1996 TOYOTA RAV4 Engine

K
1
234
13 RAV4
19 IB2 18 IB2 17 IB2 6 IB2 5 IB2 16 IB2
C12
CRUISE CONTROL SW
[COM B. SW]STP- L-MC MO VR3 VR 2 VR1 GND
C 3
CRUISE CONTROL ACTUATOR 1236 742 3
7IB241
5 13 23 24 25 12 11 261610
L-B
R-B
R-G
L-R
LG
L- O L- OLG L-R R-GR-BL-BR-Y G-W R-W
W-B W-B
W-L G-Y
CM S CCS
4 5 19 18
M
G-B
CRUISE
CANCEL
SET/
CO AST
RESUME/
ACCEL
R- YL C16
CRUISE CONTROL ECU
S 5
STO P
LIGHT
SW 2215A
DOME 2 2 1K 4 1K 1
40A AM1
1D 9 1F 82ACC
IG1
IG2
ST2 AM1 4
AM2
62W
WW
W
W W
1D 71F1
F 8
7. 5A ECU-IG
[FUSE BLOCK]
1J 5
1G 71E 6
1A 61F 4
IGRight
kick panel
W-B
W-B
80A MAIN
100A ALT
BATTERY F 7
FUSIBLE
LINK BLOCK
L-Y
3
B
B I1 0
IG N ITIO N SWB-YB-YW
B-Y B-Y
L- Y
L- Y
15 14
B-Y12
13F 8
10A GAUGE
[FUSE BLOCK]
1E 8
1B 8
2 1CA
B BBB
2IG1
2B 6A
10 B8A
IG 11 BR-L
R-L
B-W
B-W
R-L R-L R-L B-WR-L R- LG-R
8 3
4
6 J10 A , J11 B
JUNCTIO N
CONNECTOR
(
M/T)(
M/T)27
(
A/T)
(
A/T)
(
A/T) (
A/T)
C15
CRUISE
CONTROL
CLUTCH SWP 1 A , B
PAR K/N EUTR AL
POSITION SW(
2W D)
(
4W D)
(
2W D)
(
4W D)
C 9
CRUISE CONTROL
INDICATOR LIGHT
[C O M B. M E TE R]
21 9L Y- B
F rom Th r ottle
P osition Sensor
<2-3 To Engine Control
Module< 2-2
6IG13 EA1
B
B
8
W-L W-L V V To Data Link
C onnector 1
<2-3J 7
JUNCTION
CONNECTORF 8
10A STOP
[FU SE BLO C K]
1F 2
1I 11
R-W R-W W18 15
Power
SourceCruise Control
BATT B DPI IDL OD TC
G-W R- L
123
4
5
6789
1
756234
8910 A (
2WD)
P 1 GRAY
B (
4WD)
P 1 GRAY PARK/NEUTRAL POSITION SWJU NC TIO N CO N NEC TO R
AAAAAA
BBBCCCA J10
GRAY
18 19B J11
(
A/T)
GRAY
A
AJ10
JUNCTION
CONNECTOR J10
JUNCTION
CONNECTOR
Left kick panel
ID1I 9
1H 7
W-B
22
ECTP To Electronically
Controlled
T ransmission
S olenoid< 4-2
(
A/T) B-W
(
A/T) B-W From Engine
C o ntr ol M od ule
<4-3
SPD 20
V-W T o Speedometer
[Comb. Meter]
< 18-1
17 IB1
P
(
A/T)(
A/T)

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

IG0J3−02
− IGNITIONIGNITION SYSTEM
IG−1
1996 RAV4 (RM447U)
IGNITION SYSTEM
ON−VEHICLE INSPECTION
NOTICE:
”Cold” and ”Hot” in these sentences express the tempera-
ture of the coils themselves. ”Cold” is from −10°C (14°F) to
50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C
(212°F).
1. INSPECT IGNITERS AND SPARK TEST
Check that the spark occurs.
(1) Disconnect the high−tension cord (from the ignition
coil) from the distributor cap.
(2) Hold the end approx. 12.5 mm (0.50 in.) from the
body ground.
(3) See if spark occurs while engine is being cranked.
NOTICE:
To prevent gasoline from being injected from injectors dur-
ing this test, crank the engine for no more than 5 − 10 se-
conds at time.
If the spark does not occur, perform the test as follows:

