S01649
S01789
S01794
10 − 45°
Knock
Pin
P03445
Service
BoltDrive Gear
Sub−Gear
− ENGINE MECHANICALCYLINDER HEAD
EM−37
1996 RAV4 (RM447U)
31. REMOVE NO. 3 TIMING BELT COVER
Remove the 3 bolts and timing belt cover.
NOTICE:
Support the timing belt, so the meshing of the crank-
shaft timing pulley and timing belt does not shift..
Be careful not to drop anything inside the timing belt
cover
Do not allow the belt to come into contact with oil, wa-
ter or dust.
32. REMOVE CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being removed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
(a) Remove the exhaust camshaft.
(1) Set the knock pin of the intake camshaft at 10 − 45°
BTDC of camshaft angle.
HINT:
The above angle allows No. 2 and No. 4 cylinder cam lobes of
the exhaust camshaft to push their valve lifters evenly.
(2) Secure the exhaust camshaft sub gear to drive gear
with a service bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 − 20 mm (0.63 − 0.79 in.)
P05618
Turn
ADrive Gear
Sub−Gear B
S01778
80 − 11 5°
Knock
Pin
S01790
EM3373
2 − 3 mm
(0.08 − 0.12 in.)
Seal
Packing
− ENGINE MECHANICALCYLINDER HEAD
EM−57
1996 RAV4 (RM447U)
(c) Using snap ring pliers, install the snap ring.
(d) Insert a service bolt A into the service hole of the camshaft
sub gear.
(e) Using a screwdriver, align the holes of the camshaft drive
gear and sub gear by turning camshaft sub gear clock-
wise, and install a service bolt B.
NOTICE:
Be careful not to damage the camshaft.
(f) Align the gear teeth of the drive gear and sub gear, and
tighten the service bolt B.
9. INSTALL CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being installed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
(a) Install the intake camshaft.
(1) Apply MP grease to the thrust portion of the cam-
shaft.
(2) Place the intake camshaft at 80 − 11 5° BTDC of
camshaft angle on the cylinder head.
HINT:
The above angle arrows the No. 1 and No. 3 cylinder cam lobes
of the intake camshaft to push their valve lifters evenly.
(3) Apply MP grease to a new oil seal lip.
(4) Install the oil seal as far as the deepest part of the
cylinder head.
(5) Apply seal packing to the No. 1 bearing cap as
shown.
Seal packing: Part No. 08826−00080 or equivalent
S01805
S01793
9 10
3 45 6
1 2
7 8
EM7797
Seal Packing
S01649
S01645
− ENGINE MECHANICALCYLINDER HEAD
EM−59
1996 RAV4 (RM447U)
(6) Install the bearing caps in their proper locations.
(7) Apply a light coat of engine oil on the threads and
under the heads of the bearing cap bolts.
(8) Install and uniformly tighten the 10 bearing cap
bolts, in several passes, in the sequence shown.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
(9) Remove the service bolt B.
10. CHECK AND ADJUST VALVE CLEARANCE (See page
EM−5)
11. INSTALL SEMI−CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi−circular plug grooves.
Seal packing: Part No. 08826−00080 or equivalent
(c) Install the 2 semi−circular plugs to the cylinder head.
12. INSTALL NO. 3 TIMING BELT COVER
Install the timing belt cover with the 3 bolts.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)
13. TEMPORARILY INSTALL NO. 1 IDLER PULLEY AND
TENSION SPRING (See page EM−20)
14. INSTALL CAMSHAFT TIMING PULLEY AND TIMING
BELT (See page EM−20)
15. INSTALL ENGINE WIRE
(a) Install the engine wire protector to the 2 brackets on the
front side of the intake manifold.
(b) Connect the 4 injector connectors.
HINT:
The No. 1 and No. 3 injector connectors are brown, and the No.
2 and No. 4 injector connectors are gray.
127
WHEN THE IGNITION SW IS TURNED ON, CURRENT FLOWS TO TERMINAL 2 OF THE REAR WASHER MOTOR, TERMINAL 3 OF THE
REAR WIPER RELAY AND TERMINAL 1 OF THE REAR WIPER MOTOR THROUGH THE WIPER FUSE.
