1996 TOYOTA RAV4 replace battery

N14704BE6053I09123
LOCK
GND
DI−368
− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 RAV4 (RM447U)
3 Check continuity between terminal GND of ECU connector and body ground .
CHECK:
Measure resistance between terminal GND of cruise control
ECU connector and body ground.
OK:
Resistance: 1 Ω or less
NG Repair or replace harness or connector.
OK
Check and repair harness and connector be-
tween battery and ECU.

11 5
SRS
NOTICE: When inspecting or repairing the SRS, perform the operation in accordance with the following
precautionary instructions and the procedure and precautions in the Repair Manual for the applicable model
year.

Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble
codes become the most important source of information when troubleshooting.
When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before
disconnecting the battery.

Work must be started after 90 seconds from the time the ignition SW is turned to the LOCKº position and the
negative (-) terminal cable is disconnected from the battery.
(The supplemental restraint system is equipped with a back-up power source so that if work is started within
90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be activated.)
When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio
systems will be canceled. So before starting work, make a record of the contents memorized by each memory
system. When work is finished, reset the clock and audio system as before and adjust the clock.
To avoid erasing the memory of each memory system, never use a back-up power supply from outside the
vehicle.

When removing the steering wheel pad or handling a new steering wheel pad, keep the pad upper surface
facing upward. Also, lock the lock lever of the twin lock type connector at the rear of the pad and take care
not to damage the connector.
(Storing the pad with its metallic surface up may lead to a serious accident if the SRS inflates for some reason.)

Always store a removed or new front passenger airbag assembly with the airbag door facing up. Storing the
airbag assembly with the airbag door facing down could cause a serious accident if the airbag inflates.

Store the steering wheel pad where the ambient temperature remains below 935C (2005F), without high
humidity and away from electrical noise.

Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor
assembly.

Before repairing the body, remove the airbag sensor if during repair shocks are likely to be applied to the
sensors due to vibration of the body or direct tapping with tools or other parts.

Do not reuse a steering wheel pad or front airbag sensors.
After evaluating whether the center airbag sensor assembly is damaged or not, decide whether or not to reuse
it. (See the Repair Manual for the method for evaluating the center airbag sensor assembly.)

When troubleshooting the supplemental restraint system, use a high-impedance (Min. 10kW/V) tester.

The wire harness of the supplemental restraint system is integrated with the instrument panel wire harness
assembly.
The vehicle wiring harness exclusively for the airbag system is distinguished by corrugated yellow tubing, as
are the connectors.

Do not measure the resistance of the airbag squibs.
(It is possible this will deploy the airbag and is very dangerous.)

If the wire harness used in the supplemental restraint system is damaged, replace the whole wire harness
assembly.

INFORMATION LABELS (NOTICES) are attached to the periphery of the SRS components. Follow the
instructions on the notices.

SPARK TEST
CHECK CONNECTION OF IGNITION COIL, IGNITER
AND DISTRIBUTOR CONNECTORS.
CHECK RESISTANCE OF HIGH−TENSION CORDS
TRY ANOTHER IGNITER Maximum resistance: 25 kΩ per cord (See step 2)
CHECK POWER SUPPLY TO IGNITION COIL AND
IGNITER
1. Turn ignition switch to ON.
2. Check that there is battery positive voltage at ignition coil
positive (+) terminal.
Check wiring between ECM, distributor
and igniter, and then try another ECM.
CHECK IGT SIGNAL FROM ECM
NO
BAD
OK
OK
OK
Connect securely.
Replace the cord(s).
Check wiring between ignition switch
to ignition coil and igniter.
BAD
BAD
BAD
(See page DI−100)
Cold Hot
0.36 − 0.55 Ω0.45 − 0.65 Ω CHECK RESISTANCE OF IGNITION COILOKReplace the ignition coil.
BAD Resistance: (See step 4)
Primary
Secondary
9.0 − 15.4 kΩ11.4 − 18.1 kΩ
CHECK RESISTANCE OF SIGNAL GENERATOR
Resistance: Cold HotOKReplace the distributor housing assembly.(PICKUP COIL)
(See step 5)
135 − 220 Ω175 − 255 Ω
CHECK RESISTANCE OF CRANKSHAFT POSITION
SENSOR
Resistance: Cold HotOK
Replace the crankshaft position sensor.
(See step 6)
985 − 1,600 Ω1,265 − 1,890 ΩBAD
BAD
OK
CHECK AIR GAP OF DISTRIBUTOR
Air gap: 0.2 − 0.4 mm (0.008 − 0.016 in.)Replace the distributor housing assembly.(See step 5)
BAD IG−2
− IGNITIONIGNITION SYSTEM
1996 RAV4 (RM447U)

