1Az-Fe Engine Control System. Dtc P1604 Startability Malfunction

This DTC is stored when the engine does not start even though the STA signal is input or when the engine takes a long time to start, and when the engine speed is low or the engine stalls just after the engine starts.
Using the intelligent tester, the conditions present when the DTC was stored can be confirmed by referring to the freeze frame data. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.
It is necessary to check if the vehicle ran out of fuel before performing troubleshooting, as this DTC is also stored when there is engine starting trouble due to running out of fuel.

DTC No.	DTC Detection Condition	Trouble Area
P1604	Either condition is met: The engine speed is less than 500 rpm with the STA signal on for a certain amount of time (refer to the illustration below) (1 trip detection logic). After the engine starts (engine speed is 500 rpm or more), the engine speed drops to 200 rpm or less within approximately 2 seconds (1 trip detection logic).	Immobiliser system Engine assembly (excess friction, compression loss) Starter Crankshaft position sensor Engine coolant temperature sensor Fuel pump Fuel pump control system Fuel pipes Fuel injector assembly Throttle body with motor assembly Pressure regulator Battery Drive plate Spark plug Ignition coil circuit Intake system Camshaft timing oil control valve assembly Mass air flow meter Air fuel ratio sensor Valve timing Fuel Purge VSV Intake valve Exhaust valve ECM

Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.1Az-Fe Engine Control System.Sfi System.
Dtc
P1604 Startability Malfunction

INSPECTION PROCEDURE

HINT:

In contrast to normal malfunction diagnosis for components, circuits and systems, DTC P1604 is used to determine the malfunctioning area from the problem symptoms and freeze frame data when the user mentions problems such as starting difficulty.
As these DTCs can be stored as a result of certain user actions, even if these DTCs are output, if the customer makes no mention of problems, clear these DTCs without performing any troubleshooting and return the vehicle to the customer.
If any other DTCs are output, perform troubleshooting for those DTCs first.
When the Data List item "Immobiliser Fuel Cut" is ON, the engine cannot be started.
Read freeze frame data using the intelligent tester. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.
When confirming the freeze frame data, be sure to check all 5 sets of freeze frame data (RAV4_ACA30 RM000000SXU00TX.html).
When confirming freeze frame data, if there are multiple items related to the cause of the malfunction, perform troubleshooting for all related items.
Try to start the vehicle under the conditions recorded in the freeze frame data which were present when the malfunction occurred. Confirm the data at this time and compare it with the freeze frame data.
If the malfunction does not reoccur, carefully check the vehicle conditions from when the malfunction occurred using freeze frame data.
When performing inspections, jiggle the relevant wire harnesses and connectors in an attempt to reproduce malfunctions that do not always occur.
If the same inspection or replacement procedure appears 2 times when performing an inspection procedure, it is not necessary to repeat the procedure the second time.

Malfunction Recurrence and Inspection Areas

Freeze frame data exists, but the malfunction (starting difficulty) has not reoccurred and the malfunction conditions are unknown.
1. The engine speed recorded in the freeze frame data is 0 rpm (the engine does not crank).
  HINT:
  One of the following problems may be present: battery depletion, excess engine friction, a starter malfunction or a crankshaft position sensor malfunction.
  1. If the battery voltage is less than 6 V during cranking, there is a high probability that engine friction is abnormal.
  2. If the battery voltage drops to 5 V or less when starting the engine, the battery may be malfunctioning.
  3. If the battery voltage fluctuates while cranking the engine, it can be concluded that cranking is being performed. When the engine speed is 0 rpm, the crankshaft position sensor and/or ECM may be malfunctioning.
2. All engine speeds recorded in the freeze frame data are between 100 and 250 rpm (the engine cranks but there is no combustion).
  HINT:
  If the engine speed is between 100 and 250 rpm (no initial combustion), there may be a wiring problem or a complete failure of an ignition or fuel system part.
  1. Due to an engine coolant temperature sensor malfunction, the fuel injection volume is extremely high or low and the engine may not be able to be started.
3. The engine speed recorded in the freeze frame data is 250 rpm or higher (the initial combustion and starter turnoff timing is too late).
  HINT:
  If the engine speed is 250 rpm or higher (combustion occurs but the initial combustion and starter turnoff timing is too late), the fuel injection volume is often incorrect (too low or too high) and determining the cause of the malfunction is often difficult.
  1. Due to an engine coolant temperature sensor malfunction, the fuel injection volume is extremely high or low and engine starting trouble may occur.
  2. If Long FT is incorrect, there may be a fuel supply problem due to the injectors or fuel pump being clogged, etc.
  3. If the engine cranking speed is too high, compression loss may have occurred due to carbon interfering with the valve operation.
When the malfunction (starting difficulty) can be reproduced, or malfunction conditions are known, perform the following inspections ("Problem Symptoms" and "Systems to Inspect").
1. Problem Symptoms
  1. The engine does not crank.
    HINT:
    The starter is normal if a noise that indicates the starter pinion gear is extending is heard. The battery may be fully depleted or there may be excess engine friction.
  2. The engine cranking speed is abnormal.
    HINT:
    If the engine cranking speed is too high (for example, 300 rpm or higher with no combustion), compression loss may have occurred because carbon interfered with valve operation, etc.
  3. There is no initial combustion.
    HINT:
    If there is no initial combustion, there is probably a wiring problem or an ignition or fuel system part malfunction.
  4. The engine stalls after starter turnoff.
    HINT:
    If the engine stalls after starter turnoff, the air-fuel ratio may be incorrect or the VVT may have a problem returning.
  5. The initial combustion and starter turnoff occur late.
    HINT:
    If the initial combustion and starter turnoff occur late, the fuel injection volume is probably incorrect (too low or too high).
    HINT:
    Causes of fuel system malfunctions according to conditions present at the time of the malfunction.
    1. When 2 to 3 minutes have elapsed after stopping the engine: Fuel pressure loss due to the pressure regulator failing to maintain the fuel pressure.
    2. When 15 to 120 minutes have elapsed after stopping the engine: Problem with injector fuel seal.
    3. When a long time has elapsed after stopping the engine: Pressure regulator is stuck open.
2. Systems to Inspect
  1. Intake system
  2. Ignition system
  3. Fuel system

INSPECTION FLOW

Freeze frame data exists, but the malfunction (starting difficulty) has not reoccurred and the malfunction conditions are unknown.

Freeze Frame Data Item	Result	Suspected Area	Procedure
Engine Speed	0 rpm (no engine cranking at all)	Battery fully depleted Engine assembly (excess friction) Starter Immobiliser system Crankshaft position sensor ECM	4 to 9
	100 to 250 rpm (engine cranks but no initial combustion*1)	Fuel pump control system Ignition system Engine coolant temperature sensor Fuel injection system	10 to 14
	250 rpm or higher (combustion occurs but initial combustion and starter turnoff*2 occur late)	Engine assembly (compression loss) Fuel injection system Fuel pump control system	15 to 23

HINT:

*1: First combustion after cranking begins.
*2: Condition when engine speed increases and starter can be turned off.

When the malfunction (starting difficulty) can be reproduced, or when malfunction conditions are known.

Problem Symptoms

Problem Symptom	Suspected Area	Suspected Component	Procedure
The engine does not crank	Battery malfunction	Battery fully depleted	26 to 31
	Starting system	Starter (includes pinion gear wear or tooth damage) Starting system
	Immobiliser system	Immobiliser system
	Engine assembly	Engine assembly (excess friction) Drive plate wear or tooth damage
Cranking speed too low	Battery malfunction	Battery fully depleted	32 to 34
	Starting system	Starter
	Engine assembly	Engine assembly (excess friction)
Cranking speed too high	Engine assembly	Engine assembly (compression loss)
There is no initial combustion	Fuel supply problem	Cannot maintain pressure due to pressure regulator malfunction Fuel injector leak Fuel leak from fuel line Fuel pump control system Fuel pump	35 to 50
There is no initial combustion	Ignition system malfunction	Spark plug Crankshaft position sensor Ignition coil	35 to 50
Engine stalls after starter turnoff	Air suction	Intake system connections	51 to 56
	Deposits in throttle body	Throttle body with motor assembly
	VVT valve does not return properly	Camshaft timing oil control valve assembly
	Mass air flow meter malfunction	Mass air flow meter
The initial combustion and starter turnoff occur late	Engine coolant temperature sensor malfunction	Engine coolant temperature sensor	57 to 70
	Mass air flow meter malfunction	Mass air flow meter
	Abnormal A/F learned value	Air fuel ratio sensor
	Deviation from fuel injection characteristics	Fuel injector assembly
	Wet-fouled or dry-fouled spark plug	Spark plug
	Lack of fuel pressure	Pressure regulator Fuel pump Fuel pump control system

Systems to Inspect

Troubleshooting by System	Suspected Area	Suspected Component	Procedure
Fuel system troubleshooting A	Abnormal A/F learned value	Fuel injector assembly	86 to 93 94 to 101
	Rough idling	Crankshaft position sensor
	Abnormal fuel pressure	Fuel Fuel leak from fuel line Fuel pump Pressure regulator
Fuel system troubleshooting B	Abnormal concentration of HC in surge tank	Purge VSV system Fuel injector assembly	102 to 103
Fuel system troubleshooting C	Injection signal system malfunction	Fuel injector assembly Crankshaft position sensor Camshaft position sensor ECM	72 to 76
Intake system troubleshooting	Difference between ISC target value and opening angle when idling	Engine assembly (compression loss) Valve timing Engine coolant temperature sensor ECM	83 to 85 104 to 107
Ignition system troubleshooting	Camshaft and/or crankshaft position sensor signal malfunction	Crankshaft position sensor system (including sensor installation) Camshaft position sensor system (including sensor installation) ECM	77 to 82 108 to 113

1.CHECK FOR ANY OTHER DTCS OUTPUT AND RECORD FREEZE FRAME DATA

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.

