Toyota RAV4 2004 Service Manual
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Toyota RAV4 2004 Service Manual

Engine performance sfi-rav4
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SFI SYSTEM
PRECAUTION
HINT:
Any diagnostic trouble code (DTC) retained in the ECM will be erased when the negative (-) terminal cable is
removed from the battery. If necessary, read the DTC before removing the negative (-) terminal cable from the
battery.
1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE
FROM BATTERY
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL
SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS
4. MAINTENANCE PRECAUTIONS
a. To prevent engine misfire, these precautions should be taken.
1. Check the battery terminals for proper connection.
2. After repair, check that the ignition coil terminals and all other ignition system lines are
reconnected securely.
3. When cleaning the engine compartment, be especially careful to protect the electrical system
from water.
b. Observe the following when handling the heated oxygen sensors.
1. Do not drop the sensor or hit it against an object.
2. The sensor should be free from any contact with water.
5. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM (HAM, CB, ETC.)
If the vehicle is equipped with a mobile communication system, refer to the PRECAUTION .
6. AIR INDUCTION SYSTEM
a. Removal of the engine oil dipstick, oil filler cap, PCV hose may break the engine.
b. Disconnection, looseness or cracks in the parts of the air induction system between the throttle
body and cylinder head may allow air suction and break the engine.
7. ELECTRONIC CONTROL SYSTEM
a. Before removing the SFI wiring connectors, terminals, first disconnect the power by turning the
ignition switch OFF or disconnecting the negative (-) terminal cable from the battery.
HINT:
2004 Toyota RAV4
2004 Toyota RAV4
2004 ENGINE PERFORMANCE SFI - RAV4
2004 ENGINE PERFORMANCE SFI - RAV4
2004 ENGINE PERFORMANCE
SFI - RAV4

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  • Page 1 2004 Toyota RAV4 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 SFI SYSTEM PRECAUTION HINT: Any diagnostic trouble code (DTC) retained in the ECM will be erased when the negative (-) terminal cable is removed from the battery.
  • Page 2 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Be sure to check the DTC before disconnecting the negative (-) terminal cable from the battery. b. When installing the battery, be especially careful not to incorrectly connect the positive (+) and negative (-) cables.

  • Page 3: Fuel System

    2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 1: Identifying SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. FUEL SYSTEM a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Observe...
  • Page 4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 2: Disconnecting High Fuel Pressure Line Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
  • Page 5 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 3: Removing/Installing Injector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it in anyway.
  • Page 6 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 4: Installing Injector To Delivery Pipe & Cylinder Head Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Observe the following when disconnecting the fuel tube connector (quick type): 1. Check if there is any dirt like mud in the pipe and around the connector before disconnecting the fuel tube connector.
  • Page 7 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 5: Disconnecting Fuel Pipe Clamp From Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Be sure to disconnect them with hands. 4. When the connector and the pipe are stuck, push and pull the connector. Then disconnect and pull it out.
  • Page 8 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 6: Pushing & Pulling Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Observe the following when connecting the fuel tube connector (quick type): 1. Check if there is any damage or foreign objects in the connected part of the pipe.
  • Page 9 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 7: Matching Axis Of Connector With Axis Of Pipe & Pushing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. After having finished the connection, pull the pipe and the connector to ensure secure...
  • Page 10 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 8: Pulling Pipe & Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Check to make sure no fuel leak is present. If the result is not specified, repair or replace.
  • Page 11 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 9: Installing Fuel Pipe Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Check to make sure no fuel leak is present. If the result is not specified, repair or replace.
  • Page 12 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 10: Identifying Structure Of Metallic Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Check if there is any dirt like mud in the pipe and around the connector before disconnecting the fuel tube connector. If necessary, clean the dirt away.
  • Page 13 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 11: Assembling SST To Connection Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Turn the SST, align the retainers inside the connector with the SST chamfered parts and insert the SST into the connector.
  • Page 14 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 12: Aligning Retainers & Inserting SST Into Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. While holding the SST, pull the connector towards the SST to put the retainers on the SST...
  • Page 15 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 13: Pulling Connector Towards SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Slide the SST and connector together towards the fuel tube assembly. g. Observe the following when connecting the fuel tube connector (metallic type): 1.
  • Page 16 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 14: Matching Axis Of Connector With Axis Of Pipe & Pushing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. After having finished the connection, pull the pipe and the connector to ensure secure...
  • Page 17 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 15: Pulling Pipe And Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Check to make sure no fuel leak is present. If the result is not specified, repair or replace.
  • Page 18 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 16: Connecting Hand-Held Tester To DLC3 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Turn the ignition switch ON and push the hand-held tester main switch ON.  Select the ACTIVE TEST mode on the hand-held tester.

