Toyota RAV4 2004 Service Manual Download Page 37

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Fig. 34: Removing Fuel Pump Harness

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE FUEL PUMP

Pull out the fuel pump.

2004 Toyota RAV4

2004 ENGINE PERFORMANCE SFI - RAV4

Microsoft

Tuesday, July 21, 2009 4:18:50 PM

Page 37

Summary of Contents for RAV4 2004

Page 1: ...andling 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...

Page 2: ...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...

Page 3: ...L SYSTEM a When disconnecting the high fuel pressure line a large amount of gasoline will spill out Observe these procedures 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21...

Page 4: ...rn 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 wh...

Page 5: ...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...

Page 6: ...or 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...

Page 7: ...ull 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 fr...

Page 8: ...bjects 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 am...

Page 9: ...TOYOTA MOTOR SALES U S A INC 3 After having finished the connection pull the pipe and the connector to ensure secure connection 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July...

Page 10: ...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 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday...

Page 11: ...ult is not specified repair or replace f Observe the following when disconnecting the fuel tube connector metallic type HINT The structure of the metallic connector is shown in Fig 10 2004 Toyota RAV4...

Page 12: ...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 2004 Toyota RAV4...

Page 13: ...INC 3 Turn the SST align the retainers inside the connector with the SST chamfered parts and insert the SST into the connector 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July...

Page 14: ...MOTOR SALES U S A INC 4 While holding the SST pull the connector towards the SST to put the retainers on the SST chamfered parts 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday Jul...

Page 15: ...ck 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 t...

Page 16: ...TOYOTA MOTOR SALES U S A INC 3 After having finished the connection pull the pipe and the connector to ensure secure connection 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July...

Page 17: ...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...

Page 18: ...nual for further details 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...

Page 19: ...R SALES U S A INC 1 Connect the hand held tester to the DLC3 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 NOTE...

Page 20: ...he 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 fro...

Page 21: ...tesy of TOYOTA MOTOR SALES U S A INC d Disconnect the fuel tube clamp from the fuel tube connector 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 50 PM Page 21 2...

Page 22: ...r Courtesy of TOYOTA MOTOR SALES U S A INC e Disconnect the fuel inlet tube fuel tube connector from the fuel pipe 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18...

Page 23: ...9268 41047 09268 45014 09268 41250 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 splas...

Page 24: ...2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 50 PM Page 24 2005 Mitchell Repair Information Company LLC...

Page 25: ...e 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...

Page 26: ...tesy of TOYOTA MOTOR SALES U S A INC r Reconnect the fuel tube clamp to the fuel tube connector 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 50 PM Page 26 2005...

Page 27: ...r 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...

Page 28: ...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 2004 Toyota RAV4 2004 ENGINE PERFO...

Page 29: ...onnector g Reinstall the floor service hole cover h Reinstall the LH rear seat COMPONENTS NOTE These tests must be performed within 10 seconds to prevent the coil from burning out Keep the fuel pump a...

Page 30: ...MOTOR SALES U S A INC REPLACEMENT CAUTION Do not smoke or work near an open flame when working on the fuel pump 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 5...

Page 31: ...rtesy of TOYOTA MOTOR SALES U S A INC 6 REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK a Remove the 8 bolts and fuel tank vent tube set plate CAUTION Disconnect the fuel tube connector quic...

Page 32: ...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 2004 Toyota RAV4 2004 ENGINE PERFORMAN...

Page 33: ...PPORT a Using a screwdriver pry out the fuel suction support b Remove the rubber cushion NOTE Do not damage the fuel suction filter Be careful not to bend the arm of the sender gauge NOTE Be careful n...

Page 34: ...of TOYOTA MOTOR SALES U S A INC 8 REMOVE FUEL SUCTION PLATE a Disconnect the fuel sender gauge connector and ground plate 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 20...

Page 35: ...Ground Plate Courtesy of TOYOTA MOTOR SALES U S A INC b Using 2 screwdrivers pry out the fuel suction plate 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 50 PM...

Page 36: ...YOTA MOTOR SALES U S A INC c Remove the fuel pump harness NOTE Be careful not to damage the suction support and suction plate 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 2...

