1996 TOYOTA RAV4 service

S01649
S01789
S01794
10 − 45°
Knock
Pin
P03445
Service
BoltDrive Gear
Sub−Gear
− ENGINE MECHANICALCYLINDER HEAD
EM−37
1996 RAV4 (RM447U)
31. REMOVE NO. 3 TIMING BELT COVER
Remove the 3 bolts and timing belt cover.
NOTICE:
Support the timing belt, so the meshing of the crank-
shaft timing pulley and timing belt does not shift..
Be careful not to drop anything inside the timing belt
cover
Do not allow the belt to come into contact with oil, wa-
ter or dust.
32. REMOVE CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being removed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
(a) Remove the exhaust camshaft.
(1) Set the knock pin of the intake camshaft at 10 − 45°
BTDC of camshaft angle.
HINT:
The above angle allows No. 2 and No. 4 cylinder cam lobes of
the exhaust camshaft to push their valve lifters evenly.
(2) Secure the exhaust camshaft sub gear to drive gear
with a service bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 − 20 mm (0.63 − 0.79 in.)

P05613
P05614
TurnB
A
P05615
P05616
(1)
(2)
(3) EM−40
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
33. DISASSEMBLE EXHAUST CAMSHAFT
(a) Mount the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Insert service bolt A into the service hole of the camshaft
sub gear.
(c) Using a screwdriver, turn the sub gear clockwise, and re-
move service bolt B.
NOTICE:
Be careful not to damage the camshaft.
(d) Using snap ring pliers, remove the snap ring.
(e) Remove the wave washer (1), camshaft sub gear (2) and
camshaft gear spring (3).

P05618
Turn
ADrive Gear
Sub−Gear B
S01778
80 − 11 5°
Knock
Pin
S01790
EM3373
2 − 3 mm
(0.08 − 0.12 in.)
Seal
Packing
− ENGINE MECHANICALCYLINDER HEAD
EM−57
1996 RAV4 (RM447U)
(c) Using snap ring pliers, install the snap ring.
(d) Insert a service bolt A into the service hole of the camshaft
sub gear.
(e) Using a screwdriver, align the holes of the camshaft drive
gear and sub gear by turning camshaft sub gear clock-
wise, and install a service bolt B.
NOTICE:
Be careful not to damage the camshaft.
(f) Align the gear teeth of the drive gear and sub gear, and
tighten the service bolt B.
9. INSTALL CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being installed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
(a) Install the intake camshaft.
(1) Apply MP grease to the thrust portion of the cam-
shaft.
(2) Place the intake camshaft at 80 − 11 5° BTDC of
camshaft angle on the cylinder head.
HINT:
The above angle arrows the No. 1 and No. 3 cylinder cam lobes
of the intake camshaft to push their valve lifters evenly.
(3) Apply MP grease to a new oil seal lip.
(4) Install the oil seal as far as the deepest part of the
cylinder head.
(5) Apply seal packing to the No. 1 bearing cap as
shown.
Seal packing: Part No. 08826−00080 or equivalent

S01805
S01793
9 10
3 45 6
1 2
7 8
EM7797
Seal Packing
S01649
S01645
− ENGINE MECHANICALCYLINDER HEAD
EM−59
1996 RAV4 (RM447U)
(6) Install the bearing caps in their proper locations.
(7) Apply a light coat of engine oil on the threads and
under the heads of the bearing cap bolts.
(8) Install and uniformly tighten the 10 bearing cap
bolts, in several passes, in the sequence shown.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
(9) Remove the service bolt B.
10. CHECK AND ADJUST VALVE CLEARANCE (See page
EM−5)
11. INSTALL SEMI−CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi−circular plug grooves.
Seal packing: Part No. 08826−00080 or equivalent
(c) Install the 2 semi−circular plugs to the cylinder head.
12. INSTALL NO. 3 TIMING BELT COVER
Install the timing belt cover with the 3 bolts.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)
13. TEMPORARILY INSTALL NO. 1 IDLER PULLEY AND
TENSION SPRING (See page EM−20)
14. INSTALL CAMSHAFT TIMING PULLEY AND TIMING
BELT (See page EM−20)
15. INSTALL ENGINE WIRE
(a) Install the engine wire protector to the 2 brackets on the
front side of the intake manifold.
(b) Connect the 4 injector connectors.
HINT:
The No. 1 and No. 3 injector connectors are brown, and the No.
2 and No. 4 injector connectors are gray.

