1996 TOYOTA RAV4 fuel pump

BE6653S00839S01830A06622
FC
(+)
Fuel Inlet Hose
ON
DI−120
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
OBDII scan tool (exculding TOYOTA hand−held tester)
1 Check fuel pump operation.
PREPARATION:
(a) Remove side trim cover (See page SF−61).
(b) Turn ignition switch ON.
CHECK:
(a) Connect between terminal FC of ECM and body ground.
(b) Check for fuel pressure in the inlet hose when it is pinched
off.
OK:
There is pressure in the inlet hose.
HINT:
At this time, you will hear a fuel flowing noise.
OK Check for starter signal circuit (See page
DI−105).
NG
2 Check for ECM power source circuit (See page DI−11 3).
NG Repair or replace.
OK
3 Check circuit opening relay (See page SF−40).
NG Replace circuit opening relay.
OK

− DIAGNOSTICSENGINE
DI−121
1996 RAV4 (RM447U)
4 Check voltage between terminal FC of ECM and body ground (See page DI−11 6,
step 4).
NG Check for open in harness and connector be-
tween EFI main relay (Marking: EFI) and circuit
opening relay, circuit opening relay and ECM.
OK
5 Check fuel pump (See page SF−5).
NG Repair or replace fuel pump.
OK
6 Check for open in harness and connector between circuit opening relay and fuel
pump, fuel pump and body ground (See page IN−30).
NG Repair or replace harness or connector.
OK
Check and replace ECM (See page IN−30).

EM0EV−02
A04063
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable part
29 (300, 22)
Hold Down ClampHold Down Clamp
BatteryEngine Hood
Battery Tray
Lower Radiator
HosePS Pump
w/ BracketCharcoal Canister
Battery Tray
IAT Sensor ConnectorAir Cleaner Cap
 Gasket
 Gasket
Fuel Inlet Hose
Fuel Filter
Water Inlet
Upper Radiator
Hose
Heater Hose
PS Pump Drive Belt
Generator Drive
Belt
Accelerator Cable
Generator
Generator Drive Belt
Adjusting Bar
Air Filter
EVAP VSV Connector
Air Cleaner Case
Radiator
Reservoir
Relay Block No. 2
Upper Cover
Relay Block No. 2
Wire Harness
A/C Compressor
Type B Type A
Type B Type A
− ENGINE MECHANICALENGINE UNIT
EM−65
1996 RAV4 (RM447U)
ENGINE UNIT
COMPONENTS

32
G ELECTRICAL WIRING ROUTING
Position of Parts in Body
[2-Door]
A 21 ABS Speed Sensor Rear LH L 1 License Plate Light
A 22 ABS Speed Sensor Rear RH
P 3 Personal Light
B 7 Back Door Open Detection SW and Door Lock P 4 Power Window Master SW
Motor P 5 Power Window Motor (Driver's Side)
P 6 Power Window Motor (Front Passenger's Side)
D 6 Door Courtesy SW (Driver's Side) P 9 Power Window SW (Front Passenger's Side)
D 7 Door Courtesy SW (Front Passenger's Side)
D 10 Door Lock Control SW (Front Passenger's Side) R 8 Rear Combination Light LH
D 13 Door Lock Motor, Door Key Lock and Unlock SW R 9 Rear Combination Light RH
(Driver's Side) R 10Rear Side Marker Light LH
D 14 Door Lock Motor, Door Key Lock and Unlock SW R 11 Rear Side Marker Light RH
(Front Passenger's Side) R 12 Rear Speaker LH
R 13 Rear Speaker RH
F 9 Front Speaker LH R 14 Rear Window Defogger (+)
F 10 Front Speaker RH R 15 Rear Window Defogger (-)
F 11 Fuel Sender (Main) and Fuel Pump R 16 Rear Wiper Motor
F 12 Fuel Sender (Sub) R 17 Rear Wiper Relay
R 18 Remote Control Mirror LH
H 5 High Mounted Stop Light R 19 Remote Control Mirror RH
I 11 Interior Light

33
G
Position of Parts in Body
[4-Door]
A 21 ABS Speed Sensor Rear LH L 1 License Plate Light
A 22 ABS Speed Sensor Rear RH
P 3 Personal Light
B 7 Back Door Open Detection SW and Door Lock P 4 Power Window Master SW
Motor P 5 Power Window Motor (Driver's Side)
P 6 Power Window Motor (Front Passengerºs Side)
D 6 Door Courtesy SW (Driver's Side) P 7 Power Window Motor (Rear LH)
D 7 Door Courtesy SW (Front Passenger's Side) P 8 Power Window Motor (Rear RH)
D 8 Door Courtesy SW (Rear LH) P 9 Power Window SW (Front Passenger's Side)
D 9 Door Courtesy SW (Rear RH) P 10 Power Window SW (Rear LH)
D 10 Door Lock Control SW (Front Passenger's Side) P 11 Power Window SW (Rear RH)
D 11 Door Lock Motor (Rear LH)
D 12 Door Lock Motor (Rear RH) R 8 Rear Combination Light LH
D 13 Door Lock Motor, Door Key Lock and Unlock SW R 9 Rear Combination Light RH
(Driver's Side) R 10Rear Side Marker Light LH
D 14 Door Lock Motor, Door Key Lock and Unlock SW R 11 Rear Side Marker Light RH
(Front Passenger's Side) R 12 Rear Speaker LH
R 13 Rear Speaker RH
F 9 Front Speaker LH R 14 Rear Window Defogger (+)
F 10 Front Speaker RH R 15 Rear Window Defogger (-)
F 11 Fuel Sender (Main) and Fuel Pump R 16 Rear Wiper Motor
F 12 Fuel Sender (Sub) R 17 Rear Wiper Relay
R 18 Remote Control Mirror LH
H 5 High Mounted Stop Light R 19 Remote Control Mirror RH
I 11 Interior Light

