wiring diagram TOYOTA RAV4 1996 Service Repair Manual

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

P25423
Manifold Absolute Pressure Sensor
3
2
1E51
2
BR LG−R Y
VC
PIM
E25 V ECM
9 E5
E5
E1
A00389
ON
E2
(−)VC
(+)
DI−22
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT:
If DTC P0105, P0110, P0115, P0120 are output simultaneously, E2 (sensor ground) may be open.
1 Connect OBDII scan tool or TOYOTA hand−held tester, and read value of man-
ifold absolute pressure.
PREPARATION:
(a) Connect the OBDII scan tool or TOYOTA hand−held tester to the DLC3.
(b) Turn ignition switch ON and OBDII scan tool or TOYOTA hand−held tester main switch ON.
CHECK:
Read value of manifold absolute pressure on the OBDII scan tool or TOYOTA hand−held tester.
OK:
Same as atmospheric pressure.
OK Check for intermittent problems
(See page DI−3).
NG
2 Check voltage between terminals VC and E2 of ECM connector.
PREPARATION:
(a) Remove side trim cover (See page SF−61).
(b) Turn ignition switch ON.
CHECK:
Measure voltage between terminals VC and E2 of ECM con-
nector.
OK:
Voltage : 4.5 − 5.5V

DI−24
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
DTC P0106 Manifold Absolute Pressure Circuit Range/
Performance Problem
CIRCUIT DESCRIPTION
Refer to Manifold Absolute Pressure / Barometric Pressure Circuit Malfunction on page DI−21.
DTC No.DTC Detecting ConditionTrouble Area
P0106
After the engine is warmed up, conditions (a) and (b) continue
with engine speed 400 ∼ 1,000 rpm
(2 trip detection logic)
(a) Throttle valve fully closed
(b) Manifold absolute pressure sensor output > 3.0 V
Manifold absolute pressure sensor.Condition (c) and (d) continue with engine speed 2,500 rpm or
less
(2 trip detection logic)
(c) VTA > 1.8
(d) Manifold absolute pressure sensor output < 1.0 V
WIRING DIAGRAM
Refer to Manifold Absolute Pressure / Barometric Pressure Circuit Malfunction on page DI−21.
INSPECTION PROCEDURE
HINT:
If DTC ”P0105” (Manifold Absolute Pressure / Barometric Pressure Circuit Malfunction) and ”P0106” (Man-
ifold Absolute Pressure / Barometric Pressure Circuit Range / Performance Problem) are output simulta-
neously, manifold absolute pressure sensor circuit may be open.
Perform troubleshooting of DTC P0105 first.
1 Are there any other codes (besides DTC P0106) being output?
YES Go to relevant DTC chart.
NO
Replace manifold absolute pressure sensor.
DI3ZD−01

P19745
Intake Air Temp. Sensor
Y−B
BRE5
E5E2 THAR5V
E1 93ECM
2
1
DI−26
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT:
If DTC ”P0105” (Manifold Absolute Pressure / Barometric Pressure Circuit Malfunction), ”P0110” (Intake Air
Temp. Circuit Malfunction), ”P0115” (Engine Coolant Temp. Circuit Malfunction), ”P0120” (Throttle / Pedal
Position Sensor / Switch ”A” Circuit Malfunction) are output simultaneously, E2 (sensor ground) may be
open.
1 Connect the OBDII scan tool or TOYOTA hand−held tester, and read value of
intake air temperature.
PREPARATION:
(a) Connect the OBDII scan tool or TOYOTA hand−held tester to the DLC3.
(b) Turn ignition switch ON and OBDII scan tool or TOYOTA hand−held tester main switch ON.
CHECK:
Read temperature value on the OBDII scan tool or TOYOTA hand−held tester.
OK:
Same as actual intake air temperature.
HINT:
If there is open circuit, OBDII scan tool or TOYOTA hand−held tester indicates − 40°C (− 40°F).
If there is short circuit, OBDII scan tool or TOYOTA hand−held tester indicates 140°C (284°F) or more.
NG− 40°C (− 40°F) .... Go to step 2.
140°C (284°F) .... Go to step 4.
OK
Check for intermittent problems.
(See page DI−3).

