change time TOYOTA RAV4 1996 Service Repair Manual

BR2237
BR02Q−02
BR2238
GOOD
1st2nd3rdNO GOOD BR−16
− BRAKEBRAKE BOOSTER ASSEMBLY
1996 RAV4 (RM447U)
BRAKE BOOSTER ASSEMBLY
ON−VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine
OFF and check that there is no change in the pedal re-
serve distance.
(b) Depress the brake pedal and start the engine.
If the pedal goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down farthest at the 1st time, but gradually
rises after at the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed.
If there is no change in the pedal reserve travel after holding the
pedal for 30 seconds, the booster is air−tight.

Manual NamePub. No.

3S-FE Engine Repair Manual

TOYOTA RAV4 Chassis and Body Repair
Manual

TOYOTA RAV4 Chassis and Body Repair
Manual Supplement

TOYOTA RAV4 Electrical Wiring
Diagram

TOYOTA RAV4 Electrical Wiring
Diagram Supplement

TOYOTA RAV4 New Car Features

TOYOTA RAV4 Repair Manual
For Collision Damage

Fundamental Painting Procedures

Fundamental Body Repair ProceduresBRM024E
BRM002E NCF108E
BRM045E EWD234F EWD206Y RM454E RM395E
FOREWORD
This repair manual has been prepared to provide essential
information on body panel repair methods (including cutting
and welding operations, but excluding painting) for the
TOYOTA RAV4 5-DOOR.
Applicable models: SXA11 series
This manual consists of body repair methods, exploded diaœ
grams and illustrations of the body components and other
information relating to body panel replacement such as hanœ
dling precautions, etc. However, it should be noted that the
front fenders of the TOYOTA model is bolted on and require
no welding.
When repairing, don't cut and join areas that are not shown in
this manual. Only work on the specified contents to maintain
body strength.
Body construction will sometimes differ depending on specifiœ
cations and country of destination. Therefore, please keep in
mind that the information contained herein is based on veœ
hicles for general destinations.
For the repair procedures and specifications other than colliœ
sion-damaged body components of the TOYOTA RAV 4
5-DOOR refer to the following repair manuals.
If you require the above manuals, please contact your TOœ
YOTA Dealer.
All information contained in this manual is the most up-to-
date at the time of publication. However, specifications and
procedures are subject to change without prior notice.
TOYOTA MOTOR CORPORATION
RM401E

FI6606FI7210A06619
Atmosphere
Flange
Platinum Electrode
Solid Electrolyte
(Zirconia Element)
Platinum Electrode
Coating (Ceramic)
Richer−air Fuel Ratio−Leaner Ideal Air−Fuel Mixture
Output Voltage
Cover
Exhaust Gas
− DIAGNOSTICSENGINE
DI−39
1996 RAV4 (RM447U)
DTC P0125 Insufficient Coolant Temp. for Closed Loop
Fuel Control
CIRCUIT DESCRIPTION
To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three−way cata-
lytic converter is used, but for the most efficient use of the three−way catalytic converter, the air−fuel ratio
must be precisely controlled so that it is always close to the stoichiometric air−fuel ratio.
The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the
stoichiometric air−fuel ratio. This characteristic is used to detect the oxygen concentration in the exhaust
gas and provide feedback to the computer for control of the air−fuel ratio.
When the air−fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen
sensor informs the ECM of the LEAN condition (small electromotive force: 0 V).
When the air−fuel ratio is RICHER than the stoichiometric air−fuel ratio the oxygen concentration in the ex-
haust gas is reduced and the oxygen sensor informs the ECM of the RICH condition (large electromotive
force: 1 V).
The ECM judges by the electromotive force from the oxygen sensor whether the air−fuel ratio is RICH or
LEAN and controls the injection time accordingly. However, if malfunction of the oxygen sensor causes out-
put of abnormal electromotive force, the ECM is unable to perform accurate air−fuel ratio control.
DTC No.DTC Detecting ConditionTrouble Area
P0125
After the engine is warmed up, oxygen sensor output does not
indicate RICH even once when conditions (a), (b), and (c)
continue for at least 1.5 minutes
(a) Engine speed: 1,500 rpm or more
(b) Vehicle speed: 40 ∼ 100 km/h (25 ∼ 62 mph)
(c) Throttle valve does not fully closed
Open or short in oxygen sensor circuit
oxygen sensor
HINT:
After confirming DTC P0125 use the OBDII scan tool or TOYOTA hand−held tester to confirm voltage output
of oxygen sensor from ”CURRENT DATA”.
If voltage output of oxygen sensor is 0 V, oxygen sensor circuit may be open or short.
DI3ZJ−01

