TOYOTA RAV4 2006 Service Repair Manual

2GR-FE FUEL – FUEL SYSTEMFU–5
FU
PARTS LOCATION
A136128E01

FU–62GR-FE FUEL – FUEL SYSTEM
FU
SYSTEM DIAGRAM
1. FUEL FLOW DIAGRAM
A137426E01

2GR-FE FUEL – FUEL SYSTEMFU–7
FU
2. FUEL SYSTEM WIRING DIAGRAM
A136308E01

FU–82GR-FE FUEL – FUEL SYSTEM
FU
3. FUEL SYSTEM WIRING DIAGRAM
A136306E01

IN–38INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
IN
ELECTRONIC CIRCUIT INSPECTION
PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF
ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance
measurements should be made at an ambient
temperature of 20
C (68F). Resistance
measurements may be inaccurate if measured
at high temperatures, i.e. immediately after the
vehicle has been running. Measurements should
be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze
the mating halves tightly together to release the
lock, and then press the lock claw and separate
the connector.
(2) When disconnecting a connector, do not pull on
the harnesses. Grasp the connector directly and
separate it.
(3) Before connecting a connector, check that there
are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until
it locks with a "click" sound.
(5) If checking a connector with a TOYOTA
electrical tester, check the connector from the
backside (harness side) using a mini test lead.
NOTICE:
• As a waterproof connector cannot be
checked from the backside, check it by
connecting a sub-harness.
• Do not damage the terminals by moving
the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected:
Squeeze the connector together to confirm that
they are fully connected and locked.
(2) Checking when a connector is disconnected:
Pull the wire harness lightly from the backside of
the connector. Visually check for the following: 1)
unlatched terminals, missing terminals, loose
crimps and broken conductor wires; 2)
corrosion, metallic matter, foreign matter and
water; and 3) bent, rusted, overheated,
contaminated and deformed terminals.
D100803E01
D100734E01

INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMSIN–39
IN
(3) Checking the contact pressure of the terminal:
Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
when inserting and after full engagement.
NOTICE:
When testing a gold-plated female terminal,
always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal,
clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper as
the plating may come off.
(2) If there is abnormal contact pressure, replace
the female terminal. If the male terminal is gold-
plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a
silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals
should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and
clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness
more than necessary.
(3) The wire harness should never come into
contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other
sharp items.
(4) When installing parts, never pinch the wire
harness.
(5) Ne ver c ut or break th e c ov er of t he w ir e har ness .
If it is cut or broken, repair the cover with vinyl
tape or replace the wire harness.
2. CHECK FOR OPEN CIRCUIT
(a) For an open circuit in the wire harness in Fig. 1,
check the resistance or voltage, as described below.
D100735
D100736E01
D100784E01
D100785E01

IN–40INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
IN
(b) Check the resistance.
(1) Disconnect connectors A and C, and measure
the resistance between them.
Standard resistance (Fig. 2)
HINT:
Measure the resistance while lightly shaking the
wire harness vertically and horizontally.
If the results match the examples above, an
open circuit exists between terminal 1 of
connector A and terminal 1 of connector C.
(2) Disconnect connector B and measure the
resistance between the connectors.
Standard resistance (Fig. 3)
If the results match the examples above, an
open circuit exists between terminal 1 of
connector B2 and terminal 1 of connector C.
(c) Check the voltage.
(1) In a circuit in which voltage is applied to the ECU
connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure
the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of
connector A, 2) terminal 1 of connector B, and 3)
terminal 1 of connector C.
Standard voltage (Fig. 4)
If the results match the examples above, an
open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of
connector C.
D100786E01
Tester Connection Specified Condition
Connector A terminal 1 - Connector
C terminal 110 k
or higher
Connector A terminal 2 - Connector
C terminal 2Below 1
D100787E01
Tester Connection Specified Condition
Connector A terminal 1 - Connector
B1 terminal 1Below 1
Connector B2 terminal 1 - Connector
C terminal 110 k or higher
D100788E01
Tester Connection Specified Condition
Connector A terminal 1 - Body
ground5 V
Connector B terminal 1 - Body
ground5 V
Connector C terminal 1 - Body
groundBelow 1 V

INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMSIN–41
IN
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate
the section by conducting a resistance check with
the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C, and measure
the resistance.
Standard resistance (Fig. 6)
HINT:
Measure the resistance while lightly shaking the
wire harness vertically and horizontally.
If the results match the examples above, a short
circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the
resistance.
Standard resistance (Fig. 7)
If the results match the examples above, a short
circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE:
• The connector should not be disconnected from
the ECU. Perform the inspection from the
backside of the connector on the wire harness
side.
• When no measuring condition is specified,
perform the inspection with the engine stopped
and the ignition switch ON.
• Check that the connectors are fully seated. Check
for loose, corroded or broken wires.
D100789E01
D100790E01
Tester Connection Specified Condition
Connector A terminal 1 - Body
groundBelow 1
Connector A terminal 2 - Body
ground10 k or higher
D100800E01
Tester Connection Specified Condition
Connector A terminal 1 - Body
ground10 k
or higher
Connector B2 terminal 1 - Body
ground Below 1

IN–42INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
IN
(a) First, check the ECU ground circuit. If it is faulty,
repair it. If it is normal, the ECU could be faulty.
Temporarily replace the ECU with a normally
functioning one and check if the problem symptoms
occur. If the problem symptoms disappear, replace
the original ECU.
(1) Measure the resistance between the ECU
ground terminal and body ground.
Standard resistance:
Below 1
(2) Disconnect the ECU connector. Check the
ground terminal on the ECU side and wire
harness side for bending, corrosion or foreign
matter. Lastly, check the contact pressure of the
female terminals.
D100801E01
D100802E02

IN–48INTRODUCTION – TERMS
IN
GLOSSARY OF SAE AND TOYOTA
TERMS
This glossary lists all SAE-J1930 terms and abbreviations
used in this manual in compliance with SAE
recommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMS TOYOTA TERMS ( )-ABBREVIATIONS
3GR Third Gear -
4GR Fourth Gear -
A/C Air Conditioning Air Conditioner
ACL Air Cleaner Air Cleaner, A/CL
AIR Secondary Air Injection Air Injection (AI)
AP Accelerator Pedal -
B+ Battery Positive Voltage +B, Battery Voltage
BARO Barometric Pressure HAC
CAC Charge Air Cooler Intercooler
CARB Carburetor Carburetor
CFI Continuous Fuel Injection -
CKP Crankshaft Position Crank Angle
CL Closed Loop Closed Loop
CMP Camshaft Position Cam Angle
CPP Clutch Pedal Position -
CTOX Continuous Trap Oxidizer -
CTP Closed Throttle Position LL ON, Idle ON
DFI Direct Fuel Injection Direct Injection (DI/INJ)
DI Distributor Ignition -
DLC3 Data Link Connector 3 OBD II Diagnostic Connector
DTC Diagnostic Trouble Code Diagnostic Trouble Code
DTM Diagnostic Test Mode -
ECL Engine Coolant Level -
ECM Engine Control Module Engine Electronic Control Unit (ECU)
ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW)
EEPROM Electrically Erasable Programmable Read Only MemoryElectrically Erasable Programmable Read Only Memory
(EEPROM)
EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV)
EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR)
EI Electronic Ignition Distributorless Ignition (DLI)
EM Engine Modification Engine Modification (EM)
EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)
EVAP Evaporative Emission Evaporative Emission Control (EVAP)
FC Fan Control -
FEEPROMFlash Electrically Erasable Programmable Read Only
Memory-
FEPROM Flash Erasable Programmable Read Only Memory -
FF Flexible Fuel -
FP Fuel Pump Fuel Pump
GEN Generator Alternator
GND Ground Ground (GND)
HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S)
IAC Idle Air Control Idle Speed Control (ISC)