TOYOTA RAV4 1996 Service Repair Manual

1999-2000 BRAKES
Anti-Lock - RAV4
DESCRIPTION
Anti-Lock Brake System (ABS) consists of hydraulic actuator, solenoids, pump motor, ABS Electronic Control
Unit (ECU), relays, deceleration sensor (4WD) and wheel speed sensors. See Fig. 1
.
An ABS warning light is located on the instrument cluster. Warning light comes on for 3 seconds as a bulb test
when ignition is turned on. A primary check is performed after each engine start and initial vehicle speed
exceeds 6 MPH. An actuator noise is heard as vehicle is started or as speed exceeds 6 MPH. This is normal.
Anti-lock systems remains active until vehicle speed drops below 3 MPH.

1999 Toyota RAV4
1999-2000 BRAKES Anti-Lock - RAV4

1999 Toyota RAV4
1999-2000 BRAKES Anti-Lock - RAV4
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Fig. 1: Locating ABS Components
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
OPERATION
Under normal driving conditions, ABS functions as a standard brake system. With detection of wheel lock-up,
short pedal pulsations occurring in rapid succession will be felt in brake pedal. Pedal pulsation will continue
until there is no longer a need for ABS function or until vehicle speed falls below 3 MPH. Maintaining a
constant force on the brake pedal provides shortest stopping distance.
BLEEDING BRAKE SYSTEM
MASTER CYLINDER
Ensure brake fluid reservoir is full. Disconnect brakelines from master cylinder. Have an assistant slowly
depress brake pedal and hold. Block off outlet ports on master cylinder with finger, then have assistant release
brake pedal. Repeat 3 or 4 times or until master cylinder is bled.
BRAKELINES
Install bleeder hose with container of clean brake fluid on wheel cylinder or caliper. Depress brake pedal several
times and hold, then loosen bleeder valve. Tighten bleeder valve when fluid flow stops, then release brake
pedal. Repeat until air bubbles are no longer present for each wheel.
TROUBLE SHOOTING
PRELIMINARY INSPECTION
Begin diagnosis with a basic visual inspection of brake fluid level, tire size and other mechanical brake system
components which may affect anti-lock operation. Check system sensors, wire harnesses and connectors for
proper installation, routing and connection. Ensure all system fuses are okay. Repair as necessary. NOTE: For more information on brake system, see DISC & DRUM
- FWD CARS article.
CAUTION: See ANTI-LOCK BRAKE SAFETY PRECAUTIONS article in GENERAL
INFORMATION.
CAUTION: Brake fluid will damage painted surfaces. If brake fluid contacts a painted
surface, wipe off immediately and clean with alcohol. Use only DOT 3
brake fluid from a sealed container. DO NOT mix brake fluid with any other
type.
NOTE: Bleed brakes from farthest wheel first to closest wheel.

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If cause of faulty operation cannot be located with basic diagnosis, ABS electronic control system must be
checked. See DIAGNOSIS & TESTING
.
When ignition is turned on, ABS warning light should come on, then go out after 3 seconds. If ABS warning
light does not operate as specified, go to ABS WARNING LIGHT under DIAGNOSIS & TESTING
.
DIAGNOSIS & TESTING
RETRIEVING DIAGNOSTIC TROUBLE CODES
ABS Warning Light Diagnostics
1. Ensure battery voltage is 12 volts. Turn ignition switch to ON position. ABS warning light should
illuminate, then go out after 3 seconds. If ABS warning light does not illuminate, check fuse, bulb, and
wiring harness. See ABS WARNING LIGHT
.
2. Remove short pin from DLC1. DLC1 is located in engine compartment, on left side of engine. See Fig.
2 . Using a jumper wire, jumper DLC1 terminals Tc and E1 . If a malfunction is detected, ABS warning
light will begin to flash a 2-digit Diagnostic Trouble Code (DTC). First number of blinks will equal first
digit in DTC. After a 1.5-second pause, second number of blinks will equal second digit in DTC.
3. If 2 or more DTCs are stored, there will be a 2.5-second pause between each DTC. After all DTCs are
flashed, there will be a 4 second pause and all DTCs will repeat. If ABS system is functioning properly,
ABS warning light will blink 2 times per second. For code definitions, see DTC DEFINITIONS
. For
DTC diagnosis, see DIAGNOSTIC TESTS
.
4. After replacing or repairing components, clear DTCs. If battery cables were disconnected during repairs,
all DTCs will be erased. If battery cables were not disconnected during repairs, see CLEARING DTCS
.
DTC DEFINITIONS NOTE: DO NOT start engine when retrieving DTCs.
NOTE: Speed sensor diagnostics and code retrieval use different DLC1 terminals to
access DTCs. If a speed sensor or speed sensor circuit problem is suspected,
see SPEED SENSOR DIAGNOSTICS
.
DTCCircuit/Malfunction
ABS-Related DTCs (1)
11 Open In ABS Solenoid Relay Circuit
12 Short In ABS Solenoid Relay Circuit
13 Open In ABS Pump Motor Relay Circuit
14 Short In ABS Pump Motor Relay Circuit
21 Open/Shorted RF Solenoid, Defective ABS
Actuator
22 Open/Shorted LF Solenoid, Defective ABS
Actuator