− DIAGNOSTICSENGINE
DI−45
1996 RAV4 (RM447U)
DTC P0133 Oxygen Sensor Circuit Slow Response
(Bank 1 Sensor 1)
CIRCUIT DESCRIPTION
Refer to ”Insufficient Coolant Temp. for Closed Loop Fuel Control” on page DI−39.
DTC No.DTC Detecting ConditionTrouble Area
P0133
Response time for the oxygen sensor’s voltage output to
change from rich to lean, or from lean to rich, is 1 sec. or more
during idling after the engine is warmed up
(2 trip detection logic)
Oxygen sensor
HINT:
Sensor 1 refers to the sensor closer to the engine body.
INSPECTION PROCEDURE
1 Are there any other codes (besides DTC P0133) being output?
YES Go to relevant DTC chart.
NO
Replace oxygen sensor.
DI3ZL−01

DI−48
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
DTC P0171 System too Lean (Fuel Trim)
DTC P0172 System too Rich (Fuel Trim)
CIRCUIT DESCRIPTION
”Fuel trim” refers to the feedback compensation value compared against the basic injection time. Fuel trim
includes short−term fuel trim and long−term fuel trim.
”Short−term fuel trim” is the short−term fuel compensation used to maintain the air−fuel ration at its ideal
theoretical value. The signal from the oxygen sensor indicates whether the air−fuel ratio is RICH or LEAN
compared to the ideal theoretical value, triggering a reduction in fuel volume if the air−fuel ratio is rich, and
an increase in fuel volume if it is lean.
”Long−term fuel trim” is overall fuel compensation carried out long−term to compensate for continual devi-
ation of the short−term fuel trim from the central value due to individual engine differences, wear over time
and changes in the usage environment.
If both the short−term fuel trim and long−term fuel trim are LEAN or RICH beyond a certain value, it is de-
tected as a malfunction and the MIL lights up.
DTC No.DTC Detecting ConditionTrouble Area
P0171
When the air fuel ratio feedback is stable after engine warning
up, the fuel trim is considerably in error on the RICH side
(2 trip detection logic)
Fuel line pressure
Injector blockage
Oxygen sensor malfunction
Manifold absolute pressure sensor
Engine coolant temp. sensor
P0172
When the air fuel ratio feedback is stable after engine warning
up, the fuel trim is considerably in error on the LEAN side
(2 trip detection logic)
Fuel line pressure
Injector blockage, leak
Oxygen sensor malfunction
Manifold absolute pressure sensor
Engine coolant temp. sensor.
HINT:
When DTC P0171 is recorded, the actual air−fuel ratio is on the LEAN side. When DTC P0172 is re-
corded, the actual air−fuel ratio is on the RICH side.
If the vehicle runs out of fuel, the air−fuel ratio is LEAN and DTC P0171 is detected. The MIL then
comes on.
If the total of the short−term fuel trim value and long−term fuel trim value is within ±25 %, the system
is functioning normally.
INSPECTION PROCEDURE
1 Check air induction system (See page SF−1).
NG Repair or replace.
OK
DI3ZN−01

