heater TOYOTA RAV4 2006 Service Owner's Manual

ES–322AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM
ES
VPA (A9-55) - EPA (A9-59) W - YAccelerator pedal position
sensor (for engine control)Ignition switch ON,
Accelerator pedal released0.5 to 1.1 V
Ignition switch ON,
Accelerator pedal fully depressed2.6 to 4.5 V
VPA2 (A9-56) - EPA2 (A9-60) R - OAccelerator pedal position
sensor (for sensor
malfunctioning detection)Ignition switch ON,
Accelerator pedal released1.2 to 2.0 V
Ignition switch ON,
Accelerator pedal fully depressed3.4 to 5.0 V
VCPA (A9-57) - EPA (A9-59) B - YPower source of
accelerator pedal position
sensor (for VPA)Ignition switch ON 4.5 to 5.5 V
VCP2 (A9-58) - EPA2 (A9-60) L - OPower source of
accelerator pedal position
sensor (for VPA2)Ignition switch ON 4.5 to 5.5 V
HA1A (B30-109) - E04 (B30-46) L - W-B A/F sensor heaterIdling Below 3.0 V
Ignition switch ON 9 to 14 V
A1A+ (B30-112) - E1 (B30-104) B -BR A/F sensor Ignition switch ON 3.3 V*
A1A- (B30-113) - E1 (B30-104) R - BR A/F sensor Ignition switch ON3.0 V*
HT1B (B30-47) - E03 (B30-86) R - W-BHeated oxygen sensor
heaterIdling Below 3.0 V
Ignition switch ON 9 to 14 V
OX1B (B30-64) - EX1B (B30-87) B - BR Heated oxygen sensorEngine speed maintained at 2,500
rpm for 2 minutes after warming up
sensorPulse generation (see
waveform 2)
#10 (B30-108) - E01 (B30-45)
#20 (B30-107) - E01 (B30-45)
#30 (B30-106) - E01 (B30-45)
#40 (B30-105) - E01 (B30-45)L - W-B
G - W-B
B - W-B
W - W-BInjectorIgnition switch ON 9 to 14 V
IdlingPulse generation (see
waveform 3)
KNK1 (B30-110) - EKNK (B30-
111 )B - W Knock sensorEngine speed maintained at 4,000
after warming up enginePulse generation (see
waveform 4)
G2+ (B30-99) - G2- (B30-98) L - Y Camshaft position sensor IdlingPulse generation (see
waveform 5)
NE+ (B30-122) - NE- (B30-121) W - B Crankshaft position sensor IdlingPulse generation (see
waveform 5)
IGT1 (B30-85) - E1 (B30-104)
IGT2 (B30-84) - E1 (B30-104)
IGT3 (B30-83) - E1 (B30-104)
IGT4 (B30-82) - E1 (B30-104)R - BR
P - BR
G - BR
L - BRIgnition coil (ignition
signal)IdlingPulse generation (see
waveform 6)
IGF1 (B30-81) - E1 (B30-104) W - BRIgnition coil (ignition
confirmation signal)Ignition switch ON 4.5 to 5.5 V
IdlingPulse generation (see
waveform 6)
PRG (B30-49) - E1 (B30-104) G - BR Purge VSVIgnition switch ON 9 to 14 V
IdlingPulse generation (see
waveform 7)
SPD (A9-8) - E1 (B30-104) V - BRSpeed signal from
combination meterDriving at 20 km/h (12 mph)Pulse generation (see
waveform 8)
STA (A9-48) - E1 (B30-104) LG - BR Starter signal Cranking 5.5 V or
more
STAR (B30-52) - E1 (B30-104) W - BR Starter relay controlIgnition switch ON Below 1.5 V
Cranking 6.0 V or more
STP (A9-36) - E1 (B30-104) L - BR Stop light switchBrake pedal depressed 7.5 to 14 V
Brake pedal released Below 1.5 V
ST1- (A9-35) - E1 (B30-104) GR - BRStop light switch
(opposite to STP terminal)Ignition switch ON,
Brake pedal depressedBelow 1.5 V
Ignition switch ON,
Brake pedal released7.5 to 14 V
M+ (B30-42) - ME01 (B30-43) B - W-B Throttle actuator Idling with warm enginePulse generation (see
waveform 9) Symbols (Terminal No.) Wiring Colors Terminal Descriptions ConditionsSpecified
Conditions