Page 37: ...ss Courtesy of TOYOTA MOTOR SALES U S A INC 9 REMOVE FUEL PUMP Pull out the fuel pump 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 50 PM Page 37 2005 Mitchell...

Page 38: ...R SALES U S A INC 10 REMOVE FUEL SUCTION FILTER FROM FUEL PUMP a Using a small screwdriver pry out the clip 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 50 PM...

Page 39: ...SALES U S A INC b Pull out the suction filter 11 REINSTALL FUEL SUCTION FILTER Install the suction filter with a new clip 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 20...

Page 40: ...Clip Courtesy of TOYOTA MOTOR SALES U S A INC 12 REINSTALL FUEL PUMP Push into the fuel pump 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 50 PM Page 40 2005 Mi...

Page 41: ...TOYOTA MOTOR SALES U S A INC 13 REINSTALL FUEL SUCTION PLATE a Connect the fuel pump harness 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 50 PM Page 41 2005 M...

Page 42: ...tesy of TOYOTA MOTOR SALES U S A INC b Install the fuel suction plate and fuel filter assembly 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 50 PM Page 42 2005...

Page 43: ...Assembly Courtesy of TOYOTA MOTOR SALES U S A INC c Connect the fuel sender gauge connector and ground plate 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 50 PM...

Page 44: ...R SALES U S A INC 14 INSTALL FUEL SUCTION SUPPORT a Install the rubber cushion b Install the fuel suction support to the fuel filter assembly 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsof...

Page 45: ...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 2004 Toyota RAV4 2004 ENGINE PERFORMAN...

Page 46: ...of the set plate with bolt hole position A e Install the fuel tank vent tube set plate with the 8 bolts Torque 4 0 N m 40 kgf cm 35 in lbf NOTE Do not damage the fuel suction filter Be careful not to...

Page 47: ...of TOYOTA MOTOR SALES U S A INC 16 RECONNECT FUEL TANK MAIN TUBE Connect the main tube with the tube joint clip 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 5...

Page 48: ...rted 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 2004 Toyota RAV4...

Page 49: ...OR SERVICE HOLE COVER 21 REINSTALL LH REAR SEAT FUEL PRESSURE REGULATOR COMPONENTS Fig 46 Identifying Fuel Tube Joint Fuel Suction Plate Fuel Pump Tube Clip O Ring Courtesy of TOYOTA MOTOR SALES U S A...

Page 50: ...SALES U S A INC REPLACEMENT 1 REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK See REPLACEMENT 2 REMOVE FUEL SUCTION PLATE 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday...

Page 51: ...Plate Courtesy of TOYOTA MOTOR SALES U S A INC b Using 2 screwdrivers pry out the fuel suction plate NOTE Be careful not to damage the suction support and fuel suction plate 2004 Toyota RAV4 2004 ENGI...

Page 52: ...ing Screwdrivers Courtesy of TOYOTA MOTOR SALES U S A INC c Disconnect the fuel pump connector 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 51 PM Page 52 2005...

Page 53: ...RESSURE 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 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RA...

Page 54: ...ulator Courtesy of TOYOTA MOTOR SALES U S A INC 4 REINSTALL FUEL PRESSURE REGULATOR a Install a new O ring to the pressure regulator 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday...

Page 55: ...A INC 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 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tu...

Page 56: ...Jet Tube To Clamp Courtesy of TOYOTA MOTOR SALES U S A INC 5 REINSTALL FUEL SUCTION PLATE a Connect the fuel pump connector 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21...

Page 57: ...TOYOTA MOTOR SALES U S A INC b Install the fuel suction plate to the fuel filter and fuel pump assembly 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 51 PM Pag...

Page 58: ...Pump Assembly Courtesy of TOYOTA MOTOR SALES U S A INC c Connect the fuel sender gauge connector and ground plate 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18...

Page 59: ...REMOVE AIR CLEANER ASSEMBLY a Disconnect the MAF meter connector 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 INS...

Page 60: ...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...

Page 61: ...U S A INC If the resistance is not as specified replace the injector c Reconnect the injector connector 4 REINSTALL AIR CLEANER ASSEMBLY COMPONENTS 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Mi...

