engine TOYOTA RAV4 2006 Service Repair Manual

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEMAX–37
AX
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.
B127989E02
A076900E02

U241E AUTOMATIC TRANSAXLE – FLOOR SHIFT ASSEMBLYAX–139
AX
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.
C117121E01
C117120E01
C117119E01

AX–150U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY
AX
5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
(a) Install the automatic transaxle with the 5 upper side
mounting bolts to the engine.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) for bolt A
46 N*m (469 kgf*cm, 34 ft.*lbf) for bolt B
(b) Install the 4 lower side mounting bolts.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
(c) Install the 6 torque converter clutch mounting bolts.
Torque: 41 N*m (418 kgf*cm, 30 ft.*lbf)
HINT:
First install the green colored bolt and then the 5
bolts.
(d) Install the flywheel housing under cover.
6. INSTALL ENGINE MOUNTING BRACKET LH
(a) Install the mounting bracket with the 3 bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
7. INSTALL ENGINE MOUNTING BRACKET FR
(a) Install the mounting bracket with the 4 bolts.
Torque: 64 N*m (657 kgf*cm, 47 ft.*lbf) for 14
mm head bolt
12 N*m (122 kgf*cm, 9 ft.*lbf) for 12 mm
head bolt
C127822E01
C127820
C129381
C129380
C130912

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLYAX–151
AX
8. INSTALL ENGINE MOUNTING BRACKET RR
(a) Install the mounting bracket with the 3 bolts.
Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf)
9. INSTALL TRANSMISSION OIL COOLER
(a) Install the oil cooler (see page AX-127).
10. CONNECT WIRE HARNESS
(a) Connect the wire harness clamps.
(b) Connect the speed sensor connectors.
(c) Connect the transaxle wire connector.
(d) Connect the park/neutral position switch connector.
11. INSTALL STARTER ASSEMBLY
(a) Install the starter with the 2 bolts.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
(b) Connect the starter wire with the nut.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
(c) Connect the starter connector.
(d) Install the terminal nut and cover the nut with the
cap.
Torque: 9.8 N*m (100 kgf*cm, 7 in.*lbf)
12. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the engine with transaxle (see page EM-105).
13. ADD AUTOMATIC TRANSAXLE FLUID
Fluid type:
Toyota Genuine ATF WS
14. INSPECT AUTOMATIC TRANSAXLE FLUID
(a) Inspect the automatic transaxle fluid (see page AX-
102).
15. PERFORM RESET MEMORY
(a) Perform the RESET MEMORY procedures (A/T
initialization) (see page AX-18).
C129395
C127821
A124921
A124920

TF–6GF1A TRANSFER – ACTIVE TORQUE CONTROL 4WD SYSTEM
TF
SYSTEM DESCRIPTION
1. GENERAL DESCRIPTION
(a) The active torque control 4WD system detects the
driving conditions based on signals from each ECU,
each switch, the steering angle sensor, the wheel
speed sensor, and the yaw rate sensor. The system
controls the electronic current passing through the
linear solenoid of the electromagnetic coupling, and
performs electronic control to distribute the optimum
torque to the rear wheels.
(b) Main components and their functions.
C128585E01
Component Function
4WD Indicator Light Displays warning to driver when system malfunctions
Stop Light Switch Detects brake operation
Throttle Position Sensor Detects opening angle of throttle
Park/Neutral Position Switch Detects "P" position
Steering Angle Sensor Detects turning of steering wheel
4WD Linear Solenoid Detects electronic control limiting clutch operation using signals from
4WD control ECU
Skid Control ECU with Actuator Detects signals from each sensor and outputs them to 4WD control
ECU
4WD Control ECU Detects signals from each sensor via skid control ECU to operate
linear solenoid and control system
Crankshaft Position Sensor Detects engine rpm and inputs it into ECM
Yaw Rate Sensor Detects forward and rearward acceleration of vehicle, and inputs it into
skid control ECU

