sensor TOYOTA RAV4 1996 Service Repair Manual

EM−2
− ENGINE MECHANICALCO/HC
1996 RAV4 (RM447U)
6. TROUBLESHOOTING
If the CO/HC concentration does not comply with regulations,
troubleshoot in the order given below.
(a) Check the oxygen sensor operation (See page DI−42).
(b) See the table below for possible causes, then inspect and
correct the applicable causes if necessary.
HCCOProblemsCauses
HighNormalRough idle4. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs
Open or or crossed high−tension cords
Cracked distributor cap
5. Incorrect valve clearance
6. Leaky EGR valve
7. Leaky intake and exhaust valves
8. Leaky cylinder
HighLowRough idle
(Fluctuating HC reading)1. Vacuum leaks:
PCV hose
EGR valve
Intake manifold
Throttle body
IAC valve
Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(Black smoke from exhaust)1. Restricted air filter
2. Faulty SFI system:
Faulty pressure regulator
Clogged fuel return line
Defective ECT sensor
Defective IAT sensor
Faulty ECM
Faulty injector
Faulty throttle position sensor
MAP sensor

S01650
S01656
SST
SST
S01620
P25458
S01614
SST
− ENGINE MECHANICALTIMING BELT
EM−17
1996 RAV4 (RM447U)
(a) Loosen the mounting bolt of the No. 1 idler pulley and shift
the pulley toward the left as far as it will go, and temporari-
ly tighten it.
(b) Remove the timing belt from the camshaft timing pulley.
18. REMOVE CAMSHAFT TIMING PULLEY
Using SST, remove the pulley bolt and timing pulley.
SST 09249−63010, 09960−10010 (09962−01000,
09963−01000)
19. REMOVE CRANKSHAFT PULLEY
HINT:
When re−using timing belt:
Remove the pulley without turning it.
20. REMOVE NO. 1 TIMING BELT COVER
(a) Disconnect the engine wire from the timing belt cover.
(b) Remove the 4 bolts and timing belt cover.
21. REMOVE TIMING BELT GUIDE
22. REMOVE TIMING BELT
HINT:
(When re−using timing belt): Draw a direction arrow on the tim-
ing belt (in the direction of engine revolution), and place match-
marks on the timing belt and crankshaft timing pulley.
23. REMOVE NO. 1 IDLER PULLEY AND TENSION
SPRING
24. REMOVE NO. 2 IDLER PULLEY
25. REMOVE CRANKSHAFT TIMING PULLEY
If the pulley cannot be removed by hand, use SST to remove
the timing pulley.
SST 09950−50010 (09951−05010, 09952−05010,
09953−05010, 09953−05020, 09954−05010)
NOTICE:
Do not scratch the angle sensor of the timing pulley.

EM0EO−03
S01634
SST
S01637
Inward
Sensor
S01625
35 mm
S01654
42 mm
S01657
Pry
Move EM−20
− ENGINE MECHANICALTIMING BELT
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL OIL PUMP PULLEY
(a) Align the cutouts of the pulley and shaft, and slide on the
pulley.
(b) Using SST, install the nut.
SST 09960−10010 (09962−01000, 09963−00600)
Torque: 24 N·m (245 kgf·cm, 18 ft·lbf)
2. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the timing pulley set key with the key groove of the
pulley.
(b) Install the timing pulley, facing the sensor side inward.
NOTICE:
Do not scratch the sensor part of the crankshaft timing
pulley.
3. INSTALL NO. 2 IDLER PULLEY
(a) Install the pulley with the bolt.
Torque: 42 N·m (425 kgf·cm, 31 ft·lbf)
HINT:
Use a bolt 35 mm (1.38 in.) in length.
(b) Check that the idler pulley moves smoothly.
4. TEMPORARILY INSTALL NO. 1 IDLER PULLEY AND
TENSION SPRING
(a) Align the bracket pin hole with the pivot pin.
(b) Install the pulley with the bolt. Do not tighten the bolt yet.
HINT:
Use a bolt 42 mm (1.65 in.) in length.
(c) Install the tension spring.
(d) Pry the pulley toward the left as far as it will go and tighten
the bolt.
(e) Check that the idler pulley moves smoothly.

EM1B8−02
S01285
S01557
− ENGINE MECHANICALCYLINDER HEAD
EM−33
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. A/T only:
DISCONNECT THROTTLE CABLE FROM THROTTLE
BODY
4. DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
5. REMOVE AIR CLEANER CAP AND CASE
6. REMOVE GENERATOR (See page CH−7)
7. REMOVE DISTRIBUTOR
8. REMOVE FRONT EXHAUST PIPE
(a) Using a 14 mm deep socket wrench, remove the 3 nuts
holding the front exhaust pipe to the front TWC.
(b) Remove the 2 bolts holding the front exhaust pipe to the
TWC w/ pipe.
(c) Remove the front exhaust pipe and 2 gaskets.
9. REMOVE EXHAUST MANIFOLD AND HEAT INSULA-
TOR ASSEMBLY
(a) Disconnect the oxygen sensor (bank 1 sensor 1) connec-
tor.
(b) Disconnect the oxygen sensor (bank 1 sensor 2) connec-
tor.
(c) Remove the 6 bolts and manifold upper heat insulator.
(d) Remove the 2 bolts holding the RH exhaust manifold stay
to the cylinder block.
(e) Remove the 6 nuts, the exhaust manifold and heat insula-
tor assembly.

