Part 2
INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION - (Continued)
3. ELECTRONIC CONTROL
(a) REMOVAL AND INSTALLATION OF BATTERY TERMINAL
NOTICE:
Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
(1) Before performing electronic work, disconnect the cable from the negative (-) battery terminal to prevent component and wire damage caused by accidental short circuits.
(2) When disconnecting the cable, turn the ignition switch OFF and headlight dimmer switch OFF and loosen the cable nut completely. Perform these operations without twisting or prying the cable. Then disconnect the cable.
(3) Clock settings, radio settings, audio system memory, DTCs and other data are erased when the cable is disconnected from the negative (-) battery terminal. Write down any necessary data before disconnecting the cable.
(b) HANDLING OF ELECTRONIC PARTS
(1) Do not open the cover or case of the ECU unless absolutely necessary. If the IC terminals are touched, the IC may be rendered inoperative by static electricity.
(2) Do not pull the wires when disconnecting electronic connectors. Pull the connector.
(3) Be careful not to drop electronic components, such as sensors or relays. If they are dropped on a hard surface, they should be replaced.
(4) When cleaning the engine with steam, protect the electronic components, air filter and emission-related components from water.
(5) Never use an impact wrench to remove or install temperature switches or temperature sensors.
(6) When measuring the resistance of a wire connector, insert the tester probe carefully to prevent terminals from bending.
4. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) PLACE FOR REMOVING AND INSTALLING FUEL SYSTEM PARTS
(1) Work in a location with good air ventilation that does not have welders, grinders, drills, electric motors, stoves, or any other ignition sources.
(2) Never work in a pit or near a pit as vaporized fuel will collect in those places.
(b) REMOVING AND INSTALLING FUEL SYSTEM PARTS
(1) Prepare a fire extinguisher before starting the operation.
(2) To prevent static electricity, install a ground wire to the fuel changer, vehicle and fuel tank, and do not spray the surrounding area with water. Be careful when performing work in this area, as the work surface will become slippery. Do not clean up gasoline spills with water, as this may cause the gasoline to spread, and possibly create a fire hazard.
(3) Avoid using electric motors, working lights and other electric equipment that can cause sparks or high temperatures.
(4) Avoid using iron hammers as they may create sparks.
(5) Dispose of fuel-contaminated cloth separately using a fire resistant container.
5. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS
(a) If any metal particles enter inlet system parts, they may damage the engine.
(b) When removing and installing inlet system parts, cover the openings of the removed parts and engine openings. Use gummed tape or other suitable materials.
(c) When installing inlet system parts, check that no metal particles have entered the engine or the installed parts.
6. HANDLING OF HOSE CLAMPS
(a) Before removing the hose, check the clamp position so that it can be reinstalled in the same position.
(b) Replace any deformed or dented clamps with new ones.
(c) When reusing a hose, attach the clamp on the clamp track portion of the hose.
(d) For a spring type clamp, you may want to spread the tabs slightly after installation by pushing in the direction of the arrows as shown in the illustration.
7. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS
(a) Install the antenna as far away from the ECU and sensors of the vehicle electronic systems as possible.
(b) Install an antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic systems. For details about ECU and sensor locations, refer to the section of the applicable components.
(c) Keep the antenna and feeder separate from other wiring as much as possible. This will prevent signals of the communication equipment from affecting vehicle equipment and vice versa.
(d) Check that the antenna and feeder are correctly adjusted.
(e) Do not install a high-powered mobile communication system.
8. FOR VEHICLES EQUIPPED WITH VEHICLE STABILITY (VSC) SYSTEM
(a) NOTICES WHEN USING DRUM TESTER
(1) Before beginning testing, disable the VSC. To disable the VSC, turn the ignition switch OFF and connect SST to terminals 12 (TS) and 4 (CG) of the DLC3.
SST : 09843-18040
NOTICE:
* Confirm that the VSC warning light blinks.
* VSC system will be reset when the engine is started.
* For safety, secure the vehicle with restraint chains while using a wheel dynamometer.
(b) NOTICES OF RELATED OPERATIONS TO VSC
(1) Do not carry out unnecessary installation and removal as it might affect the adjustment of VSC related parts.
(2) Be sure to follow the instructions for work preparation and final confirmation of proper operation of the VSC system.
9. WHEN SERVICING ACTIVE TORQUE CONTROL 4WD VEHICLES
(a) The active torque control 4WD RAV4 is equipped with the 4 wheel drive control system.
If incorrect preparations or test procedures are used, the test will not only be unsuccessful, but may be dangerous as well.
CAUTION:
* Never accelerate or decelerate the vehicle suddenly.
* Observe the other cautions given for each individual test.
NOTICE:
* Sudden shifting, braking, acceleration or deceleration is not allowed.
* Do not use the parking brake while the vehicle's wheels are rotating.
* Do not perform the measurements continuously for a long period of time.
* Make sure to activate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system to an operational condition after the test. Check that the VSC warning indicator light goes off when restarting the engine.
(b) Therefore, before beginning any such servicing or test, be sure to check the following items:
(1) Whether the tires are touching the ground or jacked up
(2) Transmission gear position
(3) Maximum testing vehicle speed
(4) Maximum testing time
(c) When using a braking force tester (not free roller type):
When performing measurements using a low-speed type (Vehicle Speed: Below 0.5 km/h or 0.3 mph) brake tester, observe the following instructions.