1. REAR WIPER NORMAL OPERATION
WITH THE IGNITION SW TURNED ON AND REAR WIPER AND WASHER SW TURNED ON, THE CURRENT FLOWING TO TERMINAL 3
OF THE REAR WIPER RELAY FLOWS TO TERMINAL 6 OF THE RELAY "TERMINAL 10 OF THE REAR WIPER AND WASHER SW "
TERMINAL 2 "TOGROUND. THUS, THE RELAY COIL IS ACTIVATED AND THE CURRENT TO TERMINAL 3 OF THE RELAY FLOWS TO
TERMINAL 4 " TERMINAL 4 OF THE REAR WIPER MOTOR " MOTOR "TO GROUND AND CAUSES THE MOTOR TO OPERATE THE
WIPER.
2. REAR WIPER INTERMITTENT OPERATION
WHEN THE IGNITION SW IS ON AND THE REAR WIPER AND WASHER SW IS TURNED TO INT POSITION, CURRENT FLOWING TO
TERMINAL 3 OF THE REAR WIPER RELAY FLOWS TO TERMINAL 2 OF THE RELAY "TERMINAL 13 OF THE REAR WIPER AND
WASHER SW "TERMINAL 2 "GROUND.
THIS CAUSES THE MOTOR TO OPERATE (THE POINT CHANGES) AND THE INTERMITTENT CIRCUIT OF THE RELAY OPERATES.
INTERMITTENT OPERATION OF THE CIRCUIT IS CONTROLLED BY THE CHARGING AND DISCHARGING OF THE CONDENSER
INSTALLED INSIDE THE RELAY.
3. WASHER OPERATION
WITH THE IGNITION SW TURNED ON AND THE REAR WIPER AND WASHER SW TURNED TO ON POSITION, WHEN THE WIPER SW IS
TURNED FURTHER, THE CURRENT FLOWING TO TERMINAL 2 OF THE REAR WASHER MOTOR FLOWS TO TERMINAL 1 OF THE
MOTOR "TERMINAL 12 OF THE REAR WIPER AND WASHER SW "TERMINAL 2 "TO GROUND SO THAT THE WASHER MOTOR
ROTATES AND THE WINDOW WASHER EJECTS THE SPRAY, ONLY WHILE THE SWITCH IS FULLY TURNED.
WHEN THE WIPER SW IS OFF AND THEN TURNED TO WASHER ON (WIPER OFF SIDE), ONLY THE WASHER OPERATES.
R 2 REAR WASHER MOTOR
2-GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION
1-GROUND : CONTINUITY WITH WASHER SW TURNED ON
R15 REAR WIPER RELAY
3-GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION
2-GROUND : CONTINUITY WITH REAR WIPER SW INT POSITION
6-GROUND : CONTINUITY WITH REAR WIPER SW ON POSITION
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
C1430J1029R1632 (2-DOOR), 33 (4-DOOR)
F 831R 229R1732 (2-DOOR), 33 (4-DOOR)
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
1F20FUSE BLOCK ASSY WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1I20INSTRUMENT PANEL WIRE AND J/B NO 1 (LOWER FINISH PANEL)1J20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1L20FLOOR WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
: CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS
CODESEE PAGEJOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION)
ID136FLOOR WIRE AND INSTRUMENT PANEL WIRE (LEFT KICK PANEL)
BK140 (2-DOOR)BACK DOOR NO 1 WIRE AND FLOOR WIRE (BESIDE RIGHT REAR COMB LIGHT)BK142 (4-DOOR)BACK DOOR NO. 1 WIRE AND FLOOR WIRE (BESIDE RIGHT REAR COMB. LIGHT)
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
IG36RIGHT KICK PANEL
: SPLICE POINTS
CODESEE PAGEWIRE HARNESS WITH SPLICE POINTSCODESEE PAGEWIRE HARNESS WITH SPLICE POINTS
E 134ENGINE ROOM MAIN WIREB1042 (4-DOOR)BACK DOOR NO. 1 WIRE
B1040 (2-DOOR)BACK DOOR NO. 1 WIRE
SYSTEM OUTLINE
SERVICE HINTS
155
