check engine light TOYOTA RAV4 1996 Service Owner's Guide

BE6443
(1)
(2)
(1)
No.Operation MethodCRUISE MAIN Indicator Light
Blinking PatternDiagnosis
1 Turn SET/COAST switch ON
2Turn RES/ACC switch ON
3Turn CANCEL switch ON
Turn stop light switch ON
Depress brake pedal
Turn PNP switch OFF
(Shift to except D position)
4Drive at about 40 km/h
(25 mph)or higher
Drive at about 40 km/h
(25 mph) or below
LightON
OFF
LightON
OFF
LightON
OFFSwitch ON
Switch OFF
LightON
OFFSwitch OFF
Switch ONSET/COAST switch circuit
is normal
RES/ACC switch circuit
is normal
CANCEL switch circuit
is normal
Stop light switch circuit
is normal
PNP switch circuit is
normal
Vehicle Speed Sensor is
normal
LightON
OFF LightON
OFF
1sec.
0.25 sec.0.25 sec.
Turn clutch switch OFF
(Depress clutch pedal)Clutch switch circuit
is normal
− DIAGNOSTICSCRUISE CONTROL SYSTEM
DI−331
1996 RAV4 (RM447U)
4. INPUT SIGNAL CHECK
HINT:
(1) For check No.1 − No.2.
Turn the ignition switch ON.
(2) For check No.3.
Turn ignition switch ON.
Shift to D position. (A/T Vehicle)
(3) For check No.4.
Jack up the vehicle.
Start the engine.
Shift to D position. (A/T Vehicle)
(a) Press the control switch to the SET/COAST or RES/ACC
position and hold it down or hold it up (1).
(b) Push the main switch ON (2).
(c) Check that the CRUISE MAIN indicator light blinks twice
or 3 times repeatedly after 3 seconds.
(d) Turn the SET/COAST or RES/ACC switch OFF.
(e) Operate each switch as listed in the table below.
(f) Read the blinking pattern of the CRUISE MAIN indicator
light.
(g) After performing the check, turn the main switch OFF.
HINT:
When 2 or more signals are input to the ECU, the lowest num-
bered code will be displayed first.

S01590
Disconnect
S01562
Engine Stopped
Air
S01561
Engine
2,500 rpmAir
P02553
− EMISSION CONTROLEXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC−9
1996 RAV4 (RM447U)
HINT:
As a large amount of exhaust gas enters, the engine will misfire
slightly.
7. REMOVE VACUUM GAUGE
Remove the vacuum gauge, and reconnect the vacuum hoses
to the proper locations.
8. INSPECT EGR VALVE
(a) Apply vacuum directly to the EGR valve with the engine
idling.
(b) Check that the engine runs rough or dies.
(c) Reconnect the vacuum hoses to the proper locations.
HINT:
As exhaust gas is increasingly recirculated, the engine will start
to misfire.
9. REMOVE SST FROM DLC1 (See page SF−1)
SST 09843−18020
10. INSPECT EGR VACUUM MODULATOR OPERATION
(a) Disconnect the vacuum hoses from ports P, Q and R of
the EGR vacuum modulator.
(b) Block ports P and R with your finger.
(c) Blow air into port Q, and check that the air passes through
to the air filter side freely.
(d) Start the engine, and maintain speed at 2,500 rpm.
(e) Repeat the above test. Check that there is a strong resis-
tance to air flow.
(f) Reconnect the vacuum hoses to the proper locations.
11. REMOVE THROTTLE BODY (See page SF−30)
12. REMOVE EGR VALVE
13. INSPECT EGR VALVE
Check for sticking and heavy carbon deposits.
If a problem is found, replace the valve.

