TOYOTA RAV4 1996 Service Repair Manual

62
CHARGING
2
5A
ALT-S
2 12 13
IG1 2
IG 2 2EA1 1 9 FROM POWER SOURCE SYSTEM (
SEE PAGE 54)
WWR-LW
W
YW
R-L
B-O R-
B R-L
W
W ARNING
ETER]
BATTERYSIBLE
NK BLOCK
TO BACK-UP LIGHT SW
R-L R-L
I 5
Y
W
A C
B B JUNCTION
CONNECTORB J10 , J11A
10A
GAUGE7. 5A
IG N 310
411FUSE
BLOCK F 8
1E 8
1B 81E 1
1C 11
L
-O
8CHARGE
LIGHT
[CO M B. M C1 1
42
FU
LI
100A ALT
80A M AIN
F 7IG L S B
IC RE G U LA TO R
B G 1 , G 2A
GENERATORA 1 B 3 B 1 B 2

63
G 2 (B) GENERATOR
(B) 3-GROUND :13.9-15.1 VOLTS WITH THE ENGINE RUNNING AT 2000 RPM AND 25
C (77
F)
13.9-14.3 VOLTS WITH THE ENGINE RUNNING AT 2000 RPM AND 11 5
C (239
F)
(B) 1-GROUND :0-4 VOLTS WITH THE IGNITION SW AT ON POSITION AND THE ENGINE NOT RUNNING
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
C1130G 1A28J11B31
F 728G 2B28
F 831J10A31
: RELAY BLOCKS
CODESEE PAGERELAY BLOCKS (RELAY BLOCK LOCATION)
223R/B NO. 2 (ENGINE COMPARTMENT LEFT)
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
1B20INSTRUMENT PANEL WIRE AND J/B NO 1 (LOWER FINIS PANEL)1C20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINIS 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)
EA134ENGINE WIRE AND ENGINE ROOM MAIN WIRE (INSIDE OF R/B NO. 2)
IG138ENGINE WIRE AND INSTRUMENT PANEL WIRE (UNDER THE INSTRUMENT PANEL)IG238ENGINE WIRE AND INSTRUMENT PANEL WIRE (UNDER THE INSTRUMENT PANEL)
1
123 A G 1
BBROWN G 2
(
SEE PAGE 25)(
SEE PAGE 26) F 7 F 8
9 8 X
CCC BBBC11
GRAY
(
HINT : SEE PAGE 7)(
HINT : SEE PAG E 7) AGRAY J10
BGRAY J11
SERVICE HINTS

