SF−1

SFI − SFI SYSTEM

SFI SYSTEM SF0Q4−03

PRECAUTION
1. BEFORE WORKING ON THE FUEL SYSTEM, DISCON-
NECT THE NEGATIVE (−) TERMINAL CABLE FROM
THE BATTERY
HINT:
Any diagnostic trouble code retained by the computer will be
erased when the negative (−) terminal cable is removed.
Therefore, if necessary, read the diagnosis before removing the
terminal.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME
WHEN WORKING ON THE FUEL SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATH-
ER PARTS
4. MAINTENANCE PRECAUTIONS
(a) In event of engine misfire, these precautions should be
taken.
(1) Check proper connection to battery terminals, etc.
(2) After repair work, check that the ignition coil termi-
nals and all other ignition system lines are recon-
nected securely.
(3) When cleaning the engine compartment, be espe-
cially careful to protect the electrical system from
water.
(b) Precautions when handling oxygen sensor.
(1) Do not allow oxygen sensor to drop or hit against an
object.
(2) Do not allow the sensor to come into contact with
water.
5. IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYS-
TEM (HAM, CB, ETC.)
If the vehicle is equipped with a mobile communication system,
refer to the precaution in the IN section.
6. AIR INDUCTION SYSTEM
(a) Separation of the engine oil dipstick, oil filler cap, PCV
hose, etc. may cause the engine to run out of tune.
(b) Disconnection, looseness or cracks in the parts of the air
induction system between the throttle body and cylinder
head will allow air suction and cause the engine to run out
of tune.
7. ELECTRONIC CONTROL SYSTEM
(a) Before removing SFI wiring connectors, terminals, etc.,
first disconnect the power by either turning the ignition
switch to LOCK or disconnecting the negative (−) terminal
cable from the battery.
HINT:
Always check the diagnostic trouble code before disconnecting
the negative (−) terminal cable from the battery.

1996 RAV4 (RM447U)

SF−2
SFI − SFI SYSTEM

(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 SST 09842−30070

FI2553

8. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out, so observe the following
procedures:
Fuel
(1) Disconnect the fuel pump connector.
Pump (2) Start the engine. After the engine has stopped on
Connector its own, turn the ignition switch to LOCK.

S01837

(3) Put a container under the connection.

(4) Slowly loosen the connection.
Plug
(5) Disconnect the connection.
(6) Plug the connection with a rubber plug.

1996 RAV4 (RM447U)

S01832
 SF−3
SFI − SFI SYSTEM

(b) When connecting the flare nut or union bolt on the high
pressure pipe union, observe the following procedures:
(1) Union Bolt Type:
Always use 2 new gaskets.
(2) Union Bolt Type:
Tighten the union bolt by hand.
(3) Union Bolt Type:
New Gasket Tighten the union bolt to the specified torque.
S01831 Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

Fulcrum Length (4)Flare Nut Type:

Apply a light coat of engine oil to the flare nut, and
30 mm
tighten the flare nut by hand.
SST (5) Flare Nut Type:
Using SST, tighten the flare nut to specified torque.
SST 09631−22020
NOTICE:
Do not rotate the fuel pipe, when tightening the flare nut.
FI1654 Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
28 N·m (285 kgf·cm, 21 ft·lbf) for SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

O−Ring CORRECT (c) Observe the following precautions when removing and
installing the injectors.
(1) Never reuse the O−ring.
Injector Delivery Pipe (2) When placing a new O−ring on the injector, take
Grommet
care not to damage it in any way.
(3) Coat a new O−ring with spindle oil or gasoline be-
WRONG fore installing−never use engine, gear or brake oil.

FI0420

(4) Install the injector to the delivery pipe and intake

O−Ring
manifold as shown in the illustration.

Insulator

Grommet
O−Ring

Injector

P15485

1996 RAV4 (RM447U)

SF−4
SFI − SFI SYSTEM

TOYOTA (d) Check that there are no fuel leaks after performing main-
Hand−Held Tester tenance anywhere on the fuel system.
(1) Connect the TOYOTA hand−held tester to the
DLC3.
(2) Turn the ignition switch ON and TOYOTA hand−
held tester main switch ON.
NOTICE:
Do not start the engine.
S01354 (3) Select the active test mode on the TOYOTA hand−
held tester.
(4) Please refer to the TOYOTA hand−held tester oper-
ator’s manual for further details.
(5) If you have no TOYOTA hand−held tester, connect
the positive (+) and negative (−) leads from the bat-
tery to the fuel pump connector (See page
SF−5).

(6) Pinch the fuel inlet hose.

The pressure in the high pressure line will rise to
approx. 400 kPa (4 kgf/cm2, 57 psi). In this state,
check that there are no leaks from any part of the
fuel system.
NOTICE:
Fuel Inlet Hose
Always pinch the hose. Avoid bending as it may cause the
hose to crack.
S01830 (7) Turn the ignition switch to LOCK.
(8) Disconnect the TOYOTA hand−held tester from the
DLC3.
(9) Start the engine.
NOTICE:
Keep cranking the engine until the air is removed from the
fuel line.
(10) After the engine starts, check again that there are
no fuel leaks.

1996 RAV4 (RM447U)

 SF−5
SFI − FUEL PUMP

TOYOTA
Hand−Held Tester
FUEL PUMP SF0Q5−03

ON−VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION
(a) Connect the TOYOTA hand−held tester to the DLC3.
(b) Turn the ignition switch ON and TOYOTA hand−held tes-
ter main switch ON.
NOTICE:
S01354
Do not start the engine.
(c) Select the active test mode on the TOYOTA hand−held
tester.
(d) Please refer to the TOYOTA hand−held tester operator’s
manual for further details.
(e) If you have no TOYOTA hand−held tester, connect the
positive (+) and negative (−) leads from the battery to the
fuel pump connector (See page SF−5).