  • Page 19: Fuel Pump

    Connect the hand-held tester to the DLC3. Fig. 17: Connecting Hand-Held Tester To DLC3 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect the hand-held tester to the DLC3. 2. Turn the ignition switch ON and push the hand-held tester main switch ON.
  • Page 20 Check that there is pressure in the fuel inlet tube from the fuel line. Fig. 18: Checking Pressure In Fuel Inlet Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: If there is fuel pressure, you will hear the sound of the fuel flowing.
  • Page 21 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 19: Identifying Fuel Tube Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect the fuel tube clamp from the fuel tube connector.
  • Page 22 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 20: Disconnecting Fuel Tube Clamp From Fuel Tube Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disconnect the fuel inlet tube (fuel tube connector) from the fuel pipe.
  • Page 23 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 21: Disconnecting Fuel Inlet Tube From Fuel Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Disconnect the fuel tube connector (quick type) after observing  the precaution (see SFI SYSTEM ).
  • Page 24 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4...
  • Page 25 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 22: Installing SST (Pressure Gauge) Using SST & Fuel Tube Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Wipe off any splattered gasoline. h. Reconnect the negative (-) terminal cable to the battery.
  • Page 26 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 23: Reconnecting Fuel Inlet Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. r. Reconnect the fuel tube clamp to the fuel tube connector.

  • Page 27: Inspect Fuel Pump

    2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 24: Reconnecting Fuel Tube Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. s. Reconnect the negative (-) terminal cable to the battery. t. Check for fuel leak (see SFI SYSTEM ).
  • Page 28 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 25: Measuring Resistance Between Terminals 4 And 5 Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Inspect the fuel pump operation. Connect the battery's positive (+) lead to terminal 4 of the connector and the negative (-) lead to...
  • Page 29 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 26: Connecting Battery Leads To Terminal 4 & 5 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: These tests must be performed within 10 seconds to prevent the  coil from burning out.
  • Page 30 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 27: Identifying Fuel Pump Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT CAUTION: Do not smoke or work near an open flame when working on the fuel pump.
  • Page 31 Remove the tube joint clip and disconnect the main tube. Fig. 28: Removing Tube Joint Clip & Disconnecting Main Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK a. Remove the 8 bolts and fuel tank vent tube set plate.
  • Page 32 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 29: Removing Bolts & Fuel Tank Vent Tube Set Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Lift up the fuel pump and sender gauge assembly, and disconnect the fuel sub suction hose from the...
  • Page 33 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 30: Disconnecting Fuel Sub Suction Hose From Fuel Return Jet Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Do not damage the fuel suction filter.  Be careful not to bend the arm of the sender gauge.
  • Page 34 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 31: Prying Out Fuel Suction Support Using Screwdriver Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE FUEL SUCTION PLATE a. Disconnect the fuel sender gauge connector and ground plate.
  • Page 35 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 32: Disconnecting Fuel Sender Gauge Connector And Ground Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using 2 screwdrivers, pry out the fuel suction plate.
  • Page 36 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 33: Prying Out Fuel Suction Plate Using Screwdrivers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Be careful not to damage the suction support and suction plate. c. Remove the fuel pump harness.
  • Page 37 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 34: Removing Fuel Pump Harness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE FUEL PUMP Pull out the fuel pump.
  • Page 38 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 35: Pulling Out Fuel Pump Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE FUEL SUCTION FILTER FROM FUEL PUMP a. Using a small screwdriver, pry out the clip.
  • Page 39 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 36: Prying Out Clip Using Screwdriver Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Pull out the suction filter. 11. REINSTALL FUEL SUCTION FILTER Install the suction filter with a new clip.
  • Page 40 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 37: Installing Suction Filter With Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REINSTALL FUEL PUMP Push into the fuel pump.
  • Page 41 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 38: Pushing In Fuel Pump Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REINSTALL FUEL SUCTION PLATE a. Connect the fuel pump harness.
  • Page 42 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 39: Connecting Fuel Pump Harness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the fuel suction plate and fuel filter assembly.
  • Page 43 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 40: Installing Fuel Suction Plate And Fuel Filter Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Connect the fuel sender gauge connector and ground plate.
  • Page 44 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 41: Connecting Fuel Sender Gauge Connector And Ground Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. INSTALL FUEL SUCTION SUPPORT a. Install the rubber cushion. b. Install the fuel suction support to the fuel filter assembly.
  • Page 45 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 42: Installing Fuel Suction Support To Fuel Filter Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REINSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY TO FUEL TANK a. Install a new gasket to the suction plate.
  • Page 46 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 43: Connecting Sub Suction Hose To Fuel Return Jet Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Insert the fuel pump assembly into the fuel tank. NOTE: Do not damage the fuel suction filter.
  • Page 47 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 44: Installing Fuel Tank Vent Tube With Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. RECONNECT FUEL TANK MAIN TUBE Connect the main tube with the tube joint clip.
  • Page 48 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 45: Connecting Main Tube With Tube Joint Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Check that the connector is inserted fully and securely.  Check that the clip of the tube joint is on the collar of the connector.

