TOYOTA RAV4 1996 Service Repair Manual

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

− DIAGNOSTICSCRUISE CONTROL SYSTEM
DI−335
1996 RAV4 (RM447U) CCS ↔ GND
18 − 13
IG ON. Main switch ON.
Switch neutral position.10 − 16 V
IG ON. Main switch ON.
CANCEL switch hold ON.5.1 − 8.3 V
IG ON. Main switch ON.
SET/COAST switch hold ON.2.4 − 4.0 V
IG ON. Main switch ON.
RESUME/ACCEL switch hold ON.0.8 − 1.4 V
CMS ↔ GND19 − 13
IG ON. Main switch hold ON.
(Indicator light ON)Below 1 V
IG ON. Main switch hold OFF.
(Indicator light OFF)10 − 16 V
SPD ↔ GND20 − 13
Engine start.
Car stationary.4.7 − 5.2 V
During driving. (Pulse generated)3 − 7 V
IDL ↔ GND21 − 13IG ON. Throttle valve fully opened.Below 1 V
IG ON. Throttle valve fully closed.10 − 16 V
ECT ↔ GND22 − 13
During cruise control driving.
O/D switch ON.Below 1 V
During cruise control driving.
O/D switch OFF (3rd driving).10 − 16 V
VR1 ↔ GND23 − 13Ignition switch ON.4.7 − 5.2 V
VR2 ↔ VR324 − 25
During cruise control driving.1.0 − 4.7 V
IG ON. Control plate fully opened.4.2 − 4.7 V
IG ON. Control plate fully closed.1.0 − 1.2 V
VR3 ↔ GND25 − 13Always.Below 1 V
L− ↔ GND26 − 13Always.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

− DIAGNOSTICSCRUISE CONTROL SYSTEM
DI−337
1996 RAV4 (RM447U) O/D does not Resume, even through the road is not uphill.
1. Electronically Controlled Transaxle Communication
Circuit
2. Cruise Control ECUDI−357
IN−30
DTC memory is erased.1. Back−up Power Source Circuit
2. Cruise Control ECUDI−369
IN−30
DTC is not output, or is output when is should not be.1. Cruise Control ECUIN−30
Cruise MAIN indicator light remains ON or fails to light up.Combination meter troubleshooting on page BE−2

DI42N−02
Duty Ratio =A + BA
x 100 (%)
ON
OFFA
B
1 cycle
N07458
Cruise Control
Actuator
Motor5
Limit SwitchCruise Control
ECU
R−B 7
6
612
R−G R−G R−B
IB2
IB2MC
MO 11
DI−338
− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 RAV4 (RM447U)
CIRCUIT INSPECTION
DTC 11, 14 Actuator Motor Circuit
CIRCUIT DESCRIPTION
The actuator motor is operated by signals from the ECU. Acceleration and deceleration signals are trans-
mitted by changes in the Duty Ratio (See note below).
Duty Ratio:
The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity
in one cycle, and B is the period of non−continuity, then.
DTC No.Detection ItemTrouble Area
11Short in motor circuitCruise control actuator motor
Harness or connector between actuator motor and ECU
ECU
14Open in actuator motor circuit
WIRING DIAGRAM

N14648N17426I09111
Acceleration
SideDeceleration
Side
Control
Plate (+)5
4
(−)
− DIAGNOSTICSCRUISE CONTROL SYSTEM
DI−339
1996 RAV4 (RM447U)
INSPECTION PROCEDURE
1 Check actuator motor.
PREPARATION:
(a) Remove cruise control actuator.
(b) Disconnect actuator connector.
CHECK:
(a) Connect positive + lead to terminal 5 and negative − lead
to terminal 4 of actuator connector (Magnetic clutch ON).
NOTICE:
Do not connect the high tension cables to the wrong bat-
tery terminal.
You will damage the cruise control actuator.
(b) When battery positive voltage is applied to each terminal
of actuator connector, check that the control plate moves
smoothly without hesitating.
Moving directionTerminal No. to connect
Acceleration sidePositive + − 6Negative − − 7
Deceleration sidePositive + − 7Negative − − 6
(c) With the motor rotating as in 2., check that the motor is
stopped by limit switches when the control plate moves to
fully opened or fully closed position.
NG Replace actuator assembly.
OK
2 Check harness and connector between cruise control ECU and actuator motor
(See page IN−30).
NG Repair or replace harness or connector.
OK
Proceed to next circuit inspection shown on matrix chart (See page DI−336).
However, when DTC 11, 14 is displayed, check and replace cruise control ECU.