B 2 BRAKE FLUID LEVEL WARNING SW
1-2 : CLOSED WITH THE FLOAT DOWN
P 2 PARKING BRAKE SW
1-GROUND : CLOSED WITH THE PARKING BRAKE LEVER PULLED UP
O 1 OIL PRESSURE SW
1-GROUND : CLOSED WITH THE OIL PRESSURE ABOVE APPROX. 20 KPA (2.8 PSI, 0.2 KG/CM2)W 1 WATER TEMP. SENDER
1-GROUND : APPROX. 160-240 W (50C, 122F)
APPROX. 17.1-21.2 W (120C, 288F)
F11 FUEL SENDER (MAIN)
2-3 : APPROX. 3 W AT FUEL FULL
APPROX. 11 0 W AT FUEL EMPTY
C 9 (A), C10 (B), C11 (C) COMBINATION METER
(A) 8, (C) 9-GROUND : APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION
(A) 12, (B) 2, (B) 5-GROUND : ALWAYS CONTINUITY
(C) 2-GROUND : ALWAYS APPROX. 12 VOLTS
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
A 528F1232 (2-DOOR), 33 (4-DOOR)J10A31
B 228J 131J11B31
C9A30J 431O 129
C10B30J 531P 231
C11C30J 731V 229
F 831J 8A31W 129
F 1132 (2-DOOR), 33 (4-DOOR)J 9B31
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
1B20INSTRUMENT PANEL WIRE AND J/B NO 1(LOWER FINISH PANEL)1C20INSTRUMENT PANEL WIRE AND J/B NO. 1(LOWER FINISH PANEL)
1E20FUSE BLOCK ASSY WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1G
1I20INSTRUMENT PANEL WIRE AND J/B NO 1 (LOWER FINISH PANEL)1J20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1M
: CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS
CODESEE PAGEJOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION)
IB136ENGINE ROOM MAIN WIRE AND INSTRUMENT PANEL WIRE (LEFT KICK PANEL)
ID136FLOOR WIRE AND INSTRUMENT PANEL WIRE (LEFT KICK PANEL)
IG138ENGINE WIRE AND INSTRUMENT PANEL WIRE (UNDER THE INSTRUMENT PANEL CENTER)IG238ENGINE WIRE AND INSTRUMENT PANEL WIRE (UNDER THE INSTRUMENT PANEL CENTER)
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
EA34RADIATOR RIGHT
EC34INTAKE MANIFOLD
IF36INSTRUMENT PANEL BRACE RH
IG36RIGHT KICK PANEL
SERVICE HINTS
159
FAN MOTOR OPERATION
WHEN THE IGNITION SW IS TURNED ON, CURRENT FROM THE ECU-IG FUSE FLOWS TO THE FAN NO. 1 RELAY (COIL SIDE) AND
THE FAN NO. 2 RELAY (COIL SIDE) "TERMINAL 2 OF THE A/C SINGLE PRESSURE SW "TERMINAL 3 "TERMINAL 2 OF THE A/C
WATER TEMP. SW "TERMINAL 1 "GROUND, AND THE FAN NO. 1 RELAY AND THE FAN NO. 2 RELAY ARE TURNED ON.
AT THE SAME TIME THAT THIS CURRENT FLOWS, CURRENT FROM THE ECU-IG FUSE FLOWS TO THE E/G MAIN RELAY (COIL
SIDE) "GROUND, AND THE E/G MAIN RELAY IS TURNED ON. AS A RESULT, CURRENT FROM THE ALT FUSE FLOWS TO THE CDS
FA N FUSE AND RDI FAN FUSE.
*LOW SPEED OPERATION
WHEN THE IGNITION SW IS TURNED ON AND THE A/C IS ACTIVATED, CURRENT FLOWS FROM THE MG/C RELAY (POINT SIDE) "
THE FAN NO. 3 RELAY (COIL SIDE) "GROUND, AND THE FAN NO. 3 RELAY IS TURNED ON. AS A RESULT, CURRENT FROM THE
CDS FAN FUSE FLOWS TO TERMINAL 2 OF THE A/C CONDENSER FAN MOTOR "TERMINAL 1 "THE FAN NO. 2 RELAY (POINT
SIDE) "THE FAN NO. 3 RELAY (POINT SIDE) "TERMINAL 2 OF THE RADIATOR FAN MOTOR "TERMINAL 1 "GROUND, AND
BOTH OF THE FAN MOTORS, WITH THE RESULT THAT THE FANS ARE ACTIVATED AT LOW SPEED.
