TOYOTA RAV4 1996 Service Repair Manual

D02310
3
1
54 2
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−231
1996 RAV4 (RM447U)
3 Check pattern select switch.
PREPARATION:
Remove the pattern select switch.
CHECK:
Measure the resistance between terminals 1 and 3 of the pat-
tern select switch connector when the select switch is set to
PWR and NORM positions.
OK:
PatternResistance
PWR0 Ω (continuity)
NORM∞ Ω (open)
NG Replace pattern select switch.
OK
4 Check harness and connector between battery and pattern select switch, and
pattern select switch and ECM (See page IN−30).
NG Repair or replace harness or connector.
OK
Check and replace ECM.

DI41C−02
Vehicle Brought to Workshop
Customer Problem Analysis
P. DI−233
Check and Clear DTC (Pre−check)
P.
DI−234
Items inside
are titles of pages in this manual,
with the page number in the bottom portion. See
the indicated pages for detailed explanations.
Problem Symptom ConfirmationSymptom Simulation
P. IN−30
Symptom
does not occur
Symptom
occurs
DTC Check
P. DI−234
Sensor CheckCircuit Inspection
P. DI−246 −DI−282
DTC Chart
P. DI−239Problem Symptoms Table
P. DI−245
Check for Fluid Leakage
P. DI−282
Identification of Problem
Normal code
Repair
Confirmation Test
End
1
2
3
4
5
67
89
10
11
Step 8:Diagnostic steps permitting the use of the
TOYOTA hand−held tester, or TOYOTA
brake−out−box.
DI−232
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
1996 RAV4 (RM447U)
ANTI−LOCK BRAKE SYSTEM
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshooting in accordance with the procedure on the following pages.

DI41D−01
:
Customer ’s Name
Date Vehicle
Brought InRegistration Year Registration No.
Frame No.
Odometer Reading/ /
/ /
Date Problem First Occurred
Frequency Problem Occurs/ /
ContinuousIntermittent ( times a day)
ABS does not operate.
ABS does not operate efficiently.
ABS Warning Light
AbnormalRemains ONDoes not Light Up
DTC Check1st Time
2nd TimeNormal Code
Malfunction Code (Code )
Normal CodeMalfunction Code (Code )
Symptomskm
miles Inspector ’s
name
ABS Check Sheet
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
DI−233
1996 RAV4 (RM447U)
CUSTOMER PROBLEM ANALYSIS CHECK

R10638
DI98E−01
R06980
Short Pin
DLC1
F15316
E1
Tc DLC1
R01346
0.25 sec.
0.25 sec.
ON
OFF
ON
OFF0.5 sec.
4 sec.1.5
sec.2.5 sec.
Code 11Code 21
2 sec.
0.5 sec.
Codes 11 and 21Normal Code DI−234
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
1996 RAV4 (RM447U)
PRE−CHECK
1. DIAGNOSIS SYSTEM
(a) Check the indicator.
When the ignition switch is turned ON, check that the ABS
warning light goes on for 3 seconds.
HINT:
If the indicator check result is not normal, proceed to trouble-
shooting for the ABS warning light circuit (See page DI−275).
(b) Check the DTC.
(1) Turn the ignition switch ON.
(2) Disconnect the short pin from the DLC1.
(3) Using SST, connect terminals Tc and E1 of the
DLC1.
SST 09843−18020
(4) Read the DTC from the ABS warning light on the
combination meter.
HINT:
If no code appears, inspect the diagnostic circuit or ABS
warning light circuit (See page DI−278 or DI−275).
As an example, the blinking patterns for normal code and
codes 11 and 21 are shown in the illustration.
(5) Codes are explained in the code table on page
DI−242.
(6) After completing the check, disconnect terminals Tc
and E1, and turn off the display.
If 2 or more malfunctions are indicated at the same time, the
lowest numbered DTC will be displayed 1st.

