2005 Toyota RAV4 Base, AWD, AutomaticFACTORY OEM SERVICE PROCEDURE

On-Vehicle Inspection

NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F).
  1. INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST 

    Check that spark occurs.

    1. Remove the ignition coils (see IGNITION COIL ).
    2. Remove the spark plugs.
    3. Install the spark plugs to each ignition coil and connect the ignition coil connector.
    4. Disconnect the 4 injector connectors.
    5. Ground the spark plug.
    6. Check if the spark occurs while the engine is being cranked.
      NOTE: To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 5 - 10 seconds at one time.

      If the spark does not occur, do the test as follows:

      Fig 1: Ignition System Testing Chart
      G02925765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a 16 mm plug wrench, reinstall the spark plugs.

      Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 

    8. Reinstall the ignition coils (see IGNITION COIL ).
  2. INSPECT SPARK PLUGS 
    NOTE:
    • Never use a wire brush for cleaning.
    • Never attempt to adjust the electrode gap on used spark plug.
    1. Remove the air cleaner assembly.
    2. Remove the ignition coils (see IGNITION COIL ).
    3. Check the electrode.
      • Using a megger (insulation resistance meter), measure the insulation resistance.

        Correct insulation resistance: 10 MΩ or more 

        If the resistance is less than the specified value, proceed to step (d).

        HINT:

        If a megger is not available, the following simple method of inspection provides fairly accurate results.

        Fig 2: Measuring Insulation Resistance
        G02639605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • Simple Method:
          • Quickly race the engine to 4,000 rpm 5 times.
          • Remove the spark plug (see step (d)).
            • Fig 3: Removing Spark Plugs
            G02639607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          • Visually check the spark plug.

            If the electrode is dry ... OK.

            If the electrode is wet ... Proceed to (step  g).

          • Reinstall the spark plug (see step  h).
            Fig 4: Checking Spark Plug
            G02639606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Using a 16 mm plug wrench, remove the spark plugs.
      • Check the spark plug for thread damage and insulator damage.

        If abnormal, replace the spark plug.

        Recommended spark plug: 

        DENSO MADE SPECIFICATION

        DENSO made SK20R11
        NGK made IFR6A11
      • Check the spark plug electrode gap.

        Maximum electrode gap for used spark plug: 1.3 mm (0.047 in.) 

        If the gap is greater than maximum, replace the spark plug.

        Correct electrode gap for new spark plug: 1.0 to 1.1 mm (0.039 to 0.043 in.) 

        NOTE: When adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on a used plug.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.