1996 TOYOTA RAV4 fuel pressure

− DIAGNOSTICSENGINE
DI−83
1996 RAV4 (RM447U) DTC No..
DTC Detecting ConditionTrouble Area
P0441
The pressure in the charcoal canister does not drop during
purge control
(2 trip detection logic)
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 cracks, hole, blocked, damaged or discon-
nected ( (1), (4), (5) and (6) in fig. 1 )
Charcoal canister cracks, hole or damaged
During purge cut−off, the pressure in the charcoal canister is
very low compared with atmospheric pressure
(2 trip detection logic)
P0446
When VSV for vapor pressure sensor is OFF, ECM judges that
there is no continuity between vapor pressure sensor and
charcoal canister
(2 trip detection logic)
When VSV for vapor pressure sensor is ON, ECM judges that
there is no continuity between vapor pressure sensor and fuel
tank
(2 trip detection logic)
After the purge cut off operates, the pressure in the charcoal
canister is maintained at atmospheric pressure
(2 trip detection logic)
WIRING DIAGRAM
Refer to Evaporative Emission Control System Malfunction on page DI−76.
INSPECTION PROCEDURE
HINT:
If DTC P0441, P0446 or P0450 is output after DTC P0440, first troubleshoot DTC P0441, P0446 or P0450.
If no malfunction is detected, troubleshoot DTC P0440 next.
TOYOTA hand−held tester
1 Check the VSV connector for EVAP, VSV connector for vapor pressure sensor
and vapor pressure sensor connector for looseness and disconnection.
NG Repair or connect the VSV or sensor connector.
OK
2 Check the vacuum hose between intake manifold and VSV for EVAP,VSV for
EVAP and charcoal canister, charcoal canister and VSV for vapor pressure sen-
sor, and VSV for vapor pressure sensor and vapor pressure sensor.
CHECK:
(a) Check that the vacuum hose is connected correctly.
(b) Check the vacuum hose for looseness and disconnection.
(c) Check the vacuum hose for cracks, hole, damage, and blockage.
NG Repair or replace.

A00411
Engine
VSV for
Vapor Pressure
VSV for
EVAP
OFF OFF
ON Stop
ONStart
5 sec. 5 sec.
PTNK
(+)E2
(−)
DI−88
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
14 Check the charcoal canister.
PREPARATION:
(a) Connect the TOYOTA hand−held tester to the DLC3.
(b) Remove the fuel rank cap.
(c) Disconnect the VSV connector for vapor pressure sensor.
(d) Select the ACTIVE TEST mode on the TOYOTA hand−
held tester.
(e) Remove side trim cover (See page SF−61).
(f) Start the engine.
(g) VSV for EVAP is ON by TOYOTA hand−held tester and
remains on for 5 sec.
CHECK:
Measure voltage between terminals PTNK and E2 of ECM con-
nector 5 secs. after switching VSV for EVAP from ON to OFF.
OK:
Voltage: 2.5 V or less
NG Replace charcoal canister.
OK
Check and replace ECM (See page IN−30).
OBDII scan tool (excluding TOYOTA hand−held tester)
1 Check the VSV connector for EVAP, VSV connector for vapor pressure sensor
and vapor pressure sensor connector for looseness and disconnection.
NG Repair or connect the VSV or sensor connector.
OK
2 Check the vacuum hose between intake manifold and VSV for EVAP,VSV for
EVAP and charcoal canister, charcoal canister and VSV for vapor pressure sen-
sor, and VSV for vapor pressure sensor and vapor pressure sensor.
CHECK:
(a) Check that the vacuum hose is connected correctly.
(b) Check the vacuum hose for looseness and disconnection.

S00042
VSV
for EVAPECM
Vapor Pressure
VSV for Vapor
Pressure Sensor
Charcoal Canister Fuel Tank DI−92
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
DTC P0450 Evaporative Emission Control System
Pressure Sensor Malfunction
CIRCUIT DESCRIPTION
The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evap-
orative emission control system.
The ECM decides whether there is an abnormality in the evaporative emission control system based on the
vapor pressure sensor signal.
DTC P0450 is recorded by the ECM when the vapor pressure sensor malfunction.
DTC No.DTC Detecting ConditionTrouble Area
P0450
Condition (a) or (b) continues.
(2 trip detection logic)
(a) PTNK < 0.5 V
(b) PTNK > 4.5 VOpen or short in vapor pressure sensor circuit
Vapor pressure sensor
ECM
WIRING DIAGRAM
Refer to Evaporative Emission Control System Malfunction on page DI−76.
DI3ZY−01