Page 62: ...OR SALES U S A INC REMOVAL 1 DISCONNECT PCV HOSE 2 REMOVE AIR CLEANER INLET AND AIR CLEANER ASSEMBLY WITH MAF METER 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 1...

Page 63: ...g Injector Connectors Removing Bolts Courtesy of TOYOTA MOTOR SALES U S A INC c Disconnect the delivery pipe together with the 4 injectors from the cylinder head d Remove the 2 spacers and 4 grommets...

Page 64: ...TOYOTA MOTOR SALES U S A INC a Disconnect the fuel pipe clamp from the fuel tube connector CAUTION Keep injector clear of sparks during the test 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Micro...

Page 65: ...r Courtesy of TOYOTA MOTOR SALES U S A INC b Disconnect the fuel inlet tube fuel tube connector from the fuel pipe 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18...

Page 66: ...l tube Part No 23901 22110 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...

Page 67: ...TOYOTA MOTOR SALES U S A INC d Connect SST hose and fuel tube connector to the fuel pipe SST 09268 41047 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 51 PM Pa...

Page 68: ...o the injector f Connect SST union and hose to the injector SST 09268 41047 09268 41110 09268 41300 CAUTION Disconnect the fuel tube connector quick type observing the precautions see SFI SYSTEM 2004...

Page 69: ...to a graduated cylinder h Connect the hand held tester to the DLC3 CAUTION Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out 2004 Toyota RAV4 2004 ENGINE PERFORMAN...

Page 70: ...he hand held tester HINT Please refer to the hand held tester operator s manual for further details If you have no hand held tester connect the positive and negative leads from the battery to the fuel...

Page 71: ...s 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...

Page 72: ...jector Courtesy of TOYOTA MOTOR SALES U S A INC Fuel drop 1 drop or less per 12 minutes 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 51 PM Page 72 2005 Mitchel...

Page 73: ...the fuel tube fuel tube connector Fig 70 Reconnecting Fuel Tube Courtesy of TOYOTA MOTOR SALES U S A INC g Reconnect the fuel pipe clamp to the fuel tube connector CAUTION Disconnect the fuel tube con...

Page 74: ...INC 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 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV...

Page 75: ...O Ring Courtesy of TOYOTA MOTOR SALES U S A INC b Install the 2 spacers and 4 new grommets to the cylinder head 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 51...

Page 76: ...he 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 downw...

Page 77: ...U S A INC 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 2004 Toyota RAV4 2004 ENGINE PE...

Page 78: ...ors 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 2004 Toyota RAV4 2...

Page 79: ...tesy of TOYOTA MOTOR SALES U S A INC j Tighten the 2 bolts holding the delivery pipe to the cylinder head Torque 20 N m 205 kgf cm 15 ft lbf 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft...

Page 80: ...S A INC k Connect the 4 injector connectors 2 INSTALL AIR CLEANER ASSEMBLY WITH MAF METER 3 CONNECT PCV HOSE FUEL PRESSURE PULSATION DAMPER COMPONENTS 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4...

Page 81: ...Damper Components Courtesy of TOYOTA MOTOR SALES U S A INC REPLACEMENT 1 REMOVE AIR CLEANER HOSE 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 51 PM Page 81 20...

Page 82: ...Fig 79 Removing Installing Bolts Pulsation Damper Courtesy of TOYOTA MOTOR SALES U S A INC b Connect the fuel tube connector metallic connector see SFI SYSTEM CAUTION Disconnect the fuel tube connect...

Page 83: ...NTS CAUTION Always use new gaskets when replacing the fuel tank or component parts Apply the proper torque to all the parts to be tightened 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft...

Page 84: ...e Fig 80 Identifying Fuel Tank And Line Components Courtesy of TOYOTA MOTOR SALES U S A INC 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 51 PM Page 84 2005 Mit...

Page 85: ...c Check the filter neck for damage or fuel leak Fig 81 Identifying Deformed Damaged Cracked Or Leaking Pipe Courtesy of TOYOTA MOTOR SALES U S A INC d Check that hose and tube connections are as shown...

Page 86: ...OTOR SALES U S A INC If a problem is found repair or replace the part as necessary MASS AIR FLOW MAF METER COMPONENTS 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4...