  • Page 49: Fuel Pressure Regulator

    2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 46: Identifying Fuel Tube Joint, Fuel Suction Plate, Fuel Pump Tube, Clip & O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. RECONNECT VAPOR PRESSURE SENSOR CONNECTOR 18. RECONNECT FUEL PUMP and SENDER GAUGE CONNECTOR 19.
  • Page 50 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 47: Identifying Fuel Pressure Regulator Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT 1. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK (See REPLACEMENT ) 2. REMOVE FUEL SUCTION PLATE...
  • Page 51 2004 ENGINE PERFORMANCE SFI - RAV4 a. Disconnect the fuel sender gauge connector and ground plate. Fig. 48: Disconnecting Fuel Sender Gauge Connector & Ground Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using 2 screwdrivers, pry out the fuel suction plate. NOTE:...
  • Page 52 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 49: Prying Out Fuel Suction Plate Using Screwdrivers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect the fuel pump connector.
  • Page 53 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 50: Disconnecting Fuel Pump Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE FUEL PRESSURE REGULATOR a. Disconnect the fuel return jet tube from the clamp. b. Pull out the pressure regulator.
  • Page 54 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 51: Disconnecting Fuel Return Jet Tube From Clamp & Pulling Out Pressure Regulator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REINSTALL FUEL PRESSURE REGULATOR a. Install a new O-ring to the pressure regulator.
  • Page 55 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 52: Installing O-Ring To Pressure Regulator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Apply a light coat of gasoline to the O-ring, and push into the pressure regulator. c. Connect the fuel return jet tube to the clamp.
  • Page 56 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 53: Pushing O-Ring Into Pressure Regulator & Connecting Fuel Return Jet Tube To Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REINSTALL FUEL SUCTION PLATE a. Connect the fuel pump connector.
  • Page 57 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 54: Connecting Fuel Pump Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the fuel suction plate to the fuel filter and fuel pump assembly.
  • Page 58 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 55: Installing Fuel Suction Plate To Fuel Filter And Fuel Pump Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Connect the fuel sender gauge connector and ground plate.
  • Page 59 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 56: Connecting Fuel Sender Gauge Connector And Ground Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REINSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY TO FUEL TANK (See REPLACEMENT )
  • Page 60 Fig. 57: Using Sound Scope To Check For Normal Operating Noise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. If you have no sound scope, you can check it by feeling the injector operating vibration with your finger.
  • Page 61 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 58: Measuring Resistance Between Terminals Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the resistance is not as specified, replace the injector. c. Reconnect the injector connector. 4. REINSTALL AIR CLEANER ASSEMBLY...
  • Page 62 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 59: Identifying Injector Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. DISCONNECT PCV HOSE 2. REMOVE AIR CLEANER INLET AND AIR CLEANER ASSEMBLY WITH MAF METER...
  • Page 63 Remove the 2 bolts holding the delivery pipe to the cylinder head. Fig. 60: Disconnecting Injector Connectors & Removing Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect the delivery pipe together with the 4 injectors from the cylinder head.
  • Page 64 2004 ENGINE PERFORMANCE SFI - RAV4 INSPECTION 1. INSPECT INJECTOR INJECTION Fig. 61: Inspecting Injector Injection Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Keep injector clear of sparks during the test. a. Disconnect the fuel pipe clamp from the fuel tube connector.
  • Page 65 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 62: Disconnecting Fuel Pipe Clamp From Fuel Tube Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the fuel inlet tube (fuel tube connector) from the fuel pipe.
  • Page 66 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 63: Disconnecting Fuel Inlet Tube From Fuel Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Disconnect the fuel tube connector (quick type) observing  the precaution (see SFI SYSTEM ).
  • Page 67 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 64: Identifying Fuel Tube Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Connect SST (hose) and fuel tube connector to the fuel pipe. SST 09268-41047...
  • Page 68 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 65: Connecting SST (Hose) And Fuel Tube Connector To Fuel Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Disconnect the fuel tube connector (quick type) observing the precautions (see SFI SYSTEM ).
  • Page 69 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 66: Connecting SST (Union & Hose) To Injector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Put the injector into a graduated cylinder. CAUTION: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out.
  • Page 70 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 67: Connecting Hand-Held Tester To DLC3 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect the hand-held tester to the DLC3. 2. Connect the battery negative (-) terminal cable to the battery.
  • Page 71 Test each injector 2 or 3 times. SST 09842-30080 Fig. 68: Connecting Battery To Injector With SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Injection volume: 76 to 92 cm (4.6 to 5.6 cu in.) per 15 seconds. Difference between each injector: 16 cm (1.0...
  • Page 72 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 69: Checking Fuel Leak From Injector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Fuel drop: 1 drop or less per 12 minutes.
  • Page 73 Reconnect the fuel tube (fuel tube connector). CAUTION: Disconnect the fuel tube connector (quick type) observing the precaution (see SFI SYSTEM ). Fig. 70: Reconnecting Fuel Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Reconnect the fuel pipe clamp to the fuel tube connector.

