headlight TOYOTA RAV4 1996 Service Repair Manual

BE0J5−06
− BODY ELECTRICALHEADLIGHT AND TAILLIGHT SYSTEM
BE−13
1996 RAV4 (RM447U)
HEADLIGHT AND TAILLIGHT SYSTEM
LOCATION

BE0J6−01
N17327
Light Control SwitchSwitch BodyWiper and Washer Switch
Spiral Cable BE−14
− BODY ELECTRICALHEADLIGHT AND TAILLIGHT SYSTEM
1996 RAV4 (RM447U)
COMPONENTS

BE1MW−01
Z17623
HEAD
TA I L
OFFRight
LeftFlash
8
7
17 16
1413
Z13558
3
4
21
3
4 2
1
Z05657
3 21 3
21
55
− BODY ELECTRICALHEADLIGHT AND TAILLIGHT SYSTEM
BE−15
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT LIGHT CONTROL SWITCH CONTINUITY
Switch positionTester connectionSpecified condition
OFF−No continuity
TAIL14 − 16Continuity
HEAD13 − 14 − 16Continuity
If continuity is not as specified, replace the switch.
2. INSPECT HEADLIGHT DIMMER SWITCH CONTINU-
ITY
Switch positionTester connectionSpecified condition
Flash7 − 8 − 16Continuity
Low beam16 − 17Continuity
High beam7 − 16Continuity
If continuity is not as specified, replace the switch.
3. INSPECT HEADLIGHT CONTROL RELAY CONTINU-
ITY
ConditionTester connectionSpecified condition
Constant3 − 4Continuity
Apply B+ between
terminals 3 and 4.1 − 2Continuity
If continuity is not as specified, replace the relay.
4. INSPECT TAILLIGHT CONTROL RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant1 − 2Continuity
Apply B+ between
terminals 1 and 2.3 − 5Continuity
If continuity is not as specified, replace the relay.
5. Light−on Warning System:
INSPECT INTEGRATION RELAY OPERATION
(a) Connect the positive (+) lead from the battery to terminal
1 and 12, the negative (−) lead to terminals 10.
(b) Check that the buzzer sounds when the negative (−) lead
from the battery is connected to terminal 6.
If operation is not as specified, replace the relay.
6. INSPECT DOOR COURTESY SWITCH CONTINU-
ITY(See pageBE−22)

BE1MX−01
N18226
Beam Angle Gauge
(Vertical Direction)
Beam is
UpwardBeam is
Downward
FrontOK
Bubble OKOK
Z17543
FrontAcceptable Range”O” Reading
Adjusting
Screw B Beam Angle Gauge
(Horizontal Direction) BE−16
− BODY ELECTRICALHEADLIGHT AND TAILLIGHT SYSTEM
1996 RAV4 (RM447U)
ADJUSTMENT
1. ADJUST HEADLIGHT AIM
(a) Do the following before inspection.
Make sure that the body around the headlight is not
deformed.
Park the vehicle on a level spot.
The driver gets into the driver’s seat and puts the
vehicle in a state ready for driving (with a full tank).
Bounce the vehicle several times.
(b) Adjust the headlight aim in vertical direction.
If the bubble is outside the acceptable range of the beam angle
gauge, adjust it by using adjusting screw A.
(c) Adjust the headlight aim in horizontal direction.
If ”0” mark is not within the acceptable range, adjust the ”0”
reading to the ”0” mark using adjusting screw B.

N18226
Beam Angle Gauge
(Vertical Direction)
Beam is
UpwardBeam is
Downward
FrontOK
Bubble OKOK
Z17544
Beam Angle Gauge
(Horizontal Direction)
FrontAcceptable Range”O” Reading
Adjusting
Screw B Holder Assembly
N18085
”O” Reading Holer Assembly
Adjusting Screw B
N18086
”O” Reading
PawlTemporary Pawl
− BODY ELECTRICALHEADLIGHT AND TAILLIGHT SYSTEM
BE−17
1996 RAV4 (RM447U)
2. ADJUST HEADLIGHT AIM
(a) Replace the headlight.
(b) Do the following before inspection.
Make sure that the body around the headlight is not
deformed.
Park the vehicle on a level spot.
The driver gets into the driver’s seat and puts the
vehicle in a state ready for driving (with a full tank).
Bounce the vehicle several times.
(c) Adjust the headlight aim in vertical direction.
(1) Using adjusting screw A, adjustment the headlight
aim to within the specifications.
(2) Make sure that the gauge bubble is within the ac-
ceptable range.
HINT:
If the gauge bubble is outside the acceptable range, check that
the vehicle is parked on a level spot.
Readjust the headlight aim after parking the vehicle on a level
spot.
(d) Adjust the headlight aim in horizontal direction.
Using adjusting screw B, adjust the headlight aim to within
the specifications.
3. HOW TO RESET LH AND RH AIMING INDICATORS
(Unlocking method)
HINT:
These operations should be done only when the head adjust-
ment of the headlight aim is necessary, for example in case the
headlight aim ”0” mark deviates from the acceptable range
when the headlight is reassembled after repair.
(a) Turn the adjusting screw B to the right, and remove the
holder assembly from the cylindrical part of the housing.
(b) Unlock the holder assembly.

