shift TOYOTA RAV4 1996 Service Owners Manual

DI42H−01
CRUISE CONTROL SYSTEM Check Sheet
Inspector ’s name:
Customer ’s Name
Date of VehicleRegistration No.
Registration Year
Frame No.
Odometer Reading / /km
Mile
Condition of
Problem Occurrence
Date of Problem
Frequency Problem
Occurrence
Occurs
Vehicle Speed when
Problem Occurred / /
Continuous Intermittent ( Times a day)
km
Mile Brought in
Auto cancel
occurs Driving condition
 City driving  Freeway  Up hill  Down hill
 After cancel occurred, did the driver activate cruise control
again?
 Yes  No
 Cancel does not
occur With brake ON
 Except D position shift  At 40 km/h (25 mph) or less
 When control SW turns to CANCEL position
 Cruise control
malfunction Slip to acceleration side
 Slip to deceleration side
 Hunting occurs
 O/D cut off does not occur
 O/D does not return
 Switch
malfunction SET  ACCEL  COAST  RESUME  CANCEL
 Faulty CRUISE
MAIN indicator light Remains ON  Does not light up  Blinking Symptoms
DTC Check1st Time2nd Time
 Normal Code  Malfunction Code (Code )
 Normal Code  Malfunction Code (Code )
− DIAGNOSTICSCRUISE CONTROL SYSTEM
DI−327
1996 RAV4 (RM447U)
CUSTOMER PROBLEM ANALYSIS CHECK

BE6443
(1)
(2)
(1)
No.Operation MethodCRUISE MAIN Indicator Light
Blinking PatternDiagnosis
1 Turn SET/COAST switch ON
2Turn RES/ACC switch ON
3Turn CANCEL switch ON
Turn stop light switch ON
Depress brake pedal
Turn PNP switch OFF
(Shift to except D position)
4Drive at about 40 km/h
(25 mph)or higher
Drive at about 40 km/h
(25 mph) or below
LightON
OFF
LightON
OFF
LightON
OFFSwitch ON
Switch OFF
LightON
OFFSwitch OFF
Switch ONSET/COAST switch circuit
is normal
RES/ACC switch circuit
is normal
CANCEL switch circuit
is normal
Stop light switch circuit
is normal
PNP switch circuit is
normal
Vehicle Speed Sensor is
normal
LightON
OFF LightON
OFF
1sec.
0.25 sec.0.25 sec.
Turn clutch switch OFF
(Depress clutch pedal)Clutch switch circuit
is normal
− DIAGNOSTICSCRUISE CONTROL SYSTEM
DI−331
1996 RAV4 (RM447U)
4. INPUT SIGNAL CHECK
HINT:
(1) For check No.1 − No.2.
Turn the ignition switch ON.
(2) For check No.3.
Turn ignition switch ON.
Shift to D position. (A/T Vehicle)
(3) For check No.4.
Jack up the vehicle.
Start the engine.
Shift to D position. (A/T Vehicle)
(a) Press the control switch to the SET/COAST or RES/ACC
position and hold it down or hold it up (1).
(b) Push the main switch ON (2).
(c) Check that the CRUISE MAIN indicator light blinks twice
or 3 times repeatedly after 3 seconds.
(d) Turn the SET/COAST or RES/ACC switch OFF.
(e) Operate each switch as listed in the table below.
(f) Read the blinking pattern of the CRUISE MAIN indicator
light.
(g) After performing the check, turn the main switch OFF.
HINT:
When 2 or more signals are input to the ECU, the lowest num-
bered code will be displayed first.

DI7HO−01
I10026CRUISE Control ECU DI−334
− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 RAV4 (RM447U)
TERMINALS OF ECU
SymbolsTerminalsConditionStandard Value
D ↔ GND2 − 13
M/T: Depress clutch pedal.
A/T: Shift to except D position.Below 1 V
M/T: Release clutch pedal.
A/T: Shift to D position.10 − 16 V
Pi ↔ GND7 − 13
IG ON. Main switch ON.
Main indicator light ON.Below 1.2 V
IG ON. Main switch OFF.
Main indicator light OFF.10 − 16 V
Tc ↔ GND8 − 13Ignition switch ON.10 − 16 V
O/D ↔ GND9 − 13
Except during cruise control driving.10 − 16 V
O/D Switch ON.
During cruise control driving .
(Driving on flat road).
10 − 16 V
O/D Switch OFF.
During cruise control driving .
(3rd driving).
Below 1 V
L ↔ GND10 − 13During cruise control driving.9 − 15 V
Except during cruise control driving.Below 1 V
MC ↔ GND11 − 13
During cruise control driving .
COAST switch hold ON.9 − 16 V
During cruise control driving .
ACCEL switch hold ON.Below 1 V
MO ↔ GND12 − 13
During cruise control driving.
ACCEL switch hold ON.9 − 15 V
During cruise control driving.
COAST switch hold ON.Below 1 V
GND ↔ Body Ground13 −
Body GroundAlways.Below 1 V
B ↔ GND14 − 13Ignition switch ON.10 − 16 V
BATT ↔ GND15 − 13Always.10 − 16 V
STP− ↔ GND16 − 13Depress brake pedal.10 − 16 V
Release brake pedal.Below 1 V

