sensor TOYOTA RAV4 1996 Service User Guide

Component to be alignedSection of repair manual
for relevant model
Front Wheels
Suspension and Axle (SA) section
Rear Wheels
Suspension and Axle (SA) section
1. Never disassemble the steering wheel pad assembly.
2. Do not subject the steering wheel pad to shocks or bring magnets close to it.
3. Do not expose the steering wheel pad to high temperatures or fire.
4. If grease, cleaner, oil or water gets on the steering wheel pad, promptly wipe it off with a dry cloth.
5. Do not drop the steering wheel pad. Never use a steering wheel pad which has been dropped.
6. Never install the steering wheel and pad in another vehicle.
7. When the steering wheel pad is removed, store it on a stable, flat place with the pad surface facing upœ
wards. Never place anything on top of the pad.
8. When work on the vehicle will produce too strong a shock, first loosen the sensor lock release bolt until
it turns freely and perform the work after sensor lock occurs.
9. Even in cases where the vehicle is in a low-impact accident where the airbag is not activated, always
check the pad surface and airbag sensor part. If dents, cracks or deformation is visible, replace the airœ
bag with a new assembly.
10. When disposing of the vehicle or steering wheel, always deploy the airbag first.
11. The deployed inflator inside the steering wheel pad is hot, so dispose of it after it has been cooled by
atmospheric air. Never apply water to cool it down.
2. BRAKE SYSTEM
The brake system is one of the most important safety components. Always follow the directions and
notes given in section BR of the repair manual for the relevant model year when handling brake system
parts.
3. DRIVE TRAIN AND CHASSIS
The drive train and chassis are components that can have great effects on the running performance
and vibration resistance of the vehicle. After installing components in the sections listed in the table
below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate
repair of the body must also be done to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions
given in the repair manual for the relevant model during alignment and section DI of this manual.
INTRODUCTIONINœ7

CO0BG−02
S01613
P15462
P15546
1
3
2
P15463
Disconnect
− COOLINGWATER PUMP
CO−5
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE TIMING BELT (See page EM−15)
4. DISCONNECT LOWER RADIATOR HOSE FROM
WATER INLET
5. REMOVE TIMING BELT TENSION SPRING AND NO.2
IDLER PULLEY
6. REMOVE GENERATOR DRIVE BELT ADJUSTING
BAR
(a) Disconnect the crankshaft position sensor connector
clamp.
(b) Remove the bolt and adjusting bar.
7. REMOVE WATER PUMP AND WATER PUMP COVER
ASSEMBLY
(a) Remove the 2 nuts holding the water pump to the water
bypass pipe.
(b) Remove the 3 bolts in the sequence shown.
(c) Disconnect the water pump cover from the water bypass
pipe, and remove the water pump and water pump cover
assembly.
(d) Remove the gasket and 2 O−ring from the water pump
and water bypass pipe.

CO0BI−03
P13480
New O−Ring
New Gasket
P15547
New O−Ring
P15464
Connect
Z16489
3
1
2 CO−8
− COOLINGWATER PUMP
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL WATER PUMP TO WATER PUMP COVER
Install a new gasket and the water pump with the 3 bolts.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
2. INSTALL WATER PUMP AND WATER PUMP COVER
ASSEMBLY
(a) Install new O−ring and gasket to water pump cover.
(b) Install a new O−ring to the water bypass pipe.
(c) Apply soapy water to the O−ring on the water bypass
pipe.
(d) Connect the water pump cover to the water bypass pipe.
Do not install the nuts yet.
(e) Install the water pump with the 3 bolts. Tighten the bolts
in the sequence shown.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(f) Install the 2 nuts holding the water pump cover to the wa-
ter bypass pipe.
Torque: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
3. INSTALL GENERATOR DRIVE BELT ADJUSTING BAR
(a) Install the adjusting bar with the bolt.
Torque: 27 N·m (275 kgf·cm, 20 ft·lbf)
(b) Connect the crankshaft position sensor connector clamp.
4. INSTALL NO.2 IDLER PULLEY AND TIMING BELT
TENSION SPRING
5. CONNECT LOWER RADIATOR HOSE
6. INSTALL TIMING BELT (See page EM−20)
7. FILL WITH ENGINE COOLANT
8. START ENGINE AND CHECK FOR COOLANT LEAKS
9. INSTALL RH ENGINE UNDER COVER