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEMES–25
ES
Rear Oxygen Sensor Heater
Misfire
$3D $D1 Multiply by 0.001 kPa Test value for reference orifice high flow (P043F)
$3D $D4 Multiply by 0.001 kPa Test value for purge VSV stuck closed (P0441)
$3D $D5 Multiply by 0.001 kPa Test value for purge VSV stuck open (P0441)
$3D $D7 Multiply by 0.001 kPa Test value for purge flow insufficient (P0441)
Monitor ID Test ID Scaling Unit Description
$42 $91 Multiply by 0.001 Ohm Oxygen sensor heater resistance bank 1 sensor 2
$46 $91 Multiply by 0.001 Ohm Oxygen sensor heater resistance bank 2 sensor 2
Monitor ID Test ID Scaling Unit Description
$A1 $0B Multiply by 1 TimeExponential Weighted Moving Average (EWMA) misfire for all
cylinders:
EWMA = Total misfire counts for last driving cycle * 0.1 + Last
EWMA * 0.9
Misfire counts for last 10 driving cycles - Total
$A1 $0C Multiply by 1 TimeIgnition switch ON: Total misfire counts for last driving cycle
Engine running: Total misfire counts for current driving cycle
Misfire counts for last or current driving cycle - all cylinders
$A2 $0B Multiply by 1 TimeExponential Weighted Moving Average (EWMA) misfire for
cylinder 1:
EWMA = Total misfire counts for last driving cycle * 0.1 + Last
EWMA * 0.9
Misfire counts for last 10 driving cycles - Total
$A2 $0C Multiply by 1 TimeIgnition switch ON: Total misfire counts for last driving cycle
Engine running: Total misfire counts for current driving cycle
Misfire counts for last or current driving cycle - cylinder 1
$A3 $0B Multiply by 1 TimeExponential Weighted Moving Average (EWMA) misfire for
cylinder 2:
EWMA = Total misfire counts for last driving cycle * 0.1 + Last
EWMA * 0.9
Misfire counts for last 10 driving cycles - Total
$A3 $0C Multiply by 1 TimeIgnition switch ON: Total misfire counts for last driving cycle
Engine running: Total misfire counts for current driving cycle
Misfire counts for last or current driving cycle - cylinder 2
$A4 $0B Multiply by 1 TimeExponential Weighted Moving Average (EWMA) misfire for
cylinder 3:
EWMA = Total misfire counts for last driving cycle * 0.1 + Last
EWMA * 0.9
Misfire counts for last 10 driving cycles - Total
$A4 $0C Multiply by 1 TimeIgnition switch ON: Total misfire counts for last driving cycle
Engine running: Total misfire counts for current driving cycle
Misfire counts for last or current driving cycle - cylinder 3
$A5 $0B Multiply by 1 TimeExponential Weighted Moving Average (EWMA) misfire for
cylinder 4:
EWMA = Total misfire counts for last driving cycle * 0.1 + Last
EWMA * 0.9
Misfire counts for last 10 driving cycles - Total
$A5 $0C Multiply by 1 TimeIgnition switch ON: Total misfire counts for last driving cycle
Engine running: Total misfire counts for current driving cycle
Misfire counts for last or current driving cycle - cylinder 4
$A6 $0B Multiply by 1 TimeExponential Weighted Moving Average (EWMA) misfire for
cylinder 5:
EWMA = Total misfire counts for last driving cycle * 0.1 + Last
EWMA * 0.9
Misfire counts for last 10 driving cycles - Total
$A6 $0C Multiply by 1 TimeIgnition switch ON: Total misfire counts for last driving cycle
Engine running: Total misfire counts for current driving cycle
Misfire counts for last or current driving cycle - cylinder 5 Monitor ID Test ID Scaling Unit Description

