check engine TOYOTA RAV4 1996 Service Owner's Guide

DI−8
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
6. BASIC INSPECTION
When the Malfunction code is not confirmed in the DTC check, troubleshooting should be performed in the
order for all possible circuits to be considered as the causes of the problems.
In many cases, by carrying out the basic engine check shown in the following flow chart, the location causing
the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine trouble-
shooting.
1 Is battery positive voltage 11 V or more when engine is stopped?
NO Charge or replace battery.
YES
2 Is engine cranked?
NO Proceed to STARTING and continue to trouble-
shoot.
YES
3 Does engine start?
NO Go to step 7.
YES

P00495
Outside
Inside
− DIAGNOSTICSENGINE
DI−9
1996 RAV4 (RM447U)
4 Check air filter.
PREPARATION:
Remove air filter.
CHECK:
Visually check that the air cleaner element is not excessively
dirty or oily.
HINT:
If necessary, clean element with compressed air.
First blow from inside thoroughly,then blow from outside of ele-
ment.
NG Repair or replace.
OK
5 Check idle speed.
PREPARATION:
(a) Warm up engine to normal operating temperature.
(b) Switch off all accessories.
(c) Switch off air conditioning.
(d) Shift transmission into ”N” position.
(e) Connect the OBDII scan tool or TOYOTA hand−held tes-
ter to DLC3 on the vehicle.
CHECK:
Use CURRENT DATA to check the engine idle speed.
OK:
Idling speed: 650 − 750 rpm
NG Proceed to matrix chart of problem symptoms
on page DI−20.
OK

S01261S01272A04480
DLC1
TE1
SST
E1
DI−10
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
6 Check ignition timing.
PREPARATION:
(a) Warm up engine to normal operating temperature.
(b) Shift transmission into ”N” position.
(c) Keep the engine speed at idle.
(d) Using SST, connect terminals TE1 and E1 of DLC1.
SST 09843−18020
(e) Using a timing light, connect the tester to No.1 high−ten-
sion cord.
CHECK:
Check ignition timing.
OK:
Ignition timing: 10° BTDC at idle
NG Proceed to IGNITION and continue to trouble-
shoot.
OK
Proceed to matrix chart of problem symp-
toms on page DI−20.

S01830
Fuel Inlet Hose
P25066
− DIAGNOSTICSENGINE
DI−11
1996 RAV4 (RM447U)
7 Check fuel pressure.
PREPARATION:
(a) Be sure that enough fuel is in the tank.
(b) Turn ignition switch ON.
(c) Connect the TOYOTA hand−held tester to DLC3 on the
vehicle.
(d) Use ACTIVE TEST mode to operate the fuel pump.
(e) 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).
CHECK:
Check for fuel pressure in the inlet hose when it is pinched off.
HINT:
At this time, you will hear a fuel flowing noise.
NG Proceed to page SF−5 and continue to trouble-
shoot.
OK
8 Check for spark.
PREPARATION:
(a) Disconnect the high−tension cord from spark plug.
(b) Remove spark plug.
(c) Install spark plug to high−tension cord.
(d) Disconnect injector connector.
(e) Ground the spark plug.
CHECK:
Check if spark occurs while engine is being cranked.
NOTICE:
To prevent excess fuel being injected from the injectors
during this test, do not crank the engine for more than 5 −
10 seconds at a time.
NG Proceed to page IG−1 and continue to trouble-
shoot.
OK
Proceed to matrix chart of problem systems
on page DI−20.

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

DI3ZB−02
DI−20
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
PROBLEM SYMPTOMS TABLE
When the malfunction code is not confirmed the DTC check and the problem still can not be confirmed in
the basic inspection, then proceed to this step and perform troubleshooting according to the numbered order
given in the table below.
SymptomSuspect AreaSee page
Does not start (Engine does not crank1. Starter and starter relayST Section
Does not start (No combustion)
1. ECM power source circuit
2. Fuel pump control circuit
3. Engine control module (ECM)DI−11 3
DI−11 6
IN−30
Does not start (No complete combustion)1. Fuel pump control circuitDI−11 6
Difficult to start (Engine cranks normally)1. Fuel pump control circuit
2. CompressionDI−11 6
EM−3
Difficult to start (Cold engine)1. Starter signal circuit
2. Fuel pump control circuitDI−105
DI−11 6
Difficult to start (Hot engine)1. Starter signal circuit
2. Fuel pump control circuitDI−105
DI−11 6
Poor idling (High engine idle speed)1. A/C signal circuit
2. ECM power source circuitAC−64
DI−11 3
Poor idling (Low engine idle speed)1. A/C signal circuit
2. Fuel pump control circuitAC−64
DI−11 6
Poor idling (Rough idling)1. Compression
2. Fuel pump control circuitEM−3
DI−11 6
Poor idling (Hunting)1. ECM power source circuit
2. Fuel pump control circuitDI−11 3
DI−11 6
Poor Driveability (Hesitation / Poor acceleration)
1. Fuel pump control circuit
2. A/T faulty
3. A/C cut control circuitDI−11 6
DI−141
DI−122
Poor Driveability (Surging)1. Fuel pump control circuitDI−11 6
Engine stall (Soon after starting)1. Fuel pump control circuitDI−11 6
Engine stall (During A/C operation)1. A/C signal circuit
2. Engine control module (ECM)AC−64
IN−30

