Engine 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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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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1999-2000 BRAKES Anti-Lock - RAV4
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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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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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1999-2000 BRAKES Anti-Lock - RAV4
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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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1999-2000 BRAKES Anti-Lock - RAV4
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DTC Detecting Condition
Detection of any of the following conditions may set DTC 13 or DTC 14 if condition occurs for .2 seconds or
more:
If voltage at ABS control relay connector terminal A8-4 is less than 1.5 volts, and voltage at connector
terminal A8-2 is zero volts, DTC 13 may set.
If voltage at ABS control relay connector terminal A8-4 is 10-14 volts, and voltage at connector terminal
A8-2 is 10-14 volts, DTC 14 may set.
Diagnostic Procedure
1. Disconnect ABS control relay connector A8, located in engine compartment at front of vehicle. See Fig.
1 . Measure voltage between ground and motor relay connector terminal A8-1. See Fig. 5 . If voltage is
10-14 volts, go to next step. If voltage is not 10-14 volts, repair wiring harness between battery and motor
relay. See WIRING DIAGRAMS
.
2. Disconnect 2 ABS actuator connectors. Check for continuity on Blue/Red wire between ABS actuator
connector terminal A7-2 and ABS control relay connector terminal A8-2. Also check for continuity on
Blue/Red wire between ABS actuator connector terminal A7-3 and ABS ECU connector terminal A16-
10. See Fig. 5
. Continuity should exist. If continuity is not present on either wire, repair open circuit on
affected wire between ABS control relay and ABS ECU. If continuity is present on both wires, go to next
step.
3. Check resistance between ABS actuator terminals A7-2 and A7-3. Resistance should be 26-40 ohms. If
resistance is as specified, go to next step. If resistance is not as specified, replace ABS actuator.
4. Check ABS control relay. See MOTOR RELAY SECTION
under ABS CONTROL RELAY under
COMPONENT TESTS. Replace relay as necessary. If relay tests okay, go to next step.
5. Check for open or short circuit in wiring harness between ABS control relay and ABS ECU. Repair as
necessary. See WIRING DIAGRAMS
. If circuit is okay, go to next step.
6. Clear DTCs and then recheck for DTCs. See RETRIEVING DTCS
under DIAGNOSIS & TESTING. If
same DTC is output after DTC is cleared, check contact condition of each connection. Repair as
necessar
y. If connections are okay, replace ABS ECU.

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1999-2000 BRAKES Anti-Lock - RAV4
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battery.
2. Place Sheet "A" (09990-00163) on actuator checker. Start engine and let idle. Turn actuator checker
SELECTOR switch to FRONT RH position. See Fig. 9
. Press and hold MOTOR switch for a few
seconds. Ensure motor can be heard running. Depress and hold brake pedal for 15 seconds. Ensure brake
pedal does not go down. While holding brake pedal, press MOTOR switch for a few seconds. Ensure
brake pedal does not pulsate.
Fig. 9: Identifying Actuator Checker Switches

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
3. Press and hold POWER switch for a few seconds and ensure brake pedal does not go down. While
holding brake pedal, release POWER switch. Ensure brake pedal goes down. While holding brake pedal,
press MOTOR switch and ensure brake pedal returns. Release brake pedal.
4. Set SELECTOR switch to each of the other wheels and repeat steps 2 -3 . When checking REAR LH
position, press REAR LH POWER switch, instead of POWER switch. Left rear wheel can be checked in
any selector switch position.
5. After checking remaining wheels, press and hold MOTOR switch for a few seconds. Stop engine.
Remove actuator checker and test harnesses. Reconnect vehicle harnesses to actuator and control relay.
Clear diagnostic DTCs. See CLEARING DTCS
under DIAGNOSIS & TESTING.
DECELERATION SENSOR CHECK
NOTE: DO NOT press POWER switch for more than 10 seconds.
NOTE: During deceleration sensor diagnosis, ABS functions like a standard brake

