TOYOTA RAV4 1996 Service Repair Manual

EM0F3−03
− ENGINE MECHANICALEXHAUST SYSTEM
EM−105
1996 RAV4 (RM447U)
EXHAUST SYSTEM
COMPONENTS

2
A INTRODUCTION
This manual consists of the following 11 sections:
No.
SectionDescription
A
INDEXIndex of the contents of this manual.
A
INTRODUCTIONBrief explanation of each section.
BHOW TO USE THIS
MANUALInstructions on how to use this manual.
CTROUBLE-
SHOOTINGDescribes the basic inspection procedures for electrical circuits.
DABBREVIATIONSDefines the abbreviations used in this manual.
E
GLOSSARY OF
TERMS AND
SYMBOLS
Defines the symbols and functions of major parts.
FRELAY LOCATIONSShows position of the Electronic Control Unit, Relays, Relay Block, etc.
This section is closely related to the system circuit.
GELECTRICAL
WIRING ROUTINGDescribes position of Parts Connectors, Splice points, Ground points, etc.
This section is closely related to the system circuit.
HPOWER SOURCE
(Current Flow Chart)Describes power distribution from the power supply to various electrical
loads.
INDEXIndex of the system circuits.
I
SYSTEM CIRCUITS
Electrical circuits of each system are shown from the power supply through
ground points. Wiring connections and their positions are shown and
classified by code according to the connection method. (Refer to the
section, How to use this manualº).
The System Outlineº and Service Hintsº useful for troubleshooting are also
contained in this section.
JGROUND POINTSShows ground positions of all the parts decribed in this manual.
K
OVERALL
ELECTRICAL
WIRING DIAGRAM
Provides circuit diagrams showing the circuit connections.

3
HOW TO USE THIS MANUAL B
This manual provides information on the electrical circuits installed on vehicles by
dividing them into a circuit for each system.
The actual wiring of each system circuit is shown from the point where the power
source is received from the battery as far as each ground point. (All circuit diagrams
are shown with the switches in the OFF position.)
When troubleshooting any problem, first understand the operation of the circuit where
the problem was detected (see System Circuit section), the power source supplying
power to that circuit (see Power Source section), and the ground points (see Ground
Points section). See the System Outline to understand the circuit operation.
When the circuit operation is understood, begin troubleshooting of the problem circuit
to isolate the cause. Use Relay Location and Electrical Wiring Routing sections to find
each part, junction block and wiring harness connectors, wiring harness and wiring
harness connectors, splice points, and ground points of each system circuit. Internal
wiring for each junction block is also provided for better understanding of connection
within a junction block.
Wiring related to each system is indicated in each system circuit by arrows (from

, t o ). When overall connections are required, see the Overall Electrical Wiring
Diagram at the end of this manual.

* The system shown here is an EXAMPLE ONLY. It is different to the
actual circuit shown in the SYSTEM CIRCUITS SECTION.
4
B HOW TO USE THIS MANUAL

A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
5
B
:System Title
:Indicates a Relay Block. No shading is used and only
the Relay Block No. is shown to distinguish it from the
J/B.
Example: Indicates Relay Block No. 1.
:Indicates the connector to be connected to a part (the
numeral indicates the pin No.)
Explanation of pin use.
The pins shown are only for the highest grade, or only
include those in the specification.
:Connector Color
Connectors not indicated are milky white in color.
:( ) is used to indicate different wiring and connector,
etc. when the vehicle model, engine type, or
specification is different.
:Indicates related system.
:Indicates the wiring harness and wiring harness
connector. The wiring harness with male terminal is
shown with arrows ( ).
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and
wiring harness connector(s) indicates the component's
location, e.g., Eº for the Engine Compartment, Iº for the
Instrument Panel and Surrounding area, and Bº for the
Body and Surrounding area.
When more than one code has the first and second
letters in common, followed by numbers (e.g., IH1, IH2),
this indicates the same type of wiring harness and
wiring harness connector.
:Represents a part (all parts are shown in sky blue). The
code is the same as the code used in parts position.
:Junction Block (The number in the circle is the J/B No.
and the connector code is shown beside it). Junction
Blocks are shaded to clearly separate them from other
parts (different junction blocks are shaded differently for
further clarification).
3B indicates
that it is inside
Junction Block
No. 3.
Example::Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red
BR = Brown LG = Light Green V = Violet
G = Green O = Orange W = White
GR = Gray P = Pink Y = Yellow
The first letter indicates the basic wire color and the
second letter indicates the color of the stripe.
Example: L - Y
(Blue) (Yellow)
:Indicates a wiring Splice Point (Codes are Eº for the
Engine Room, Iº for the Instrument Panel, and Bº for
the Body).
Example:
The Location of Splice Point I 5 is indicated by the
shaded section.
:Page No.
:Indicates a shielded cable.
:Indicates a ground point.
The first letter of the code for each ground point(s)
indicates the component's location, e.g., Eº for the
Engine Compartment, Iº for the Instrument Panel and
Surrounding area, and Bº for the Body and
Surrounding area.
:Indicates the pin number of the connector.
The numbering system is different for female and male
connectors.
Example: Numbered in order
from upper left to
lower rightNumbered in order
from upper right to
lower left
:When 2 parts both use one connector in common, the
parts connector name used in the wire routing section
is shown in square brackets [ ].

