ECU TOYOTA RAV4 1996 Service Repair Manual

AX04X−02
Q08861
Key Interlock SolenoidStop Light Switch
Shift Lock Override Button Cover
Shift Lock Solenoid
Shift Lock Control Switch
Shift Lock Control ECU HINT:
 The shift indicator housing ordered as
supply parts does not include the cover
of the shift−lock override button.
So, if you replace the shift indicator
housing, install cover from the old
housing into the new housing.
 Install the cover with its cutout facing
toward the rear of the vehicle.
− AUTOMATIC TRANSAXLE (A241E)SHIFT LOCK SYSTEM
AX−11
1996 RAV4 (RM447U)
SHIFT LOCK SYSTEM
LOCATION

AX0T7−02
Z19320
STPSLS
+
P2
IG
ACC
KLS
+EP1
P
SLS−
Wire Harness Side ABC
AT5027
AT5029
Battery AX−12
− AUTOMATIC TRANSAXLE (A241E)SHIFT LOCK SYSTEM
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT SHIFT LOCK CONTROL ECU
Using a voltmeter, measure the voltage at each terminal.
HINT:
Do not disconnect the ECU connector.
ConnectorTerminalMeasuring conditionVoltage (V)
A
5 − 4 (ACC − E)Ignition switch ACC10 − 14
1 − 4 (IG − E)Ignition switch ON10 − 14
2 − 4 (STP − E)Depress brake pedal10 − 14
6 − 4 (KLS+ − E)
2. Ignition switch ACC and P position0
3. Ignition switch ACC and except P position7.5 − 11
4. (After−approx. 1 second)5.5 − 10
B1 − 2 (SLS+ − SLS−)
1. Ignition switch ON and P position0
2. Depress brake pedal8.5 − 14
3. Except P position0
C
1 − 2 (P1 − P)1. Ignition switch ON, P position and depress brake pedal0
2. Shift except P position under condition above10 − 14
3 − 2 (P2 − P)1. Ignition switch ACC and P position10 − 14
2. Shift except P position under condition above0
2. INSPECT SHIFT LOCK SOLENOID
(a) Disconnect the solenoid connector.
(b) Using an ohmmeter, measure the resistance between the
terminals.
Standard resistance: 26 − 33 Ω
If resistance value is not as specified, replace the solenoid.
(c) Apply battery positive voltage between the terminals.
Check that the solenoid can be heard operating.
If solenoid operation is not as specified, replace the solenoid.

Q08774
Q08768
D01757
Q08769
C
D
NutAB C
D
A
B
B
B
Nut
Q08770
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
AX−17
1996 RAV4 (RM447U)
15. DISCONNECT FOLLOWING CONNECTORS
Shift solenoid valve SL connector
Park/neutral position switch connector
Vehicle speed sensor connector
16. DISCONNECT 2 OIL COOLER HOSES
Loosen the 2 clips and disconnect the 2 oil cooler hoses.
17. REMOVE 2 POWER STEERING GEAR MOUNTING
BOLTS AND NUTS
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
NOTICE:
Support the power steering gear housing securely.
18. REMOVE FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY WITH STABILIZER BAR
Remove the 10 bolts, 2 nuts and front suspension crossmem-
ber assembly with stabilizer bar.
Torque:
A bolt: 206 N·m (2,100 kgf·cm, 152 ft·lbf)
B bolt: 137 N·m (1,400 kgf·cm, 101 ft·lbf)
C bolt: 35 N·m (360 kgf·cm, 26 ft·lbf)
D bolt: 72 N·m (730 kgf·cm, 53 ft·lbf)
Nut: 73 N·m (740 kgf·cm, 54 ft·lbf)
19. REMOVE STIFFENER PLATE
Remove the 3 bolts and stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

AX04X−03
Q08861
Key Interlock SolenoidStop Light Switch
Shift Lock Override Button Cover
Shift Lock Solenoid
Shift Lock Control Switch
Shift Lock Control ECU HINT:
 The shift indicator housing ordered as
supply parts does not include the cover
of the shift−lock override button.
So, if you replace the shift indicator
housing, install cover from the old
housing into the new housing.
 Install the cover with its cutout facing
toward the rear of the vehicle.
− AUTOMATIC TRANSAXLE (A540H)SHIFT LOCK SYSTEM
AX−15
1996 RAV4 (RM447U)
SHIFT LOCK SYSTEM
LOCATION

AX0ZJ−02
Z19320
STPSLS
+
P2
IG
ACC
KLS
+EP1
P
SLS−
Wire Harness Side ABC
AT5027
AT5029
Battery AX−16
− AUTOMATIC TRANSAXLE (A540H)SHIFT LOCK SYSTEM
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT SHIFT LOCK CONTROL ECU
Using a voltmeter, measure the voltage at each terminal.
HINT:
Do not disconnect the ECU connector.
ConnectorTerminalMeasuring conditionVoltage (V)
A
1 − 3 (ACC − E)IG SW ACC10 − 14
5 − 3 (IG − E)IG SW ON10 − 14
4 − 3 (STP − E)Depress brake pedal10 − 14
2 − 3
(KLS+ − E)
3. IG SW ACC and shift lever at P position0
4. Shift lever at R, N, D, 2, L position7.5 − 11
5. (after approx 1 second)5.5 − 10
B2 − 1
(SLS+ − SLS−)
1. IG SW ON and shift lever at P position0
2. Depress brake pedal8.5 − 14
3. Except P position0
C
3 − 2
(P1 − P)1. IG SW ON, shift lever at P position and depress brake
pedal0
2. Shift except P position under condition above10 − 14
1 − 2
(P2 − P)1. IG SW ACC and shift lever at P position10 − 14
2. Shift except P position under condition above0
2. INSPECT SHIFT LOCK SOLENOID
(a) Disconnect the solenoid connector.
(b) Using an ohmmeter, measure resistance between the ter-
minals.
Standard resistance: 26 − 33 Ω
If resistance value is not as specified, replace the solenoid.
(c) Apply battery positive voltage between the terminals.
Check that the solenoid can be heard operating.
If the solenoid does not operated, replace the solenoid.

