torque TOYOTA RAV4 2006 Service Repair Manual

STEERING COLUMN – STEERING COLUMN ASSEMBLYSR–21
SR
(b) Attach the 4 claws to install the lower steering
column cover.
11. INSTALL STEERING WHEEL ASSEMBLY
(a) Align the matchmarks and install the steering wheel
onto the steering column.
(b) Install the nut.
Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf)
(c) Connect all the connectors to the spiral cable.
12. INSTALL STEERING PAD (See page RS-336)
13. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
14. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
15. INSPECT SRS WARNING LIGHT
(a) Inspect the SRS warning light (see page RS-52).
C128491
C132123E02

PS–8POWER STEERING – ELECTRONIC POWER STEERING SYSTEM
PS
PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help determine the cause of the
problem symptom. The potential causes of the symptoms are
listed in order of probability in the "Suspected area" column of
the table. Check each symptom by checking the suspected
areas in the order they are listed. Replace parts as
necessary.
Electronic power steering system
Symptom Suspected area See page
Heavy steering1. Front tires (improperly inflated, unevenly worn)TW-1
2. Front wheel alignment (incorrect)SP-3
3. Front suspension (lower ball joint)SP-27
4. Steering gear assemblyPS-42
5. Power steering motor PS-25
6. Power source voltage of power steering ECUPS-37
7. Power steering ECUPS-46
Steering effort differs between turning right and left, or
steering effort uneven1. Front tires (improperly inflated, unevenly worn)TW-1
2. Front wheel alignment (incorrect)SP-3
3. Front suspension (lower ball joint)SP-27
4. Steering gear assemblyPS-42
5. Torque sensor (built into steering column) PS-22
6. Steering column assemblySR-11
7. Power steering motor PS-25
8. Power steering ECUPS-46
While driving, steering effort does not change in
accordance with vehicle speed or steering wheel does
not return properly1. Front suspension (lower ball joint)SP-27
2. Speed sensorBC-28
3. Skid control ECUBC-41
4. Torque sensor (built into steering column) PS-22
5. Power steering motor PS-25
6. Power steering ECUPS-46
7. Controlling CAN communication systemCA-8
Friction occurs when turning steering wheel during low
speed driving1. Power steering motor PS-25
2. Steering column assemblySR-11
High-pitched sound (squeaking) occurs when turning
steering wheel slowly with vehicle stopped1. Power steering motor PS-25
Steering wheel vibrates and noise occurs when turning
steering wheel with vehicle stopped1. Power steering motor PS-25
2. Steering column assemblySR-11
P/S warning always indicated on combination meter1. Power source voltage of power steering ECUPS-37
2. Combination meterME-53
3. Power steering ECUPS-46

POWER STEERING – ELECTRONIC POWER STEERING SYSTEMPS–9
PS
TERMINALS OF ECU
1. CHECK POWER STEERING ECU
HINT:
Measurements cannot be performed on the C connector
side of the power steering ECU.
(a) Measure the voltage and resistance of the
connectors.
F100917E04
Symbols Wiring Color Terminal Description
U W U phase motor output
V B V phase motor output
W W-R W phase motor output
Symbols (Terminal No.) Wiring Color Terminal Description ConditionSpecified Condition
PIG (A1-1) - PGND (A1-2) W-B - W-B Power source Always 10 to 14 V
IG (E18-5) - PGND (A1-2) L - W-B IG power source Ignition switch ON 10 to 14 V
TRQ1 (e1-6) - TRQG (e1-
1)G - B Torque sensor signal Ignition switch ON
Steering wheel not turned
(without load)2.3 to 2.7 V
Ignition switch ON
Steering wheel turned to
right with vehicle stopped2.5 to 4.04 V
Ignition switch ON
Steering wheel turned to
left with vehicle stopped0.95 to 2.5 V
TRQ2 (e1-2) - TRQG (e1-
1)Y - B Torque sensor signal Ignition switch ON
Steering wheel not turned
(without load)2.3 to 2.7 V
Ignition switch ON
Steering wheel turned to
right with vehicle stopped0.95 to 2.5 V
Ignition switch ON
Steering wheel turned to
left with vehicle stopped2.5 to 4.04 V
TRQF (e1-4) - TRQG (e1-
1)W - B Torque sensor reference
voltageIgnition switch ON 3.35 to 3.37 V
TRQV (e1-3) - TRQG (e1-
1)R - B Torque sensor voltage
sourceIgnition switch ON 8.5 to 10.5 V
TRQG (e1-1) - Body
groundB - Body ground Torque sensor ground Always Below 1