N17894
Cruise Control
Actuator
457
16 IB2 STOP FuseStop Light SwitchCruise Control ECU
STP−
L
L− 26 1016 1
3 4 2
G−W
G−B
L−B L−B R−Y
R−Y R−W
GNDL
IB2 DI−340
− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 RAV4 (RM447U)
DTC 12 Actuator Magnetic Clutch Circuit
CIRCUIT DESCRIPTION
This circuit turns on the magnetic clutch inside the actuator during cruise control operation according to the
signal from the ECU. If a malfunction occurs in the actuator or vehicle speed sensor, etc. during cruise con-
trol, the rotor shaft between the motor and control plate is released.
When the brake pedal is depressed, the stop light switch turns on, supplying electrical power to the stop light.
Power supply to the magnetic clutch is mechanically cut and the magnetic clutch is turned OFF.
When driving downhill, if the vehicle speed exceeds the set speed by 15 km/h (9 mph), the ECU turns the
magnetic clutch OFF. If the vehicle speed later drops to within 10 km/h (6 mph) above the set speed, then
cruise control at the set speed is resumed.
DTC No.Detection ItemTrouble Area
12Short in magnetic clutch circuit
Open (0.8 sec.) in magnetic clutch circuit
Cruise contorl actuator magnetic clutch
Harness or connector between ECU and magnetic clutch,
magnetic clutch and body ground
ECU
STOP Fuse
WIRING DIAGRAM
DI42O−02

N17923
STOP Fuse
N14648N17895I09112
(+)
5
4
Control
Plate
(−)
− DIAGNOSTICSCRUISE CONTROL SYSTEM
DI−341
1996 RAV4 (RM447U)
INSPECTION PROCEDURE
1 Check STOP fuse.
PREPARATION:
Remove STOP fuse from fuse block.
CHECK:
Check continuity of STOP fuse.
OK:
Continuity
NG Check for short in all the harness and compo-
nents connected to the STOP fuse (See at-
tached wiring diagram).
OK
2 Check actuator magnetic clutch.
PREPARATION:
(a) Remove cruise control actuator.
(b) Disconnect actuator connector.
CHECK:
Move the control plate by hand.
OK:
Control plate moves. (Magnetic clutch off)
CHECK:
(a) Connect positive + lead to terminal 5 and negative − lead
to terminal 4 of actuator connector.
(b) Move the control plate by hand.
NOTICE:
Do not connect the high tension cables to the wrong bat-
tery terminal.
You will damage the cruise control actuator.
OK:
Control plate does not move. (Magnetic clutch on)
NG Replace actuator assembly.
OK

BE1444BE6234I09113
2
1
43
Switch Pin
DI−342
− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 RAV4 (RM447U)
3 Check stop light switch.
PREPARATION:
Disconnect stop light switch connector.
CHECK:
Check continuity between terminals.
OK:
Switch positionTerminal No. to continuity
Switch pin free
(Brake pedal depressed)1 − 2
Switch pin pushed in
(Brake pedal released)3 − 4
NG Replace stop light switch.
OK
4 Check for open and short in harness and connectors between ECU and stop
light switch, stop light switch and magnetic clutch, magnetic clutch and body
ground (See page IN−30).
NG Repair or replace harness or connector.
OK
Proceed to next circuit inspection shown on matrix chart (See page DI−336).
However, when DTC 12 is displayed, check harness and connector for loose connection.
If connection is normal, check and replace ECU.

N07460
Cruise Control Actuator
IB2
VR1
VR2
VR3L−O
LG
L−RL−R LG L−OVR1
VR2
VR3 25 24 23 1
2
319
18
17Cruise Control ECU
IB2
IB2 Position
Sensor
− DIAGNOSTICSCRUISE CONTROL SYSTEM
DI−343
1996 RAV4 (RM447U)
DTC 13, 14 Actuator Position Sensor Circuit
CIRCUIT DESCRIPTION
The circuit detects the rotation position of the actuator control plate and sends a signal to the ECU.
DTC No.Detection ItemTrouble Area
13Position sensor detects abnormal voltageCruise control actuator motor
Cruise control actuator position sensor
Harness or connector between actuator position sensor and
body ground
Harness or connector between actuator motor and ECU
 ECU
14
Open in actuator motor circuit
Position sensor signal value does not change when the motor
operates
WIRING DIAGRAM
DI42P−02