(f) Check that there is pressure in the fuel inlet hose from the
fuel filter.
HINT:
If there is fuel pressure, you will hear the sound of fuel flowing.
If there is no pressure, check the H−fuse, fuses, EFI main relay,
circuit opening relay, fuel pump, ECM and wiring connections.
Fuel Inlet Hose (g) Turn the ignition switch to LOCK.
(h) Disconnect the TOYOTA hand−held tester from the
S01830 DLC3.
2. CHECK FUEL PRESSURE
(a) Check the battery positive voltage is above 12 V.
(b) Disconnect the negative (−) terminal cable from the bat-
tery.
(c) Remove the air cleaner assembly (See page ST−4).
(d) Remove the 2 bolts, and disconnect the engine comport-
ment R/B No.2 from the bracket on the body.

(e) Remove the union bolt and 2 gaskets, and disconnect the
fuel inlet hose from the fuel filter outlet.
CAUTION:
Put a shop towel under the fuel filter. Slowly loosen the
union bolt.

S01827

1996 RAV4 (RM447U)

SF−6
SFI − FUEL PUMP

Gasket (f) Install the fuel inlet hose and SST (pressure gauge) to the
SST (Union) fuel filter outlet with the 3 gaskets and SST (union bolt).
Gasket SST 09268−45012
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
SST (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.
SST (Union) (j) Turn the ignition switch ON.
Fuel Inlet Hose
S01834

(k) Measure the fuel pressure.

301 − 347 kPa Fuel pressure:
301 − 347 kPa (3.1 − 3.5 kgf/cm2, 44 − 50 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check these parts:
S Fuel hoses and connections
S Fuel pump
S Fuel filter
S01835 S 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/cm2, 44 − 50 psi)
(o) Stop the engine.

For 5 Minutes After Engine has Stopped (p) Check that the fuel pressure remains as specified for 5
147 kPa minutes after the engine has stopped.
or More Fuel pressure:
147 kPa (1.5 kgf/cm2, 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
S01836 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.
1996 RAV4 (RM447U)
 SF−7
SFI − FUEL PUMP

(c) Disconnect the fuel pump and sender gauge connector.

(d) Inspect the fuel pump resistance.

Ohmmeter Using an ohmmeter, measure the resistance between ter-
minals 4 and 5.
4 5
Resistance: At 20°C (68°F): 0.2 − 3.0 Ω
If the resistance is not as specified, replace the fuel pump.

S01908

(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
4 5
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
Battery
away from the battery as possible. Always do the switching
S01914 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.

1996 RAV4 (RM447U)

SF−8
SFI − FUEL PUMP
SF0Q6−01

COMPONENTS

3 Door Vehicles 5 Door Vehicles

LH Rear Seat Assembly LH Rear Seat Assembly

37 (375, 27)

37 (375, 27)

Rear Seat Hinge Cover

Floor Service Hole Cover

Fuel Pump & Sender
Gauge Connector
29 (300, 22)
z Gasket z Gasket
Fuel Outlet Pipe
Fuel Return
Vent Hose x8

Fuel Suction w/ Pump &

Gauge Assembly
Fuel Hose

Fuel Pump Connector

Ground Strap

Fuel Pump Clamp Fuel Pump

z Gasket
Fuel Pump Filter
z Clip
Rubber Cushion

N·m (kgf·cm, ft·lbf) : Specified torque

z Non−reusable part
S01937

1996 RAV4 (RM447U)

 SF−9
SFI − FUEL PUMP
SF0Q7−02

REMOVAL
CAUTION:
Do not smoke or work near an open flame when working on
the fuel pump.
1. REMOVE LH REAR SEAT ASSEMBLY
2. REMOVE FLOOR SERVICE HOLE COVER
(a) Take out the floor carpet.
(b) Remove the 4 screws and service hole cover.
HINT:
At the time of installation, plaese refer to the following items.
Check for fuel leakage (See page SF−1).
3. DISCONNECT FUEL PUMP & SENDER GAUGE CON-
NECTOR
4. DISCONNECT FUEL PIPE AND HOSE FROM FUEL
SUCTION TUBE
CAUTION:
Remove the fuel filler cap to prevent the fuel from flowing
out.

(a) Remove the union bolt and 2 gaskets, and disconnect the
outlet pipe from the suction tube.
HINT:
At the time of installation, plaese refer to the following items.
Install the outlet pipe with 2 new gaskets and bolt.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(b) Disconnect the return vent hose from the suction tube.
5. REMOVE FUEL SUCTION w/ PUMP & GAUGE TUBE
(a) (b)
S01828 ASSEMBLY
(a) Remove the 8 bolts.
Torque: 3.5 N·m (35 kgf·cm, 31 in.·lbf)

(b) Pull out the suction w/ pump & gauge tube assembly.
NOTICE:
Do not damage the fuel pump filter. Be careful that the arm
of the sender gauge should not bent.
(c) Remove the gasket from the set plate.
HINT:
At the time of installation, plaese refer to the following items.
Install a new gasket to the set plate.
S01829

1996 RAV4 (RM447U)

SF−10
SFI − FUEL PUMP
SF0Q8−02

DISASSEMBLY
1. DISCONNECT FUEL PUMP CONNECTOR
2. REMOVE FUEL PUMP FROM FUEL PUMP BRACKET
(a) Disconnect the ground strap from the fuel pump clamp.
(b) Pull off the lower side of the fuel pump from the pump
bracket.
Pull
(c) Disconnect the fuel hose from the fuel pump, and remove
the fuel pump.
S01896
(d) Remove the rubber cushion from the fuel pump.