  • Page 74: Installation

    2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 71: Reconnecting Fuel Pipe Clamp To Fuel Tube Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. INSTALL INJECTORS AND DELIVERY PIPES a. Apply a light coat of spindle oil or gasoline to a new O-ring, and install it to each injector.
  • Page 75 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 72: Applying Light Coat Of Spindle Oil Or Gasoline To O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 2 spacers and 4 new grommets to the cylinder head.
  • Page 76 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 73: Installing Spacers And Grommets To Cylinder Head Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Apply a light coat of spindle oil or gasoline to the place where a delivery pipe touches the O-ring.
  • Page 77 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 74: Pushing Injector To Delivery Pipes & Positioning Injector Connector Downward Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Attach the delivery pipe together with the 4 injectors to the cylinder head. g. Temporarily install the 2 bolts holding the delivery pipe to the cylinder head.
  • Page 78 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 75: Installing Bolts Holding Delivery Pipe To Cylinder Head Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the possible cause is incorrect installation of the O-ring. Replace the O-ring.
  • Page 79 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 76: Checking Injectors Rotate Smoothly & Positioning Injector Connector Downward Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. j. Tighten the 2 bolts holding the delivery pipe to the cylinder head. Torque: 20 N.m (205 kgf.cm, 15 ft.lbf)
  • Page 80 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 77: Tightening Bolts Holding Delivery Pipe To Cylinder Head Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. k. Connect the 4 injector connectors. 2. INSTALL AIR CLEANER ASSEMBLY WITH MAF METER 3.
  • Page 81 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 78: Identifying Fuel Pressure Pulsation Damper Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT 1. REMOVE AIR CLEANER HOSE...
  • Page 82 Install the pulsation damper with the 2 bolts. Torque: 9 N.m (90 kgf.cm, 80 in.lbf) Fig. 79: Removing/Installing Bolts & Pulsation Damper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the fuel tube connector (metallic connector) (see SFI SYSTEM ).

