check engine light TOYOTA RAV4 1996 Service Owner's Manual

Q08870
Fuse Block
Junction Connector
FL Block
Stop Light RH Stop Light LHTo ABS ECU
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−159
1996 RAV4 (RM447U)
Stop Light Switch Circuit
CIRCUIT DESCRIPTION
The purpose of this circuit is to prevent the engine from stalling, while driving in lock−up condition, when
brakes are suddenly applied.
When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels of the lock−up
clutch while braking is in progress.
WIRING DIAGRAM
INSPECTION PROCEDURE
1 Check operation of stop light.
CHECK:
Check if the stop lights go on and off normally when the brake pedal is operated and released.
NG Check and repair stop light circuit.
OK
DI98Q−03

Q08848
DI−174
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
The diagnosis system operates in normal mode
during normal vehicle use, and also has a check
mode for technicians to simulate malfunction symp-
toms and perform troubleshooting. Most DTCs use
2 trip detection logic (*) to prevent erroneous detec-
tion. By switching the ECM to check mode when
troubleshooting, the technician can cause the MIL
to light up for a malfunction that is only detected
once or momentarily (TOYOTA hand−held tester)
(See step 3).
*2 trip detection logic:
When a logic malfunction is first detected, the mal-
function is temporarily stored in the ECM memory.
If the same malfunction is detected again during the second test
drive, this second detection causes the MIL to light up.
2. Normal Mode:
INSPECT DIAGNOSIS
(a) Check the MIL.
(1) The MIL comes on when the ignition switch is turned
ON and the engine is not running.
HINT:
If the MIL does not light up, troubleshoot the combination meter
(See page BE−2).
(2) When the engine starts, the MIL should go off. If the
lamp remains on, the diagnosis system has a mal-
function or abnormality in the system.
(b) Check the DTC.
NOTICE:
TOYOTA hand−held tester only:
When the diagnostic system is switched from the normal
mode to the check mode, it erases all DTCs and freezed
frame data recorded in the normal mode. So before switch-
ing modes, always check the DTCs and freezed frame data,
and note them down.
(1) Prepare the OBD II scan tool (complying with SAE
J1978) or TOYOTA hand−held tester.
(2) Connect the OBD II scan tool or TOYOTA hand−
held tester to the DLC3.
(3) Turn the ignition switch ON and turn the OBD II scan
tool or TOYOTA hand−held tester switch ON.
(4) Use the OBD II scan tool or TOYOTA hand−held
tester to check the DTCs and freezed frame data.
Note them down (For operating instructions, see
the OBDII scan tool’s instruction book.).

FI3605
ON
OFF
0.13 sec.
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−175
1996 RAV4 (RM447U)
(5) See page DI−189 to confirm the details of the
DTCs.
NOTICE:
When simulating symptoms with an OBD II scan tool (ex-
cluding TOYOTA hand−held tester) to check the DTCs, use
the normal mode. For codes on the DTC chart subject to ”2
trip detection logic”, turn the ignition switch off after the
symptoms have been simulated for the first time. Then re-
peat the simulation process again. When the program has
been simulated twice, the MIL lights up and the DTCs are
recorded in the ECM.
3. Check Mode:
INSPECT DIAGNOSIS
HINT:
TOYOTA hand−held tester only:
Compared to the normal mode, the check mode has high sens-
ing ability to detect malfunctions.
Furthermore, the same diagnostic items which are detected in
the normal mode can also be detected in the check mode.
(a) Check the DTC.
(1) Initial conditions.
Battery positive voltage 11 V or more.
Throttle valve fully closed
Transaxle in the PARK position
Air conditioning switched off
(2) Prepare the TOYOTA hand−held tester.
(3) Connect the TOYOTA hand−held tester to the
DLC3.
(4) Turn the ignition switch ON and switch the TOYOTA
hand−held tester ON.
(5) Switch the TOYOTA hand−held tester from the nor-
mal mode to the check mode (Check that the MIL
flashes.).
(6) Start the engine (The MIL goes off after the engine
start.).
(7) Simulate the conditions of the malfunction de-
scribed by the customer.
NOTICE:
Leave the ignition switch ON until you have checked the
DTCs, etc.
(8) After simulating the malfunction conditions, use the
TOYOTA hand−held tester diagnosis selector to
check the DTCs and freezed frame data, etc.
HINT:
Take care not to turn the ignition switch OFF. Turning the ignition
switch off switches the diagnosis system from check mode to
normal mode, so all DTCs, etc. are erased.
(9) After checking the DTC, inspect the applicable cir-
cuit.

