vacuum TOYOTA RAV4 1996 Service Workshop Manual

SF0RC−02
S01943
Voltmeter
E2 VC
S01925
Vacuum
ECM
PIM
E2 Voltmeter
66.7
500
19.69Applied
Vacuum
kPa
mmHg
in.Hg
Voltage
drop V0.3 − 0.5 0.7 − 0.9 1.1 − 1.3 1.5 − 1.7 1.9 − 2.1 13.3
100
3.94 26.7
200
7.87 40.0
300
11.81 53.5
400
15.75
− SFIMANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
SF−53
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT POWER SOURCE VOLTAGE OF MAP SEN-
SOR
(a) Disconnect the MAP sensor connector.
(b) Turn the ignition switch ON.
(c) Using a voltmeter measure the voltage between connec-
tor terminals VC and E2 of the wiring harness side.
Voltage: 4.5 − 5.5 V
(d) Turn the ignition switch to LOCK.
(e) Reconnect the MAP sensor connector.
2. INSPECT POWER OUTPUT OF MAP SENSOR
(a) Turn the ignition switch ON.
(b) Disconnect the vacuum hose on the air intake chamber
side.
(c) Connect a voltmeter to terminals PIM and E2 of the ECM,
and measure the output voltage under ambient atmo-
spheric pressure.
(d) Apply vacuum to the MAP sensor in 13.3 kPa (100 mmHg,
3.94 in.Hg) segments to 66.7 kPa (500 mmHg, 19.69
in.Hg).
(e) Measure the voltage drop from step (c) above for each
segment.
Voltage drop
(f) Reconnect the vacuum hose to the air intake chamber.

SF0RE−02
− SFIVAPOR PRESSURE SENSOR
SF−55
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT POWER SOURCE VOLTAGE OF VAPOR
PRESSURE SENSOR
(a) Disconnect the vapor pressure sensor connector.
(b) Turn the ignition switch ON.
(c) Using a voltmeter, measure the voltage between connec-
tor terminals VC and E2 of the wiring harness side.
Voltage: 4.5 − 5.5 V
(d) Turn the ignition switch to LOCK.
(e) Reconnect the vapor pressure sensor connector.
2. INSPECT POWER OUTPUT OF VAPOR PRESSURE
SENSOR
(a) Turn the ignition switch ON.
(b) Disconnect the EVAP hose from the vapor pressure sen-
sor.
(c) Connect a voltmeter to terminals PTNK and E2 of the
ECM, and measure the output voltage under the following
conditions:
(1) Apply vacuum (2.0 kPa, 15 mmHg, 0.59 in.Hg) to
the vapor pressure sensor.
Voltage: 1.3 − 2.1 V
(2) Release the vacuum from the vapor pressure sen-
sor.
Voltage: 3.0 − 3.6 V
(3) Apply pressure (1.5 kPa, 15 gf/cm
2, 0.22 psi) to the
vapor pressure sensor.
Voltage: 4.2 − 4.8 V
(d) Reconnect the EVAP hose to the vapor pressure sensor.

R10958
SR0FE−01
SR−8
− STEERINGAIR CONTROL VALVE
1996 RAV4 (RM447U)
AIR CONTROL VALVE
INSPECTION
INSPECT AIR CONTROL VALVE
(a) Turn the air conditioner switch OFF.
(b) Start the engine and run it at idle.
(c) Full turn the steering wheel.
(d) Check that the engine rpm decreases when the vacuum
hose of the air control valve is pinched.
(e) Check that the engine rpm increases when the hose is re-
leased.

SR0FV−02
Z19806
Union Bolt
PS Gear Assembly
Tube ClampPressure Feed Tube
Return Hose
Vacuum Hose
13 (130, 9)
44 (450, 32)
*36 (365, 26)
52 (525, 38)
29 (300, 22)
3 Door vehicle 64 (650, 47)
5 Door vehicle 113 (1,150, 83)
43 (440, 32)
113 (1, 150, 83)
x7
x6
13 (130, 9)
 Gasket
N·m (kgf·cm, ft·lbf)Bracket
BushingDrive Belt
PS Vane Pump Assembly
with Pump Bracket
62 (630, 46)
29 (300, 22)
BushingBracket
 Gasket
Clamp
(A/T)
Front Exhaust Pipe
 Gasket Stabilizer Bar
with Link
Front Suspension
Crossmember Assembly
137 (1, 400, 101)
206 (2, 100, 152)
127 (1, 300, 94)
Engine Under
Cover
127 (1, 300, 94)
137 (1, 400, 101)
112 (1, 140, 82)
8.3 (84, 73 in.·lbf)
48 (490, 35)