IF THE ENGINE COOLANT TEMPERATURE IS APPROX. 90C (194F) OR LESS, AND THE REFRIGERANT PRESSURE IS APPROX.
15.5 KG/CM
2 (1323 KPA, 191.7 PSI) OR LESS, BOTH THE A/C WATER TEMP. SW AND THE A/C SINGLE PRESSURE SW ARE CLOSED,
SO THAT THE FAN NO. 1 RELAY AND THE FAN NO. 2 RELAY ARE TURNED ON. AS A RESULT, BOTH OF THE FAN MOTOR OPERATE
AT LOW SPEED.
*HIGH SPEED OPERATION
WHEN, DURING A/C OPERATION, THE REFRIGERANT PRESSURE BECOMES HIGHER THAN ORDINARY LEVEL (APPROX. 15.5
KG/CM
2 (1323 PSI. 191.7 KPA)), THE A/C SINGLE PRESSURE SW IS TURNED OFF. AS A RESULT, THE FAN NO. 1 RELAY AND THE
FAN NO. 2 RELAY ARE TURNED OFF, AND THE CURRENT FLOWS FROM THE RDI FAN FUSE TO FAN NO. 1 RELAY (POINT SIDE) "
TERMINAL 2 OF THE RADIATOR FAN MOTOR "TERMINAL 1 "GROUND, AND CURRENT FROM THE CDS FAN FUSE FLOWS TO
TERMINAL 2 OF THE A/C CONDENSER FAN MOTOR "TERMINAL 1 "THE FAN NO. 2 RELAY (POINT SIDE) "GROUND, AND TO
BOTH OF THE FAN MOTORS IN PARALLEL, THUS CAUSING THE FAN MOTORS TO OPERATE AT HIGH SPEED.
NOTE THAT, BECAUSE THE CURRENT FLOWS IN THE SAME MANNER EVEN IF THE COOLANT TEMPERATURE IS APPROX. 90C
(194F) OR HIGHER, THE FAN MOTORS STILL OPERATE AT HIGH SPEED.
A 3 A/C SINGLE PRESSURE SW
2-3 : OPEN ABOVE APPROX. 15.5 KG/CM2 (191.7 PSI, 1323 KPA)
CLOSE BELOW APPROX. 12.5 KG/CM2 (142 PSI, 980 KPA)A 4 A/C WATER TEMP. SW
1-2 : OPEN ABOVE APPROX. 90C (194F)
CLOSED BELOW APPROX. 83C (181.4F)
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
A 128F 728R 129
A 328F 831
A 428J 131
: RELAY BLOCKS
CODESEE PAGERELAY BLOCKS (RELAY BLOCK LOCATION)
223R/B NO. 2 (ENGINE COMPARTMENT LEFT)
625R/B NO. 6 (ENGINE COMPARTMENT LEFT)
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
1A20INSTRUMENT PANEL WIRE AND J/B NO.1 (LOWER FINISH PANEL)
1E20FUSE BLOCK ASSY WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
: CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS
CODESEE PAGEJOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION)
IB236ENGINE ROOM MAIN WIRE AND INSTRUMENT PANEL WIRE (RIGHT KICK PANEL)
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
EA34RADIATOR RIGHT
EB34RADIATOR LEFT
SYSTEM OUTLINE
SERVICE HINTS
162
AIR CONDITIONING
HEATER BLOWER MOTOR OPERATION
CURRENT IS APPLIED AT ALL TIMES THROUGH THE HTR FUSE TO TERMINAL 5 OF THE HEATER RELAY.
WHEN THE IGNITION SW IS TURNED ON, CURRENT FLOWS THROUGH THE GAUGE FUSE TO TERMINAL 1 OF THE HEATER RELAY
"THE COIL "TERMINAL 3 "TERMINAL 5 OF THE BLOWER SW.
*LOW SPEED OPERATION
WHEN THE BLOWER SW IS MOVED TO LO POSITION, THE CURRENT FLOWS TO TERMINAL 5 OF THE BLOWER SW "TERMINAL 6
"GROUND, CAUSING THE HEATER RELAY TO SWITCH ON. THIS CAUSES THE CURRENT TO FLOW FROM THE HTR FUSE "
TERMINAL 5 OF THE HEATER RELAY "TERMINAL 4 "TERMINAL 1 OF THE BLOWER MOTOR "TERMINAL 2 "TERMINAL 1 OF
THE BLOWER RESISTOR "TERMINAL 4 "GROUND, CAUSING THE BLOWER MOTOR TO ROTATE AT LOW SPEED.
