nut From Flange

c. Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03020)
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2004 Toyota RAV4
Fig. 3: Removing Companion Flange

4. REMOVE FRONT OIL SEAL AND OIL SLINGER

a. Using SST, remove the oil seal.
SST 09308-10010
b. Remove the oil slinger.
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2004 Toyota RAV4
Fig. 4: Removing Front Oil Seal & Oil Slinger

5. REMOVE FRONT BEARING AND BEARING SPACER

a. Using SST, remove the front bearing.
SST 09556-22010
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Fig. 5: Removing Front Bearing

b. Remove the bearing spacer.

6. INSTALL NEW BEARING SPACER AND FRONT BEARING
a. Install a new bearing spacer on the shaft.
b. Install the front bearing on the shaft.
7. INSTALL OIL SLINGER AND NEW OIL SEAL
a. Install the oil slinger.
b. Using SST, install a new oil seal.
SST 09554-22010
Oil seal drive in depth: 2.0 mm (0.079 in.)
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Fig. 6: Installing Oil Seal

c. Apply MP grease to the oil seal lip.

8. INSTALL COMPANION FLANGE
a. Using SST, install the companion flange on the shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03020)
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2004 Toyota RAV4
Fig. 7: Installing Companion Flange On Shaft

b. Coat the threads of a new nut with hypoid gear oil.

c. Using SST to hold the flange, torque the nut.
SST 09330-00021
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2004 Toyota RAV4
Fig. 8: Holding Flange & Torquing Nut

d. Adjust the preload of bearing on the drive pinion (See REASSEMBLY ).

9. STAKE DRIVE PINION NUT
10. INSTALL PROPELLER SHAFT (See COMPONENTS )
11. FILL DIFFERENTIAL WITH DIFFERENTIAL OIL (See REPLACE REAR DIFFERENTIAL
OIL )
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2004 Toyota RAV4
2004 ENGINE PERFORMANCE SFI - RAV4
2004 ENGINE PERFORMANCE
SFI - RAV4
SFI SYSTEM
PRECAUTION
HINT:
Any diagnostic trouble code (DTC) retained in the ECM will be erased when the negative (-) terminal cable is
removed from the battery. If necessary, read the DTC before removing the negative (-) terminal cable from the
battery.
1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE

FROM BATTERY
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL
SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS
4. MAINTENANCE PRECAUTIONS
a. To prevent engine misfire, these precautions should be taken.
1. Check the battery terminals for proper connection.
2. After repair, check that the ignition coil terminals and all other ignition system lines are
reconnected securely.
3. When cleaning the engine compartment, be especially careful to protect the electrical system
from water.
b. Observe the following when handling the heated oxygen sensors.
1. Do not drop the sensor or hit it against an object.
2. The sensor should be free from any contact with water.
5. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM (HAM, CB, ETC.)
If the vehicle is equipped with a mobile communication system, refer to the PRECAUTION .
6. AIR INDUCTION SYSTEM

a. Removal of the engine oil dipstick, oil filler cap, PCV hose may break the engine.
b. Disconnection, looseness or cracks in the parts of the air induction system between the throttle
body and cylinder head may allow air suction and break the engine.
7. ELECTRONIC CONTROL SYSTEM
a. Before removing the SFI wiring connectors, terminals, first disconnect the power by turning the
ignition switch OFF or disconnecting the negative (-) terminal cable from the battery.
HINT:
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2004 Toyota RAV4
Be sure to check the DTC before disconnecting the negative (-) terminal cable from the battery.
b. When installing the battery, be especially careful not to incorrectly connect the positive (+) and
negative (-) cables.
c. Do not give a severe impact to the SFI parts during removal or installation. Handle all the SFI parts
carefully, especially the ECM.
d. Be careful during troubleshooting. Numerous transistor circuits are used and even slight terminal
contact can cause further troubles.
e. Do not open the ECM cover.
f. When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the
engine compartment, prevent water from getting into the SFI parts and wiring connectors.
g. Parts should be replaced as an assembly.
h. Care should be taken when pulling out and inserting the wiring connectors.
1. Release the lock and pull out the connector, pulling on the connectors.
2. Fully insert the connector and check that it is locked.
i. Use SST for the inspection or test of the injector or its wiring connector.
SST 09842-30080
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2004 Toyota RAV4
Fig. 1: Identifying SST

8. FUEL SYSTEM
a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Observe
these procedures:
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2004 Toyota RAV4
Fig. 2: Disconnecting High Fuel Pressure Line

1. Disconnect the fuel pump connector.

2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
3. Put a container under the connection.
4. Slowly loosen the connection.
5. Disconnect the high fuel pressure line.
6. Reconnect the fuel pump connector.
b. Observe the following when removing and installing the injector:
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2004 Toyota RAV4
Fig. 3: Removing/Installing Injector

1. Never reuse the O-ring.

2. When placing a new O-ring on the injector, take care not to damage it in anyway.
3. Coat a new O-ring with spindle oil or gasoline before installing. Never use engine oil, gear
oil and brake oil.
c. Install the injector to the delivery pipe and cylinder head, as shown in Fig. 4 .
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2004 Toyota RAV4
Fig. 4: Installing Injector To Delivery Pipe & Cylinder Head

d. Observe the following when disconnecting the fuel tube connector (quick type):
1. Check if there is any dirt like mud in the pipe and around the connector before disconnecting
the fuel tube connector. If necessary, clean the dirt away.
2. Disconnect the fuel pipe clamp from the connector.
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2004 Toyota RAV4
Fig. 5: Disconnecting Fuel Pipe Clamp From Connector

3. Be sure to disconnect them with hands.

4. When the connector and the pipe are stuck, push and pull the connector. Then disconnect and
pull it out. Do not use any tools at this time.
5. Check if there is any dirt on the seal surface of the disconnected pipe. If necessary, clean the
dirt away.
6. Prevent the disconnected pipe and connector from being damaged and foreign objects mixing
in by covering them with a vinyl bag.
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2004 Toyota RAV4
Fig. 6: Pushing & Pulling Connector

e. Observe the following when connecting the fuel tube connector (quick type):
1. Check if there is any damage or foreign objects in the connected part of the pipe.
2. Match the axis of the connector with the axis of the pipe, and push into the connector until a
"click" sound is heard. If the connection is tight, apply little amount of fresh engine oil on the
tip of the pipe.
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2004 Toyota RAV4
Fig. 7: Matching Axis Of Connector With Axis Of Pipe & Pushing

3. After having finished the connection, pull the pipe and the connector to ensure secure
connection.
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2004 Toyota RAV4
Fig. 8: Pulling Pipe & Connector

4. Check to make sure no fuel leak is present.
If the result is not specified, repair or replace.
5. Install the fuel pipe clamp to the connector.
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2004 Toyota RAV4
Fig. 9: Installing Fuel Pipe Clamp

f. Observe the following when disconnecting the fuel tube connector (metallic type):
HINT:
The structure of the metallic connector is shown in Fig. 10 .
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2004 Toyota RAV4
Fig. 10: Identifying Structure Of Metallic Connector

