sensor TOYOTA RAV4 1996 Service Repair Manual

K OVERALL ELECTRICAL WIRING DIAGRAM
1
234
20 RAV4
1 AC C
IG 1
IG 2
ST2 AM1
2
AM2
1D 9
1K 4
21D 7
1E 81F 1
1B 84B 74A2
22 1
M 4B 5 4B 1
2IH1 1IH12 1
5 3 66
66
6 EA1
3 IB210
3IG2
11 IB2 4C 7 4C 1 4C 8 4B 8
4
4 87 10 13 14 9 12 2 5 1 2 8
6
IG 2 3 1
1 2 1
4
5 HI M2 M1 LO64 5
15
6
1 I1 0
IG N ITION S W
F 8
10A
GAUGE
[FU S E
BLOCK]
BBB-WB-WB- W
W W R-L L-R
BR-LR-LR-L O
L-R L- B B-R B-R Y
W-RR-Y Y-GB
Y
G-W
L BR BR W-R
L-B
W-BL-Y
L-B
OW-B W-B
W-B W-B
R-B
BR
W
B-L
R-W B-L
B-L
B 4
BLOWER RESISTOR
Power Source Air Conditioning
R ight kick panel 34 B-Y
7. 5A A/C
B 3
BLOWER MOTORB-L
A 3
A/C DUAL PRESSURE SW
L- Y
F 7
FUSIBLE
LINK BLOCK
BATTERY
50A HTR 100A ALT
B 5
BLO W ER SWA13
A/C CONTROL
SW
2 1
A 2
A/C MAGNETIC CLUTCH
AND LOCK SENSOR
A14
A/C THERMISTOR
IG- E IG+ MGC TE SSR- SSR+ LED+ A/C ACT AC1
A12
A/C AMPLIFIER
To E ngine C ontrol
M odule< 2- 2 F rom Ign iter< 5- 4
B-L MG/C RELAY ON
OFF
HEATER
RELAY
40A
AM1
521
43
2 24
G-W
B- L
To FAN NO. 3
Relay< 19-4 B-L
4IG2
12 IB2
BR F rom E ngine C ontrol
Module<2-2
B-L 4B 94B4
BR
A
A
A
J 3
JUNCTION
CONNECTOR
B- L
B-L
1 2B- L
Y D 3
D EFR OSTER
MODE SW
W-B
CA
BB J10 A , J11 B
JU NC TION
CONNECTOR
AAAAAA
BBBCCC JUNCTION CONNECTOR
B J11 G R A YA J10 G R A Y
OFF

SPARK TEST
CHECK CONNECTION OF IGNITION COIL, IGNITER
AND DISTRIBUTOR CONNECTORS.
CHECK RESISTANCE OF HIGH−TENSION CORDS
TRY ANOTHER IGNITER Maximum resistance: 25 kΩ per cord (See step 2)
CHECK POWER SUPPLY TO IGNITION COIL AND
IGNITER
1. Turn ignition switch to ON.
2. Check that there is battery positive voltage at ignition coil
positive (+) terminal.
Check wiring between ECM, distributor
and igniter, and then try another ECM.
CHECK IGT SIGNAL FROM ECM
NO
BAD
OK
OK
OK
Connect securely.
Replace the cord(s).
Check wiring between ignition switch
to ignition coil and igniter.
BAD
BAD
BAD
(See page DI−100)
Cold Hot
0.36 − 0.55 Ω0.45 − 0.65 Ω CHECK RESISTANCE OF IGNITION COILOKReplace the ignition coil.
BAD Resistance: (See step 4)
Primary
Secondary
9.0 − 15.4 kΩ11.4 − 18.1 kΩ
CHECK RESISTANCE OF SIGNAL GENERATOR
Resistance: Cold HotOKReplace the distributor housing assembly.(PICKUP COIL)
(See step 5)
135 − 220 Ω175 − 255 Ω
CHECK RESISTANCE OF CRANKSHAFT POSITION
SENSOR
Resistance: Cold HotOK
Replace the crankshaft position sensor.
(See step 6)
985 − 1,600 Ω1,265 − 1,890 ΩBAD
BAD
OK
CHECK AIR GAP OF DISTRIBUTOR
Air gap: 0.2 − 0.4 mm (0.008 − 0.016 in.)Replace the distributor housing assembly.(See step 5)
BAD IG−2
− IGNITIONIGNITION SYSTEM
1996 RAV4 (RM447U)

B11568
B11569
IG−6
− IGNITIONIGNITION SYSTEM
1996 RAV4 (RM447U)
6. INSPECT CRANKSHAFT POSITION SENSOR
(a) Disconnect the crankshaft position sensor connector
from generator drive belt adjusting bar.
(b) Inspect the crankshaft position sensor resistance.
Using an ohmmeter, measure the resistance between ter-
minals.
Resistance:
Cold985 − 1,600 Ω
Hot1,265 − 1,890 Ω
If the resistance is not as specified, replace the crankshaft posi-
tion sensor.
(c) Reconnect the crankshaft position sensor connector.

IG06J−03
IG−14
− IGNITIONCRANKSHAFT POSITION SENSOR
1996 RAV4 (RM447U)
CRANKSHAFT POSITION SENSOR
COMPONENTS

IG06K−02
B11571
− IGNITIONCRANKSHAFT POSITION SENSOR
IG−15
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT CRANKSHAFT POSITION SENSOR
CONNECTOR FROM GENERATOR DRIVE BELT AD-
JUSTING BAR
2. REMOVE NO.1 TIMING BELT COVER
(See page EM−15)
3. REMOVE CRANKSHAFT POSITION SENSOR
Remove the bolt and disconnect the crankshaft position sensor.

