TOYOTA RAV4 1996 Service Repair Manual

SF0QH−03
− SFIINJECTOR
SF−17
1996 RAV4 (RM447U)
COMPONENTS

SF−18
− SFIINJECTOR
1996 RAV4 (RM447U)

SF0QI−03
S01903
S01939
(1)
(2)
S01827
S01949
Disconnect
Spacer
− SFIINJECTOR
SF−19
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE AIR CLEANER ASSEMBLY (See page
ST−4)
2. REMOVE CYLINDER HEAD COVER (See page
EM−33)
3. DISCONNECT THROTTLE BODY FROM INTAKE MAN-
IFOLD (See page SF−30)
4. REMOVE DISTORIBUTOR (See page IG−9)
5. DISCONNECT ENGINE WIRE FROM INTAKE MAN-
IFOLD
(a) Disconnect the 4 injector connectors.
(b) Disconnect the 2 clamps of the engine wire from the wire
brackets on intake manifold.
(c) Remove the bolt, and disconnect the engine wire protec-
tor from the RH side of the intake manifold.
(d) Disconnect the clamp of the engine wire from the wire
clamp.
6. REMOVE EGR VALVE AND PIPE
(a) Disconnect these hoses from the EGR valve:
(1) Vacuum hose from port E of VSV
(2) EGR hose from vacuum modulator
(b) Loosen the cylinder head side of the EGR pipe union nut.
(c) Remove the 2 nuts, the EGR valve, pipe assembly and
gasket.
7. DISCONNECT ENGINE COMPORTMENT R/B NO.2
8. REMOVE FUEL INLET HOSE AND DELIVERY PIPE
(a) Remove the union bolt and 2 gaskets, and disconnect the
fuel inlet hose from the fuel filter outlet.
CAUTION:
Put a shop towel under the fuel filter. Slowly loosen the
union bolt.
(b) Disconnect the air hose for the air assist system from the
intake manifold port, and remove the air hose.
(c) Loosen the 2 bolts holding the delivery pipe to the cylinder
head.
(d) Disconnect the delivery pipe from the 4 injectors, and re-
move the delivery pipe and fuel inlet hose assembly.
9. REMOVE INJECTORS AND SPACERS
(a) Remove the 4 injectors and 2 spacers from the cylinder
head.
NOTICE:
Be careful not to drop the injectors and spacers.

SF−20
− SFIINJECTOR
1996 RAV4 (RM447U)
(b) Remove the 2 O−rings, insulator and grommet from each
injector.

SF0QJ−04
S01900
Union Bolt
SST (Union)SST
(Hose)SST
(Clamp)
Injector Fuel Filter
(On−Vehicle)SST
(Union)
S01833
Union Bolt
SST
(Hose)
Fuel FilterSST
(Union)
Gasket
P25498
SST
(Hose)
SST
(Clamp) SST
(Union)
O−Ring
Vinyl
Tube
S01354
TOYOTA
Hand−Held Tester
− SFIINJECTOR
SF−21
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT INJECTOR INJECTION
CAUTION:
Keep injector clear of sparks during the test.
(a) Connect SST (union and hose) to the fuel filter outlet with
the 2 gaskets and union bolt.
SST 09268−41046 (90405−09015)
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
HINT:
Use the vehicle’s fuel filter.
(b) Install the grommet and O−ring to the injector.
(c) Connect SST (union and hose) to the injector, and hold
the injector and union with SST (clamp).
SST 09268−41046
(d) Put the injector into a graduated cylinder.
HINT:
Install a suitable vinyl hose onto the injector to prevent gasoline
from splashing out.
(e) Connect the TOYOTA hand−held tester to the DLC3.
(f) Turn the ignition switch ON and TOYOTA hand−held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(g) Select the active test mode on the TOYOTA hand−held
tester.
(h) Please refer to the TOYOTA hand−held tester operator’s
manual for further details.
(i) If you have no TOYOTA hand−held tester, connect the
positive (+) and negative (−) leads from the battery to the
fuel pump connector (See page SF−5).

P25497
SST
(Wire)
Connect
P10811
SF−22
− SFIINJECTOR
1996 RAV4 (RM447U)
(j) Connect SST (wire) to the injector and battery for 15 se-
conds, and measure the injection volume with a gra-
duated cylinder. Test each injector 2 or 3 times.
SST 09842−30070
Volume:
54 − 69 cm
3 (3.1 − 4.2 cu in.) per 15 sec.
Difference between each injector:
5 cm
3 (0.8 cu in.) or less
If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE
(a) In the condition above, disconnect the test probes of SST
(wire) from the battery and check the fuel leakage from
the injector.
SST 09842−30070
Fuel drop:
One drop or less per minute
(b) Turn the ignition switch to LOCK.
(c) Disconnect the negative (−) terminal cable from the bat-
tery.
(d) Remove the SST.
SST 09268−41046, 09842−30070
(e) Disconnect the TOYOTA hand−held tester from the
DLC3.

