engine TOYOTA RAV4 1996 Service Repair Manual

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

72
ENGINE CONTROL
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
C 228I 229K 129
C 830I 3A29M 129
C 930I 4B29N 129
D 128I 529O 229
D 230I 629O 329
D 430I 729P1A29
E 228I 829P 1B29
E 4A31I 929S 531
E 5B31I 1031T 129
E 6C31J 131V 129
F 728J 231V 229
F 831J 531V 729
F1132 (2-DOOR), 33 (4-DOOR)J10A31V 829
I 129J11B31V 929
: RELAY BLOCKS
CODESEE PAGERELAY BLOCKS (RELAY BLOCK LOCATION)
223R/B NO. 2 (ENGINE COMPARTMENT LEFT)
524R/B NO. 5 (LEFT KICK PANEL)
625R/B NO. 6 (ENGINE COMPARTMENT LEFT)
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
1 B20INSTRUMENT PANEL WIRE AND J/B NO 1 (LOWER FINISH PANEL)1 D20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1 E20FUSE BLOCK ASSY WIRE AND J/B NO 1 (LOWER FINISH PANEL)1 F20FUSE BLOCK ASSY WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1 H
1 I20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1 J
()
: 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)
IB136ENGINE ROOM MAIN WIRE AND INSTRUMENT PANEL WIRE (LEFT KICK PANEL)
IB236ENGINE ROOM MAIN WIRE AND INSTRUMENT PANEL WIRE (RIGHT KICK PANEL)
IG138ENGINE WIRE AND INSTRUMENT PANEL WIRE (UNDER THE INSTRUMENT PANEL CENTER)IG238ENGINE WIRE AND INSTRUMENT PANEL WIRE (UNDER THE INSTRUMENT PA N E L CENTER)
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
EA34RADIATOR RIGHT
EC34INTAKE MANIFOLD
IG36RIGHT KICK PANEL
BH38 (2-DOOR)UNDER THE CENTER PILLAR LHBH40 (4-DOOR)UNDER THE CENTER PILLAR LH
: SPLICE POINTS
CODESEE PAGEWIRE HARNESS WITH SPLICE POINTSCODESEE PAGEWIRE HARNESS WITH SPLICE POINTS
E 134ENGINE ROOM MAIN WIREI 538ENGINE WIRE
I 138INSTRUMENT PANEL WIREI1138INSTRUMENT PANEL WIRE
I 438ENGINE WIRE

74
ENGINE CONTROL

77
(2) H-LP RELAY
(2) 2 - (2) 1 : CLOSED WITH LIGHT CONTROL SW AT HEAD POSITION OR DIMMER SW AT FLASH POSITION
C13 LIGHT CONTROL SW [COMB. SW]
14-17 : CLOSED WITH LIGHT CONTROL SW AT HEAD POSITION
C13 DIMMER SW [COMB. SW]
8-17 : CLOSED WITH DIMMER SW HIGH OR FLASH POSITION
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
C1030F 728H 228
C1330H 128J1031
: 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)
1C
1G20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1J
()
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
ID36LEFT KICK PANEL
IG36RIGHT KICK PANEL
: SPLICE POINTS
CODESEE PAGEWIRE HARNESS WITH SPLICE POINTSCODESEE PAGEWIRE HARNESS WITH SPLICE POINTS
E 134ENGINE ROOM MAIN WIRE
X 2 121X
XX
XX X14X9 8 X
18 17 X
X
1
231
23
AAAAAA
(
HINT : SEE PAGE 7) (
SEE PAGE 25)C10
BLUE (
A/T)
C13
J10
GRAY H 2
BLACK H 1
BLACK F 7C10
BLUE (
M/T)
SERVICE HINTS