DI−12
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
7. ENGINE OPERATING CONDITION
NOTICE:
The value given below for ”Normal Condition” are representative values, so a vehicle may still be
normal even it its value varies from those listed here. So do not decide whether a part is faulty or not
solely according to the ”Normal Condition” here.
(a) CARB Mandated Signals
TOYOTA hand−held tester displayMeasurement ItemNormal Condition *
FUEL SYS #1
Fuel System Bank 1
OPEN: Air−fuel ratio feedback stopped
CLOSED: Air−fuel ratio feedback operating
Idling after warning up: CLOSED
CALC LOAD
Calculator Load:
Current intake air volume as a proportion of max.
intake air volumeIdling: 20.7 − 48.4 %
Racing without load (2,500 rpm) : 17.7 − 45.3 %
COOLANT TEMPEngine Coolant Temperature Sensor ValueAfter warning up: 80 − 95°C (176 − 203°F)
SHORT FT #1Short−term Fuel Trim Bank 10 ± 20 %
LONG FT #1Long−term Fuel Trim Bank 10 ± 20 %
ENGINE SPDEngine SpeedIdling: 700 ± 50 rpm
VEHICLE SPDVehicle SpeedVehicle Stopped: 0 km/h (0 mph)
IGN ADVANCEIgnition Advance
Ignition Timing of Cylinder No.1Idling: BTDC 0 − 10°
INTAKE AIRIntake Air Temperature Sensor ValueEquivalent to Ambient Temp.
MAPAbsolute Pressure Inside Intake ManifoldIdling: 21 − 49 kPa
Racing without load (2,500 rpm): 17 − 46 kPa
THROTTLE POS
Voltage Output of Throttle Position Sensor
Calculated as a Percentage
0V → 0 %, 5V → 100 %Throttle Fully Closed: 6 − 16 %
Throttle Fully Open: 64 − 98 %
O2S B1, S1Voltage Output of Oxygen Sensor
Bnak 1,Sensor 1Idling : 0.1 − 0.9 V
O2FT B1, S1Oxygen Sensor Fuel Trim Bank 1, Sensor 1
(Same as SHORT FT #1)0 ± 20 %
O2S B1, S2Voltage Output of Oxygen Sensor
Bank 1, Sensor 2Driving 50 km/h (31 mph): 0.1 − 0.9 V
*: If no conditions are specifically stated for ”Idling”, it means the shift lever is at N or P position, the A/C switch
is OFF and all accessory switches are OFF.

− DIAGNOSTICSENGINE
DI−13
1996 RAV4 (RM447U)
(b) TOYOTA Enhanced Signals
TOYOTA hand−held tester displayMeasurement ItemNormal Condition *
MISFIRE RPMEngine RPM for first misfire rangeMisfire 0: 0 RPM
MISFIRE LOADEngine load for first misfire rangeMisfire 0: 9 g/r
INJECTORFuel injection time for cylinder No.1Idling: 1.9 − 3.3 ms
IAC DUTY RATIOIntake Air Control Valve Duty Ratio Opening
ratio rotary solenoid type IAC valveIdling: 25 − 60 %
STARTER SIGStarter SignalCranking: ON
A/C SIGA/C Switch SignalA/C ON: ON
PNP SWPark / Neutral Position Switch SignalP or N position: ON
ELCTRCL LOAD SIGElectrical Load SignalDefogger S/W ON: ON
STOP LIGHT SWStop Light Switch SignalStop light switch ON: ON
FC IDLFuel Cut Idle: Fuel cut when throttle valve fully
closed, during decelerationFuel cut operating: ON
FC TAUFuel Cut TAU: Fuel cut during very light loadFuel cut operating: ON
CYL#1
CYL#2
CYL#3
CYL#4
Abnormal revolution variation for each cylinder0 %
IGNITIONTotal number of ignitions for every 1,000
revolutions0 − 2,000
EGR SYSTEMEGR system operating conditionIdling: OFF
FUEL PUMPFuel Pump SignalIdling: ON
EVAP (PURGE) VSVEVAP VSV SignalVSV operating: ON
VAPOR PRESS VSVVapor Pressure VSV SignalVSV operating: ON
A/C CUT SIGA/C Cut SignalA/C S/W OFF: ON
TOTAL FT B1Total Fuel Trim Bank 1: Average value for fuel
trim system of bank 1Idling: 0.8 − 1.2
O2 LR B1, S1
Oxygen Sensor Lean Rich Bank 1, Sensor 1
Response time for oxygen sensor output to
switch from lean to rich.
Idling after warned up: 0 − 1,000 msec.
O2 RL B1, S1
Oxygen Sensor Rich Lean Bank 1, Sensor 1
Response time for oxygen sensor output to
switch from rich to lean.
Idling after warned up: 0 − 1,000 msec.
*: If conditions are specifically stated for ”Idling” , it means the shift lever is at N or P Position, the A/C switch
is OFF and all accessory switches are OFF.