TF–14GF1A TRANSFER – ACTIVE TORQUE CONTROL 4WD SYSTEM
TF
NOTICE:
If a part of the 4WD system has a defect, the
4WD indicator light will illuminate.
(c) Check if the 4WD indicator light has changed to the
test mode display.
(d) Start the engine.
3. CONFIRM MODE CHANGE
HINT:
Operate the 4WD lock switch, and check that the 4WD
control mode changes.
C128629E01
4WD Lock Switch Status 4WD Lock Mode Indicator Status 4WD Control Status
OFF Turns off 4WD auto mode
ON Illuminates 4WD lock mode
Switch changed from OFF to ON Blinks twice, then illuminates At moment of illumination, changes to 4WD
lock mode

TF–16GF1A TRANSFER – ACTIVE TORQUE CONTROL 4WD SYSTEM
TF
TERMINALS OF ECU
1. CHECK 4WD CONTROL ECU
(a) Measure the voltage and resistance of the
connector.
If the result is not as specified, the 4WD control
ECU may have a malfunction.
(b) Using an oscilloscope, check the waveform 1.
Waveform 1 (Reference)
G032017E06
Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition
CANH (E57-14) - CANL
(E57-16)P - W CAN communication Ignition switch OFF 54 to 69
GND (E57-23) - Body
groundW-B - Body ground Ground Always Below 1
4WDL (E57-7) - Body
groundR - W-B Ground 4WD lock mode switch ON Below 1
IG1 (E57-11) - GND (E57-
23)L - W-B Power source voltage Ignition switch ON 10 to 14 V
SLC+ (E57-13) - SLC-
(E57-32)W - B 4WD linear solenoid signal Ignition switch ON Pulse generation (See
waveform 1)
BSLC (E57-9) - GND
(E57-23)R - W-B Power source voltage Ignition switch ON 10 to 14 V
C065158E02
Symbols (Terminal No.) Content
Tool setting 5 V/DIV., 2 msec. / DIV.
Vehicle condition Engine stop, ignition switch ON

GF1A TRANSFER – ACTIVE TORQUE CONTROL 4WD SYSTEMTF–21
TF
DATA LIST / ACTIVE TEST
1. READ DATA LIST
HINT:
Using the intelligent tester's (with CAN VIM) DATA LIST
allows switch, sensor 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.
(c) Read the DATA LIST according to the display on the
tester.
4WD control ECU
Item Measurement Item/Range
(Display)Normal Condition Diagnostic Note
4WD WARN LAMP 4WD indicator light /OFF or ON OFF: 4WD indicator light OFF
ON: 4WD indicator light ON-
SLIP INDI LAMP Slip indicator light /OFF or ON OFF: SLIP indicator light OFF
ON: SLIP indicator light ON-
STOP LAMP SW Stop light switch /OFF or ON OFF: Brake pedal released
ON: Brake pedal depressed-
STEERING ANGLE Steering angle value /
Min.: -3276.8 deg
Max.: 3276.7 degMin.: -3276.8 deg
Max.: 3276.7 deg-
FR WHEEL SPD FR wheel speed /
Min.: 0 km/h (0 mph)
Reading : Max.: 326.4 km/h
(202.8 mph)Actual wheel speed Almost no difference from the
speedometer
FL WHEEL SPD FL wheel speed /
Min.: 0 km/h (0 mph)
Reading : Max.: 326.4 km/h
(202.8 mph)Actual wheel speed Almost no difference from the
speedometer
RR WHEEL SPD RR wheel speed /
Min.: 0 km/h (0 mph)
Reading : Max.: 326.4 km/h
(202.8 mph)Actual wheel speed Almost no difference from the
speedometer
RLWHEEL SPD RL wheel speed /
Min.: 0 km/h (0 mph)
Reading : Max.: 326.4 km/h
(202.8 mph)Actual wheel speed Almost no difference from the
speedometer
AMBI TEMP Ambient temperature /
Min.: -128
C (198.4 F)
Max.: 127 C (260.6 F)Min.: -128 (198.4
F)
Max.: 127 (260.6
F)-
COOLANT TEMP Engine coolant temperature /
Min.: 0
C (32 F)
Max.: 127.5
C (261.5 F)Min.: 0
C (32 F)
Max.: 127.5 C (261.5 F)-
LOCK SW 4WD lock switch / OFF or ON OFF: 4WD lock switch off
ON: 4WD lock switch on-
SLC CUR SLC solenoid (4WD linear
solenoid) current /
Min.: 0 A
Max.: 3 AMin.: 0 A
Max.: 3 A-