64
ENGINE CONTROL
THE ENGINE CONTROL SYSTEM UTILIZES A MICROCOMPUTER AND MAINTAINS OVERALL CONTROL OF THE ENGINE ETC. AN
OUTLINE OF ENGINE CONTROL IS GIVEN HERE.
1. INPUT SIGNALS
(1) ENGINE COOLANT TEMP. SENSOR SIGNAL SYSTEM
THE ENGINE COOLANT TEMP. SENSOR DETECTS THE ENGINE COOLANT TEMP. AND HAS A BUILT-IN THERMISTOR WITH A
RESISTANCE WHICH VARIES ACCORDING TO THE ENGINE COOLANT TEMP. THUS THE ENGINE COOLANT TEMP. IS INPUT IN
THE FORM OF A CONTROL SIGNAL TO TERMINAL THW OF THE ENGINE CONTROL MODULE.
(2) INTAKE AIR TEMP. SIGNAL SYSTEM
THE INTAKE AIR TEMP. SENSOR DETECTS THE INTAKE AIR TEMP. , WHICH IS INPUT AS A CONTROL SIGNAL TO TERMINAL THA
OF THE ENGINE CONTROL MODULE.
(3) OXYGEN SENSOR SIGNAL SYSTEM
THE OXYGEN SENSOR DETECTS THE OXYGEN DENSITY IN THE EXHAUST EMISSION WHICH IS INPUT AS A CONTROL SIGNAL
TO TERMINALS OX1 AND OX2 OF THE ENGINE CONTROL MODULE.
(4) THROTTLE SIGNAL SYSTEM
THE THROTTLE POSITION SENSOR DETECTS THE THROTTLE VALVE OPENING ANGLE, WHICH IS INPUT AS A CONTROL
SIGNAL TO TERMINAL VTA OF THE ENGINE CONTROL MODULE, OR WHEN THE VALVE IS FULLY CLOSED.
(5) VEHICLE SPEED CIRCUIT
THE VEHICLE SPEED IS DETECTED BY VEHICLE SPEED SENSOR INSTALLED IN THE TRANSMISSION AND THE SIGNAL IS INPUT
TO TERMINAL SPD OF THE ENGINE CONTROL MODULE VIA THE COMBINATION METER.
(6) PARK/NEUTRAL POSITION SW SIGNAL SYSTEM
THE PARK/NEUTRAL POSITION SW DETECTS WHETHER THE SHIFT POSITION IS IN NEUTRAL OR NOT, AND INPUTS A CONTROL
SIGNAL TO TERMINAL NSW OF THE ENGINE CONTROL MODULE.
(7) A/C SW SIGNAL SYSTEM
THE OPERATING VOLTAGE OF THE A/C MAGNETIC CLUTCH IS DETECTED AND INPUT IN THE FORM OF A CONTROL SIGNAL TO
TERMINAL ACI OF THE ENGINE CONTROL MODULE.
(8) BATTERY SIGNAL SYSTEM
VOLTAGE IS CONSTANTLY APPLIED TO TERMINAL BATT OF THE ENGINE CONTROL MODULE. WHEN THE IGNITION SW IS
TURNED TO ON, VOLTAGE FOR THE ENGINE CONTROL MODULE OPERATION IS APPLIED VIA THE EFI MAIN RELAY TO
TERMINAL +B OF THE ENGINE CONTROL MODULE.
(9) INTAKE AIR VOLUME SIGNAL SYSTEM
INTAKE AIR VOLUME IS DETECTED BY THE MANIFOLD ABSOLUTE PRESSURE SENSOR AND IS INPUT AS A CONTROL SIGNAL
TO TERMINAL PIN OF THE ENGINE CONTROL MODULE.
(10) STARTER SIGNAL SYSTEM
TO CONFIRM THAT THE ENGINE IS CRANKING, THE VOLTAGE APPLIED TO THE STARTER MOTOR DURING CRANKING IS
DETECTED AND IS INPUT AS A CONTROL SIGNAL TO TERMINAL STA OF THE ENGINE CONTROL MODULE.
(11) ELECTRICAL LOAD SIGNAL SYSTEM
THE SIGNAL WHEN SYSTEMS SUCH AS THE REAR WINDOW DEFOGGER, HEADLIGHT, ETC. WHICH CAUSE A HIGH ELECTRICAL
BURDEN ARE ON IS INPUT TO TERMINAL ELS AS A CONTROL SIGNAL.
SYSTEM OUTLINE

65
2. CONTROL SYSTEM
*SFI
THE SFI SYSTEM MONITORS THE ENGINE CONDITION THROUGH THE SIGNALS, WHICH ARE INPUT FROM EACH SENSOR (INPUT
SIGNALS (1) TO (11)). THE BEST FUEL INJECTION VOLUME IS DECIDED BASED ON THIS DATA AND THE PROGRAM MEMORIZED
BY THE ENGINE CONTROL MODULE, AND THE CONTROL SIGNAL IS OUTPUT TO TERMINALS #10, #20, #30, AND #40 OF THE
ENGINE CONTROL MODULE TO OPERATE THE INJECTOR (INJECT THE FUEL). THE SFI SYSTEM PRODUCES CONTROL OF FUEL
INJECTION OPERATION BY THE ENGINE CONTROL MODULE IN RESPONSE TO THE DRIVING CONDITIONS.
*IDLE SPEED CONTROL SYSTEM
THE IDLE SPEED CONTROL SYSTEM INCREASES THE RPM AND PROVIDES IDLING STABILITY FOR FAST IDLE-UP WHEN THE
ENGINE IS COLD AND WHEN THE IDLE SPEED HAS DROPPED DUE TO ELECTRICAL LOAD, ETC. THE ENGINE CONTROL MODULE
EVALUATES THE SIGNALS FROM EACH SENSOR (INPUT SIGNALS (1 TO 5, 11), OUTPUTS CURRENT TO TERMINAL ISCO AND ISCC,
AND CONTROLS THE IDLE AIR CONTROL VALVE.
*A/C CUT CONTROL SYSTEM
WHEN THE VEHICLE SUDDENLY ACCELERATES FROM LOW ENGINE SPEED, THIS SYSTEM CUTS OFF AIR CONDITIONING
OPERATION FOR A FIXED PERIOD OF TIME IN RESPONSE TO THE SPEED SENSOR, THROTTLE VALVE OPENING ANGLE AND
INTAKE MANIFOLD PRESSURE IN ORDER TO MAINTAIN ACCELERATION PERFORMANCE.
THE ENGINE CONTROL MODULE RECEIVES INPUT SIGNALS (4, 5 AND 9), AND INPUTS SIGNALS TO TERMINAL ACT.
3. DIAGNOSIS SYSTEM
WITH THE DIAGNOSIS SYSTEM, WHEN THERE IS A MALFUNCTION IN THE ENGINE CONTROL MODULE SIGNAL SYSTEM, THE
MALFUNCTIONING SYSTEM IS RECORDED IN THE MEMORY. THE MALFUNCTIONING SYSTEM CAN THEN BE FOUND BY READING
THE DISPLAY (CODE) OF THE MALFUNCTION INDICATOR LAMP.
4. FAIL-SAFE SYSTEM
WHEN A MALFUNCTION OCCURS ON ANY SYSTEM, IF THERE IS A POSSIBILITY OF ENGINE THROUBLE BEING CAUSED BY
CONTINUED CONTROL BASED IN THE SIGNALS FROM THAT SYSTEM, THE FAIL-SAFE SYSTEM EITHER CONTROLS THE SYSTEM BY
USING DATA (STANDARD VALUES) RECORDED IN THE ENGINE CONTROL MODULE MEMORY OR ELSE STOPS THE ENGINE.