2
A INTRODUCTION
This manual consists of the following 11 sections:
No.
SectionDescription
A
INDEXIndex of the contents of this manual.
A
INTRODUCTIONBrief explanation of each section.
BHOW TO USE THIS
MANUALInstructions on how to use this manual.
CTROUBLE-
SHOOTINGDescribes the basic inspection procedures for electrical circuits.
DABBREVIATIONSDefines the abbreviations used in this manual.
E
GLOSSARY OF
TERMS AND
SYMBOLS
Defines the symbols and functions of major parts.
FRELAY LOCATIONSShows position of the Electronic Control Unit, Relays, Relay Block, etc.
This section is closely related to the system circuit.
GELECTRICAL
WIRING ROUTINGDescribes position of Parts Connectors, Splice points, Ground points, etc.
This section is closely related to the system circuit.
HPOWER SOURCE
(Current Flow Chart)Describes power distribution from the power supply to various electrical
loads.
INDEXIndex of the system circuits.
I
SYSTEM CIRCUITS
Electrical circuits of each system are shown from the power supply through
ground points. Wiring connections and their positions are shown and
classified by code according to the connection method. (Refer to the
section, How to use this manualº).
The System Outlineº and Service Hintsº useful for troubleshooting are also
contained in this section.
JGROUND POINTSShows ground positions of all the parts decribed in this manual.
K
OVERALL
ELECTRICAL
WIRING DIAGRAM
Provides circuit diagrams showing the circuit connections.