1. Check if there is any dirt like mud in the pipe and around the connector before disconnecting
the fuel tube connector. If necessary, clean the dirt away.
2. Assemble SST to the connection, as shown in Fig. 11 .
SST 09268-21010
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2004 Toyota RAV4
Fig. 11: Assembling SST To Connection

3. Turn the SST, align the retainers inside the connector with the SST chamfered parts and
insert the SST into the connector.
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2004 Toyota RAV4
Fig. 12: Aligning Retainers & Inserting SST Into Connector

4. While holding the SST, pull the connector towards the SST to put the retainers on the SST
chamfered parts.
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2004 Toyota RAV4
Fig. 13: Pulling Connector Towards SST

5. Slide the SST and connector together towards the fuel tube assembly.
g. Observe the following when connecting the fuel tube connector (metallic type):
1. Check if there is any damage or foreign objects in the connected part of the pipe.
2. Match the axis of the connector with the axis of the pipe, and push into the connector until a
"click" sound is heard. If the connection is tight, apply little amount of fresh engine oil on the
tip of the pipe.
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2004 Toyota RAV4
Fig. 14: Matching Axis Of Connector With Axis Of Pipe & Pushing
3. After having finished the connection, pull the pipe and the connector to ensure secure
connection.
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2004 Toyota RAV4
Fig. 15: Pulling Pipe And Connector

h. Observer the following when handling the nylon tube:

1. Pay attention not to turn the connected part of the nylon tube and the quick connector with
tube when connecting them.
2. Pay attention not to kink the nylon tube.
3. Do not remove the nylon tube.
4. Do not close the piping with the nylon tube by bending it.
i. Check that there is no fuel leak after doing maintenance anywhere on the fuel system.
 Connect the hand-held tester to the DLC3.
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2004 Toyota RAV4

 Turn the ignition switch ON and push the hand-held tester main switch ON.
 Select the ACTIVE TEST mode on the hand-held tester.
NOTE: Do not start the engine.
HINT:
If you have no hand-held tester, connect the battery's positive (+) and negative (-) leads to the
fuel pump connector (see FUEL PUMP ).
2. Check that there is no leak from any parts of the fuel system.
4. Disconnect the hand-held tester from the DLC3.
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2004 Toyota RAV4
FUEL PUMP
1. CHECK FUEL PUMP OPERATION



2. Turn the ignition switch ON and push the hand-held tester main switch ON.
3. Select the ACTIVE TEST mode on the hand-held tester.
HINT:
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2004 Toyota RAV4
If you have no hand-held tester, connect the battery's positive (+) negative (-) leads the fuel pump
connector (see step 3 ).
b. Check that there is pressure in the fuel inlet tube from the fuel line.
Fig. 18: Checking Pressure In Fuel Inlet Tube

HINT:
If there is fuel pressure, you will hear the sound of the fuel flowing.
If there is no pressure, check the fusible link, fuses, EFI Main relay, fuel pump, ECM and wiring
connector.
c. Turn the ignition switch OFF.

d. Disconnect the hand-held tester from the DLC3.
2. CHECK FUEL PRESSURE
a. Check the battery positive voltage is above 12 V.
b. Disconnect the negative (-) terminal cable from the battery.
c. Purchase a new fuel tube and remove the fuel tube connector from its pipe.
Fuel tube: Part No. 23901-22110
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2004 Toyota RAV4
Fig. 19: Identifying Fuel Tube Connector

d. Disconnect the fuel tube clamp from the fuel tube connector.
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2004 Toyota RAV4
Fig. 20: Disconnecting Fuel Tube Clamp From Fuel Tube Connector
e. Disconnect the fuel inlet tube (fuel tube connector) from the fuel pipe.
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2004 Toyota RAV4
Fig. 21: Disconnecting Fuel Inlet Tube From Fuel Pipe

NOTE:  Disconnect the fuel tube connector (quick type) after observing
the precaution (see SFI SYSTEM ).
 If there is retained pressure in the fuel line, prevent it from
splashing inside the engine compartment.
f. Install SST (pressure gauge) as shown in Fig. 22 using SST and fuel tube connector.
SST 09268-41047, 09268-45014 (09268-41250)
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2004 Toyota RAV4
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2004 Toyota RAV4
Fig. 22: Installing SST (Pressure Gauge) Using SST & Fuel Tube Connector
g. Wipe off any splattered gasoline.

h. Reconnect the negative (-) terminal cable to the battery.
i. Connect the hand-held tester to the DLC3 (see step 1 ).
j. Measure the fuel pressure.
Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm2 ,44 to 50 psi)
If the pressure is high, replace the fuel pressure regulator.
If the pressure is low, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure
regulator.
k. Disconnect the hand-held tester from the DLC3.

l. Start the engine.
m. Measure the fuel pressure at idle.
Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm2 ,44 to 50 psi)
n. Stop the engine.

o. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Fuel pressure: 147 kPa (1.5 kgf/cm2 ,21 psi) or more
If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
p. After checking the fuel pressure, disconnect the negative (-) terminal cable from the battery and
carefully remove the SST and fuel tube connector to prevent gasoline from splashing.
SST 09268-41047, 09268-45014
q. Reconnect the fuel inlet tube (fuel tube connector).
CAUTION: Connect the fuel tube connector (quick type) observing the
precaution (See SFI SYSTEM ).
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2004 Toyota RAV4
Fig. 23: Reconnecting Fuel Inlet Tube

r. Reconnect the fuel tube clamp to the fuel tube connector.
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2004 Toyota RAV4
Fig. 24: Reconnecting Fuel Tube Clamp

s. Reconnect the negative (-) terminal cable to the battery.

t. Check for fuel leak (see SFI SYSTEM ).
3. INSPECT FUEL PUMP
a. Remove the LH rear seat.
b. Remove the floor service hole cover.
c. Disconnect the fuel pump & sender gauge connector.
d. Using an ohmmeter, measure the resistance between terminals 4 and 5.
Resistance: 0.2 to 3.0 ohm at 20°C (68°F)
If the resistance is not as specified, replace the fuel pump.
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2004 Toyota RAV4
Fig. 25: Measuring Resistance Between Terminals 4 And 5 Using Ohmmeter

e. Inspect the fuel pump operation.
Connect the battery's positive (+) lead to terminal 4 of the connector and the negative (-) lead to
terminal 5. Check that the pump operates.
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2004 Toyota RAV4
Fig. 26: Connecting Battery Leads To Terminal 4 & 5

NOTE:  These tests must be performed within 10 seconds to prevent the

coil from burning out.
 Keep the fuel pump as far away from the battery as possible.
If operation is not as specified, replace the fuel pump.
f. Reconnect the fuel pump & sender gauge connector.