Read the DTCs and record the freeze frame data.
HINT:
1. This freeze frame data shows the actual engine conditions when engine starting trouble occurred.
2. When confirming the freeze frame data, be sure to check all 5 data sets of freeze frame data.
3. The fourth set of freeze frame data is the data recorded when the DTC is stored.
Result
Result
Proceed to
Only DTC P1604 is output
A
DTCs other than P1604 are output
B

GO TO DTC CHART (RAV4_ACA30 RM000000PDF0FLX.html)

A

2.CHECK ENGINE IMMOBILISER SYSTEM

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Turn the intelligent tester on.

Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Immobiliser Fuel Cut.

Read the value displayed on the intelligent tester.
OK:
Immobiliser Fuel Cut is OFF.
HINT:
After reconnecting the battery cable, if the engine is started immediately (without waiting 1.8 seconds after turning the ignition switch on (IG)), the engine will stop (due to the key verification process). The engine can be started after that.

REPAIR ENGINE IMMOBILISER SYSTEM (RAV4_ACA30 RM000001RLT005X.html)

OK

3.CHECK MALFUNCTION CONDITION

Confirm the problem symptoms.

Result
Result	Proceed to
Freeze frame data exists, but the starting difficulty cannot be reproduced and it is unknown what kind of starting difficulty occurred	A
The problem symptoms can be reproduced, or the malfunction conditions are known	B

Go to step 25

A

4.CHECK FREEZE FRAME DATA

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Using the intelligent tester, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored (RAV4_ACA30 RM000000SXU00TX.html).

Result
Freeze Frame Data Item		Suspected Area	Proceed to
Engine Speed	Battery Voltage	Suspected Area	Proceed to
All 5 sets of freeze frame data are 0 rpm (no engine cranking at all)	Minimum voltage is below 5 V	Battery fully depleted	A
	Minimum voltage is 5 V or higher	Starter malfunction Crankshaft position sensor system Excess engine friction Immobiliser system ECM	B
60 to 250 rpm (engine cranks but no initial combustion)	-	Fuel pump control system Ignition system Engine coolant temperature sensor Immobiliser system Fuel injection system	C
250 rpm or higher (combustion occurs but initial combustion and starter turnoff occur late)	-	Engine assembly Fuel injection system Fuel pump control system	D

HINT:

When DTC P1604 is stored, either "Engine Start Hesitation"*1 or "Low Rev for Eng Start"*2 in the freeze frame data will be ON. If "Low Rev for Eng Start" is ON, proceed to E.

*1: This value turns ON when the engine speed does not reach a certain value for a certain period of time when starting the engine.

*2: This value turns ON when the engine stalls immediately after starting the engine. If "Low Rev for Eng Start" is ON, as there is a possibility that the low engine speed or engine stall was caused by the user, confirm the following freeze frame data items.

Immobiliser Fuel Cut
Engine Speed (starter off)
Shift SW Status (R, D)

CHARGE OR REPLACE BATTERY

5.CHECK FREEZE FRAME DATA

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Using the intelligent tester, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored (RAV4_ACA30 RM000000SXU00TX.html).

Result
Freeze Frame Data Item	Result	Suspected Area	Proceed to
Battery Voltage	Minimum voltage is 6 V or higher and voltage does not fluctuate*1	Starter system	A
	Minimum voltage is 6 V or higher and voltage fluctuates2, 3	Crankshaft position sensor system ECM	B
	Minimum voltage is 5 to 6 V*4	Excess engine friction Battery fully depleted	C

HINT:

*1: The 5 sets of freeze frame data show approximately the same battery voltage.
*2: The 5 sets of freeze frame data show different battery voltages.
*3: If the voltage fluctuates, it can be determined that cranking is being performed. When the engine speed is 0 rpm, the crankshaft position sensor system and/or the ECM may be malfunctioning.
*4: There may be excess engine friction. Make sure that the crankshaft rotates smoothly when turning it by hand. Excess engine friction may have occurred temporarily. Remove the cylinder head cover and oil pan, and check for foreign matter such as iron fragments. If there is a malfunction or signs of a malfunction present, perform a detailed inspection by disassembling all the parts.

Go to step 6

CHECK AND REPAIR ENGINE OR BATTERY

CHECK STARTER SIGNAL CIRCUIT (RAV4_ACA30 RM000001FLC034X.html)

6.CHECK SENSOR INSTALLATION

Check the tightening and installation condition of the crankshaft position sensor bolt.

Check the connection of the crankshaft position sensor connector.

Result
Result
Proceed to
Normal
A
Abnormal
B

SECURELY REINSTALL SENSOR (RAV4_ACA30 RM0000017VB00NX.html)

A

7.CHECK CRANKSHAFT POSITION SENSOR

Disconnect the crankshaft position sensor connector.

Check for oil on the connector terminals.
OK:
No oil on the terminals.

REPLACE CRANKSHAFT POSITION SENSOR (RAV4_ACA30 RM0000017VB00NX.html)

OK

8.CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

Disconnect the crankshaft position sensor connector.

Disconnect the ECM connector.

Measure the resistance according to the value(s) in the table below.
Standard Resistance (Check for Open):
Tester Connection
Condition
Specified Condition
B22-1 - B32-122 (NE+)
Always
Below 1 Ω
B22-2 - B32-121 (NE-)
Always
Below 1 Ω
Standard Resistance (Check for Short):
Tester Connection
Condition
Specified Condition
B22-1 or B32-122 (NE+) - Body ground
Always
10 kΩ or higher
B22-2 or B32-121 (NE-) - Body ground
Always
10 kΩ or higher
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. Make sure there is not an excessive amount of force applied to the wire harness.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

9.CHECK CRANKSHAFT POSITION SENSOR

Replace the crankshaft position sensor (RAV4_ACA30 RM0000017VB00NX.html).

Check the engine start operation.
OK:
Malfunction has been repaired successfully.

REPLACE ECM (RAV4_ACA30 RM0000017UO01FX.html)

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

10.CHECK FREEZE FRAME DATA

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Using the intelligent tester, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored (RAV4_ACA30 RM000000SXU00TX.html).

Result
Freeze Frame Data Item			Suspected Area	Proceed to
Coolant Temp, Ambient Temperature, Intake Air	Coolant Temp, Ambient Temperature	Fuel Pump/Speed Status	Suspected Area	Proceed to
Difference between Coolant Temp, Ambient Temperature and Intake Air is 10°C or more*1	Coolant Temp is 125°C or higher, or below Ambient Temperature by 15°C or more	-	Engine coolant temperature sensor	A
	Other than above	All 5 sets of freeze frame data are ON	-	B
	Other than above	At least 1 of the 5 sets of freeze frame data is OFF	Fuel pump control system	C
Difference between Coolant Temp, Ambient Temperature and Intake Air is less than 10°C*2	-	At least 1 of the 5 sets of freeze frame data is OFF	Fuel pump control system	C
	-	All 5 sets of freeze frame data are ON	-	B

HINT:

*1: A long time had not elapsed after stopping the engine.
*2: A long time had elapsed after stopping the engine.

Go to step 11

CHECK FUEL PUMP CONTROL SYSTEM (RAV4_ACA30 RM000001DN701UX.html)

REPLACE ENGINE COOLANT TEMPERATURE SENSOR (RAV4_ACA30 RM0000017U900UX.html)

11.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP / SPEED)

Connect the intelligent tester to the DLC3.

Disconnect the connector from the fuel suction tube.

Turn the ignition switch on (IG).

Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

Measure the voltage according to the value(s) in the table below.
Standard Voltage:
Tester Connection
Condition
Specified Condition
T1-4 - Body ground
Active Test is being performed
11 to 14 V
Text in Illustration
*a
Front view of wire harness connector
(to Fuel Pump)
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. Make sure there is not an excessive amount of force applied to the wire harness.

REPAIR FUEL PUMP CONTROL SYSTEM (RAV4_ACA30 RM000001DN701UX.html)

OK

12.CHECK HARNESS AND CONNECTOR (FUEL INJECTOR POWER SOURCE)

Disconnect the injector assembly connector.

Turn the ignition switch on (IG).

Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Cylinder	Tester Connection	Switch Condition	Specified Condition
No. 1	B16-1 - Ground	Ignition switch on (IG)	11 to 14 V
No. 2	B15-1 - Ground	Ignition switch on (IG)	11 to 14 V
No. 3	B14-1 - Ground	Ignition switch on (IG)	11 to 14 V
No. 4	B13-1 - Ground	Ignition switch on (IG)	11 to 14 V

Text in Illustration
*a	Front view of wire harness connector (to Fuel Injector Assembly)

HINT:

Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
Make sure there is not an excessive amount of force applied to the wire harness.

REPAIR FUEL INJECTOR POWER SOURCE CIRCUIT

OK

13.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP / SPEED)

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump/Speed.

When performing the Active Test, check for fuel leakage from the fuel pipes.

Result
Result
Proceed to
Fuel leakage or signs of fuel leakage are present
A
No fuel leakage or signs of fuel leakage
B
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. When performing the Active Test, if there is no operating noise from the fuel pump, the fuel pump system may be malfunctioning.
3. Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.

Go to step 14

REPAIR OR REPLACE FUEL LINE

14.CHECK FUEL SYSTEM

Check for foreign matter such as iron particles around the fuel pump (fuel pump, fuel pump filter, and inside the fuel tank), and for signs that the fuel pump was stuck.

Result
Result
Proceed to
There is foreign matter or signs that fuel pump was stuck
A
There is no foreign matter and no signs that fuel pump was stuck
B

Go to step 24

REPAIR OR REPLACE FUEL SYSTEM

15.CHECK FREEZE FRAME DATA

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Using the intelligent tester, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored (RAV4_ACA30 RM000000SXU00TX.html).

