1996 TOYOTA RAV4 fuel pressure

155
B 2 BRAKE FLUID LEVEL WARNING SW
1-2 : CLOSED WITH THE FLOAT DOWN
P 2 PARKING BRAKE SW
1-GROUND : CLOSED WITH THE PARKING BRAKE LEVER PULLED UP
O 1 OIL PRESSURE SW
1-GROUND : CLOSED WITH THE OIL PRESSURE ABOVE APPROX. 20 KPA (2.8 PSI, 0.2 KG/CM2)W 1 WATER TEMP. SENDER
1-GROUND : APPROX. 160-240 W (50
C, 122
F)
APPROX. 17.1-21.2 W (120
C, 288
F)
F11 FUEL SENDER (MAIN)
2-3 : APPROX. 3 W AT FUEL FULL
APPROX. 11 0 W AT FUEL EMPTY
C 9 (A), C10 (B), C11 (C) COMBINATION METER
(A) 8, (C) 9-GROUND : APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION
(A) 12, (B) 2, (B) 5-GROUND : ALWAYS CONTINUITY
(C) 2-GROUND : ALWAYS APPROX. 12 VOLTS
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
A 528F1232 (2-DOOR), 33 (4-DOOR)J10A31
B 228J 131J11B31
C9A30J 431O 129
C10B30J 531P 231
C11C30J 731V 229
F 831J 8A31W 129
F 1132 (2-DOOR), 33 (4-DOOR)J 9B31
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
1B20INSTRUMENT PANEL WIRE AND J/B NO 1(LOWER FINISH PANEL)1C20INSTRUMENT PANEL WIRE AND J/B NO. 1(LOWER FINISH PANEL)
1E20FUSE BLOCK ASSY WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1G
1I20INSTRUMENT PANEL WIRE AND J/B NO 1 (LOWER FINISH PANEL)1J20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1M
: CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS
CODESEE PAGEJOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION)
IB136ENGINE ROOM MAIN WIRE AND INSTRUMENT PANEL WIRE (LEFT KICK PANEL)
ID136FLOOR WIRE AND INSTRUMENT PANEL WIRE (LEFT KICK PANEL)
IG138ENGINE WIRE AND INSTRUMENT PANEL WIRE (UNDER THE INSTRUMENT PANEL CENTER)IG238ENGINE WIRE AND INSTRUMENT PANEL WIRE (UNDER THE INSTRUMENT PANEL CENTER)
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
EA34RADIATOR RIGHT
EC34INTAKE MANIFOLD
IF36INSTRUMENT PANEL BRACE RH
IG36RIGHT KICK PANEL
SERVICE HINTS

