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Fuel pump Circuit opening relay not engaging.

3K views 3 replies 2 participants last post by  Cayman  
#1 ·
Can someone please help me solve this electrical problem?

On my 1996 JDM Rav4, the circuit opening relay is in a relay block under the panel that houses the fuse block and the hood opening latch. I know I am working with the correct relay because when I manually engage it, the fuel pump runs.
My problem is that the relay will not engage when I crank the engine.

Things tried:
Tested the relay, and it works.
Checked blue wire with a black stripe from the fuel pump connector to the diagnostic port for continuity. OK
tested the fuel pump relay, in the engine compartment. OK
Both 7.5 am fuses, EFI in engine compartment fuse box, and 7.5 under the dash by Circuit opening relay. OK
The fuel pump works when it is provided 12V, directly and when the circuit opening relay is manually closed.

An observation: The tachometer does not move when I crank the engine. The engine attempts to start each time I try as if on fumes because the pump is not sending any fuel.
 
#2 · (Edited)
Cayman, I studied what you posted. I am using the attached two wiring diagrams to ponder this. Based on past experience, my first suspicion is that the engine computer is not grounding the Circuit Opening Relay's coil side. In the past one cause of this has been an improper camshaft position sensor signal and/or crankshaft position sensor signal. In brief, these produce the NE signal shown on the attached fuel pump control circuit diagram. When the NE signal is correct, the transistor shown in the "Fuel Pump Control Circuit" drawing grounds the coil side of the C.O. relay.

Is your Rav4 throwing any codes?

I cannot remember the details of your Rav4. If you post the VIN, I can check on a few things with regard to these two sensors.

Edit: From prior posts, this is a Japan SXA10G-AZPGK, built 1995-ish? I do not think this Rav has a crankshaft position sensor. However built into the distributor housing is a camshaft position sensor (a.k.a. "pickup coil" or "signal generator"). I think the distributor p/n is 19100-74081. Googling on the latter part number turns up photos that show the connector for the sensor. Cayman, make sure this sensor is correctly plugged in. Consider taking off the distributor cap and inspecting the sensor. With the engine off, check the resistance across the two terminals of the sensor. The resistances at cold and hot engine should be about:
Cold 135 − 220 ohms
Hot 175 − 255 ohms
Photos showing the sensor's connector on the distributor:
Image


Image
 

Attachments

#4 ·
Cayman, I studied what you posted. I am using the attached two wiring diagrams to ponder this. Based on past experience, my first suspicion is that the engine computer is not grounding the Circuit Opening Relay's coil side. In the past one cause of this has been an improper camshaft position sensor signal and/or crankshaft position sensor signal. In brief, these produce the NE signal shown on the attached fuel pump control circuit diagram. When the NE signal is correct, the transistor shown in the "Fuel Pump Control Circuit" drawing grounds the coil side of the C.O. relay.

Is your Rav4 throwing any codes?

I cannot remember the details of your Rav4. If you post the VIN, I can check on a few things with regard to these two sensors.

Edit: From prior posts, this is a Japan SXA10G-AZPGK, built 1995-ish? I do not think this Rav has a crankshaft position sensor. However built into the distributor housing is a camshaft position sensor (a.k.a. "pickup coil" or "signal generator"). I think the distributor p/n is 19100-74081. Googling on the latter part number turns up photos that show the connector for the sensor. Cayman, make sure this sensor is correctly plugged in. Consider taking off the distributor cap and inspecting the sensor. With the engine off, check the resistance across the two terminals of the sensor. The resistances at cold and hot engine should be about:
Cold 135 − 220 ohms
Hot 175 − 255 ohms
Photos showing the sensor's connector on the distributor