transaxle TOYOTA RAV4 2006 Service Repair Manual

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DIAGNOSIS SYSTEM
1. DESCRIPTION
(a) When troubleshooting On-Board Diagnostic (OBD
II) vehicles, the vehicle must be connected to the
OBD II scan tool (complying with SAE J1987).
Various data output from the vehicle's ECM can
then be read.
(b) 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
(2) The powertrain control components (which affect
vehicle emissions)
(3) The computer
In addition, the applicable Diagnostic Trouble
Codes (DTCs) prescribed by SAE J2012 are
recorded in the ECM memory.
When the malfunction does not reoccur, the MIL
stays illuminated until the ignition switch is
turned OFF, and the MIL turns OFF when the
engine is started. However, the DTCs remain
recorded in the ECM memory.
(c) To check DTCs, connect the intelligent tester to the
Data Link Connector 3 (DLC3) of the vehicle. The
tester displays DTCs, the freeze frame data and a
variety of the engine data.
The DTCs and freeze frame data can be erased
with the tester (see page AX-29).
2. NORMAL MODE AND CHECK MODE
(a) 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. "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.
3. 2 TRIP DETECTION LOGIC
(a) When a malfunction is first detected, the
malfunction is temporarily stored in the ECM
memory (1st trip). If the same malfunction is
detected during the next drive cycle, the MIL is
illuminated (2nd trip).
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4. FREEZE FRAME DATA
(a) 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.
(b) The intelligent tester records freeze frame data in 5
different instances: 1) 3 times before the DTC is set,
2) once when the DTC is set, and 3) once after the
DTC is set. These data can be used to simulate the
vehicle's condition around the time when the
malfunction occurred. The data may help find the
cause of the malfunction, or judge if the DTC is
being caused by a temporary malfunction or not.
5. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECM uses the ISO 15765-4 for
communication protocol. The terminal arrangement
of the DLC3 complies with SAE J1962 and matches
the ISO 15765-4 format.
HINT:
*: Before measuring the resistance, leave the vehicle as is for
at least 1 minute and do not operate the ignition switch, other
switches or doors.
If the result is not as specified, the DLC3 may have a
malfunction. Repair or replace the harness and connector.
HINT:
Connect the cable of the intelligent tester to the DLC3, turn
the ignition switch ON and attempt to use the tester. If the
screen displays UNABLE TO CONNECT TO VEHICLE, a
problem exists in the vehicle side or the tester side.
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Symbols (Terminal No.) Terminal Description Condition Specified Condition
SIL (7) - SG (5) Bus "+" line During transmission Pulse generation
CG (4) - Body ground Chassis ground Always Below 1
SG (5) - Body ground Signal ground Always Below 1
BAT (16) - Body ground Battery positive Always 9 to 14 V
CANH (6) - CANL (14) HIGH-level CAN bus line Ignition switch OFF 54 to 69
CANH (6) - Battery positive HIGH-level CAN bus line Ignition switch OFF 1 M or higher
CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch OFF 200
or higher
CANL (14) - Battery positive LOW-level CAN bus line Ignition switch OFF 1 M
or higher
CANL (14) - CG (4) LOW-level CAN bus line Ignition switch OFF 200
or higher

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If communication is normal when the tester is connected to
another vehicle, inspect the DLC3 on the original vehicle.
If communication is still not possible when the tester is
connected to another vehicle, the problem is probably in the
tester itself. Consult the Service Department listed in the
tester's instruction manual.
6. CHECK MIL
(a) Check that the MIL illuminates when turning the
ignition switch ON.
If the MIL does not illuminate, there is a problem in
the MIL circuit (see page ES-386).
(b) When the engine is started, the MIL should turn off.
7. ALL READINESS
(a) For this vehicle, using the intelligent tester allows
readiness codes corresponding to all DTCs to be
read. When the diagnosis (normal or
malfunctioning) has been completed, readiness
codes are set. Enter the following menus:
ENHANCED OBD II / MONITOR STATUS.
