1996 TOYOTA RAV4 TIMING

CO0BG−02
S01613
P15462
P15546
1
3
2
P15463
Disconnect
− COOLINGWATER PUMP
CO−5
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE TIMING BELT (See page EM−15)
4. DISCONNECT LOWER RADIATOR HOSE FROM
WATER INLET
5. REMOVE TIMING BELT TENSION SPRING AND NO.2
IDLER PULLEY
6. REMOVE GENERATOR DRIVE BELT ADJUSTING
BAR
(a) Disconnect the crankshaft position sensor connector
clamp.
(b) Remove the bolt and adjusting bar.
7. REMOVE WATER PUMP AND WATER PUMP COVER
ASSEMBLY
(a) Remove the 2 nuts holding the water pump to the water
bypass pipe.
(b) Remove the 3 bolts in the sequence shown.
(c) Disconnect the water pump cover from the water bypass
pipe, and remove the water pump and water pump cover
assembly.
(d) Remove the gasket and 2 O−ring from the water pump
and water bypass pipe.

CO0BH−02
CO0877
− COOLINGWATER PUMP
CO−7
1996 RAV4 (RM447U)
INSPECTION
INSPECT WATER PUMP
(a) Visually check the drain hole for coolant leakage.
If leakage is found, replace the water pump.
If engine coolant has leaked onto the timing belt, replace the
timing belt.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and quietly.
If necessary, replace the water pump.

CO0BI−03
P13480
New O−Ring
New Gasket
P15547
New O−Ring
P15464
Connect
Z16489
3
1
2 CO−8
− COOLINGWATER PUMP
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL WATER PUMP TO WATER PUMP COVER
Install a new gasket and the water pump with the 3 bolts.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
2. INSTALL WATER PUMP AND WATER PUMP COVER
ASSEMBLY
(a) Install new O−ring and gasket to water pump cover.
(b) Install a new O−ring to the water bypass pipe.
(c) Apply soapy water to the O−ring on the water bypass
pipe.
(d) Connect the water pump cover to the water bypass pipe.
Do not install the nuts yet.
(e) Install the water pump with the 3 bolts. Tighten the bolts
in the sequence shown.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(f) Install the 2 nuts holding the water pump cover to the wa-
ter bypass pipe.
Torque: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
3. INSTALL GENERATOR DRIVE BELT ADJUSTING BAR
(a) Install the adjusting bar with the bolt.
Torque: 27 N·m (275 kgf·cm, 20 ft·lbf)
(b) Connect the crankshaft position sensor connector clamp.
4. INSTALL NO.2 IDLER PULLEY AND TIMING BELT
TENSION SPRING
5. CONNECT LOWER RADIATOR HOSE
6. INSTALL TIMING BELT (See page EM−20)
7. FILL WITH ENGINE COOLANT
8. START ENGINE AND CHECK FOR COOLANT LEAKS
9. INSTALL RH ENGINE UNDER COVER

− DIAGNOSTICSENGINE
DI−7
1996 RAV4 (RM447U)
(10) After checking the DTC, inspect the applicable cir-
cuit.
(b) Clear the DTC.
The following actions will erase the DTC and freezed
frame data.
(1) Operating the OBDII scan tool (complying with SAE
J1978) or TOYOTA hand−held tester to erase the
codes.
(See the OBDII scan tool’s instruction book for oper-
ating instructions.)
(2) Disconnecting the battery terminals or EFI fuse.
NOTICE:
If the TOYOTA hand−held tester switches the ECM from
normal mode to check mode or vice−versa, or it the ignition
switch is turned from ON to ACC or OFF during check
mode, the DTC and freezed frame data will be erased.
4. FAIL−SAFE CHART
If any of the following codes is recorded, the ECM enters fail−sate mode.
DTC No.Fail−Safe OperationFail−Safe Deactivation Conditions
P0105Ignition timing fixed at 5° BTDCReturned to normal condition
P0110Intake air temp. is fixed at 68°F (20°C)Returned to normal condition
P0115Engine coolant temp. is fixed at 176°F (80°C)Returned to normal condition
P0120VTA is fixed at 0°
The following condition must be repeated at least
2 times consecutively
When closed throttle position switch is ON:
0.1 V  VTA  0.95 V
P0325Max. timing retardationIgnition switch OFF
P1300Fuel cutIGF signal is detected for 1 ignition
5. CHECK FOR INTERMITTENT PROBLEMS
TOYOTA hand−held tester only:
By putting the vehicle’s ECM in check mode, 1 trip detection logic possible instead of 2 trip detection logic
and sensitivity to detect open circuit is increased. This makes it easier to detect intermittent problems.
(1) Clear the diagnostic trouble codes (See page DI−3)
(2) Set the check mode (See page DI−3)
(3) Perform a simulation test (See page IN−20)
(4) Check the connector and terminal inspection (See page IN−30)
(5) Visual check and contact pressure (See page IN−30)
(6) Handle the connector (See page IN−30)

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.

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−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

DI3ZC−01
P01242
(V)
(3.96)
3.6
2.4
1.2
150 450 750 (840)mmHg
20
60
100(112)
Manifold Absolute PressurekPa
Output Voltage
− DIAGNOSTICSENGINE
DI−21
1996 RAV4 (RM447U)
CIRCUIT INSPECTION
DTC P0105 Manifold Absolute Pressure / Barometric
Pressure Circuit Malfunction
CIRCUIT DESCRIPTION
By a built−in sensor unit, the manifold absolute pressure sensor
detects the intake manifold pressure as a voltage. The ECM
then determines the basic injection duration and basic injection
advance angle based on this voltage. Since the manifold abso-
lute pressure sensor does not use the atmospheric pressure as
a criterion, but senses the absolute pressure inside the intake
manifold (the pressure in proportion to the present absolute
vacuum 0) , it is not influenced by fluctuations in the atmospher-
ic pressure due to high altitude and other factors. This permits
it to control the air−fuel ratio at the proper lever under all condi-
tions.
DTC No.DTC Detecting ConditionTrouble Area
P0105Open or short manifold absolute pressure sensor circuit
Open or short in manifold absolute pressure sensor circuit
Manifold absolute pressure sensor
ECM
If the ECM detects DTC ”P0105” it operates the fail safe function, keeping the ignition timing and injection
volume constant and making it possible to drive the vehicle.
HINT:
After confirming DTC P0105 use the OBDII scan tool or TOYOTA hand−held tester to confirm the manifold
absolute pressure from ”CURRENT DATA”.
Manifold Absolute PressureMalfunction
0 kpaPIM circuit short
130 kpa or more
VC circuit open or short
PIM circuit open
E2 circuit open