1996 TOYOTA RAV4 Service Repair Manual

EC−12− EMISSION CONTROLTHREE−WAY CATALYTIC CONVERTER (TWC)
SYSTEM
1996 RAV4 (RM447U)

EC05M−02
− EMISSION CONTROLTHREE−WAY CATALYTIC CONVERTER (TWC)
SYSTEMEC−13
1996 RAV4 (RM447U)
INSPECTION
1. CHECK CONNECTIONS FOR LOOSENESS OR DAMAGE
2. CHECK CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE
3. CHECK FOR DENTS OR DAMAGE
If any part of the protector is damaged or dented to the extent that it contacts the TWC, repair or replace
it.
4. CHECK HEAT INSULATOR FOR DAMAGE
5. CHECK FOR ADEQUATE CLEARANCE BETWEEN CATALYTIC CONVERTER AND HEAT INSU-
LATOR

EM0EG−02
S01353
CO/HC Meter
− ENGINE MECHANICALCO/HC
EM−1
1996 RAV4 (RM447U)
CO/HC
INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/
HC complies with regulations.
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
HINT:
All vacuum hoses for EGR systems, etc. should be properly
connected.
(f) SFI system wiring connectors fully plugged
(g) Ignition timing check correctly
(h) Transmission in neutral position
(i) Tachometer and CO/HC meter calibrated by hand.
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SE-
CONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST
40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT
IDLE AND/OR 2,500 RPM
Complete the measuring within 3 minutes.
HINT:
When performing the 2 mode (2,500 rpm and idle) test, follow
the measurement order prescribed by the applicable local regu-
lations.

EM−2
− ENGINE MECHANICALCO/HC
1996 RAV4 (RM447U)
6. TROUBLESHOOTING
If the CO/HC concentration does not comply with regulations,
troubleshoot in the order given below.
(a) Check the oxygen sensor operation (See page DI−42).
(b) See the table below for possible causes, then inspect and
correct the applicable causes if necessary.
HCCOProblemsCauses
HighNormalRough idle4. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs
Open or or crossed high−tension cords
Cracked distributor cap
5. Incorrect valve clearance
6. Leaky EGR valve
7. Leaky intake and exhaust valves
8. Leaky cylinder
HighLowRough idle
(Fluctuating HC reading)1. Vacuum leaks:
PCV hose
EGR valve
Intake manifold
Throttle body
IAC valve
Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(Black smoke from exhaust)1. Restricted air filter
2. Faulty SFI system:
Faulty pressure regulator
Clogged fuel return line
Defective ECT sensor
Defective IAT sensor
Faulty ECM
Faulty injector
Faulty throttle position sensor
MAP sensor

EM0EH−03
S01361
Compression
Gauge
− ENGINE MECHANICALCOMPRESSION
EM−3
1996 RAV4 (RM447U)
COMPRESSION
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. DISCONNECT DISTRIBUTOR CONNECTOR
3. DISCONNECT HIGH−TENSION CORDS FROM SPARK
PLUGS AND IGNITION COIL
4. REMOVE SPARK PLUGS
5. CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine speed of
250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
1,275 kPa (13.0 kgf/cm
2, 185 psi) or more
Minimum pressure: 932 kPa (9.5 kgf/cm
2, 135 psi)
Difference between each cylinder:
98 kPa (1.0 kgf/cm
2, 14 psi) or less
(e) If the cylinder compression in one or more cylinders is low,
pour a small amount of engine oil into the cylinder through
the spark plug hole and repeat steps (a) through (c) for
cylinders with low compression.
If adding oil helps the compression, it is likely that
the piston rings and/or cylinder bore are worn or
damaged.
If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.
6. REINSTALL SPARK PLUGS
7. RECONNECT HIGH−TENSION CORDS TO SPARK
PLUGS AND IGNITION COIL

EM−4
− ENGINE MECHANICALCOMPRESSION
1996 RAV4 (RM447U)
8. RECONNECT DISTRIBUTOR CONNECTOR

EM0EI−02
S01653
21
S01367
− ENGINE MECHANICALVALVE CLEARANCE
EM−5
1996 RAV4 (RM447U)
VALVE CLEARANCE
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. DISCONNECT PS RESERVOIR
2. REMOVE CYLINDER HEAD COVER
(a) Disconnect the accelerator cable from the throttle body.
(b) Disconnect the accelerator cable from the clamp on the
intake manifold.
(c) Disconnect the accelerator cable from the clamp on the
generator bracket.
(d) Disconnect the A/T throttle control cable from the throttle
body.
(e) Disconnect the PCV hose from the air cleaner hose.
(f) Disconnect the PCV hose from the intake manifold.
(g) Disconnect the high−tension cords from the spark plugs.
(h) Remove the 2 bolts, and disconnect the accelerator cable
bracket from the intake manifold.
(i) Disconnect the engine wire protector from the 2 mounting
bolts of the No. 2 timing belt cover in the sequence shown.
(j) Remove the 4 nuts, grommets, cylinder head cover and
gasket.
HINT:
Arrange the grommets in the correct order, so that they can be
reinstalled into their original positions. This minimizes any pos-
sibility of oil leakage due to reuse of the grommets in different
positions.

P25455
Turn
P03443
1
1
2
2
1
13
3
P03442
2 233 44
44
P13927
Upward
Cam Lobe
Spark Plug SideNotch EM−6
− ENGINE MECHANICALVALVE CLEARANCE
1996 RAV4 (RM447U)
3. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley and align its groove with timing
mark ”0” of the No. 1 timing belt cover.
(b) Check that the valve lifters on the No.1 cylinder are loose
and valve lifters on the No.4 are tight.
If not, turn the crankshaft 1 revolution (360°) and align the mark
as above.
4. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
Record the out−of−specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake0.19 − 0.29 mm (0.007 − 0.011 in.)
Exhaust0.28 − 0.38 mm (0.011 − 0.015 in.)
(b) Turn the crankshaft 1 revolution (360°) and align the mark
as above (See procedure in step 3).
(c) Check only the valves indicated as shown. Measure the
valve clearance (See procedure in step (a)).
5. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
Turn the crankshaft so that the cam lobe of the cam-
shaft on the adjusting valve points upward.
Position the notch of the valve lifter facing the spark
plug side.