DI42M−01
DI−336
− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 RAV4 (RM447U)
PROBLEM SYMPTOMS TABLE
If a normal code is displayed during the DTC check but the trouble still occurs (reappears), troubleshoot for
each problem symptom, checking the circuits for each symptom in the order given in the table below. Pro-
ceed to the page indicated for each circuit.
HINT:
If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow chart
for each circuit, proceed to the circuit with the next highest number in the table to continue the check.
If the trouble still reappears even through there are no abnormalities in any of the other circuits, then
check or replace the cruise control ECU as the last step.
SymptomSuspect AreaSee page
SET not occurring or CANCEL occurring.
(DTC is Normal)
1. Main Switch Circuit (Cruise Control Switch)
2. Vehicle Speed Sensor Circuit
3. Control Switch Circuit (Cruise Control Switch)
4. Stop Light Switch Circuit
5. Park/Neutral Position Switch Circuit
6. Clutch Switch Circuit
7. Actuator
8. Cruise Control ECUDI−371
DI−346
DI−348
DI−351
DI−360
DI−363
DI−338
IN−30
SET not occurring or CANCEL occurring.
(DTC does not output)1. ECU Power Source Circuit
2. Cruise Control ECUDI−366
IN−30
Actual vehicle speed deviates above or below the set speed.
1. Actuator Control Cable
2. Vehicle Speed Sensor Circuit
3. Actuator
4. Cruise Control ECUDI−376
DI−346
DI−338
IN−XXX
Gear shifting is frequent between 3rd and OD when driving on
uphill road. (Hunting)1. Electronically Controlled Transaxle Communication
Circuit
2. Cruise Control ECUDI−357
IN−30
Cruise control not cancelled, even when brake pedal is de-
pressed.
1. Actuator Control Cable
2. Stop Light Switch Circuit
3. Actuator
4. Cruise Control ECUDI−376
DI−351
DI−338
IN−30
Cruise control not cancelled, even when transmission is shifted to
except D position. (A/T)
1. Actuator Control Cable
2. Park/Neutral Position Switch Circuit
3. Actuator
4. Cruise Control ECUDI−376
DI−360
DI−338
IN−30
Cruise control not cancelled, even when clutch pedal depressed.
(M/T)
1. Actuator Control Cable
2. Clutch Switch Circuit
3. Actuator
4. Cruise Control ECUDI−376
DI−363
DI−338
IN−30
Control switch does not operate.
(SET/COAST, ACC/RES, CANCEL not possible)
1. Actuator Control Cable
2. Control Switch Circuit (Cruise Control Switch)
3. Actuator
4. Cruise Control ECUDI−376
DI−363
DI−338
IN−30
SET possible at 40 km/h (25 mph) or less, or CANCEL does not
operate at 40 km/h (25 mph) or less.
1. Actuator Control Cable
2. Vehicle Speed Sensor Circuit
3. Actuator
4. Cruise Control ECUDI−376
DI−346
DI−338
IN−30
Poor response in ACCEL and RESUME modes.
1. Actuator Control Cable
2. Electronically Controlled Transaxle Communication
Circuit
3. Control Switch Circuit (Cruise Control Switch)
4. Actuator
5. Cruise Control ECUDI−3764
DI−357
DI−363
DI−338
IN−30

N17899
ECM
E6
E4
E10
E116
1 1520
P
P
IG16
P229 Y−B
OD
ECTCruise Control ECU
*1*2*1: FF
*2: 4WD Electronically
Controlled
Transaxle
SolenoidOD1
S2
P
− DIAGNOSTICSCRUISE CONTROL SYSTEM
DI−357
1996 RAV4 (RM447U)
Electronically Controlled Transaxle Communication Circuit
CIRCUIT DESCRIPTION
When driving uphill under cruise control, in order to reduce shifting due to ON−OFF overdrive operation and
to provide smooth driving, when down shifting in the electronically controlled transaxle occurs, a signal to
prevent upshift until the end of the uphill slope is sent from the cruise control ECU to the electronically con-
trolled transaxle.
Terminal ECM of the cruise control ECU detects the shift change signal (output to electronically controlled
transaxle No.2 solenoid) from the electronically controlled transaxle.
If vehicle speed down, also when terminal electronically controlled transaxle of the cruise control ECU re-
ceive down shifting signal, it sends a signal from terminal OD to OD1 to cut overdrive until the end of the
uphill slope, and the gear shifts are reduced and gear shift points in the electronically controlled transaxle
are changed.
WIRING DIAGRAM
DI42U−02