Page 87: ...YOTA MOTOR SALES U S A INC INSPECTION 1 DISCONNECT MAF METER CONNECTOR 2 REMOVE MAF METER Remove the 2 screws and MAF meter 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21...

Page 88: ...OTOR SALES U S A INC 3 INSPECT MAF METER a Using an ohmmeter measure the resistance between terminals THA and E2 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 5...

Page 89: ...e MAF meter connector b Connect the negative terminal cable to the battery c Turn the ignition switch ON d Using a voltmeter connect the positive tester probe to terminal VG and negative tester probe...

Page 90: ...e 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 scr...

Page 91: ...ound Courtesy of TOYOTA MOTOR SALES U S A INC 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...

Page 92: ...entage 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 w...

Page 93: ...SOR 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 POSIT...

Page 94: ...MOTOR SALES U S A INC REMOVAL 1 DRAIN ENGINE COOLANT 2 REMOVE AIR CLEANER INLET AND AIR CLEANER ASSEMBLY WITH MAF METER 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 200...

Page 95: ...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 C...

Page 96: ...TOYOTA MOTOR SALES U S A INC INSTALLATION 1 INSTALL THROTTLE BODY a Install a new gasket on the intake manifold as shown in Fig 93 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday...

Page 97: ...SALES U S A INC b Install the throttle body bracket and fuel hose clamp with the 4 bolts Torque 30 N m 305 kgf cm 22 ft lbf 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21...

Page 98: ...TOYOTA MOTOR SALES U S A INC c Connect the 5 hoses to the throttle body d Connect the throttle position sensor control motor connector 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesd...

Page 99: ...TH ENGINE COOLANT CAMSHAFT TIMING OIL CONTROL VALVE ON VEHICLE INSPECTION Inspect Camshaft Timing Oil Control Valve OCV Resistance a Disconnect the OCV connector b Using an ohmmeter measure the resist...

Page 100: ...f TOYOTA MOTOR SALES U S A INC If the resistance is not as specified replace the OCV c Reconnect the OCV connector COMPONENTS 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 2...

Page 101: ...MOTOR SALES U S A INC INSPECTION 1 REMOVE CAMSHAFT TIMING OIL CONTROL VALVE OCV a Disconnect the OCV connector b Remove the bolt and OCV 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tue...

Page 102: ...MSHAFT 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 2004 Toyo...

Page 103: ...Voltage Specification Table Courtesy of TOYOTA MOTOR SALES U S A INC 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 2004...

Page 104: ...1 REMOVE RELAY BOX COVER 2 REMOVE EFI MAIN RELAY Fig 101 Removing Relay Box Cover EFI Main Relay Courtesy of TOYOTA MOTOR SALES U S A INC 3 INSPECT EFI MAIN RELAY a Inspect the relay continuity 2004 T...

Page 105: ...Continuity Between Terminals 3 5 Using Ohmmeter Courtesy of TOYOTA MOTOR SALES U S A INC If there is continuity replace the relay b Inspect the relay operation 1 Apply battery positive voltage to term...

Page 106: ...ity replace the relay 4 REINSTALL EFI MAIN RELAY 5 REINSTALL RELAY BOX COVER A F SENSOR HEATER RELAY INSPECTION 1 REMOVE RELAY BOX COVER 2 REMOVE A F SENSOR HEATER RELAY Marking A F 2004 Toyota RAV4 2...

Page 107: ...relay continuity 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...

Page 108: ...there is continuity replace the relay b Inspect the relay operation 1 Apply battery positive voltage to terminals 1 and 2 2 Using an ohmmeter check that there is continuity between terminals 3 and 5 2...

Page 109: ...replace the relay 4 REINSTALL A F SENSOR HEATER RELAY 5 REINSTALL RELAY BOX COVER CIRCUIT OPENING RELAY INSPECTION 1 REMOVE RELAY BOX COVER 2 REMOVE CIRCUIT OPENING RELAY Marking C OPN 2004 Toyota RA...

Page 110: ...ng 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 If there is continuity...

Page 111: ...R SALES U S A INC b Inspect the relay operation 1 Apply battery positive voltage to terminals 1 and 2 2 Using an ohmmeter check that there is continuity between terminals 3 and 5 2004 Toyota RAV4 2004...