(1) Press the 4WD LOCK-MODE SWITCH to OFF to disable the 4WD system.
(2) If the vehicle is equipped with the Vehicle Stability Control (VSC) & Traction Control (TRAC) system, prohibit the system from activating.
(3) Position the front wheels to be tested on the tester.
(4) Jack up the rear wheels.
(5) Ensure that the vehicle does not move using wires.
(6) Shift the transmission shift lever to the "N" position.
(7) Idle the engine, operate the brake booster and perform the test.
CAUTION:
The maximum driving time should be 1 minute.
(d) When using a braking force tester (free roller type):
When performing measurements using a low-speed type (Vehicle Speed: Below 0.5 km/h or 0.3 mph) brake tester, observe the following instructions.
(1) Press the 4WD LOCK-MODE SWITCH to turn it OFF and disable the 4WD system.
(2) If the vehicle is equipped with the Vehicle Stability Control (VSC) & Traction Control (TRAC) system, prohibit the system from activating.
(3) Position the front wheels on the tester roller.
(4) Position the rear wheels on the free roller.
(5) Ensure that the vehicle does not move using wires.
(6) Shift the transmission shift lever to the "N" position.
(7) Idle the engine, operate the brake booster and perform the test.
CAUTION:
The maximum driving time should be 1 minute.
(e) When using a speedometer (not free roller type):
Observe the following instructions and then measure with the rear wheels.
(1) Press the 4WD LOCK-MODE SWITCH to turn it OFF and disable the 4WD system.
(2) If the vehicle is equipped with the Vehicle Stability Control (VSC) & Traction Control (TRAC) system, prohibit the system from activating.
(3) Position the front wheels on the tester.
(4) Jack up the rear wheels.
(5) Ensure that the vehicle does not move using wires.
(6) Shift the transmission shift lever to the "D" position.
CAUTION:
* The maximum speed should be less than 50 km/h (31 mph).
* If the measurement is required with over 50 km/h (31 mph), remove the propeller shaft.
(f) When using a speedometer (free roller type):
Observe the following instructions and then measure with the rear wheels.
(1) Press the 4WD LOCK-MODE SWITCH to turn it OFF and disable the 4WD system.
(2) If the vehicle is equipped with the Vehicle Stability Control (VSC) & Traction Control (TRAC) system, prohibit the system from activating.
(3) Position the front wheels on the tester roller.
(4) Position the rear wheels on the free roller.
(5) Ensure that the vehicle does not move using wires.
(6) Shift the transmission shift lever to the "D" position.
CAUTION:
* The maximum speed should be less than 50 km/h (31 mph).
* If the measurement is required with over 50 km/h (31 mph), remove the propeller shaft.
(g) Using chassis dynamometer
(h) When performing high speed, high load measurements on a chassis dynamometer, observe the following instructions and then measure with the front wheels.
(1) If the vehicle is equipped with the Vehicle Stability Control (VSC) & Traction Control (TRAC) system, prohibit the system from activating.
(2) Ensure that the vehicle is securely fixed in place.
HINT
* Sudden shifting, braking, acceleration or deceleration is not allowed.
* Make sure to activate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system after the test. Check that the VSC warning indicator light goes off when restarting the engine.
(i) On-Vehicle Wheel Balancing:
(j) When performing on-vehicle wheel balancing on an active torque control 4WD vehicle, to prevent each wheel from being rotated at a different speed and in different directions, always be sure to observe the following precautions.
(1) All 4 wheels should be jacked up and lifted off of the ground completely.
(2) Press the 4WD LOCK-MODE SWITCH to turn it OFF and disable the 4WD system.
CAUTION:
Propeller shaft should be removed.
(3) If the vehicle is equipped with a Vehicle Stability Control (VSC) system, prohibit the system from activating (see previous step).
(4) The parking brake lever should be fully released.
(5) None of the brakes should be applied.
(6) The wheels should be driven on the wheel balancer with the engine running.
(7) Carry out the wheel balancing with the transmission in the D position.
HINT
* When performing the wheel balancing, pay attention to the other wheels rotating at the same time.
* Sudden acceleration, deceleration or braking is not allowed.
* Do not forget to change the Vehicle Stability Control (VSC) system to an operational condition after the test. Check that the VSC warning indicator light goes off when restarting the engine.
10. WHEN TOWING ACTIVE TORQUE CONTROL 4WD VEHICLES
* Use one of the methods shown below to tow the vehicle.
* If the vehicle has trouble in the chassis and drivetrain, use method 1 (flat bed truck).
NOTICE:
Do not use any towing method other than those shown above.
* For example, the towing methods shown below are dangerous or damage the vehicle, so do not use them.
11. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER
CAUTION:
If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause overheating and create a fire hazard. To prevent this, observe the following precautions.
(a) Use only unleaded gasoline.
(b) Avoid idling the engine for more than 20 minutes.
(c) Avoid performing unnecessary spark jump tests.
(1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid a prolonged engine compression measurement. Engine compression measurements must be performed as rapidly as possible.
(e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter.
12. INSPECTION AND ADJUSTMENT OF JOINT ANGLE DURING REMOVAL AND INSTALLATION OF PROPELLER SHAFT (4WD)
(a) When performing operations which involve the removal and installation of the propeller shaft, always check the joint angle. Make adjustments if necessary Component Tests and General Diagnostics.