P19746
Engine Coolant Temp. Sensor
W
BRE5
E5E2THW5V
E1 94ECM
2
1
− DIAGNOSTICSENGINE
DI−29
1996 RAV4 (RM447U)
DTC P0115 Engine Coolant Temp. Circuit Malfunction
CIRCUIT DESCRIPTION
A thermistor built into the engine coolant temperature sensor changes the resistance value according to the
engine coolant temperature.
The structure of the sensor and connection to the ECM is the same as in the intake air temp. circuit malfunc-
tion shown on page DI−25.
If the ECM detects the DTC P0115, it operates the fail safe function in which the engine coolant temp. is
assumed to be 80°C (176°F).
DTC No.DTC Detecting ConditionTrouble Area
P0115Open or short in engine coolant temp. sensor circuit
Open or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM
HINT:
After confirming DTC P0115 use the OBDII scan tool or TOYOTA hand−held tester to confirm the engine
coolant temperature from ”CURRENT DATA”.
Temperature DisplayedMalfunction
− 40°C (− 40°F)Open circuit
140°C (284°F) or moreShort circuit
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT:
If DTC ”P0105” (Manifold Absolute Pressure / Barometric Pressure Circuit Malfunction), ”P0110” (Intake Air
Temp. Circuit Malfunction), ”P0115” (Engine Coolant Temp. Circuit Malfunction), ”P0120” (Throttle / Pedal
Position Sensor / Switch ”A” Circuit Malfunction) are output simultaneously, E2 (sensor ground) may be
open.
DI3ZF−01

P25426
Throttle Position Sensor
4
E5
3
2L
1
BR L−R Y5V
VC
VTA
E2
E1 From Cruise
Control ECU1
11
9 E5
E5ECM
FI7052
− DIAGNOSTICSENGINE
DI−35
1996 RAV4 (RM447U)
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT:
If DTC P0105” (Manifold Absolute Pressure / Barometric Pressure Circuit Malfunction), ”P0110” (Intake Air
Temp. Circuit Malfunction), ”P0115” (Engine Coolant Temp. Circuit Malfunction), ”P0120” (Throttle / Pedal
Position Sensor / Switch ”A” Circuit Malfunction) are output simultaneously, E2 (sensor ground) may be
open.
1 Connect OBDII scan tool or TOYOTA hand−held tester and read the throttle valve
opening percentage.
PREPARATION:
(a) Connect the OBDII scan tool or TOYOTA hand−held tester to the DLC3.
(b) Turn ignition switch ON and OBDII scan tool or TOYOTA hand−held tester main switch ON.
CHECK:
Read the throttle valve opening percentage.
OK:
Throttle valveThrottle valve opening position
expressed as percentage
Fully openApprox. 70 %
Fully closedApprox. 10 %

S02514
1
Oxygen Sensor
(Bank1 Sensor 2)
21
2B
B6
5
14ECM
E5
E5
E4 BR A
A
AA
ECJ2 Junction
Connector Oxygen Sensor
(Bank 1 Sensor 1)
BROX1
OX2
E1
BR
BR
DI−40
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
WIRING DIAGRAM
INSPECTION PROCEDURE
1 Connect the OBDII scan tool or TOYOTA hand−held tester and read value for
voltage output of oxygen sensor.
PREPARATION:
(a) Connect the OBDII scan tool or TOYOTA hand−held tester to the DLC 3.
(b) Warm up engine to normal operating temperature.
CHECK:
Read voltage output of oxygen sensor (bank 1 sensor 1) when engine is suddenly raced.
HINT:
Perform quick racing to 4,000 rpm 3 times using accelerator pedal.
OK:
Oxygen sensor output a RICH signal (0.45 V or more) at least once.
OK Check and replace ECM (See page IN−30).
NG

