İdle TOYOTA RAV4 1996 Service Repair Manual

BR1811
R00326
R00324
R00325
BR1813
BR−36
− BRAKEABS ACTUATOR
1996 RAV4 (RM447U)
(c) Place the ”SHEET A” (SST) on the actuator checker.
SST 09990−00163
4. INSPECT BRAKE ACTUATOR OPERATION OF
FRONT RH WHEEL
(a) Start the engine, and run it at idle.
(b) Turn the selector switch of the actuator checker to
”FRONT RH” position.
(c) Push and hold in the MOTOR switch for a few seconds.
Make sure that you can hear the motor running.
(d) Depress the brake pedal and hold it for about 15 seconds,
and check that the brake pedal does not go down.
(e) With your foot still applying onto the brake pedal, push
MOTOR switch and check that the pedal does not pul-
sate.
(f) Depress the brake pedal and hold it. As you hold the ped-
al down, push and hold in the POWER SWITCH for a few
seconds. Check that the pedal does not go down.
NOTICE:
Do not keep the POWER SWITCH pushed for more than 10
seconds.
(g) With your foot still applying onto the brake pedal, release
the POWER SWITCH and check that the pedal goes
down.
(h) With your foot still applying onto the brake pedal, push the
MOTOR switch and check that the brake pedal returns.
(i) Release the brake pedal.
5. INSPECT FRONT LH WHEEL
(a) Turn the selector switch to ”REAR RH” position.
(b) Repeating (c) to (i) in the step 4, check the actuator oper-
ating similarly.
6. INSPECT REAR RH WHEEL
(a) Turn the selector switch to ”FRONT LH” position.
(b) Repeating (c) to (i) in the step 4, check the actuator opera-
tion similarly.

Q08873
Push Rod Play
Adjust Point
Pedal Height
Adjust Point
Push Rod
Play
Pedal HeightCL04G−02
CL0042
Pedal Freeplay
CL0512
25 mm (0.98 in.) or more
Release Point
Full Stroke
End Position CL−2
− CLUTCHCLUTCH PEDAL
1996 RAV4 (RM447U)
CLUTCH PEDAL
INSPECTION
1. CHECK PEDAL HEIGHT IS CORRECT
Pedal height from asphalt sheet:
157.6 − 167.6 mm (6.205 − 6.598 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and turn the stopper bolt until the height is
correct. Tighten the lock nut.
3. CHECK PEDAL FREEPLAY AND PUSH ROD PLAY
(a) Push in on the pedal until the beginning of clutch resis-
tance is felt.
Pedal freeplay: 5.0−15.0 mm (0.197−0.591 in.)
(b) Gently push on the pedal until the resistance begins to in-
crease a little.
Push rod play at pedal top:
1.0−5.0 mm (0.039−0.197 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
(d) Connect the air duct and install the lower finish panel.
5. INSPECT CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start the engine and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into the reverse position until the gears contact.
(d) Gradually depress the clutch pedal and measure the
stroke distance from the point the gear noise stops (re-
lease point) up to the full stroke end position.
Standard distance:
25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified.
Inspect pedal height.
Inspect push rod play and pedal freeplay.
Bleed the clutch line.
Inspect the clutch cover and disc.

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

DI3Z6−01
ENGINE CONTROL SYSTEM Check Sheet
Customer’s Name
Driver’s Name
Data Vehicle
Brought in
License No.
Model and Model
Year
Frame No.
Engine Model
Odometer Reading
km
miles
Problem Symptoms
Engine does
not Start
Difficult to
Start
Poor Idling
Poor
Driveaability
Engine Stall
Others
Engine does not crankNo initial combustionNo complete combustion
Engine cranks slowly
Other
Incorrect first idleIdling rpm is abnormalHigh ( rpm)Low ( rpm)
Rough idling
Other
HesitationBack fireMuffler explosion (after−fire)Surging
Knocking
Other
Soon after startingAfter accelerator pedal depressed
After accelerator pedal released
During A/C operation
Shifting from N to D
Other
Datas Problem
Occurred
Problem Frequency
Condition When
Problem Occurs
Weather
Engine Operation
Engine Temp. Place Outdoor
TemperatureConstant
Sometimes ( times per day/month)Once only
Other
Fine
CloudyRainySnowyVarious/Other
Hot
Warm CoolCold (approx. °F/ °C)
Highway
SuburbsInner CityUphillDownhill
Rough road
Other
Cold
Warming upAfter Warming upAny temp.Other
Starting
Just after starting ( min.)IdlingRacing
Driving
Constant speedAccelerationDeceleration
A/C switch ON/OFF
Other
Condition of MILRemains on Sometimes light up Does not light up
NormalMalfunction code(s) (code )
Freeze frame data ( )
NormalMalfunction code(s) (code )
Freeze frame data ( )
Normal mode
(Precheck)
Check Mode DTC InspectionInspector’s
Name
DI−2
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
CUSTOMER PROBLEM ANALYSIS CHECK

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.

− 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.

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

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