1996 TOYOTA RAV4 reset

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.

BE277−01
BE−68
− BODY ELECTRICALAUDIO SYSTEM
1996 RAV4 (RM447U)
TROUBLESHOOTING
NOTICE:
When replacing the internal mechanism (computer part) of the audio system, be careful that no part
of your body or clothing comes in contact with the terminals of the leads from the IC etc. of the re-
placement part (spare part).
HINT:
This inspection procedure is a simple troubleshooting which should be carried out on the vehicle during sys-
tem operation and was prepared on the assumption of system component troubles (except for the wires and
connectors, etc.).
Always inspect the trouble taking the following items into consideration.
Open or short circuit of the wire harness
Connector or terminal connection fault
ProblemNo.
RadioNo power coming in.1
Power coming in, but radio not operating.2
Noise present, but AM − FM not operating.3
Either speaker does not work.4
Either AM or FM does not work.5
Reception poor (Volume faint).5
Few preset tuning bands.5
Sound quality poor.6
Cannot set station select button.6
Preset memory disappears.7
Tape PlayerCassette tape cannot be inserted.8
Cassette tape inserted, but no power.9
Power coming in, but tape player not operating.10
Either speaker does not work.11
Sound quality poor (Volume faint).12
Tape jammed, malfunction with tape speed or auto−reverse.13
APS, SKIP, RPT buttons not operating.14
Cassette tape will not ejected.15
AntennaAntenna−related.16
NoiseNoise produced by vibration or shock while driving.17
Noise produced when engine starts.18

V07432
5
RadioEITHER AM OR FM DOES NOT WORK, RECEPTION
POOR (VOLUME FAINT), FEW PRESET TUNING BANDS
Problem with radio wave signals or location?Poor signals or poor location. Ye s
No
Are both AM and FM defective?No
Is power for the antenna being output from
the radio assembly?Ye s
Ye s
Go to No.17.
Temporarily install another speaker.
Functions OK?Speaker faulty. Ye s
NoRadio assembly faulty.
No
If radio side faulty.
NoYe s
Is tape player operating normaly?
Radio assembly faulty.
Radio assembly faulty.
BE−72
− BODY ELECTRICALAUDIO SYSTEM
1996 RAV4 (RM447U)

V07433
6
RadioSOUND QUALITY POOR
Is sound quality always bad?
Is sound quality bad in
certain areas only? No Yes
Poor signals or poor
location.
No
Go to No.23.
If radio side faulty
Radio assembly faulty.
Is speaker properly installed?No
Install properly.
Ye s
Temporarily install another speaker.
Function OK?Ye s
Speaker faulty.
No
Go to No.17.If radio side faulty
7
RadioCANNOT SET STATION SELECT BUTTON, PRESET
MEMORY DISAPPEARS
Can cassette tape be inserted in tape player?Ye s
Radio assembly faulty.
No
Check if DOME fuse is OK?NG
Replace fuse.
OK
Is +B applied to radio or radio assembly?No
+B wire harness faulty.
Ye s
Check if GND (wire harness side) to
radio assembly is OK?
OKNG
GND faulty.
Radio assembly faulty.Radio assembly faulty.
Radio assembly faulty. Is tape player operating normaly?Ye s
Ye s
No
− BODY ELECTRICALAUDIO SYSTEM
BE−73
1996 RAV4 (RM447U)

Fuse BlockEngine ECU R/B No. 5 J/B No. 1J/B No. 4 ABS ECUDaytime Running
Light Relay (*1) Door Look Control RelayA/C Amplifier J/B No. 3
4. ECU (ELECTRONIC CONTROL UNIT)
Locations of ECUs
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.

Before starting electric welding operations, disconnect the negative (-) terminal cable from the battery.
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all
equipped with memory function, it is not possible to make a record of the memory contents.
So when the operation is finished, it will be necessary to explain this fact to the customer, and request
the customer to adjust the features and reset the memory.

Do not expose the ECUs to ambient temperatures above 80°C (176°F).
NOTICE: If it is possible the ambient temperature may reach 80 °C (176 °F) or more, remove the ECUs
from the vehicle before starting work.

Be careful not to drop the ECUs and not to apply physical shocks to them.
4. COMPONENTS ADJACENT TO THE BODY PANELS
Various types of component parts are mounted directly on or adjacently to the body panels.
Strictly observe the following precautions to prevent damaging these components and the body panels
during handling.

Before repairing the body panels, remove their components or apply protective covers over the comœ
ponents.

Before prying components off using screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components and the body paint.

Before removing components from the outer surface of the body, attach protective tape to the body to
ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.

Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.
INTRODUCTIONINœ8

S01787
S01792
1
23
4
5
6
S01788
EM−38
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
HINT:
When removing the camshaft, make sure that the torsional
spring force of the sub gear has been eliminated by the above
operation.
(3) Remove the 2 bolts and rear bearing cap.
(4) Uniformly loosen and remove the 6 bolts on the No.
1, No. 2 and No. 4 bearing caps, in several passes,
in the sequence shown.
NOTICE:
Do not remove the No. 3 bearing cap bolts at this stage.
(5) Remove the No. 1, No. 2 and No. 4 bearing caps.
(6) Alternately loosen and remove the 2 bolts on the
No. 3 bearing cap.
HINT:
As the 2 No. 3 bearing cap bolts are loosened, make sure
that the camshaft is lifted out straight and level.
If the camshaft is not being lifted out straight and level, re-
tighten the 2 No. 3 bearing cap bolts. Then do steps (f) to
(a) and reset the knock pin of the intake camshaft at 10
− 45° BTDC, and repeat steps (b) to (f) once again.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
(7) Remove the No. 3 bearing cap and exhaust cam-
shaft.

S01777
80 − 11 5°
Knock
Pin
S01769
S01771
1 2
3 45 6
S01768
− ENGINE MECHANICALCYLINDER HEAD
EM−39
1996 RAV4 (RM447U)
(b) Remove the intake camshaft.
(1) Set the knock pin of the intake camshaft at 80 −
11 5° BTDC of camshaft angle.
HINT:
The above angle allows the No. 1 and No. 3 cylinder cam lobes
of intake camshaft to push their valve lifters evenly.
(2) Remove the 2 bolts, front bearing cap and oil seal.
(3) Uniformly loosen and remove the 6 bolts on the No.
1, No. 3 and No.4 bearing caps, in several passes,
in the sequence shown.
NOTICE:
Do not remove the No. 2 bearing cap bolts at this stage.
(4) Remove the No. 1, No. 3 and No. 4 bearing caps.
(5) Alternately loosen and remove the 2 bolts on the
No. 2 bearing cap.
HINT:
As the 2 No. 2 bearing cap bolts are loosened, make sure
that the camshaft is lifted out straight and level, after
breaking adhesion on the front bearing cap.
If the camshaft is not being lifted out straight and level, re-
tighten the 2 No. 2 bearing cap bolts. Do steps (e) to (a)
and reset the knock pin of the intake camshaft at 80 −
11 5° BTDC, and repeat steps (b) to (e) once again.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
(6) Remove the No. 2 bearing cap and camshaft.

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