ES–302GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM
ES
– Air-fuel ratio feedback control is performed.
(b) Drive Pattern for front A/F sensor and HO2 sensor
(1) Connect the intelligent tester to the DLC3.
(2) Turn the ignition switch ON.
(3) Turn the tester ON.
(4) Clear DTCs (see page ES-39).
(5) Start the engine, and warm it up until the ECT
reaches 75
C (167F) or higher.
(6) Drive the vehicle at between 60 km/h (38 mph)
and 120 km/h (75 mph) for at least 10 minutes.
(7) Change the transmission to 2nd gear.
(8) Accelerate the vehicle to 64 km/h (40 mph) or
more by depressing the accelerator pedal for at
least 10 seconds.
(9) Soon after performing step (8) above, release
the accelerator pedal for at least 4 seconds without
depressing the brake pedal in order to execute fuel-
cut control.
(10) Allow the vehicle to decelerate until the vehicle
speed declines to less than 10 km/h (6 mph).
(11) Repeat steps from (8) through (10) above at
least 3 times in one driving cycle.
(c) Monitor Status
(1) Check the Readiness Monitor status displayed
on the tester.
(2) If the status does not switch to COMPL
(complete), make sure that the preconditions
have been met, and then perform steps from (5)
through (11) in the Drive Pattern above.
5. AIR-FUEL RATIO (A/F) AND HEATED OXYGEN (HO2)
SENSOR HEATER MONITORS (FRONT A/F AND
REAR HO2 SENSOR TYPE)
A121604E06

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEMES–35
ES
THW (B30-79) - ETHW (B30-78) L - BR Engine coolant
temperature sensorIdling, Engine coolant temperature
80
C (176F)0.2 to 1.0 V
VCTA (B30-96) - ETA (B30-97) B - W Power source of throttle
position sensor (specific
voltage)Ignition switch ON 4.5 to 5.5 V
VTA1 (B30-98) - ETA (B30-97) Y - W Throttle position sensor
(for engine control)Ignition switch ON,
Throttle valve fully closed0.5 to 1.1 V
Ignition switch ON,
Throttle valve fully open3.3 to 4.9 V
VTA2 (B30-99) - ETA (B30-97) GR - W Throttle position sensor
(for sensor malfunction
detection)Ignition switch ON,
Throttle valve fully closed2.1 to 3.1 V
Ignition switch ON,
Throttle valve fully open4.6 to 5.0 V
VPA (A9-55) - EPA (A9-59) W - Y Accelerator pedal position
sensor (for engine control)Ignition switch ON,
Accelerator pedal released0.5 to 1.1 V
Ignition switch ON,
Accelerator pedal fully depressed2.6 to 4.5 V
VPA2 (A9-56) - EPA2 (A9-60) R - O Accelerator pedal position
sensor (for sensor
malfunctioning detection)Ignition switch ON,
Accelerator pedal released1.2 to 2.0 V
Ignition switch ON,
Accelerator pedal fully depressed3.4 to 5.0 V
VCPA (A9-57) - EPA (A9-59) B - Y Power source of
accelerator pedal position
sensor (for VPA)Ignition switch ON 4.5 to 5.5 V
VCP2 (A9-58) - EPA2 (A9-60) L - O Power source of
accelerator pedal position
sensor (for VPA2)Ignition switch ON 4.5 to 5.5 V
HA1A (B30-86) - E04 (B30-23)
HA2A (B30-109) - E04 (B30-23) G - BR
B - BRA/F sensor heater Idling Below 3.0 V
Ignition switch ON 9 to 14 V
A1A+ (B30-93) - E1 (B30-81) W -BR A/F sensor Ignition switch ON 3.3 V*
A1A- (B30-116) - E1 (B30-81) BR - BR A/F sensor Ignition switch ON3.0 V*
A2A+ (B30-120) - E1 (B30-81) L - BR A/F sensor Ignition switch ON 3.3 V*
A2A- (B30-119) - E1 (B30-81) Y - BR A/F sensor Ignition switch ON 3.0 V*
HT1B (B30-48) - E03 (B30-104)
HT2B (B30-47) - E03 (B30-104)LG - BR
Y - BRHeated oxygen sensor
heaterIdling Below 3.0 V
Ignition switch ON 9 to 14 V
OX1B (B30-88) - EX1B (B30-65)
OX2B (B30-87) - EX2B- (B30-64)W - GR
B - B-WHeated oxygen sensor Engine speed maintained at 2,500
rpm for 2 minutes after warming up
sensorPulse generation (see
waveform 2)
#10 (B30-45) - E01 (B30-22)
#20 (B30-85) - E01 (B30-22)
#30 (B30-44) - E01 (B30-22)
#40 (B30-84) - E01 (B30-22)
#50 (B30-43) - E01 (B30-22)
#60 (B30-83) - E01 (B30-22)Y - BR
W - BR
B - BR
BR - BR
L - BR
G - BRInjector Ignition switch ON 9 to 14 V
Idling Pulse generation (see
waveform 3)
KNK1 (B30-95) - EKNK (B30-94)
KNK2 (B30-118) - EKN2 (B30-
11 7 )R - G
B - WKnock sensor Engine speed maintained at 4,000
rpm after warming up enginePulse generation (see
waveform 4)
VCV1 (B30-115) - E1 (B30-81) G-R - BR Power source for VVT
sensor (specific voltage)Ignition switch ON 4.5 to 5.0 V
VCV2 (B30-113) - E1 (B30-81) V - BR Power source for VVT
sensor (specific voltage)Ignition switch ON 4.5 to 5.0 V
VCE1 (B30-114) - E1 (B30-81) GR - BR Power source for VVT
sensor specific voltage)Ignition switch ON 4.5 to 5.0 V
VCE2 (B30-112) - E1 (B30-81) Y - BR Power source for VVT
sensor (specific voltage)Ignition switch ON 4.5 to 5.0 V
VV1+ (B30-69) - VV1- (B30-92) P - L-B Variable valve timing
(VVT) sensor (Intake side
(bank 1))Idling Pulse generation
(see waveform 5) Symbol (Terminal No.) Wiring Color Terminal Description Condition Specified Condition

