1996 TOYOTA RAV4 Service Repair Manual

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.

S01830
Fuel Inlet Hose
P25066
− DIAGNOSTICSENGINE
DI−11
1996 RAV4 (RM447U)
7 Check fuel pressure.
PREPARATION:
(a) Be sure that enough fuel is in the tank.
(b) Turn ignition switch ON.
(c) Connect the TOYOTA hand−held tester to DLC3 on the
vehicle.
(d) Use ACTIVE TEST mode to operate the fuel pump.
(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).
CHECK:
Check for fuel pressure in the inlet hose when it is pinched off.
HINT:
At this time, you will hear a fuel flowing noise.
NG Proceed to page SF−5 and continue to trouble-
shoot.
OK
8 Check for spark.
PREPARATION:
(a) Disconnect the high−tension cord from spark plug.
(b) Remove spark plug.
(c) Install spark plug to high−tension cord.
(d) Disconnect injector connector.
(e) Ground the spark plug.
CHECK:
Check if spark occurs while engine is being cranked.
NOTICE:
To prevent excess fuel being injected from the injectors
during this test, do not crank the engine for more than 5 −
10 seconds at a time.
NG Proceed to page IG−1 and continue to trouble-
shoot.
OK
Proceed to matrix chart of problem systems
on page DI−20.

DI−12
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
7. ENGINE OPERATING CONDITION
NOTICE:
The value given below for ”Normal Condition” are representative values, so a vehicle may still be
normal even it its value varies from those listed here. So do not decide whether a part is faulty or not
solely according to the ”Normal Condition” here.
(a) CARB Mandated Signals
TOYOTA hand−held tester displayMeasurement ItemNormal Condition *
FUEL SYS #1
Fuel System Bank 1
OPEN: Air−fuel ratio feedback stopped
CLOSED: Air−fuel ratio feedback operating
Idling after warning up: CLOSED
CALC LOAD
Calculator Load:
Current intake air volume as a proportion of max.
intake air volumeIdling: 20.7 − 48.4 %
Racing without load (2,500 rpm) : 17.7 − 45.3 %
COOLANT TEMPEngine Coolant Temperature Sensor ValueAfter warning up: 80 − 95°C (176 − 203°F)
SHORT FT #1Short−term Fuel Trim Bank 10 ± 20 %
LONG FT #1Long−term Fuel Trim Bank 10 ± 20 %
ENGINE SPDEngine SpeedIdling: 700 ± 50 rpm
VEHICLE SPDVehicle SpeedVehicle Stopped: 0 km/h (0 mph)
IGN ADVANCEIgnition Advance
Ignition Timing of Cylinder No.1Idling: BTDC 0 − 10°
INTAKE AIRIntake Air Temperature Sensor ValueEquivalent to Ambient Temp.
MAPAbsolute Pressure Inside Intake ManifoldIdling: 21 − 49 kPa
Racing without load (2,500 rpm): 17 − 46 kPa
THROTTLE POS
Voltage Output of Throttle Position Sensor
Calculated as a Percentage
0V → 0 %, 5V → 100 %Throttle Fully Closed: 6 − 16 %
Throttle Fully Open: 64 − 98 %
O2S B1, S1Voltage Output of Oxygen Sensor
Bnak 1,Sensor 1Idling : 0.1 − 0.9 V
O2FT B1, S1Oxygen Sensor Fuel Trim Bank 1, Sensor 1
(Same as SHORT FT #1)0 ± 20 %
O2S B1, S2Voltage Output of Oxygen Sensor
Bank 1, Sensor 2Driving 50 km/h (31 mph): 0.1 − 0.9 V
*: If no 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.

− 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.