Z13341
Q06243
Q06242
BE2682
MX−74
− MANUAL TRANSAXLEDIFFERENTIAL LOCKING SYSTEM (4WD)
1996 RAV4 (RM447U)
2. INSPECT DIFFERENTIAL LOCK CONTROL COM-
PONENTS
(a) Inspect the differential lock control switch continuity.
Switch PositionTester ConnectionSpecified Condition
OFF (Free)7−10Continuity
ON (Lock)7−8Continuity
Illumination circuit2−3Continuity
If continuity is not as specified, check the bulb or replace the
switch.
(b) Inspect the differential lock warning buzzer.
(1) Remove the combination meter, then remove the
differential lock warning buzzer.
(2) Taking care to match the polarity of the buzzer, ap-
ply battery positive voltage to the terminals of the
buzzer and check that the buzzer sounds.
(c) Inspect the differential lock indicator switch continuity.
Switch PositionTester ConnectionSpecified Condition
Free1 − 2No continuity
Push1 − 2Continuity
If continuity is not as specified, replace the switch.

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.

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.

S01908
Ohmmeter
45
S01914
45
Battery
− SFIFUEL PUMP
SF−7
1996 RAV4 (RM447U)
(c) Disconnect the fuel pump and sender gauge connector.
(d) Inspect the fuel pump resistance.
Using an ohmmeter, measure the resistance between ter-
minals 4 and 5.
Resistance: At 20°C (68°F): 0.2 − 3.0 Ω
If the resistance is not as specified, replace the fuel pump.
(e) Inspect the fuel pump operation.
Connect the positive (+) lead from the battery to terminal
4 of the connector, and the negative (−) lead to terminal
5. Check that the fuel pump operates.
NOTICE:
These tests must be done quickly (within 10 seconds) to
prevent the coil burning out. Keep the fuel pump as far
away from the battery as possible. Always do the switching
at the battery side.
If operation is not as specified, replace the fuel pump or lead
wire.
(f) Reconnect the fuel pump and sender gauge connector.
(g) Reinstall the floor service hole cover.
(h) Reinstall the LH rear seat assembly.

P25497
SST
(Wire)
Connect
P10811
SF−22
− SFIINJECTOR
1996 RAV4 (RM447U)
(j) Connect SST (wire) to the injector and battery for 15 se-
conds, and measure the injection volume with a gra-
duated cylinder. Test each injector 2 or 3 times.
SST 09842−30070
Volume:
54 − 69 cm
3 (3.1 − 4.2 cu in.) per 15 sec.
Difference between each injector:
5 cm
3 (0.8 cu in.) or less
If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE
(a) In the condition above, disconnect the test probes of SST
(wire) from the battery and check the fuel leakage from
the injector.
SST 09842−30070
Fuel drop:
One drop or less per minute
(b) Turn the ignition switch to LOCK.
(c) Disconnect the negative (−) terminal cable from the bat-
tery.
(d) Remove the SST.
SST 09268−41046, 09842−30070
(e) Disconnect the TOYOTA hand−held tester from the
DLC3.