3. REMOVE FUEL PUMP CLAMP

4. REMOVE FUEL PUMP FILTER FROM FUEL PUMP
(a) Using a small screwdriver, remove the clip.
(b) Pull out the pump filter.
HINT:
At the time of installation, plaese refer to the following items.
Install the pump filter with a new clip.

FI6376

1996 RAV4 (RM447U)

 SF−11
SFI − FUEL PUMP
SF1QF−01

REASSEMBLY
Reassembly is in the reverse order of disassembly (See page SF−10 ).

1996 RAV4 (RM447U)

SF−12
SFI − FUEL PUMP
SF1QG−01

INSTALLATION
Installation is in the reverse order of removal (See page SF−9).

1996 RAV4 (RM447U)

 SF−13
SFI − FUEL PRESSURE REGULATOR

FUEL PRESSURE REGULATOR

SF0QB−01

COMPONENTS

3 Door Vehicles 5 Door Vehicles

LH Rear Seat Assembly LH Rear Seat Assembly

37 (375, 27)

37 (375, 27)

Rear Seat Hinge Cover

Floor Service Hole Cover

Fuel Pump & Sender

Gauge Connector 29 (300, 22)
z Gasket z Gasket
Fuel Outlet Pipe
Fuel Return
Vent Hose x8

Fuel Suction w/ Pump &

Gauge Tube Assembly
Fuel Hose

Fuel Filter

z O−Ring
z Gasket
Fuel Pressure Regulator
Clip

N·m (kgf·cm, ft·lbf) : Specified torque

z Non−reusable part S01959

1996 RAV4 (RM447U)

SF−14
SFI − FUEL PRESSURE REGULATOR
SF0QC−02

REMOVAL
CAUTION:
Do not smoke or work near an open flame when working on
the fuel pump.
1. REMOVE FUEL SUCTION TUBE (See page SF−9)

2. REMOVE FUEL PRESSURE REGULATOR

(a) Remove the clip from the fuel filter.
(b) Disconnect the fuel hose from the pressure regulator.
(c) Remove the screw, and pull out the pressure regulator.
(d) Remove the O−ring from the pressure regulator.
HINT:
At the time of installation, plaese refer to the following items. Ap-
ply a light coat of gasoline to a new O−ring, and install it to the
S01942 pressure regulator.

Support Tube

New O−Ring

Pressure
Regulator

CORRECT WRONG WRONG

S01973

1996 RAV4 (RM447U)

 SF−15
SFI − FUEL PRESSURE REGULATOR
SF1QH−01

INSTALLATION
Installation is in the reverse order of removal (See page SF−14).

1996 RAV4 (RM447U)

SF−16
SFI − INJECTOR

Sound
INJECTOR SF0QG−02

Scope ON−VEHICLE INSPECTION

1. INSPECT INJECTOR OPERATION
Check operation sound from each injector.
(1) With the engine running or cranking, use a sound
scope to check that there is normal operating noise
in proportion to engine speed.
S01952
(2) If you have no sound scope, you can check the in-
jector transmission operation with your finger.
If no sound or unusual sound is heard, check the wiring connec-
tor, injector or injection signal from the ECM.

Ohmmeter 2. INSPECT INJECTOR RESISTANCE

(a) Remove the cylinder head cover (See page EM−33).
(b) Disconnect the injector connectors.
(c) Using an ohmmeter, measure the resistance between the
terminals.
Resistance: Approx. 13.8 Ω
If the resistance is not as specified, replace the injector.
(d) Reconnect the injector connectors.
S01950 (e) Reinstall the cylinder head cover (See page EM−55).

1996 RAV4 (RM447U)

 SF−17
SFI − INJECTOR
SF0QH−03

COMPONENTS

1996 RAV4 (RM447U)

SF−18
SFI − INJECTOR

1996 RAV4 (RM447U)

 SF−19
SFI − INJECTOR
SF0QI−03

REMOVAL
1. REMOVE AIR CLEANER ASSEMBLY (See page
ST−4)
2. REMOVE CYLINDER HEAD COVER (See page
EM−33)
3. DISCONNECT THROTTLE BODY FROM INTAKE MAN-
IFOLD (See page SF−30)
4. REMOVE DISTORIBUTOR (See page IG−9)

5. DISCONNECT ENGINE WIRE FROM INTAKE MAN-

IFOLD
(a) Disconnect the 4 injector connectors.
(b) Disconnect the 2 clamps of the engine wire from the wire
brackets on intake manifold.
(c) Remove the bolt, and disconnect the engine wire protec-
tor from the RH side of the intake manifold.
(d) Disconnect the clamp of the engine wire from the wire
S01903 clamp.

6. REMOVE EGR VALVE AND PIPE

(1)
(a) Disconnect these hoses from the EGR valve:
(1) Vacuum hose from port E of VSV
(2) EGR hose from vacuum modulator
(b) Loosen the cylinder head side of the EGR pipe union nut.
(c) Remove the 2 nuts, the EGR valve, pipe assembly and
(2) gasket.
7. DISCONNECT ENGINE COMPORTMENT R/B NO.2
S01939

8. REMOVE FUEL INLET HOSE AND DELIVERY PIPE

(a) Remove the union bolt and 2 gaskets, and disconnect the
fuel inlet hose from the fuel filter outlet.
CAUTION:
Put a shop towel under the fuel filter. Slowly loosen the
union bolt.
(b) Disconnect the air hose for the air assist system from the
intake manifold port, and remove the air hose.
S01827

(c) Loosen the 2 bolts holding the delivery pipe to the cylinder
head.
(d) Disconnect the delivery pipe from the 4 injectors, and re-
Disconnect
move the delivery pipe and fuel inlet hose assembly.
9. REMOVE INJECTORS AND SPACERS
(a) Remove the 4 injectors and 2 spacers from the cylinder
head.
NOTICE:
Spacer S01949 Be careful not to drop the injectors and spacers.

