clock TOYOTA RAV4 1996 Service User Guide

S01602
Turn
S01597
S01603
Turn
S01238
P25229
Length = 735 mm (28.94 in.)
Length = 230 mm (9.06 in.) EM−24
− ENGINE MECHANICALTIMING BELT
1996 RAV4 (RM447U)
(b) Slowly turn the crankshaft pulley 2 revolutions from TDC
to TDC.
NOTICE:
Always turn the crankshaft clockwise.
(c) Check that each pulley aligns with the timing marks as
shown in the illustration.
If the timing marks do not align, remove the timing belt and rein-
stall it.
(d) Slowly turn the crankshaft pulley 1 and 7/8 revolutions,
and align its groove with the mark at 45 ° BTDC (for No.
1 cylinder) of the No.1 timing belt cover.
NOTICE:
Always turn the crankshaft clockwise.
(e) Torque the mounting bolt of the No.1 idler pulley.
Torque: 42 N·m (425 kgf·cm, 31 ft·lbf)
13. PLACE RH ENGINE MOUNTING BRACKET IN POSI-
TION
HINT:
Do not install the bolts.
14. INSTALL NO. 2 TIMING BELT COVER
(a) Check that the timing belt cover gaskets has no cracks or
peeling, etc.
If the gasket has cracks or peeling, etc., replace it using these
steps:
Using a screwdriver and gasket scraper, remove all
the old gasket material.
Thoroughly clean all components to remove all the
loose material.

P05613
P05614
TurnB
A
P05615
P05616
(1)
(2)
(3) EM−40
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
33. DISASSEMBLE EXHAUST CAMSHAFT
(a) Mount the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Insert service bolt A into the service hole of the camshaft
sub gear.
(c) Using a screwdriver, turn the sub gear clockwise, and re-
move service bolt B.
NOTICE:
Be careful not to damage the camshaft.
(d) Using snap ring pliers, remove the snap ring.
(e) Remove the wave washer (1), camshaft sub gear (2) and
camshaft gear spring (3).

P05618
Turn
ADrive Gear
Sub−Gear B
S01778
80 − 11 5°
Knock
Pin
S01790
EM3373
2 − 3 mm
(0.08 − 0.12 in.)
Seal
Packing
− ENGINE MECHANICALCYLINDER HEAD
EM−57
1996 RAV4 (RM447U)
(c) Using snap ring pliers, install the snap ring.
(d) Insert a service bolt A into the service hole of the camshaft
sub gear.
(e) Using a screwdriver, align the holes of the camshaft drive
gear and sub gear by turning camshaft sub gear clock-
wise, and install a service bolt B.
NOTICE:
Be careful not to damage the camshaft.
(f) Align the gear teeth of the drive gear and sub gear, and
tighten the service bolt B.
9. INSTALL CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being installed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
(a) Install the intake camshaft.
(1) Apply MP grease to the thrust portion of the cam-
shaft.
(2) Place the intake camshaft at 80 − 11 5° BTDC of
camshaft angle on the cylinder head.
HINT:
The above angle arrows the No. 1 and No. 3 cylinder cam lobes
of the intake camshaft to push their valve lifters evenly.
(3) Apply MP grease to a new oil seal lip.
(4) Install the oil seal as far as the deepest part of the
cylinder head.
(5) Apply seal packing to the No. 1 bearing cap as
shown.
Seal packing: Part No. 08826−00080 or equivalent

S01770
S01772
9
10 3
45
61
27
8
S01776
10 − 45°
Knock
Pin
S01773
Assembly
Timing Reference
Mark
Mark EM−58
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(6) Install the bearing caps in their proper locations.
(7) Apply a light coat of engine oil on the threads and
under the heads of the bearing cap bolts.
(8) Install and uniformly tighten the 10 bearing cap
bolts, in several passes, in the sequence shown.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
(b) Install the exhaust camshaft.
(1) Set the knock pin of the intake camshaft at 10 − 45°
BTDC of camshaft angle.
HINT:
The above angle allows the No. 2 and No. 4 cylinder cam lobes
of the exhaust camshaft to push their valve lifters evenly.
(2) Apply MP grease to the thrust portion of the cam-
shaft.
(3) Engage the exhaust camshaft gear to the intake
camshaft gear by matching the timing marks on
each gear.
(4) Roll down the exhaust camshaft onto the bearing
journals while engaging gears with each other.
NOTICE:
There are also assembly reference marks on each gear as
shown in the illustration. Do not use these marks.
(5) Turn the intake camshaft clockwise or counterclock-
wise a little until the exhaust camshaft sits in the
bearing journals evenly without rocking the cam-
shaft on the bearing journals.
NOTICE:
It is very important to replace the camshaft in the bearing
journals evenly while tightening bearing caps in the subse-
quent steps.

