relay TOYOTA RAV4 1996 Service Repair Manual

AX0T8−01
Z18886
RH Drive Shaft
LH Drive Shaft  Snap Ring
64 (650, 47)
 Cotter Pin
Lock Cap
216 (2,200, 159)
 Gasket
49 (500, 36)
7.0 (75, 65 in.·lbf)
62 (630, 46)
48 (490, 35)
Front Exhaust PipeEngine Mounting
Center MemberPS Gear Assembly
Front Suspension Crossmember
Assembly with Stabilizer Bar
RH Engine Under Cover
LH Engine Under Cover
137 (1,400, 101)
206 (2,100, 152)
127 (1,300, 94)
72 (730, 53)

73 (740, 54)
N·m (kgf·cm, ft·lbf)
: Specified torque
 Non−reusable part
113 (1,150 83)
 Cotter Pin
 Gasket
35 (360, 26)
64 (650, 47)
64 (650, 47)
19 (194, 14)
25 (250, 18)
46 (470, 34)
27 (280, 20)
25 (250, 18)
9.0 (95, 78 in.·lbf)
64 (650, 47)
9.0 (95, 78 in.·lbf)
37 (380, 27)
13 (135, 10)
39 (400, 29)64 (650, 47)
 GasketStarterEngine Wire
Clamp Plug for Line
Pressure Test
Shift Control
Cable ClipRear End Plate Stiffener Platex 6 Torque Converter
ClutchEngine Coolant Reservoir TankABS RelayAir Intake Connector
Air Cleaner
Case Assembly AX−14
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
1996 RAV4 (RM447U)
AUTOMATIC TRANSAXLE UNIT
COMPONENTS

D02186
AX127−01
Q08747
Q08761
D02187
Q08763
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
AX−15
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT THROTTLE CABLE
2. REMOVE ENGINE COOLANT RESERVOIR TANK
3. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the connector and ABS relay.
(b) Remove the 3 bolts and air cleaner assembly.
4. REMOVE GROUND CABLE
Remove the bolt from the transaxle.
Torque: 19 N·m (194 kgf·cm, 14 ft·lbf)
5. REMOVE SET NUT OF ENGINE WIRE CLAMP
6. REMOVE STARTER
(a) Disconnect the connector and nut from the starter.
(b) Remove the 2 bolts and disconnect the engine wire.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Remove the starter.
7. REMOVE 3 UPPER SIDE TRANSAXLE MOUNTING
BOLTS
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
8. INSTALL ENGINE SUPPORT FIXTURE

N11771
1
82 3
4
65 7
BE0J4−04
Z10028
1
2
OFF
ON
N01923
N01924
N01925
− BODY ELECTRICALIGNITION SWITCH AND KEY UNLOCK WARNING
SWITCHBE−11
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT IGNITION SWITCH CONTINUITY
Switch positionTester connectionSpecified condition
LOCK−No continuity
ACC2 − 3Continuity
ON2 − 3 − 4, 6 − 7Continuity
START1−2−4, 6−7−8Continuity
If continuity is not as specified, replace the switch.
2. INSPECT KEY UNLOCK WARNING SWITCH CONTI-
NUITY
Switch positionTester connectionSpecified condition
SW OFF
(Key removed) −No continuity
SW ON (Key set)1 − 2Continuity
If continuity is not as specified, replace the switch.
3. Key Unlock Warning System:
INSPECT INTEGRATION RELAY OPERATION
(a) Connect the positive (+) lead from the battery to terminal
A1.
(b) Connect the negative (−) lead from the battery to termi-
nals A5, A6 and A10.
(c) Check the buzzer sounds.
(d) Disconnect the negative (−) lead from the battery to termi-
nals A6.
(e) Check that the buzzer stops sounding.
(f) Connect the negative (−) lead from the battery to termi-
nals A6.
(g) Disconnect the negative (−) lead from the battery to termi-
nals A5.
(h) Check that the buzzer stops sounding.
If operation is not as specified, replace the relay.

BE−12− BODY ELECTRICALIGNITION SWITCH AND KEY UNLOCK WARNING
SWITCH
1996 RAV4 (RM447U)
4. INSPECT INTEGRATION RELAY CIRCUIT (See page
BE−37)
5. INSPECT DOOR COURTESY SWITCH CONTINUITY
(See Page BE−22)

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)

N20864
Washer 1
ON
OFFINT
Washer 2
1 2
10
16
Z09992
Relay Side
1
2
3 4
5 6
N05767
Battery Voltage
No Voltage3 4
6
5
N05768
Within 9
to 15
Seconds2
4
53 BE−30
− BODY ELECTRICALWIPER AND WASHER SYSTEM
1996 RAV4 (RM447U)
4. INSPECT REAR WIPER AND WASHER SWITCH CON-
TINUITY
Switch positionTester connectionSpecified condition
Washer 12 − 16Continuity
Wiper OFF−No continuity
Wiper INT10 − 16Continuity
Wiper ON1 − 16Continuity
Washer 21 − 2 − 16Continuity
If continuity is not as specified, replace the switch.
5. INSPECT REAR WIPER RELAY CONTINUITY
(a) Check that no continuity exists between terminals 3 and
4.
(b) Check that continuity exists between terminals 4 and 5.
If continuity is not as specified, replace the relay.
6. INSPECT REAR WIPER RELAY OPERATION
(a) Connect the positive (+) lead from the battery to terminal
3 and the negative (−) lead to terminal 6.
(b) Connect the positive (+) lead from the voltmeter to termi-
nal 5 and the negative (−) lead to terminal 6, check that
the meter needle indicates 0 volts.
(c) Connect the positive (+) lead from the voltmeter to termi-
nal 4 and the negative (−) lead to terminal 6, check that
the meter needle indicates battery positive voltage.
If operation is not as specified, replace the relay.
7. INSPECT REAR WIPER RELAY INTERMITTENT OP-
ERATION
(a) Connect the positive (+) lead from the battery to terminal
5 and the negative (−) lead to terminal 2 more than 2 se-
conds.
(b) Connect the positive (+) lead from the voltmeter to termi-
nal 4 and the negative (−) lead to terminal 2.