B11562
P17875
Ohmmeter
IG0147
Megger
Ground
N00917
− IGNITIONIGNITION SYSTEM
IG−3
1996 RAV4 (RM447U)
2. INSPECT HIGH−TENSION CORDS
(a) Disconnect the high−tension cords from spark plug.
Disconnect the high−tension cords at the rubber boot. Do
not pull on the high−tension cords.
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.
(b) Disconnect the high−tension cords from ignition coil.
(c) Disconnect the high−tension cords from distributor cap.
(d) Inspect the high−tension cord resistance.
Using an ohmmeter, measure the resistance.
Maximum resistance: 25 kΩ per cord
If the resistance is greater than maximum, check the terminals.
If necessary, replace the high−tension cord.
(e) Reconnect the high−tension cords to distributor cap.
(f) Reconnect the high−tension cord to ignition coil.
(g) Reconnect the high−tension cords to spark plugs.
3. INSPECT SPARK PLUGS
NOTICE:
Never use a wire brush for cleaning.
Never attempt to adjust the electrode gap on a used
spark plug.
Spark plugs should be replaced every 100,000 km
(60,000 miles).
(a) Disconnect the high−tension cords from the spark plugs.
(b) Using a megger (insulation resistance meter), measure
the insulation resistance.
Standard correct insulation resistance:
10 MΩ or more
If the resistance is less than specified, proceed to step (d).
HINT:
If a megger is not available, the following simple method of in-
spection provides fairly accurate results.
Simple Method:
Quickly race the engine to 4,000 rpm 5 times.
Remove the spark plug. (See step (c))
Visually check the spark plug.
If the electrode is dry... OK
If the electrode is wet... Proceed to step (d)
Reinstall the spark plug. (See step (g))

IG0J9−01
B11573
B11574
− IGNITIONDISTRIBUTOR
IG−13
1996 RAV4 (RM447U)
INSTALLATION
1. SET NO. 1 CYLINDER TO DTC/COMPRESSION
Turn the crankshaft clockwise, and position the slit of the intake
camshaft as shown in the illustration.
2. INSTALL DISTRIBUTOR
(a) Install a new O−ring to the housing.
(b) Apply a light coat of engine oil on the O−ring.
(c) Align the cutout of the coupling with the line of the hous-
ing.
(d) Insert the distributor, aligning the center of the flange with
that of bolt hole on the cylinder head.
(e) Tighten the hold−down bolt.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
3. CONNECT HIGH−TENSION CORDS TO SPARK
PLUGS
Firing order:
1 − 3 − 4 − 2
4. CONNECT HIGH−TENSION CORD TO IGNITION COIL
5. CONNECT DISTRIBUTOR CONNECTOR
6. INSTALL AIR CLEANER CAP ASSEMBLY

LU060−04
S01260
Oil Pressure Gauge
P13638
Adhesive
− LUBRICATIONOIL AND FILTER
LU−1
1996 RAV4 (RM447U)
OIL AND FILTER
INSPECTION
1. CHECK ENGINE OIL QUALITY
Check the oil for deterioration, entry of water, discoloring or thin-
ning.
If the quality is visibly poor, replace the oil.
Oil grade:
API grade SH, Energy − Conserving II multigrade en-
gine oil or ILSAC multigrade engine oil.
Recommended viscosity is as shown in the illustra-
tion.
2. CHECK ENGINE OIL LEVEL
The oil level should be between the ”L” and ”F” marks on the dip-
stick.
If low, check for leakage and add oil up to ”F” mark.
3. REMOVE OIL PRESSURE SWITCH, AND INSTALL OIL
PRESSURE GAUGE
4. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
5. CHECK OIL PRESSURE
Oil pressure:
At idle
29 kPa (0.3 kgf/cm
2, 4.3 psi) or more
At 3,000 rpm
245 − 490 kPa
(2.5 − 5.0 kgf/cm
2, 36 − 71 psi)
6. REMOVE OIL PRESSURE GAUGE AND REINSTALL
OIL PRESSURE SWITCH
(a) Remove the oil pressure gauge.
(b) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Reinstall the oil pressure switch.
7. START ENGINE AND CHECK FOR LEAKS

LU061−02
S01264
SST
LU0555
S01266
LU−2
− LUBRICATIONOIL AND FILTER
1996 RAV4 (RM447U)
REPLACEMENT
CAUTION:
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In addi-
tion, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Care should be taken, therefore, when changing en-
gine oil to minimize the frequency and length of time
your skin is exposed to used engine oil. Protective
clothing and gloves that cannot be penetrated by oil
should be worn. The skin should be thoroughly
washed with soap and water, or use water−less hand
cleaner, to remove any used engine oil. Do not use
gasoline, thinners, or solvents.
In order to preserve the environment, used oil and
used oil filters must be disposed of only at desig-
nated disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug, and drain the oil into a contain-
er.
2. REPLACE OIL FILTER
(a) Using SST, remove the oil filter.
SST 09228−06501
(b) Check and clean the oil filter installation surface.
(c) Lubricate the filter rubber gasket with clean engine oil.
(d) Lightly tighten the oil filter by hand until the rubber gasket
contacts the seat of the filter mounting.

S01263
SST
3/4
Turn
− LUBRICATIONOIL AND FILTER
LU−3
1996 RAV4 (RM447U)
(e) Using SST, give it an additional 3/4 turn to seat the filter.
SST 09228−06501
3. FILL WITH ENGINE OIL
(a) Clean and install the oil drain plug with a new gasket.
Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
(b) Fill with new engine oil.
Capacity:
Drain and refill
w/ Oil filter change
3.9 liters (4.1 US qts, 3.4 lmp. qts)
w/o Oil filter change
3.7 liters (3.9 US qts, 3.3 lmp. qts)
Dry fill
4.4 liters (4.7 US qts, 3.9 lmp. qts)
(c) Reinstall the oil filler cap.
4. START ENGINE AND CHECK FOR OIL LEAKS
5. RECHECK ENGINE OIL LEVEL