Q
R
S
T
U
V
W
X
6
B HOW TO USE THIS MANUAL
WITH THE IGNITION SW TURNED ON, THE CURRENT FLOWS TO TERMINAL 3 OF THE POWER WINDOW MASTER SW, TERMINAL 2 OF THE POWER WINDOW CONTROL
RELAY AND TERMINAL 8 OF THE POWER WINDOW SW THROUGH THE DOOR FUSE.
1.DRIVER'S WINDOW MANUAL UPº OPERATION BY MASTER SW
HOLDING MANUAL SW (DRIVER'S) ON UPº POSITION LOCATED IN POWER WINDOW MASTER SW, THE CURRENT FLOWS TO TERMINAL 5 OF THE POWER WINDOW
CONTROL RELAY THROUGH TERMINAL 3 OF THE MASTER SW TERMINAL 2 TO OPERATE A POWER WINDOW CONTROL RELAY. THUS THE CURRENT INSIDE THE RELAY
FLOWS FROM TERMINAL 2 OF THE RELAY TERMINAL 1 TERMINAL 2 OF THE POWER WINDOW MOTOR TERMINAL 1 TERMINAL 4 OF THE RELAY TERMINAL
3 TO GROUND. THE MOTOR TURNS TO ASCENT THE WINDOW. RELEASING THIS SW, THE ROTATION OF MOTOR IS STOPPED AND THE WINDOWS CAN STOP AT WILL
POINT.
(FOR THE MANUAL DOWNº OPERATION, CURRENT FLOWS IN THE REVERSE DIRECTION BECAUSE THE TERMINALS WHERE IT FLOW ARE CHANGED).
2.DRIVER'S WINDOW AUTO DOWNº OPERATION BY MASTER SW
ONCE THE AUTO DOWNº BUTTON OF THE MASTER SW IS PUSHED, THE CURRENT FLOW TERMINAL 9 OF THE POWER WINDOW CONTROL RELAY THROUGH TERMINAL
3 OF THE MASTER SW TERMINALS 8 AND 9 TO OPERATE THE RELAY. THUS THE CURRENT INSIDE THE POWER WINDOW CONTROL RELAY FLOWS FROM TERMINAL
2 OF THE RELAY TERMINAL 4 TERMINAL 1 OF THE POWER WINDOW MOTOR TERMINAL 2 TERMINAL 1 OF THE RELAY TERMINAL 3 TO GROUND.
THE MOTOR CONTINUES THE ROTATION ENABLING TO DESCENT THE WINDOW.
THE WINDOW DESCENDS TO THE END POSITION. THE CURRENT WILL BE CUT OFF TO RELEASE THE AUTO DOWN FUNCTION BASED ON THE INCREASING CURRENT
BETWEEN TERMINAL 2 OF THE RELAY AND TERMINAL 1 IN RELAY.
3.DRIVER'S WINDOW AUTO DOWN RELEASE OPERATION BY MASTER SW
HOLDING THE MANUAL SW (DRIVER'S) ON UPº POSITION IN OPERATING AUTO DOWN. THE CURRENT FROM TERMINAL 3 OF THE MASTER SW PASSING TERMINAL 2
FLOWS TERMINAL 5 OF THE RELAY AND RELEASES THE AUTO DOWN FUNCTION IN THE POWER WINDOW CONTROL RELAY. RELEASING THE HAND FROM SW, WINDOW
STOPS AND CONTINUING ON TOUCHING SW, THE FUNCTION SWITCHES TO MANUAL UP OPERATION.
4.PASSENGER'S WINDOW UP OPERATION (MASTER SW) AND WINDOW LOCK SW OPERATION
HOLDING PASSENGER'S WINDOW SW (MASTER SW) ON UPº, THE CURRENT FLOWS FROM TERMINAL 3 OF THE MASTER SW PASSING TERMINAL 6 TO TERMINAL 3 OF
THE POWER WINDOW SW (PASSENGER'S) TERMINAL 4 TERMINAL 2 OF THE MOTOR TERMINAL 1 TERMINAL 9 OF THE POWER WINDOW SW TERMINAL
7 TERMINAL 1 OF THE MASTER SW TERMINAL 4 TO GROUND. THE MOTOR RUNS TO ASCENT THE WINDOW. RELEASING THIS SW, THE ROTATION OF MOTOR
IS STOPPED AND WINDOW CAN STOP AT WILL PLACE.
SWITCHING THE WINDOW LOCK SW IN LOCKº POSITION, THE CIRCUIT IS OPENED AND STOPPED THE MOTOR ROTATION.
(FOR THE DOWN OPERATION, CURRENT FLOWS IN THE REVERSE DIRECTION BECAUSE THE TERMINALS WHERE IT FLOWS ARE CHANGED).
P 2 POWER WINDOW CONTROL RELAY
3-GROUND: ALWAYS CONTINUITY
2-GROUND: APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION
5-GROUND: APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION AND THE MASTER SW AT UP POSITION
8-GROUND: APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION AND THE MASTER SW AT AUTO DOWN POSITION
9-GROUND: APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION AND THE MASTER SW AT DOWN OR AUTO DOWN POSITION
P 4 POWER WINDOW MASTER SW
4-GROUND: ALWAYS CONTINUITY
3-GROUND: APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION
WINDOW LOCK SW
OPEN WITH THE WINDOW LOCK SW AT LOCK POSITION
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
P 221P 421P 621
P 321P 521
: RELAY BLOCKS
CODESEE PAGERELAY BLOCK (RELAY BLOCK LOCATION)
116R/B NO. 1 (INSTRUMENT PANEL LEFT)
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
3B14J/B NO. 3 AND COWL WIRE (INSTRUMENT PANEL LEFT SIDE)
: CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS
CODESEE PAGEJOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION)
ID126FRONT DOOR RH WIRE AND COWL WIRE (RIGHT KICK PANEL)
IH126FRONT DOOR LH WIRE AND COWL WIRE (LEFT KICK PANEL)
: GROUND POINTS
CODESEE PAGEGROUND POINT LOCATION
IC24COWL LEFT
: SPLICE POINTS
CODESEE PAGEWIRE HARNESS WITH SPLICE POINTSCODESEE PAGEWIRE HARNESS WITH SPLICE POINTS
I 524COWL WIRE
SYSTEM OUTLINE
SERVICE HINTS