PS–14POWER STEERING – ELECTRONIC POWER STEERING SYSTEM
PS
FREEZE FRAME DATA
1. FREEZE FRAME DATA
NOTICE:
• It is difficult to show the specified values
(judgment values) clearly because freeze frame
data values change significantly due to
differences in measurement conditions,
surroundings, or vehicle conditions. For this
reason, there may be a problem even when the
values are within specifications.
• Turn the ignition switch ON and park the vehicle
on level ground. Check the freeze frame data by
using intelligent tester.
(a) Connect the intelligent tester (with CAN VIM) to the
DLC3.
(b) Turn the ignition switch ON and check the freeze
frame data by following the prompts on the
intelligent tester display.
Power steering ECU
Item Item Description: Range
(Display)Inspection Condition Reference Value
BATTERY VOLTAGE Battery voltage:
Min.: 0 V
Max.: 25.5 V- 10 to 14 V
SPD Vehicle speed from meter:
Min.: 0 km/h (0 mph)
Max.: 300 km/h (187.5 mph)Vehicle stopped 0 km/h (mph)
Vehicle driven at constant speedNo significant fluctuation
ENGINE REV Show the engine revolution:
Min.: 0 rpm
Max.: 12800 rpmEngine is running at a constant
speedNo significant fluctuation
MOTOR ACTUAL Amount of current to motor:
Min.: -327.68 A
Max.: 327.67 APower steering is in operationValue changes in proportion to
steering effort
COMMAND VALUE Demanded amount of current to
motor:
Min.: -327.68 A
Max.: 327.68 APower steering is in operationValue changes in proportion to
steering effort
STR ANGL VEL Steering angle speed:
Min.: -32768
/sec.
Max.: 32767/sec.Steering wheel is turned Value changes in proportion to
steering effort
STEERING TORQUE Steering wheel torque:
Min.: -7 Nm
Max.: 7 Nm--
THERMISTOR TEMP ECU substrate temperature:
Min.: -40
C
Max.: 150
CIgnition switch ON -
PIG SUPPLY Power source voltage to activate
motor:
Min.: 0 V
Max.: 20.1531 VPower steering in operation 10 to 14 V
IG SUPPLY ECU power source voltage:
Min.: 0 V
Max.: 20.1531 VIgnition switch ON 10 to 14 V
MOTOR ROTATE Motor rotation angle:
Min.: 0
Max.: 360
Power steering in operation During steering operation, motor
rotation angle value changes from
0 to 360
MOTOR VOLTAGE Motor power supply voltage:
0 V
Max.: 45.955 VPower steering in operation -

PS–16POWER STEERING – ELECTRONIC POWER STEERING SYSTEM
PS
FAIL-SAFE CHART
If a problem occurs in the electric power steering system, the
P/S warning light will come on in the combination meter and
steering power assist will be stopped, fixed at a particular
point, or decreased simultaneously to protect the system.
Electronic power steering system
HINT:
The amount of power assist may be decreased to prevent the
motor and ECUs from overheating if the steering wheel is
continuously turned when the vehicle is either stopped or
driven at a low speed, or if the steering wheel is kept at either
full lock position for a long time. In such cases, the amount of
power assist returns to normal if the steering wheel is not
turned for approximately 10 minutes with the engine idling.
DTC No. Detection Condition Fail-safe
C1511/11 Torque sensor malfunction Power assist stops
C1512/11
C1513/11
C1514/11
C1521/25 Motor malfunction
C1524/24
C1528/12 Motor rotation angle sensor malfunction
C1531/25 ECU malfunction
C1532/25
C1534/25
C1551/25 IG power source voltage error
C1552/22 PIG power source voltage error
C1554/23 Power source relay malfunction
C1555/25 Motor relay malfunction
C1533/25 ECU malfunction Assist force restricted
U0073/49 CAN bus malfunction Amount of power assist is locked at 140 km/h
(87.5 mph) level of power assist
U0121/42 Skid control ECU communication error
U0105/41 ECM communication error Power assist stops