DI−178
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
(6) Check for the lock−up mechanism.
Drive in the D position, O/D gear, at a steady speed (lock−up ON) of about 75 km/h (47
mph).
Lightly depress the accelerator pedal and check that the engine speed does not change
abruptly.
If there is a big jump in engine speed, there is no lock−up.
(b) 2 position test.
Shift into the 2 position and, while driving with the accelerator pedal held constantly at the full throttle
valve opening position, push in one of the pattern selectors and check on the following points.
(1) Check to see that the 1 → 2 up−shift takes place and that the shift point conforms to that shown
on the automatic shift schedule (See page SS−35).
(2) While running in the 2 points and 2nd gear, release the accelerator pedal and check the engine
braking effect.
Evaluation:
ProblemPossible cause
If these is no engine braking effect2nd coast brake is defective
(3) Check for abnormal noises during acceleration and deceleration, and for shock at up−shift and
down−shift.
(c) L position test.
(1) While running in the L position, check to see that there in no up−shift to 2nd gear.
(2) While running in the L position, release the accelerator pedal and check the engine braking ef-
fect.
Evaluation:
ProblemPossible cause
If these is no engine braking effect1st and reverse brake defective
(3) Check for abnormal noises during acceleration and deceleration.
(d) R position test.
Shift into the R position and, while starting at full throttle, check for slipping.
CAUTION:
Before conducting this test ensure that the test area is free from personnel an obstructions.
(e) P position test.
Stop the vehicle on a gradient (more than 5°) and after shifting into the P position, release the parking
brake. Then check to see that the parking lock pawl holds the vehicle in place.

Q06077NRP
Q06078
Neutral
Basic
Line
Groove
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−183
1996 RAV4 (RM447U)
(3) Return the lever 2 notches to the NEUTRAL posi-
tion.
(4) Set the shift lever in the N position.
(5) While holding the lever lightly toward the ”R” posi-
tion side, tighten the shift lever nut.
(i) Adjust the park/neutral position switch.
If the engine will start with the shift selector in any position other
than the N or P position, adjustment is required.
(1) Loosen the park/neutral position switch bolts and
set the shift selector to the N position.
(2) Align the groove and neutral basic line.
(3) Hold in position and tighten the bolts.
Torque: 5.4 N·m(55 kgf·cm,48 in·lbf)
(j) Inspect the idle speed.
Idle speed: 750 ± 50 rpm (In N position and A/C OFF)
8. MECHANICAL SYSTEM TESTS
(a) Measure the stall speed.
The object of this test is to check the overall performance of the transaxle and engine by measuring
the stall speeds in the D and R positions.
NOTICE:
Do the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear, level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Connect OBD II scan tool or TOYOTA hand−held tester to the DLC3.
(3) Fully apply the parking brake.
(4) Keep your left foot pressed firmly on the brake pedal.
(5) Start the engine.
(6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot.
Quickly read the stall speed at this time.
Stall speed: 2,400 ± 150 rpm
(7) Do the same test in R position.
Stall speed: 2,400 ± 150 rpm
Evaluation:
ProblemPossible cause
Stall speed low in D and R positions
Engine output may be insufficient
Stator one−way clutch is operating properly
HINT:
If more than 600 rpm below the specified value, the torque converter clutch could
be faulty