BR3890
R06980
Short Pin
DLC1
N09348
Interface Box
Harness VehicleTOYOTA
Tester Hand−held
TOYOTA Break−out−box
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
DI−235
1996 RAV4 (RM447U)
(c) Clear the DTC.
(1) Using SST, connect terminals Tc and E1 of the
DLC1.
SST 09843−18020
(2) Disconnect the short pin from the DLC1.
(3) Turn the ignition switch ON.
(4) Clear the DTC stored in ECU by depressing the
brake pedal 8 or more times within 3 seconds (4WD
models) or 5 seconds (2WD models).
(5) Check that the warning light shows the normal
code.
(6) Remove the SST from the terminals of the DLC1.
SST 09843−18020
(7) Connect the short pin to the DLC1.
HINT:
4WD vehicles:
Cancellation can also be done by removing the ECU−B fuse,
but in this case, other memory systems will also canlelled out.
(d) Using TOYOTA break−out−box and TOYOTA hand−held
tester, measure the ECU terminal values.
(1) Turn the ignition switch OFF.
(2) Hook up the TOYOTA hand−held tester and TOYO-
TA break−out−box to the vehicle.
(3) Turn the ignition switch ON.
(4) Read the ECU input / output values by following the
prompts on the tester screen.
HINT:
TOYOTA hand−held tester has a ”Snapshot” function. This re-
cords the measured values and is effective in the diagnosis of
intermittent problems. Please refer to the TOYOTA hand−held
tester / TOYOTA break−out−box operators manual for further
details.

F15316
E1
TsTc DLC1
BR3904
0.13 sec. 0.13 sec.
ON
OFF
BR3893
72 67
ON
OFF
0.5 sec. 0.5 sec. 0.5 sec. 0.5 sec.1.5 sec.
2.5 sec.4 sec.
Repeat Malfunction Code (Example Code 72, 76) DI−236
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
1996 RAV4 (RM447U)
2. SPEED SENSOR SIGNAL CHECK
(a) Check the speed sensor signal.
(1) Turn the ignition switch OFF.
(2) Using SST, connect terminals Ts and E1 of the
DLC1.
SST 09843−18020
(3) Start the engine.
(4) Check that the ABS warning light blinks.
HINT:
If the ABS warning light does not blink, inspect the ABS warning
light circuit (See page DI−275).
(5) Drive vehicle straight forward.
HINT:
Drive vehicle faster than 45 km/h (28 mph) for several seconds.
(6) Stop the vehicle.
(7) Using SST, connect terminals Tc and E1 of the
DLC1.
SST 09843−18020
(8) Read the number of blinks of the ABS warning light.
HINT:
See the list of DTC shown on the next page.
If every sensor is normal, a normal code is output (A cycle
of 0.25 sec. ON and 0.25 sec. OFF is repeated).
If 2 or more malfunctions are indicated at the same time,
the lowest numbered code will be displayed 1st.
(9) After doing the check, disconnect terminals Ts and
E1, and Tc and E1 of the DLC1, and turn the ignition
switch OFF.

− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
DI−237
1996 RAV4 (RM447U)
(b) Check the DTC of the sensor function.
Code No.DiagnosisTrouble Area
71Low output voltage of right front speed sensor
Right front speed sensor
Sensor installation
Sensor rotor
72Low output voltage of left front speed sensor
Left front speed sensor
Sensor installation
Sensor rotor
73Low output voltage of right rear speed sensor
Right rear speed sensor
Sensor installation
Sensor rotor
74Low output voltage of left rear speed sensor
Left rear speed sensor
Sensor installation
Sensor rotor
75Abnormal change in output voltage of right front speed sensorRight front speed sensor rotor
76Abnormal change in output voltage of left front speed sensorLeft front speed sensor rotor
77Abnormal change in output voltage of right rear speed sensorRight rear speed sensor rotor
78Abnormal change in output voltage of left rear speed sensorLeft rear speed sensor rotor
*79Deceleration sensor is faultyDeceleration sensor
Sensor installation
*: 4WD models