P13988Spark Plug Side SST (A)
SST (B)
P13926
Magnetic
Finger
EM0494
P13989
SST (A)
SST (B)
− ENGINE MECHANICALVALVE CLEARANCE
EM−7
1996 RAV4 (RM447U)
Using SST (A), press down the valve lifter and place
SST (B) between the camshaft and valve lifter. Re-
move SST (A).
SST 09248−55040 (09248−05410, 09248−05420)
HINT:
Apply SST (B) at slight angle on the side marked with ”9”, at the
position shown in the illustration.
Remove the adjusting shim with a small screwdriver
and magnetic finger.
(b) Determine the replacement adjusting shim size by follow-
ing the Formula or Charts:
Using a micrometer, measure the thickness of the
removed shim.
Calculate the thickness of a new shim so that the
valve clearance comes within specified value.
T ........... Thickness of removed shim
A ........... Measured valve clearance
N ........... Thickness of new shim
Intake: N = T + (A − 0.24 mm (0.009 in.))
Exhaust: N = T + (A − 0.33 mm (0.013 in.))
Select a new shim with a thickness as close as pos-
sible to the calculated value.
HINT:
Shims are available in 17 sizes in increments of 0.05 mm
(0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
(c) Install a new adjusting shim.
Place a new adjusting shim on the valve lifter.
Using SST (A), press down the valve lifter and re-
move SST (B).
SST 09248−55040 (09248−05410, 09248−05420)
(d) Recheck the valve clearance.

EM0EJ−01
S01354
TOYOTA
Hand−held Tester
S01261
DLC1
TE1
E1SST
S01272
− ENGINE MECHANICALIGNITION TIMING
EM−11
1996 RAV4 (RM447U)
IGNITION TIMING
INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
2. CONNECT TOYOTA HAND−HELD TESTER OR OBD II
SCAN TOOL
(a) Remove the fuse cover on the instrument panel.
(b) Connect the TOYOTA hand−held tester or OBD II scan
tool to the DLC3.
(c) Please refer to the TOYOTA hand−held tester or OBD II
scan tool operator’s manual for further details.
3. CONNECT TIMING LIGHT TO ENGINE
4. INSPECT IGNITION TIMING
(a) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843−18020
(b) Using a timing light, check the ignition timing.
Ignition timing:
8 − 12° BTDC @ idle
(Transmission in neutral position)
(c) Remove the SST from the DLC1.
SST 09843−18020
5. FURTHER CHECK IGNITION TIMING
Ignition timing:
0 − 10° BTDC @ idle
(Transmission in neutral position)
HINT:
The timing mark moves in a range between 0° and 10°
6. DISCONNECT TIMING LIGHT FROM ENGINE
7. DISCONNECT TOYOTA HAND−HELD TESTER OR
OBD II SCAN TOOL

EM2534
Overall Length
EM0255
EM3300
45° Carbide
Cutter
Z00055
Width
− ENGINE MECHANICALCYLINDER HEAD
EM−47
1996 RAV4 (RM447U)
(d) Check the valve overall length.
Standard overall length:
Intake97.60 mm (3.8425 in.)
Exhaust98.45 mm (3.8760 in.)
Minimum overall length:
Intake97.1 mm (3.823 in.)
Exhaust98.0 mm (3.858 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than the minimum length.
7. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(c) Check the valve face and seat for the following:
If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
Check that the seat contact is in the middle of the
valve face with the following width:
1.0 − 1.4 mm (0.039 − 0.055 in.)

EM0ET−02
P03274
SST
Z00573
SSTIntake
Painted
BlackExhaust
Painted
Brown
P03265
SST
P03276
EM−54
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets and oil seals with new ones.
1. INSTALL VALVES
(a) Using SST, push in a new oil seal.
SST 09201−41020
HINT:
The intake valve oil seal is brown and the exhaust valve oil seal
is black.
(b) Install the valve, spring seat, valve spring and spring re-
tainer.
(c) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202−70020 (09202−00010)
(d) Using a plastic−faced hammer, lightly tap the valve stem
tip to assure proper fit.
2. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.