g. Reinstall the floor service hole cover.
h. Reinstall the LH rear seat.
COMPONENTS
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2004 Toyota RAV4
Fig. 27: Identifying Fuel Pump Components

REPLACEMENT
CAUTION: Do not smoke or work near an open flame when working on the fuel pump.
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2004 Toyota RAV4
1. REMOVE LH REAR SEAT

2. REMOVE FLOOR SERVICE HOLE COVER
3. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
4. DISCONNECT VAPOR PRESSURE SENSOR CONNECTOR
5. DISCONNECT FUEL TANK MAIN TUBE
CAUTION:  Disconnect the fuel tube connector (quick type) observing the
precaution (see SFI SYSTEM ).
 As there is retained pressure in the fuel line, prevent it from
splashing inside the luggage compartment.
Remove the tube joint clip and disconnect the main tube.
Fig. 28: Removing Tube Joint Clip & Disconnecting Main Tube
6. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK
a. Remove the 8 bolts and fuel tank vent tube set plate.
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2004 Toyota RAV4
Fig. 29: Removing Bolts & Fuel Tank Vent Tube Set Plate
b. Lift up the fuel pump and sender gauge assembly, and disconnect the fuel sub suction hose from the
fuel return jet tube. Remove the fuel pump, sender gauge assembly and gasket.
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2004 Toyota RAV4
Fig. 30: Disconnecting Fuel Sub Suction Hose From Fuel Return Jet Tube
NOTE:  Do not damage the fuel suction filter.

 Be careful not to bend the arm of the sender gauge.
c. Remove the gasket from the suction plate.

7. REMOVE FUEL SUCTION SUPPORT
a. Using a screwdriver, pry out the fuel suction support.
NOTE: Be careful not to damage the suction support.
b. Remove the rubber cushion.
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2004 Toyota RAV4
Fig. 31: Prying Out Fuel Suction Support Using Screwdriver

8. REMOVE FUEL SUCTION PLATE

a. Disconnect the fuel sender gauge connector and ground plate.
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2004 Toyota RAV4
Fig. 32: Disconnecting Fuel Sender Gauge Connector And Ground Plate
b. Using 2 screwdrivers, pry out the fuel suction plate.
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2004 Toyota RAV4
Fig. 33: Prying Out Fuel Suction Plate Using Screwdrivers

NOTE: Be careful not to damage the suction support and suction plate.
c. Remove the fuel pump harness.
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2004 Toyota RAV4
Fig. 34: Removing Fuel Pump Harness

9. REMOVE FUEL PUMP
Pull out the fuel pump.
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2004 Toyota RAV4
Fig. 35: Pulling Out Fuel Pump

10. REMOVE FUEL SUCTION FILTER FROM FUEL PUMP

a. Using a small screwdriver, pry out the clip.
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2004 Toyota RAV4
Fig. 36: Prying Out Clip Using Screwdriver

b. Pull out the suction filter.

11. REINSTALL FUEL SUCTION FILTER
Install the suction filter with a new clip.
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2004 Toyota RAV4
Fig. 37: Installing Suction Filter With Clip

12. REINSTALL FUEL PUMP
Push into the fuel pump.
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2004 Toyota RAV4
Fig. 38: Pushing In Fuel Pump

13. REINSTALL FUEL SUCTION PLATE

a. Connect the fuel pump harness.
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2004 Toyota RAV4
Fig. 39: Connecting Fuel Pump Harness

b. Install the fuel suction plate and fuel filter assembly.
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2004 Toyota RAV4
Fig. 40: Installing Fuel Suction Plate And Fuel Filter Assembly
c. Connect the fuel sender gauge connector and ground plate.
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2004 Toyota RAV4
Fig. 41: Connecting Fuel Sender Gauge Connector And Ground Plate
14. INSTALL FUEL SUCTION SUPPORT

a. Install the rubber cushion.
b. Install the fuel suction support to the fuel filter assembly.
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2004 Toyota RAV4
Fig. 42: Installing Fuel Suction Support To Fuel Filter Assembly

15. REINSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY TO FUEL TANK
a. Install a new gasket to the suction plate.
b. Connect the sub suction hose to the fuel return jet tube.
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2004 Toyota RAV4
Fig. 43: Connecting Sub Suction Hose To Fuel Return Jet Tube
c. Insert the fuel pump assembly into the fuel tank.
NOTE:  Do not damage the fuel suction filter.

 Be careful not to bend the arm of the sender gauge.
d. Align the positioning mark of the set plate with bolt hole position A.
e. Install the fuel tank vent tube set plate with the 8 bolts.
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2004 Toyota RAV4
Fig. 44: Installing Fuel Tank Vent Tube With Bolts

16. RECONNECT FUEL TANK MAIN TUBE
Connect the main tube with the tube joint clip.
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2004 Toyota RAV4
Fig. 45: Connecting Main Tube With Tube Joint Clip

NOTE:  Check that the connector is inserted fully and securely.

 Check that the clip of the tube joint is on the collar of the connector.
 After installing the clip of the tube joint, check that the connector is not
pulled off.
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2004 Toyota RAV4
Fig. 46: Identifying Fuel Tube Joint, Fuel Suction Plate, Fuel Pump Tube,
Clip & O-Ring
17. RECONNECT VAPOR PRESSURE SENSOR CONNECTOR

18. RECONNECT FUEL PUMP and SENDER GAUGE CONNECTOR
19. CHECK FOR FUEL LEAK (See SFI SYSTEM )
20. REINSTALL FLOOR SERVICE HOLE COVER
21. REINSTALL LH REAR SEAT
FUEL PRESSURE REGULATOR

COMPONENTS
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Fig. 47: Identifying Fuel Pressure Regulator Components

REPLACEMENT
1. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK (See
REPLACEMENT )
2. REMOVE FUEL SUCTION PLATE
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a. Disconnect the fuel sender gauge connector and ground plate.
Fig. 48: Disconnecting Fuel Sender Gauge Connector & Ground Plate
b. Using 2 screwdrivers, pry out the fuel suction plate.
NOTE: Be careful not to damage the suction support and fuel suction plate.
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Fig. 49: Prying Out Fuel Suction Plate Using Screwdrivers

c. Disconnect the fuel pump connector.
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Fig. 50: Disconnecting Fuel Pump Connector