1996 RAV4 (RM447U)

SF−20
SFI − INJECTOR

(b) Remove the 2 O−rings, insulator and grommet from each

injector.

1996 RAV4 (RM447U)

 SF−21
SFI − INJECTOR
SF0QJ−04

Union Bolt SST SST INSPECTION

(Hose) (Clamp) 1. INSPECT INJECTOR INJECTION
SST (Union) CAUTION:
Keep injector clear of sparks during the test.
SST
Fuel Filter (Union)
(On−Vehicle)
Injector
S01900

(a) Connect SST (union and hose) to the fuel filter outlet with
Union Bolt SST
the 2 gaskets and union bolt.
(Union)
Gasket
SST 09268−41046 (90405−09015)
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
HINT:
SST
Use the vehicle’s fuel filter.
(Hose)
Fuel Filter

S01833

SST (b) Install the grommet and O−ring to the injector.

(Hose) (c) Connect SST (union and hose) to the injector, and hold
SST
(Union) the injector and union with SST (clamp).
SST 09268−41046
O−Ring
SST (d) Put the injector into a graduated cylinder.
(Clamp) HINT:
Install a suitable vinyl hose onto the injector to prevent gasoline
Vinyl from splashing out.
Tube
P25498

TOYOTA (e) Connect the TOYOTA hand−held tester to the DLC3.

Hand−Held Tester (f) Turn the ignition switch ON and TOYOTA hand−held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(g) Select the active test mode on the TOYOTA hand−held
tester.
(h) Please refer to the TOYOTA hand−held tester operator’s
S01354 manual for further details.
(i) If you have no TOYOTA hand−held tester, connect the
positive (+) and negative (−) leads from the battery to the
fuel pump connector (See page SF−5).

1996 RAV4 (RM447U)

SF−22
SFI − INJECTOR

(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
SST
(Wire) Volume:
54 − 69 cm3 (3.1 − 4.2 cu in.) per 15 sec.
Connect Difference between each injector:
5 cm3 (0.8 cu in.) or less
P25497 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.
P10811 (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.

1996 RAV4 (RM447U)

 SF−23
SFI − INJECTOR
SF0QK−03

New Insulator INSTALLATION

1. INSTALL INJECTORS AND SPACERS
(a) Install new insulator and grommet to each injector.
(b) Apply a light coat of gasoline onto 2 new O−rings, and
New O−Ring install them to each injector.

New O−Ring

New Grommet
P10889

(c) Place the 2 spacers in position on the cylinder head.

(d) Push in the 4 injectors to the cylinder head.

Push

Spacer
S01951

2. INSTALL DELIVERY PIPE AND FUEL INLET HOSE

(a) Place the delivery pipe together with the 2 bolts between
the intake manifold and cylinder head.
Push (b) While turning the injector left and right, push it to the deliv-
ery pipe.
Turn

S01967

(c) Temporarily install the 2 bolts holding the delivery pipe to

the cylinder head.

S01940

(d) Check that the injectors rotate smoothly.

HINT:
If injectors do not rotate smoothly, the probable cause is incor-
Upward Connector rect installation of O−rings. Replace the O−rings.
(e) Position the injector connector upward.

Turn
S01947

1996 RAV4 (RM447U)

SF−24
SFI − INJECTOR

(f) Tighten the 2 bolts holding the delivery pipe to the cylinder
head.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

S01941

(g) Install the air hose for the air assist system to the intake
manifold port.
(h) Connect the fuel inlet hose to the fuel filter with 2 new gas-
kets and the union bolt.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
3. INSTALL ENGINE COMPARTMENT R/B NO.2
Install
4. INSTALL EGR VALVE AND PIPE
HINT:
Air Hose
S01953 Place a new gasket on the intake manifold.
Torque:
Nut:
13 N·m (130 kgf·cm, 9 ft·lbf)
Union nut:
59 N·m (600 kgf·cm, 43 ft·lbf)

5. CONNECT ENGINE WIRE TO INTAKE MANIFOLD

Gray HINT:
No.1
No.2 The No.1 and No.3 injector connectors are brown, and the No.2
No.3 and No.4 injector connectors are gray.
No.4 6. CONNECT THROTTLE BODY TO INTAKE MANIFOLD
7. INSTALL CYLINDER HEAD COVER (See page EM−55
)
Brown 8. INSTALL AIR CLEANER ASSEMBLY
S01948 9. INSTALL DISTORIBUTOR (See page IG−13)

1996 RAV4 (RM447U)

 SF−25
SFI − FUEL TANK AND LINE

FUEL TANK AND LINE

SF0QM−02

COMPONENTS
CAUTION:
S Always use new gaskets when replacing the fuel tank or component parts.
S Apply the proper torque to all parts tightened

3.5 (35, 31 in.·lbf)

Fuel Suction w/ Pump
& Gauge Tube Assembly
x7
Fuel Vent Tube Fuel Tank Cap
w/ Gauge Assembly x8
Fuel return Vent tube 3.5 (35, 31 in.·lbf)
Gasket

Fuel Tank Inlet Pipe

z Gasket
z Gasket
1.8 (18, 16 in.·lbf) Fuel Tank 1.8 (18, 16 in.·lbf)
Breather Tube
Breather Hose
EVAP Vent Tube z
z Gasket x5
z Gasket Fuel
Tank Filler Pipe Shield
Fuel Cut Off Valve
z Gasket Filler Pipe