POWER STEERING – ELECTRONIC POWER STEERING SYSTEMPS–17
PS
DATA LIST / ACTIVE TEST
1. READ DATA LIST
HINT:
Using the intelligent tester's 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 save time.
(a) Connect the intelligent tester (with CAN VIM) to the
DLC3.
(b) Turn the ignition switch ON and press the intelligent
tester main switch ON.
(c) Read the DATA LIST by following the directions on
the tester screen.
Tester Display Measurement Item/Range Normal Condition Reference Value
BATTERY VOLTAGE Battery voltage:
Min.: 0 V
Max.: 25.5 V- 10 to 14 V
SPD Vehicle speed from meter:
Min.: 0 km/h (0 mph)
Max.: 300 km/h (187.5 mph)Vehicle stopped 0 km/h (0 mph)
Vehicle driven at constant speed No significant fluctuation
SPD SIG INVALID Record of vehicle speed signal
invalid:
REC or UNREC- UNREC
ENGINE REV Show the engine revolution:
Min.: 0 rpm
Max.: 12800 rpmEngine is running at a constant
speedNo significant fluctuation
ENG REV INTER Record of engine revolution
signal interruption
REC or UNREC- UNREC
MOTOR ACTUAL Amount of current to motor:
Min.: -327.68 A
Max.: 327.67 APower steering is in operation Value changes in proportion to
steering effort
COMMAND VALUE Demanded amount of current to
motor:
Min.: -327.68 A
Max.: 327.68 APower steering is in operation Value changes in proportion to
steering effort
STR ANGL VEL Steering angle speed:
Min.: -32768
/sec.
Max.: 32767
/sec.Steering wheel is turned Value changes in proportion to
steering effort
STEERING TORQUE Steering wheel torque:
Min.: -7 Nm
Max.: 7 Nm--
THERMISTOR TEMP ECU substrate temperature:
Min.: -40
C
Max.: 150
CIgnition switch ON -
PIG SUPPLY Power source voltage to activate
motor:
Min.: 0 V
Max.: 20.1531 VPower steering in operation 10 to 14 V
IG SUPPLY ECU power source voltage:
Min.: 0 V
Max.: 20.1531 VIgnition switch ON 10 to 14 V
MTR OVERHEAT Continuous overheat prevention
control record:
REC or UNREC- UNREC
MTR LOW POWER PIG power source voltage drop
record:
REC or UNREC- UNREC

POWER STEERING – ELECTRONIC POWER STEERING SYSTEMPS–19
PS
DIAGNOSTIC TROUBLE CODE CHART
HINT:
If any DTCs are displayed during the DTC check, inspect the
circuit listed for these DTCs. For details of each DTC, refer to
the page indicated in the DTC chart.
Electric Power Steering System
DTC No. Detection Item Trouble Area Normal Function
Return ConditionP/S Warning Light See page
C1511/11 Torque Sensor 1
Malfunction- Steering column
assembly (Torque
sensor)
- Power steering ECUIgnition switch ON
again
PS-18
C1512/11 Torque Sensor 2
Malfunction- Steering column
assembly (Torque
sensor)
- Power steering ECUIgnition switch ON
again
PS-18
C1513/11 Torque Sensor
Deviation Excessive- Steering column
assembly (Torque
sensor)
- Power steering ECUIgnition switch ON
again
PS-18
C1514/11 Torque Sensor Power
Supply Voltage
Malfunction- Steering column
assembly (Torque
sensor)
- Power steering ECUIgnition switch ON
again
PS-18
C1521/25 Short in Motor Circuit - Power steering ECU Ignition switch ON
again
PS-21
C1524/24 Motor Terminal
Voltage Malfunction- Steering column
assembly (Torque
sensor)
- Power steering ECUIgnition switch ON
again
PS-22
C1528/12 Motor Rotation Angle
Sensor Malfunction- Steering column
assembly (Torque
sensor)
- Power steering ECUIgnition switch ON
again
PS-24
C1531/25 ECU Malfunction - Power steering ECU Ignition switch ON
again
PS-26
C1532/25 ECU Malfunction - Power steering ECU Ignition switch ON
again
PS-26
C1533/25 Temperature Sensor
Circuit is Low or High- Power steering ECU Ignition switch ON
again or after normal
confirmation
PS-26
C1534/25 EEPROM
Malfunction- Power steering ECU Ignition switch ON
again
PS-26
C1551/25 IG Power Supply
Voltage Malfunction- ECU-IG1 fuse
- IG power source
circuit
- Power steering ECUIgnition switch ON
again or after normal
confirmation
PS-27
C1552/22 PIG Power Supply
Voltage Malfunction- PIG power source
circuit
- Power steering ECUIgnition switch ON
again or after normal
confirmation
PS-29
C1554/23 Power Supply Relay
Failure- PIG power source
circuit
- Power steering ECUIgnition switch ON
again
PS-31
C1555/25 Motor Relay Welding
Failure- Power steering ECU Ignition switch ON
again
PS-31
C1581/26 Assist Map Number
Un-Writing- Power steering ECU Assist map write or
ignition switch ON
again
PS-32
U0073/49 Control Module
Communication Bus
Off- CAN
communication
systemIgnition switch ON
again
PS-34