79
INTEGRATION RELAY
1-GROUND : ALWAYS APPROX. 12 VOLTS
6-GROUND : CONTINUITY WITH THE DRIVER'S SIDE DOOR OPEN
10-GROUND : ALWAYS CONTINUITY
D 6, D 7, D 8, D 9 DOOR COURTESY SW (DRIVER'S SIDE), (FRONT PASSENGER'S SIDE), (REAR LH, RH)
1-GROUND : CLOSED WITH THE DOOR OPEN
B 7 BACK DOOR OPEN DETECTION SW
2-GROUND : CLOSED WITH THE BACK DOOR OPEN
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
B 732 (2-DOOR), 33 (4-DOOR)D 732 (2-DOOR), 33 (4-DOOR)J 431
C10A30D 833 (4-DOOR)P 332 (2-DOOR), 33 (4-DOOR)
C11B30D 933 (4-DOOR)
D 632 (2-DOOR), 33 (4-DOOR)I1132 (2-DOOR), 33 (4-DOOR)
: 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)
1A
1B20INSTRUMENT PANEL WIRE AND J/B NO 1 (LOWER FINISH PANEL)1H20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1J
1L20FLOOR 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)
ID136FLOOR WIRE AND INSTRUMENT PANEL WIRE (LEFT KICK PANEL)
IE136ROOF WIRE AND INSTRUMENT PANEL (LEFT KICK PANEL)
BK240 (2-DOOR)BACK DOOR NO 1 WIRE AND FLOOR WIRE (BESIDE RIGHT REAR COMB LIGHT)BK242 (4-DOOR)BACK DOOR NO. 1 WIRE AND FLOOR WIRE (BESIDE RIGHT REAR COMB. LIGHT)
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
ID36LEFT KICK PANEL
IG36RIGHT KICK PANEL
BI38 (2-DOOR)UNDER THE CENTER PILLAR RHBI40 (4-DOOR)UNDER THE CENTER PILLAR RH
BJ38 (2-DOOR)BACK DOOR LEFTBJ40 (4-DOOR)BACK DOOR LEFT
: SPLICE POINTS
CODESEE PAGEWIRE HARNESS WITH SPLICE POINTSCODESEE PAGEWIRE HARNESS WITH SPLICE POINTS
B140 (2-DOOR)ROOF WIREB1040 (2-DOOR)BACK DOOR NO 1 WIREB 142 (4-DOOR)ROOF WIREB1042 (4-DOOR)BACK DOOR NO. 1 WIRE
B 942 (4-DOOR)FLOOR WIREB1242 (4-DOOR)FLOOR WIRE
SERVICE HINTS

83
(5) TURN SIGNAL FLASHER
(5) 2-GROUND : APPROX. 12 VOLTS WITH THE IGNITION SW ON OR THE HAZARD SW ON
(5) 1-GROUND : CHANGES FROM 12 TO 0 VOLTS WITH THE IGNITION SW ON AND THE TURN SIGNAL SW LEFT OR RIGHT,
OR WITH THE HAZARD SW ON
(5) 3-GROUND : ALWAYS CONTINUITY
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
C 9A30F 831J 11B31
C10B30H 431R 832 (2-DOOR), 33 (4-DOOR)
C1330J 131R 932 (2-DOOR), 33 (4-DOOR)
F 328J 431
F 428J10A31
: RELAY BLOCKS
CODESEE PAGERELAY BLOCKS (RELAY BLOCK LOCATION)
223R/B NO. 2 (ENGINE COMPARTMENT LEFT)
524R/B NO. 5 (LEFT KICK PANEL)
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
1A
1B20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1C
20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1E20FUSE BLOCK ASSY WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1G
1H20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1J
20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1L20FLOOR 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)
IB236ENGINE ROOM MAIN WIRE AND INSTRUMENT PANEL WIRE (RIGHT KICK PANEL)
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
EA34RADIATOR RIGHT
IG36RIGHT KICK PANEL
BH38 (2-DOOR)UNDER THE CENTER PILLAR LHBH40 (4-DOOR)UNDER THE CENTER PILLAR LH
BI38 (2-DOOR)UNDER THE CENTER PILLAR RHBI40 (4-DOOR)UNDER THE CENTER PILLAR RH
SERVICE HINTS