3. REMOVE FUEL PRESSURE REGULATOR

a. Disconnect the fuel return jet tube from the clamp.
b. Pull out the pressure regulator.
c. Remove the O-ring from the pressure regulator.
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Fig. 51: Disconnecting Fuel Return Jet Tube From Clamp & Pulling Out Pressure Regulator
4. REINSTALL FUEL PRESSURE REGULATOR

a. Install a new O-ring to the pressure regulator.
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Fig. 52: Installing O-Ring To Pressure Regulator

b. Apply a light coat of gasoline to the O-ring, and push into the pressure regulator.
c. Connect the fuel return jet tube to the clamp.
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Fig. 53: Pushing O-Ring Into Pressure Regulator & Connecting Fuel Return Jet Tube To
Clamp
5. REINSTALL FUEL SUCTION PLATE

a. Connect the fuel pump connector.
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Fig. 54: Connecting Fuel Pump Connector

b. Install the fuel suction plate to the fuel filter and fuel pump assembly.
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Fig. 55: Installing Fuel Suction Plate To Fuel Filter And Fuel Pump Assembly
c. Connect the fuel sender gauge connector and ground plate.
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Fig. 56: Connecting Fuel Sender Gauge Connector And Ground Plate
6. REINSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY TO FUEL TANK (See
REPLACEMENT )
INJECTOR

b. Disconnect the VSV hose for CCV.
c. Remove the 3 bolts and air cleaner assembly, air cleaner inlet, MAF meter together in one piece.
2. INSPECT INJECTOR OPERATION
Check the each injectors for operation sound.

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1. With the engine running or cranking, use a sound scope to check that there is normal operating
noise in proportion to the engine speed.
Fig. 57: Using Sound Scope To Check For Normal Operating Noise
2. If you have no sound scope, you can check it by feeling the injector operating vibration with your
finger.
If no sound or unusual sound is heard, check the wiring connector, injector or injection signal from the
ECM.
3. INSPECT INJECTOR RESISTANCE

a. Disconnect the injector connector.
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Fig. 58: Measuring Resistance Between Terminals Using Ohmmeter

If the resistance is not as specified, replace the injector.
c. Reconnect the injector connector.

4. REINSTALL AIR CLEANER ASSEMBLY
COMPONENTS
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Fig. 59: Identifying Injector Components

REMOVAL
1. DISCONNECT PCV HOSE

2. REMOVE AIR CLEANER INLET AND AIR CLEANER ASSEMBLY WITH MAF METER
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c. Remove the 3 bolts and air cleaner assembly, air cleaner inlet, MAF meter together in one piece.
3. REMOVE INJECTORS
a. Disconnect the 4 injector connectors.
b. Remove the 2 bolts holding the delivery pipe to the cylinder head.
Fig. 60: Disconnecting Injector Connectors & Removing Bolts

c. Disconnect the delivery pipe together with the 4 injectors from the cylinder head.
NOTE: Be careful not to drop the injectors when disconnecting the delivery
pipe.
d. Remove the 2 spacers and 4 grommets.

e. Pull out the 4 injectors from the delivery pipe.
f. Remove the O-ring from each injector.
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INSPECTION
1. INSPECT INJECTOR INJECTION
Fig. 61: Inspecting Injector Injection

CAUTION: Keep injector clear of sparks during the test.
a. Disconnect the fuel pipe clamp from the fuel tube connector.
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Fig. 62: Disconnecting Fuel Pipe Clamp From Fuel Tube Connector
b. Disconnect the fuel inlet tube (fuel tube connector) from the fuel pipe.
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Fig. 63: Disconnecting Fuel Inlet Tube From Fuel Pipe

CAUTION:  Disconnect the fuel tube connector (quick type) observing

the precaution (see SFI SYSTEM ).
 As there is retained pressure in the fuel line, prevent it
from splashing inside the engine compartment.
c. Purchase a new fuel tube. Remove the fuel tube connector from its pipe.
Fuel tube: Part No. 23901-22110
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Fig. 64: Identifying Fuel Tube Connector

d. Connect SST (hose) and fuel tube connector to the fuel pipe.
SST 09268-41047
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Fig. 65: Connecting SST (Hose) And Fuel Tube Connector To Fuel Pipe
CAUTION: Disconnect the fuel tube connector (quick type) observing the
precautions (see SFI SYSTEM ).
e. Install the grommet and O-ring to the injector.

f. Connect SST (union and hose) to the injector.
SST 09268-41047 (09268-41110, 09268-41300)
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Fig. 66: Connecting SST (Union & Hose) To Injector

g. Put the injector into a graduated cylinder.
CAUTION: Install a suitable vinyl hose onto the injector to prevent gasoline
from splashing out.
h. Connect the hand-held tester to the DLC3.
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2. Connect the battery negative (-) terminal cable to the battery.
3. Turn the ignition switch ON and push the hand-held tester main switch ON.
4. Select the ACTIVE TEST mode on the hand-held tester.
HINT:
If you have no hand-held tester, connect the positive (+) and negative (-) leads from the
battery to the fuel pump connector (see FUEL PUMP ).
i. Connect the battery to the injector with SST (wire) for 15 seconds, and measure the injection
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volume with a graduated cylinder. Test each injector 2 or 3 times.
SST 09842-30080
Fig. 68: Connecting Battery To Injector With SST

Injection volume:
76 to 92 cm3 (4.6 to 5.6 cu in.) per 15 seconds. Difference between each injector: 16 cm3 (1.0
cu in.) or less
If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE
a. In the above condition, disconnect the tester probes of SST (wire) from the battery and check the
fuel leak from the injector.
SST 09842-30080
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Fig. 69: Checking Fuel Leak From Injector

Fuel drop: 1 drop or less per 12 minutes.
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c. Disconnect the negative (-) terminal cable from the battery.
d. Remove SST and fuel tube connector.
SST 09268-41047
e. Disconnect the hand-held tester from the DLC3.

f. Reconnect the fuel tube (fuel tube connector).
CAUTION: Disconnect the fuel tube connector (quick type) observing the
precaution (see SFI SYSTEM ).
Fig. 70: Reconnecting Fuel Tube

g. Reconnect the fuel pipe clamp to the fuel tube connector.
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Fig. 71: Reconnecting Fuel Pipe Clamp To Fuel Tube Connector

INSTALLATION
1. INSTALL INJECTORS AND DELIVERY PIPES

a. Apply a light coat of spindle oil or gasoline to a new O-ring, and install it to each injector.
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Fig. 72: Applying Light Coat Of Spindle Oil Or Gasoline To O-Ring

b. Install the 2 spacers and 4 new grommets to the cylinder head.
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Fig. 73: Installing Spacers And Grommets To Cylinder Head

c. Apply a light coat of spindle oil or gasoline to the place where a delivery pipe touches the O-ring.
d. Push the injector to the delivery pipes turning the injector as shown in Fig. 74 . Then install the 4
injectors.
e. Position the injector connector downward.
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Fig. 74: Pushing Injector To Delivery Pipes & Positioning Injector Connector Downward
f. Attach the delivery pipe together with the 4 injectors to the cylinder head.
g. Temporarily install the 2 bolts holding the delivery pipe to the cylinder head.
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Fig. 75: Installing Bolts Holding Delivery Pipe To Cylinder Head

h. Check that the injectors rotate smoothly.
HINT:
If injectors do not rotate smoothly, the possible cause is incorrect installation of the O-ring. Replace
the O-ring.
i. Position the injector connector downward.
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Fig. 76: Checking Injectors Rotate Smoothly & Positioning Injector Connector Downward
j. Tighten the 2 bolts holding the delivery pipe to the cylinder head.
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Fig. 77: Tightening Bolts Holding Delivery Pipe To Cylinder Head

k. Connect the 4 injector connectors.