  • Page 83: Fuel Tank And Line

    2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 5. RECONNECT ACCELERATOR CABLE 6. RECONNECT AIR CLEANER HOSE FUEL TANK AND LINE COMPONENTS CAUTION: Always use new gaskets when replacing the fuel tank or component  parts. Apply the proper torque to all the parts to be tightened.
  • Page 84 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 80: Identifying Fuel Tank And Line Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION Inspect Fuel Tank And Line...
  • Page 85 Check the filter neck for damage or fuel leak. Fig. 81: Identifying Deformed, Damaged, Cracked Or Leaking Pipe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Check that hose and tube connections are as shown in Fig. 82 .
  • Page 86 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 82: Checking Hose And Tube Connections Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If a problem is found, repair or replace the part as necessary. MASS AIR FLOW (MAF) METER...
  • Page 87 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 83: Identifying Mass Air Flow (MAF) Meter Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter.
  • Page 88 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 84: Removing Screws And MAF Meter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSPECT MAF METER a. Using an ohmmeter, measure the resistance between terminals THA and E2.
  • Page 89 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 85: Measuring Resistance Between Terminals THA And E2 Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Resistance: RESISTANCE SPECIFICATION -20°C (-4°F) 13.6 to 18.4 ohm 20°C (68°F) 2.21 to 2.69 ohm 60°C (140°F) 0.49 to 0.67 ohm...

  • Page 90: Throttle Body

    2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 86: Connecting Tester Probes To Terminals VG & E2G Using Voltmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter.
  • Page 91 Also, check that there is no friction sound. Fig. 87: Inspecting Throttle Control Motor Operating Sound Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the result is not as specified, check the throttle control motor (see step 2), wiring and ECM.
  • Page 92 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 88: Connecting Hand-Held Tester To DLC3 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Turn the ignition switch ON. 3. Make sure that the check engine warning lamp (CHK ENG) does not illuminate.
  • Page 93 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 89: Measuring Resistance Between Terminals Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the result is not as specified, replace the throttle body. 3. INSPECT THROTTLE POSITION SENSOR (See DTC P0120: THROTTLE/PEDAL POSITION SENSOR/SWITCH "A"...
  • Page 94 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 90: Identifying SFI Throttle Body Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. DRAIN ENGINE COOLANT...
  • Page 95 Disconnect the throttle position sensor & control motor connector. Fig. 91: Disconnecting Throttle Position Sensor & Control Motor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the 5 hoses. c. Remove the 4 bolts, bracket and throttle body from the intake manifold.
  • Page 96 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 92: Removing Bolts, Bracket & Throttle Body From Intake Manifold Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. INSTALL THROTTLE BODY a. Install a new gasket on the intake manifold, as shown in Fig. 93 .
  • Page 97 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 93: Installing Gasket On Intake Manifold Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the throttle body, bracket and fuel hose clamp with the 4 bolts. Torque: 30 N.m (305 kgf.cm, 22 ft.lbf)
  • Page 98 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 94: Installing Throttle Body, Bracket & Fuel Hose Clamp With Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Connect the 5 hoses to the throttle body. d. Connect the throttle position sensor & control motor connector.
  • Page 99 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 95: Connecting Throttle Position Sensor & Control Motor Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL AIR CLEANER HOSE 3. INSTALL AIR CLEANER ASSEMBLY WITH MAF METER AND BRACKET 4.
  • Page 100 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 96: Measuring Resistance Between Terminals Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the resistance is not as specified, replace the OCV. c. Reconnect the OCV connector. COMPONENTS...
  • Page 101 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 97: Identifying Camshaft Timing Oil Control Valve Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE (OCV) a. Disconnect the OCV connector. b. Remove the bolt and OCV.
  • Page 102 Remove the O-ring from the OCV. Fig. 98: Removing Camshaft Timing Oil Control Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE (OCV) OPERATION Connect the battery's positive (+) lead to terminal 1 and negative (-) lead to terminal 2. Check the...
  • Page 103 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 99: Connecting Battery Positive Lead To Terminal 1 And Negative Lead To Terminal 2 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Fig. 100: Battery Voltage Specification Table Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

  • Page 104: Efi Main Relay

    EFI MAIN RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE EFI MAIN RELAY Fig. 101: Removing Relay Box Cover & EFI Main Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSPECT EFI MAIN RELAY a. Inspect the relay continuity.
  • Page 105 2. Check that there is no continuity between terminals 3 and 5. Fig. 102: Checking Continuity Between Terminals 1 + 2 & No Continuity Between Terminals 3 + 5 Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If there is continuity, replace the relay. b. Inspect the relay operation.
  • Page 106 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 103: Checking Continuity Between Terminals 3 + 5 Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If there is no continuity, replace the relay. 4. REINSTALL EFI MAIN RELAY 5.
  • Page 107 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 104: Removing Relay Box Cover & A/F Sensor Heater Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSPECT A/F SENSOR HEATER RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
  • Page 108 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 105: Checking Continuity Between Terminals 1 + 2 & No Continuity Between Terminals 3 + 5 Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If there is continuity, replace the relay. b. Inspect the relay operation.