Q
R
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6
B HOW TO USE THIS MANUAL
WITH THE IGNITION SW TURNED ON, THE CURRENT FLOWS TO TERMINAL 3 OF THE POWER WINDOW MASTER SW, TERMINAL 2 OF THE POWER WINDOW CONTROL
RELAY AND TERMINAL 8 OF THE POWER WINDOW SW THROUGH THE DOOR FUSE.
1.DRIVER'S WINDOW MANUAL UPº OPERATION BY MASTER SW
HOLDING MANUAL SW (DRIVER'S) ON UPº POSITION LOCATED IN POWER WINDOW MASTER SW, THE CURRENT FLOWS TO TERMINAL 5 OF THE POWER WINDOW
CONTROL RELAY THROUGH TERMINAL 3 OF THE MASTER SW TERMINAL 2 TO OPERATE A POWER WINDOW CONTROL RELAY. THUS THE CURRENT INSIDE THE RELAY
FLOWS FROM TERMINAL 2 OF THE RELAY TERMINAL 1 TERMINAL 2 OF THE POWER WINDOW MOTOR TERMINAL 1 TERMINAL 4 OF THE RELAY TERMINAL
3 TO GROUND. THE MOTOR TURNS TO ASCENT THE WINDOW. RELEASING THIS SW, THE ROTATION OF MOTOR IS STOPPED AND THE WINDOWS CAN STOP AT WILL
POINT.
(FOR THE MANUAL DOWNº OPERATION, CURRENT FLOWS IN THE REVERSE DIRECTION BECAUSE THE TERMINALS WHERE IT FLOW ARE CHANGED).
2.DRIVER'S WINDOW AUTO DOWNº OPERATION BY MASTER SW
ONCE THE AUTO DOWNº BUTTON OF THE MASTER SW IS PUSHED, THE CURRENT FLOW TERMINAL 9 OF THE POWER WINDOW CONTROL RELAY THROUGH TERMINAL
3 OF THE MASTER SW TERMINALS 8 AND 9 TO OPERATE THE RELAY. THUS THE CURRENT INSIDE THE POWER WINDOW CONTROL RELAY FLOWS FROM TERMINAL
2 OF THE RELAY TERMINAL 4 TERMINAL 1 OF THE POWER WINDOW MOTOR TERMINAL 2 TERMINAL 1 OF THE RELAY TERMINAL 3 TO GROUND.
THE MOTOR CONTINUES THE ROTATION ENABLING TO DESCENT THE WINDOW.
THE WINDOW DESCENDS TO THE END POSITION. THE CURRENT WILL BE CUT OFF TO RELEASE THE AUTO DOWN FUNCTION BASED ON THE INCREASING CURRENT
BETWEEN TERMINAL 2 OF THE RELAY AND TERMINAL 1 IN RELAY.
3.DRIVER'S WINDOW AUTO DOWN RELEASE OPERATION BY MASTER SW
HOLDING THE MANUAL SW (DRIVER'S) ON UPº POSITION IN OPERATING AUTO DOWN. THE CURRENT FROM TERMINAL 3 OF THE MASTER SW PASSING TERMINAL 2
FLOWS TERMINAL 5 OF THE RELAY AND RELEASES THE AUTO DOWN FUNCTION IN THE POWER WINDOW CONTROL RELAY. RELEASING THE HAND FROM SW, WINDOW
STOPS AND CONTINUING ON TOUCHING SW, THE FUNCTION SWITCHES TO MANUAL UP OPERATION.
4.PASSENGER'S WINDOW UP OPERATION (MASTER SW) AND WINDOW LOCK SW OPERATION
HOLDING PASSENGER'S WINDOW SW (MASTER SW) ON UPº, THE CURRENT FLOWS FROM TERMINAL 3 OF THE MASTER SW PASSING TERMINAL 6 TO TERMINAL 3 OF
THE POWER WINDOW SW (PASSENGER'S) TERMINAL 4 TERMINAL 2 OF THE MOTOR TERMINAL 1 TERMINAL 9 OF THE POWER WINDOW SW TERMINAL
7 TERMINAL 1 OF THE MASTER SW TERMINAL 4 TO GROUND. THE MOTOR RUNS TO ASCENT THE WINDOW. RELEASING THIS SW, THE ROTATION OF MOTOR
IS STOPPED AND WINDOW CAN STOP AT WILL PLACE.
SWITCHING THE WINDOW LOCK SW IN LOCKº POSITION, THE CIRCUIT IS OPENED AND STOPPED THE MOTOR ROTATION.
(FOR THE DOWN OPERATION, CURRENT FLOWS IN THE REVERSE DIRECTION BECAUSE THE TERMINALS WHERE IT FLOWS ARE CHANGED).
P 2 POWER WINDOW CONTROL RELAY
3-GROUND: ALWAYS CONTINUITY
2-GROUND: APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION
5-GROUND: APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION AND THE MASTER SW AT UP POSITION
8-GROUND: APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION AND THE MASTER SW AT AUTO DOWN POSITION
9-GROUND: APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION AND THE MASTER SW AT DOWN OR AUTO DOWN POSITION
P 4 POWER WINDOW MASTER SW
4-GROUND: ALWAYS CONTINUITY
3-GROUND: APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION
WINDOW LOCK SW
OPEN WITH THE WINDOW LOCK SW AT LOCK POSITION
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
P 221P 421P 621
P 321P 521
: RELAY BLOCKS
CODESEE PAGERELAY BLOCK (RELAY BLOCK LOCATION)
116R/B NO. 1 (INSTRUMENT PANEL LEFT)
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
3B14J/B NO. 3 AND COWL WIRE (INSTRUMENT PANEL LEFT SIDE)
: CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS
CODESEE PAGEJOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION)
ID126FRONT DOOR RH WIRE AND COWL WIRE (RIGHT KICK PANEL)
IH126FRONT DOOR LH WIRE AND COWL WIRE (LEFT KICK PANEL)
: GROUND POINTS
CODESEE PAGEGROUND POINT LOCATION
IC24COWL LEFT
: SPLICE POINTS
CODESEE PAGEWIRE HARNESS WITH SPLICE POINTSCODESEE PAGEWIRE HARNESS WITH SPLICE POINTS
I 524COWL WIRE
SYSTEM OUTLINE
SERVICE HINTS