30
G ELECTRICAL WIRING ROUTING
Position of Parts in Instrument Panel
A 12 A/C Amplifier C 6 Cigarette Lighter Illumination
A 13 A/C Control SW C 7 Clock
A 14 A/C Thermistor C 8 Clutch Start SW
A 15 ABS Deceleration Sensor C 9 Combination Meter
A 16 ABS ECU C 10 Combination Meter
A 17 ABS ECU C 11 Combination Meter
A 18 Airbag Sensor Assembly C 12 Combination SW
A 19 Airbag Squib (Front Passenger Airbag Assembly) C 13 Combination SW
A 20 Airbag Squib (Steering Wheel Pad) C 14 Combination SW
C 15 Cruise Control Clutch SW
B 3 Blower Motor C 16 Cruise Control ECU
B 4 Blower Resisitor
B 5 Blower SW D 2 Data Link Connector 3
B 6 Buckle SW LH D 3 Defroster Mode SW
D 4 Diode (Engine Idle-Up)
C 4 Center Diff. Lock Control SW D 5 Door Lock Control Relay
C 5 Cigarette Lighter

85
B 6
BH ID
W-B
W-B W-B
W-B
W-BSW
ROL SW
LLED TRANSM ISSIO NG
G
G
G
(
M/T)
G
(
A/T)
GG
G
G
G
(
M/T)
(
A/T)
W-B
W-B
W-B
W-B GG
G
W-B
5 1
2 3
6 2
323
1 4
TAILLIGHT LH
[REA R C O M B. L IG H T L H] R 8
W-B
W-BG
CLOCK C 7
REAR WINDOW DEFOGGER R 5
HAZARD SW H 4
CENTER DIFF. LOCK CONT C 4
ELECTRONICALLY CONTRO
PATTERN SELECT SW E 3 JUNCTION
CONNECTER J10
B
W-B
2
1 2
REAR SIDE MARKER LIGHT LH R10
G
1H 71I 9
B

11 0
CIGARETTE LIGHTER AND CLOCK
2 FRO M POW ER SOURCE SYSTEM (
SEE PAGE 54)
W-B W-B
W-B L-YGR
CIG
LIGH15A
CIG & RAD
[FUSE BLOCK]15A
DOME
C 5
CK 1
G
FROM " TAIL" FUSE
719 618
G
L-YGR
IGF 8
ID B A
A ACD
B CD
UNCTION
CO NNECTOR10
JUN CTIO N
CONNECTO RB J10 , J11
AR
W-B W-B
L-Y
1J 5
1I 22 1E 4
1H 21H 3
GRR
1I 9
1H 7
B
J J
CLO C 7
32 41
JUNCTION
CO NNECTO J 3ARETTE
TER2

111
C 5 CIGARETTE LIGHTER
2-GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ACC OR ON POSITION
1-GROUND ; ALWAYS CONTINUITY
C 7 CLOCK
1-GROUND : ALWAYS APPROX. 12 VOLTS (POWER FOR CLOCK)
4-GROUND : APPROX. 12 VOLTS WITH THE IGNITION SW AT ACC OR ON POSITION (POWER FOR INDICATION)
2-GROUND : ALWAYS CONTINUITY
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
C 530F 831J10A31
C 730J 331J11B31
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
1E20FUSE BLOCK ASSY WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1H
1I20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1J
()
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
ID36LEFT KICK PANEL
IG36RIGHT KICK PANEL
1
2
CCCDDD
AAAAAA
BBB
AAAAAAC 5 C 7 J 3
BLACK A GRAYJ10
BGRAY J1 1
(
HINT : SEE PAGE 7)(
HINT : SEE PAGE 7) (
HINT : SEE PAGE 7) 123 4F 8
(
SEE PAGE 26)
SERVICE HINTS

11 5
SRS
NOTICE: When inspecting or repairing the SRS, perform the operation in accordance with the following
precautionary instructions and the procedure and precautions in the Repair Manual for the applicable model
year.

Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble
codes become the most important source of information when troubleshooting.
When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before
disconnecting the battery.