2. INSTALL AIR CLEANER ASSEMBLY WITH MAF METER
3. CONNECT PCV HOSE
FUEL PRESSURE PULSATION DAMPER

COMPONENTS
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Fig. 78: Identifying Fuel Pressure Pulsation Damper Components

REPLACEMENT
1. REMOVE AIR CLEANER HOSE
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2. DISCONNECT ACCELERATOR CABLE

3. REMOVE FUEL PRESSURE PULSATION DAMPER
a. Disconnect the fuel tube connector (metallic connector) (see SFI SYSTEM ).
CAUTION:  Disconnect the fuel tube connector (metallic connector)

after observing the precautions.
 As there is retained pressure in the fuel pipe line, prevent
it from splashing inside the engine compartment.
b. Remove the 2 bolts and pulsation damper.

4. REINSTALL FUEL PRESSURE PULSATION DAMPER
a. Install the pulsation damper with the 2 bolts.
Torque: 9 N.m (90 kgf.cm, 80 in.lbf)
Fig. 79: Removing/Installing Bolts & Pulsation Damper

b. Connect the fuel tube connector (metallic connector) (see SFI SYSTEM ).
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5. RECONNECT ACCELERATOR CABLE

6. RECONNECT AIR CLEANER HOSE
FUEL TANK AND LINE

COMPONENTS
CAUTION:  Always use new gaskets when replacing the fuel tank or component
parts.
 Apply the proper torque to all the parts to be tightened.
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Fig. 80: Identifying Fuel Tank And Line Components

INSPECTION
Inspect Fuel Tank And Line
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a. Check the fuel lines for cracks or leak, and all connections for deformation.
b. Check the fuel tank for deformation, cracks fuel leak or tank band looseness.
c. Check the filter neck for damage or fuel leak.
Fig. 81: Identifying Deformed, Damaged, Cracked Or Leaking Pipe

d. Check that hose and tube connections are as shown in Fig. 82 .
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Fig. 82: Checking Hose And Tube Connections

If a problem is found, repair or replace the part as necessary.
MASS AIR FLOW (MAF) METER

COMPONENTS
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Fig. 83: Identifying Mass Air Flow (MAF) Meter Components

INSPECTION
1. DISCONNECT MAF METER CONNECTOR

2. REMOVE MAF METER
Remove the 2 screws and MAF meter.

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Fig. 84: Removing Screws And MAF Meter

3. INSPECT MAF METER

a. Using an ohmmeter, measure the resistance between terminals THA and E2.
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Fig. 85: Measuring Resistance Between Terminals THA And E2 Using Ohmmeter
Resistance:
RESISTANCE SPECIFICATION
-20°C (-4°F) 13.6 to 18.4 ohm
20°C (68°F) 2.21 to 2.69 ohm
60°C (140°F) 0.49 to 0.67 ohm
If the resistance is not as specified, replace the MAF meter.
b. Inspect operation.
a. Connect the MAF meter connector.
b. Connect the negative (-) terminal cable to the battery.
d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-)
tester probe to terminal E2G.
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Fig. 86: Connecting Tester Probes To Terminals VG & E2G Using Voltmeter
e. Blow air into the MAF meter, and check that the voltage fluctuates.
If operation is not as specified, replace the MAF meter.
f. Turn the ignition switch OFF.

g. Disconnect the negative (-) terminal cable from the battery.
h. Disconnect the MAF meter connector.
4. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
5. RECONNECT MAF METER CONNECTOR
THROTTLE BODY
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CAUTION: When removing deposits on the throttle body, be sure to remove the
connector or remove the battery.
1. INSPECT SYSTEM OPERATION

a. Inspect the throttle control motor operating sound.
2. When turning the accelerator pedal position sensor lever, check the running sound of the
motor. Also, check that there is no friction sound.
Fig. 87: Inspecting Throttle Control Motor Operating Sound

If the result is not as specified, check the throttle control motor (see step 2), wiring and ECM.
b. Inspect the accelerator pedal position sensor.

1. Connect the hand-held tester or OBD II scan tool to the DLC3.
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3. Make sure that the check engine warning lamp (CHK ENG) does not illuminate.
4. When turning the accelerator pedal position sensor lever to the full-open position, make sure
that the CURRENT DATA throttle valve opening percentage (THROTTLE POS) shows the
standard value below.
Standard throttle valve opening percentage: 60 % or more
If the result is not as specified, check that the accelerator pedal position sensor (see step 4 ), wiring
and ECM.
2. INSPECT THROTTLE CONTROL MOTOR RESISTANCE

a. Disconnect the connector.
Resistance: 0.3 to 100 ohm at 20°C (68°F)
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If the result is not as specified, replace the throttle body.
3. INSPECT THROTTLE POSITION SENSOR (See DTC P0120: THROTTLE/PEDAL POSITION

SENSOR/SWITCH "A" CIRCUIT MALFUNCTION, DTC P0122 THROTTLE/PEDAL
POSITION SENSOR/SWITCH "A" CIRCUIT LOW INPUT, DTC P0123 THROTTLE/PEDAL
POSITION SENSOR/SWITCH "A" CIRCUIT HIGH INPUT, DTC P0220 THROTTLE/PEDAL
POSITION SENSOR/SWITCH "B" CIRCUIT MALFUNCTION, DTC P0222
THROTTLE/PEDAL POSITION SENSOR/SWITCH "B" CIRCUIT LOW INPUT, DTC P0223
THROTTLE/PEDAL POSITION SENSOR/SWITCH "B" CIRCUIT HIGH INPUT, DTC P2135
THROTTLE/PEDAL POSITION SENSOR/SWITCH "A"/"B" VOLTAGE CORRECTION )
If necessary, replace the throttle body assembly (see REMOVAL and INSTALLATION ).
4. INSPECT ACCELERATOR PEDAL POSITION SENSOR (See INSPECT ACCELERATOR

PEDAL POSITION SENSOR )
If necessary, replace the accelerator pedal assembly (see REMOVAL and INSTALLATION ).
COMPONENTS
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Fig. 90: Identifying SFI Throttle Body Components

REMOVAL

2. REMOVE AIR CLEANER INLET AND AIR CLEANER ASSEMBLY WITH MAF METER
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c. Remove the 3 bolts and air cleaner inlet, air cleaner assembly and MAF meter together in one
piece.
3. REMOVE AIR CLEANER HOSE AND PCV HOSE
a. Disconnect the VSV connector for EVAP.
b. Disconnect the VSV hose for EVAP.
c. Disconnect the PCV hose.
d. Remove the air cleaner hose.
4. REMOVE THROTTLE BODY
a. Disconnect the throttle position sensor & control motor connector.
Fig. 91: Disconnecting Throttle Position Sensor & Control Motor Connector
b. Disconnect the 5 hoses.