− DIAGNOSTICSENGINE
DI−51
1996 RAV4 (RM447U)
DTC P0300 Random / Multiple Cylinder Misfire
Detected
DTC P0301 Cylinder 1 Misfire Detected
DTC P0302 Cylinder 2 Misfire Detected
DTC P0303 Cylinder 3 Misfire Detected
DTC P0304 Cylinder 4 Misfire Detected
CIRCUIT DESCRIPTION
Misfire: The ECM uses the crankshaft position sensor and camshaft position sensor to monitor changes in
the crankshaft rotation for each cylinder.
The ECM counts the number of times the engine speed change rate indicates that misfire has occurred. And
when the misfire rate equals or exceeds the count indicating that the engine condition has deteriorated, the
MIL lights up.
If the misfire rate is high enough and the driving conditions will cause catalyst overheating, the MIL blinks
when misfiring occurs.
DTC No.DTC Detecting ConditionTrouble Area
P0300Misfiring of random cylinder is detected during any particular
200 or 1,000 revolutionsIgnition system
Injector
Fuel line pressure
EGR
Compression pressure
Valve clearance not to specification
Valve timing
Manifold absolute pressure sensor
Engine coolant temp. sensor
P0301
P0302
P0303
P0304
For any particular 200 revolutions of the engine, misfiring is
detected which can cause catalyst overheating
(This causes MIL to blink)
For any particular 1,000 revolutions of the engine, misfiring is
detected which causes a deterioration in emissions
(2 trip detection logic)
HINT:
When the 2 or more codes for a misfiring cylinder are recorded repeatedly but no Random Misfire code is
recorded, it indicates that the misfires were detected and recorded at different times.
DI3ZO−01

Position
DNORMAL
Solenoid valve
No. 2
ONGear
L 2ON ONOFF
ON OFF
OFF OFF
OFF ON
ON ON
OFF ON
ON OFF
ON ON1st
2nd
3rd
O/D
1st
2nd
3rd
1st
2ndSolenoid valve
No. 1 No. 2
X
X
X
X
X
X
X
X
XON
ON
ON
OFF
ON
ON
ON
OFF
ONGear
3rd
3rd
3rd
O/D
3rd
3rd
3rd
1st
2ndNo. 1 No. 2Solenoid valve
Gear
1st ON X
X
X
X
X
X
X
X
X OFF
OFF
OFF
ON ON OFF OFFON SHIFT SOLENOID NO.1
MALFUNCTIONINGSHIFT SOLENOID NO.2
MALFUNCTIONING
O/D
O/D
O/D
1st
1st
1stMALFUNCTIONING BOTH SOLENOIDS
Gear when shift selector is
manually operated
O/D
O/D
O/D
O/D
3rd
3rd
3rd
1st
1st
X: Malfunctions3rd
3rd No. 1
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−147
1996 RAV4 (RM447U)
DTC P0753, P0758 Shift Solenoid A/B Electrical Malfunc-
tion (Shift Solenoid Valve No. 1/No. 2)
CIRCUIT DESCRIPTION
Shifting from 1st to O/D is done in combination with ON and OFF of the shift solenoid valves No. 1 and No.
2 controlled by ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls
the remaining normal shift solenoid valve to allow the vehicle to be operated safely (Fail safe function).
Fail Safe Function:
If either of the shift solenoid valve circuits develops an open or a short, the ECM turns the other shift solenoid
ON and OFF to shift to the gear positions shown in the table below. The ECM also turns the shift solenoid
valve SL OFF at the same time. If both solenoids are malfunction, hydraulic control cannot be done electroni-
cally so it must be done manually.
Manual shifting as shown in the following table must be done. (In the case of a short circuit, the ECM stops
sending current to the short circuited solenoid).
HINT:
Check the shift solenoid valve No. 1 when DTC P0753 is output and check the shift solenoid valve No. 2
when DTC P0758 is output.
DTC No.DTC Detecting ConditionTrouble Area
P0753
P0758
The ECM checks for an open or short circuit in the shift sole-
noid valves No. 1 and No. 2 circuit when it changes
The ECM records DTC P0753 or P0758 if condition a) or b) is
detected once, but it does not light up the MIL
After ECM detects condition a) or b) continuously 2 times or
more in one−trip, it causes the MIL light up until condition a) or
b) disappears
After that, if the ECM detects condition (a) or (b) once, it starts
lighting up the MIL again
(a) Solenoid resistance is 8 Ω or less short circuit when sole-
noid is energized
(b) Solenoid resistance is 100 kΩ or more open circuit when
solenoid is not energized
Open or short in shift solenoid valve No. 1/No. 2 circuit
Shift solenoid valve No. 1/No. 2
ECM
DI40I−01