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23 Open/Shorted RR Solenoid, Defective ABS
Actuator
24 Open/Shorted LR Solenoid, Defective ABS
Actuator
31 (2) Malfunction In RF Speed Sensor Signal
32 (2) Malfunction In LF Speed Sensor Signal
33 (2) Malfunction In RR Speed Sensor Signal
34 (2) Malfunction In LR Speed Sensor Signal
37 (3) One Tire Is Different Size Than The Others
41 Excessively Low/High Battery Voltage
43 (4) Deceleration Sensor Malfunction (Constant
Output)
44 (4) Open/Short In Deceleration Sensor Circuit
45 (5) Deceleration Sensor Malfunction
49 (4) Open In Stoplight Switch Circuit
51 Pump Motor Locked Up, Open Ground
Circuit
Speed Sensor-Related DTCs (6)
71 RF Speed Sensor Signal Low Voltage
72 LF Speed Sensor Signal Low Voltage
73 RR Speed Sensor Signal Low Voltage
74 LR Speed Sensor Signal Low Voltage
75 RF Speed Sensor Abnormal Change In
Output Voltage
76 LF Speed Sensor Abnormal Change In
Output Voltage
77 RR Speed Sensor Abnormal Change In
Output Voltage
78 LR Speed Sensor Abnormal Change In
Output Voltage
79 (4) Deceleration Sensor Faulty
(1)For ABS ECU DTCs, connect jumper wire between terminals Tc and E1 of DLC1.
(2)To clear DTC, either drive vehicle over 12 MPH for 30 seconds or more, or use procedure to clear
DTC. See CLEARING DIAGNOSTIC TROUBLE CODES
.
(3)2WD models.
(4)4WD models.
(5)4WD 2 door models.
(6)For speed sensor DTCs, connect jumper wire between terminals Ts and E1 of DLC1. See SPEED

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Fig. 2: Identifying DLC1 Terminals
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
CLEARING DIAGNOSTIC TROUBLE CODES
Remove short pin from DLC1. DLC1 is located in engine compartment on left side of engine. See Fig. 2
. Using
a jumper wire, jumper DLC1 terminals Tc and E
1 . Turn ignition on. With vehicle stopped, depress brake pedal
8 or more times within 5 seconds. DTCs are now erased. Ensure ABS warning light blinks 2 times per second.
Remove jumper wire. Reconnect short pin.
SPEED SENSOR DIAGNOSTICS
1. Ensure battery voltage exists. Turn ignition on. Ensure ABS warning light illuminates, then goes out after
about 3 seconds. If ABS warning light does not illuminate, check fuse, bulb and wiring harness. See ABS
WARNING LIGHT .
2. Turn ignition off. Using a jumper wire, jumper terminals Ts and E
1 of DLC1. DLC1 is located in engine
compartment on left side of en
gine. See Fig. 2. Start engine. Ensure ABS warning light blinks 4 times
.SENSOR DIAGNOSTICS

NOTE: While diagnosing speed sensors, brake system functions as a conventional
system.