DTC CHECK / CLEAR
1. CHECK DTC
(a) DTCs which are stored in the ECM can be displayed
with the intelligent tester.
The intelligent tester can display pending DTCs and
current DTCs. Some DTCs are not stored unless a
malfunction is detected in consecutive driving
cycles. When a malfunction is detected in only one
driving cycle, it is stored as a pending DTC.
(1) Connect the intelligent tester to the CAN VIM.
Then connect the CAN VIM to the DLC3.
(2) Turn the ignition switch ON and turn the tester
ON.
(3) Enter the following menus: DIAGNOSIS /
ENHANCED OBD II / DTC INFO / CURRENT
CODES (or PENDING CODE).
(4) Confirm the DTCs and freeze frame data and
then write them down.
(5) Confirm the details of the DTCs (see page AX-
35).
NOTICE:
When simulating a symptom with the scan
tool to check for DTCs, use normal mode.
For codes on the DIAGNOSTIC TROUBLE
CODE CHART subject to "2 trip detection
logic", perform the following actions.
Turn the ignition switch OFF after the
symptom is simulated once. Then repeat the
simulation process again. When the
symptom has been simulated twice, the MIL
illuminates and the DTCs are recorded in the
ECM.
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2. CLEAR DTC
(a) When using the intelligent tester:
(1) Connect the intelligent tester to the CAN VIM.
Then connect the CAN VIM to the DLC3.
(2) Turn the ignition switch ON and turn the tester
ON.
(3) Enter the following menus: DIAGNOSIS /
ENHANCED OBD II / DTC INFO / CLEAR
CODES. Then and press YES.
HINT:
When operating the tester to erase the codes,
the DTCs and freeze frame data will be erased.
(b) When not using the intelligent tester:
(1) Disconnect the battery terminal or remove the
EFI MAIN and ETCS fuses from the engine
room No. 1 relay block and engine room No. 1
junction block for 60 seconds or more. However,
if you disconnect the battery terminal, perform
the "INITIALIZATION" procedure (see page AX-
18).
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CHECK MODE PROCEDURE
1. DESCRIPTION
(a) Check mode has a higher sensitivity to malfunctions
and can detect malfunctions that normal mode
cannot detect. Check mode can also detect all the
malfunctions that normal mode can detect. In check
mode, DTCs are detected with 1 trip detection logic.
2. CHECK MODE PROCEDURE
(a) Make sure that the following conditions below are
met:
(1) Battery positive voltage 11 V or more
(2) Throttle valve fully closed
(3) Transaxle in the P or N position
(4) A/C OFF
(b) Turn the ignition switch OFF.
(c) Connect the intelligent tester to the CAN VIM. Then
connect the CAN VIM to the DLC3.
(d) Turn the ignition switch ON and turn the tester ON.
(e) Enter the following menus: DIAGNOSIS /
ENHANCED OBD II / CHECK MODE.
(f) Change the ECM to check mode. Make sure the
MIL flashes as shown in the illustration.
NOTICE:
All DTCs and freeze frame data recorded will be
erased if: 1) the intelligent 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.
Before check mode, make notes of the DTCs
and freeze frame data.
(g) Start the engine. The MIL should turn off after the
engine starts.
(h) Perform "MONITOR DRIVE PATTERN" for the ECT
test (see page AX-19).
(Or, simulate the conditions of the malfunction
described by the customer.)
(i) After simulating the malfunction conditions, use the
tester to check the DTC and freeze frame data.
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ADJUSTMENT
1. INSPECT SHIFT LEVER POSITION
(a) When shifting the lever from P to the R position with
the ignition switch ON and the brake pedal
depressed, make sure that the shift lever moves
smoothly and moves correctly into position.
(b) Start the engine and make sure that the vehicle
moves forward when shifting the lever from N to the
D position and moves rearward when shifting the
lever to the R position.
If the operation cannot be performed as specified,
inspect the park/neutral position switch assembly
and check the shift lever assembly installation
condition.