Position
NORMALSHIFT SOLENOID NO. 1
MALFUNCTIONING
Solenoid valveNo. 1 No. 2GearSHIFT SOLENOID NO. 2
MALFUNCTIONINGBOTH SOLENOIDS MAL-
FUNCTIONINGSolenoid valve
No. 1 No. 2GearSolenoid valve
No. 1 No. 2GearGear when shift selector is
manually operated
D
2
LON
ONOFF
ON
ON OFF
OFF OFF
ON
ONOFF
ON
ON OFF
ON
ON ONOFF1st
2nd
3rd
O/D
1st
2nd
3rd
1st
2ndX
X
X
X
X
X
X
X
XON
ON
OFF
OFFON
ON
ON3rd 3rd
O/D
3rd
3rd
1st
2ndX
X
X
X
X
X
X
X
X OFF
OFFON
ON OFF OFF
OFF
ON
ON1st
O/D
1st O/D O/D
1st
1stO/D O/D O/D
O/D
1st
1st
X: MalfunctionsON
ON3rd
3rd
3rd
3rd3rd
3rd
3rd
DI−198
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
DTC P0753, P0758 Shift Solenoid A/B Electrical Malfunc-
tion (Shift Solenoid Valve No. 1/No. 2)
CIRCUIT DESCRIPTION
Shifting from 1st to O/D is done in combination with ON and OFF of the shift solenoid valves No. 1 and No.
2 controlled by ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls
the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (Fail safe function).
Fail Safe Function:
If either of the shift solenoid valve circuits develops an open or a short, the ECM turns the other shift solenoid
ON and OFF to shift to the gear positions shown in the table below. The ECM also turns the shift solenoid
valve SL OFF at the same time. If both solenoids are malfunction, hydraulic control cannot be done electroni-
cally so it must be done manually.
Manual shifting as shown in the following table must be done. (In the case of a short circuit, the ECM stops
sending current to the short circuited solenoid).
HINT:
Check the shift solenoid valve No. 1 when DTC P0753 is output and check the shift solenoid valve No. 2
when DTC P0758 is output.
DTC No.DTC Detecting ConditionTrouble Area
P0753
P0758
The ECM checks for an open or short circuit in the shift sole-
noid valves No.1 and No.2 circuit when it changes
The ECM records DTC P0753 or P0758 if condition (a) or (b) is
detected once, but it does not light up the MIL
After ECM detects condition (a) or (b) continuously 2 times or
more in one−trip, it causes the MIL light up until condition (a) or
(b) disappears
After that, if the ECM detects condition (a) or (b) once, it starts
lighting up the MIL
(d) Solenoid resistance is 8 Ω or less short circuit when sole-
noid is energized
(e) Solenoid resistance is 100 kΩ or more open circuit when
solenoid is not energized
Open or short in shift solenoid valve No. 1/No. 2 circuit
Shift solenoid valve No. 1/No. 2
ECM
DI410−01

BR3583
BR3582F00010
RotorSpeed Sensor
Magnet
To ECU
Low Speed High SpeedN S
+V
−V
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
DI−257
1996 RAV4 (RM447U)
DTC 31, 32, 33, 34, 35 Speed Sensor Circuit
CIRCUIT DESCRIPTION
The speed sensor detects the wheel speed and sends the ap-
propriate signals to the ECU. These signals are used to control
the ABS system. The front and rear rotors each have 48 serra-
tions.
When the rotor rotate, the magnetic field emitted by the perma-
nent magnet in the speed sensor generates an AC voltage.
Since the frequency of this AC voltage changes in direct propor-
tion to the speed of the rotor, the frequency is used by the ECU
to detect the speed of each wheel.
DTC No.DTC Detecting ConditionTrouble Area
31, 32, 33, 34
Detection of any of conditions 1 through 3:
1. At vehicle speed of 10 km/h (6 mph) or more, pulses are not
input for 5 sec.
2. Momentary interruption of the speed sensor signal occurs
at least 7 times in the time between switching the ignition
switch ON and switching it OFF
3. Abnormal fluctuation of speed sensor signals with the ve-
hicle speed 20 km/h (12 mph) or more
Right front, left front, right rear or left rear speed sensor
Open or short in each speed sensor circuit
Sensor rotor
ECU
*35
Speed sensor signal is not input for about 1 sec. while the
speed sensor signals are being checked at vehicle speed of 0
km/hOpen in speed sensor circuit
ECU
*: 4WD models
HINT:
DTC No. 31 is for the right front speed sensor.
DTC No. 32 is for the left front speed sensor.
DTC No. 33 is for the right rear speed sensor.
DTC No. 34 is for the left rear speed sensor.
Fail safe function:
If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control (solenoid) relay and
prohibits ABS control.
DI98Z−01