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1. Check charging system voltage. Ensure 10-14 volts is present. If charging system voltage is okay, go to
next step. If charging system voltage is not okay, check and repair charging system.
2. Turn ignition switch to ON position. Ensure ABS warning light comes on, then goes out after 3 seconds.
If ABS warning light does not illuminate, check fuse, bulb, and wiring harness. See ABS WARNING
LIGHT under DIAGNOSIS & TESTING. Turn ignition off.
3. Using a jumper wire, jumper terminals Ts and E
1 of DLC1. DLC1 is located in engine compartment on
left side of engine. See Fig. 2
. Ensure ABS warning light blinks 4 times per second. If ABS light does
not blink, go to ABS WARNING LIGHT
under DIAGNOSIS & TESTING. If ABS warning light
blinks, go to next step.
4. Using a floor jack, slowly jack up rear of vehicle. On vehicles with 215/70R16 tires, raise vehicle to a
height of 25.59-27.95" (650-710 mm). On vehicles with 235/60R16 tires, raise vehicle to a height of
26.38-28.74" (670-730 mm). If ABS warning light illuminates at specified height, check deceleration
sensor installation. If installation is okay, replace deceleration sensor. Lower vehicle.
5. Using a floor jack, slowly jack up front of vehicle. On vehicles with 215/70R16 tires, raise vehicle to a
height of 21.20-23.56" (550-610 mm). On vehicles with 235/60R16 tires, raise vehicle to a height of
22.44-24.80" (570-630 mm). If ABS warning light illuminates at specified height, check deceleration
sensor installation. If installation is okay, replace deceleration sensor. Lower vehicle.
6. Drive vehicle straight ahead at speed of 13 MPH or more. Lightly depress brake pedal. Ensure ABS
warning light pattern is normal (light blinks 4 times per second).
7. While driving vehicle straight ahead at speed of 13 MPH or more, moderately depress brake pedal.
Ensure ABS warning light illuminates in a solid pattern (light does not blink) while braking.
8. While driving vehicle straight ahead at speed of 13 MPH or more, firmly depress brake pedal. Ensure
ABS warning light illumination pattern changes from a solid pattern (light does not blink) to a normal
pattern (light blinks 4 times per second), then back to a solid pattern while braking.
9. If ABS warning light does not illuminate as described in steps 6 -8 , check deceleration sensor
installation. If installation is okay, replace deceleration sensor. Stop vehicle and turn ignition off. Remove
jumper wire from DLC1.
REMOVAL & INSTALLATION
ACTUATOR
Removal & Installation
Turn ignition off. Disconnect brakelines attached to actuator. Remove power steering hose retaining bracket
bolt and power steering reservoir. Disconnect actuator electrical connectors. Remove bolts, nuts and washers.
Remove actuator assembly. Remove actuator from actuator bracket. Remove cushions and holders from NOTE: When measuring vehicle height in following steps, measure at center of
lower body of vehicle.
WARNING:Hydraulic system may be under high pressure. Use caution when opening
hydraulic system.

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1999-2000 BRAKES Anti-Lock - RAV4
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Fig. 13: Measuring Pedal Height
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
BRAKE PEDAL FREE PLAY
1. Brake pedal free play is distance brake pedal travels before feeling resistance with engine stopped. To
check brake pedal free play, depress brake pedal several times to exhaust vacuum from power brake unit.
Depress brake pedal and measure travel until initial resistance is felt.
2. Brake pedal free play should be .04-.24" (1.0-6.0 mm). If free play is not within specification, adjust by
turning brake booster push rod. See Fig. 13
. After adjusting brake pedal free play, check brake pedal
height. See BRAKE PEDAL HEIGHT
. Install instrument panel lower finish panel.
STOPLIGHT SWITCH
Stoplight switch is located above brake pedal. See Fig. 13
. To adjust stoplight switch, remove instrument panel
lower finish panel. Loosen stoplight switch lock nut. Turn stoplight switch until clearance between switch and
brake pedal stop is .02-.09" (.5-2.4 mm). Tighten lock nut. Check stoplight operation. Check brake pedal free
play, see BRAKE PEDAL FREE PLAY .
BRAKE PEDAL DEPRESSED HEIGHT
NOTE: Stoplight switch adjustment should be performed before brake pedal free play
adjustment is made. See STOPLIGHT SWITCH
.

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1999-2000 BRAKES Anti-Lock - RAV4
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Brake pedal depressed height is measured from face of brake pedal pad to asphalt sheet under carpet with
brakes applied. Measure brake pedal depressed height with engine running and weight of 110 lbs. (50 kg)
applied against brake pedal. Minimum brake pedal depressed height should be 2.95" (75.0 mm). If measured
distance is less than minimum height, inspect brake system.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
WIRING DIAGRAMS
ApplicationFt. Lbs. (N.m)
Actuator Bracket Mounting Bolts14 (19)
Brakeline Fittings11 (15)
Hub Nut83 (110)
Push Rod Lock Nut18 (25)
Speed Sensor Harness-To-Rear Suspension Arm Bolts9 (13)
INCH Lbs. (N.m)
Actuator-To-Bracket Mounting Nuts48 (5.4)
Speed Sensor Harness-To-Body Bolts48 (5.4)
Wheel Speed Sensor Mounting Bolt71 (8)

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1999-2000 BRAKES Anti-Lock - RAV4
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