K OVERALL ELECTRICAL WIRING DIAGRAM
1
234
2 RAV4
ACC
IG1
IG2
ST2 AM1
6 7AM2
1H 14
21E 2
5566 21I 171B 1 8IG1
11 IB 1
2 1
5 3
2 1
5 31 2
1 2
1 2
1 2 3IG1
20 IB2 7EA1 11 IG1
1C 12A 11A 10A12 C A 8 B 22 A 23 A 6 B
2B 7B C C C C
14C13 21
1 2
1 2
B
B-R
R- W LG
B-OB R- Y Y- GL
L-Y
B-O
B-R B-RB-R B-R B-R
B-R
B-L B- Y R- WP B-W
B- R B- R
B- O B-Y
B-Y
B-R
B-R B-O B-O
B-Y
B-R
B-Y
B- RB-OB-R B-Y
B-R B-R B-R B-R
B- O
FC ELS ACT AC1 OD1 PTNK PIM17 15
21
20
2
80A MAIN
5566
4ID1
EA BH
L-B B-R
11 2
A A53
5 BB4A 17A C
L-WRG R
C
14 A A
16B A4BE1 EO2 EO3 IG F TH W
B 1BVTA VC
B
B
L- Y
B WL
L- R
Y
11 12 2
LG-RBR
BR BR
BR BR BR
BR
BR BR BRY
432 323
E2 E2
R-W
2EA1 I10
IG NIT IO N SW
I 5
IN JE C TO R NO . 1 I 7
IN JE C TO R NO . 3 I 6
IN JE C TO R NO . 2 I 8
IN JE C TO R NO . 4
R- W
9
5
11
I 1
IDLE AIR CONTROL VALVEV 9
VSV(
Vapor Pressure Sensor) V 8
VSV(
EVAP) V 7
VSV(
EG R) O 3
OXYGEN SENSOR(
Bank 1 Sensor 2)
2
BR
BATT # 10 # 20 +B ISCO ISCC TPC EVP EGR OX1 OX2
20A A M2E F I M A IN R EL AY
CIRCUIT OPENING RELAYF11
FUEL PU M P
Under the center
p illar L HR adiator right
From D iode(
Engine Idle-Up)
< 8- 2 <12-4
E 4 A , E 6 C
J 1
JUNCTION
CONNECTOR From A/C A mplifier
<20-4 To A/C Amplifier
<20-4 To Cruise Control ECU
<13-4
PTN K VCC PIM VCV 1
VAPOR PRESSURE SENSOR M 1
MANIFOLD ABSOLUTE PRESSURE SENSOR
16
F rom M alfunction Indicator
Lamp[Comb. M eter]< 18-2
From Igniter
<5-4
26 3
T 1
THROTTLE POSITION SENSOR
E 2
ENG INE COOLANT TEMP. SENSORI 9
INTAKE AIR TEM P. SENSOR
TE1 W N E+ N E- SD LE1
AB D 1
DATA LINK
CONNECTOR
1
ENGINE CONTROL MODULE
Power
SourceEngine Control
BATTERY
G-R
B-R G-R
, E 5 B
B- O
17
M 54
W-B
L-BW-B W-B
20 10 21C
G-W(
A/T)B/KFrom Stop Light SW
<9-34 22C
B-W(
A/T)NSWTo P ark /N eutral
Position SW<1-3C
To ST Relay< 1-3 B-W(
M/T)
STA
11
R-W F 8
7. 5A O B D
[FUSE BLOCK]
F 7
FUSIBLE LINK BLOCK G-R
IG 1 9
15
B-R
9BR
20B BKNK E2
B
A IG T
10
15A EFI16 2
171D 8
1E 9
100A ALT62 2
W
W
1F 8
1K 1
R-W
#30 25 A
#40 24 A2 1
1 2
5IG1
Y-B(
A/T)To Cruise C ontrol
E CU < 13- 3
BR
EC Intake manifold 11
TC
O 2
OXYGEN SENSOR(
Bank 1 Sensor 1)
Y
Y
1 THA
B 3
Y-BK 1
KNOCK SENSOR
EO1
13ABRBR BR
5A
G+ 10
F 8
7. 5A IG N
[FUSE BLOCK]B-O11
1E 1
1J 2B-O
W
IG Right kick panel
(
SH IE LD E D)
A A
AA
A
A
A
A
A
A
(SHIELDED)
(
SHIELDED)
AAB
AA
(
SHIELDED)54 216
IG 211
BR
BR
BR
BR
(
SHIELDED)
12
34567891011 12 13
14 15
16 17 18 19 20 21 22 2324 25 2612345678
9 1011121314151612
34567891011
12 13
14 15 16 17 18 19 20 2122
J10 A , J11 B
JUNCTIO N CONNECTOR
AAAAAA
BBBCCC B E 5 D AR K G RAY CE 6 DARK GRAY
B J11A J10
GRAY A E 4 DARK GRAY
ENGINE CONTROL MODULEJUNCTION CONNECTOR
J 2
JU NC T IO N
CONNECTOR
BR BR BR BRW-BW-B
SG CG SD L BAT
(
SHIELDED)
W WW-LBR BRL
W
D 2
DATA LINK CONNECTOR 3
GRAY
C SPD
To S peedometer[C omb. M eter]
<18-19V- W
B(
A/T)
To ST Relay< 1-3 C 2
CRANKSHAFT POSITION SEN SORFrom Ignition Coil
and D istributor< 5-3
2
1
G WW From C ruise C ontrol
ECU< 13-4
From Airbag Sensor
Assembly< 11-2
+B 12
B-R8TE1
From
Airbag
Sensor
Assembly
<11-2
W-L