R10305
GL2GL1
VGS
GGND
Rear Side
Front Side
DI−238
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
1996 RAV4 (RM447U)
3. DECELERATION SENSOR OPERATION DIAGNOSIS
SYSTEM
CAUTION:
While checking the deceleration sensor operating diagno-
sis system, the Anti−lock Brake System does not work and
brake system works as a conventional brake system.
Check the deceleration sensor output.
(1) Connect 3 dry batteries of 1.5 V in series.
(2) Connect VGS terminal to the batteries’ positive (+)
terminal, and GGND terminal to the batteries’ nega-
tive (−) terminal, apply about 4.5 V between VGS−
GGND terminals.
NOTICE:
Do not apply voltage of 6 V or more to terminals VGS and
GGND.
(3) Check the output of GL1 and GL2 terminals.
SymbolsConditionStandard Value
GL1Horizontalabout 2.3 V
GL1Lean forward0 − about 2.3 V
GL1Lean rearwardabout 2.3 V − 4.5 V
GL2Horizontalabout 2.3 V
GL2Lean forwardabout 2.3 V − 4.5 V
GL2Lean rearward0 − about 2.3 V
HINT:
If the senor is tilted too much it may show the wrong value.
If dropped, the sensor should be replaced with a new one.
The sensor removed from the vehicle should not be
placed upside down.

DI41F−02
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
DI−239
1996 RAV4 (RM447U)
DIAGNOSTIC TROUBLE CODE CHART
If a malfunction code is displayed during the DTC check, check the circuit listed for that code. For details
of each code, turn to the page referred to under the ”See page” for the respective ”DTC No.” in the DTC chart.
HINT:
Using SST 09843−18020, connect the terminals Tc and E1, and remove the short pin.
If any abnormality is not found when inspect each inspection parts, inspect the ECU.
DTC No.
(See page)Detection ItemTrouble Area
11
(DI−246)Open circuit in ABS control (solenoid) relay circuit
ABS control (solenoid) relay
Open or short in ABS control (solenoid) relay circuit
ECU
12
(DI−246)Short circuit in ABS control (solenoid) relay circuit
ABS control (solenoid) relay
B+ short in ABS control (solenoid) relay circuit
ECU
*3 13
(DI−250)Open circuit in ABS control (motor) relay circuit
ABS control (motor) relay
Open or short in ABS control (motor) relay circuit
ECU
14
(DI−250)Short circuit in ABS control (motor) relay circuit
ABS control (motor) relay
B+ short in ABS control (motor) relay circuit
ECU
21
(DI−254)Open or short circuit in 2−position solenoid circuit for right front
wheelABS actuator
Open or short in SFRR or SFRH circuit
ECU
22
(DI−254)Open or short circuit in 2−position solenoid circuit for left front
wheelABS actuator
Open or short in SFLR or SFLH circuit
ECU
23
(DI−254)Open or short circuit in 2−position solenoid circuit for right rear
wheelABS actuator
Open or short in SRRR or SRRH circuit
ECU
24
(DI−254)Open or short circuit in 2−position solenoid circuit for left rear
wheelABS actuator
Open or short in SRLR or SRLH circuit
ECU
*3 31
(DI−257)Right front wheel speed sensor signal malfunction
Right front, left front, right rear or left rear speed sensor
Open or short in each speed sensor circuit
Speed rotor
ECU*3 32
(DI−257)Left front wheel speed sensor signal malfunction
*3 33
(DI−257)Right rear wheel speed sensor signal malfunction
*3 34
(DI−257)Left rear wheel speed sensor signal malfunction
*2 35
(DI−257)Open circuit in speed sensor circuitOpen in speed sensor circuit
*1 37
(DI−261)Some tire is different size from other tiresTire size
ECU
41
(DI−262)Low battery positive voltage
Abnormal high battery positive voltage (2WD Vehicles)
Battery
IC regulator
Open or short in power source circuit
ECU
*2 43
(DI−266)Malfunction in deceleration sensor (constant output)
Deceleration sensor
Wire harness for deceleration sensor system
ECU

DI−240
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
1996 RAV4 (RM447U)*
2 44
(DI−267)Open or short in deceleration sensor circuit
Deceleration sensor
Open or short in deceleration sensor circuit
ECU
*2 45
(DI−266)Malfunction in deceleration sensorDeceleration sensor
Wire harness for deceleration sensor system
51
(DI−269)Pump motor is locked
Open in pump motor groundABS pump motor
Always ON
(DI−270)Malfunction in ECU
Abnormal high battery positive voltage (2WD Vehicles)
Battery *1
IC regulator *1
Open or short in pwer source circuit *1
ECU
*1: 2WD models
*
2: 4WD models
*
3: As the DTC cannot be erased by replacing parts alone, do either of the following operations.
1. Clear DTC (See page DI−234).
2. At the vehicle speed of 20 km/h (12 mph), drive the vehicle for 30 sec. or more.