66
ENGINE CONTROL
6
8
20A
AM25A IG N
USE
LOCK]15A
EFI FROM PO WER SO URCE SYSTEM (
SEE PAGE 54)
2
25 1355
5525 1366
66
2 2
IG 1 8IG13
ID1 4 IG 1 11
IG 1 4
EA1 2
IB 1 11
1 1 1 1
BH EA17
2011
2110B-O
B-R
B-W(
A/T)
R-W
G-R
B-Y
B-R B-Y
B-YR-W
W
B-O
B-O B-Y B-RB-Y B-R
WW-BB-Y
L- B G-RB-R B-R
B-O
B-O
R-WB-Y
B-O
B-R B-R
B-R B-R
B-WB
B- OR-W
O
BATTERY
IN
IN
IN
IN I
I
I
I
EFI M A IN R ELA Y CIRCUIT OPENING
RELAY F
B-Y B-Y
EA1 7
B-R
16
8
F
B-R
I 1
I 1E 1 B (
M/T)
B-R B-Y
W
7AM2AM 1ACC
IG 1
IG 2
ST2
IG NITIO N SW I1 0
7.
[F
B F
1H 14 1E9 1D8
1D3
1H13
1I 171E 1
1J2
B-
A A
5 4
2 2 2 2
B-O B-O B-O B-O
-BL-B 5
JUNCTION
CONNECTOR
FUEL
PUM P F11J 1
I 5 I 5
-B
80A M AIN
2
USIBLE LINK BLOCK 7
JECTOR NO. 1
JECTOR NO. 2
JECTOR NO. 3
JECTOR NO. 4 6
7
8
M

67
IG 1 12 I 5 B-O
B-W(
A/T)
R-W
G-R
B-Y
B-RB-R B-R B-O
B-R B-R B-R B-R B-R B-RB-R
B
B-O
B
G-
B-
B-
R-Y
Y-GN 1
FROM A/C AMPLIFIER
TO A/C AMPLIFIERB-
B-
B-Y
B-RIG 1 10
EA1 9
EC B (
M/T)I 4
I 4I 4I 5I 5
I 5 B
BR
B
B BR
B
R
(
M/T)(
A/T) (
A/T)
(
A/T)
(
A/T)
(
A/T)
JU N TO R J 2
TO ST RELAY
B-R
B-R
B-R
B-R E
A AA B-W
B
-WB-W(
M/T)
(
A/T)
(
A/T) JUNCTION CONNECTOR J 5
C 1
BATTC 22
NEWA 10
IS C OA 9
ISC CA 23
EGRB 8
TPCA 22
EVP
C 11STA
C 14FC
A 11#20
A 12#10
C 21ACT
C 10AC1 2 1P
N
B BR
R
Y
RB-L
B-Y
B-W
R-W
P R-W
B-WPARK/NEUTRAL
POSITION SW NOISE FILTER
(
IGNITION SYSTEM)ENGINE CONTROL MODULEB E 4 , E 5AC, E 6
A 24 A25
Y
R
IB2 20
A 3
B 6 B 5A 2(
2W D)
(
4W D)
(
2WD)
(
4WD)
I 5
B-W
B-W B-W
B-W (
M/T) (
M/T)
(
A/T)
(
A/T) C C 8
B P 1 , A#40 #30
(
A/T)
AC C A
B B-W
B-W(
A/T)
(
A/T)(
M/T) CTION CONNECJUN CTIO N
CONNECTOR J 513
ID
C
V
NSI 1 2
2 1
1 2 2LE AIR
ONTROL VALVE
VSV (
EGR)
(
VAPOR PRESSUR
OR)
VSV (
EVAP) 1
V 7
V 8 VS
SE V 9
2 1LUTCH START SW