IG06M−02
IG−16
− IGNITIONCRANKSHAFT POSITION SENSOR
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
Install the crankshaft position sensor with the bolt.
Torque: 9.5 N·m (97 kgf·cm, 84 in.·lbf)
2. INSTALL NO.1 TIMING BELT COVER (See page EM−20)
3. CONNECT CRANKSHAFT POSITION SENSOR CONNECTOR TO GENERATOR DRIVE BELT AD-
JUSTING BAR

P04349
S02326
Engine
Hanger
No.1
S01635
SST
S01599
S01581
LU−8
− LUBRICATIONOIL PUMP
1996 RAV4 (RM447U)
7. REMOVE OIL PAN BAFFLE PLATE AND OIL STRAIN-
ER
Remove the 2 bolts, 2 nuts, oil strainer, baffle plate and gasket.
8. SUSPEND ENGINE WITH ENGINE SLING DEVICE
Install a engine hanger No. 1 in the correct direction.
Part No. :
Engine hanger No. 1 12281−74060
Bolt 91611−B1020
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
9. REMOVE TIMING BELT (See page EM−15)
10. REMOVE NO.2 IDLER PULLEY AND CRANKSHAFT
TIMING PULLEY (See page EM−81)
11. REMOVE OIL PUMP PULLEY
Using SST, remove the nut and pulley.
SST 09960−10010 (09962−01000, 09963−00600)
12. REMOVE CRANKSHAFT POSITION SENSOR
(a) Disconnect the connector from the generator drive belt
adjusting bar.
(b) Remove the bolt and crankshaft position sensor.
13. REMOVE OIL PUMP
(a) Remove the 12 bolts.

LU0O5−01
Z17341
A
B AA A
A A
A
AAA
B
S01599
S01633
SST LU−14
− LUBRICATIONOIL PUMP
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL OIL PUMP
Install a new gasket and the oil pump with the 12 bolts. Uniform-
ly tighten the bolts is several passes.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
HINT:
Each bolt length is indicated in the illustration.
Bolt length:
A: 25 mm (0.98 in.)
B: 35 mm (1.38 in.)
2. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the crankshaft position sensor with the bolt.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(b) Connect the connector to the generator drive belt adjust-
ing bar.
3. INSTALL OIL PUMP PULLEY
(a) Align the cutouts of the pulley and shaft, and slide on the
pulley.
(b) Using SST, install the pulley nut.
SST 09960−10010 (09962−01000, 09963−00600)
Torque: 24 N·m (245 kgf·cm, 18 ft·lbf)
4. INSTALL CRANKSHAFT TIMING PULLEY AND NO.2
IDLER PULLEY (See page EM−20)
5. INSTALL TIMING BELT (See page EM−20)
6. REMOVE ENGINE SLING DEVICE
Remove the engine hanger No.1.

MX05N−02
Q10400
Air Intake Connector
Engine Coolant
Reservoir Tank Clutch Release Cylinder
and Line
Vehicle Speed
Sensor Connector
Back−Up Light Switch
Connector
Control Cable
Clip
Ground Cable
Transaxle Case Protector
Tie Rod End RH Drive Shaft
Stiffener PlateNo.2 Rear
End Plate
 Snap Ring
 Cotter Pin LH Drive
Shaft
PS Gear Assembly
Engine Mounting
Center Member
RH Engine
Under Cover
LH Engine Under CoverFront Suspension Crossmember
Assembly with Stabilizer BarClipAir Cleaner Case
Assembly
with Air Hose
Snap Ring
Engine
Wire
Clamp
 Cotter Pin
Lock Cap Starter
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 
4.9 (50, 43 in.·lbf)
12 (120, 9)
29 (300, 22)
35 (360, 26)32 (330, 24)46 (470, 34)
64 (650, 47)
35 (360, 26)
64 (650, 47)
12 (120, 9)
64 (650, 47)
25 (250, 18)
25 (250, 18)
9.0 (95, 78 in.·lbf)
37 (380, 27)
39 (400, 29)
9.0 (95, 78 in.·lbf)
29 (300, 22)
37 (380, 27)49 (500, 36)
113 (1,150, 83)
137 (1,400, 101)
206 (2,100, 152)
216 (2,200, 159)
113 (1,150, 83)
64 (650, 47)
48 (490, 35)
80 (820, 59)
115 (1,170, 85)
127 (1,300, 94)
62 (630, 46)
Front Exhaust Pipe
 GasketClip
Washer
MX−2
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
1996 RAV4 (RM447U)
MANUAL TRANSAXLE UNIT (2WD)
COMPONENTS

MX05O−02
Q08747
Q08748
A
B
Q08749
Q08750
A B
A
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
MX−3
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR
HOSE
2. REMOVE ENGINE COOLANT RESERVOIR TANK
3. REMOVE ENGINE WIRE CLAMP SET NUT
4. REMOVE STARTER
(a) Disconnect the connector and wire from the starter.
(b) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
5. DISCONNECT CLUTCH RELEASE CYLINDER AND
LINE
(a) Remove the 2 set bolts of the clutch line bracket.
Torque:
Bolt A: 12 N·m (120 kgf·cm, 9 ft·lbf)
Bolt B: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
(b) Remove the 2 bolts, release cylinder and line.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
6. DISCONNECT GROUND CABLE
Remove the set bolt of the ground cable from the transaxle.
7. DISCONNECT VEHICLE SPEED SENSOR AND
BACK−UP LIGHT SWITCH CONNECTORS
8. DISCONNECT CONTROL CABLE
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
9. REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING
BOLTS
Torque:
Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf)
Bolt B: 35 N·m (360 kgf·cm, 26 ft·lbf)