A01666
Vehicle speed
50 − 65 km/h
(31 − 40 mph)
Idling
IG SW OFF
1 − 3 min.
1 min.
Time (1)(2)(4)
(5) (3) DI−42
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
DTC P0130 Oxygen Sensor Circuit Malfunction
(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
P0130
Voltage output of oxygen sensor remains at 0.35 V or more,
0.55 V or less, during idling after the engine is warmed up
(2 trip detection logic)Oxygen sensor
Fuel trim malfunction
HINT:
Sensor 1 refers to the sensor closer to the engine body.
The oxygen sensor’s output voltage and the short−term fuel trim value can be read using the OBDII scan
tool or TOYOTA hand−held tester.
WIRING DIAGRAM
Refer to page DI−39 for the WIRING DIAGRAM.
CONFIRMATION DRIVING PATTEN
(1) Connect the TOYOTA hand−held tester to the DLC3.
(2) Switch the TOYOTA hand−held tester from normal mode to check mode (See page DI−3).
(3) Start the engine and warm it up with all accessory switches OFF.
(4) Drive the vehicle at 50 − 65 km/h (31 − 40 mph) for 1 − 3 minutes to warm up the oxygen sensor.
(5) Idle the engine for 1 minute.
HINT:
If a malfunction exists, the MIL will light up during step (5).
NOTICE:
If the conditions in this test are not strictly followed, detection of the malfunction will not be possible.
If you do not hove a TOYOTA hand−held tester, turn the ignition switch OFF after performing steps
(3) to (5), then perform steps (3) to (5) again.
DI3ZK−01

DI−46
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
DTC P0136 Oxygen Sensor Circuit Malfunction
(Bank 1 Sensor 2)
CIRCUIT DESCRIPTION
Refer to ”Insufficient Coolant Temp. for Closed Loop Fuel Control” on page DI−39.
DTC No.DTC Detecting ConditionTrouble Area
P0136
Voltage output of the oxygen sensor (bank 1 sensor 2)
remains at 0.4 V or more or 0.5 V or less when the vehicle is
driven at 40km/h (25 mph) or more after the engine is warmed
up
(2 trip detection logic)
Oxygen sensor
HINT:
Sensor 2 refers to the sensor farther away from the engine body.
WIRING DIAGRAM
Refer to page DI−39 for the WIRING DIAGRAM.
INSPECTION PROCEDURE
1 Are there any other codes (besides DTC P0136) being output?
YES Go to relevant DTC chart.
NO
2 Check for open and short in harness and connector between ECM and oxygen
sensor (See page IN−30).
NG Repair or replace harness or connector.
OK
DI3ZM−01

S02386
1H
1DEA1
IG1 22 IG1 IG1
E4
E4
E4
E4
E4
E4 B−R
B−Y
B−R
B−Y
BR
BRE02 E01#40 #30 #20 #10ECM
Injector 8
J/B No.1
IG Switch
8 14
7
11
7 621
202
2
2
2 B−O 31
1
1
1 No.1
No.2
No.3
No.4 B−O
B−O
B−O B−O B−O12
11
25
24
13
26
EC
BatteryFusible Link Block
MAIN
W B−R2
B
B−R
B−YB−Y
B−R
J/B No.2
AM2
FI6588
FI6538
A00064
10 V/
Division10 V/
Division(Magnification)
100 m sec./Division (idling)1 m sec./Division (Idling)
Injection durationGND GND
DI−52
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
WIRING DIAGRAM
Reference INSPECTION USING OSCILLOSCOPE
INJECTOR SIGNAL WAVEFORM
With the engine idling, measure between terminals #10, #20, #30, #40 and E01 of ECM.
HINT:
The correct waveform is as shown.