  • Page 109: Circuit Opening Relay

    2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 106: Checking Continuity Between Terminals 3 + 5 Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If there is no continuity, replace the relay. 4. REINSTALL A/F SENSOR HEATER RELAY 5.
  • Page 110 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 107: Removing Relay Box Cover & Circuit Opening Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSPECT CIRCUIT OPENING RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
  • Page 111 Fig. 108: Checking Continuity Between Terminals 1 + 2 & No Continuity Between Terminals 3 + 5 Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Inspect the relay operation. 1. Apply battery positive voltage to terminals 1 and 2.
  • Page 112 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 109: Checking Continuity Between Terminals 3 + 5 Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If there is no continuity, replace the relay. 4. REINSTALL CIRCUIT OPENING RELAY 5.
  • Page 113 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 110: Identifying VSV For Evaporative Emission (EVAP) Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. REMOVE VSV 2. INSPECT VSV...
  • Page 114 Using an ohmmeter, check that there is continuity between the terminals. Resistance: 30 to 34 ohm at 20°C (68°F) Fig. 111: Checking Continuity Between Terminals Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If there is no continuity, replace the VSV. b. Inspect the VSV for ground.
  • Page 115 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 112: Checking For No Continuity Between Each Terminal And VSV Body Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If there is continuity, replace the VSV. c. Inspect the VSV operation. 1. Check that air flows with a little difficulty from ports E to F.
  • Page 116 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 113: Checking Air Flows From Ports E To F Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Apply battery positive voltage to the terminals. 3. Check that air flows from ports E to F.
  • Page 117 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 114: Applying Battery Positive Voltage To Terminals & Checking Air Flows From Ports E To F Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the operation is not as specified, replace the VSV. 3. REINSTALL VSV...
  • Page 118 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 115: Identifying VSV For Canister Closed Valve (CCV) Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. REMOVE VSV...
  • Page 119 Using an ohmmeter, measure the resistance between the terminals. Fig. 116: Measuring Resistance Between Terminals Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Resistance: 25 to 30 ohm at 20°C (68°F) If the result is not as specified, replace the VSV.
  • Page 120 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 117: Checking For No Continuity Between Each Terminal And VSV Body Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If there is continuity, replace the VSV. c. Inspect the VSV operation. 1. Check that air flows from ports E to F.
  • Page 121 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 118: Checking Air Flows From Ports E To F Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Apply battery positive voltage to the terminals. 3. Check that air does not flow from ports E to F.
  • Page 122 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 119: Applying Battery Positive Voltage To Terminals & Checking Air Flows From Ports E To F Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the operation is not as specified, replace the VSV. 3. REINSTALL VSV...
  • Page 123 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 120: Identifying VSV For Pressure Switching Valve Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION...
  • Page 124 Using an ohmmeter, measure the resistance between the terminals. Resistance: 30 to 36 ohm at 20°C (68°F) Fig. 121: Measuring Resistance Between Terminals Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the result is not as specified, replace the VSV. b. Inspect the VSV for ground.
  • Page 125 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 122: Checking For No Continuity Between Each Terminal And VSV Body Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the result is not as specified, replace the VSV. c. Inspect the VSV operation.
  • Page 126 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 123: Checking Air Does Not Flow From Ports E To F Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Apply battery positive voltage to the terminals. 3. Check that air flows from ports E to F.

  • Page 127: Engine Coolant Temperature (Ect) Sensor

    2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 124: Applying Battery Positive Voltage To Terminals & Checking Air Flows From Ports E To F Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the operation is not as specified, replace the VSV. 3. REINSTALL VSV...
  • Page 128 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 125: Identifying Engine Coolant Temperature (ECT) Sensor Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR a. Disconnect the sensor connector.
  • Page 129 2004 ENGINE PERFORMANCE SFI - RAV4 b. Using a 19 mm deep socket wrench, remove the sensor and gasket. Fig. 126: Removing ECT Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals.
  • Page 130 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4...