*MEDIUM SPEED OPERATION (OPERATION AT M1, M2)
WHEN THE BLOWER SW IS MOVED TO M1 POSITION, THE CURRENT FLOWING TO TERMINAL 5 OF THE BLOWER SW "
TERMINAL 6 "GROUND, TURNS THE HEATER RELAY ON. THIS CAUSES THE CURRENT TO FLOW FROM THE HTR FUSE "
TERMINAL 5 OF THE HEATER RELAY "TERMINAL 4 "TERMINAL 1 OF THE BLOWER MOTOR "TERMINAL 2 "TERMINAL 1 OF
THE BLOWER RESISTOR "TERMINAL 2 "TERMINAL 1 OF THE BLOWER SW "TERMINAL 6 "GROUND. THIS TIME, THE
BLOWER RESISTANCE OF THE BLOWER RESISTOR IS LESS THAN AT LOW SPEED, SO THE BLOWER MOTOR ROTATES AT
MEDIUM LOW SPEED.
WHEN THE BLOWER SW IS MOVED TO M2 POSITION, CURRENT FLOWING THROUGH THE MOTOR FLOWS FROM TERMINAL 1 OF
THE BLOWER RESISTOR "TERMINAL 3 "TERMINAL 2 OF THE BLOWER SW "TERMINAL 6 "GROUND. THIS TIME,
RESISTANCE OF THE BLOWER RESISTOR IS LESS THAN AT M1 POSITION, SO THE BLOWER MOTOR ROTATES AT MEDIUM HIGH
SPEED.
*HIGH SPEED OPERATION
WHEN THE BLOWER SW IS MOVED TO HI POSITION, THE CURRENT FLOWS TO TERMINAL 5 OF THE BLOWER SW "TERMINAL 6
"GROUND AND TURNS THE HEATER RELAY ON.
THIS CAUSES THE CURRENT TO FLOW FROM THE HTR FUSE TO TERMINAL 5 OF THE HEATER RELAY "TERMINAL 4 "
TERMINAL 1 OF THE BLOWER MOTOR "TERMINAL 2 "TERMINAL 8 OF THE BLOWER SW "TERMINAL 6 "GROUND, CAUSING
THE BLOWER MOTOR TO ROTATE AT HIGH SPEED.
A 3 A/C DUAL PRESSURE SW
1-4 : OPEN WITH THE PRESSURE LESS THAN 2.0 KG/CM2 (30 PSI, 206 KPA) OR ABOVE 32 KG/CM2 (384 PSI, 2648 KPA)A12 A/C AMPLIFIER
12-5 : CONTINUITY WITH THE A/C CONTROL SW ON AND THE IGNITION SW AT ON POSITION
13-GROUND : ALWAYS CONTINUITY
05-GROUND : ALWAYS CONTINUITY
02-GROUND : APPROX. 12 VOLTS WITH THE IGNITION SW ON
A14 A/C THERMISTOR
1-2 : APPROX. 2341 234 W AT 15C (59F)
B 4 BLOWER RESISTOR
1-3 : APPROX. 0.4 W
1-2 : APPROX. 1.1 W
1-4 : APPROX. 2.8 W
B 5 BLOWER SW
5-6 : CONTINUITY WITH THE BLOWER SW AT LO, M1, M2 OR HI POSITION
1-6 : CONTINUITY WITH THE BLOWER SW AT M1 POSITION
2-6 : CONTINUITY WITH THE BLOWER SW AT M2 POSITION
8-6 : CONTINUITY WITH THE BLOWER SW AT HI POSITION
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
A 228B 430I 229
A 328B 530J 331
A1230D 330J 431
A1330E 631J10A31
A1430F 728J11B31
B 330F 831
: RELAY BLOCKS
CODESEE PAGERELAY BLOCKS (RELAY BLOCK LOCATION)
625R/B NO. 6 (ENGINE COMPARTMENT LEFT)
SYSTEM OUTLINE
SERVICE HINTS
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.