TOYOTA RAV4 1996 Service Repair Manual
Manufacturer: TOYOTA, Model Year: 1996,
Model line: RAV4,
Model: TOYOTA RAV4 1996
Pages: 1354, PDF Size: 30.43 MB
TOYOTA RAV4 1996 Service Repair Manual
RAV4 1996
TOYOTA
TOYOTA
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TOYOTA RAV4 1996 Service Repair Manual
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Page 661 of 1354

EC05K−03
S01587
Cap
Filter
S01588
Vacuum
Gauge
S01261
DLC1
TE1
E1SST
S01589
High Vacuum
at 2,500 rpm
Port R
Disconnect HOT EC−8
− EMISSION CONTROLEXHAUST GAS RECIRCULATION (EGR) SYSTEM
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT AND CLEAN FILTER IN EGR VACUUM MOD-
ULATOR
(a) Remove the cap and filter.
(b) Check the filter for contamination or damage.
(c) Using compressed air, clean the filter.
(d) Reinstall the filter and cap.
HINT:
Install the filter with the coarser surface facing the atmospheric
side (outward).
2. INSTALL VACUUM GAUGE
Using a 3−way connector, connect a vacuum gauge to the hose
between the EGR valve and VSV.
3. INSPECT SEATING OF EGR VALVE
Start the engine and check that the engine starts and runs at
idle.
4. CONNECT TERMINALS TE1 AND E1 OF DLC1
Using SST, connect terminals TE1 and E1 of the DLC1
SST 09843−18020
5. INSPECT VSV OPERATION WITH COLD ENGINE
(a) The engine coolant temperature should be below
55°C (131°F).
(b) Check that the vacuum gauge indicates zero at 2,500
rpm.
6. INSPECT OPERATION OF VSV AND EGR VACUUM
MODULATOR WITH HOT ENGINE
(a) Warm up the engine to above 60°C (140°F).
(b) Check that the vacuum gauge indicates low vacuum at
2,500 rpm.
(c) Disconnect the vacuum hose port R of the EGR vacuum
modulator and connect port R directly to the intake man-
ifold with another hose.
(d) Check that the vacuum gauge indicates high vacuum at
2,500 rpm.
Page 662 of 1354

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.
Page 663 of 1354
S01616
EC−10
− EMISSION CONTROLEXHAUST GAS RECIRCULATION (EGR) SYSTEM
1996 RAV4 (RM447U)
14. REINSTALL EGR VALVE
(a) Install a 2 new gaskets and the EGR valve with the 2 nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(b) Install the EGR pipe with the 2 union nuts.
Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
15. REINSTALL THROTTLE BODY (See page SF−33)
Page 664 of 1354
EC0FI−02
− EMISSION CONTROLTHREE−WAY CATALYTIC CONVERTER (TWC)
SYSTEMEC−11
1996 RAV4 (RM447U)
THREE−WAY CATALYTIC CONVERTER (TWC) SYSTEM
COMPONENTS
Page 665 of 1354
EC−12− EMISSION CONTROLTHREE−WAY CATALYTIC CONVERTER (TWC)
SYSTEM
1996 RAV4 (RM447U)
Page 666 of 1354
EC05M−02
− EMISSION CONTROLTHREE−WAY CATALYTIC CONVERTER (TWC)
SYSTEMEC−13
1996 RAV4 (RM447U)
INSPECTION
1. CHECK CONNECTIONS FOR LOOSENESS OR DAMAGE
2. CHECK CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE
3. CHECK FOR DENTS OR DAMAGE
If any part of the protector is damaged or dented to the extent that it contacts the TWC, repair or replace
it.
4. CHECK HEAT INSULATOR FOR DAMAGE
5. CHECK FOR ADEQUATE CLEARANCE BETWEEN CATALYTIC CONVERTER AND HEAT INSU-
LATOR
Page 667 of 1354

EM0EG−02
S01353
CO/HC Meter
− ENGINE MECHANICALCO/HC
EM−1
1996 RAV4 (RM447U)
CO/HC
INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/
HC complies with regulations.
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
HINT:
All vacuum hoses for EGR systems, etc. should be properly
connected.
(f) SFI system wiring connectors fully plugged
(g) Ignition timing check correctly
(h) Transmission in neutral position
(i) Tachometer and CO/HC meter calibrated by hand.
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SE-
CONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST
40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT
IDLE AND/OR 2,500 RPM
Complete the measuring within 3 minutes.
HINT:
When performing the 2 mode (2,500 rpm and idle) test, follow
the measurement order prescribed by the applicable local regu-
lations.
Page 668 of 1354

EM−2
− ENGINE MECHANICALCO/HC
1996 RAV4 (RM447U)
6. TROUBLESHOOTING
If the CO/HC concentration does not comply with regulations,
troubleshoot in the order given below.
(a) Check the oxygen sensor operation (See page DI−42).
(b) See the table below for possible causes, then inspect and
correct the applicable causes if necessary.
HCCOProblemsCauses
HighNormalRough idle4. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs
Open or or crossed high−tension cords
Cracked distributor cap
5. Incorrect valve clearance
6. Leaky EGR valve
7. Leaky intake and exhaust valves
8. Leaky cylinder
HighLowRough idle
(Fluctuating HC reading)1. Vacuum leaks:
PCV hose
EGR valve
Intake manifold
Throttle body
IAC valve
Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(Black smoke from exhaust)1. Restricted air filter
2. Faulty SFI system:
Faulty pressure regulator
Clogged fuel return line
Defective ECT sensor
Defective IAT sensor
Faulty ECM
Faulty injector
Faulty throttle position sensor
MAP sensor
Page 669 of 1354

EM0EH−03
S01361
Compression
Gauge
− ENGINE MECHANICALCOMPRESSION
EM−3
1996 RAV4 (RM447U)
COMPRESSION
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. DISCONNECT DISTRIBUTOR CONNECTOR
3. DISCONNECT HIGH−TENSION CORDS FROM SPARK
PLUGS AND IGNITION COIL
4. REMOVE SPARK PLUGS
5. CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine speed of
250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
1,275 kPa (13.0 kgf/cm
2, 185 psi) or more
Minimum pressure: 932 kPa (9.5 kgf/cm
2, 135 psi)
Difference between each cylinder:
98 kPa (1.0 kgf/cm
2, 14 psi) or less
(e) If the cylinder compression in one or more cylinders is low,
pour a small amount of engine oil into the cylinder through
the spark plug hole and repeat steps (a) through (c) for
cylinders with low compression.
If adding oil helps the compression, it is likely that
the piston rings and/or cylinder bore are worn or
damaged.
If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.
6. REINSTALL SPARK PLUGS
7. RECONNECT HIGH−TENSION CORDS TO SPARK
PLUGS AND IGNITION COIL
Page 670 of 1354
EM−4
− ENGINE MECHANICALCOMPRESSION
1996 RAV4 (RM447U)
8. RECONNECT DISTRIBUTOR CONNECTOR
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