Toyota RAV4 Service Manual: Basic inspection

1. When measuring resistance of electronic parts

1. Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°c (68°f). Resistance measurements may be inaccurate if measured at high temperatures, i.E. Immediately after the vehicle has been running. Measurements should be made after the engine has cooled down.

2. Handling connectors

1. When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector.
2. When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it.
3. Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals.
4. When connecting a connector, press firmly until it locks with a "click" sound.
5. If checking a connector with a toyota electrical tester, check the connector from the backside (harness side) using a mini test lead.

Notice:

• As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness.
• Do not damage the terminals by moving the inserted tester needle.

3. Checking connectors

1. Checking when a connector is connected: squeeze the connector together to confirm that they are fully connected and locked.
2. Checking when a connector is disconnected: pull the wire harness lightly from the backside of the connector. Visually check for the following: 1) unlatched terminals, missing terminals, loose crimps and broken conductor wires; 2) corrosion, metallic matter, foreign matter and water; and 3) bent, rusted, overheated, contaminated and deformed terminals.

3. Checking the contact pressure of the terminal: prepare a spare male terminal. Insert it into a female terminal, and check for ample tension when inserting and after full engagement.

Notice:

When testing a gold-plated female terminal, always use a gold-plated male terminal.

4. Repair method of connector terminal

1. If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.

   Never rub the contact point using sandpaper as the plating may come off.

2. If there is abnormal contact pressure, replace the female terminal. If the male terminal is goldplated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
3. Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced.

5. Handling of wire harness

1. If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way.
2. Never twist, pull or slacken the wire harness more than necessary.
3. The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items.
4. When installing parts, never pinch the wire harness.
5. Never cut or break the cover of the wire harness.

   If it is cut or broken, repair the cover with vinyl tape or replace the wire harness.