  • Page 131: Vapor Pressure Sensor

    2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 127: Measuring Resistance Between Terminals Using Ohmmeter & Graph Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the resistance is not as specified, replace the sensor. 4. REINSTALL ECT SENSOR a.
  • Page 132 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 128: Identifying Vapor Pressure Sensor Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. REMOVE LUGGAGE COMPARTMENT BOX...
  • Page 133 Voltage: 4.5 to 5.5 V Fig. 129: Measuring Voltage Between Terminals VC And E2 Of Wiring Harness Side Connector Using Voltmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Turn the ignition switch OFF. 5. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR...
  • Page 134 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 a. Connect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under the following conditions: 1.
  • Page 135 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 130: Inspecting Power Output Of Vapor Pressure Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REINSTALL VAPOR PRESSURE SENSOR...

  • Page 136: Knock Sensor

    2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 a. Reinstall the vapor pressure sensor and clip. b. Reconnect the vapor pressure sensor connector. c. Reinstall the 2 bolts and No. 3 fuel tank protector. 7. REINSTALL FLOOR SERVICE HOLE COVER 8.
  • Page 137 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 131: Identifying Knock Sensor Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION...
  • Page 138 Disconnect the knock sensor connector. b. Remove the nut and knock sensor. Fig. 132: Removing Knock Sensor & Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSPECT KNOCK SENSOR Using an ohmmeter, make sure there is continuity between the terminals.
  • Page 139 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 133: Inspecting Knock Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If there is no continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR a. Install the knock sensor with the nut.
  • Page 140 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 134: Installing Knock Sensor To Proper Angle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the knock sensor connector. 6. REINSTALL INTAKE MANIFOLD AND THROTTLE BODY ASSEMBLY (See INSTALLATION ) 7.
  • Page 141 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 135: Identifying Air-Fuel Ration (A/F) Sensor Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. INSPECT HEATER RESISTANCE OF A/F SENSOR a. Disconnect the sensor connector.

  • Page 142: Heated Oxygen Sensor

    Resistance: 1.8 to 3.4 ohm at 20°C (68°F) Fig. 136: Measuring Resistance Between Terminals +B And HT Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the resistance is not as specified, replace the sensor. Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) c.
  • Page 143 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 137: Identifying Heated Oxygen Sensor Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. INSPECT HEATER RESISTANCE OF OXYGEN SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT.

  • Page 144: Accelerator Pedal Position Sensor

    2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 138: Measuring Resistance Between Terminals +B And HT Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the resistance is not as specified, replace the sensor. Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) c.
  • Page 145 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 Fig. 139: Identifying Accelerator Pedal Position Sensor Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION Inspect Accelerator Pedal Position Sensor...
  • Page 146 2004 ENGINE PERFORMANCE SFI - RAV4 a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the each terminals. Fig. 140: Measuring Resistance Between Each Terminal Using Ohmmeter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Resistance: TERMINAL RESISTANCE SPECIFICATION Terminals...

  • Page 147: Engine Control Module (Ecm)

    2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 ENGINE CONTROL MODULE (ECM) COMPONENTS Fig. 141: Identifying Engine Control Module (ECM) Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

  • Page 148: Fuel Cut Rpm

    Warm up the engine to the normal operating temperature. 2. CONNECT HAND-HELD TESTER OR OBD II SCAN TOOL TO DLC3 a. Connect the hand-held tester or OBD II scan tool to the DLC3. Fig. 142: Connecting Hand-Held Tester To DLC3 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT:...
  • Page 149 Use a sound scope to check for the injector operating noise. Fig. 143: Using Sound Scope To Check For Injector Operating Noise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. When the accelerator pedal is released, injector operation sounds stop momentarily and then resumes.
  • Page 150 2004 Toyota RAV4 2004 ENGINE PERFORMANCE SFI - RAV4 RPM SPECIFIED CONDITION Item Specified Condition Fuel cutoff RPM 1,050 to 1,150 RPM (M/T), 1,350 to 1,450 RPM (A/T) Fuel injector restart RPM 850 to 950 RPM (M/T), 1,050 to 1,150 RPM (A/T) If the result is not as specified, check for DTCs.

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