Work must be started after 90 seconds from the time the ignition SW is turned to the LOCKº position and the
negative (-) terminal cable is disconnected from the battery.
(The supplemental restraint system is equipped with a back-up power source so that if work is started within
90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be activated.)
When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio
systems will be canceled. So before starting work, make a record of the contents memorized by each memory
system. When work is finished, reset the clock and audio system as before and adjust the clock.
To avoid erasing the memory of each memory system, never use a back-up power supply from outside the
vehicle.

When removing the steering wheel pad or handling a new steering wheel pad, keep the pad upper surface
facing upward. Also, lock the lock lever of the twin lock type connector at the rear of the pad and take care
not to damage the connector.
(Storing the pad with its metallic surface up may lead to a serious accident if the SRS inflates for some reason.)

Always store a removed or new front passenger airbag assembly with the airbag door facing up. Storing the
airbag assembly with the airbag door facing down could cause a serious accident if the airbag inflates.

Store the steering wheel pad where the ambient temperature remains below 935C (2005F), without high
humidity and away from electrical noise.

Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor
assembly.

Before repairing the body, remove the airbag sensor if during repair shocks are likely to be applied to the
sensors due to vibration of the body or direct tapping with tools or other parts.

Do not reuse a steering wheel pad or front airbag sensors.
After evaluating whether the center airbag sensor assembly is damaged or not, decide whether or not to reuse
it. (See the Repair Manual for the method for evaluating the center airbag sensor assembly.)

When troubleshooting the supplemental restraint system, use a high-impedance (Min. 10kW/V) tester.

The wire harness of the supplemental restraint system is integrated with the instrument panel wire harness
assembly.
The vehicle wiring harness exclusively for the airbag system is distinguished by corrugated yellow tubing, as
are the connectors.

Do not measure the resistance of the airbag squibs.
(It is possible this will deploy the airbag and is very dangerous.)

If the wire harness used in the supplemental restraint system is damaged, replace the whole wire harness
assembly.

INFORMATION LABELS (NOTICES) are attached to the periphery of the SRS components. Follow the
instructions on the notices.

165
PERSONAL LIGHT
W IPER AND W ASHER SW
[COMB. SW ]
REAR WINDOW
DEFOGGER SW
COMBINATION M ETER
CRUISE CONTROL ECU
DOOR LO CK CONTROL
SW (
FRONT
PASSENGER' S SIDE)
DOOR KEY LOCK AND
UNLOCK SW (
FR ON T
PASSENGER' S SIDE)
BLOW ER SWTU RN SIG NA L FLA SHER
DATA LINK
CONNECTOR 3
CIGARETTE LIGHTER
O /D M AIN SW
REM OTE CONTROL
MIRROR SW
BUCKLE SW LH
CLOCK
CRUISE CONTROL SW
[COMB. SW ]
UNLOCK W ARNING SW
LIGHT CONTROL SW
[COMB. SW ]
FUEL SENDER (
MAIN)
RADIO AND PLAYER
C O M B IN A TIO N M E TE R SHIFT LOCK ECU
KEY INTERLOCK
SOLENOID
A/C AMPLIFIER
BLOW ER RESISTOR
DOOR LO CK CONTROL
RELAY
POWER W INDOW MASTER
SW
DOOR KEY LOCK AND
UNLOCK SW
(
DRIVER' S SIDE)
RHEOSTATIE 16
A A
A A
A A
A A
A A
IGA AB A
B A
B A
B A
B A
B 8
II1 16
B C
B C
B C A B
A B
A B
ID I 2 IC 116
B 2
IF IEID 110 W-B
W-B
W-BW-B
W-B
W-B
W-B
W-B
W-BW-B
W-B
W-B
W-B
W-B
W-B
W-B
W-B
W-B
W-B
W-B
BR
BR
BR W-
W-
W-
W-
W-
W-B
W-B
W-B
W-B
W-B W -B5
(
A/T)
B J10 , J11
A
JUNCTION CONNECTOR
B J10 , J11
A
JUNCTION CONNECTOR
(
A/
W-B
W-B W-B
W W-B
BR-B
W-B W-B
(
E2)
(
E1) AIRBAG SENSOR
ASSEMBLY
B
B
B
B
B T)W-B -BW
-B
4C3
4C10
4C7
4C8
4C94C 1
4C2
W
1D5
1H16
1H 71I 9