c. Remove the 4 bolts, bracket and throttle body from the intake manifold.
d. Remove the gasket.
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Fig. 92: Removing Bolts, Bracket & Throttle Body From Intake Manifold
INSTALLATION
1. INSTALL THROTTLE BODY

a. Install a new gasket on the intake manifold, as shown in Fig. 93 .
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Fig. 93: Installing Gasket On Intake Manifold

b. Install the throttle body, bracket and fuel hose clamp with the 4 bolts.
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Fig. 94: Installing Throttle Body, Bracket & Fuel Hose Clamp With Bolts
c. Connect the 5 hoses to the throttle body.

d. Connect the throttle position sensor & control motor connector.
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Fig. 95: Connecting Throttle Position Sensor & Control Motor Connector
2. INSTALL AIR CLEANER HOSE

3. INSTALL AIR CLEANER ASSEMBLY WITH MAF METER AND BRACKET
4. FILL RADIATOR WITH ENGINE COOLANT
CAMSHAFT TIMING OIL CONTROL VALVE

Inspect Camshaft Timing Oil Control Valve (OCV) Resistance

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If the resistance is not as specified, replace the OCV.
c. Reconnect the OCV connector.
COMPONENTS
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Fig. 97: Identifying Camshaft Timing Oil Control Valve Components

INSPECTION
1. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE (OCV)

b. Remove the bolt and OCV.
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c. Remove the O-ring from the OCV.
Fig. 98: Removing Camshaft Timing Oil Control Valve

2. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE (OCV) OPERATION
Connect the battery's positive (+) lead to terminal 1 and negative (-) lead to terminal 2. Check the
movement of the valve as shown in Fig. 99 and Fig. 100 .
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Fig. 99: Connecting Battery Positive Lead To Terminal 1 And Negative Lead To Terminal 2
Fig. 100: Battery Voltage Specification Table

If operation is not as specified, replace the OCV.
3. REINSTALL CAMSHAFT OIL CONTROL VALVE (OCV)

a. Install a new O-ring to the OCV.
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b. Install the OCV completely, and tighten the bolt.
c. Connect the OCV connector.
EFI MAIN RELAY

INSPECTION
1. REMOVE RELAY BOX COVER

2. REMOVE EFI MAIN RELAY
Fig. 101: Removing Relay Box Cover & EFI Main Relay
3. INSPECT EFI MAIN RELAY

a. Inspect the relay continuity.
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1. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
2. Check that there is no continuity between terminals 3 and 5.
Fig. 102: Checking Continuity Between Terminals 1 + 2 & No Continuity Between

Terminals 3 + 5 Using Ohmmeter
If there is continuity, replace the relay.
b. Inspect the relay operation.

1. Apply battery positive voltage to terminals 1 and 2.
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Fig. 103: Checking Continuity Between Terminals 3 + 5 Using Ohmmeter

4. REINSTALL EFI MAIN RELAY

5. REINSTALL RELAY BOX COVER
A/F SENSOR HEATER RELAY

INSPECTION

2. REMOVE A/F SENSOR HEATER RELAY (Marking: A/F)
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Fig. 104: Removing Relay Box Cover & A/F Sensor Heater Relay
3. INSPECT A/F SENSOR HEATER RELAY

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4. REINSTALL A/F SENSOR HEATER RELAY

CIRCUIT OPENING RELAY

INSPECTION

2. REMOVE CIRCUIT OPENING RELAY (Marking: C/OPN)
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Fig. 107: Removing Relay Box Cover & Circuit Opening Relay
3. INSPECT CIRCUIT OPENING RELAY


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4. REINSTALL CIRCUIT OPENING RELAY

VSV FOR EVAPORATIVE EMISSION (EVAP)

COMPONENTS
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Fig. 110: Identifying VSV For Evaporative Emission (EVAP) Components

INSPECTION
1. REMOVE VSV
2. INSPECT VSV
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a. Inspect the VSV for open circuit.
Using an ohmmeter, check that there is continuity between the terminals.
Resistance: 30 to 34 ohm at 20°C (68°F)
Fig. 111: Checking Continuity Between Terminals Using Ohmmeter

If there is no continuity, replace the VSV.
b. Inspect the VSV for ground.
Using an ohmmeter, check that there is no continuity between each terminal and the VSV body.
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Fig. 112: Checking For No Continuity Between Each Terminal And VSV Body Using
Ohmmeter
If there is continuity, replace the VSV.
c. Inspect the VSV operation.

1. Check that air flows with a little difficulty from ports E to F.
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Fig. 113: Checking Air Flows From Ports E To F

2. Apply battery positive voltage to the terminals.

3. Check that air flows from ports E to F.
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Fig. 114: Applying Battery Positive Voltage To Terminals & Checking Air Flows From
Ports E To F
If the operation is not as specified, replace the VSV.
3. REINSTALL VSV
VSV FOR CANISTER CLOSED VALVE (CCV)

COMPONENTS
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Fig. 115: Identifying VSV For Canister Closed Valve (CCV) Components
INSPECTION
1. REMOVE VSV
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2. INSPECT VSV
Using an ohmmeter, measure the resistance between the terminals.

If the result is not as specified, replace the VSV.
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Ohmmeter
If there is continuity, replace the VSV.

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Fig. 118: Checking Air Flows From Ports E To F


3. Check that air does not flow from ports E to F.
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Ports E To F
3. REINSTALL VSV
VSV FOR PRESSURE SWITCHING VALVE

COMPONENTS
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Fig. 120: Identifying VSV For Pressure Switching Valve Components

INSPECTION
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1. REMOVE VSV
2. INSPECT VSV

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Ohmmeter

1. Check that air does not flow from ports E to F.
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Fig. 123: Checking Air Does Not Flow From Ports E To F


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Ports E To F
3. REINSTALL VSV
ENGINE COOLANT TEMPERATURE (ECT) SENSOR

COMPONENTS
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Fig. 125: Identifying Engine Coolant Temperature (ECT) Sensor Components

INSPECTION

2. REMOVE ECT SENSOR
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b. Using a 19 mm deep socket wrench, remove the sensor and gasket.
Fig. 126: Removing ECT Sensor

3. INSPECT ECT SENSOR
Resistance: Refer to Fig. 127
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Fig. 127: Measuring Resistance Between Terminals Using Ohmmeter & Graph
If the resistance is not as specified, replace the sensor.
4. REINSTALL ECT SENSOR

a. Install a new gasket to the sensor.
b. Using a 19 mm deep socket wrench, install the sensor.
c. Connect the sensor connector.