DI3Z8−02
DI−14
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
DIAGNOSTIC TROUBLE CODE CHART
HINT:
Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument
or other factors.
If a malfunction code is displayed during the DTC check in check mode, check the circuit for that code listed
in the table below, for details of each code, turn to the page referred to under the ”See page” for the respec-
tive ”DTC No.” in the DTC chart.
SAE DEFINED
DTC No.
(See Page)Detection ItemTrouble AreaMILMemory
P0105
(DI−21)
Manifold Absolute
Pressure / Barometric
Pressure Circuit
MalfunctionOpen or short in Manifold absolute pressure sensor circuit
Manifold absolute pressure sensor
ECM
 *1
P0106
(DI−24)
Manifold Absolute
Pressure / Barometric
Pressure Circuit
Ranger / Performance
Problem
Manifold absolute pressure sensor *1
P0110
(DI−25)Intake Air Temp. Circuit
MalfunctionOpen or short in take air temp. sensor circuit
Intake air temp. sensor
ECM
 *1
P0115
(DI−29)Engine Coolant Temp. Circuit
MalfunctionOpen or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM
 *1
P0116
(DI−33)Engine Coolant Temp. Circuit
Range / Performance ProblemEngine coolant temp. sensor
Cooling system *1
P0120
(DI−34)Throttle / Pedal Position
Sensor / Switch ”A” Circuit
MalfunctionOpen or short in throttle position sensor circuit
Throttle position sensor
ECM
 *1
P0121
(DI−38)Throttle / Pedal Position
Sensor / Switch ”A” Circuit
Range / Performance Problem
Throttle position sensor *1
P0125
(DI−39)Insufficient Coolant Temp. for
Closed Loop Fuel ControlOpen or short in oxygen sensor circuit
Oxygen sensor *1
P0130
(DI−42)Oxygen Sensor Circuit Malfunc-
tion
(Bank 1 Sensor 1)Oxygen sensor
Fuel trim malfunction *1
P0133
(DI−45)Oxygen Sensor Circuit Slow
Response
(Bank 1 Sensor 1)
Oxygen sensor *1
P0136
(DI−46)Oxygen Sensor Circuit
Malfunction
(Bank 1 Sensor 2)
Oxygen sensor *1
P0171
(DI−48)System too Lean
(Fuel Trim)
Air Intake (hose loose)
Fuel line pressure
Injector blockage
Oxygen sensor malfunction
Manifold absolute pressure sensor
Engine coolant temp. sensor
 *1
*1: MIL lights up