Filler Pipe Protector

x5 Fuel Inlet Hose

3.5 (35, 31 in.·lbf)

Protector
Fuel Main Tube

Fuel Tank Protector

Center Exhaust Pipe

39 (390, 29)
z Gasket

39 (390, 29)

Fuel Tank Band

49 (500, 36)
21 (210, 15)

z Gasket

4WD
Propeller Shaft Assembly 74 (750, 54)
Protector

Protector

Protector 37 (375, 27)

N·m (kgf·cm, ft·lbf) : Specified torque

z Non−reusable part S01936
1996 RAV4 (RM447U)
SF−26
SFI − FUEL TANK AND LINE
SF0QN−01

INSPECTION
INSPECT FUEL TANK AND LINE
(a) Check the fuel lines for cracks, leakage and all connec-
Crack Leakage tions for deformation.
(b) Check the fuel tank vapor vent system hoses and connec-
tions for looseness, sharp bends or damage.
(c) Check the fuel tank for deformation, cracks, fuel leakage
Deformation and tank band looseness.
BO0919
(d) Check the filler neck for damage or fuel leakage.

2 − 7 mm (0.08 − 0.28 in.) (e) Hose and tube connections are as shown in the illustra-
Pipe Hose tion.
If a problem is found, repair or replace the part as necessary.

Clip
0 − 3 mm (0 − 0.12 in.) FU0041

1996 RAV4 (RM447U)

 SF−27
SFI − THROTTLE BODY

THROTTLE BODY SF0QO−03

ON−VEHICLE INSPECTION
1. INSPECT THROTTLE BODY
(a) Check that the throttle linkage moves smoothly.

S01898

P (b) Check the vacuum at each port.

E S Start the engine.
R
S Check the vacuum with your finger.
Port name At idle Other than idle
P No vacuum Vacuum
E No vacuum Vacuum
R No vacuum No vacuum

S01946

Ohmmeter 2. INSPECT THROTTLE POSITION SENSOR

(a) Apply vacuum to the throttle opener.
(b) Disconnect the sensor connector.
Throttle Position Sensor (c) Using an ohmmeter, measure the resistance between
each terminal.
VC
Clearance between Between
VTA Resistance
lever and stop screw terminals
E2
0 mm (0 in.) VTA − E2 0.2 − 5.7 kΩ
S00037 Throttle valve fully
VTA − E2 2.0 − 10.2 kΩ
open
− VC − E2 2.5 − 5.9 kΩ

(d) Reconnect the sensor connector.

3. INSPECT AND ADJUST THROTTLE OPENER
4. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
5. CHECK IDLE SPEED
Idle speed: 700 ± 50 rpm

6. CHECK AND ADJUST THROTTLE OPENER SETTING

SPEED
Plug (a) Disconnect the vacuum hose from the throttle opener,
and plug the hose end.
(b) Maintain the engine at 2,500 rpm.
Disconnect (c) Release the throttle valve.
(d) Check that the throttle opener is set.
Throttle opener setting speed:
S01901 1,300 − 1,500 rpm (w/ cooling fan OFF)

1996 RAV4 (RM447U)

SF−28
SFI − THROTTLE BODY

(e) Adjust the throttle opener setting speed by turning the

throttle opener adjusting screw.
(f) Reconnect the vacuum hose to the throttle opener.
2.5 mm Hexagon Wrench

Throttle Opener
Adjusting Screw
S01945

1996 RAV4 (RM447U)

 SF−29
SFI − THROTTLE BODY
SF0QP−02

COMPONENTS

1996 RAV4 (RM447U)

SF−30
SFI − THROTTLE BODY
SF0QQ−03

REMOVAL
1. DRAIN ENGINE COOLANT
2. A/T:
DISCONNECT THROTTLE CABLE FROM THROTTLE
BODY
3. DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
4. REMOVE AIR CLEANER CAP ASSEMBLY (See page
ST−4)

(3)
5. REMOVE THROTTLE BODY
(2) (a) Disconnect the throttle position sensor connector.
(b) Disconnect the IAC valve connector.
(c) Disconnect these hoses from the throttle body:
(1) PCV hose from air tube
(2) Vacuum hose from port ”R” of EGR vacuum modu-
lator
(1) (4)
(3) Vacuum hose from port ”P” of EGR vacuum modu-
S01905 lator
(4) EVAP hose from chacoal canister
(d) Remove the 4 bolts (Type A) or the 2 bolts, 2 nuts (Type
A A B) and gasket, and diaconnect the throttle body from the
B intake manifold.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
Protrusion HINT:
B At the time of installation, plaese refer to the following items.
(Bolt: Type A) S Place a new gasket on the intake chamber, facing the pro-
(Nut: Type B) trusion downward.
S01907 S Each bolt is indicated in the illustration (Type A).
Bolt length:
A: 40 mm (1.57 in.)
B: 55 mm (2.17 in.)

(e) Disconnect these hoses from the throttle body:

(1) Water bypass hose from water outlet
(2) Water bypass hose from water bypass pipe
(3) Air hose from intake manifold

(1)

(2)
(3) S01902

1996 RAV4 (RM447U)

 SF−31
SFI − THROTTLE BODY
SF1QE−01

INSPECTION
1. CLEAN THROTTLE BODY
(a) Using a soft brush and carburetor cleaner, clean the cast
parts.
(b) Using compressed air, clean all the passages and aper-
tures.
NOTICE:
To prevent deterioration, do not clean the
S01897
throttle position sensor.

Throttle Lever 2. INSPECT THROTTLE VALVE

(a) Apply vacuum to the throttle opener.
(b) Check that there is no clearance between the throttle stop
screw and throttle lever when the throttle valve is fully
closed.