GF1A TRANSFER – ACTIVE TORQUE CONTROL 4WD SYSTEMTF–23
TF
DIAGNOSTIC TROUBLE CODE CHART
DTC No. Detection Item Trouble Area See page
C1241/94 Low Power Supply Voltage -Battery
-generator
-ECU-IG1
-Wire harness
-4WD control ECUTF-21
C1280/82 Engine Circuit Malfunction -Throttle position sensor
-Throttle position sensor wire
harness and connector
-CAN communication systemTF-24
C1296/96 ABS Malfunction -Wire harness
-4WD control ECU
-Skid control ECU
-Speed sensor
-Yaw rate sensor
-CAN communication systemTF-25
C1297/97 Steering Angle Sensor -Steering angle sensor
-CAN communication system
-Wire harness
-4WD control ECUTF-27
C1298/98 Linear Solenoid Circuit -Wire harness
-Electromagnetic coupling
-4WD control ECUTF-30
C1299/99 Cancellation of 4WD Control -Tire size
-Electromagnetic coupling
-4WD control ECUTF-32
U0073/86 Control Module Communication
Bus OFF-Wire harness (CANH, CANL
circuit)
-4WD control ECUTF-34
U0100/85 Lost Communication with ECM /
PCM "A"-Wire harness (CANH, CANL
circuit)
-4WD control ECU
-ECMTF-34
U0126/84 Lost Communication with
Steering Angle Sensor Module-Wire harness (CANH, CANL
circuit)
-4WD control ECU
-Steering angle sensorTF-34
U0129/83 Lost Communication with Brake
System Control Module-Wire harness (CANH, CANL
circuit)
-4WD control ECU
-Skid control ECUTF-34

GF1A TRANSFER – ACTIVE TORQUE CONTROL 4WD SYSTEMTF–25
TF
(a) Clear the DTC (see page TF-16).
(b) Turn the ignition switch ON and check that no CAN
communication system DTC is output.
(c) Start the engine.
(d) Drive the vehicle, accelerate to a speed of 3 km/h (2
mph) or more, and check that no speed sensor DTC
(brake control system DTC) is output (see page BC-57).
Result
B
C
A
(a) Remove the ECU-IG1 fuse from the instrument junction
block
(b) Measure the resistance of the fuse.
Standard resistance:
Below 1
HINT:
Check for short circuits in all harnesses and connector
connected to the ECU-IG1 fuse (see page IN-5).
NG
OK
(a) Disconnect the E57 ECU connector.
(b) Measure the voltage of the wire harness side connector.
Standard voltage
NG
1CHECK FOR DTC
Result Proceed to
Neither CAN communication system DTC nor speed sensor DTC
(Brake control system DTC) is outputA
CAN communication system DTC is output B
Speed Sensor DTC (Brake control system DTC) is output C
REPAIR CIRCUIT INDICATOR BY OUTPUT
CODE (CAN COMMUNICATION SYSTEM)
REPAIR CIRCUIT INDICATOR BY OUTPUT
CODE (BRAKE CONTROL SYSTEM)
2INSPECT FUSE (ECU-IG)
REPLACE FUSE
3CHECK WIRE HARNESS (4WD CONTROL ECU - BATTERY)
C107387E11
Tester Connection Condition Specified Condition
E57-11 (IG1) - Body
GroundIgnition switch ON 10 to 14 V
REPAIR OR REPLACE HARNESS AND
CONNECTOR