H03790
N08495
BO3986
− BODYWINDSHIELD
BO−43
1996 RAV4 (RM447U)
10. INSTALL GLASS
(a) Position the glass so that the reference marks are lined
up, and press in gently along the rim.
(b) Using a spatula, apply adhesive on the glass rim.
HINT:
Confirm that the dam is attached to the body panel, as shown
in the illustration.
(c) Use a scraper to remove any excessive or protruding
adhesive.
(d) Hold the windshield glass in place securely with a protec-
tive tape or equivalent until the adhesive hardenes.
NOTICE:
Take care not to drive the vehicle during the time described
in the chart below.
TemperatureMinimum time prior to driving the vehicle
35°C (95°F)1.5 hours
20°C (68°F)5 hours
5°C (41°F)24 hours
11. INSTALL WINDSHIELD MOULDING
Place the moulding onto the body and install it by hand.
12. INSPECT FOR LEAKS AND REPAIR
(a) Do a leak test after the hardening time has elapsed.
(b) Seal any leak with auto glass sealer.
Part No. 08833−00030 or equivalent.
13. INSTALL COWL TOP VENTILATOR LOUVER
14. INSTALL WIPER ARMS
15. INSTALL FRONT PILLAR GARNISHES
16. INSTALL SUN VISORS AND HOLDERS

H03898
BO3986
− BODYBACK DOOR GLASS
BO−55
1996 RAV4 (RM447U)
10. INSTALL GLASS
(a) Position the glass so that the reference marks are lined
up, and press in gently along the rim.
(b) Using a spatula, apply adhesive on the glass rim.
(c) Use a scraper to remove any excess or protruding adhe-
sive.
(d) Hold the windshield glass in place securely with a protec-
tive tape or equivalent until the adhesive hardenes.
NOTICE:
Take care not to drive the vehicle during the time described
in the chart below.
TemperatureMinimum time prior to driving the vehicle
35°C (95°F)1.5 hours
20°C (68°F)5 hours
5°C (41°F)24 hours
11. INSPECT FOR LEAKS AND REPAIR
(a) Do a leak test after the hardening time has elapsed.
(b) Seal any leak with auto glass sealer.
Part No. 08833−00030 or equivalent.
12. INSTALL WIPER ARM
13. INSTALL STOP LIGHT
14. INSTALL UPPER SIDE GARNISHES
15. INSTALL UPPER GARNISHES
16. INSTALL STOP LIGHT COVER

BR0M4−01
R10627
R10628
− BRAKEFRONT BRAKE PAD
BR−21
1996 RAV4 (RM447U)
REPLACEMENT
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with the hub
nuts.
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace the pads if they are not within the specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. LIFT UP CALIPER
(a) Remove the flexible hose from the shock absorber brack-
et.
(b) Hold the sliding pin on the bottom and loosen the installa-
tion bolt.
(c) Remove the installation bolt.
(d) Lift up the caliper and suspend it securely.
HINT:
Do not disconnect the flexible hose from the caliper.
4. REMOVE THESE PARTS:
2 brake pads
4 anti−squeal shims
4 pad support plates
NOTICE:
The support plates can be used again provided that they
have sufficient rebound, no deformation, cracks or wear,
and have had all rust, dirt and foreign particles cleaned off.
5. CHECK DISC THICKNESS AND RUNOUT
(See page BR−26)
6. INSTALL 4 PAD SUPPORT PLATES

BR0M5−01
R10630
BR−24
− BRAKEFRONT BRAKE CALIPER
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Install the flexible hose lock securely in the lock hole in the cali-
per.
(b) Use a container to catch the brake fluid as it drains out.
2. REMOVE CALIPER
(a) Hold the sliding pin and loosen the 2 installation bolts.
Torque: 26 N·m (270 kgf·cm, 20 ft·lbf)
(b) Remove the 2 installation bolts.
(c) Remove the caliper from the torque plate.
3. REMOVE THESE PARTS:
2 brake pads with anti−squeal shims
4 pad support plates

Fuse BlockEngine ECU R/B No. 5 J/B No. 1J/B No. 4 ABS ECUDaytime Running
Light Relay (*1) Door Look Control RelayA/C Amplifier J/B No. 3
4. ECU (ELECTRONIC CONTROL UNIT)
Locations of ECUs
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.

Before starting electric welding operations, disconnect the negative (-) terminal cable from the battery.
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all
equipped with memory function, it is not possible to make a record of the memory contents.
So when the operation is finished, it will be necessary to explain this fact to the customer, and request
the customer to adjust the features and reset the memory.

Do not expose the ECUs to ambient temperatures above 80°C (176°F).
NOTICE: If it is possible the ambient temperature may reach 80 °C (176 °F) or more, remove the ECUs
from the vehicle before starting work.

Be careful not to drop the ECUs and not to apply physical shocks to them.
4. COMPONENTS ADJACENT TO THE BODY PANELS
Various types of component parts are mounted directly on or adjacently to the body panels.
Strictly observe the following precautions to prevent damaging these components and the body panels
during handling.

Before repairing the body panels, remove their components or apply protective covers over the comœ
ponents.

Before prying components off using screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components and the body paint.

Before removing components from the outer surface of the body, attach protective tape to the body to
ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.

Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.
INTRODUCTIONINœ8