Throttle No Clearance
Stop
Screw Vacuum
S01911

3. INSPECT THROTTLE POSITION SENSOR

(a) Apply vacuum to the throttle opener.
(b) Using an ohmmeter, measure the resistance between
VC each terminal.
VTA
IDL Clearance between
Between terminals Resistance
lever and stop screw
E2
E2 IDL VTA VC 0 mm (0 in.) VTA − E2 0.2 − 5.7 kΩ
Throttle valve fully
VTA − E2 2.0 − 10.2 kΩ
P00025 open

− VC − E2 2.5 − 5.9 kΩ

4. IF NECESSARY, ADJUST THROTTLE POSITION SEN-

SOR
(a) Loosen the 2 set screws of the sensor.

S01899

1996 RAV4 (RM447U)

SF−32
SFI − THROTTLE BODY

(b) Apply vacuum to the throttle opener.

(c) Insert a 0.60 mm (0.024 in.) thikness gauge between the
Ohmmeter throttle stop screw and stop lever.
(d) Connect the test probe of an ohmmeter to the terminals
0.60 mm IDL and E2 of the sensor.
(e) Gradually turn the sensor clockwise untill the ohmmeter
IDL Vacuum deflects, and secure it with the 2 set screws.
E2
S01910

(f) Recheck the continuity between terminals IDL and E2.

Clearance between
Continuity (IDL − E2)
Ohmmeter lever and stop screw
0.50 or
0.70 mm 0.50 mm (0.020 in.) Continuity
0.70 mm (0.028 in.) No continuity

IDL Vacuum
E2
S01910

1996 RAV4 (RM447U)

 SF−33
SFI − THROTTLE BODY
SF0QS−01

INSTALLATION
Installation is in the reverse order of removal (See page SF−30).

1996 RAV4 (RM447U)

SF−34
SFI − IDLE AIR CONTROL (IAC) VALVE

IDLE AIR CONTROL (IAC) VALVE SF0QT−02

ON−VEHICLE INSPECTION
1. INSPECT IAC VALVE OPERATION
(a) Initial conditions:
S Engine at normal operating temperature
S Idle speed check correctly
S Transmission in neutral position

DLC1 (b) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843−18020
TE1 (c) Maintain engine speed in the range between 900 − 1,300
SST
E1 rpm for 5 seconds. Check that it returns to idle speed.
If the engine speed operation is not as specified, check the IAC
valve, wiring and ECM.
(d) Remove the SST.
SST 09843−18020
S01261

RSC 2. INSPECT IAC VALVE RESISTANCE

+B NOTICE:
RSO
”Cold” and ”Hot” in these sentences express the tempera-
Ohmmeter
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).
(a) Disconnect the IAC valve connector.
(b) Using an ohmmeter, measure the resistance between ter-
IAC Valve minal +B and other terminals (RSC, RSO).
S01904

Resistance:
Cold: 17.0 − 24.5 Ω
Hot: 21.5 − 28.5 Ω
If resistance is not as specified, replace the IAC valve.
(c) Reconnect the IAC valve connector.

1996 RAV4 (RM447U)

 SF−35
SFI − IDLE AIR CONTROL (IAC) VALVE
SF0QU−02

COMPONENTS

1996 RAV4 (RM447U)

SF−36
SFI − IDLE AIR CONTROL (IAC) VALVE
SF0QV−03

REMOVAL
1. REMOVE THROTTLE BODY (See page SF−30)
2. REMOVE IAC VALVE
Remove the 4 screws, IAC valve and gasket.
HINT:
At the time of installation, plaese refer to the following items.
Place a new gasket on the throttle body.

S01895

1996 RAV4 (RM447U)

 SF−37
SFI − IDLE AIR CONTROL (IAC) VALVE
SF0QW−01

INSPECTION
RSC
+B
INSPECT IAC VALVE OPERATION
(a) Connect the positive (+) lead from the battery to terminal
Battery +B and negative (−) lead to terminal RSC, and check that
the valve is closed.

Closed

Z16510

(b) Connect the positive (+) lead from the battery to terminal
+B +B and negative (−) lead to terminal RSO, and check that
RSO the valve is open.
Battery

Open

Z16511

1996 RAV4 (RM447U)

SF−38
SFI − IDLE AIR CONTROL (IAC) VALVE
SF1QD−01

INSTALLATION
Installation is in the reverse order of removal (See page SF−36).

1996 RAV4 (RM447U)

SF−42
SFI − VSV FOR EXHAUST GAS RECIRCULATION (EGR)

VSV FOR EXHAUST GAS RECIRCULATION (EGR)

SF0R1−01

COMPONENTS

Hold−Down Clamp

4WD

Battery

Vacuum Hose
Vacuum Hose

VSV

S01935

1996 RAV4 (RM447U)

 SF−43
SFI − VSV FOR EXHAUST GAS RECIRCULATION (EGR)
SF0R2−02

Ohmmeter
INSPECTION
Continuity 1. 4WD:
REMOVE BATTERY
2. REMOVE VSV
3. INSPECT VSV
4. INSPECT VSV FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
terminals.
S01917
Resistance: At 20°C (68°F): 33 − 39 Ω
If there is no continuity, replace the VSV.

No Continuity 5. INSPECT VSV FOR GROUND

Ohmmeter
Using an ohmmeter, check that there is no continuity between
each terminal and the body.
If there is continuity, replace the VSV.

S01918

Air 6. INSPECT VSV OPERATION

(a) Check that air flows from ports E to G.

S01919

(b) Apply battery positive voltage across the terminals.