P25423
Manifold Absolute Pressure Sensor
3
2
1E51
2
BR LG−R Y
VC
PIM
E25 V ECM
9 E5
E5
E1
A00389
ON
E2
(−)VC
(+)
DI−22
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT:
If DTC P0105, P0110, P0115, P0120 are output simultaneously, E2 (sensor ground) may be open.
1 Connect OBDII scan tool or TOYOTA hand−held tester, and read value of man-
ifold absolute pressure.
PREPARATION:
(a) Connect the OBDII scan tool or TOYOTA hand−held tester to the DLC3.
(b) Turn ignition switch ON and OBDII scan tool or TOYOTA hand−held tester main switch ON.
CHECK:
Read value of manifold absolute pressure on the OBDII scan tool or TOYOTA hand−held tester.
OK:
Same as atmospheric pressure.
OK Check for intermittent problems
(See page DI−3).
NG
2 Check voltage between terminals VC and E2 of ECM connector.
PREPARATION:
(a) Remove side trim cover (See page SF−61).
(b) Turn ignition switch ON.
CHECK:
Measure voltage between terminals VC and E2 of ECM con-
nector.
OK:
Voltage : 4.5 − 5.5V

A00390
ON
PIM
(+)E2
(−)
− DIAGNOSTICSENGINE
DI−23
1996 RAV4 (RM447U)
NG Check and replace ECM (See page IN−30).
OK
3 Check voltage between terminals PIM and E2 of ECM connector.
PREPARATION:
(a) Remove side trim cover (See page SF−61).
(b) Turn ignition switch ON.
CHECK:
Measure voltage between terminals PIM and E2 of ECM con-
nector.
OK:
Voltage : 3.3 − 3.9 V
OK Check and replace ECM (See page IN−30).
NG
4 Check for open and short in harness and connector between manifold absolute
pressure sensor and ECM.
NG Repair or replace harness or connector.
OK
Replace manifold absolute pressure sensor.

P19745
Intake Air Temp. Sensor
Y−B
BRE5
E5E2 THAR5V
E1 93ECM
2
1
DI−26
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT:
If DTC ”P0105” (Manifold Absolute Pressure / Barometric Pressure Circuit Malfunction), ”P0110” (Intake Air
Temp. Circuit Malfunction), ”P0115” (Engine Coolant Temp. Circuit Malfunction), ”P0120” (Throttle / Pedal
Position Sensor / Switch ”A” Circuit Malfunction) are output simultaneously, E2 (sensor ground) may be
open.
1 Connect the OBDII scan tool or TOYOTA hand−held tester, and read value of
intake air temperature.
PREPARATION:
(a) Connect the OBDII scan tool or TOYOTA hand−held tester to the DLC3.
(b) Turn ignition switch ON and OBDII scan tool or TOYOTA hand−held tester main switch ON.
CHECK:
Read temperature value on the OBDII scan tool or TOYOTA hand−held tester.
OK:
Same as actual intake air temperature.
HINT:
If there is open circuit, OBDII scan tool or TOYOTA hand−held tester indicates − 40°C (− 40°F).
If there is short circuit, OBDII scan tool or TOYOTA hand−held tester indicates 140°C (284°F) or more.
NG− 40°C (− 40°F) .... Go to step 2.
140°C (284°F) .... Go to step 4.
OK
Check for intermittent problems.
(See page DI−3).

A00391
Intake Air
Temp. SensorON
2
1E5
E53
95V
E2THA
E1 ECM
A00392
Intake Air
Temp. SensorON
E5
E53
95V
E2THA
E1 ECM
THA
E2
− DIAGNOSTICSENGINE
DI−27
1996 RAV4 (RM447U)
2 Check for open in harness or ECM.
PREPARATION:
(a) Disconnect the intake air temp. sensor connector.
(b) Connect sensor wire harness terminals together.
(c) Turn ignition switch ON.
CHECK:
Read temperature value on the OBDII scan tool or TOYOTA
hand−held tester.
OK:
Temperature value: 140°C (284°F) or more
OK Confirm good connection at sensor.
If OK, replace intake air temp. sensor.
NG
3 Check for open in harness or ECM.
PREPARATION:
(a) Remove side trim cover (See page SF−61).
(b) Connect between terminals THA and E2 of ECM connec-
tor.
HINT:
Intake air temp. sensor connector is disconnected. Before
checking do a visual and contact pressure check for the ECM
connector (See page IN−30).
(c) Turn ignition switch ON.
CHECK:
Read temperature value on the OBDII scan tool or TOYOTA
hand−held tester.
OK:
Temperature value : 140°C (294°F) or more
OK Open in harness between terminals E2 or THA,
repair or replace harness.
NG
Confirm good connection at ECM.
If OK, replace ECM.