Result
Freeze Frame Data Item				Suspected Area	Proceed to
Coolant Temp, Ambient Temperature, Intake Air	Coolant Temp, Ambient Temperature	Long FT	Engine Speed	Suspected Area	Proceed to
Difference between Coolant Temp, Ambient Temperature and Intake Air is 10°C or more	Coolant Temp is 125°C or higher, or below Ambient Temperature by 15°C or more	-	-	Engine coolant temperature sensor	A
	Other than above	-15% or less, or +15% or more	-	Fuel pump control system Fuel injector assembly	B
		-15 to +15%	Minimum speed is 300 rpm or more*1	Engine assembly	C
		-15 to +15%	Minimum speed is less than 300 rpm	Fuel system Intake air system	D
Difference between Coolant Temp, Ambient Temperature and Intake Air is less than 10°C	-	-15% or less, or +15% or more	-	Fuel pump control system Fuel injector assembly	B
		-15 to +15%	Minimum speed is 300 rpm or more*1	Engine assembly	C
		-15 to +15%	Minimum speed is less than 300 rpm	Fuel system Intake air system	D

HINT:

*1: Compression loss may have occurred in the engine assembly.

Go to step 16

CHECK AND REPAIR ENGINE

Go to step 18

REPLACE ENGINE COOLANT TEMPERATURE SENSOR (RAV4_ACA30 RM0000017U900UX.html)

16.INSPECT FUEL INJECTOR ASSEMBLY

Check that no carbon is stuck to the fuel injector assembly.
OK:
No carbon present.

REPLACE FUEL INJECTOR ASSEMBLY (RAV4_ACA30 RM0000017R800PX.html)

OK

17.CHECK FUEL SYSTEM

Check for foreign matter such as iron particles around the fuel pump (fuel pump, fuel pump filter, and inside the fuel tank), and for signs that the fuel pump was stuck.

Result
Result
Proceed to
There is foreign matter or signs that fuel pump was stuck
A
There is no foreign matter and no signs that fuel pump was stuck
B

Go to step 24

REPAIR OR REPLACE FUEL SYSTEM

18.CHECK FREEZE FRAME DATA

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Using the intelligent tester, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored (RAV4_ACA30 RM000000SXU00TX.html).

Result
Freeze Frame Data Item	Result	Suspected Area	Proceed to
Coolant Temp	Engine coolant temperature is 40°C or less*1	Pressure regulator	A
	Engine coolant temperature is 40 to 90°C*2	Fuel injector assembly	B
	Engine coolant temperature is 90°C or higher*3	Pressure regulator	A

HINT:

*1: If the engine coolant temperature is 40°C or less (after stopping the engine and the vehicle has not been driven for a long period of time), the pressure regulator may be stuck open. Attach a fuel pressure gauge and check the ability of the system to maintain fuel pressure after stopping the engine.

*2: If the engine coolant temperature is 40 to 90°C (15 to 120 minutes have passed after stopping the engine), there may be fuel leaking from a fuel injector assembly.

*3: If the engine coolant temperature is 90°C or more (2 to 5 minutes have passed after stopping the engine), there may be a problem with the pressure regulator failing to maintain the fuel pressure. Attach a fuel pressure gauge and check the ability of the pressure regulator to maintain fuel pressure after stopping the engine.

Go to step 20

A

19.CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures (RAV4_ACA30 RM000000QE3013X_02_0005.html).

HINT:

If the engine cannot be started, read the values after cranking the engine.

Result
Result	Proceed to
Normal	A
Abnormal	B

Go to step 24

REPLACE FUEL PRESSURE REGULATOR ASSEMBLY (RAV4_ACA30 RM0000017RJ03OX.html)

20.CHECK FUEL INJECTOR ASSEMBLY

Clean the inside of the surge tank with compressed air.

After stopping the engine, measure the HC concentration inside the surge tank for 15 minutes.

Result
Result
Proceed to
400 ppm or more
A
Less than 400 ppm
B
HINT:
If the concentration is 400 ppm or more, a fuel injector assembly may have a sealing problem.

Go to step 22

A

21.CHECK FUEL INJECTOR ASSEMBLY

Inspect the fuel injector assembly (RAV4_ACA30 RM000000VZW010X_01_0001.html).

Result
Result
Proceed to
Abnormal
A
Normal
B

Go to step 22

REPLACE FUEL INJECTOR ASSEMBLY (RAV4_ACA30 RM0000017R800PX.html)

22.CHECK THROTTLE BODY WITH MOTOR ASSEMBLY

Check if carbon is in the airflow passage.

Result
Result
Proceed to
Carbon in passage
A
No carbon present
B

Go to step 23

CLEAN OR REPLACE THROTTLE BODY

23.CHECK INTAKE SYSTEM

Check the intake system for vacuum leaks (RAV4_ACA30 RM000001RLS00FX_01_0002.html).
OK:
No leaks in intake system.

REPAIR OR REPLACE INTAKE SYSTEM

OK

24.PERFORM SIMULATION TEST

Check if the engine can be started.

Result
Result
Proceed to
Engine can be started
A
Engine cannot be started
B

Go to step 25

END

25.CONFIRM PROBLEM SYMPTOM

Confirm the problem symptoms.

HINT:

The problem symptoms below can be determined by reading the freeze frame data.

Result
Problem Symptom	Suspected Area	Proceed to
The engine does not crank	Battery fully depleted Starter (includes pinion gear wear or tooth damage) Starter system Engine assembly (excess friction) Drive plate wear or tooth damage	A
Abnormal cranking speed	Battery fully depleted Starter Engine assembly (excess friction, compression loss)	B
There is no initial combustion (combustion does not occur even once)*1	Pressure regulator fuel pressure maintenance Fuel injector leak Fuel leak from fuel line Fuel pump control system Fuel pump Spark plug Crankshaft position sensor system Ignition coil system	C
The engine stalls after starter turnoff (engine stalls immediately after the first time the engine speed increases)*2	Intake system connections Throttle body with motor assembly Camshaft timing oil control valve Mass air flow meter system	D
The initial combustion and starter turnoff occur late*3	Engine coolant temperature sensor Mass air flow meter Air fuel ratio sensor Heated oxygen sensor Fuel injector Spark plug Pressure regulator Fuel pump Fuel pump control system	E

HINT:

If there is hesitation (cranking speed is slow and combustion occurs before passing TDC) during the initial cranking period, the battery charge may be insufficient or the starter may be malfunctioning.
*1: If there is no initial combustion, a wire harness may be malfunctioning, or the ignition or fuel system may be malfunctioning.
*2: If the engine stalls after starter turnoff, the air-fuel ratio may be incorrect or the camshaft timing oil control valve may have a problem returning.
*3: If the initial combustion and starter turnoff occur late, the fuel injection volume may be incorrect (too low or too high).

A

26.PERFORM SIMULATION TEST

When cranking the engine, check for a noise indicating that the starter pinion gear is extending, and check that the starter pinion gear is not spinning freely.

Result
Problem Symptom	Suspected Area	Proceed to
A noise indicating that the starter pinion gear is extending is heard and the starter pinion gear is not spinning freely*1	Battery Excess engine friction Starter	A
A noise indicating that the starter pinion gear is extending is heard but the starter pinion gear is spinning freely	Drive plate Starter	B
A noise indicating that the starter pinion gear is extending is not heard	Battery Starter Starter system	C

HINT:

*1: The battery may be fully depleted or there may be excess engine friction.

Go to step 29

Go to step 30

A

27.INSPECT BATTERY

Check the electrolyte quantity.
Standard:
Electrolyte quantity is within the specified range.

Inspect the specific gravity.
1. Inspect the specific gravity of each cell.
  Standard specific gravity:
  1.25 to 1.29 (electrolyte is at 20°C (68°F))
  HINT:
  1. If the result is not as specified, recharge or replace the battery.
  2. It is not necessary to inspect a maintenance-free battery.

Inspect the battery voltage.
1. Turn the ignition switch off and turn on the headlights for 20 to 30 seconds. This will remove the surface charge from the battery.
2. Measure the battery voltage.
  Standard voltage:
  12.5 to 12.9 V (electrolyte is at 20°C (68°F))
  HINT:
  If the result is not as specified, recharge or replace the battery.
3. Measure the battery voltage when cranking the engine.
  Standard:
  Approximately 6 V or higher (0°C (32°F) or higher)
  HINT:
  When the battery is depleted, the horn becomes quieter.

CHARGE OR REPLACE BATTERY

OK

28.CHECK ENGINE ASSEMBLY

Check that the crankshaft rotates smoothly when rotating it by hand.
OK:
Crankshaft rotates smoothly.
HINT:
Excess engine friction may have occurred temporarily. Remove the cylinder head cover and oil pan, and check for foreign matter such as iron fragments. If there is a malfunction or signs of a malfunction present, perform a detailed inspection by disassembling all the parts.

REPAIR OR REPLACE ENGINE ASSEMBLY

INSPECT STARTER

29.CHECK STARTER ASSEMBLY

Remove the starter (RAV4_ACA30 RM000000YQ400RX.html).

Check for starter pinion gear wear and damage.
OK:
There is no wear or damage.

REPLACE STARTER ASSEMBLY (RAV4_ACA30 RM000000YQ400RX.html)

REPLACE DRIVE PLATE AND RING GEAR

30.INSPECT BATTERY

Check the electrolyte quantity.
Standard:
Electrolyte quantity is within the specified range.

Inspect the specific gravity.
1. Inspect the specific gravity of each cell.
  Standard specific gravity:
  1.25 to 1.29 (electrolyte is at 20°C (68°F))
  HINT:
  1. If the result is not as specified, recharge or replace the battery.
  2. It is not necessary to inspect a maintenance-free battery.

Inspect the battery voltage.
1. Turn the ignition switch off and turn on the headlights for 20 to 30 seconds. This will remove the surface charge from the battery.
2. Measure the battery voltage.
  Standard voltage:
  12.5 to 12.9 V (electrolyte is at 20°C (68°F))
  HINT:
  If the result is not as specified, recharge or replace the battery.
3. Measure the battery voltage when cranking the engine.
  Standard:
  Approximately 6 V or higher (0°C (32°F) or higher)
  HINT:
  When the battery is depleted, the horn becomes quieter.

CHARGE OR REPLACE BATTERY

OK

31.INSPECT STARTER ASSEMBLY

Inspect the starter (RAV4_ACA30 RM000000YQ200SX.html).

