light TOYOTA RAV4 1996 Service Repair Manual

Q06117
AX055−02
AT5641
Q057310.8−1.5 mm (0.031−0.059 in.) 200 mm (7.87 in.)
− AUTOMATIC TRANSAXLE (A241E)THROTTLE CABLE
AX−9
1996 RAV4 (RM447U)
THROTTLE CABLE
ON−VEHICLE REPAIR
1. DISCONNECT THROTTLE CABLE FROM ENGINE
2. REMOVE NO.2 ENGINE UNDER COVER
3. REMOVE PARK/NEUTRAL POSITION SWITCH (See
page AX−4)
4. REMOVE VALVE BODY (See page AX−5)
5. REMOVE THROTTLE CABLE
(a) Remove the retaining bolt and plate.
(b) Pull out the cable from the transaxle case.
6. INSTALL THROTTLE CABLE
If throttle cable is new, do the following operations (a) − (c).
(a) Bend the cable so there is a radius of about 200 mm (7.87
in.).
(b) Pull theinner cable lightly until a slight resistance is felt,
and hold it.
(c) Stake the stopper 0.8 − 1.5 mm (0.031 − 0.059 in.) from
the end of outer cable.
(d) Be sure to push it in all the way.
(e) Install the bolt.
7. INSTALL VALVE BODY (See page AX−5)
8. INSTALL PARK/NEUTRAL POSITION SWITCH (See
page AX−4)
9. INSTALL NO.2 ENGINE UNDER COVER
10. CONNECT THROTTLE CABLE
11. ADJUST THROTTLE CABLE (See page DI−127)
12. FILL ATF AND CHECK ATF (See page DI−127)

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

Q06117
AX04R−02
Q06068
Q057310.8 − 1.5 mm (0.031 − 0.059 in.) 200 mm
(7.87 in.)
− AUTOMATIC TRANSAXLE (A540H)THROTTLE CABLE
AX−13
1996 RAV4 (RM447U)
THROTTLE CABLE
ON−VEHICLE REPAIR
1. DISCONNECT THROTTLE CABLE FROM LINKAGE
2. REMOVE PARK/NEUTRAL POSITION SWITCH
(See page AX−6)
3. REMOVE VALVE BODY
(See page AX−8)
4. REMOVE THROTTLE CABLE
(a) Remove the bolt and pull the cable out of the transaxle
case.
(b) Remove the O−ring from the throttle cable.
5. INSTALL THROTTLE CABLE INTO TRANSAXLE
CASE
If the throttle cable is new do the following operations (a) − (c).
(a) Bend the cable so there is a radius of about 200 mm (7.87
in.).
(b) Pull the inner cable lightly until a slight resistance is felt,
and hold it.
(c) Stake the stopper 0.8 − 1.5 mm (0.031 − 0.059 in.) from
the end of outer cable.
(d) Install a new O−ring to the throttle cable.
(e) Make sure to push it in all the way.
(f) Install and torque the bolt.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
6. INSTALL VALVE BODY
(See page AX−8)
7. CONNECT THROTTLE CABLE TO LINKAGE
8. ADJUST THROTTLE CABLE
(See page DI−173)
9. INSTALL PARK/NEUTRAL POSITION SWITCH
(See page AX−6)
10. TEST DRIVE VEHICLE

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

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.