Cable Transmission TOYOTA RAV4 1996 Service Repair Manual

S02459
− DIAGNOSTICSENGINE
DI−5
1996 RAV4 (RM447U) Terminal No.
Connection / Voltage or ResistanceCondition
2Bus  Line / Pulse generationDuring transmission
4Chassis Ground / ↔ Body Ground 1 Ω or lessAlways
5Signal Ground / ↔ Body Ground 1 Ω or lessAlways
16Battery Positive / ↔ Body Ground 9 ∼ 14VAlways
HINT:
If your display shows ”UNABLE TO CONNECT TO VEHICLE”
when you have connected the cable of the OBDII scan tool or
TOYOTA hand−held tester to DLC3, turned the ignition switch
ON and operated the scan tool, there is a problem on the ve-
hicle side or tool side.
If communication is normal when the tool is connected to
another vehicle, inspect DLC3 on the original vehicle.
If communication is still not possible when the tool is con-
nected to another vehicle, the problem is probably in the
tool itself, so consult the Service Department listed in the
tool’s instruction manual.
2. INSPECT DIAGNOSIS (Normal Mode)
(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.
(2) When the engine is started, the MIL should go off.
If the lamp remains on,the diagnosis system has
detected a malfunction or abnormality in the sys-
tem.
(b) Check the DTC.
NOTICE:
TOYOTA hand−held tester only:
When the diagnosis system is switched from normal mode
to check mode, it erases all DTC and freezed frame data re-
corded in normal mode. So before switching modes, al-
ways check the DTC and freezed frame data, and note them
down.
(1) Prepare the OBDII scan tool (complying with SAE
J1978) or TOYOTA hand−held tester.
(2) Connect the OBDII scan tool or TOYOTA hand−
held tester to DLC3 at the lower of the instrument
panel.
(3) Turn the ignition switch ON and turn the OBDII scan
tool or TOYOTA hand−held tester switch ON.
(4) Use the OBDII scan tool or TOYOTA hand−held tes-
ter to check the DTC and freezed frame data, note
them down.
(5) See page DI−14 to confirm the details of the
DTC.

D00697
Ok if hot
Add if hot
AT4252
0 − 1 mm
D02248
DI−182
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
(f) Check the fluid leaks.
Check for leaks in the transmission and transfer.
If there are leaks, it is necessary to repair or replace O − rings,
FIPG’s, oil seals or other parts.
(g) Inspect and adjust the throttle cable.
(1) Check that the throttle valve is fully closed.
(2) Check that the inner cable is not slack.
(3) Loosen the adjustment nuts.
(4) Adjust the outer cable so that the distance between
the end of the boot and stopper on the cable is as
standard.
Standard boot and cable stopper distance:
0 − 1 mm (0 − 0.04 in.)
(5) Tighten the adjusting nuts.
(6) Recheck the adjustments.
(h) Adjust the shift control cable.
(1) Loosen the nut on the lever.
(2) Push the manual lever fully toward the right side of
the vehicle.

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

EM0EG−02
S01353
CO/HC Meter
− ENGINE MECHANICALCO/HC
EM−1
1996 RAV4 (RM447U)
CO/HC
INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/
HC complies with regulations.
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
HINT:
All vacuum hoses for EGR systems, etc. should be properly
connected.
(f) SFI system wiring connectors fully plugged
(g) Ignition timing check correctly
(h) Transmission in neutral position
(i) Tachometer and CO/HC meter calibrated by hand.
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SE-
CONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST
40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT
IDLE AND/OR 2,500 RPM
Complete the measuring within 3 minutes.
HINT:
When performing the 2 mode (2,500 rpm and idle) test, follow
the measurement order prescribed by the applicable local regu-
lations.