FI2553
SST
S01837
Fuel
Pump
Connector
S01832
Plug SF−2
− SFISFI SYSTEM
1996 RAV4 (RM447U)
(b) When installing the battery, be especially careful not to in-
correctly connect the positive (+) and negative (−) cables.
(c) Do not permit parts to receive a severe impact during re-
moval or installation. Handle all SFI parts carefully, espe-
cially the ECM.
(d) Do not be careless during troubleshooting as there are
numerous transistor circuits and even slight terminal con-
tact can cause further troubles.
(e) Do not open the ECM cover.
(f) When inspecting during rainy weather, take care to pre-
vent entry of water. Also, when washing the engine
compartment, prevent water from getting on the SFI parts
and wiring connectors.
(g) Parts should be replaced as an assembly.
(h) Care is required when pulling out and inserting wiring con-
nectors.
(i) Release the lock and pull out the connector, pulling on the
connectors.
(j) Fully insert the connector and check that it is locked.
(k) Use SST for inspection or test of the injector or its wiring
connector.
SST 09842−30070
8. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out, so observe the following
procedures:
(1) Disconnect the fuel pump connector.
(2) Start the engine. After the engine has stopped on
its own, turn the ignition switch to LOCK.
(3) Put a container under the connection.
(4) Slowly loosen the connection.
(5) Disconnect the connection.
(6) Plug the connection with a rubber plug.

S01354
TOYOTA
Hand−Held Tester
S01830
Fuel Inlet Hose SF−4
− SFISFI SYSTEM
1996 RAV4 (RM447U)
(d) Check that there are no fuel leaks after performing main-
tenance anywhere on the fuel system.
(1) Connect the TOYOTA hand−held tester to the
DLC3.
(2) Turn the ignition switch ON and TOYOTA hand−
held tester main switch ON.
NOTICE:
Do not start the engine.
(3) Select the active test mode on the TOYOTA hand−
held tester.
(4) Please refer to the TOYOTA hand−held tester oper-
ator ’s manual for further details.
(5) If you have no TOYOTA hand−held tester, connect
the positive (+) and negative (−) leads from the bat-
tery to the fuel pump connector (See page
SF−5).
(6) Pinch the fuel inlet hose.
The pressure in the high pressure line will rise to
approx. 400 kPa (4 kgf/cm
2, 57 psi). In this state,
check that there are no leaks from any part of the
fuel system.
NOTICE:
Always pinch the hose. Avoid bending as it may cause the
hose to crack.
(7) Turn the ignition switch to LOCK.
(8) Disconnect the TOYOTA hand−held tester from the
DLC3.
(9) Start the engine.
NOTICE:
Keep cranking the engine until the air is removed from the
fuel line.
(10) After the engine starts, check again that there are
no fuel leaks.

S01354
TOYOTA
Hand−Held Tester
SF0Q5−03
S01830
Fuel Inlet Hose
S01827
− SFIFUEL PUMP
SF−5
1996 RAV4 (RM447U)
FUEL PUMP
ON−VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION
(a) Connect the TOYOTA hand−held tester to the DLC3.
(b) Turn the ignition switch ON and TOYOTA hand−held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(c) Select the active test mode on the TOYOTA hand−held
tester.
(d) Please refer to the TOYOTA hand−held tester operator’s
manual for further details.
(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).
(f) Check that there is pressure in the fuel inlet hose from the
fuel filter.
HINT:
If there is fuel pressure, you will hear the sound of fuel flowing.
If there is no pressure, check the H−fuse, fuses, EFI main relay,
circuit opening relay, fuel pump, ECM and wiring connections.
(g) Turn the ignition switch to LOCK.
(h) Disconnect the TOYOTA hand−held tester from the
DLC3.
2. CHECK FUEL PRESSURE
(a) Check the battery positive voltage is above 12 V.
(b) Disconnect the negative (−) terminal cable from the bat-
tery.
(c) Remove the air cleaner assembly (See page ST−4).
(d) Remove the 2 bolts, and disconnect the engine comport-
ment R/B No.2 from the bracket on the body.
(e) Remove the union bolt and 2 gaskets, and disconnect the
fuel inlet hose from the fuel filter outlet.
CAUTION:
Put a shop towel under the fuel filter. Slowly loosen the
union bolt.