EM–862AZ-FE ENGINE MECHANICAL – CYLINDER HEAD
EM
22. INSTALL ENGINE MOUNTING INSULATOR RH (See
page EM-41)
23. INSTALL RADIATOR RESERVOIR (See page EM-112)
24. INSTALL GENERATOR ASSEMBLY (See page CH-15)
25. INSTALL FAN AND GENERATOR V BELT (See page
EM-7)
26. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-7)
27. CONNECT ENGINE WIRE
(a) Connect the ground cable with the bolt.
Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
(b) Connect the camshaft position sensor connector.
(c) Connect the engine coolant temperature sensor
connector.
(d) Connect the engine oil pressure switch connector.
(e) Connect the radio setting condenser connector.
(f) Connect the heater water inlet hose.
28. CONNECT NO. 1 RADIATOR HOSE
(a) Connect the hose to the cylinder head.
29. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
ASSEMBLY (See page ES-396)
30. INSTALL EXHAUST MANIFOLD CONVERTER SUB-
ASSEMBLY
(a) Install a new gasket onto the cylinder head.
(b) Temporarily tighten the exhaust manifold converter
with the 5 nuts.
(c) Tighten the 5 nuts in the sequence shown in the
illustration.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
(d) Connect the air-fuel ratio sensor connector.
A098748E01
A114348
A112190E01
A098744E01

EM–1002AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
25. DISCONNECT HEATER WATER INLET HOSE
(a) Disconnect the heater water inlet hose from the
heater unit.
26. DISCONNECT HEATER WATER OUTLET HOSE
(a) Disconnect the heater water outlet hose from the
heater unit.
27. DISCONNECT FUEL TUBE (See page FU-10)
28. REMOVE THROTTLE BODY (See page ES-412)
29. DISCONNECT NO. 2 VENTILATION HOSE (See page
FU-10)
30. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
(See page FU-10)
31. REMOVE INTAKE MANIFOLD (See page ES-419)
32. REMOVE INTAKE MANIFOLD INSULATOR (See page
ES-420)
33. REMOVE TRANSAXLE CONTROL CABLE
ASSEMBLY
(a) Remove the transaxle control cable for U241E
(2WD) (see page AX-129).
(b) Remove the transaxle control cable for U140F
(4WD) (see page AX-129).
34. REMOVE FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-6)
35. REMOVE FAN AND GENERATOR V BELT (See page
EM-6)
36. REMOVE GENERATOR ASSEMBLY (See page CH-9)
37. REMOVE COOLER COMPRESSOR ASSEMBLY
(a) Remove the cooler compressor (see page AC-216).
HINT:
Disconnect the compressor together with the low-
pressure and high-pressure hoses, then secure it to
the vehicle side using rope.
38. REMOVE ECM (See page ES-429)
39. DISCONNECT ENGINE WIRE
(a) Remove the engine room relay block cover.
A124832
A124831