N17900
Park/Neutral
Position Switch
P1
P1IG11
10
8
E66
B−WCruise Control ECU
D
*1*2
ECM
DB−W
B−WB−W
*1 FF
*2: 4WD
DI−360
− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 RAV4 (RM447U)
Park/Neutral Position Switch Circuit
CIRCUIT DESCRIPTION
When the shift position is put in except D position, a signal is sent from the park/neutral position switch to
the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control.
WIRING DIAGRAM
INSPECTION PROCEDURE
1 Check operation of starter.
CHECK:
Check that the starter operates normally and that the engine starts.
NG Proceed to engine troubleshooting
(See page DI−1).
OK
DI42V−02

ON
OFFShifting into
except D position
BE3840N14702I09121
ON
IG ON
D (−) (+)
− DIAGNOSTICSCRUISE CONTROL SYSTEM
DI−361
1996 RAV4 (RM447U)
2 Input signal check.
PREPARATION:
(a) See input signal check on page DI−328.
(b) Check the indicator light when shifting into except D posi-
tion.
OK:
The indicator light goes off when shifting into except
D position.
OK Proceed to next circuit inspection shown on
matrix chart (See page DI−336).
NG
3 Check voltage between terminal D of ECU connector and body ground.
PREPARATION:
Remove ECU with connectors still connected.
CHECK:
(a) Turn ignition switch ON.
(b) Measure voltage between terminal D of ECU connector
and body ground, when shifting into D position and other
positions.
OK:
Shift PositionVoltage
D position10 − 16 V
Other positionsBelow 1 V
OK Proceed to next circuit inspection shown on
matrix chart (See page DI−336).
NG

ON
OFFClutch pedal is depressed
BE3840N14702I09121
ON
IG ON
D (−) (+)
DI−364
− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 RAV4 (RM447U)
2 Input signal check.
CHECK:
(a) See input signal check on page DI−328.
(b) Check the indicator light when the clutch pedal is de-
pressed.
OK:
The indicator light goes off when the clutch pedal is
depressed.
OK Proceed to next circuit inspection shown on
matrix chart (See page DI−336).
NG
3 Check voltage between terminal D of ECU connector and body ground.
PREPARATION:
Remove ECU with connectors still connected.
CHECK:
(a) Turn ignition switch ON.
(b) Measure voltage between terminal D of ECU connector
and body ground, when the clutch pedal is depressed.
OK:
Shift PositionVoltage
ON (pedal depressed)Below 1 V
OFF10 − 16 V
OK Proceed to next circuit inspection shown on
matrix chart (See page DI−336).
NG

S01650
S01656
SST
SST
S01620
P25458
S01614
SST
− ENGINE MECHANICALTIMING BELT
EM−17
1996 RAV4 (RM447U)
(a) Loosen the mounting bolt of the No. 1 idler pulley and shift
the pulley toward the left as far as it will go, and temporari-
ly tighten it.
(b) Remove the timing belt from the camshaft timing pulley.
18. REMOVE CAMSHAFT TIMING PULLEY
Using SST, remove the pulley bolt and timing pulley.
SST 09249−63010, 09960−10010 (09962−01000,
09963−01000)
19. REMOVE CRANKSHAFT PULLEY
HINT:
When re−using timing belt:
Remove the pulley without turning it.
20. REMOVE NO. 1 TIMING BELT COVER
(a) Disconnect the engine wire from the timing belt cover.
(b) Remove the 4 bolts and timing belt cover.
21. REMOVE TIMING BELT GUIDE
22. REMOVE TIMING BELT
HINT:
(When re−using timing belt): Draw a direction arrow on the tim-
ing belt (in the direction of engine revolution), and place match-
marks on the timing belt and crankshaft timing pulley.
23. REMOVE NO. 1 IDLER PULLEY AND TENSION
SPRING
24. REMOVE NO. 2 IDLER PULLEY
25. REMOVE CRANKSHAFT TIMING PULLEY
If the pulley cannot be removed by hand, use SST to remove
the timing pulley.
SST 09950−50010 (09951−05010, 09952−05010,
09953−05010, 09953−05020, 09954−05010)
NOTICE:
Do not scratch the angle sensor of the timing pulley.

S01649
S01789
S01794
10 − 45°
Knock
Pin
P03445
Service
BoltDrive Gear
Sub−Gear
− ENGINE MECHANICALCYLINDER HEAD
EM−37
1996 RAV4 (RM447U)
31. REMOVE NO. 3 TIMING BELT COVER
Remove the 3 bolts and timing belt cover.
NOTICE:
Support the timing belt, so the meshing of the crank-
shaft timing pulley and timing belt does not shift..
Be careful not to drop anything inside the timing belt
cover
Do not allow the belt to come into contact with oil, wa-
ter or dust.
32. REMOVE CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being removed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
(a) Remove the exhaust camshaft.
(1) Set the knock pin of the intake camshaft at 10 − 45°
BTDC of camshaft angle.
HINT:
The above angle allows No. 2 and No. 4 cylinder cam lobes of
the exhaust camshaft to push their valve lifters evenly.
(2) Secure the exhaust camshaft sub gear to drive gear
with a service bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 − 20 mm (0.63 − 0.79 in.)