68
ENGINE CONTROL
I 4 IG 1 9
C 12
+BB 6
OX1B 5
OX2B 15
TE 1
B 2PIM
B 1VC
B 11VTA
B 3TH A
B 4TH W
B 7PTNK
B 9E2 B- R B- R B-O
BR
BR
Y
BR BR BR
B-R B-R
L-W B- R
BR LG-R
YY
L-R
Y-B
W
L- Y
BR BR
BR
B
B
BR
BR(
SHIELDED) (
SHIELDED)
A 5
G+ A 4
NE+A 17
NE -A 3
IG F
C 17ELS
B 10KNK
2
B B
(
SHIELDED)
(
SHIELDED)
MANIFOLD
ABSO LUTE
PRESSURE
SENSORTHROTTLE
POSITION
SENSOR
FROM TAI
RELAY (
L)
FR O M D EF
RELAY (
L)
CK
SO R ENGINE CONTROL MODULEB E 4 , E 5
AC, E 6
ENSOR
A 2 G-
A 1 G+ IGNITION COIL AND DISTRIBUTOR
I I 2 B1
B2
DISTRIBUTOR
B-O
BB-O
IG N ITIO N
COIL
A 20
IG T
R
G
R
B
L-Y (
SHIELDED)
BRB-O
1 2
1 2
OXYGEN SENSOR
(
BANK 1 SENSO R1)
OXYGEN SENSOR
(
BANK 1 SENSO R2) O 2
O 3
L
TO CRUISE
CONTROL ECU
V V
BR
B BBR
BR (
SHIELDED) (
SHIELDED)
I 5 I 5 I 5 I 4
DATA LINK CO NNECTOR 1 D 1
(
SHIELDED) (
SHIELDED)
B
TO A/C
AM PLIFIER
B-W
I 4W
G
I 5
B I 3 , I 4
A
IG2 8
1 2
CRANKSHAFT POSITION
SENSOR C 2
G
1 2
1 2
1 3 232
E2
Y
R
R
Y
L-Y
VCC PTNK1
G
BL-R
L Y
INTAKE AIR TEM P. SENSOR I 9
DIO
(
EN D 4
LLIG H T
OGGER
KNO
SEN K 1
ENGINE COOLANT TEMP. S E 2
IG 1 5
APOR PRESSURE SENSOR 1
I 5
8 12 3
TE 1+B E1
534
-C B TAC
IG T IG F
21 GNITER
3 1DE
GINE IDLE-UP)
1E2 VC PIM
M 11 432
T 1

69
BR BR
BR
EC A 13EO1
A 26EO2
A 14E1
C 5W
C 9SPD
BR
BR
BR
G-R
V-W
BR BR
(
SHIELDED)
(
SHIELDED)
(
SHIELDED)
(
SHIELDED)
(
SHIELDED)
(
SHIELDED)
(
SHIELDED)
ENGINE CONTROL MODULEB E 4 , E 5
AC, E 6 B/K
G-W
C 4 (
SHIELDED)
BR B 16
I 5
BR
C 16
I11
IG 2 11
IG FROM POWER SOURCE SYSTEM (
SEE PAGE 54)
L
BR W
W-B BR
W-BW
BR
V-W
G-RR-L
BR BR
BR
BR
EO 3 SDL
(
A/T)
JU NC J10(
SHIELDED)
D DG-W
G-W
NCTION
NNECTORR-WFUS
BLO F 8
LG
R- W STOP LIGHT SW S 5(
A/T)
1I 141I 13
1I 11
1F2
1E 2
1B 1
254 16
SDL SG CG BATDATA LINK
CONNECTOR 3 D 2
AABR
BR
BR
BR
BR
J 2
JU NC TIO N
CONNECTOR
A AB A
BR
A A
TIO N C O NN EC TO RB , J 1 1 A
10A
GAUGE 10A
STOP
18 4 15 3
E
CK7. 5A
OBD
17
12
JU
CO J 5
AAAAAA
A

70
ENGINE CONTROL
IG 2 10 IG 2 9 IG 1 28 R-L
R-L
R-L
L-B
R-YL-B
R-
V- W
G-R
VEHICLE SPE ED SENSOR
(
CO MBINATION M ETER) COMBINATION
METER C 9
G-R V-WR-B J10 , J11
A
A C
B B
B B LJUNCTION CONNECTOR
R-L
11 1 0 2 9
Y
3 2 1
V 2
MALFANCTION
INDICATOR LAMP
SPEED
1B8
1E8