206 (2, 100, 152)
: Specified torque
* For use with SST  Non−reusable part
W02019
3 Door vehicle 64 (650, 47)
5 Door vehicle 113 (1,150, 83)
− STEERINGPOWER STEERING VANE PUMP
SR−31
1996 RAV4 (RM447U)
POWER STEERING VANE PUMP
COMPONENTS

SR0FW−02
R10965
Z13365
Pressure
Feed Tube
SST
R10984
R10966
− STEERINGPOWER STEERING VANE PUMP
SR−33
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE RH AND LH ENGINE UNDER COVERS
Remove the 13 bolts.
2. REMOVE FRONT EXHAUST PIPE
Remove the 2 bolts, 3 nuts and 2 gaskets.
3. REMOVE STABILIZER BAR WITH LINK
(See page SA−48)
4. DISCONNECT RH AND LH LOWER SUSPENSION
ARMS (See page SA−40)
5. REMOVE 2 PS GEAR ASSEMBLY SET BOLTS AND
NUTS
6. REMOVE FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY (See page SA−40)
7. DISCONNECT 2 TUBE CLAMPS
Remove the bolt.
8. DISCONNECT 2 VACUUM HOSES
9. DISCONNECT RETURN HOSE
NOTICE:
Take care not to spill fluid on the drive belt.
10. REMOVE DRIVE BELT
Loosen the 2 bolts.
11. DISCONNECT PRESSURE FEED TUBE
Using SST, disconnect the tube.
SST 09631−22020
12. REMOVE PS VANE PUMP ASSEMBLY WITH PUMP
BRACKET
Remove the 3 bolts.
13. REMOVE PRESSURE FEED TUBE
Remove the union bolt, gasket and tube from the PS vane
pump assembly.

SR0G0−03
W01943
Stopper
Pressure Feed
Tube
R10966
W01119
SST
Fulcrum Length
R10981
SR−42
− STEERINGPOWER STEERING VANE PUMP
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL PRESSURE FEED TUBE
Torque the union bolt over a new gasket.
Torque: 52 N·m (525 kgf·cm, 38 ft·lbf)
HINT:
Make sure the tube is touching the stopper of the pressure feed
No.2 tube, as shown, then torque the union bolt.
2. INSTALL PS VANE PUMP ASSEMBLY WITH PUMP
BRACKET
Torque the 3 bolts.
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
3. CONNECT PRESSURE FEED TUBE
Using SST, connect the tube.
SST 09631−22020
Torque: 36 N·m (365 kgf·cm, 26 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.)
This torque value is effective in case that SST is parallel
to a torque wrench.
4. INSTALL DRIVE BELT
(a) Adjust drive belt tension (See page SR−3)
(b) Torque the 3 bolts.
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
5. CONNECT RETURN HOSE
6. CONNECT 2 VACUUM HOSES
7. CONNECT 2 TUBE CLAMPS
Torque the bolt.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
8. INSTALL FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY (See page SA−42)
9. TORQUE 2 PS GEAR ASSEMBLY SET BOLTS AND
NUTS
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
10. CONNECT RH AND LH LOWER SUSPENSION ARMS
(See page SA−42)
11. INSTALL STABILIZER BAR WITH LINK
(See page SA−42)

W01258
SST
W01259
SST
Bearing
W04191
SST
Oil SealPress SR−56
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
5. INSTALL CYLINDER END STOPPER
(a) Install the stopper into the rack housing.
(b) Using snap ring pliers, install a new snap ring to the rack
housing.
6. AIR TIGHTNESS TEST
(a) Install SST to the union of the rack housing.
SST 09631−22030
(b) Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for
about 30 seconds.
(c) Check that there is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil
seals.
7. INSTALL CONTROL VALVE ASSEMBLY
(a) Coat the teflon rings with power steering fluid.
(b) Install the control valve assembly into the rack housing.
NOTICE:
Be careful not to damage the teflon rings and oil seal.
8. INSTALL BEARING
Using SST, press in a new bearing.
SST 09612−22011
9. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST and a press, press in the oil seal.
SST 09612−22011
NOTICE:
Make sure to install the oil seal facing the correct direction.
(c) Using snap ring pliers, install a new snap ring to the rack
housing.
10. INSTALL DUST COVER
11. INSTALL BEARING
Install the spacer and a new bearing into the rack housing.