K OVERALL ELECTRICAL WIRING DIAGRAM
1
234
18 RAV4
Power
SourceCombination Meter2ACC
IG 1 AM1 4
2
1
2 1D 91E 8
21B 8
1K 47
1D1
1F
8A
11A 10A 2A 6C 6B 13A 12A 5B 9A 8B 7B
2IG19IG2
10 IG25 ID1 9 ID1 7 IG2
6 IG2 5 IG2B 4
100A ALT
3
F 8
10A
GAUGE
[FUSE BLOCK]
F 7
FUSIBLE LINK BLOCKW 1
WATER TEMP.
SEND ER
From Engine Control
Module< 2-2 < 4-4
From C ruise C ontrol
ECU< 13-4From Engine Contro
Module< 2-3 See ABS System
<17-3See SRS System< 11-2
SPEED
TACHOFU EL FU EL WATER TEMP. MALFUNCTION
INDICATO R LAM POIL ABS
4 B
R- L
WWWR-LL- B R- Y V-WR-L Y-RBR
BR Y- G G-RY-R
R- L R-L R- L
I1 0
IG NIT IO N S W
, C1 1 C
2
111
IF EC ID110
Intake
manifold Instrument panel
brace RH V 2
VEHICLE SPEED SENSOR
(
C o mbina tion M et er)COM B INA T IO N M ET E R C 9 A , J 1 1 B
F11
FUEL SENDER(
Main) F12
FUEL SENDER(
Sub) B 2
BRAKE FLUID
LEVEL WARNING SW
3
2 1
3
R-L L- B R- YR- L Y-R Y-B
BRBR BR Y-GY-R
BATTER Y
BR9C 2C 3C7A 9B 1B 4A 3A 13B
7C 8C 5A 10B 11B B C2B
17 IG2 1B 19
S ee Charging
System< 1-4
BR AKE BU ZZER
S ee E lectronically C ontrolled
Transmission S ystem< 4- 4S e e C ente r D iff. L o ck
(
M/T)
System< 11-4
S ee Headlight
System< 3-4
See Turn Signal and
Hazard Warning
Light System< 7-2 See SRS System< 11-2
S ee Interior Light
System< 6-2
S ee C harging S ys tem< 1- 4 S ee Ele ctr on ic ally C o ntr olled
T ransmission System< 4-4S ee Inte rior Lig ht
System<6-2
R- B W-B
R
(
4W D A /T)
1I 1J
O 1
OIL PRESSURE SW
1
EAIG R adiator rightRight kick panel
P 2
PARKING BRAKE SW1
A 5
A/T FLU ID TEM P. SW
1 2
R-BW-B RW-B
(
4WD A/T)
R-B
2124
1 40A
AM 1
6
B
F ro m Ig nite r< 5- 4
B-Y
10 13 9 8 7 6 5 4 3 2 1101112 139 8 7 6 5 4 3 2 1101112
10 9 8 7 6 5 4 3 2 1B C10 BLUE A C 9 BROWN
C C11 GRAYCO M BINATION M ETER
W-B
CA
BB BBJ10 A
JUNCTION
CONNECTOR
3B
BU LB C HEC K From C lutch
Start SW< 1-2B-W
A AA
A
J 1
JU NC TIO N
CONNECTOR J10
JUNCTION
CONNECTOR
From ABS ECU< 17-4 R-B
C 5S ee U nlock and S eat
B elt W arning S ystem
<3-2
C
ASee Taillight and
Illu min ation Sy ste m
<8-3S ee Ta illig h t a n d
Illumination System< 8- 3
10
1 A
S ee C ruise Control S ystem
<13-36 , C10 B
TUR N LH TUR N RH
HIGH BEAM
ECT PW R C. D IFF
LO C KSRS
ILLUMINATION
OPEN DOOR
CHARGE O/D
OFF A/T OIL
TEM P. BELT CRUISE
AAAAAA
BBBCCCA J10 G R A Y
J11 B G R A Y JUNCTION
CONNECTOR
(M /T )
(
A/T) B
From P a rk/N eu tra l
Position SW <1-315