71
E 4 (A), E 5 (B), E 6 (C) ENGINE CONTROL MODULE
BATT -E1 : ALWAYS 9.0-14.0 VOLTS
+B -E1 :9.0-14.0 VOLTS (IGNITION SW AT ON POSITION)
VC -E2 :4-5-5.5 VOLTS (IGNITION SW AT ON POSITION)
VTA -E2 :0.3-0.8 VOLTS (IGNITION SW ON AND THROTTLE VALVE FULLY CLOSED)
:3.2-4.9 VOLTS (IGNITION SW ON AND THROTTLE VALVE OPEN)
PIM -E2 :3.3-3.9 VOLTS (IGNITION SW AT ON POSITION)
#10,#20, #30, #40-E01, E02 : 9.0-14.0 VOLTS (IGNITION SW AT ON POSITION)
THA -E2 :0.5-3.4 VOLTS (IGNITION SW ON AND THE INTAKE AIR TEMP 20
C, 68
F)
THW -E2 :0.2-1.0 VOLTS (IGNITION SW ON AND THE COOLANT TEMP 80
C, 176
F)
STA -E1 :6.0-14.0 VOLTS (ENGINE CRANKING)
IGT -E1 :0.8-1.2 VOLTS (ENGINE CRANKING OR IDLING)
W -E1 :9.0-14.0 VOLTS (NO TROUBLE AND ENGINE RUNNING)
ACT -E1 :4.5-5.5 VOLTS (IGNITION SW ON AND AIR CONDITIONING ON)
AC1 -E1 :0-3.0 VOLTS (IGNITION SW ON AND AIR CONDITIONING ON)
ISCO, ISCC-E1 :9.0-14.0 VOLTS (IGNITION SW AT ON POSITION)
TE1 -E1 :9.0-14.0 VOLTS (IGNITION SW ON AND DATA LINK CONNECTOR 1 TE1-E1 NOT CONNECTED)
:0-3.0 VOLTS (IGNITION SW ON AND DATA LINK CONNECTOR 1 TE1-E1 CONNECTED)
NSW -E1 :0-3.0 VOLTS (IGNITION SW ON AND PARK/NEUTRAL POSITION SW P OR N RANGE)
:9.0-14.0 VOLTS (IGNITION SW ON AND PARK/NEUTRAL POSITION SW EXCEPT POSITION P AND N RANGE)
RESISTANCE OF ENGINE CONTROL MODULE WIRING CONNECTOR
(DISCONNECT WIRING CONNECTOR)
VTA -E2 :3.3-10.0 KW (THROTTLE VALVE FULLY OPEN)
:0.2-0.8 KW (THROTTLE VALVE FULLY CLOSED)
VC -E2 :3.0-7.0 KW
THA -E2 :2.0-3.0 KW (INTAKE AIR TEMP 20
C, 68
F)
THW -E2 :0.2-0.4 KW (COOLANT TEMP 80
C, 176
F)
G+ -G- :0.17-0.21 KW
ISCO, ISCC-+B :19.3-22.3 W
(5) CIRCUIT OPENING RELAY
(5) 3 -(5) 5 : CLOSED WITH THE IGNITION SW ON OR ST POSITION
(6) EFI MAIN RELAY
(6) 3-(6) 5 : CLOSED WITH THE IGNITION SW ON OR ST POSITION
E 2 ENGINE COOLANT TEMP. SENSOR
1-2 :14.6-17.8 KW (-20
C, -4
F)
5.88 KW (0
C, 32
F)
2.21-2.69 KW (20
C, 68
F)
1.14 KW (40
C, 104
F)
0.584 KW (60
C, 140
F)
0.29-0.354 KW (80
C, 176
F)
I 5, I 6, I 7, I 8 INJECTOR
1-2 : APPROX. 13.8 W
T 1 THROTTLE POSITION SENSOR
3-1 :0.2-5.7 KW WITH CLEARANCE BETWEEN LEVER AND THE STOP SCREW 0 MM (0 IN.)
3-1 :2.0-10.2 KW WITH THROTTLE VALVE FULLY OPEN
2-1 : LESS THAN 2.3 KW WITH CLEARANCE BETWEEN THE LEVER AND THE STOP SCREW 0.5 MM (0.02 IN.)
WITH CLEARANCE BETWEEN LEVER AND THE STOP SCREW 0.7 MM (0.028 IN.)
SERVICE HINTS