REPLACE STARTER ASSEMBLY (RAV4_ACA30 RM000000YQ400RX.html)

CHECK STARTER SIGNAL CIRCUIT (RAV4_ACA30 RM000001FLC034X.html)

32.PERFORM SIMULATION TEST

Check the cranking speed.
Result
Problem Symptom
Suspected Area
Proceed to
Cranking speed is slow (100 rpm or less)
Battery
Starter
Excess engine friction
A
Cranking speed is fast (300 rpm or more)*1
Engine compression loss
B
HINT:
*1: If the cranking speed is fast, there may be compression loss.

CHECK AND REPAIR ENGINE

A

33.INSPECT BATTERY

Check the electrolyte quantity.
Standard:
Electrolyte quantity is within the specified range.

Inspect the specific gravity.
1. Inspect the specific gravity of each cell.
  Standard specific gravity:
  1.25 to 1.29 (electrolyte is at 20°C (68°F))
  HINT:
  1. If the result is not as specified, recharge or replace the battery.
  2. It is not necessary to inspect a maintenance-free battery.

Inspect the battery voltage.
1. Turn the ignition switch off and turn on the headlights for 20 to 30 seconds. This will remove the surface charge from the battery.
2. Measure the battery voltage.
  Standard voltage:
  12.5 to 12.9 V (electrolyte is at 20°C (68°F))
  HINT:
  If the result is not as specified, recharge or replace the battery.
3. Measure the battery voltage when cranking the engine.
  Standard:
  Approximately 6 V or higher (0°C (32°F) or higher)
  HINT:
  When the battery is depleted, the horn becomes quieter.

CHARGE OR REPLACE BATTERY

OK

34.CHECK ENGINE

Check that the crankshaft rotates smoothly when rotating it by hand.
OK:
Crankshaft rotates smoothly.
HINT:
Excess engine friction may have occurred temporarily. Remove the cylinder head cover and oil pan, and check for foreign matter such as iron fragments. If there is a malfunction or signs of a malfunction present, perform a detailed inspection by disassembling all the parts.

REPAIR OR REPLACE ENGINE

INSPECT STARTER

35.CHECK FUEL INJECTOR ASSEMBLY

Using a sound scope or screwdriver, check for an injector operating noise while cranking the engine.
OK:
Fuel injector operating noise is heard.

Go to step 48

OK

36.CHECK FUEL PRESSURE

Inspect the fuel pressure (RAV4_ACA30 RM000000QE3013X_02_0005.html).

Go to step 46

OK

37.CHECK SPARK PLUG AND SPARK

Check for sparks (RAV4_ACA30 RM000001QVP01KX_01_0001.html).

Go to step 41

OK

38.CONFIRM VEHICLE CONDITION

Confirm the conditions present when the malfunction occurred based on the customer problem analysis.

Result
Problem Symptom	Suspected Area	Proceed to
When the engine is stopped and a long time has passed, engine starting trouble occurs*1	Pressure regulator is stuck open	A
When the engine is stopped and approximately 15 to 120 minutes have passed, engine starting trouble occurs*2	Fuel injector leak	B
When the engine is stopped and approximately 2 to 3 minutes have passed, engine starting trouble occurs*3	Failure to maintain fuel pressure by pressure regulator	A
Condition other than above, or there is an inconsistency in the conditions present when engine starting trouble occurs	-	C*4

HINT:

*1: The pressure regulator may be stuck open. Attach a fuel pressure gauge and check the ability of the system to maintain fuel pressure after stopping the engine.

*2: Fuel may be leaking from a fuel injector assembly.

*3: The pressure regulator may not be able to maintain the fuel pressure. Attach a fuel pressure gauge and check the ability of the pressure regulator to maintain fuel pressure after stopping the engine.

*4: From step 71, perform fuel system troubleshooting C (steps 72 to 76).

Go to step 40

Go to step 71

A

39.CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures (RAV4_ACA30 RM000000QE3013X_02_0005.html).

Attach a fuel pressure gauge and check the fuel pressure after stopping the engine.

Result
Result
Proceed to
147 kPa (1.5 kgf/cm²) or higher (5 minutes after stopping the engine)
A*1
Below 147 kPa (1.5 kgf/cm²) (5 minutes after stopping the engine)
B
HINT:
1. If the engine cannot be started, check the fuel pressure after cranking the engine.
2. *1: From step 71, perform fuel system troubleshooting C (steps 72 to 76).

Go to step 71

REPLACE FUEL PRESSURE REGULATOR ASSEMBLY (RAV4_ACA30 RM0000017RJ03OX.html)

40.CHECK FUEL INJECTOR ASSEMBLY

After stopping the engine, measure the HC concentration inside the surge tank for 15 minutes.

Result
Result
Proceed to
400 ppm or more
A
Less than 400 ppm
B*1
HINT:
1. If the concentration is 400 ppm or more, a fuel injector assembly may have a sealing problem.
2. *1: From step 71, perform fuel system troubleshooting C (steps 72 to 76).

Go to step 71

REPLACE FUEL INJECTOR ASSEMBLY (RAV4_ACA30 RM0000017R800PX.html)

41.CHECK SPARK PLUG

Inspect the spark plugs (RAV4_ACA30 RM000001QVP01KX_01_0002.html).

HINT:

Even if the spark plug of only one cylinder is malfunctioning, replace the spark plugs of all cylinders.

REPLACE SPARK PLUG

OK

42.READ VALUE USING INTELLIGENT TESTER (ENGINE SPEED)

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Enter the following menus: Powertrain / Engine and ECT / Data List / Engine Speed.

Start the engine.

While running the engine, read the value of Engine Speed.
Standard:
A value that matches the actual engine speed is constantly output.
HINT:
1. Check the engine speed using a line graph.
2. If the engine cannot be started, check the engine speed while cranking the engine.
3. If the engine speed is 0 rpm, the crankshaft position sensor may have an open or short circuit.

CHECK CRANKSHAFT POSITION SENSOR CIRCUIT (RAV4_ACA30 RM000000TCW0ADX.html)

OK

43.CHECK HARNESS AND CONNECTOR (IGNITION COIL POWER SOURCE)

Disconnect the ignition coil assembly connector.

Turn the ignition switch on (IG).

Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Tester Connection	Switch Condition	Specified Condition
B12-1 (+B) - B12-4 (GND)	Ignition switch on (IG)	11 to 14 V
B11-1 (+B) - B11-4 (GND)	Ignition switch on (IG)	11 to 14 V
B10-1 (+B) - B10-4 (GND)	Ignition switch on (IG)	11 to 14 V
B9-1 (+B) - B9-4 (GND)	Ignition switch on (IG)	11 to 14 V

Text in Illustration
*a	Front view of wire harness connector (to Ignition Coil Assembly)

HINT:

Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
Make sure there is not an excessive amount of force applied to the wire harness.

CHECK POWER SOURCE CIRCUIT (RAV4_ACA30 RM000001DN807EX.html)

OK

44.CHECK HARNESS AND CONNECTOR (IGNITION COIL ASSEMBLY - ECM)

Disconnect the ignition coil assembly connector.

Disconnect the ECM connector.

Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for Open):

Tester Connection	Condition	Specified Condition
B9-2 (IGF) - B32-81 (IGF1)	Always	Below 1 Ω
B10-2 (IGF) - B32-81 (IGF1)	Always	Below 1 Ω
B11-2 (IGF) - B32-81 (IGF1)	Always	Below 1 Ω
B12-2 (IGF) - B32-81 (IGF1)	Always	Below 1 Ω

Standard Resistance (Check for Short):

Tester Connection	Condition	Specified Condition
B9-2 (IGF) or B32-81 (IGF1) - Body ground	Always	10 kΩ or higher
B10-2 (IGF) or B32-81 (IGF1) - Body ground	Always	10 kΩ or higher
B11-2 (IGF) or B32-81 (IGF1) - Body ground	Always	10 kΩ or higher
B12-2 (IGF) or B32-81 (IGF1) - Body ground	Always	10 kΩ or higher

HINT:

Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
Make sure there is not an excessive amount of force applied to the wire harness.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

45.CHECK HARNESS AND CONNECTOR (IGNITION COIL ASSEMBLY - ECM)

Disconnect the ignition coil assembly connector.

Disconnect the ECM connector.

Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for Open):

Tester Connection	Condition	Specified Condition
B12-3 (IGT1) - B32-85 (IGT1)	Always	Below 1 Ω
B11-3 (IGT2) - B32-84 (IGT2)	Always	Below 1 Ω
B10-3 (IGT3) - B32-83 (IGT3)	Always	Below 1 Ω
B9-3 (IGT4) - B32-82 (IGT4)	Always	Below 1 Ω

Standard Resistance (Check for Short):

Tester Connection	Condition	Specified Condition
B12-3 (IGT1) or B32-85 (IGT1) - Body ground	Always	10 kΩ or higher
B11-3 (IGT2) or B32-84 (IGT2) - Body ground	Always	10 kΩ or higher
B10-3 (IGT3) or B32-83 (IGT3) - Body ground	Always	10 kΩ or higher
B9-3 (IGT4) or B32-82 (IGT4) - Body ground	Always	10 kΩ or higher

HINT:

Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
Make sure there is not an excessive amount of force applied to the wire harness.
If the wire harness is normal, after replacing the ignition coil, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 71 and perform troubleshooting for the ignition system (steps 77 to 82).

REPAIR OR REPLACE HARNESS OR CONNECTOR

REPLACE IGNITION COIL ASSEMBLY (RAV4_ACA30 RM000001QVM017X.html)

46.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP / SPEED)

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

When performing the Active Test, check for an operating sound from the fuel pump.
Standard:
Control the Fuel Pump / Speed
Specified Condition
ON
Operating sound heard
OFF
Operating sound not heard
HINT:
Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.

CHECK FUEL PUMP CONTROL SYSTEM (RAV4_ACA30 RM000001DN701UX.html)

OK

47.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP / SPEED)

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

When performing the Active Test, check for fuel leakage from the fuel pipes.

Result
Result
Proceed to
Fuel leakage or signs of fuel leakage are present
A
No fuel leakage or signs of fuel leakage
B
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.
3. If there are no fuel leaks, after inspecting the fuel pump control system, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 71 and perform fuel system troubleshooting (steps 72 to 76).