84
TAILLIGHT AND ILLUMINATION
IDE 1 E 1B 9
EA BIB 5
17
LIGHT CONTROL SW C13
BATTERY
W
LG W
W-BW-B
W-B
W-B
W-BG
G
G
G
1
TAIL
SE BLOCK]
G G
G FRON IG HT RH F 2
FRON LH F 3
FRON RH F 4
FRON IG HT LH F 1
REAR GHT RH R11
W-B
G G
G
W-G
I 7G
G
TO DIODE
(
ENGINE IDLE-UP)
GG
TAILL
[REA H ] R 9
W-B G
BJ
LICE N L 1
W-B G
210A
[FU F 8
1J 11L12 1E 31I2
2 2
OFF
TAIL
HEADTEDH 15
[C O M B . S W ]
2 1
2 1
1 2
1 2
1 2
T SIDE MARKER L
T PARKING LIGHT
T PARKING LIGHT
T SIDE MARKER L
SIDE MARKER LI5 1IG HT R H
R COM B. LIGHT R
2 1SE PLATE LIG HT
FUSIBLE LINK
BLOCK F 7
100A A LT
W-B
AAAA
JUNCTION
CONNECTOR J 1 6
A
23 15
1K 11G31F6 TAILLIGHT
RELAY

87
TAILLIGHT RELAY
5-3 : CLOSED WITH THE LIGHT CONTROL SW AT TAIL OR HEAD POSITION
C13 LIGHT CONTROL SW [COMB. SW]
15-17 : CLOSED WITH THE LIGHT CONTROL SW AT TAIL OR HEAD POSITION
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
A1330F 228L 132 (2-DOOR), 33 (4-DOOR)
B 530F 328O 431
C 430F 428R 3A31
C 630F 728R 4B31
C 730F 831R 531
C 9A30H 431R 731
C11C30J 131R 832 (2-DOOR), 33 (4-DOOR)
C1330J 8A31R 932 (2-DOOR), 33 (4-DOOR)
E 331J 9B31R1032 (2-DOOR), 33 (4-DOOR)
F 128J1031R1132 (2-DOOR), 33 (4-DOOR)
: 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)
1E20FUSE BLOCK ASSY WIRE AND J/B NO 1 (LOWER FINISH PANEL)1F20FUSE BLOCK ASSY WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1G
1H20INSTRUMENT PANEL WIRE AND J/B NO 1 (LOWER FINISH PANEL)1I20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1J
1K20ENGINE ROOM MAIN WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1L20FLOOR WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
EA34RADIATOR RIGHT
ID36LEFT KICK PANEL
IE36INSTRUMENT PANEL BRACE LH
BH38 (2-DOOR)UNDER THE CENTER PILLAR LHBH40 (4-DOOR)UNDER THE CENTER PILLAR LH
BI38 (2-DOOR)UNDER THE CENTER PILLAR RHBI40 (4-DOOR)UNDER THE CENTER PILLAR RH
BJ38 (2-DOOR)BACK DOOR LEFTBJ40 (4-DOOR)BACK DOOR LEFT
: SPLICE POINTS
CODESEE PAGEWIRE HARNESS WITH SPLICE POINTSCODESEE PAGEWIRE HARNESS WITH SPLICE POINTS
E 134ENGINE ROOM MAIN WIREB640 (2-DOOR)FLOOR WIREI 738INSTRUMENT PANEL WIREB 642 (4-DOOR)FLOOR WIRE
B640 (2-DOOR)FLOOR WIREB940 (2-DOOR)FLOOR WIREB 642 (4-DOOR)FLOOR WIREB 942 (4-DOOR)FLOOR WIRE
SERVICE HINTS