56
POWER SOURCE
(2) H-LP RELAY
(2) 2 - (2) 1 : CLOSED WITH THE LIGHT CONTROL SW AT HEAD POSITION OR THE DIMMER SW AT
FLASH POSITION
TAILLIGHT RELAY
5-3 : CLOSED WITH LIGHT CONTROL SW AT TAIL OR HEAD POSITION
I10 IGNITION SW
2-3 : CLOSED WITH THE IGNITION KEY AT ACC OR ON POSITION
2-4 : CLOSED WITH THE IGNITION KEY AT ON OR ST POSITION
7-6 : CLOSED WITH THE IGNITION KEY AT ON OR ST POSITION
7-8 : CLOSED WITH THE IGNITION KEY AT ST POSITION
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
F 728I1031
F 831J 131
: RELAY BLOCKS
CODESEE PAGERELAY BLOCKS (RELAY BLOCK LOCATION)
223R/B NO. 2 (ENGINE COMPARTMENT LEFT)
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
1C20INSTRUMENT PANEL WIRE AND J/B NO 1 (LOWER FINISH PANEL)1D20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1E20FUSE BLOCK ASSY WIRE AND J/B NO 1 (LOWER FINISH PANEL)1F20FUSE BLOCK ASSY WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1K20ENGINE ROOM MAIN WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
4A22ENGINE WIRE AND J/B NO. 4 (RIGHT KICK PANEL)
: CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS
CODESEE PAGEJOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION)
EA134ENGINE WIRE AND ENGINE ROOM MAIN WIRE (INSIDE OF R/B NO.2)
IG138ENGINE WIRE AND INSTRUMENT PANEL WIRE (UNDER THE INSTRUMENT PANEL CENTER)
: SPLICE POINTS
CODESEE PAGEWIRE HARNESS WITH SPLICE POINTSCODESEE PAGEWIRE HARNESS WITH SPLICE POINTS
I 338ENGINE ROOM MAIN WIRE
SERVICE HINTS

12
X
X78A A A A A
AAAA AAAA A A
CCC
X23
XX
56
X C 8 F 7 I10 J 1
BLUEJ 5
BLACK
BGRAY P 1 (
4WD)
AGRAY P 1 (
2WD)(
HINT : SEE PAGE 7) (
HINT : SEE PAGE 7) (
SEE PAGE 25)
X1
1 ABLACK S 3
B S 2
59
I10 IGNITION SW
7-8 : CLOSED WITH IGNITION SW AT ST POSITION
P 1 (A) PARK/NEUTRAL POSITION SW (2WD)
(A) 2 -(A) 3 : CLOSED WITH THE SHIFT LEVER IN P OR N POSITION
P 1 (B) PARK/NEUTRAL POSITION SW (4WD)
(B) 5 -(B) 6 : CLOSED WITH THE SHIFT LEVER IN P OR N POSITION
(2) ST RELAY
(2) 5 -(2) 3 : CLOSED WITH THE PARK/NEUTRAL POSITION SW AT P OR N POSITION AND THE
IGNITION SW AT ST POSITION (A/T)
(2) 5 -(2) 3 : CLOSED WITH THE CLUTCH START SW ON AND IGNITION SW AT ST POSITION (M/T)
S 2 (B), S 3 (A) STARTER
POINTS CLOSED WITH THE PARK/NEUTRAL POSITION SW AT P OR N POSITION AND THE IGNITION SW AT ST POSITION (A/T)
POINTS CLOSED WITH THE CLUTCH START SW ON AND THE IGNITION SW AT ST POSITION (M/T)
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
C 830J 131P 1B29
F 728J 531S 2B29
I1031P 1A29S 3A29
: RELAY BLOCKS
CODESEE PAGERELAY BLOCKS (RELAY BLOCK LOCATION)
223R/B NO. 2 (ENGINE COMPARTMENT LEFT)
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
1D20INSTRUMENT PANEL WIRE AND J/B NO 1 (LOWER FINISH PANEL)1H20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
: CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS
CODESEE PAGEJOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION)
EA134ENGINE WIRE AND ENGINE ROOM MAIN WIRE (INSIDE OF R/B NO. 2)
IG138ENGINE WIRE AND INSTRUMENT PANEL WIRE (UNDER THE INSTRUMENT PANEL CENTER)
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
EA34RADIATOR RIGHT
: SPLICE POINTS
CODESEE PAGEWIRE HARNESS WITH SPLICE POINTSCODESEE PAGEWIRE HARNESS WITH SPLICE POINTS
I 538ENGINE WIREI 638INSTRUMENT PANEL WIRE
SERVICE HINTS