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per second. If ABS light does not blink, go to ABS WARNING LIGHT. If ABS warning light blinks,
go to next step.
3. Drive vehicle straight ahead above 28 MPH for several seconds. Stop vehicle. Jumper terminals Tc and
E
1 of DLC1. See Fig. 2 . If all sensors are okay, a normal DTC is displayed (ABS warning light blinks 2
times a second). If a malfunction is detected, ABS warning light will begin to flash a 2-digit DTC. First
number of blinks will equal first digit in a DTC. After a 1.5-second pause, second number of blinks will
equal second digit in a DTC.
4. If 2 or more DTCs are stored, there will be a 2.5-second pause between each DTC. After all DTCs are
flashed, there will be a 4 second pause and all DTCs will repeat.
5. Record DTCs. Turn ignition off. Repair as necessary. See DTC DEFINITIONS
. Remove jumper wire
from DLC1. Clear DTCs. See CLEARING DTCS
.
ABS WARNING LIGHT
Circuit Description
If ABS ECU detects a system malfunction, ABS ECU illuminates ABS warning light while at the same time
prohibiting ABS control. At this time, ABS ECU records a DTC in memory. After removing short pin from
DLC1, connecting terminals Tc and E
1 of DLC1 causes ABS warning light to blink and output a DTC. See Fig.
2 .
Diagnostic Procedure
1. If ABS warning light stays on, go to step 3 . If ABS warning light does not illuminate, check fuse, light
bulb and wiring. Repair or replace as necessary. If bulb is okay, diagnose combination meter (instrument
panel). See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. If no
problems were found, go to next step.
2. Check ABS control relay. See SOLENOID RELAY SECTION
under ABS CONTROL RELAY under
COMPONENT TESTS. Replace as necessary. If ABS control relay is okay, go to next step.
3. Retrieve DTCs. See RETRIEVING DTCS
under DIAGNOSIS & TESTING. If DTC is present, perform
appropriate test under DIAGNOSTIC TESTS. If DTC is not present, and ABS warning light goes off
when short pin is removed, go to next step. If ABS warning light does not turn off, check for short circuit
in wiring harness between ABS warning light, DLC1 and ABS ECU. Repair as necessary. See WIRING
DIAGRAMS .
4. Check ABS control relay. See SOLENOID RELAY SECTION
under ABS CONTROL RELAY under
COMPONENT TESTS. Replace relay as necessary. If relay is okay, check for short circuit in wiring
harness between DLC1 and ABS control relay. Repair as necessary. See WIRING DIAGRAMS
.
TC TERMINAL
Circuit Description
Connecting terminals Tc and E1 of DLC1 causes ABS warning light to blink and output a DTC. See Fig. 2 .
Diagnostic Procedure

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1999-2000 BRAKES Anti-Lock - RAV4
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Turn ignition on. Measure voltage between terminals Tc and E1of DLC1. If voltage is 10-14 volts, circuit is
okay. If ABS warning light does not blink even after terminals are connected, malfunction may exist in ABS
ECU. If voltage is not 10-14 volts, check for open or short circuit in wiring harness between ABS actuator and
DLC1, or between ground and DLC1. See WIRING DIAGRAMS
. Repair as necessary. If wiring harness is
okay, replace ABS ECU.
TS TERMINAL
Circuit Description
Sensor check circuit detects abnormalities in speed sensor signal which cannot be detected when checking for
DTCs. Connecting terminals Ts and E
1 of DLC1 in engine compartment starts DTC check. See Fig. 2 .
Diagnostic Procedure
Turn ignition on. Measure voltage between terminals Ts and E1 of DLC1. If voltage is 10-14 volts, circuit is
okay. If ABS warning light does not blink even after terminals are connected, malfunction may exist in ABS
ECU. If voltage is not 10-14 volts, check for open or short circuit in wiring harness between ABS ECU and
DLC1, or between ground and DLC1. See WIRING DIAGRAMS
. Repair as necessary. If wiring harness is
okay, replace ABS ECU.
ABS ECU PIN VOLTAGES
ABS circuits and harness can be tested by backprobing ABS ECU connectors and comparing measured voltages
with ABS ECU standard values chart. See Fig. 3
.

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Fig. 3: ABS ECU Standard Values Chart
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
SYMPTOM DIAGNOSIS
If a normal DTC is displayed during DTC check but problem still occurs, check circuits for each problem
symptom in order given in SYMPTOM DIAGNOSIS
, then see specified procedure or appropriate test under
DIAGNOSIS & TESTING
, DIAGNOSTIC TESTS or COMPONENT TESTS .
SYMPTOM DIAGNOSIS
SymptomCircuitCircuit, DTC Or Procedure
Check DTC, Confirm Normal DTC
RETRIEVING DIAGNOSTIC TROUBLE