P10889
New Insulator
New O−Ring
New Grommet New O−Ring
SF0QK−03
S01951
Push
Spacer
S01967
Push
Turn
S01940
S01947
ConnectorUpward
Turn
− SFIINJECTOR
SF−23
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL INJECTORS AND SPACERS
(a) Install new insulator and grommet to each injector.
(b) Apply a light coat of gasoline onto 2 new O−rings, and
install them to each injector.
(c) Place the 2 spacers in position on the cylinder head.
(d) Push in the 4 injectors to the cylinder head.
2. INSTALL DELIVERY PIPE AND FUEL INLET HOSE
(a) Place the delivery pipe together with the 2 bolts between
the intake manifold and cylinder head.
(b) While turning the injector left and right, push it to the deliv-
ery pipe.
(c) Temporarily install the 2 bolts holding the delivery pipe to
the cylinder head.
(d) Check that the injectors rotate smoothly.
HINT:
If injectors do not rotate smoothly, the probable cause is incor-
rect installation of O−rings. Replace the O−rings.
(e) Position the injector connector upward.

S01941
S01953
Install
Air Hose
S01948
No.1
No.2
No.3
No.4
Gray
Brown SF−24
− SFIINJECTOR
1996 RAV4 (RM447U)
(f) Tighten the 2 bolts holding the delivery pipe to the cylinder
head.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(g) Install the air hose for the air assist system to the intake
manifold port.
(h) Connect the fuel inlet hose to the fuel filter with 2 new gas-
kets and the union bolt.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
3. INSTALL ENGINE COMPARTMENT R/B NO.2
4. INSTALL EGR VALVE AND PIPE
HINT:
Place a new gasket on the intake manifold.
Torque:
Nut:
13 N·m (130 kgf·cm, 9 ft·lbf)
Union nut:
59 N·m (600 kgf·cm, 43 ft·lbf)
5. CONNECT ENGINE WIRE TO INTAKE MANIFOLD
HINT:
The No.1 and No.3 injector connectors are brown, and the No.2
and No.4 injector connectors are gray.
6. CONNECT THROTTLE BODY TO INTAKE MANIFOLD
7. INSTALL CYLINDER HEAD COVER (See page EM−55
)
8. INSTALL AIR CLEANER ASSEMBLY
9. INSTALL DISTORIBUTOR (See page IG−13)

SF0QM−02
3.5 (35, 31 in.·lbf)
S01936
Fuel Vent Tube
w/ Gauge Assembly
Fuel return Vent tubeFuel Suction w/ Pump
& Gauge Tube Assembly
Fuel Tank Inlet PipeGasketFuel Tank Cap
3.5 (35, 31 in.·lbf)
 Gasket
1.8 (18, 16 in.·lbf)1.8 (18, 16 in.·lbf)
 Gasket
 Gasket Gasket
 Gasket
EVAP Vent Tube
Fuel Cut Off Valvex 7
x 8
x 5
x 5
3.5 (35, 31 in.·lbf)

Fuel Tank
Breather Tube
Breather Hose
Fuel
Tank
Filler Pipe
Fuel Inlet HoseFiller Pipe ProtectorFiller Pipe Shield
Fuel Main Tube
Protector Fuel Tank Protector
Center Exhaust Pipe
 Gasket
Fuel Tank Band
39 (390, 29)
39 (390, 29)
 Gasket
49 (500, 36)21 (210, 15)
74 (750, 54)
37 (375, 27)
Propeller Shaft Assembly4WD
Protector
ProtectorProtector
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
− SFIFUEL TANK AND LINE
SF−25
1996 RAV4 (RM447U)
FUEL TANK AND LINE
COMPONENTS
CAUTION:
Always use new gaskets when replacing the fuel tank or component parts.
Apply the proper torque to all parts tightened

SF0QN−01
BO0919
Crack
Leakage
Deformation
FU0041
PipeHose 2 − 7 mm (0.08 − 0.28 in.)
Clip
0 − 3 mm (0 − 0.12 in.)
SF−26
− SFIFUEL TANK AND LINE
1996 RAV4 (RM447U)
INSPECTION
INSPECT FUEL TANK AND LINE
(a) Check the fuel lines for cracks, leakage and all connec-
tions for deformation.
(b) Check the fuel tank vapor vent system hoses and connec-
tions for looseness, sharp bends or damage.
(c) Check the fuel tank for deformation, cracks, fuel leakage
and tank band looseness.
(d) Check the filler neck for damage or fuel leakage.
(e) Hose and tube connections are as shown in the illustra-
tion.
If a problem is found, repair or replace the part as necessary.