N05769
1 3
N05770
1 2
N05771
1 3
N05772
1 3
65
− BODY ELECTRICALWIPER AND WASHER SYSTEM
BE−31
1996 RAV4 (RM447U)
(c) After disconnecting the positive (+) lead from terminal 5
connect it to terminal 3, and than, check that the meter
needle rises from 0 volts to battery positive voltage within
9 to 15 seconds.
If operation is not as specified, replace the relay.
8. INSPECT FRONT WIPER MOTOR OPERATION
(a) Inspect the motor operation at low speed.
Connect the positive (+) lead from the battery to terminal
3 and the negative (−) lead from the battery to terminal 1,
check that the motor operates at low speed.
If operation is not as specified, replace the motor.
(b) Inspect the motor operation at high speed.
Connect the positive (+) lead from the battery to terminal
2 and the negative (−) lead from the battery to terminal 1,
check that the motor operates at high speed.
If operation is not as specified, replace the motor.
(c) Inspect the motor operation when stopping it.
(1) Operate the motor at low speed and stop the motor
operation anywhere except at the stop position by
disconnecting the positive (+) lead from terminal 3.
(2) Connect terminals 3 and 5.
(3) Connect the positive (+) lead from the battery to ter-
minal 6 and negative (−) lead from the battery termi-
nal 1, check that the motor stops running at the stop
position after the motor operates again.
If operation is not as specified, replace the motor.

BE275−01
Z13284
Z05657
5
2 31
2
51
3
BE4029
Tester Probe
Heat Wire
Tin Foil
BE−46
− BODY ELECTRICALDEFOGGER SYSTEM
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT DEFOGGER SWITCH CONTINUITY
Switch positionTester connectionSpecified condition
Switch OFF−No continuity
Switch ON3 − 5 − 8Continuity
Switch ON
Illumination circuit3 − 5Continuity
Illumination circuit2 − 6Continuity
If continuity is not as specified, replace the switch.
2. INSPECT DEFOGGER RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant1 − 2Continuity
Apply B + between
terminal 1 and 2.3 − 5Continuity
If continuity is not as specified, replace the relay.
3. INSPECT DEFOGGER WIRE
NOTICE:
When cleaning the glass, use a soft, dry cloth, and
wipe the glass in the direction of the wire. Take care
not to damage the wires.
Do not use detergents or glass cleaners with abrasive
ingredients.
When measuring voltage, wind a piece of tin foil
around the top of the negative probe and press the foil
against the wire with your finger, as shown.
(a) Turn the ignition switch ON.
(b) Turn the defogger switch ON.
(c) Inspect the voltage at the center of each heat wire, as
shown in the table below.
VoltageCriteria
Approx. 5VOkay (No break in wire)
Approx. 10V or 0VBroken wire
HINT:
If there is approximately 10 V, the wire is broken between the
center of the wire and the positive (+) end. If there is no voltage,
the wire is broken between the center of the wire and ground.

Z17553
within
4 to 40
secondsUP
Z17554
within
60 seconds
DOWN
Z05657
31
2
5
21
53 BE−58
− BODY ELECTRICALPOWER WINDOW CONTROL SYSTEM
1996 RAV4 (RM447U)
17. Rear door of 5 door models:
INSPECT CIRCUIT BREAKER OPERATION
(a) With the window in the fully closed position, hold the pow-
er window switch in ”UP” position and check that there is
a circuit breaker operation noise within 4 to 40 seconds.
(b) With the window in the fully closed position, hold the
switch in ”DOWN” position and check that the window be-
gins to descend within 60 seconds.
If operation is not as specified, replace the motor.
18. INSPECT POWER MAIN RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant1 − 2Continuity
Apply B+ between
terminals 1 and 23 − 5Continuity
If continuity is not as specified, replace the relay.

BR03N−04
R04103
Sub−Wire Harness C (SST)
Sub−Wire Harness I (SST) ABS
Actuator(SST)
To Body
To Body Control Relay
− BRAKEABS ACTUATOR
BR−35
1996 RAV4 (RM447U)
ABS ACTUATOR
ON−VEHICLE INSPECTION
1. INSPECT BATTERY POSITIVE VOLTAGE
Battery positive voltage: 10 −14 V
2. DISCONNECT CONNECTORS
(a) Disconnect the 2 connectors from the control relay.
(b) Disconnect the connector from, the actuator.
3. CONNECT ACTUATOR CHECKER (SST) TO ACTUA-
TOR
(a) Connect the actuator checker (SST) to the actuator, con-
trol relay and body side wire harness through the sub−
wire harness C and I (SST) as shown.
SST 09990−00150, 09990−00200, 09990−00300
(b) Connect the red cable of the checker to the battery posi-
tive (+) terminal and black cable to the negative (−) termi-
nal. Connect the black cable of the sub−wire harness to
the battery negative (−) terminal or body ground.