DI3Z8−02
DI−14
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
DIAGNOSTIC TROUBLE CODE CHART
HINT:
Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument
or other factors.
If a malfunction code is displayed during the DTC check in check mode, check the circuit for that code listed
in the table below, for details of each code, turn to the page referred to under the ”See page” for the respec-
tive ”DTC No.” in the DTC chart.
SAE DEFINED
DTC No.
(See Page)Detection ItemTrouble AreaMILMemory
P0105
(DI−21)
Manifold Absolute
Pressure / Barometric
Pressure Circuit
MalfunctionOpen or short in Manifold absolute pressure sensor circuit
Manifold absolute pressure sensor
ECM
 *1
P0106
(DI−24)
Manifold Absolute
Pressure / Barometric
Pressure Circuit
Ranger / Performance
Problem
Manifold absolute pressure sensor *1
P0110
(DI−25)Intake Air Temp. Circuit
MalfunctionOpen or short in take air temp. sensor circuit
Intake air temp. sensor
ECM
 *1
P0115
(DI−29)Engine Coolant Temp. Circuit
MalfunctionOpen or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM
 *1
P0116
(DI−33)Engine Coolant Temp. Circuit
Range / Performance ProblemEngine coolant temp. sensor
Cooling system *1
P0120
(DI−34)Throttle / Pedal Position
Sensor / Switch ”A” Circuit
MalfunctionOpen or short in throttle position sensor circuit
Throttle position sensor
ECM
 *1
P0121
(DI−38)Throttle / Pedal Position
Sensor / Switch ”A” Circuit
Range / Performance Problem
Throttle position sensor *1
P0125
(DI−39)Insufficient Coolant Temp. for
Closed Loop Fuel ControlOpen or short in oxygen sensor circuit
Oxygen sensor *1
P0130
(DI−42)Oxygen Sensor Circuit Malfunc-
tion
(Bank 1 Sensor 1)Oxygen sensor
Fuel trim malfunction *1
P0133
(DI−45)Oxygen Sensor Circuit Slow
Response
(Bank 1 Sensor 1)
Oxygen sensor *1
P0136
(DI−46)Oxygen Sensor Circuit
Malfunction
(Bank 1 Sensor 2)
Oxygen sensor *1
P0171
(DI−48)System too Lean
(Fuel Trim)
Air Intake (hose loose)
Fuel line pressure
Injector blockage
Oxygen sensor malfunction
Manifold absolute pressure sensor
Engine coolant temp. sensor
 *1
*1: MIL lights up

− DIAGNOSTICSENGINE
DI−15
1996 RAV4 (RM447U) DTC No.
(See Page)
Detection ItemTrouble AreaMILMemory
P0172
(DI−48)System too Rich
(Fuel Trim)
Fuel line pressure
Injector blockage, leak
Oxygen sensor malfunction
Manifold absolute pressure sensor
Engine coolant temp. sensor
 *1
P0300
(DI−51)Random / Multiple
Cylinder Misfire DetectedIgnition system
Injector
Fuel line pressure
EGR
Compression pressure
Valve clearance not to specification
Valve timing
Manifold absolute pressure sensor
Engine coolant temp. sensor
 *2P0301
P0302
P0303
P0304
(DI−51)Misfire Detected
− Cylinder 1
− Cylinder 2
− Cylinder 3
− Cylinder 4
P0325
(DI−56)Knock Sensor 1 Circuit
MalfunctionOpen or short in knock sensor 1 circuit
Knock sensor 1 (looseness)
ECM
 *1
P0335
(DI−59)Crankshaft Position Sensor
”A” Circuit Malfunction
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Starter
ECM
 *1
P0336
(DI−62)Camshaft Position Sensor
Circuit Range / PerformanceDistributor
ECM malfunction (for back up) *1
P0340
(DI−63)Camshaft Position Sensor
Circuit Malfunction
Open or short in camshaft position sensor circuit
Camshaft position sensor
Starter
ECM
 *1
P0401
(DI−65)Exhaust Gas Recirculation
Flow Insufficient Detected
EGR valve stuck close
Open or short in VSV circuit for EGR
Vacuum or EGR hose disconnected
Manifold absolute pressure sensor
EGR VSV open or close malfunction
ECM
 *1
P0402
(DI−71)Exhaust Gas Recirculation
Flow Excessive Detected
EGR valve stuck open
Vacuum or EGR hose is connected to wrong post
Manifold absolute pressure sensor
ECM
 *1
P0420
(DI−73)Catalyst System Efficiency
Below ThresholdThree−way catalytic converter
Open or short in oxygen sensor circuit
Oxygen sensor
 *1
P0440
(DI−76)Evaporative Emission Control
System Malfunction
Vapor pressure sensor
Fuel tank cap incorrectly installed
Fuel tank cap cracked or damaged
Vacuum hose cracked, holed, blocked, damaged or
disconnected
Hose or tube cracked, holed, damaged or loose
Fuel tank cracked, holed, or damaged
Charcoal canister cracked, holed or damaged
 *1
*1: MIL lights up
*
2: MIL lights up or blinking

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