DI40X−02
DI−192
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
PROBLEM SYMPTOMS TABLE
If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the
circuits for each symptom in the order given in the charts on the following pages and proceed to the page
given for troubleshooting.
The Matrix Chart is divided into 3 chapters.
Chapter 1: Electronic Circuit Matrix Chart
Chapter 2: On−Vehicle Repair Matrix Chart
Chapter 3: Off−Vehicle Repair Matrix Chart
When troubleshooting, check Chapter 1 first. If instructions are given in Chapter 1 to proceed to chapter 2
or 3, proceed as instructed.
(1) 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.
(2) If the trouble still occurs even though there are no abnormalities in any of the other circuits, then
check and replace the ECM.
Chapter 1: Electronic Circuit Matrix Chart
SymptomSuspect AreaSee page
No up−shift (A particular gear, from 1st to 3rd gear, is not up−
shifted)2. ECMDI−191
No up−shift (3rd → O/D)
1. O/D main switch & O/D OFF indicator light circuit
2. O/D cancel signal circuit
3. ECMDI−223
DI−221
DI−191
No down−shift (O/D → 3rd)
1. O/D main switch & O/D OFF indicator light circuit
2. O/D cancel signal circuit
3. ECMDI−223
DI−221
DI−191
No down−shift (A particular gear, from 1st to 3rd gear, is not
down−shifted)1. ECMDI−191
No lock−up1. Stop light switch circuit
2. ECMDI−227
DI−191
No lock−up off1. ECMDI−191
Shift point too high or too low1. Pattern select switch circuit
2. ECMDI−229
DI−191
Up−shifts to O/D from 3rd while O/D main switch is OFF1. O/D main switch & O/D OFF indicator light circuit
2. ECMDI−223
DI−191
Up−shifts to O/D from 3rd while engine is cold1. ECMDI−191
No kick−down1. ECMDI−191
Engine stalls when starting off or stopping1. ECMDI−191
”A/T OIL” indicator light does not light up or does not goes off1. A/T temperature switchDI−191
Chapter 2: On−Vehicle Repair
(: A540H Automatic Transaxle Repair Manual Pub. No. RM488U)
SymptomSuspect AreaSee page
Vehicle does not move in R position
1. 1−2 shift valve
2. 2−3 shift valve
3. Throttle valve
4. Off−vehicle repair matrix chart


−
Vehicle does not move in any forward position or reverse position
1. Manual valve
2. Primary regulator valve
3. Secondary regulator valve
4. Off−vehicle repair matrix chart


−

Q08870
Fuse Block
Junction Connector
FL Block
Stop Light RH Stop Light LHTo ABS ECU
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−227
1996 RAV4 (RM447U)
Stop Light Switch Circuit
CIRCUIT DESCRIPTION
The purpose of this circuit is to prevent the engine from stalling, while driving in lock−up condition, when
brakes are suddenly applied.
When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels of the lock−up
clutch while braking is in progress.
WIRING DIAGRAM
INSPECTION PROCEDURE
1 Check operation of stop light.
CHECK:
Check if the stop lights go on and off normally when the brake pedal is operated and released.
NG Check and repair stop light circuit.
OK
DI994−01

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−271
1996 RAV4 (RM447U)
INSPECTION PROCEDURE
1 Is DTC output?
Check DTC on page DI−234.
YES Repair circuit indicated by code output.
NO
2 Is normal code displayed?
YES Check ABS solenoid relay. Check for short in
harness and connector between ABS solenoid
relay and DLC1 (See page IN−30).
NO
3 Is ABS warning light go off?
YES Check for open or short in harness and connec-
tor between ECU−IG Fuse and ECU (See page
IN−30).
NO
4 Check battery positive voltage.
PREPARATION:
Start the engine.
CHECK:
Check the battery positive voltage.
OK:
Voltage: 10 − 16 V
NG Check and repair charging system.
OK

W01418F15322
EC
A
33
*2*111 E1
ABR BREA1
12 V
DLC1 J2
Junction
Connector
*
1: 2WD Models
*2: 4WD ModelsA16 A17ABS ECU
TsTs 8
LL6
F15316
E1
TsDLC1
DI−280
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
1996 RAV4 (RM447U)
Ts Terminal Circuit
CIRCUIT DESCRIPTION
The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with
the DTC check. Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check.
WIRING DIAGRAM
INSPECTION PROCEDURE
1 Check voltage between terminals Ts and E1 of DLC1.
PREPARATION:
(a) Turn the ignition switch ON.
(b) Measure the voltage between terminals Ts and E1 of the
DLC1.
OK:
Voltage: 10 − 14 V
OK If ABS warning light does not blink even after Ts
and E1 are connected, ECU may be defective.
NG
DI41W−02