N18087
”O” Reading Temporary
Pawl
Temporary PawlView A View A
Z17544
Beam Angle Gauge
(Horizontal Direction)
FrontAcceptable Range”O” Reading
Adjusting
Screw B Holder Assembly BE−18
− BODY ELECTRICALHEADLIGHT AND TAILLIGHT SYSTEM
1996 RAV4 (RM447U)
(c) Insert the holder assembly, unlock in step (b), to the screw
and housing again.
HINT:
When the assembly is inserted till the pawl for temporary set is
hooded to the cross slit of the housing as shown in view A, set-
ting is completed.
(d) Turn the adjusting screw B to the left and adjust the LH
and RH headlight aims.
(e) Pull the holder assembly backwards and lock it.

BO481−01
N11455
N11456
− BODYFRONT BUMPER
BO−5
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE FRONT FENDER MOULDING
2. REMOVE FENDER LINER
3. REMOVE FRONT BUMPER COVER
Remove the 4 bolts, 3 clips, 2 screws and the bumper cover.
4. REMOVE HEADLIGHT UNDER COVER
5. REMOVE HEADLIGHT
6. REMOVE UPPER REINFORCEMENT
Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
7. REMOVE BUMPER STAY
Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf)

METER, ANALOG
Current flow activates a magnetic
coil which causes a needle to
move, thereby providing a relative
display against a background
calibration. LED (LIGHT EMITTING DIODE)
Upon current flow, these diodes
emit light without producing the
heat of a comparable light. IGNITION COIL
Convert low-voltage DC current
into high-voltage ingition current
for firing the spark plugs. 1. SINGLE
FILAMENT
GROUND
The point at which wiring attaches
to the Body, thereby providing a
return path for an electrical circuit;
without a ground, current cannot
flow.
Current flow causes a headlight
filament to heat up and emit light.
A headlight may have either a
single (1) filament or a double (2)
filament. BATTERY
Stores chemical energy and
converts it into electrical energy.
Provides DC current for the auto's
various electrical circuits.
CAPACITOR (Condenser)
A small holding unit for temporary
storage of electrical voltage.
CIRCUIT BREAKER
Basically a reusable fuse, a circuit
breaker will heat and open if too
much current flows through it. Some
units automatically reset when cool,
others must be manually reset.
DIODE
A semiconductor which allows
current flow in only one direction.
DIODE, ZENER
A diode which allows current flow
in one direction but blocks reverse
flow only up to a specific voltage.
Above that potential, it passes the
excess voltage. This acts as a
simple voltage regulator.
PHOTODIODE
The photodiode is a semiconductor
which controls the current flow
according to the amount of light.
FUSE
A thin metal strip which burns
through when too much current
flows through it, thereby stopping
current flow and protecting a
circuit from damage.
FUSIBLE LINK
A heavy-gauge wire placed in
high amperage circuits which
burns through on overloads,
thereby protecting the circuit.
The numbers indicate the cross-
section surface area of the wires.HORN
An electric device which sounds a
loud audible signal.
LIGHT
Current flow through a filament
causes the filament to heat up
and emit light.
METER, DIGITAL
Current flow activates one or
many LED's, LCD's, or fluorescent
displays, which provide a relative
or digital display.
MOTOR
A power unit which converts
electrical energy into mechanical
energy, especially rotary motion. CIGARETTE LIGHTER
An electric resistance heating
element.
DISTRIBUTOR, IIA
Channels high-voltage current
from the ignition coil to the
individual spark plugs.2. DOUBLE
FILAMENT HEADLIGHTS
FUEL
(for High Current Fuse or
Fusible Link.)
(for Medium Current Fuse)
M
16
E GLOSSARY OF TERMS AND SYMBOLS

28
G ELECTRICAL WIRING ROUTING
Position of Parts in Engine Compartment
*1 : w/ A/C
*2 : w/o A/C
A 1 A/C Condenser Fan Motor E 1 Electronically Controlled Transmission Solenoid
A 2 A/C Magnetic Clutch and Lock Sensor E 2 Engine Coolant Temp. Sensor
A 3 A/C Triple Pressure SW (A/C Dual and Single
Pressure SW) F 1 Front Side Marker Light LH
A 4 A/C Water Temp. SW F 2 Front Side Marker Light RH
A 5 A/T Fluid Temp. SW F 3 Front Turn Signal Light LH and Front Parking
A 6 ABS Actuator Light LH
A 7 ABS Actuator F 4 Front Turn Signal Light RH and Front Parking
A 8 ABS Relay Light RH
A 9 ABS Relay F 5 Front Washer Motor
A 10 ABS Speed Sensor Front LH F 6 Front Wiper Motor
A 11 ABS Speed Sensor Front RH F 7 Fusible Link Block
B 1 Back-Up Light SW (M/T) G 1 Generator
B 2 Brake Fluid Level Warning SW G 2Generator
C 1 Center Diff. Lock Warning Buzzer SW H 1 Headlight LH
C 2 Crankshaft Position Sensor H 2 Headlight RH
C 3 Cruise Control Actuator H 3 Horn
D 1 Data Link Connector 1