2. ADJUST SHIFT LEVER POSITION
(a) Shift the shift lever to the N position.
(b) Slide the adjuster case cover in the direction shown
in the illustration and pull out the lock piece.
(c) Gently pull the cable rod toward the rear of the
vehicle by hand to pull the cable taut.
(d) Press the lock piece into the adjuster case and lock
it.
(e) Slide the cover in the direction shown in the
illustration.
NOTICE:
Slide the cover past the protrusion of the lock
piece.
(f) Inspect the operation after the adjustment.
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REASSEMBLY
1. INSTALL SHIFT LOCK RELEASE BUTTON
(a) Install the spring and button and attach the claws to
the position indicator light housing.
2. INSTALL INDICATOR LIGHT WIRE SUB-ASSEMBLY
3. INSTALL POSITION INDICATOR LIGHT HOUSING
(a) Attach the indicator light housing to the shift position
indicator housing with the 2 claws.
4. INSTALL LOWER POSITION INDICATOR HOUSING
(a) Install the position indicator slide cover with slide
cover No. 2 to the indicator housing.
(b) Attach the housing to the floor shift assembly with
the 4 claws.
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INSTALLATION
1. INSTALL FLOOR SHIFT ASSEMBLY
(a) Connect the 2 connectors and attach the clamp.
(b) Install the floor shift with the 4 bolts.
2. CONNECT TRANSAXLE CONTROL CABLE
ASSEMBLY
(a) Turn the nut of the control cable and push in the
lock.
(b) Install the control cable onto the shift lever retainer.
NOTICE:
• Install the cable with the protruding portion of
the cable outer facing upward.
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• After installing, check that the lock of the
cable outer is protruding beyond portion A-A,
as shown in the illustration.
(c) Connect the control cable to the shift lever.
NOTICE:
Connect the control cable so that the adjusting
mechanism lock of the control cable is installed
on the driver side of the vehicle.
3. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
4. INSPECT SHIFT LEVER POSITION (See page AX-138)
5. ADJUST SHIFT LEVER POSITION (See page AX-138)
6. INSTALL REAR CONSOLE BOX SUB-ASSEMBLY
(a) Install the rear console box (see page IP-26).
7. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY
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REPLACEMENT
1. REPLACE TRANSAXLE HOUSING OIL SEAL LH
(a) Drain the automatic transaxle fluid.
(1) Remove the drain plug and gasket, and drain
AT F.
(2) Install a new gasket and drain plug.
Torque: 47 N*m (479 kgf*cm, 35 ft.*lbf)
(b) Remove the front drive shaft LH (see page DS-41).
(c) Remove the transaxle housing oil seal LH.
(1) Using SST, tap out the oil seal.
SST 09308-00010
(d) Install a new transaxle housing oil seal LH.
(1) Coat the lip of a new oil seal with MP grease.
(2) Using SST and a hammer, tap in the oil seal.
SST 09726-27012 (09726-02041), 09950-
70010 (09951-07200, 09951-07200)
Standard depth:
0 +-0.5 mm (0 +-0.020 in.)
(e) Install the front drive shaft LH (see page DS-65).
(f) Add automatic transaxle fluid.
Fluid type:
Toyota Genuine ATF WS
(g) Inspect the transaxle fluid level (see page AX-102).
2. REPLACE TRANSAXLE HOUSING OIL SEAL RH
(a) Remove the engine with transaxle (see page EM-
98).
(b) Drain the automatic transaxle fluid.
(1) Remove the drain plug and gasket, and drain
AT F.
(2) Install a new gasket and the drain plug.
Torque: 47 N*m (479 kgf*cm, 35 ft.*lbf)
(c) Remove the 3 bolts and drive shaft bearing bracket.
(d) Remove the 3 bolts and engine mount bracket RR.
(e) Remove the transfer assembly (see page TF-59).
(f) Remove the transaxle housing oil seal RH.
(1) Using a screwdriver with vinyl tape wound
around its tip, remove the oil seal.
NOTICE:
Be careful not to damage the housing.
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