Page 112: ...INC If there is no continuity replace the relay 4 REINSTALL CIRCUIT OPENING RELAY 5 REINSTALL RELAY BOX COVER VSV FOR EVAPORATIVE EMISSION EVAP COMPONENTS 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI...

Page 113: ...ion EVAP Components Courtesy of TOYOTA MOTOR SALES U S A INC INSPECTION 1 REMOVE VSV 2 INSPECT VSV 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 51 PM Page 113...

Page 114: ...en Terminals Using Ohmmeter Courtesy of TOYOTA MOTOR SALES U S A INC If there is no continuity replace the VSV b Inspect the VSV for ground Using an ohmmeter check that there is no continuity between...

Page 115: ...A MOTOR SALES U S A INC 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 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SF...

Page 116: ...TA MOTOR SALES U S A INC 2 Apply battery positive voltage to the terminals 3 Check that air flows from ports E to F 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 1...

Page 117: ...tesy of TOYOTA MOTOR SALES U S A INC If the operation is not as specified replace the VSV 3 REINSTALL VSV VSV FOR CANISTER CLOSED VALVE CCV COMPONENTS 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4...

Page 118: ...losed Valve CCV Components Courtesy of TOYOTA MOTOR SALES U S A INC INSPECTION 1 REMOVE VSV 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 52 PM Page 118 2005 Mi...

Page 119: ...f TOYOTA MOTOR SALES U S A INC Resistance 25 to 30 ohm at 20 C 68 F If the result is not as specified replace the VSV b Inspect the VSV for ground Using an ohmmeter check that there is no continuity b...

Page 120: ...esy of TOYOTA MOTOR SALES U S A INC If there is continuity replace the VSV c Inspect the VSV operation 1 Check that air flows from ports E to F 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Micros...

Page 121: ...OTOR SALES U S A INC 2 Apply battery positive voltage to the terminals 3 Check that air does not flow from ports E to F 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009...

Page 122: ...tesy of TOYOTA MOTOR SALES U S A INC If the operation is not as specified replace the VSV 3 REINSTALL VSV VSV FOR PRESSURE SWITCHING VALVE COMPONENTS 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4...

Page 123: ...ssure Switching Valve Components Courtesy of TOYOTA MOTOR SALES U S A INC INSPECTION 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 52 PM Page 123 2005 Mitchell...

Page 124: ...Between Terminals Using Ohmmeter Courtesy of TOYOTA MOTOR SALES U S A INC If the result is not as specified replace the VSV b Inspect the VSV for ground Using an ohmmeter check that there is no conti...

Page 125: ...YOTA MOTOR SALES U S A INC If the result is not as specified replace the VSV c Inspect the VSV operation 1 Check that air does not flow from ports E to F 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI R...

Page 126: ...TOYOTA MOTOR SALES U S A INC 2 Apply battery positive voltage to the terminals 3 Check that air flows from ports E to F 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009...

Page 127: ...sy of TOYOTA MOTOR SALES U S A INC If the operation is not as specified replace the VSV 3 REINSTALL VSV ENGINE COOLANT TEMPERATURE ECT SENSOR COMPONENTS 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RA...

Page 128: ...rtesy of TOYOTA MOTOR SALES U S A INC INSPECTION 1 DRAIN ENGINE COOLANT 2 REMOVE ECT SENSOR a Disconnect the sensor connector 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 2...

Page 129: ...rtesy of TOYOTA MOTOR SALES U S A INC 3 INSPECT ECT SENSOR Using an ohmmeter measure the resistance between the terminals Resistance Refer to Fig 127 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4...

Page 130: ...2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 52 PM Page 130 2005 Mitchell Repair Information Company LLC...

Page 131: ...ECT SENSOR a Install a new gasket to the sensor b Using a 19 mm deep socket wrench install the sensor Torque 20 N m 200 kgf cm 15 ft lbf c Connect the sensor connector 5 REFILL WITH ENGINE COOLANT VA...

Page 132: ...Components Courtesy of TOYOTA MOTOR SALES U S A INC INSPECTION 1 REMOVE LUGGAGE COMPARTMENT BOX 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 52 PM Page 132 200...

