TOYOTA RAV4 1996 Service Repair Manual

S07292
1K1D 49
EA1IG1
1211
22
2 225
23
1
22
6
5 21
20
AA
BR 1D1F1E
1B
1H
1D3718
8
13 34 Fuse Block
B
R−L
R−LECM
E6
E6
E6
E6 19 188 22
IG17
16
IG2
IG2 15 3B 5
53A
IG2 2 IG1 10 EA17
EA113S3 1 B
B
*1: 2WD
*2: 4WD
J1
Junction
Connector Fusible
Link
BlockMAIN
Battery
To Terminal STA of ECMEAB
StarterPark/Neutral
Position
Switch
R−B5 B−W W
B−R
J/B No.1
B−RB−R
724
8B−W B−Y IG Switch
W
ST Relay
ALT
AM2
MAIN No.1
B
R−L
B−W J/B No.1
LG−R
LG
LG R−B
LG−R
W−BW−BB+
R
2
LE1
E1
E1 NSW
8
9
3
4
4
6 3 5 2 6
R
AM1
1
2
GAUGE
R/B No.2
W
W2 6*
1
*2
*12 *1
*1
*2
*1
*2
*1
*2
*2
*1
R−L
S02502S02496A07403
2WD:
4WD:4
6
2
10
− DIAGNOSTICSENGINE
DI−111
1996 RAV4 (RM447U)
WIRING DIAGRAM
INSPECTION PROCEDURE
1 Check park / neutral position switch.
PREPARATION:
Disconnect park / neutral position switch connector.
CHECK:
Check continuity between each terminal shown below when the
shift lever is positioned to each range.
OK:
Shift PositionTerminal No. to continuity
P6 − 1 *1 : 2 − 7 *22 − 3 *1 : 5 − 6 *2
R6 − 5 *1 : 2 − 8 *2
N6 − 7 *1 : 2 − 9 *22 − 3 *1 : 5 − 6 *2
D6 − 8 *1 : 2 − 10 *2
26 − 9 *1 : 2 − 3 *2
L6 − 4 *1 : 2 − 4 *2
*1: 2WD
*
2: 4WD
NG Replace park / neutral position switch.

BE6653P23734A07404
ON
NSW
(+)
DI−11 2
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
OK
2 Check voltage between terminal NSW of ECM connector and body ground.
PREPARATION:
(a) Remove side trim cover (See page SF−61).
(b) Turn ignition switch ON.
CHECK:
Measure voltage between terminal NSW of ECM connector and
body ground after the shift lever is moved to the following posi-
tions.
OK:
Shift lever positionP or NL, 2, D or R
Voltage0 − 3 V9 − 14 V
OK Check and replace ECM (See page IN−30).
NG
Check for open and short in harness and con-
nector between ECM and park / neutral posi-
tion switch (See page IN−30).

S02409
2
227
26
66
62
9
7
8
92
1 1E1D
1J
1E EA1
IG1
EA
EC A
AA
A
W
R/B No.2R−W
11
17
1621
20
10 11J2
Junction
Connector J1
Junction
ConnectorECM
B−R
Fusible
Link
Block
MAIN
Fuse BlockIGN IG
Switch
B6
B−R
B−R B−R1
2 3
5
EA1
IG1
E6
E4+B
E1 12
BR14 B−R R/B No.6
EFI Main Relay
J/B
No.1
BatteryB−R
EFI
AM1
B−O
B−O B−OW−B
W−BBR
− DIAGNOSTICSENGINE
DI−11 3
1996 RAV4 (RM447U)
ECM Power Source Circuit
CIRCUIT DESCRIPTION
When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of
the EFI relay and supplying power to the terminals +B of the ECM.
WIRING DIAGRAM
DI406−01

A00423
ON
E1
(−)+B
(+)
DI−11 4
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
INSPECTION PROCEDURE
1 Check voltage between terminals +B and E1 of ECM connector.
PREPARATION:
(a) Remove side trim cover (See page SF−61).
(b) Turn ignition switch ON.
CHECK:
Measure voltage between terminals +B and E1 of ECM connec-
tor.
OK:
Voltage: 9 − 14 V
OK Proceed to next circuit inspection shown on
matrix chart (See page DI−20).
NG
2 Check for open in harness and connector between terminal E1 of ECM and body
ground (See page IN−30).
NG Repair or replace harness or connector.
OK
3 Check EFI main relay (Making: EFI) (See page SF−39).
NG Replace EFI main relay (Making: EFI)
OK
4 Check EFI fuse (See page DI−11 0, step 2).
NG Check for short in all the harness and compo-
nents connected of EFI fuse.
OK

S02497
IGN Fuse
Fuse Block
− DIAGNOSTICSENGINE
DI−11 5
1996 RAV4 (RM447U)
5 Check for open in harness and connector between EFI main relay (Marking: EFI)
and battery, EFI main relay (Marking: EFI) and ECM (See page IN−30).
NG Repair or replace harness or connector.
OK
6 Check IGN fuse.
PREPARATION:
Remove IGN fuse from fuse block.
CHECK:
Check continuity of IGN fuse.
OK:
Continuity
NG Check for short in all the harness and compo-
nents connected to IGN fuse.
OK
7 Check ignition switch (See page BE−11).
NG Replace ignition switch.
OK
Check for open in harness and connector between IG switch and EFI main relay (Marking: EFI),
EFI main relay (Marking: EFI) and body ground (See page IN−30).