S01823
Oxygen Sensor
(Bank 1 Sensor 1)
Oxygen Sensor (Bank 1 Sensor 2)
P03152
S01368
S01365
S01594
EM−34
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
10. REMOVE OXYGEN SENSOR (BANK 1 SENSOR 1)
FROM EXHAUST MANIFOLD
11. REMOVE OXYGEN SENSOR (BANK 1 SENSOR 2)
FROM FRONT TWC
12. SEPARATE EXHAUST MANIFORD AND FRON TWC
(a) Remove the 5 bolts and lower manifold heat insulator.
(b) Remove the 8 bolts and 2 TWC heat insulators.
(c) Remove the 3 bolts, 2 nuts, TWC, gasket retainer and
cushion.
13. DISCONNECT OIL PRESSURE SWITCH CONNECTOR
14. REMOVE WATER OUTLET
(a) Disconnect the ECT sensor connector.
(b) Disconnect the ECT sender gauge connector.
(c) Disconnect the radiator hose from the water outlet.
(d) Disconnect the water bypass pipe hose from the water
outlet.
(e) Disconnect the heater water hose from the water outlet.
(f) Remove the 2 nuts, water outlet and gasket.
15. REMOVE WATER BYPASS PIPE
(a) Remove the bolt, 2 nuts and oil cooler heat protector.
(b) Disconnect the IAC valve water bypass hose from the wa-
ter bypass pipe.
(c) Disconnect the heater water hose from the water bypass
pipe.
(d) Disconnect the 2 oil cooler water bypass hoses from the
oil cooler.
(e) Remove the nut and disconnect the wire protector.
(f) Remove the 2 bolts and 2 nuts.
(g) Disconnect the water bypass pipe from the water pump
cover, and remove the water bypass pipe.
(h) Remove the gasket and O−ring.
16. REMOVE THROTTLE BODY (See page SF−30)

S01560
(3)(1)
(2)
S01806
S01644
S01791
− ENGINE MECHANICALCYLINDER HEAD
EM−35
1996 RAV4 (RM447U)
17. DISCONNECT HOSES AND GROUND STRAP
(a) Disconnect the vacuum sensor hose from the gas filter on
intake manifold.
(b) Disconnect the brake booster vacuum hose from the in-
take manifold.
(c) Disconnect the ground strap from the intake manifold.
18. DISCONNECT FUEL INLET HOSE FROM FUEL FIL-
TER
Remove the union bolt and 2 gaskets, and disconnect the inlet
hose from the fuel filter.
19. REMOVE EGR VALVE AND VACUUM MODULATOR
(a) Disconnect the 2 vacuum hoses from the VSV for the
EGR.
(b) Disconnect the vacuum modulator from the clamp on the
intake manifold.
(c) Loosen the union nut of the EGR pipe, and remove the 2
nuts, the EGR valve, vacuum modulator, vacuum hoses
assembly and gasket.
20. REMOVE INTAKE MANIFOLD STAY
Remove the 2 bolts and intake manifold stay.
21. A/T only:
DISCONENCT A/T THROTTLE CONTROL CABEL
FROM INTAKE MANIFORD
Disconnect the control cable from the clamp on the rear side of
the intake manifold.
22. DISCONNECT PS IDLE−UP AIR HOSES FROM AIR
TUBE
23. DISCONNECT KNOCK SENSOR CONNECTOR
24. DISCONNECT GROUND CABLE
Remove the bolt, and disconnect the ground cable from the in-
take manifold.
25. REMOVE VSV FOR EGR (See page SF−42)
26. REMOVE CYLINDER HEAD COVER
(a) Remove the 2 bolts and accelerator cable bracket.
(b) Disconnect the PCV hose from the intake manifold.

S01653
1 2
S01646
S01647
S01645
S01432
EM−36
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(c) Disconnect the engine wire protector from the 2 mounting
bolts of the No. 2 timing belt cover in the sequence shown.
(d) Remove the 4 nuts, grommets, head cover and gasket.
HINT:
Arrange the grommets in the correct order, so that they can be
reinstalled into their original positions. This minimizes any pos-
sibility of oil leakage due to reuse of the grommets in different
positions.
27. DISCONNECT ENGINE WIRE
(a) Remove the 2 bolts, and disconnect the engine wire pro-
tector from the LH side of the intake manifold.
(b) Disconnect the 4 injector connectors.
(c) w/ A/C:
Disconnect the A/C compressor connector.
(d) Disconnect the crankshaft position sensor connector.
(e) Disconnect the 3 clamps from the No. 2 timing bet cover
and generator drive belt adjusting bar.
(f) Disconnect the engine wire protector from the 2 brackets
on the front side of the intake manifold.
(g) Remove the RH scuff plate, RH cowl side trim and RH
floor carpet center cover.
(h) Disconnect the 2 ECM connectors.
(i) Disconnect the 2 connectors from the connectors on the
bracket.
(j) Disconnect the Connector from the J/B No. 4.
(k) Disconnect the wire clamp from the bracket.
(l) Pull out the engine wire from the cabin.
(m) Take out the engine wire between the cylinder head and
intake manifold.
28. DISCONNECT TIMING BELT FROM CAMSHAFT TIM-
ING PULLEY (See page EM−15)
29. REMOVE CAMSHAFT TIMING PULLEY (See page
EM−15)
30. REMOVE NO. 1 IDLER PULLEY AND TENSION
SPRING