Air (c) Check that air flows from port E to the filter.
If operation is not as specified, replace the VSV.
7. REINSTALL VSV
E
8. 4WD:
Filter REINSTALL BATTERY

Battery
S01920

1996 RAV4 (RM447U)

SF−44
SFI − VSV FOR EVAPORATIVE EMISSION (EVAP)

VSV FOR EVAPORATIVE EMISSION (EVAP)

SF0R3−02

COMPONENTS

1996 RAV4 (RM447U)

 SF−45
SFI − VSV FOR EVAPORATIVE EMISSION (EVAP)
SF0R4−02

Ohmmeter INSPECTION
1. REMOVE AIR CLEANER CAP ASSEMBLY (See page
ST−4)
2. REMOVE VSV
3. INSPECT VSV
4. INSPECT VSV FOR OPEN CIRCUIT
Continuity Using an ohmmeter, check that there is continuity between the
terminals.
S01912
Resistance: At 20°C (68°F): 30 −34 Ω
If there is no continuity, replace the VSV.

Ohmmeter 5. INSPECT VSV FOR GROUND

Using an ohmmeter, check that there is no continuity between
each terminal and the body.
If there is continuity, replace the VSV.

No Continuity
S01913

6. INSPECT VSV OPERATION

Air
(a) Check that air does not flow from ports E to F.
NOTICE:
E Never apply more than 60 kPa (0.61 kgf/cm2, 8.7 psi) of
pressure compressed air to the VSV.
F

S01915

(b) Apply battery positive voltage across the terminals.

Air (c) Check that air flows from ports E to F.
If operation is not as specified, replace the VSV.
7. REINSTALL VSV
E
8. REINSTALL AIR CLEANER CAP ASSEMBLY
F
Battery

S01916

1996 RAV4 (RM447U)

SF−46
SFI − VSV FOR VAPOR PRESSURE SENSOR

VSV FOR VAPOR PRESSURE SENSOR

SF0R5−03

COMPONENTS

1996 RAV4 (RM447U)

 SF−47
SFI − VSV FOR VAPOR PRESSURE SENSOR
SF0R6−02

Ohmmeter INSPECTION
1. REMOVE AIR CLEANER CAP ASSEMBLY (See page
ST−4)
2. REMOVE VSV
3. INSPECT VSV
Continuity 4. INSPECT VSV FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
terminals.
S01921
Resistance: At 20°C (68°F): 33 − 39 Ω
If there is no continuity, replace the VSV.

Ohmmeter
5. INSPECT VSV FOR GROUND
Using an ohmmeter, check that there is no continuity between
each terminal and the body.
If there is continuity, replace the VSV.

No Continuity

S01922

Air 6. INSPECT VSV OPERATION

(a) Check that the air flows from ports E to G.

G
E
F

S01923

(b) Apply battery positive voltage across the terminals.

Air (c) Check that the air flows from ports E to F.
If operation is not as specified, replace the VSV.
7. REINSTALL VSV
E 8. REINSTALL AIR CLEANER CAP ASSEMBLY

F G

Battery
S01924

1996 RAV4 (RM447U)

SF−48
SFI − ENGINE COOLANT TEMPERATURE (ECT) SENSOR

ENGINE COOLANT TEMPERATURE (ECT) SENSOR

SF0R7−01

COMPONENTS

ECT Sensor Connector

ECT Sensor

z Gasket

z Non−reusable part
S01930

1996 RAV4 (RM447U)

 SF−49
SFI − ENGINE COOLANT TEMPERATURE (ECT) SENSOR
SF0R8−01

INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE ECT SENSOR
Ohmmeter 3. INSPECT ECT SENSOR RESISTANCE
Using an ohmmeter, measure the resistance between the ter-
minals.
Resistance: Refer to the graph
30 If the resistance is not as specified, replace the sensor.
20
4. REINSTALL ECT SENSOR
10
Install a new gasket to the ECT sensor.
5 Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
RESISTANCE kΩ

3 Acceptable 5. FILL WITH ENGINE COOLANT

2
1
0.5
0.3
0.2
0.1

−20 0 20 40 60 80 100
S01196
(−4) (32)(68)(104)(140)(176)(212)
S01699
TEMPERATURE°C (°F)

Z17274

1996 RAV4 (RM447U)

SF−50
SFI − INTAKE AIR TEMPERATURE (IAT) SENSOR

INTAKE AIR TEMPERATURE (IAT) SENSOR

SF0R9−01

COMPONENTS

Grommet

IAT Sensor

IAT Sensor
Connector

S01927

1996 RAV4 (RM447U)

 SF−51
SFI − INTAKE AIR TEMPERATURE (IAT) SENSOR
SF0RA−02

Ohmmeter
INSPECTION
1. REMOVE IAT SENSOR
2. INSPECT IAT SENSOR RESISTANCE
Using an ohmmeter, measure the resistance between the ter-
minals.
30 Resistance: Refer to the graph
20 If the resistance is not as specified, replace the sensor.
10 3. REINSTALL IAT SENSOR
RESISTANCE kΩ

5 Acceptable
3
2
1
0.5
0.3
0.2
0.1
−20 0 20 40 60 80 100
(−4)(32)(68)(104)(140)(176)(212)
TEMPERATURE°C (°F)
Z17273

1996 RAV4 (RM447U)

SF−52
SFI − MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

SF0RB−02

COMPONENTS

1996 RAV4 (RM447U)

 SF−53
SFI − MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
SF0RC−02

Voltmeter INSPECTION
1. INSPECT POWER SOURCE VOLTAGE OF MAP SEN-
SOR
(a) Disconnect the MAP sensor connector.
(b) Turn the ignition switch ON.
(c) Using a voltmeter measure the voltage between connec-
tor terminals VC and E2 of the wiring harness side.
E2 VC
Voltage: 4.5 − 5.5 V
S01943
(d) Turn the ignition switch to LOCK.
(e) Reconnect the MAP sensor connector.
2. INSPECT POWER OUTPUT OF MAP SENSOR
(a) Turn the ignition switch ON.
(b) Disconnect the vacuum hose on the air intake chamber
side.