S02410
EFI
MAIN No.1
IG Switch AM2
MAIN
FL
BatteryPark/Neutral
Position Switch
(Clutch Start
Switch)EFI Main
RelayCircuit Opening
Relay
Fuel Pump
ECM
FC
Tr
STA
NE (STA Signal)
(NE Signal) Starter IGN
ST Relay DI−11 6
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
Fuel Pump Control Circuit
CIRCUIT DESCRIPTION
In the diagram below, when the engine is cranked, current flows from terminal ST of the ignition switch to
the starter relay coil and also current flows to terminal STA of ECM (STA signal).
When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to coil of the circuit
opening relay, the relay switches on, power is supplied to the fuel pump and the fuel pump operates.
While the NE signal is generated (engine running), the ECM keeps Tr ON (circuit opening relay ON) and the
fuel pump also keeps operating.
DI407−02

S07291
ECM
E1 FC 14
E6 G−R
ID1 4 R/B No.5
5
5 5
53
12 5
Circuit Opening
Relay
Fuse Block
10 11
L−B
B−O 11 17 2
1J
1E1
9 8
3
131E
1D
1D
1H
Fuel
Pump
L−B
W−BBH
IB111
B−R
6 5
1 3
2
EFI Main RelayR/B No.6
B−R
B−R
B−W
B−W
B−W (M/T) B−R
B
B R
IG1
IG12
1
Clutch Start
Switch10 IG111
EA
12 2 17
16
20
21
6 6 6
10 B−R A
W−BW−B
J1
Junction
Connector
W−BA A
EA1 B
BB
WEA1
810
652 3 B (A/T)
Starter S31
Battery
Fusible
Link
Block 252
2
2
2 2 21
3ST Relay MAIN
No.1AM2EFI
56
MAINR−W
B−R
*
1
*1*2
*2
EA1
*1: 2WD
*2: 4WDJ/B
No.1B−O
IGN B−O
IG Switch
8 76 R/B No.2
54 B−O
Park/Neutral
Position Switch
− DIAGNOSTICSENGINE
DI−11 7
1996 RAV4 (RM447U)
WIRING DIAGRAM

DI−11 8
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
INSPECTION PROCEDURE
TOYOTA hand−held tester
1 Connect the TOYOTA hand−held tester and check operation of fuel pump (See
page SF−5).
OK Check for starter signal circuit (See page
DI−105).
NG
2 Check for ECM power source circuit (See page DI−11 3).
NG Repair or replace.
OK
3 Check circuit opening relay (See page SF−41).
NG Replace circuit opening relay.
OK

A00424
FC
(+)
ON
− DIAGNOSTICSENGINE
DI−11 9
1996 RAV4 (RM447U)
4 Check voltage between terminal FC of ECM and body ground.
PREPARATION:
(a) Remove side trim cover (See page SF−61).
(b) Turn ignition switch ON.
CHECK:
Measure voltage between terminal FC of ECM and body
ground.
OK:
Voltage: 9 − 14 V
NG Check for open in harness and connector be-
tween EFI main relay (Marking: EFI) and circuit
opening relay, circuit opening relay and ECM.
OK
5 Check fuel pump (See page SF−5).
NG Repair or replace fuel pump.
OK
6 Check for open in harness and connector between circuit opening relay and fuel
pump, fuel pump and body ground (See page IN−30).
NG Repair or replace harness or connector.
OK
Check and replace ECM (See page IN−30).

BE6653S00839S01830A06622
FC
(+)
Fuel Inlet Hose
ON
DI−120
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
OBDII scan tool (exculding TOYOTA hand−held tester)
1 Check fuel pump operation.
PREPARATION:
(a) Remove side trim cover (See page SF−61).
(b) Turn ignition switch ON.
CHECK:
(a) Connect between terminal FC of ECM and body ground.
(b) Check for fuel pressure in the inlet hose when it is pinched
off.
OK:
There is pressure in the inlet hose.
HINT:
At this time, you will hear a fuel flowing noise.
OK Check for starter signal circuit (See page
DI−105).
NG
2 Check for ECM power source circuit (See page DI−11 3).
NG Repair or replace.
OK
3 Check circuit opening relay (See page SF−40).
NG Replace circuit opening relay.
OK