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.

S01831
New Gasket
FI1654
Fulcrum Length
30 mm
SST
FI0420
O−Ring
Injector
GrommetDelivery PipeCORRECT
WRONG
P15485
O−Ring
Injector Grommet
O−Ring Insulator
− SFISFI SYSTEM
SF−3
1996 RAV4 (RM447U)
(b) When connecting the flare nut or union bolt on the high
pressure pipe union, observe the following procedures:
(1) Union Bolt Type:
Always use 2 new gaskets.
(2) Union Bolt Type:
Tighten the union bolt by hand.
(3) Union Bolt Type:
Tighten the union bolt to the specified torque.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(4) Flare Nut Type:
Apply a light coat of engine oil to the flare nut, and
tighten the flare nut by hand.
(5) Flare Nut Type:
Using SST, tighten the flare nut to specified torque.
SST 09631−22020
NOTICE:
Do not rotate the fuel pipe, when tightening the flare nut.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
28 N·m (285 kgf·cm, 21 ft·lbf) for SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
(c) Observe the following precautions when removing and
installing the injectors.
(1) Never reuse the O−ring.
(2) When placing a new O−ring on the injector, take
care not to damage it in any way.
(3) Coat a new O−ring with spindle oil or gasoline be-
fore installing−never use engine, gear or brake oil.
(4) Install the injector to the delivery pipe and intake
manifold as shown in the illustration.

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.

S01834
Gasket
SST (Union)
SST
Fuel Inlet Hose Gasket
SST (Union)
S01835
301 − 347 kPa
S01836
For 5 Minutes After Engine has Stopped
147 kPa
or More SF−6
− SFIFUEL PUMP
1996 RAV4 (RM447U)
(f) Install the fuel inlet hose and SST (pressure gauge) to the
fuel filter outlet with the 3 gaskets and SST (union bolt).
SST 09268−45012
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(g) Wipe off any splattered gasoline.
(h) Connect the TOYOTA hand−held tester to the DLC3.
(i) Reconnect the negative (−) terminal cable to the battery.
(j) Turn the ignition switch ON.
(k) Measure the fuel pressure.
Fuel pressure:
301 − 347 kPa (3.1 − 3.5 kgf/cm
2, 44 − 50 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check these parts:
Fuel hoses and connections
Fuel pump
Fuel filter
Fuel pressure regulator
(l) Remove the TOYOTA hand−held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle.
Fuel pressure:
301 − 347 kPa (3.1 − 3.5 kgf/cm
2, 44 − 50 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5
minutes after the engine has stopped.
Fuel pressure:
147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, pressure
regulator and/or injectors.
(q) After checking fuel pressure, disconnect the negative (−)
terminal cable from the battery and carefully remove the
SST to prevent gasoline from splashing.
SST 09268−45012
(r) Reconnect the fuel inlet hose with 2 new gaskets and the
union bolt.
Torque: 29 N·m (300 kgf·cm, 21 ft·lbf)
(s) Reconnect the negative (−) terminal cable to the battery.
(t) Check for fuel leakage (See page SF−1).
(u) Reinstall the engine comportment R/B No.2 and air clean-
er assembly.
3. CHECK FUEL PUMP
(a) Remove the LH rear seat assembly.
(b) Remove the floor service hole cover.