5. REFILL WITH ENGINE COOLANT
VAPOR PRESSURE SENSOR

COMPONENTS
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Fig. 128: Identifying Vapor Pressure Sensor Components

INSPECTION
1. REMOVE LUGGAGE COMPARTMENT BOX

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2. REMOVE FLOOR SERVICE HOLE COVER

3. REMOVE VAPOR PRESSURE SENSOR
a. Remove the 2 bolts and No. 3 fuel tank protector.
b. Disconnect the vapor pressure sensor connector.
c. Remove the clip and vapor pressure sensor.
4. INSPECT VAPOR PRESSURE SENSOR
b. Using a voltmeter, measure the voltage between terminals VC and E2 of the wiring harness side
connector.
Fig. 129: Measuring Voltage Between Terminals VC And E2 Of Wiring Harness Side
Connector Using Voltmeter
c. Turn the ignition switch OFF.

5. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR
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a. Connect the vapor pressure sensor connector.

c. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under
the following conditions:
1. Apply vacuum (2.0 kPa (15 mmHg, 0.59 in.Hg)) to the vapor pressure sensor.
2. Release the vacuum from the vapor pressure sensor.
3. Apply pressure (1.5 kPa (15 gf/cm2 , 0.22 psi)) to the vapor pressure sensor.
d. Turn the ignition switch OFF.
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Fig. 130: Inspecting Power Output Of Vapor Pressure Sensor

6. REINSTALL VAPOR PRESSURE SENSOR

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a. Reinstall the vapor pressure sensor and clip.

b. Reconnect the vapor pressure sensor connector.
c. Reinstall the 2 bolts and No. 3 fuel tank protector.
7. REINSTALL FLOOR SERVICE HOLE COVER
8. REINSTALL LUGGAGE COMPARTMENT BOX
KNOCK SENSOR
COMPONENTS
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Fig. 131: Identifying Knock Sensor Components

INSPECTION
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1. REMOVE ENGINE FROM VEHICLE (See REMOVAL )

2. REMOVE INTAKE MANIFOLD AND THROTTLE BODY ASSEMBLY (See REMOVAL )
3. REMOVE KNOCK SENSOR
a. Disconnect the knock sensor connector.
b. Remove the nut and knock sensor.
Fig. 132: Removing Knock Sensor & Nut

4. INSPECT KNOCK SENSOR
Using an ohmmeter, make sure there is continuity between the terminals.
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Fig. 133: Inspecting Knock Sensor

If there is no continuity, replace the sensor.
5. REINSTALL KNOCK SENSOR

a. Install the knock sensor with the nut.
HINT:
Angling the knock sensor below the horizontal (below 0°) is recommended.
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Fig. 134: Installing Knock Sensor To Proper Angle

b. Connect the knock sensor connector.

6. REINSTALL INTAKE MANIFOLD AND THROTTLE BODY ASSEMBLY (See
INSTALLATION )
7. INSTALL ENGINE TO VEHICLE (See INSTALLATION )
AIR-FUEL RATION (A/F) SENSOR

COMPONENTS
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Fig. 135: Identifying Air-Fuel Ration (A/F) Sensor Components

INSPECTION
1. INSPECT HEATER RESISTANCE OF A/F SENSOR

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b. Using an ohmmeter, measure the resistance between terminals +B and HT.
Fig. 136: Measuring Resistance Between Terminals +B And HT Using Ohmmeter


2. INSPECT OPERATION OF A/F SENSOR (See DTC P2195: OXYGEN (A/F) SENSOR SIGNAL
STUCK LEAN (BANK 1 SENSOR 1), DTC P2196: OXYGEN (A/F) SENSOR SIGNAL STUCK
RICH (BANK 1 SENSOR 1) )
HEATED OXYGEN SENSOR

COMPONENTS
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Fig. 137: Identifying Heated Oxygen Sensor Components

INSPECTION
1. INSPECT HEATER RESISTANCE OF OXYGEN SENSOR

b. Using an ohmmeter, measure the resistance between terminals +B and HT.
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Fig. 138: Measuring Resistance Between Terminals +B And HT Using Ohmmeter


2. INSPECT OPERATION OF HEATED OXYGEN SENSOR (See DTC P0136: OXYGEN SENSOR
CIRCUIT MALFUNCTION (BANK 1 SENSOR 2) )
ACCELERATOR PEDAL POSITION SENSOR

COMPONENTS
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Fig. 139: Identifying Accelerator Pedal Position Sensor Components

INSPECTION
Inspect Accelerator Pedal Position Sensor
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b. Using an ohmmeter, measure the resistance between the each terminals.
Fig. 140: Measuring Resistance Between Each Terminal Using Ohmmeter

Resistance:
TERMINAL RESISTANCE SPECIFICATION

Terminals Resistance
VCP1 - EP1
2.25 to 4.75 kohm at 20°C (68°F)
VCP2 - EP2
If the resistance is not as specified, replace the accelerator pedal assembly.
NOTE:  Be careful not to give a shock to the accelerator pedal assembly.

 Be careful not to disassemble the accelerator pedal assembly.
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ENGINE CONTROL MODULE (ECM)

COMPONENTS
Fig. 141: Identifying Engine Control Module (ECM) Components

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2004 Toyota RAV4
INSPECTION
INSPECTION ECM (See TERMINALS OF ECM )
FUEL CUT RPM

INSPECTION
1. WARM UP ENGINE
Warm up the engine to the normal operating temperature.
2. CONNECT HAND-HELD TESTER OR OBD II SCAN TOOL TO DLC3


HINT:
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2004 Toyota RAV4
Select the item "DIAGNOSIS/ENHANCED OBD II/DATA LIST/ALL/FC IDL".


 Please refer to the hand-held tester or OBD II scan tool operator's manual for further details.
3. INSPECT FUEL CUTOFF/RESTART RPM

a. Increase the engine speed to at least 3,000 RPM.
b. Use a sound scope to check for the injector operating noise.
Fig. 143: Using Sound Scope To Check For Injector Operating Noise
c. When the accelerator pedal is released, injector operation sounds stop momentarily and then
resumes.
HINT:
Measure with the A/C OFF.
Standard:
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2004 Toyota RAV4
RPM SPECIFIED CONDITION

Item Specified Condition
Fuel cutoff RPM 1,050 to 1,150 RPM (M/T), 1,350 to 1,450 RPM (A/T)
Fuel injector restart RPM 850 to 950 RPM (M/T), 1,050 to 1,150 RPM (A/T)
If the result is not as specified, check for DTCs. If a DTC is present, follow the repair procedures
according to the DTC.
4. DISCONNECT HAND-HELD TESTER OR OBD II SCAN TOOL FROM DLC3
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2004 Toyota RAV4
2004 SYSTEM WIRING DIAGRAMS Toyota - RAV4
2004 SYSTEM WIRING DIAGRAMS
Toyota - RAV4
USING MITCHELL1'S WIRING DIAGRAMS