64
ENGINE CONTROL
THE ENGINE CONTROL SYSTEM UTILIZES A MICROCOMPUTER AND MAINTAINS OVERALL CONTROL OF THE ENGINE ETC. AN
OUTLINE OF ENGINE CONTROL IS GIVEN HERE.
1. INPUT SIGNALS
(1) ENGINE COOLANT TEMP. SENSOR SIGNAL SYSTEM
THE ENGINE COOLANT TEMP. SENSOR DETECTS THE ENGINE COOLANT TEMP. AND HAS A BUILT-IN THERMISTOR WITH A
RESISTANCE WHICH VARIES ACCORDING TO THE ENGINE COOLANT TEMP. THUS THE ENGINE COOLANT TEMP. IS INPUT IN
THE FORM OF A CONTROL SIGNAL TO TERMINAL THW OF THE ENGINE CONTROL MODULE.
(2) INTAKE AIR TEMP. SIGNAL SYSTEM
THE INTAKE AIR TEMP. SENSOR DETECTS THE INTAKE AIR TEMP. , WHICH IS INPUT AS A CONTROL SIGNAL TO TERMINAL THA
OF THE ENGINE CONTROL MODULE.
(3) OXYGEN SENSOR SIGNAL SYSTEM
THE OXYGEN SENSOR DETECTS THE OXYGEN DENSITY IN THE EXHAUST EMISSION WHICH IS INPUT AS A CONTROL SIGNAL
TO TERMINALS OX1 AND OX2 OF THE ENGINE CONTROL MODULE.
(4) THROTTLE SIGNAL SYSTEM
THE THROTTLE POSITION SENSOR DETECTS THE THROTTLE VALVE OPENING ANGLE, WHICH IS INPUT AS A CONTROL
SIGNAL TO TERMINAL VTA OF THE ENGINE CONTROL MODULE, OR WHEN THE VALVE IS FULLY CLOSED.
(5) VEHICLE SPEED CIRCUIT
THE VEHICLE SPEED IS DETECTED BY VEHICLE SPEED SENSOR INSTALLED IN THE TRANSMISSION AND THE SIGNAL IS INPUT
TO TERMINAL SPD OF THE ENGINE CONTROL MODULE VIA THE COMBINATION METER.
(6) PARK/NEUTRAL POSITION SW SIGNAL SYSTEM
THE PARK/NEUTRAL POSITION SW DETECTS WHETHER THE SHIFT POSITION IS IN NEUTRAL OR NOT, AND INPUTS A CONTROL
SIGNAL TO TERMINAL NSW OF THE ENGINE CONTROL MODULE.
(7) A/C SW SIGNAL SYSTEM
THE OPERATING VOLTAGE OF THE A/C MAGNETIC CLUTCH IS DETECTED AND INPUT IN THE FORM OF A CONTROL SIGNAL TO
TERMINAL ACI OF THE ENGINE CONTROL MODULE.
(8) BATTERY SIGNAL SYSTEM
VOLTAGE IS CONSTANTLY APPLIED TO TERMINAL BATT OF THE ENGINE CONTROL MODULE. WHEN THE IGNITION SW IS
TURNED TO ON, VOLTAGE FOR THE ENGINE CONTROL MODULE OPERATION IS APPLIED VIA THE EFI MAIN RELAY TO
TERMINAL +B OF THE ENGINE CONTROL MODULE.
(9) INTAKE AIR VOLUME SIGNAL SYSTEM
INTAKE AIR VOLUME IS DETECTED BY THE MANIFOLD ABSOLUTE PRESSURE SENSOR AND IS INPUT AS A CONTROL SIGNAL
TO TERMINAL PIN OF THE ENGINE CONTROL MODULE.
(10) STARTER SIGNAL SYSTEM
TO CONFIRM THAT THE ENGINE IS CRANKING, THE VOLTAGE APPLIED TO THE STARTER MOTOR DURING CRANKING IS
DETECTED AND IS INPUT AS A CONTROL SIGNAL TO TERMINAL STA OF THE ENGINE CONTROL MODULE.
(11) ELECTRICAL LOAD SIGNAL SYSTEM
THE SIGNAL WHEN SYSTEMS SUCH AS THE REAR WINDOW DEFOGGER, HEADLIGHT, ETC. WHICH CAUSE A HIGH ELECTRICAL
BURDEN ARE ON IS INPUT TO TERMINAL ELS AS A CONTROL SIGNAL.
SYSTEM OUTLINE