CHECK FUEL PUMP CONTROL SYSTEM (RAV4_ACA30 RM000001DN701UX.html)

REPAIR OR REPLACE FUEL LINE

48.READ VALUE USING INTELLIGENT TESTER (ENGINE SPEED)

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Enter the following menus: Powertrain / Engine and ECT / Data List / Engine Speed.

Start the engine.

While running the engine, read the value of Engine Speed.
Standard:
A value that matches the actual engine speed is constantly output.
HINT:
1. Check the engine speed using a line graph.
2. If the engine cannot be started, check the engine speed while cranking the engine.
3. If the engine speed is 0 rpm, the crankshaft position sensor may have an open or short circuit.

REPLACE CRANKSHAFT POSITION SENSOR (RAV4_ACA30 RM0000017VB00NX.html)

OK

49.CHECK HARNESS AND CONNECTOR (FUEL INJECTOR POWER SOURCE)

Disconnect the fuel injector assembly connector.

Turn the ignition switch on (IG).

Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Cylinder	Tester Connection	Switch Condition	Specified Condition
No. 1	B16-1 - Ground	Ignition switch on (IG)	11 to 14 V
No. 2	B15-1 - Ground	Ignition switch on (IG)	11 to 14 V
No. 3	B14-1 - Ground	Ignition switch on (IG)	11 to 14 V
No. 4	B13-1 - Ground	Ignition switch on (IG)	11 to 14 V

Text in Illustration
*a	Front view of wire harness connector (to Fuel Injector assembly)

HINT:

Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
Make sure there is not an excessive amount of force applied to the wire harness.

REPAIR POWER SOURCE CIRCUIT (RAV4_ACA30 RM000001DN807EX.html)

OK

50.CHECK HARNESS AND CONNECTOR (FUEL INJECTOR ASSEMBLY - ECM)

Disconnect the fuel injector assembly connector.

Disconnect the ECM connector.

Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Cylinder	Tester Connection	Condition	Specified Condition
No. 1	B16-2 - Body ground	Always	10 kΩ or higher
No. 1	B16-2 - B32-108 (#10)	Always	Below 1 Ω
No. 2	B15-2 - Ground	Always	10 kΩ or higher
No. 2	B15-2 - B32-107 (#20)	Always	Below 1 Ω
No. 3	B14-2 - Ground	Always	10 kΩ or higher
No. 3	B14-2 - B32-106 (#30)	Always	Below 1 Ω
No. 4	B13-2 - Ground	Always	10 kΩ or higher
No. 4	B13-2 - B32-105 (#40)	Always	Below 1 Ω

HINT:

Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
Make sure there is not an excessive amount of force applied to the wire harness.

REPAIR OR REPLACE HARNESS OR CONNECTOR

REPLACE ECM (RAV4_ACA30 RM0000017UO01FX.html)

51.CHECK MASS AIR FLOW METER

Connect the intelligent tester to the DLC3.

Start the engine and warm it up until the engine coolant temperature reaches 75°C (167°F) or higher.
HINT:
The A/C switch and all accessory switches should be off, and the shift lever should be in N or P.

Turn the intelligent tester on.

Enter the following menus: Powertrain / Engine and ECT / Data List / MAF.

Check MAF in the Data List during idling.
Standard:
1 to 3 gm/s

Go to step 56

OK

52.CHECK INTAKE SYSTEM

Check for air leakage in the intake system [vacuum hose disconnection, cracks, damaged gaskets, etc.] (RAV4_ACA30 RM000001RLS00FX_01_0002.html).
HINT:
1. If the accelerator pedal is released after racing the engine, the inspection is easier to perform because the vacuum inside the intake manifold increases and the air suction noise becomes louder.
2. If Short FT and Long FT are largely different from the normal values (differ by more than 15%) when idling (intake air volume is small) and almost the same as the normal values when racing the engine (for example, when maintaining a speed of 3000 rpm) (intake air volume is high), air leakage may be present.
OK:
There is no air leakage.

REPAIR OR REPLACE INTAKE SYSTEM

OK

53.CHECK THROTTLE BODY WITH MOTOR ASSEMBLY

Disconnect the throttle body with motor assembly connector.
HINT:
When the connector is disconnected, the vehicle enters fail-safe mode and the throttle valve opening angle is 4 to 7°.

Crank the engine and check that it starts.
Result:
Result
Proceed to
Engine starts
A
Engine does not start
B

Connect the throttle body with motor assembly connector.
HINT:
When this inspection is performed, the MIL may illuminate. After finishing the inspection, check and clear DTCs (RAV4_ACA30 RM000000PDK0VSX.html).

Go to step 55

A

54.CHECK THROTTLE BODY WITH MOTOR ASSEMBLY

Check if carbon is in the airflow passage.
OK:
No carbon present.

REMOVE FOREIGN OBJECT AND CLEAN THROTTLE BODY WITH MOTOR ASSEMBLY

OK

55.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE VVT SYSTEM)

Connect the intelligent tester to the DLC3.

Turn the intelligent tester on.

Warm up the engine.

Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the VVT System (Bank 1).
HINT:
When performing the Active Test, make sure the A/C is on and the shift lever is in P or N.

Check the engine speed while operating the Oil Control Valve (OCV) using the intelligent tester.
OK:
Tester Operation
Specified Condition
OFF
Normal engine speed
ON
Soon after OCV switched from OFF to ON, engine idles roughly or stalls
Result
Result
Proceed to
NG
A
OK
B
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. When the results of the inspection using the Active Test are normal but the valve operating noise is abnormal, check the valve for any signs of problems.

Go to step 71

REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (RAV4_ACA30 RM0000017U300QX.html)

56.CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM)

Disconnect the mass air flow meter connector.

Disconnect the ECM connector.

Measure the resistance according to the value(s) in the table below.
Standard Resistance (Check for Open):
Tester Connection
Condition
Specified Condition
B1-5 (VG) - B32-118 (VG)
Always
Below 1 Ω
B1-4 (E2G) - B32-116 (E2G)
Always
Below 1 Ω
Standard Resistance (Check for Short):
Tester Connection
Condition
Specified Condition
B1-5 (VG) or B32-118 (VG) - Body ground
Always
10 kΩ or higher
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. Make sure there is not an excessive amount of force applied to the wire harness.
3. If the wire harness is normal, after replacing the mass air flow meter, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 71 and perform intake system troubleshooting (steps 83 to 85). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 86 to 93).

REPAIR OR REPLACE HARNESS OR CONNECTOR

REPLACE MASS AIR FLOW METER (RAV4_ACA30 RM0000017TY00UX.html)

57.INSPECT ENGINE COOLANT TEMPERATURE SENSOR

Inspect the engine coolant temperature sensor (RAV4_ACA30 RM0000017U700ZX_01_0001.html).
HINT:
If the engine coolant temperature sensor is malfunctioning, after replacing it, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 71 and perform fuel system troubleshooting A (steps 96 to 101), fuel system troubleshooting B (steps 102 to 104), intake system troubleshooting (steps 105 to 107), and ignition system troubleshooting (steps 108 to 113), in that order.

REPLACE ENGINE COOLANT TEMPERATURE SENSOR (RAV4_ACA30 RM0000017U900UX.html)

OK

58.CHECK HARNESS AND CONNECTOR (ENGINE COOLANT TEMPERATURE SENSOR - ECM)

Disconnect the engine coolant temperature sensor connector.

Disconnect the ECM connector.

Measure the resistance according to the value(s) in the table below.
Standard Resistance (Check for Open):
Tester Connection
Condition
Specified Condition
B4-2 - B32-97 (THW)
Always
Below 1 Ω
B4-1 - B32-96 (ETHW)
Always
Below 1 Ω
Standard Resistance (Check for Short):
Tester Connection
Condition
Specified Condition
B4-2 or B32-97 (THW) - Body ground
Always
10 kΩ or higher
B4-1 or B32-96 (ETHW) - Body ground
Always
10 kΩ or higher
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. Make sure there is not an excessive amount of force applied to the wire harness.
3. If the wire harness or connector is malfunctioning, after replacing or repairing it, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 71 and perform fuel system troubleshooting A (steps 94 to 101), fuel system troubleshooting B (steps 102 to 104), intake system troubleshooting (steps 105 to 107), and ignition system troubleshooting (steps 108 to 113), in that order.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

59.CHECK MASS AIR FLOW METER

Connect the intelligent tester to the DLC3.

Start the engine and warm it up until the engine coolant temperature reaches 75°C (167°F) or higher.
HINT:
The A/C switch and all accessory switches should be off, and the shift lever should be in N or P.

Turn the intelligent tester on.

Enter the following menus: Powertrain / Engine and ECT / Data List / MAF.

Check MAF in the Data List during idling.
Standard:
1 to 3 gm/s
HINT:
If the mass air flow meter is malfunctioning, after replacing it, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 71 and perform fuel system troubleshooting A (steps 94 to 101), fuel system troubleshooting B (steps 102 to 104), intake system troubleshooting (steps 105 to 107), and ignition system troubleshooting (steps 108 to 113), in that order.

REPLACE MASS AIR FLOW METER (RAV4_ACA30 RM0000017TY00UX.html)

OK

60.CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM)

Disconnect the mass air flow meter connector.

Disconnect the ECM connector.

Measure the resistance according to the value(s) in the table below.
Standard Resistance (Check for Open):
Tester Connection
Condition
Specified Condition
B1-5 (VG) - B32-118 (VG)
Always
Below 1 Ω
B1-4 (E2G) - B32-116 (E2G)
Always
Below 1 Ω
Standard Resistance (Check for Short):
Tester Connection
Condition
Specified Condition
B1-5 (VG) or B32-118 (VG) - Body ground
Always
10 kΩ or higher
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. Make sure there is not an excessive amount of force applied to the wire harness.
3. If the wire harness or connector is malfunctioning, after replacing or repairing it, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 71 and perform fuel system troubleshooting A (steps 94 to 101), fuel system troubleshooting B (steps 102 to 104), intake system troubleshooting (steps 105 to 107), and ignition system troubleshooting (steps 108 to 113), in that order.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

61.READ VALUE USING INTELLIGENT TESTER

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Enter the following menus: Powertrain / Engine and ECT / Data List / Long FT and Atmosphere Pressure.