For information on using these wiring diagrams, see USING MITCHELL1'S SYSTEM WIRING
DIAGRAMS article.
AIR CONDITIONING
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2004 Toyota RAV4
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2004 Toyota RAV4
Fig. 1: Manual A/C Circuit (1 of 2)
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Fig. 2: Manual A/C Circuit (2 of 2)
ANTI-LOCK BRAKES
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Fig. 3: Anti-lock Brakes Circuit, W/ VSC (1 of 2)
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Fig. 4: Anti-lock Brakes Circuit, W/ VSC (2 of 2)
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Fig. 5: Anti-lock Brakes Circuit, W/O VSC
ANTI-THEFT
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Fig. 6: Immobilizer Circuit
BODY CONTROL MODULES
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Fig. 7: Body Control Modules Circuit
COMPUTER DATA LINES
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Fig. 8: Computer Data Lines Circuit
COOLING FAN
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Fig. 9: Cooling Fan Circuit
CRUISE CONTROL
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Fig. 10: Cruise Control Circuit
DEFOGGERS
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Fig. 11: Defoggers Circuit
ENGINE PERFORMANCE
2.4L
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Fig. 12: 2.4L, Engine Performance Circuit (1 of 5)
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EXTERIOR LIGHTS
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Fig. 17: Back-up Lamps Circuit
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Fig. 18: Exterior Lamps Circuit (1 of 2)
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Fig. 19: Exterior Lamps Circuit (2 of 2)
GROUND DISTRIBUTION
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Fig. 20: Ground Distribution Circuit (1 of 2)
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Fig. 21: Ground Distribution Circuit (2 of 2)
HEADLIGHTS
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Fig. 22: Headlights Circuit, W/ DRL
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Fig. 23: Headlights Circuit, W/O DRL
HORN
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Fig. 24: Horn Circuit
INSTRUMENT CLUSTER
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Fig. 25: Clock Circuit
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Fig. 26: Instrument Cluster Circuit (1 of 2)
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Fig. 27: Instrument Cluster Circuit (2 of 2)
INTERIOR LIGHTS
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Fig. 28: Courtesy Lamps Circuit
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Fig. 29: Instrument Illumination Circuit
POWER DISTRIBUTION
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Fig. 30: Power Distribution Circuit (1 of 2)
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Fig. 31: Power Distribution Circuit (2 of 2)
POWER DOOR LOCKS
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Fig. 32: Power Door Locks Circuit, W/ Keyless Entry
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Fig. 33: Power Door Locks Circuit, W/O Keyless Entry
POWER MIRRORS
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Fig. 34: Electrochromic Mirror Circuit
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Fig. 35: Power Mirrors Circuit
POWER SEATS
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Fig. 36: Heated Seats Circuit
POWER TOP/SUNROOF
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Fig. 37: Power Top/Sunroof Circuit
POWER WINDOWS
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Fig. 38: Power Windows Circuit
RADIO
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Fig. 39: Radio Circuit, W/ JBL
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Fig. 40: Radio Circuit, W/O JBL
SHIFT INTERLOCK
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Fig. 41: Shift Interlock Circuit
STARTING/CHARGING
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Fig. 42: Charging Circuit
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Fig. 43: Starting Circuit
SUPPLEMENTAL RESTRAINTS
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Fig. 44: Supplemental Restraints Circuit (1 of 2)
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Fig. 45: Supplemental Restraints Circuit (2 of 2)
TRANSMISSION
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Fig. 46: Transmission Circuit (1 of 4)
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WARNING SYSTEMS
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Fig. 50: Warning Systems Circuit
WIPER/WASHER
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Fig. 51: Front Wiper/Washer Circuit
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Fig. 52: Rear Wiper/Washer Circuit
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Manual de Mecánica Toyota Rav4 2004

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2004 Toyota RAV4

HOW TO PROCEED WITH TROUBLESHOOTING

Fig. 1: Troubleshooting Flow Chart

CUSTOMER PROBLEM ANALYSIS CHECK

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 4: Identifying Warning Lights

WARNING LIGHT TROUBLE AREAS

Trouble Area See

b. When not using the hand-held tester:

Check the DTC.

1. Using SST, connect terminals TC and CG of the DLC3.

Fig. 5: Connecting Terminals TC & CG of DLC3 Using SST

2. Turn the ignition switch ON.

WARNING LIGHT TROUBLE AREAS

Fig. 6: Reading DTC Codes

c. When not using the hand-held tester:

Clear the DTC.

1. Using SST, connect terminals TC and CG of the DLC3.

2. Turn the ignition switch ON.

Fig. 7: Inspecting Brake Switch

Cancellation cannot be performed by removing the battery cable or ECU-IG fuse.

d. When using the hand-held tester:

Check the DTC.

1. Connect hand-held tester to the DLC3.

Fig. 8: Connecting Hand-Held Tester to DLC3

2. Turn the ignition switch ON.

Refer to the hand-held tester operator's manual for further details.

e. When using the hand-held tester:

Clear the DTC.

1. Connect the hand-held tester to the DLC3.

Fig. 9: Connecting Hand-Held Tester to DLC3

2. Turn the ignition switch ON.

Refer to the hand-held tester operator's manual for further details.

a. Connect the hand-held tester to the DLC3.

c. Read the "DATA LIST" on the tester.

Fig. 10: Data List Table (1 Of 2)

Fig. 11: Data List Table (2 Of 2)

It is possible to display the DATA LIST during the ACTIVE TEST.

a. Connect the hand-held tester to the DLC3.

ABS MOT Operation of motor (clicking sound) can

4. FREEZE FRAME DATA

 Freeze frame data at the time a DTC is detected:

a. Connect the hand-held tester to the DLC3.

Fig. 12: Freeze Frame Data Table

a. Procedures for test mode:

Fig. 13: Connecting Terminals TS & CG of DLC3 Using SST

4. Check that the steering wheel is in the straight-ahead position.

WARNING LIGHT TROUBLE AREA

b. Check the brake pedal load sensing switch.

for 1 seconds or more with a force of approximately 59 N (6 kgf, 14 lbf) or more.

c. Check the deceleration sensor.

d. Check the master cylinder pressure sensor.

Repeat the operation until the ABS warning light is illuminated.

e. Check the speed sensor signal.

Drive the vehicle straightforward.

f. Stop the vehicle.

Fig. 14: Connecting Terminals TC & C4 of DLC3 Using SST

h. Read the number of blinks of the ABS warning light.

 See the list of DTC in Fig. 17 .

Fig. 15: Reading Malfunction Code Chart (e.g. 72,76)

a. Connect the hand-held tester to the DLC3.

Fig. 16: Connecting Hand-Held Tester to DLC3

b. Do steps 4 and from a to e .

DTC of ABS sensor check function: