stop start TOYOTA RAV4 1996 Service Repair Manual

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.

V08467
18
Noise NOISE PRODUCED WHEN ENGINE STARTS
Whistling noise which becomes high−pitched
when accelerator strongly depressed, disappears
shortly after engine stops.Ye s
Generator noise.
No
Whining noise occurs when A/C is operating.Ye s
A/C noise.
Scratching noise occurs during sudden
acceleration, driving on rough roads or when
ignition switch is turned on.No
Ye s
Fuel gauge noise.
No
Clicking sound heard when horn button is
pressed, then released. Whirring/grating sound
when pushed continuously.Ye s
Horn noise.
No
Murmuring sound stops when engine stops.
NoYe s
Ignition noise.
Tick−tock noise, occurs in co−ordination with
blinking of flasher.Ye s
Turn signal noise.
No
Noise occurs during window washer operation.Ye s
Washer noise.
No
Scratching noise occurs while engine is running,
continues a while even after engine stops.
NoEngine coolant temperature gauge noise. Ye s
Scraping noise in time with wiper beat.
NoYe s
Wiper noise.
Other type of noise.
− BODY ELECTRICALAUDIO SYSTEM
BE−79
1996 RAV4 (RM447U)

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.

Q08873
Push Rod Play
Adjust Point
Pedal Height
Adjust Point
Push Rod
Play
Pedal HeightCL04G−02
CL0042
Pedal Freeplay
CL0512
25 mm (0.98 in.) or more
Release Point
Full Stroke
End Position CL−2
− CLUTCHCLUTCH PEDAL
1996 RAV4 (RM447U)
CLUTCH PEDAL
INSPECTION
1. CHECK PEDAL HEIGHT IS CORRECT
Pedal height from asphalt sheet:
157.6 − 167.6 mm (6.205 − 6.598 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and turn the stopper bolt until the height is
correct. Tighten the lock nut.
3. CHECK PEDAL FREEPLAY AND PUSH ROD PLAY
(a) Push in on the pedal until the beginning of clutch resis-
tance is felt.
Pedal freeplay: 5.0−15.0 mm (0.197−0.591 in.)
(b) Gently push on the pedal until the resistance begins to in-
crease a little.
Push rod play at pedal top:
1.0−5.0 mm (0.039−0.197 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
(d) Connect the air duct and install the lower finish panel.
5. INSPECT CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start the engine and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into the reverse position until the gears contact.
(d) Gradually depress the clutch pedal and measure the
stroke distance from the point the gear noise stops (re-
lease point) up to the full stroke end position.
Standard distance:
25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified.
Inspect pedal height.
Inspect push rod play and pedal freeplay.
Bleed the clutch line.
Inspect the clutch cover and disc.

S01294
CO0BS−03
S01279
Disconnect
S01277
93°C
S01290
Ammeter
Battery
S01291
Ammeter
Battery CO−18
− COOLINGELECTRIC COOLING FAN
1996 RAV4 (RM447U)
ELECTRIC COOLING FAN
ON−VEHICLE INSPECTION
1. CHECK COOLING FAN OPERATION WITH LOW TEM-
PERATURE (Below 83°C (181°F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and ECT switch, and check
for a separated connector or severed wire between the cooling
fan relay and ECT switch.
(c) Disconnect the ECT switch connector.
(d) Check that the cooling fan rotates.
If not, check the fan main relay, cooling fan relay, cooling fan,
fuses, and check for short circuit between the cooling fan relay
and ECT switch.
(e) Reconnect the ECT switch connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEM-
PERATURE (Above 93°C (199°F))
(a) Start the engine, and raise coolant temperature to above
93°C (199°F).
(b) Check that the cooling fan rotates.
If not, replace the ECT switch.
3. INSPECT NO.1 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connec-
tor.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage: 10.9 − 13.9 A
(d) Reconnect the cooling fan connector.
4. INSPECT NO.2 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connec-
tor.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage: 9.1 − 11.1 A
(d) Reconnect the cooling fan connector.

DI−8
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
6. BASIC INSPECTION
When the Malfunction code is not confirmed in the DTC check, troubleshooting should be performed in the
order for all possible circuits to be considered as the causes of the problems.
In many cases, by carrying out the basic engine check shown in the following flow chart, the location causing
the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine trouble-
shooting.
1 Is battery positive voltage 11 V or more when engine is stopped?
NO Charge or replace battery.
YES
2 Is engine cranked?
NO Proceed to STARTING and continue to trouble-
shoot.
YES
3 Does engine start?
NO Go to step 7.
YES

− DIAGNOSTICSENGINE
DI−13
1996 RAV4 (RM447U)
(b) TOYOTA Enhanced Signals
TOYOTA hand−held tester displayMeasurement ItemNormal Condition *
MISFIRE RPMEngine RPM for first misfire rangeMisfire 0: 0 RPM
MISFIRE LOADEngine load for first misfire rangeMisfire 0: 9 g/r
INJECTORFuel injection time for cylinder No.1Idling: 1.9 − 3.3 ms
IAC DUTY RATIOIntake Air Control Valve Duty Ratio Opening
ratio rotary solenoid type IAC valveIdling: 25 − 60 %
STARTER SIGStarter SignalCranking: ON
A/C SIGA/C Switch SignalA/C ON: ON
PNP SWPark / Neutral Position Switch SignalP or N position: ON
ELCTRCL LOAD SIGElectrical Load SignalDefogger S/W ON: ON
STOP LIGHT SWStop Light Switch SignalStop light switch ON: ON
FC IDLFuel Cut Idle: Fuel cut when throttle valve fully
closed, during decelerationFuel cut operating: ON
FC TAUFuel Cut TAU: Fuel cut during very light loadFuel cut operating: ON
CYL#1
CYL#2
CYL#3
CYL#4
Abnormal revolution variation for each cylinder0 %
IGNITIONTotal number of ignitions for every 1,000
revolutions0 − 2,000
EGR SYSTEMEGR system operating conditionIdling: OFF
FUEL PUMPFuel Pump SignalIdling: ON
EVAP (PURGE) VSVEVAP VSV SignalVSV operating: ON
VAPOR PRESS VSVVapor Pressure VSV SignalVSV operating: ON
A/C CUT SIGA/C Cut SignalA/C S/W OFF: ON
TOTAL FT B1Total Fuel Trim Bank 1: Average value for fuel
trim system of bank 1Idling: 0.8 − 1.2
O2 LR B1, S1
Oxygen Sensor Lean Rich Bank 1, Sensor 1
Response time for oxygen sensor output to
switch from lean to rich.
Idling after warned up: 0 − 1,000 msec.
O2 RL B1, S1
Oxygen Sensor Rich Lean Bank 1, Sensor 1
Response time for oxygen sensor output to
switch from rich to lean.
Idling after warned up: 0 − 1,000 msec.
*: If conditions are specifically stated for ”Idling” , it means the shift lever is at N or P Position, the A/C switch
is OFF and all accessory switches are OFF.

(7)
(5) (4)(6)
(3)
(2)
(1)
P20769
Vehicle Speed
70 − 90 km/h
(43 − 56 mph)
Idling
IG SW OFF
Warm up
3 − 5 mins2 mins 3 − 5 mins 2 mins Time
DI−66
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
SYSTEM CHECK DRIVING PATTERN
(1) Connect the OBDII scan tool or TOYOTA hand−held tester to the DLC3.
(2) Start and warm it up the engine with all accessories switched OFF.
(3) Run the vehicle at 70 − 90 km/h (43 − 56 mph) for 3 minutes or more.
(4) Idle the engine for about 2 minutes.
(5) Stop at safe place and turn the ignition switch OFF.
(6) Start the engine and do steps (3) and (4) again.
(7) Check the ”READINESS TESTS” mode on the OBDII scan tool or TOYOTA hand−held tester. If ”COMPL”
is displayed and the MIL does not light up, the system is normal. If ”INCMPL” is displayed and the MIL does
not light up, run the vehicle again and check it.
HINT:
”INCMPL” is displayed when either condition (a) or (b) exists.
The system check is incomplete.
There is malfunction in the system.
If there is a malfunction in the system, the MIL will light up after step (2) to (6) above are done.
INSPECTION PROCEDURE
HINT:
If DTC ”P0150” and / or ”P0106” and ”P0401” are output simultaneously, perform troubleshooting or
DTC ”P0105” first.
If DTC ”P0401” and ”P0402” are output simultaneously, perform troubleshooting of DTC ”P0402” first.

A00411
Engine
VSV for
Vapor Pressure
VSV for
EVAP
OFF OFF
ON Stop
ONStart
5 sec. 5 sec.
PTNK
(+)E2
(−)
DI−88
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
14 Check the charcoal canister.
PREPARATION:
(a) Connect the TOYOTA hand−held tester to the DLC3.
(b) Remove the fuel rank cap.
(c) Disconnect the VSV connector for vapor pressure sensor.
(d) Select the ACTIVE TEST mode on the TOYOTA hand−
held tester.
(e) Remove side trim cover (See page SF−61).
(f) Start the engine.
(g) VSV for EVAP is ON by TOYOTA hand−held tester and
remains on for 5 sec.
CHECK:
Measure voltage between terminals PTNK and E2 of ECM con-
nector 5 secs. after switching VSV for EVAP from ON to OFF.
OK:
Voltage: 2.5 V or less
NG Replace charcoal canister.
OK
Check and replace ECM (See page IN−30).
OBDII scan tool (excluding TOYOTA hand−held tester)
1 Check the VSV connector for EVAP, VSV connector for vapor pressure sensor
and vapor pressure sensor connector for looseness and disconnection.
NG Repair or connect the VSV or sensor connector.
OK
2 Check the vacuum hose between intake manifold and VSV for EVAP,VSV for
EVAP and charcoal canister, charcoal canister and VSV for vapor pressure sen-
sor, and VSV for vapor pressure sensor and vapor pressure sensor.
CHECK:
(a) Check that the vacuum hose is connected correctly.
(b) Check the vacuum hose for looseness and disconnection.

S07638
IG1
1H 1DI4I4
E4
E43 20
EA17
IG111
2221
20 8
1412
67
2
W B−WB−RB−R B−W
B−W
B−W
B−W
L−Y 4
53
2
1 Tr2
Igniter To Tachometer Distributor
BatteryFusible Link BlockR/B No.2
B−R IG Switch 4ECM
IGT
IGF5V
Tr1
AM2B
B−Y
Ignition Coil
J/B No.1
MAIN DI−100
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
DTC P1300 Igniter Circuit Malfunction
CIRCUIT DESCRIPTION
This ECM determines the ignition timing, turns on Tr1 at a predetermined angle (°CA) before the desired
ignition timing and outputs an ignition signal (IGT) ”1” to the igniter.
Since the width of the IGT signal is constant, the dwell angle control circuit in the igniter determines the time
the control circuit starts primary current flow to the ignition coil based on the engine rpm and ignition timing
one revolution ago, that is, the time the Tr
2 turns on.
When it reaches the ignition timing, the ECM turns Tr
1 off and outputs the IGT signal ”O”.
This turns Tr
2 off, interrupting the primary current flow and generating a high voltage in the secondary coil
which causes the spark plug to spark. Also, by the counter electromotive force generated when the primary
current is interrupted, the igniter sends an ignition confirmation signal (IGF) to the ECM.
The ECM stops fuel injection as a fail safe function when the IGF signal is not input to the ECM.
DTC No.DTC Detecting ConditionTrouble Area
P1300No IGF signal to ECM for 8 consecutive IGT signals during
engine running.Open or short in IGF or IGT circuit from igniter to ECM
Igniter
ECM
WIRING DIAGRAM
DI401−01