− DIAGNOSTICSENGINE
DI−15
1996 RAV4 (RM447U) DTC No.
(See Page)
Detection ItemTrouble AreaMILMemory
P0172
(DI−48)System too Rich
(Fuel Trim)
Fuel line pressure
Injector blockage, leak
Oxygen sensor malfunction
Manifold absolute pressure sensor
Engine coolant temp. sensor
 *1
P0300
(DI−51)Random / Multiple
Cylinder Misfire DetectedIgnition system
Injector
Fuel line pressure
EGR
Compression pressure
Valve clearance not to specification
Valve timing
Manifold absolute pressure sensor
Engine coolant temp. sensor
 *2P0301
P0302
P0303
P0304
(DI−51)Misfire Detected
− Cylinder 1
− Cylinder 2
− Cylinder 3
− Cylinder 4
P0325
(DI−56)Knock Sensor 1 Circuit
MalfunctionOpen or short in knock sensor 1 circuit
Knock sensor 1 (looseness)
ECM
 *1
P0335
(DI−59)Crankshaft Position Sensor
”A” Circuit Malfunction
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Starter
ECM
 *1
P0336
(DI−62)Camshaft Position Sensor
Circuit Range / PerformanceDistributor
ECM malfunction (for back up) *1
P0340
(DI−63)Camshaft Position Sensor
Circuit Malfunction
Open or short in camshaft position sensor circuit
Camshaft position sensor
Starter
ECM
 *1
P0401
(DI−65)Exhaust Gas Recirculation
Flow Insufficient Detected
EGR valve stuck close
Open or short in VSV circuit for EGR
Vacuum or EGR hose disconnected
Manifold absolute pressure sensor
EGR VSV open or close malfunction
ECM
 *1
P0402
(DI−71)Exhaust Gas Recirculation
Flow Excessive Detected
EGR valve stuck open
Vacuum or EGR hose is connected to wrong post
Manifold absolute pressure sensor
ECM
 *1
P0420
(DI−73)Catalyst System Efficiency
Below ThresholdThree−way catalytic converter
Open or short in oxygen sensor circuit
Oxygen sensor
 *1
P0440
(DI−76)Evaporative Emission Control
System Malfunction
Vapor pressure sensor
Fuel tank cap incorrectly installed
Fuel tank cap cracked or damaged
Vacuum hose cracked, holed, blocked, damaged or
disconnected
Hose or tube cracked, holed, damaged or loose
Fuel tank cracked, holed, or damaged
Charcoal canister cracked, holed or damaged
 *1
*1: MIL lights up
*
2: MIL lights up or blinking

DI−16
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U) DTC No.
(See Page)
Detection ItemTrouble AreaMILMemory
P0441
(DI−82)Evaporative Emission Control
System Incorrect Purge Flow
Open or short in VSV circuit for vapor pressure sensor
VSV for vapor pressure sensor
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
Open or short in VSV circuit for EVAP
VSV for EVAP
Vacuum hose cracked, holed, blocked, damaged or
disconnected
Charcoal canister cracked, holed or damaged
 *1
P0446
(DI−82)Evaporative Emission Control
System Vent Control
Malfunction
P0450
(DI−92)Evaporative Emission Control
System Pressure Sensor
MalfunctionOpen or short in vapor pressure sensor circuit
Vapor pressure sensor
ECM
 *1
P0500
(DI−94)Vehicle Speed Sensor
Malfunction
Open or short in vehicle speed sensor circuit
Vehicle speed sensor
Combination meter
ECM
 *1
P0505
(DI−97)Idle Control System Malfunction
IAC valve is stuck or closed
Open or short in IAC valve circuit
Open or short AC1 single circuit
Air intake (hose loose)
 *1
*1: MIL lights up
MANUFACTURER DEFINED
DTC No.
(See Page)Detection ItemTrouble AreaMILMemory
P1300
(DI−100)Ignition Circuit Malfunction
Open or short in IGF or IGT circuit from igniter to ECM
Igniter
ECM
 *1
P1500
(DI−105)Starter Signal Circuit Malfunction
Open or short in starter signal circuit
Open or short in ignition switch or starter relay circuit
ECM
 *1
P1600
(DI−108)ECM BATT MalfunctionOpen in back up power source circuit
ECM *1
P1780
(DI−11 0)Park / Neutral Position Switch
MalfunctionShort in park / neutral position switch circuit
Park / neutral position switch
ECM
 *1
*1: MIL lights up