Result
Data List Item	Result	Suspected Area	Proceed to
Long FT	+25% or more or less than -25%	Air fuel ratio sensor Heated oxygen sensor Mass air flow meter Fuel injector assembly ECM	A
Atmosphere Pressure	80 kPa or less (when elevation is 0 m)		A
Both Data List items listed above	Values are other than above	-	B

Go to step 65

A

62.PERFORM SIMULATION TEST

Remove the EFI and ETCS fuses from the engine room relay block.

After 60 seconds or more elapse, install the EFI and ETCS fuses.

Check if the engine can be started.

Result
Result
Proceed to
Engine can be started
A
Engine cannot be started
B

Go to step 65

A

63.INSPECT AIR FUEL RATIO SENSOR

Connect the intelligent tester to the DLC3.

Start the engine.

Turn the intelligent tester on.

Enter the following menus: Powertrain / Engine and ECT / Data List / Fuel System Status #1.

Confirm that Fuel System Status #1 is CL.

Enter the following menus: Powertrain / Engine and ECT / Data List / AF Lambda B1S1.

Confirm that AF Lambda B1S1 is within the range of 0.95 to 1.05 when idling.

Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Injection Volume for A/F sensor.

Read the output voltage from the air fuel ratio sensor when increasing and decreasing the fuel injection volume.
Standard:
Tester Display
Injection Volume
Specified Condition
AFS Voltage B1S1
+25%
Air fuel ratio sensor output voltage is below 3.1 V
-12.5%
Air fuel ratio sensor output voltage is higher than 3.4 V
Result
Result
Proceed to
Normal
A
Abnormal
B
HINT:
1. The air fuel ratio sensor has an output delay of a few seconds and the heated oxygen sensor has a maximum output delay of approximately 20 seconds.
2. If the air fuel ratio sensor is malfunctioning, after replacing it, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 71 and perform fuel system troubleshooting A (steps 94 to 101), fuel system troubleshooting B (steps 102 to 104), intake system troubleshooting (steps 105 to 107), and ignition system troubleshooting (steps 108 to 113), in that order.

REPLACE AIR FUEL RATIO SENSOR (RAV4_ACA30 RM000001RO300SX.html)

A

64.PERFORM SIMULATION TEST

Check if the idling speed is stable after starting the engine.
OK:
Speed is stable.
HINT:
After replacing the fuel injector assembly or mass air flow meter, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 71 and perform fuel system troubleshooting A (steps 94 to 101), fuel system troubleshooting B (steps 102 to 104), intake system troubleshooting (steps 105 to 107), and ignition system troubleshooting (steps 108 to 113), in that order.

REPLACE FUEL INJECTOR ASSEMBLY (RAV4_ACA30 RM0000017R800PX.html)

REPLACE MASS AIR FLOW METER (RAV4_ACA30 RM0000017TY00UX.html)

65.CHECK FUEL PRESSURE

Inspect the fuel pressure (RAV4_ACA30 RM000000QE3013X_02_0005.html).

Go to step 70

OK

66.CHECK SPARK PLUG

Inspect the spark plugs (RAV4_ACA30 RM000001QVP01KX_01_0002.html).

Result
Result
Proceed to
All cylinders are normal
A
One cylinder is abnormal*1
B
All cylinders are abnormal*2, *3
C

HINT:

*1: If one cylinder is abnormal, replace the spark plug of that cylinder and inspect the ignition and fuel system for that cylinder. After performing repairs, check if engine starting trouble occurs again. If engine starting trouble still occurs, proceed to step 71 and perform fuel system troubleshooting A (steps 94 to 101), fuel system troubleshooting B (steps 102 to 104), intake system troubleshooting (steps 105 to 107), and ignition system troubleshooting (steps 108 to 113), in that order.
*2: If all cylinders are abnormal, replace the spark plugs of all cylinders and check if engine starting trouble occurs again. If engine starting trouble still occurs, proceed to step 71 and perform fuel system troubleshooting A (steps 94 to 101), fuel system troubleshooting B (steps 102 to 104), intake system troubleshooting (steps 105 to 107), and ignition system troubleshooting (steps 111 to 116), in that order.
*3: Engine starting trouble may occur if the vehicle is driven extremely short distances repeatedly.

REPLACE SPARK PLUG (ABNORMAL CYLINDER)

REPLACE SPARK PLUG (ALL)

A

67.CONFIRM VEHICLE CONDITION

Confirm the conditions present when the malfunction occurred based on the customer problem analysis.

Result
Problem Symptom	Suspected Area	Proceed to
When the engine is stopped and a long time has passed, engine starting trouble occurs*1	Pressure regulator is stuck open	A
When the engine is stopped and approximately 15 to 120 minutes have passed, engine starting trouble occurs*2	Fuel injector leak	B
When the engine is stopped and approximately 2 to 3 minutes have passed, engine starting trouble occurs*3	Failure to maintain fuel pressure by pressure regulator	A
Condition other than above, or there is an inconsistency in the conditions present when engine starting trouble occurs	-	C*4

HINT:

*1: The pressure regulator may be stuck open. Attach a fuel pressure gauge and check the ability of the system to maintain fuel pressure after stopping the engine.

*2: Fuel may be leaking from a fuel injector assembly.

*4: From step 71, perform fuel system troubleshooting A (steps 94 to 101), fuel system troubleshooting B (steps 102 to 104), intake system troubleshooting (steps 105 to 107), and ignition system troubleshooting (steps 108 to 113), in that order.

Go to step 69

Go to step 71

A

68.CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures (RAV4_ACA30 RM000000QE3013X_02_0005.html).

Attach a fuel pressure gauge and check the fuel pressure after stopping the engine.

Result
Result
Proceed to
147 kPa (1.5 kgf/cm²) or higher (5 minutes after stopping the engine)
A*1
Below 147 kPa (1.5 kgf/cm²) (5 minutes after stopping the engine)
B
HINT:
1. If the engine cannot be started, check the fuel pressure after cranking the engine.
2. *1: From step 71, perform fuel system troubleshooting A (steps 94 to 101), fuel system troubleshooting B (steps 102 to 104), intake system troubleshooting (steps 105 to 107), and ignition system troubleshooting (steps 108 to 113), in that order.

Go to step 71

REPLACE FUEL PRESSURE REGULATOR ASSEMBLY (RAV4_ACA30 RM0000017RJ03OX.html)

69.CHECK FUEL INJECTOR ASSEMBLY

Clean the inside of the surge tank with compressed air.

After stopping the engine, measure the HC concentration inside the surge tank for 15 minutes.

Result
Result
Proceed to
400 ppm or more
A
Less than 400 ppm
B*1
HINT:
1. If the concentration is 400 ppm or more, a fuel injector assembly may have a sealing problem.
2. *1: From step 71, perform fuel system troubleshooting A (steps 94 to 101), fuel system troubleshooting B (steps 102 to 104), intake system troubleshooting (steps 105 to 107), and ignition system troubleshooting (steps 108 to 113), in that order.

Go to step 71

REPLACE FUEL INJECTOR ASSEMBLY (RAV4_ACA30 RM0000017R800PX.html)

70.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP / SPEED)

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

When performing the Active Test, check for fuel leakage from the fuel pipes.

Result
Result
Proceed to
Fuel leakage or signs of fuel leakage are present
A
No fuel leakage or signs of fuel leakage
B
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.
3. If there are no fuel leaks, after inspecting the fuel pump control system, check if engine starting trouble occurs again. If engine starting trouble still occurs, proceed to step 71 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 114), in that order.

CHECK FUEL PUMP CONTROL SYSTEM (RAV4_ACA30 RM000001DN701UX.html)

REPAIR OR REPLACE FUEL LINE

71.CHECK MALFUNCTION CONDITION

If the malfunction could not be identified during the inspections in steps 38, 39, 40 and 47, perform fuel system troubleshooting C (steps 72 to 76).

Result
Performed Step
Troubleshooting by System
Procedure
Proceed to
Steps 38, 39, 40 and 47
Fuel system troubleshooting C
72 to 76
A

If the malfunction could not be identified during the inspection in step 45, perform ignition system troubleshooting (steps 77 to 82).

Result
Performed Step
Troubleshooting by System
Procedure
Proceed to
Step 45
Ignition system troubleshooting
77 to 82
B

If the malfunction could not be identified during the inspections in steps 55 and 56, perform intake air system troubleshooting (steps 83 to 85). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 86 to 93).

Result
Performed Step
Troubleshooting by System
Procedure
Proceed to
Step 55 and 56
Intake air system troubleshooting
83 to 85
C
Fuel system troubleshooting A
86 to 93

If the malfunction could not be identified during the inspections in steps 57, 58, 59, 60, 63, 64, 66, 67, 68, 69 and 70, perform fuel system troubleshooting A (steps 94 to 101), fuel system troubleshooting B (steps 102 to 104), intake air system troubleshooting (steps 105 to 107), and ignition system troubleshooting (steps 108 to 113), in that order.

Result
Performed Step	Troubleshooting by System	Procedure	Proceed to
Steps 57, 58, 59, 60, 63, 64, 66, 67, 68, 69 and 70	Fuel system troubleshooting A	94 to 101	D
	Fuel system troubleshooting B	102 to 104
	Intake air system troubleshooting	105 to 107
	Ignition system troubleshooting	108 to 113

Go to step 77

Go to step 83

Go to step 94

A

72.INSPECT FUEL INJECTOR ASSEMBLY

Inspect the fuel injector assembly (RAV4_ACA30 RM000000VZW010X_01_0001.html).

REPLACE FUEL INJECTOR ASSEMBLY (RAV4_ACA30 RM0000017R800PX.html)

OK

73.CHECK HARNESS AND CONNECTOR (FUEL INJECTOR POWER SOURCE)

Disconnect the fuel injector assembly connector.

Turn the ignition switch on (IG).

Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Cylinder	Tester Connection	Switch Condition	Specified Condition
No. 1	B16-1 - Ground	Ignition switch on (IG)	11 to 14 V
No. 2	B15-1 - Ground	Ignition switch on (IG)	11 to 14 V
No. 3	B14-1 - Ground	Ignition switch on (IG)	11 to 14 V
No. 4	B13-1 - Ground	Ignition switch on (IG)	11 to 14 V

Text in Illustration
*a	Front view of wire harness connector (to Fuel Injector Assembly)

HINT:

Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
Make sure there is not an excessive amount of force applied to the wire harness.

REPAIR POWER SOURCE CIRCUIT (RAV4_ACA30 RM000001DN807EX.html)

OK

74.CHECK HARNESS AND CONNECTOR (FUEL INJECTOR ASSEMBLY - ECM)

Disconnect the fuel injector assembly connector.

Disconnect the ECM connector.

Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Cylinder	Tester Connection	Condition	Specified Condition
No. 1	B16-2 - Body ground	Always	10 kΩ or higher
No. 1	B16-2 - B32-108 (#10)	Always	Below 1 Ω
No. 2	B15-2 - Ground	Always	10 kΩ or higher
No. 2	B15-2 - B32-107 (#20)	Always	Below 1 Ω
No. 3	B14-2 - Ground	Always	10 kΩ or higher
No. 3	B14-2 - B32-106 (#30)	Always	Below 1 Ω
No. 4	B13-2 - Ground	Always	10 kΩ or higher
No. 4	B13-2 - B32-105 (#40)	Always	Below 1 Ω

HINT:

Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
Make sure there is not an excessive amount of force applied to the wire harness.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

75.CHECK CRANKSHAFT POSITION SENSOR

Replace the crankshaft position sensor (RAV4_ACA30 RM0000017VB00NX.html).

Check the engine start operation.
OK:
Malfunction has been repaired successfully.

Go to step 76

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

76.CHECK CAMSHAFT POSITION SENSOR

Replace the camshaft position sensor (RAV4_ACA30 RM0000017V701WX.html).

Check the engine start operation.
OK:
Malfunction has been repaired successfully.

REPLACE ECM (RAV4_ACA30 RM0000017UO01FX.html)

END (CAMSHAFT POSITION SENSOR IS DEFECTIVE)

77.CHECK CRANKSHAFT POSITION SENSOR

Check the tightening and installation condition of the crankshaft position sensor bolt.

Check the connection of the crankshaft position sensor connector.
OK:
Sensor is installed correctly.

SECURELY REINSTALL CRANKSHAFT POSITION SENSOR (RAV4_ACA30 RM0000017VB00NX.html)

OK

78.CHECK CAMSHAFT POSITION SENSOR

Check the tightening and installation condition of the camshaft position sensor bolt.

Check the connection of the camshaft position sensor connector.
OK:
Sensor is installed correctly.

SECURELY REINSTALL CAMSHAFT POSITION SENSOR (RAV4_ACA30 RM0000017V701WX.html)

OK

79.CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

Disconnect the crankshaft position sensor connector.

Disconnect the ECM connector.

Measure the resistance according to the value(s) in the table below.
Standard Resistance (Check for Open):
Tester Connection
Condition
Specified Condition
B22-1 - B32-122 (NE+)
Always
Below 1 Ω
B22-2 - B32-121 (NE-)
Always
Below 1 Ω
Standard Resistance (Check for Short):
Tester Connection
Condition
Specified Condition
B22-1 or B32-122 (NE+) - Body ground
Always
10 kΩ or higher
B22-2 or B32-121 (NE-) - Body ground
Always
10 kΩ or higher
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. Make sure there is not an excessive amount of force applied to the wire harness.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

80.CHECK HARNESS AND CONNECTOR (CAMSHAFT POSITION SENSOR - ECM)

Disconnect the camshaft position sensor connector.

Disconnect the ECM connector.

Measure the resistance according to the value(s) in the table below.
Standard Resistance (Check for Open):
Tester Connection
Condition
Specified Condition
B6-1 - B32-99 (G2+)
Always
Below 1 Ω
B6-2 - B32-98 (G2-)
Always
Below 1 Ω
Standard Resistance (Check for Short):
Tester Connection
Condition
Specified Condition
B6-1 or B32-99 (G2+) - Body ground
Always
10 kΩ or higher
B6-2 or B32-98 (G2-) - Body ground
Always
10 kΩ or higher
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. Make sure there is not an excessive amount of force applied to the wire harness.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

81.CHECK CRANKSHAFT POSITION SENSOR

Replace the crankshaft position sensor (RAV4_ACA30 RM0000017VB00NX.html).

Check the engine start operation.
OK:
Malfunction has been repaired successfully.

Go to step 82

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

82.CHECK CAMSHAFT POSITION SENSOR

Replace the camshaft position sensor (RAV4_ACA30 RM0000017V701WX.html).

Check the engine start operation.
OK:
Malfunction has been repaired successfully.

REPLACE ECM (RAV4_ACA30 RM0000017UO01FX.html)

END (CAMSHAFT POSITION SENSOR IS DEFECTIVE)

83.READ VALUE USING INTELLIGENT TESTER (ISC LEARNING VALUE)

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Start the engine and warm it up until the engine coolant temperature stabilizes with the A/C switch and all the accessory switches off.

Enter the following menus: Powertrain / Engine and ECT / Data List / ISC Learning Value.
Result
Data List Item
Result
Suspected Area
Proceed to
ISC Learning Value
(engine displacement (liters) x 0.9) or more
Valve timing
Compression
A
Less than (engine displacement (liters) x 0.9)
-
B

Go to step 85

A

84.CHECK CYLINDER COMPRESSION PRESSURE

Inspect the compression (RAV4_ACA30 RM000001R3C00JX_01_0009.html).

REPAIR OR REPLACE ENGINE ASSEMBLY

CHECK VALVE TIMING

85.INSPECT ENGINE COOLANT TEMPERATURE SENSOR

Inspect the engine coolant temperature sensor (RAV4_ACA30 RM0000017U700ZX_01_0001.html).

REPLACE ENGINE COOLANT TEMPERATURE SENSOR (RAV4_ACA30 RM0000017U900UX.html)

OK

86.CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures (RAV4_ACA30 RM000000QE3013X_02_0005.html).

Attach a fuel pressure gauge and check the fuel pressure when cranking the engine and after stopping the engine.

Result
Vehicle State
Specified Condition
Cranking engine
304 to 343 kPa (3.1 to 3.5 kgf/cm²)
5 minutes after stopping engine
147 kPa (1.5 kgf/cm²) or higher

Go to step 92

OK

87.READ VALUE USING INTELLIGENT TESTER (LONG FT)

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Enter the following menus: Powertrain / Engine and ECT / Data List / Long FT.
Result
Data List Item
Result
Suspected Area
Proceed to
Long FT
-15 to +15%
Wire harness or connector
Fuel
A
+15% or more, or less than -15%
Fuel injector assembly
B

REPLACE FUEL INJECTOR ASSEMBLY (RAV4_ACA30 RM0000017R800PX.html)

A

88.PERFORM SIMULATION TEST

Check if the idling speed is stable after starting the engine and if an unstable idling speed has ever occurred in the past.

Result
Problem Symptom
Suspected Area
Proceed to
Current unstable idling speed or history of unstable idling speed
Crankshaft position sensor system
A
All current and past idling speeds are stable
Fuel
B
HINT:
Through the customer problem analysis, confirm the fuel being used and the location at which the fuel was added to check if the malfunction is caused by the fuel in the vehicle.

REPLACE FUEL

A

89.CHECK CRANKSHAFT POSITION SENSOR

Check the tightening and installation condition of the crankshaft position sensor bolt.

Check the connection of the crankshaft position sensor connector.
OK:
Sensor is installed correctly.

SECURELY REINSTALL CRANKSHAFT POSITION SENSOR (RAV4_ACA30 RM0000017VB00NX.html)

OK

90.CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

Disconnect the crankshaft position sensor connector.

Disconnect the ECM connector.

Measure the resistance according to the value(s) in the table below.
Standard Resistance (Check for Open):
Tester Connection
Condition
Specified Condition
B22-1 - B32-122 (NE+)
Always
Below 1 Ω
B22-2 - B32-121 (NE-)
Always
Below 1 Ω
Standard Resistance (Check for Short):
Tester Connection
Condition
Specified Condition
B22-1 or B32-122 (NE+) - Body ground
Always
10 kΩ or higher
B22-2 or B32-121 (NE-) - Body ground
Always
10 kΩ or higher
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. Make sure there is not an excessive amount of force applied to the wire harness.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

91.CHECK CRANKSHAFT POSITION SENSOR

Replace the crankshaft position sensor (RAV4_ACA30 RM0000017VB00NX.html).

Check the engine start operation.
OK:
Malfunction has been repaired successfully.

REPLACE ECM (RAV4_ACA30 RM0000017UO01FX.html)

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

92.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP / SPEED)

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

When performing the Active Test, check for fuel leakage from the fuel pipes.

Result
Result
Proceed to
Fuel leakage or signs of fuel leakage are present
A
No fuel leakage or signs of fuel leakage
B
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. When performing the Active Test, if there is no operating noise from the fuel pump, the fuel pump system may be malfunctioning.
3. Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.

Go to step 93

REPAIR OR REPLACE FUEL LINE

93.INSPECT FUEL PUMP

Inspect the fuel pump (RAV4_ACA30 RM0000017RH02BX_01_0001.html).

HINT:

Make sure there is no foreign matter such as iron particles on the fuel pump and no signs that the fuel pump was stuck.
Make sure the internal connector is securely connected.
Make sure the fuel pump filter is not clogged.

REPLACE FUEL PUMP (RAV4_ACA30 RM0000017RJ03PX.html)

REPLACE FUEL PRESSURE REGULATOR ASSEMBLY (RAV4_ACA30 RM0000017RJ03OX.html)

94.CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures (RAV4_ACA30 RM000000QE3013X_02_0005.html).

Attach a fuel pressure gauge and check the fuel pressure after stopping the engine.