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

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

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

S01797
M/T
A/T
S01785
A/T Only
S01351
M/T Only
Back−up Light
Connector EM−78
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
14. CONNECT CONNECTORS, CORD, STRAP AND
HOSES
(a) Connect the vapor pressure sensor connector.
(b) Connect the igniter connector.
(c) Connect the ignition coil connector.
(d) Connect the noise filter connector.
(e) Connect the high−tension cord to the ignition coil.
(f) Connect the MAP sensor connector.
(g) Connect the MAP sensor vacuum hose to the gas filter on
intake manifold.
(h) Connect the brake booster hose to the intake manifold.
(i) 4WD M/T:
Connect the differential lock control solenoid connector.
(j) Connect the ground strap to the cowl.
15. A/T and 4WD w/ M/T:
CONNECT TRANSAXLE OIL COOLER HOSES
16. CONNECT TRANSAXLE CONTROL CABLE(S) TO
TRANSAXLE
17. A/T only:
INSTALL TRANSAXLE CONTROL CABLE TO FRONT
SUSPENSION CROSSMEMBER AND ENGINE
MOUNTING CENTER MEMBER
18. M/T only:
INSTALL CLUTCH RELEASE CYLINDER
(a) Install the release cylinder with the 2 bolts.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
(b) Install the bracket with the bolt, and install the tube to the
bracket with the clamp.
(c) Install the tube with the clamp and bolt.
(d) Connect the back−up light switch connector.
19. CONNECT GROUND CABLE
Connect the ground cable onto the transaxle.
20. M/T only:
INSTALL STARTER (See page ST−19)
21. CONNECT FUEL INLET HOSE TO FUEL FILTER
Connect the inlet hose with 2 new gaskets and the union bolt.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
22. CONNECT HEATER HOSES
23. INSTALL WATER INLET
Install the water inlet with the 2 nuts.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
24. INSTALL RADIATOR UPPER AND LOWER HOSES

65
2. CONTROL SYSTEM
*SFI
THE SFI SYSTEM MONITORS THE ENGINE CONDITION THROUGH THE SIGNALS, WHICH ARE INPUT FROM EACH SENSOR (INPUT
SIGNALS (1) TO (11)). THE BEST FUEL INJECTION VOLUME IS DECIDED BASED ON THIS DATA AND THE PROGRAM MEMORIZED
BY THE ENGINE CONTROL MODULE, AND THE CONTROL SIGNAL IS OUTPUT TO TERMINALS #10, #20, #30, AND #40 OF THE
ENGINE CONTROL MODULE TO OPERATE THE INJECTOR (INJECT THE FUEL). THE SFI SYSTEM PRODUCES CONTROL OF FUEL
INJECTION OPERATION BY THE ENGINE CONTROL MODULE IN RESPONSE TO THE DRIVING CONDITIONS.
*IDLE SPEED CONTROL SYSTEM
THE IDLE SPEED CONTROL SYSTEM INCREASES THE RPM AND PROVIDES IDLING STABILITY FOR FAST IDLE-UP WHEN THE
ENGINE IS COLD AND WHEN THE IDLE SPEED HAS DROPPED DUE TO ELECTRICAL LOAD, ETC. THE ENGINE CONTROL MODULE
EVALUATES THE SIGNALS FROM EACH SENSOR (INPUT SIGNALS (1 TO 5, 11), OUTPUTS CURRENT TO TERMINAL ISCO AND ISCC,
AND CONTROLS THE IDLE AIR CONTROL VALVE.
*A/C CUT CONTROL SYSTEM
WHEN THE VEHICLE SUDDENLY ACCELERATES FROM LOW ENGINE SPEED, THIS SYSTEM CUTS OFF AIR CONDITIONING
OPERATION FOR A FIXED PERIOD OF TIME IN RESPONSE TO THE SPEED SENSOR, THROTTLE VALVE OPENING ANGLE AND
INTAKE MANIFOLD PRESSURE IN ORDER TO MAINTAIN ACCELERATION PERFORMANCE.
THE ENGINE CONTROL MODULE RECEIVES INPUT SIGNALS (4, 5 AND 9), AND INPUTS SIGNALS TO TERMINAL ACT.
3. DIAGNOSIS SYSTEM
WITH THE DIAGNOSIS SYSTEM, WHEN THERE IS A MALFUNCTION IN THE ENGINE CONTROL MODULE SIGNAL SYSTEM, THE
MALFUNCTIONING SYSTEM IS RECORDED IN THE MEMORY. THE MALFUNCTIONING SYSTEM CAN THEN BE FOUND BY READING
THE DISPLAY (CODE) OF THE MALFUNCTION INDICATOR LAMP.
4. FAIL-SAFE SYSTEM
WHEN A MALFUNCTION OCCURS ON ANY SYSTEM, IF THERE IS A POSSIBILITY OF ENGINE THROUBLE BEING CAUSED BY
CONTINUED CONTROL BASED IN THE SIGNALS FROM THAT SYSTEM, THE FAIL-SAFE SYSTEM EITHER CONTROLS THE SYSTEM BY
USING DATA (STANDARD VALUES) RECORDED IN THE ENGINE CONTROL MODULE MEMORY OR ELSE STOPS THE ENGINE.