S01799
1086 1 3 9
4257
S01796
90°
90°Painted Mark
S01786
Z00058
(3)
(2)
(1) EM−56
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(b) Install the cylinder head bolts.
HINT:
The cylinder head bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any cylinder head bolt is broken or deformed, replace
it.
(1) Apply a light coat of engine oil on the threads and
under the heads of the cylinder head bolts.
(2) Install and uniformly tighten the 10 cylinder head
bolts and plate washers, in several passes, in the
sequence shown.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
(3) Mark the front of the cylinder head bolt head with
paint.
(4) Retighten the cylinder head bolts 90° in the se-
quence shown above.
(5) Check that the painted mark is now at a 90° angle
to front.
7. INSTALL SPARK PLUG TUBES
(a) Clean the cylinder head tube holes of any residual adhe-
sive, oil or foreign particles. Remove any oil with kerosene
or gasoline.
(b) Screw the threads of the spark plug tube coated with
adhesive into the cylinder head.
(c) Using the spark plug tube nut and a 30 mm socket
wrench, tighten the spark plug tubes.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
8. ASSEMBLE EXHAUST CAMSHAFT
(a) Mount the hexagon wrench head portion of the camshaft
in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Install the camshaft gear spring (1), camshaft sub gear (2)
and wave washer (3).
HINT:
Align the pins on the gears with the spring ends.

S01805
S01793
9 10
3 45 6
1 2
7 8
EM7797
Seal Packing
S01649
S01645
− ENGINE MECHANICALCYLINDER HEAD
EM−59
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)
(9) Remove the service bolt B.
10. CHECK AND ADJUST VALVE CLEARANCE (See page
EM−5)
11. INSTALL SEMI−CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi−circular plug grooves.
Seal packing: Part No. 08826−00080 or equivalent
(c) Install the 2 semi−circular plugs to the cylinder head.
12. INSTALL NO. 3 TIMING BELT COVER
Install the timing belt cover with the 3 bolts.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)
13. TEMPORARILY INSTALL NO. 1 IDLER PULLEY AND
TENSION SPRING (See page EM−20)
14. INSTALL CAMSHAFT TIMING PULLEY AND TIMING
BELT (See page EM−20)
15. INSTALL ENGINE WIRE
(a) Install the engine wire protector to the 2 brackets on the
front side of the intake manifold.
(b) Connect the 4 injector connectors.
HINT:
The No. 1 and No. 3 injector connectors are brown, and the No.
2 and No. 4 injector connectors are gray.

P13437
P13438
P02892
P03216
Plastigage
P13442
− ENGINE MECHANICALCYLINDER BLOCK
EM−83
1996 RAV4 (RM447U)
(c) Using a plastic−faced hammer, lightly tap the connecting
rod bolts and lift off the connecting rod cap.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap (See page EM−99).
NOTICE:
Do not turn the crankshaft.
(i) Remove the connecting rod cap (See procedure (b) and
(c) above).
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD0.024 − 0.055 mm (0.0009 − 0.0022 in.)
U/S 0.250.023 − 0.069 mm (0.0009 − 0.0027 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.

P13450
P13448
Z17147
Front Mark
(Cavity)
FrontPush
P13451
Front Mark
(Protrusion)
P13441
− ENGINE MECHANICALCYLINDER BLOCK
EM−101
1996 RAV4 (RM447U)
(b) Install the 5 main bearing caps in their proper locations.
HINT:
Each bearing cap has a number and front mark.
(c) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(d) Install and uniformly tighten the 10 bolts of the main bear-
ing caps, in several passes, in the sequence shown.
Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
(e) Check that the crankshaft turns smoothly.
(f) Check the crankshaft thrust clearance (See page
EM−81).
8. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
9. INSTALL CONNECTING ROD CAPS
(a) Place the connecting rod cap on the connecting rod.
(1) Match the numbered connecting rod cap with the
connecting rod.
(2) Install the connecting rod cap with the front mark
facing forward.
(b) Install the connecting rod cap nuts.
HINT:
The cap nuts are tightened in 2 progressive steps (steps
(b) and (d)).
If any one of the connecting rod bolts is broken or de-
formed, replace it.
(1) Apply a light coat of engine oil on the threads and
under the nuts of the connecting rod cap.
(2) Install and alternately tighten the 2 cap nuts in sev-
eral passes.