123
WITH THE IGNITION SW TURNED ON, THE CURRENT FLOWS TO TERMINAL 17 OF THE FRONT WIPER AND WASHER SW, TERMINAL
2 OF THE FRONT WASHER MOTOR AND TERMINAL 6 OF THE FRONT WIPER MOTOR THROUGH THE WIPER FUSE.
1. LOW SPEED POSITION
WITH WIPER SW TURNED TO LOW POSITION, THE CURRENT FLOWS FROM TERMINAL 17 OF THE FRONT WIPER AND WASHER SW
" TERMINAL 7 "TERMINAL 3 OF THE FRONT WIPER MOTOR "WIPER MOTOR "TERMINAL 1 "TO GROUND AND CAUSES THE
FRONT WIPER MOTOR TO RUN AT LOW SPEED.
2. HIGH SPEED POSITION
WITH WIPER SW TURNED TO HIGH POSITION, THE CURRENT FLOWS FROM TERMINAL 17 OF THE FRONT WIPER AND WASHER SW
"TERMINAL 8 "TERMINAL 2 OF THE FRONT WIPER MOTOR "WIPER MOTOR "TERMINAL 1 "TO GROUND AND CAUSES THE
FRONT WIPER MOTOR TO RUN AT HIGH SPEED.
3. INT POSITION
WITH WIPER SW TURNED TO INT POSITION, THE RELAY OPERATES AND THE CURRENT WHICH IS CONNECTED BY RELAY
FUNCTION FLOWS FROM TERMINAL 17 OF THE FRONT WIPER AND WASHER SW "TERMINAL 2 "TO GROUND. THIS FLOW OF
CURRENT OPERATES THE INTERMITTENT CIRCUIT AND THE CURRENT FLOWS FROM TERMINAL 17 OF THE WIPER AND FRONT
WASHER SW "TERMINAL 7 "TERMINAL 3 OF THE FRONT WIPER MOTOR "WIPER MOTOR "TERMINAL 1 "TO GROUND AND
OPERATES THE WIPER.
THE INTERMITTENT OPERATION IS CONTROLLED BY A CONDENSER'S CHARGED AND DISCHARGED FUNCTION INSTALLED IN THE
RELAY AND THE INTERMITTENT TIME IS CONTROLLED BY A TIME CONTROL SW TO CHANGE THE CHARGING TIME OF THE
CONDENSER.
4. WASHER CONTINUOUS OPERATION (W/ INT CONTROL)
WITH WASHER SW TURNED TO ON, THE CURRENT FLOWS FROM TERMINAL 2 OF THE FRONT WASHER MOTOR "TERMINAL 1 "
TERMINAL 11 OF THE FRONT WIPER AND WASHER SW "TERMINAL 2 "TO GROUND AND CAUSES TO THE FRONT WASHER
MOTOR TO RUN. AND THE WINDOW WASHER EMITS A WATER SPRAY. THIS CAUSES THE CURRENT TO FLOW TO WASHER
CONTINUOUS OPERATION CIRCUIT IN TERMINAL 17 OF THE WIPER AND WASHER SW "TERMINAL 7 "TERMINAL 3 OF THE
FRONT WIPER MOTOR "WIPER MOTOR "TERMINAL 1 "TO GROUND AND OPERATES THE WIPER.
C14 FRONT WIPER AND WASHER SW [COMB. SW]
2-GROUND : ALWAYS CONTINUITY
17-GROUND : APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION
7-GROUND : APPROX. 12 VOLTS WITH THE WIPER AND WASHER SW AT LOW OR MIST POSITION
: APPROX. 12 VOLTS 2 TO 12 SECONDS INTERMITTENTLY WITH THE WIPER AND WASHER SW AT INT POSITION
16-GROUND : APPROX. 12 VOLTS WITH THE IGNITION SW ON UNLESS THE WIPER MOTOR AT STOP POSITION
8-GROUND : APPROX. 12 VOLTS WITH THE WIPER AND WASHER SW AT HIGH POSITION
F6 FRONT WIPER MOTOR
6-5 : CLOSED UNLESS THE WIPER MOTOR AT STOP POSITION
SYSTEM OUTLINE
SERVICE HINTS