POWER STEERING – ELECTRONIC POWER STEERING SYSTEMPS–21
PS
DESCRIPTION
The torque sensor converts the rotation torque input from the steering wheel into electric signals and
sends them to the power steering ECU.
WIRING DIAGRAM
DTC C1511/11 Torque Sensor 1 Malfunction
DTC C1512/11 Torque Sensor 2 Malfunction
DTC C1513/11 Torque Sensor Deviation Excessive
DTC C1514/11Torque Sensor Power Supply Voltage Malfunc-
tion
DTC No. DTC Detection Condition Trouble Area
C1511/11 Torque sensor malfunction • Torque sensor (built into steering column
assembly)
• Power steering ECU
• Connector C1512/11
C1513/11
C1514/11
C128931E01

PS–22POWER STEERING – ELECTRONIC POWER STEERING SYSTEM
PS
INSPECTION PROCEDURE
(a) Check the installation condition of the torque sensor
connector.
OK:
Torque sensor connector is securely installed to
the power steering ECU.
Result
B
A
(a) Reinstall the torque sensor connector.
(b) Check for DTCs.
OK:
DTC is not output.
B
A
(a) Turn the ignition switch ON.
(b) Measure the voltage of the ECU.
Standard voltage
1CHECK CONNECTOR CONNECTION CONDITION (TORQUE SENSOR - ECU)
Result Proceed to
NG A
OK B
Go to step 3
2RECONFIRM DTC
Result Proceed to
DTC is output A
DTC is not output B
END
3INSPECT TORQUE SENSOR
C128930E01
Tester Connection Condition Specified Condition
6 (TRQ1) - 1 (TRQG) Steering wheel not
turned (without load)2.3 to 2.7 V
Steering wheel turned
to right with vehicle
stopped2.5 to 4.04 V
Steering wheel turned
to left with vehicle
stopped0.95 to 2.5 V

AIR CONDITIONING – COMPRESSOR AND PULLEY (for 2AZ-FE)AC–217
AC
INSTALLATION
1. ADJUST ADJUST COMPRESSOR OIL
(a) When replacing the compressor and magnetic
clutch with a new one, gradually discharge the
refrigerant gas from the service valve, and drain the
following amount of oil from the new compressor
and magnetic clutch before installation.
Standard:
(Oil capacity inside the new compressor and
magnetic clutch: 130 + 15 cc (4.6 + 0.51 fl.oz.) )
-(Remaining oil amount in the removed
compressor and magnetic clutch) = (Oil
amount to be removed from the new
compressor when replacing)
NOTICE:
• When checking the compressor oil level,
observe the precautions on the cooler
removal/installation.
• If a new compressor and magnetic clutch is
installed without removing some oil
remaining in the pipes of the vehicle, the oil
amount will be too large. This prevents heat
exchange in the refrigerant cycle and causes
refrigerant failure.
• If the volume of oil remaining in the removed
compressor and magnetic clutch is too small,
check for oil leakage.
• Be sure to use ND-OIL 8 or equivalent for
compressor oil.
2. INSTALL COOLER COMPRESSOR ASSEMBLY
(a) w/o Stud Bolt:
Install the cooler compressor with the 4 bolts.
Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)
NOTICE:
Tighten the bolts in the order shown in the
illustration to install the cooler compressor.
(b) w/ Stud Bolt:
Install the cooler compressor with the 3 bolts and
nut.
Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)
NOTICE:
Tighten the bolts in the order shown in the
illustration to install the cooler compressor.
(c) Connect the connector.
E134063E01