Q
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7
B
:Explains the system outline.
:Indicates values or explains the function for reference during troubleshooting.
:Indicates the reference page showing the position on the vehicle of the parts in the system circuit.
Example: Part P 4º (Power Window Master SW) is on page 21 of the manual.
* The letter in the code is from the first letter of the part, and the number indicates its order
in parts starting with the letter.
Part is 4th in order
Power Window Master SW Example: P
4
:Indicates the reference page showing the position on the vehicle of Relay Block Connectors in the
system circuit.
Example: Connector 1º is described on page 16 of this manual and is installed on the left side of the
instrument panel.
:Indicates the reference page showing the position on the vehicle of J/B and Wire Harness in the system
circuit.
Example: Connector 3Bºconnects the Cowl Wire and J/B No. 3. It is described on page 14 of this
manual, and is installed on the instrument panel left side.
:Indicates the reference page describing the wiring harness and wiring harness connector (the female
wiring harness is shown first, followed by the male wiring harness).
Example: Connector ID1ºconnects the front door RH wire (female) and cowl wire (male). It is described
on page 26 of this manual, and is installed on the right side kick panel.
:Indicates the reference page showing the position of the ground points on the vehicle.
Example: Ground point ICº is described on page 24 of this manual and is installed on the cowl left side.
:Indicates the reference page showing the position of the splice points on the vehicle.
Example: Splice point I 5º is on the Cowl Wire Harness and is described on page 24 of this manual.
HINT:
Junction connector (code: J1, J2, J3, J4, J5, J6, J7, J8,
J9) in this manual include a short terminal which is
connected to a number of wire harnesses. Always
perform inspection with the short terminal installed.
(When installing the wire harnesses, the harnesses
can be connected to any position within the short
terminal grouping. Accordingly, in other vehicles, the
same position in the short terminal may be connected
to a wire harness from a different part.)
Wire harness sharing the same short terminal
grouping have the same color.

* The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION.
H POWER SOURCE (Current Flow Chart)
The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit
Breaker, Fuse, etc.) and other parts.
The next page and following pages show the parts to which each electrical source outputs current.
POWER SOURCE
8
B HOW TO USE THIS MANUAL
The Current Flow Chartº section, describes which parts each power source (fuses, fusible links, and circuit breakers)
transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are
explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood.

* The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION.
J GROUND POINT
9
B
The ground points circuit diagram shows the connections from all major parts to the respective ground points. When
troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the
problem ground quickly. The relationship between ground points ( , , and shown below) can also be
checked this way.

10
C TROUBLESHOOTING
VOLTAGE CHECK
(a) Establish conditions in which voltage is present at the
check point.
Example:
- Ignition SW on
- Ignition SW and SW 1 on
- Ignition SW, SW 1 and Relay on (SW2 off)
(b) Using a voltmeter, connect the negative lead to a good
ground point or negative battery terminal, and the
positive lead to the connector or component terminal.
This check can be done with a test light instead of a
voltmeter.
CONTINUITY AND RESISTANCE CHECK
(a) Disconnect the battery terminal or wire so there is no
voltage between the check points.
(b) Contact the two leads of an ohmmeter to each of the
check points.
If the circuit has diodes, reverse the two leads and check
again.
When contacting the negative lead to the diode positive side
and the positive lead to the negative side, there should be
continuity.
When contacting the two leads in reverse, there should be no
continuity.
(c) Use the volt/ohmmeter with high impedance (10 kW/V
minimum) for troubleshooting of the electrical circuit.