Result
Result
Proceed to
147 kPa (1.5 kgf/cm²) or higher (5 minutes after stopping the engine)
A
Below 147 kPa (1.5 kgf/cm²) (5 minutes after stopping the engine)
B

Go to step 100

A

95.READ VALUE USING INTELLIGENT TESTER (LONG FT)

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Enter the following menus: Powertrain / Engine and ECT / Data List / Long FT.
Result
Data List Item
Result
Suspected Area
Proceed to
Long FT
-15 to +15%
Wire harness or connector
Fuel
A
+15% or more, or less than -15%
Fuel injector assembly
B

REPLACE FUEL INJECTOR ASSEMBLY (RAV4_ACA30 RM0000017R800PX.html)

A

96.PERFORM SIMULATION TEST

Check if the idling speed is stable after starting the engine and if an unstable idling speed has ever occurred in the past.

Result
Problem Symptom
Suspected Area
Proceed to
Current unstable idling speed or history of unstable idling speed
Crankshaft position sensor system
A
All current and past idling speeds are stable
Fuel
B
HINT:
Through the customer problem analysis, confirm the fuel being used and the location at which the fuel was added to check if the malfunction is caused by the fuel in the vehicle.

REPLACE FUEL

A

97.CHECK CRANKSHAFT POSITION SENSOR

Check the tightening and installation condition of the crankshaft position sensor bolt.

Check the connection of the crankshaft position sensor connector.
OK:
Sensor is installed correctly.

SECURELY REINSTALL CRANKSHAFT POSITION SENSOR (RAV4_ACA30 RM0000017VB00NX.html)

OK

98.CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

Disconnect the crankshaft position sensor connector.

Disconnect the ECM connector.

Measure the resistance according to the value(s) in the table below.
Standard Resistance (Check for Open):
Tester Connection
Condition
Specified Condition
B22-1 - B32-122 (NE+)
Always
Below 1 Ω
B22-2 - B32-121 (NE-)
Always
Below 1 Ω
Standard Resistance (Check for Short):
Tester Connection
Condition
Specified Condition
B22-1 or B32-122 (NE+) - Body ground
Always
10 kΩ or higher
B22-2 or B32-121 (NE-) - Body ground
Always
10 kΩ or higher
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. Make sure there is not an excessive amount of force applied to the wire harness.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

99.CHECK CRANKSHAFT POSITION SENSOR

Replace the crankshaft position sensor (RAV4_ACA30 RM0000017VB00NX.html).

Check the engine start operation.
OK:
Malfunction has been repaired successfully.

REPLACE ECM (RAV4_ACA30 RM0000017UO01FX.html)

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

100.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP / SPEED)

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

When performing the Active Test, check for fuel leakage from the fuel pipes.

Result
Result
Proceed to
Fuel leakage or signs of fuel leakage are present
A
No fuel leakage or signs of fuel leakage
B
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. When performing the Active Test, if there is no operating noise from the fuel pump, the fuel pump system may be malfunctioning.
3. Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.

Go to step 101

REPAIR OR REPLACE FUEL LINE

101.INSPECT FUEL PUMP

Inspect the fuel pump (RAV4_ACA30 RM0000017RH02BX_01_0001.html).

HINT:

Make sure there is no foreign matter such as iron particles on the fuel pump and no signs that the fuel pump was stuck.
Make sure the internal connector is securely connected.
Make sure the fuel pump filter is not clogged.

REPLACE FUEL PUMP (RAV4_ACA30 RM0000017RJ03PX.html)

OK

102.CHECK PURGE VSV

Disconnect the vacuum hose (on the canister side) of the purge VSV.

Start the engine.

Idle the engine.

Disconnect the connector of the purge VSV.

Check if air flows through the purge VSV.
OK:
Air does not flow

Connect the connector of the purge VSV.

Connect the vacuum hose of the purge VSV.
HINT:
When this inspection is performed, the MIL may illuminate. After finishing the inspection, check and clear DTCs (RAV4_ACA30 RM000000PDK0VSX.html).

INSPECT PURGE VSV (RAV4_ACA30 RM000001RMW013X_01_0001.html)

OK

103.CHECK FUEL INJECTOR ASSEMBLY

Clean the inside of the surge tank with compressed air.

After stopping the engine, measure the HC concentration inside the surge tank for 15 minutes.

Result
Result
Proceed to
400 ppm or more
A
Less than 400 ppm
B
HINT:
If the concentration is 400 ppm or more, a fuel injector assembly may have a sealing problem.

Go to step 104

REPLACE FUEL INJECTOR ASSEMBLY (RAV4_ACA30 RM0000017R800PX.html)

104.CHECK INTAKE VALVE

Check if carbon is on the intake valves.

Result:

Result
Proceed to
Carbon present
A
No carbon present
B

Go to step 105

CLEAN INTAKE VALVE

105.READ VALUE USING INTELLIGENT TESTER (ISC LEARNING VALUE)

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG).

Start the engine, turn off all accessory switches and warm up the engine until the engine coolant temperature stabilizes.

Enter the following menus: Powertrain / Engine and ECT / Data List / ISC Learning Value.
Result
Data List Item
Result
Suspected Area
Proceed to
ISC Learning Value
(engine displacement (liters) x 0.9) or more
Valve timing
Compression
A
Less than (engine displacement (liters) x 0.9)
-
B

Go to step 107

A

106.CHECK CYLINDER COMPRESSION PRESSURE

Inspect the compression (RAV4_ACA30 RM000001R3C00JX_01_0009.html).

REPAIR OR REPLACE ENGINE ASSEMBLY

ADJUST VALVE TIMING

107.INSPECT ENGINE COOLANT TEMPERATURE SENSOR

Inspect the engine coolant temperature sensor (RAV4_ACA30 RM0000017U700ZX.html).

REPLACE ENGINE COOLANT TEMPERATURE SENSOR (RAV4_ACA30 RM0000017U900UX.html)

OK

108.CHECK CRANKSHAFT POSITION SENSOR

Check the tightening and installation condition of the crankshaft position sensor bolt.

Check the connection of the crankshaft position sensor connector.
OK:
Sensor is installed correctly.

SECURELY REINSTALL CRANKSHAFT POSITION SENSOR (RAV4_ACA30 RM0000017VB00NX.html)

OK

109.CHECK CAMSHAFT POSITION SENSOR

Check the tightening and installation condition of the camshaft position sensor bolt.

Check the connection of the camshaft position sensor connector.
OK:
Sensor is installed correctly.

SECURELY REINSTALL CAMSHAFT POSITION SENSOR (RAV4_ACA30 RM0000017V701WX.html)

OK

110.CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

Disconnect the crankshaft position sensor connector.

Disconnect the ECM connector.

Measure the resistance according to the value(s) in the table below.
Standard Resistance (Check for Open):
Tester Connection
Condition
Specified Condition
B22-1 - B32-122 (NE+)
Always
Below 1 Ω
B22-2 - B32-121 (NE-)
Always
Below 1 Ω
Standard Resistance (Check for Short):
Tester Connection
Condition
Specified Condition
B22-1 or B32-122 (NE+) - Body ground
Always
10 kΩ or higher
B22-2 or B32-121 (NE-) - Body ground
Always
10 kΩ or higher
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. Make sure there is not an excessive amount of force applied to the wire harness.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

111.CHECK HARNESS AND CONNECTOR (CAMSHAFT POSITION SENSOR - ECM)

Disconnect the camshaft position sensor connector.

Disconnect the ECM connector.

Measure the resistance according to the value(s) in the table below.
Standard Resistance (Check for Open):
Tester Connection
Condition
Specified Condition
B6-1 - B32-99 (G2+)
Always
Below 1 Ω
B6-2 - B32-98 (G2-)
Always
Below 1 Ω
Standard Resistance (Check for Short):
Tester Connection
Condition
Specified Condition
B6-1 or B32-99 (G2+) - Body ground
Always
10 kΩ or higher
B6-2 or B32-98 (G2-) - Body ground
Always
10 kΩ or higher
HINT:
1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
2. Make sure there is not an excessive amount of force applied to the wire harness.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

112.CHECK CRANKSHAFT POSITION SENSOR

Replace the crankshaft position sensor (RAV4_ACA30 RM0000017VB00NX.html).

Check the engine start operation.
OK:
Malfunction has been repaired successfully.

Go to step 113

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

113.CHECK CAMSHAFT POSITION SENSOR

Replace the camshaft position sensor (RAV4_ACA30 RM0000017V701WX.html).

Check the engine start operation.
OK:
Malfunction has been repaired successfully.

REPLACE ECM (RAV4_ACA30 RM0000017UO01FX.html)

END (CAMSHAFT POSITION SENSOR IS DEFECTIVE)

Result	Proceed to
Only DTC P1604 is output	A
DTCs other than P1604 are output	B

Result	Proceed to
Fuel leakage or signs of fuel leakage are present	A
No fuel leakage or signs of fuel leakage	B

Result	Proceed to
There is foreign matter or signs that fuel pump was stuck	A
There is no foreign matter and no signs that fuel pump was stuck	B

Result	Proceed to
Engine can be started	A
Engine cannot be started	B

Result	Proceed to
147 kPa (1.5 kgf/cm²) or higher (5 minutes after stopping the engine)	A*1
Below 147 kPa (1.5 kgf/cm²) (5 minutes after stopping the engine)	B

Control the Fuel Pump / Speed	Specified Condition
ON	Operating sound heard
OFF	Operating sound not heard

Tester Operation	Specified Condition
OFF	Normal engine speed
ON	Soon after OCV switched from OFF to ON, engine idles roughly or stalls

Tester Display	Injection Volume	Specified Condition
AFS Voltage B1S1	+25%	Air fuel ratio sensor output voltage is below 3.1 V
AFS Voltage B1S1	-12.5%	Air fuel ratio sensor output voltage is higher than 3.4 V

Result	Proceed to
All cylinders are normal	A
One cylinder is abnormal*1	B
All cylinders are abnormal2, 3	C

Vehicle State	Specified Condition
Cranking engine	304 to 343 kPa (3.1 to 3.5 kgf/cm²)
5 minutes after stopping engine	147 kPa (1.5 kgf/cm²) or higher