− DIAGNOSTICSENGINE
DI−19
1996 RAV4 (RM447U) FC (E6−14) − E1 (E4−14)
G−R ↔ BRIG switch ON9 ∼ 14
EGR (E4−23) − E1 (E4−14)B−W ↔ BRIG switch ON0 ∼ 3
ISCC (E4−9) − E1 (E4−14)B−Y ↔ BRIG switch ON
Disconnect E4 of ECM connector9 ∼ 14
ISCO (E4−10) − E1 (E4−14)B−L ↔ BRIG switch ON
Disconnect E4 of ECM connector9 ∼ 14
OX1 (E5−6) − E1 (E4−14)B ↔ BRMaintain engine speed at 2,500 rpm for 2 mins. after
warning up.Pulse generation
OX2 (E5−5) − E1 (E4−14)B ↔ BRMaintain engine speed at 2,500 rpm for 2 mins. after
warning up.Pulse generation
KNK (E5−10) − E1 (E4−14)B ↔ BRIdlingPulse generation
(See page DI−56)
* NSW (E6−22) − E1 (E4−14)B−W ↔ BR
IG switch ON
Other shift position in ”P” , ”N” position9 ∼ 14
IG switch ON
Shift position in ”P” , ”N” position0 ∼ 3.0
SPD (E6−9) − E1 (E4−14)V−W ↔ BRIG switch ON
Rotate driver wheel slowly.Pulse generation
(See page DI−94)
TE1 (E5−15) − E1 (E4−14)L−W ↔ BRIG switch ON9 ∼ 14
W (E6−5) − E1 (E4−14)G−R ↔ BRIdling9 ∼ 14
IG switch ONBelow 3.0
AC (E6−10) − E1 (E4−14)Y−G ↔ BRIdling, A/C switch ONBelow 2.0
Idling, A/C switch OFF9 ∼ 14
ACT (E6−21) − E1 (E4−14)R−Y ↔ BRIdling, A/C switch ON9 ∼ 14
Idling, A/C switch OFFBelow 2.0
* OD2 (E6−7) − E1 (E4−14)LG ↔ BRIG switch ON, O/D main switch pushed out9 ∼ 14
IG switch ON, O/D main switch pushed in0 ∼ 3
* OD1 (E6−20) − E1 (E4−14)Y−B ↔ BRIG switch ON, Cruise control ECU no request O/D cut9 ∼ 14
IG switch ON, Cruise control ECU request O/D cut0 ∼ 3
EVP (E4−22) − E1 (E4−14)P ↔ BRIG switch ON9 ∼ 14
TPC (E5−8) − E1 (E4−14)R−W ↔ BRIG switch ON9 ∼ 14
PTNK (E5−7) − E2 (E5−9)L−Y ↔ BR
IG switch ON, Disconnect vacuum hose from vapor
pressure sensor2.9 ∼ 3.7
Apply vacuum
(4.0 kPa, 30 mmHg, 1.18 in. Hg)
(less than 66.7 kPa, 500 mmHg, 19.7 in. Hg)
Below 0.5
ELS (E6−17) − E1 (E4−14)B ↔ BRDefogger switch and taillight switch ON7.5 ∼ 14
Defogger switch and taillight switch OFF0 ∼ 1.5
SDL (E6−16) − E1 (E4−14)W ↔ BRDuring transmissionPules generation
*: A/T only

DI3ZC−01
P01242
(V)
(3.96)
3.6
2.4
1.2
150 450 750 (840)mmHg
20
60
100(112)
Manifold Absolute PressurekPa
Output Voltage
− DIAGNOSTICSENGINE
DI−21
1996 RAV4 (RM447U)
CIRCUIT INSPECTION
DTC P0105 Manifold Absolute Pressure / Barometric
Pressure Circuit Malfunction
CIRCUIT DESCRIPTION
By a built−in sensor unit, the manifold absolute pressure sensor
detects the intake manifold pressure as a voltage. The ECM
then determines the basic injection duration and basic injection
advance angle based on this voltage. Since the manifold abso-
lute pressure sensor does not use the atmospheric pressure as
a criterion, but senses the absolute pressure inside the intake
manifold (the pressure in proportion to the present absolute
vacuum 0) , it is not influenced by fluctuations in the atmospher-
ic pressure due to high altitude and other factors. This permits
it to control the air−fuel ratio at the proper lever under all condi-
tions.
DTC No.DTC Detecting ConditionTrouble Area
P0105Open or short manifold absolute pressure sensor circuit
Open or short in manifold absolute pressure sensor circuit
Manifold absolute pressure sensor
ECM
If the ECM detects DTC ”P0105” it operates the fail safe function, keeping the ignition timing and injection
volume constant and making it possible to drive the vehicle.
HINT:
After confirming DTC P0105 use the OBDII scan tool or TOYOTA hand−held tester to confirm the manifold
absolute pressure from ”CURRENT DATA”.
Manifold Absolute PressureMalfunction
0 kpaPIM circuit short
130 kpa or more
VC circuit open or short
PIM circuit open
E2 circuit open