Page 133: ...ltmeter measure the voltage between terminals VC and E2 of the wiring harness side connector Voltage 4 5 to 5 5 V Fig 129 Measuring Voltage Between Terminals VC And E2 Of Wiring Harness Side Connector...

Page 134: ...Pa 15 mmHg 0 59 in Hg to the vapor pressure sensor Voltage 1 3 to 2 1 V 2 Release the vacuum from the vapor pressure sensor Voltage 3 0 to 3 6 V 3 Apply pressure 1 5 kPa 15 gf cm2 0 22 psi to the vapo...

Page 135: ...r Pressure Sensor Courtesy of TOYOTA MOTOR SALES U S A INC 6 REINSTALL VAPOR PRESSURE SENSOR 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 52 PM Page 135 2005 M...

Page 136: ...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 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4...

Page 137: ...nock Sensor Components Courtesy of TOYOTA MOTOR SALES U S A INC INSPECTION 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 52 PM Page 137 2005 Mitchell Repair Inf...

Page 138: ...connector b Remove the nut and knock sensor Fig 132 Removing Knock Sensor Nut Courtesy of TOYOTA MOTOR SALES U S A INC 4 INSPECT KNOCK SENSOR Using an ohmmeter make sure there is continuity between th...

Page 139: ...REINSTALL KNOCK SENSOR a Install the knock sensor with the nut Torque 20 N m 204 kgf cm 15 ft lbf HINT Angling the knock sensor below the horizontal below 0 is recommended 2004 Toyota RAV4 2004 ENGIN...

Page 140: ...or 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 2004 Toyota RAV4 2004 ENGINE PER...

Page 141: ...of TOYOTA MOTOR SALES U S A INC INSPECTION 1 INSPECT HEATER RESISTANCE OF A F SENSOR a Disconnect the sensor connector 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009...

Page 142: ...ot as specified replace the sensor Torque 44 N m 450 kgf cm 32 ft lbf c Reconnect the sensor connector 2 INSPECT OPERATION OF A F SENSOR See DTC P2195 OXYGEN A F SENSOR SIGNAL STUCK LEAN BANK 1 SENSOR...

Page 143: ...ER RESISTANCE OF OXYGEN SENSOR a Disconnect the sensor connector b Using an ohmmeter measure the resistance between terminals B and HT Resistance 11 to 16 ohm at 20 C 68 F 2004 Toyota RAV4 2004 ENGINE...

Page 144: ...Torque 44 N m 450 kgf cm 32 ft lbf c Reconnect the sensor connector 2 INSPECT OPERATION OF HEATED OXYGEN SENSOR See DTC P0136 OXYGEN SENSOR CIRCUIT MALFUNCTION BANK 1 SENSOR 2 ACCELERATOR PEDAL POSIT...

Page 145: ...r Components Courtesy of TOYOTA MOTOR SALES U S A INC INSPECTION Inspect Accelerator Pedal Position Sensor 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 52 PM P...

Page 146: ...If the resistance is not as specified replace the accelerator pedal assembly c Reconnect the sensor connector Terminals Resistance VCP1 EP1 2 25 to 4 75 kohm at 20 C 68 F VCP2 EP2 NOTE Be careful not...

Page 147: ...141 Identifying Engine Control Module ECM Components Courtesy of TOYOTA MOTOR SALES U S A INC 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI RAV4 Microsoft Tuesday July 21 2009 4 18 52 PM Page 147 2005...

Page 148: ...NECT HAND HELD TESTER OR OBD II SCAN TOOL TO DLC3 a Connect the hand held tester or OBD II scan tool to the DLC3 Fig 142 Connecting Hand Held Tester To DLC3 Courtesy of TOYOTA MOTOR SALES U S A INC HI...

Page 149: ...a sound scope to check for the injector operating noise Fig 143 Using Sound Scope To Check For Injector Operating Noise Courtesy of TOYOTA MOTOR SALES U S A INC c When the accelerator pedal is releas...

Page 150: ...ECT HAND HELD TESTER OR OBD II SCAN TOOL FROM DLC3 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 RP...

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Toyota RAV4 2004, Service Manual

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