2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–111
EM
(e) Connect the 2 engine wire connectors and install
the nut.
(f) Install the engine room relay block cover.
(g) Attach the clamp of the engine wire cover.
(h) Install the engine wire cover to with the bolt.
19. INSTALL ECM (See page ES-430)
20. INSTALL COOLER COMPRESSOR ASSEMBLY (See
page AC-217)
21. INSTALL GENERATOR ASSEMBLY (See page CH-15)
22. INSTALL FAN AND GENERATOR V BELT (See page
EM-7)
23. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-7)
24. INSTALL TRANSAXLE CONTROL CABLE
ASSEMBLY
(a) Install the transaxle control cable for U241E (see
page AX-130).
(b) Install the transaxle control cable for U140F (see
page AX-130).
25. INSTALL INTAKE MANIFOLD INSULATOR (See page
ES-421)
26. INSTALL INTAKE MANIFOLD (See page ES-421)
27. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
(See page FU-13)
28. CONNECT NO. 2 VENTILATION HOSE (See page FU-
14)
29. INSTALL THROTTLE BODY ASSEMBLY (See page
ES-413)
30. CONNECT FUEL TUBE (See page FU-14)
31. CONNECT HEATER WATER OUTLET HOSE
(a) Connect the heater water outlet hose to the air
conditioner tube.
A124834
A124847
A124831

EM–1122AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
32. CONNECT HEATER WATER INLET HOSE
(a) Connect the heater water inlet hose to the air
conditioner tube.
33. CONNECT UNION TO CONNECTOR TUBE HOSE
(a) Connect the 2 union to connector tube hoses to the
booster vacuum tube.
34. INSTALL BATTERY CARRIER BRACKET
(a) Install the battery carrier bracket with the nut and 2
bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
35. INSTALL BATTERY BRACKET REINFORCEMENT
(a) Install the battery bracket reinforcement with the 2
bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
36. INSTALL FRONT BATTERY CARRIER
(a) Install the front battery carrier with the 4 bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
(b) Connect the 2 clamps of the engine wire.
37. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
(a) Connect the air cleaner case to the No. 1 air cleaner
inlet.
A124832
A124830
A124829
A124828
A124827

2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–39
EM
(b) 4WD:
Connect the control cable (see page AX-154).
46. CONNECT RADIATOR HOSE INLET
47. CONNECT RADIATOR HOSE OUTLET
48. CONNECT OIL COOLER HOSE
49. CONNECT SUCTION HOSE SUB-ASSEMBLY (See
page AC-221)
50. INSTALL DISCHARGE HOSE SUB-ASSEMBLY (See
page AC-221)
51. INSTALL RADIATOR RESERVOIR TANK ASSEMBLY
(a) Install the reservoir tank with the 2 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(b) Connect the 2 hoses
52. INSTALL ECM (See page ES-471)
53. CONNECT HOSES AND CONNECTORS
(a) Connect the 2 ECM connectors.
(b) Connect the 2 heater hoses.
(c) Connect the fuel hoses.
(d) Connect the starter wire with the nut.
Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
(e) Connect the 3 connectors and wire with the nut.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
(f) Install the engine room junction block cover (upper).
54. INSTALL AIR CLEANER CASE
(a) Install the air cleaner case with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(b) Connect the harness clamp.
55. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
(a) Install the air cleaner filter element onto the air
cleaner case.
(b) Insert the hinge part of the air cleaner cap into the
air cleaner case, then hang the 2 hook clamps.
A124838
A137898
A137901E01

2GR-FE CHARGING – CHARGING SYSTEMCH–7
CH
8. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn the high
beam headlights ON and turn the heater blower
switch to the "HI" position.
(b) Check the reading on the ammeter.
Standard amperage:
30 A or more
If the ammeter reading is less than the standard
amperage, repair the generator.
HINT:
If the battery is fully charged, the indication will
sometimes be less than the standard amperage.
If this is the case, add more electrical load (operate
the wipers, rear window defogger, etc.) and check
the reading on the ammeter again.