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SYMPTOM TESTS
ABS LIGHT ON: ABS ECU MALFUNCTION
Circuit Description
This circuit is the power source for ABS ECU and actuator.
DTC Detecting Condition
If voltage at ABS ECU terminal IG1 remains more than 17 volts, this DTC will set. If a malfunction occurs in
power source circuit, ABS ECU cuts off current to ABS control relay and prohibits ABS control.
Diagnostic Procedure
1. Retrieve DTCs. See RETRIEVING DTCS under DIAGNOSIS & TESTING. If DTC is output using
ABS warning light, perform appropriate test under DIAGNOSTIC TESTS
. If ABS warning light does
not operate normally, go to next step. If ABS warning light operates normally (lights blink 2 times per
second and no DTCs are present), check ABS control (solenoid) relay. See SOLENOID RELAY
SECTION under ABS CONTROL RELAY under COMPONENT TESTS. Check for short circuit in
ABS Inoperative (1)
Is OutputCODES
IG Power Source CircuitDTC 41
Speed Sensor CircuitDTCS 31, 32, 33 & 34: SPEED SENSOR
CIRCUIT
Check ABS Actuator (2) ACTUATOR CHECK
ABS Operates
Intermittently
(1)
Check DTC, Confirm Normal DTC
Is OutputRETRIEVING DIAGNOSTIC TROUBLE
CODES
Speed Sensor CircuitDTCS 31, 32, 33 & 34: SPEED SENSOR
CIRCUIT
Stoplight Switch CircuitDTC 49: STOPLIGHT SWITCH
CIRCUIT
Check ABS Actuator (2) ACTUATOR CHECK
ABS Warning Light
AbnormalABS Warning Light CircuitABS WARNING LIGHT
ABS ECUABS LIGHT ON: ABS ECU
MALFUNCTION
Unable To Perform
DTC Check
(1)
ABS Warning Light CircuitABS WARNING LIGHT
Tc Terminal CircuitTc TERMINAL
Unable To Do Speed
Sensor DiagnosticsTs Terminal CircuitTs TERMINAL
ABS ECUABS LIGHT ON: ABS ECU
MALFUNCTION
(1)If all circuits check okay and problem is still occurring, replace ABS ECU.
(2)If actuator check is abnormal, check for hydraulic leakage, perform visual inspection.

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wiring harness between ABS control relay and DLC1. Repair or replace as necessary. See WIRING
DIAGRAMS .
2. If ABS warning light is on, go to next step. If ABS warning light is off, check for open or short circuit in
wiring harness between ECU-IG fuse and ABS ECU. Repair as necessary. See WIRING DIAGRAMS
.
3. Start engine and check charging system voltage. If voltage is 10-16 volts, go to next step. If voltage is not
10-16 volts, diagnose charging system. Repair as necessary.
4. Turn ignition off. Disconnect appropriate ABS ECU connector supporting IG1 terminal. See Fig. 3
. Turn
ignition switch to ON position. Ensure ABS warning light turns off. If light turns off, replace ABS ECU.
If light does not turn off, check for short circuit in wiring harness between combination meter (instrument
panel) and ABS ECU, or between combination meter and DLC1. Repair as necessary. See WIRING
DIAGRAMS .
DIAGNOSTIC TESTS
DTC 11 & DTC 12: ABS CONTROL (SOLENOID) RELAY CIRCUIT
Circuit Description
This relay supplies power to each ABS solenoid. After ignition switch is turned to ON position, if initial check
is okay, this relay turns on. If malfunction occurs in ABS control relay circuit, ABS ECU cuts off current to
ABS control relay and prohibits ABS control.
DTC Detecting Condition
Detection of following conditions may set DTC 11 or DTC 12 if condition occurs for .2 seconds or more:
If voltage at ABS control relay connector terminal A9-1 is less than 1.5 volts and voltage at connector
terminal A9-5 is zero volts, DTC 11 may set.
If voltage at ABS control relay connector terminal A9-1 is 10-14 volts and voltage at connector terminal
A9-5 is 10-14 volts, DTC 12 may set.
Diagnostic Procedure
1. Disconnect ABS control relay 6-pin connector A9, located in engine compartment at front of vehicle. See
Fig. 1
. Measure voltage between connector terminals A9-2 and A9-6. See Fig. 4 . If voltage is 10-14
volts, go to next step. If voltage is not 10-14 volts, repair wiring harness between ground, battery and
ABS control relay.
2. Measure resistance between ABS control relay terminal A9-5 and appropriate ABS ECU terminals. See
ABS ECU
-TO-ACTUATOR CIRCUIT IDENTIFICATION/RESISTANCE VALUES . See Fig. 3 .
If resistance on every circuit is between 26-40 ohms, go to next step. If resistance is not as specified,
check for open or short circuit in appropriate wiring between ABS control relay, ABS actuator and ABS
ECU. See WIRING DIAGRAMS
. Repair as necessary. If wiring is okay, replace ABS actuator.
ABS ECU-TO-ACTUATOR CIRCUIT IDENTIFICATION/RESISTANCE VALUES
CircuitABS ECU
Connector/TerminalWire Color

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