S01647
S01432
P03283
: Seal Packing
S01658Marking 15°
15°
Z17351
12 EM−60
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(c) Install the engine wire protector to the LH side of the in-
take manifold with the 2 bolts.
(d) Push in the engine wire through the cowl panel.
(e) Install the wire clamp to the bracket.
(f) Connect the 2 ECM connectors.
(g) Connect the 2 connectors to the connectors on the brack-
et.
(h) Connect the connector to the J/B No. 4.
(i) Install the RH floor carpet center cover.
(j) Install the RH cowl side trim.
(k) Install the RH scuff plate.
16. INST ALL CYLINDER HEAD COVER
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as shown in the
illustration.
Seal packing: Part No. 08826−00080 or equivalent
(c) Install the gasket to the head cover.
(d) Install the head cover with the 4 grommets and nuts. Uni-
formly tighten the nuts in several passes.
Torque: 23 N·m (230 kgf·cm, 17 ft·lbf)
HINT:
Install the grommets so that their markings are as shown in the
illustration.
(e) Install the engine wire protector to the 2 mounting bolts of
the No. 2 timing belt cover in the sequence shown.
(f) Connect the 3 clamps to the No. 2 timing belt cover and
generator drive belt adjusting bar.
(g) Connect the crankshaft position sensor connector.
(h) w/ A/C:
Connect the A/C compressor connector.

S01791
S01644
S01806
− ENGINE MECHANICALCYLINDER HEAD
EM−61
1996 RAV4 (RM447U)
(i) Connect the PCV hose to the intake manifold.
(j) Install the accelerator cable bracket with the 2 bolts.
17. INSTALL VSV FOR EGR (See page SF−42)
18. CONNECT GROUND CABLE
Connect the ground cable to the intake manifold with the bolt.
19. CONNECT KNOCK SENSOR CONNECTOR
20. CONNECT PS IDLE−UP AIR HOSES TO AIR TUBE
21. A/T only:
CONNECT A/T THROTTLE CONTROL CABLE TO IN-
TAKE MANIFOLD
Connect the control cable to the clamp on the rear side of the
intake manifold.
22. INSTALL INTAKE MANIFOLD STAY
Install the intake manifold stay with the 2 bolts.
Torque: 42 N·m (425 kgf·cm, 31 ft·lbf)
23. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket and the EGR valve with the union nut
and 2 nuts.
Torque:
13 N·m (130 kgf·cm, 9 ft·lbf) for nut
59 N·m (600 kgf·cm, 43 ft·lbf) for union nut
(b) Install the vacuum modulator to the clamp on the intake
manifold.
(c) Connect the 2 vacuum hoses to the VSV for the EGR.
24. CONNECT FUEL INLET HOSE TO FUEL FILTER
Connect the inlet hose with 2 new gaskets and the union bolt.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

S01560
(1)
(2)
(3)
P15451
ConnectNew
New
Gasket
O−Ring
S01594
S01368
EM−62
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
25. INSTALL HOSES AND GROUND STRAP
(a) Connect the vacuum sensor hose to the gas filter on the
intake manifold.
(b) Connect the brake booster vacuum hose to the intake
manifold.
(c) Connect the ground strap to the intake manifold.
26. INSTALL THROTTLE BODY (See page SF−33)
27. INSTALL WATER BYPASS PIPE
(a) Install a new gasket to the water pump cover.
(b) Install a new O−ring to the bypass pipe.
(c) Apply soapy water on the O−ring.
(d) Connect the water bypass pipe to the water pump cover.
(e) Install the bypass pipe with the 2 nuts and 2 bolts.
Torque:
9.3 N·m (95 kgf·cm, 82 in.·lbf) fot nut
19 N·m (195 kgf·cm, 14 ft·lbf) fot bolt
(f) Connect the engine wire protector with the nut.
(g) Connect the IAC valve water bypass hose to the water by-
pass pipe.
(h) Connect the heater water hose to the water bypass pipe.
(i) Connect the 2 oil cooler water bypass hoses to the oil
cooler.
(j) Install the oil cooler heat protector with the 2 nuts and bolt.
28. INSTALL WATER OUTLET
(a) Install a new gasket and the water outlet with the 2 nuts.
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
(b) Connect the radiator hose to the water outlet.
(c) Connect the water bypass pipe hose to the water outlet.
(d) Connect the heater water hose to the water outlet.
(e) Connect the IAC valve water bypass hose to the water
outlet.
(f) Connect the ECT sensor connector.
(g) Connect the ECT sender gauge connector.