(c) Connect a voltmeter to terminals PIM and E2 of the ECM,

and measure the output voltage under ambient atmo-
spheric pressure.
(d) Apply vacuum to the MAP sensor in 13.3 kPa (100 mmHg,
3.94 in.Hg) segments to 66.7 kPa (500 mmHg, 19.69
in.Hg).
(e) Measure the voltage drop from step (c) above for each
segment.
Vacuum
Voltage drop
ECM PIM Applied 13.3 26.7 40.0 53.5 66.7
Vacuum
kPa
mmHg 100 200 300 400 500
Voltmeter in.Hg 3.94 7.87 11.81 15.75 19.69
E2

Voltage
drop V 0.3 − 0.5 0.7 − 0.9 1.1 − 1.3 1.5 − 1.7 1.9 − 2.1

S01925

(f) Reconnect the vacuum hose to the air intake chamber.

1996 RAV4 (RM447U)

SF−54
SFI − VAPOR PRESSURE SENSOR

VAPOR PRESSURE SENSOR

SF0RD−03

COMPONENTS

1996 RAV4 (RM447U)

 SF−55
SFI − VAPOR PRESSURE SENSOR
SF0RE−02

INSPECTION
1. INSPECT POWER SOURCE VOLTAGE OF VAPOR
PRESSURE SENSOR
(a) Disconnect the vapor pressure sensor connector.
(b) Turn the ignition switch ON.
(c) Using a voltmeter, measure the voltage between connec-
tor terminals VC and E2 of the wiring harness side.
Voltage: 4.5 − 5.5 V
(d) Turn the ignition switch to LOCK.
(e) Reconnect the vapor pressure sensor connector.
2. INSPECT POWER OUTPUT OF VAPOR PRESSURE
SENSOR
(a) Turn the ignition switch ON.
(b) Disconnect the EVAP hose from the vapor pressure sen-
sor.

(c) Connect a voltmeter to terminals PTNK and E2 of the

ECM, and measure the output voltage under the following
conditions:
(1) Apply vacuum (2.0 kPa, 15 mmHg, 0.59 in.Hg) to
the vapor pressure sensor.
Voltage: 1.3 − 2.1 V
(2) Release the vacuum from the vapor pressure sen-
sor.
Voltage: 3.0 − 3.6 V
(3) Apply pressure (1.5 kPa, 15 gf/cm2, 0.22 psi) to the
vapor pressure sensor.
Voltage: 4.2 − 4.8 V
(d) Reconnect the EVAP hose to the vapor pressure sensor.

1996 RAV4 (RM447U)

SF−56
SFI − KNOCK SENSOR

KNOCK SENSOR
SF0RF−01

COMPONENTS

Knock Sensor
Connector
Knock Sensor 1

S01929

1996 RAV4 (RM447U)

 SF−57
SFI − KNOCK SENSOR
SF0RG−02

2WD INSPECTION
1. 4WD:
REMOVE ENGINE AND TRANSAXLE ASSEMBLY (See
SST page EM−68)
2. REMOVE KNOCK SENSOR
(a) Disconnect the knock sensor connector.
(b) Using SST, remove the knock sensor.
SST 09816−30010
S01838
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)

3. INSPECT KNOCK SENSOR

Using an ohmmeter, check that there is no continuity between
Ohmmeter
the terminal and body.
If there is continuity, replace the sensor.
4. REINSTALL KNOCK SENSOR
Installation is in the reverse order of removal.
5. 4WD:
REINSTALL ENGINE AND TRANSAXLE ASSEMBLY
P01630 (See page EM−74)

1996 RAV4 (RM447U)

SF−58
SFI − HEATED OXYGEN SENSOR

HEATED OXYGEN SENSOR

SF1QB−01

COMPONENTS

1996 RAV4 (RM447U)

 SF−59
SFI − HEATED OXYGEN SENSOR

1996 RAV4 (RM447U)

SF−60
SFI − HEATED OXYGEN SENSOR
SF1QC−01

INSPECTION
Bank 1 sensor 1, 2:
INSPECT OPERATION OF OXYGEN SENSOR (See page DI−42)

1996 RAV4 (RM447U)

 SF−61
SFI − ENGINE CONTROL MODULE (ECM)

ENGINE CONTROL MODULE (ECM)

SF0RK−01

COMPONENTS

ECM Assembly

Floor Carpet
Center Cover LH

ECM Connector

Bracket

ECM Cover

Bracket ECM
Bracket

S01842

1996 RAV4 (RM447U)

SF−62
SFI − ENGINE CONTROL MODULE (ECM)
SF0RL−02

INSPECTION
1. REMOVE ECM
2. INSPECT ECM (See page DI−18)
3. REINSTALL ECM

1996 RAV4 (RM447U)

 SF−63
SFI − FUEL CUT RPM

FUEL CUT RPM SF0RM−02

INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
2. CONNECT TOYOTA HAND−HELD TESTER OR OBD II
SCAN TOOL (See page SF−1)

3. INSPECT FUEL CUT−OFF PRM

Sound (a) Increase the engine speed to at least 2,500 rpm.
Scope (b) Use a sound scope to check for injector operating noise.
(c) Check that when the throttle lever is released, injector op-
eration noise stops momentarily and then resumes.
HINT:
Measure with the A/C OFF.
Fuel return rpm: 1,500 rpm
S01952 4. DISCONNECT TOYOTA HAND−HELD TESTER OR
OBD II SCAN TOOL

1996 RAV4 (RM447U)