1996 TOYOTA RAV4 Service Repair Manual

144
ABS
12
345
A22
GRAY B GRAY (
4WD) A 6BLACK(
2WD)
1234
5678A GRAY (
4WD) A 7BLACK(
2WD)
12
34AGRAY A 8
1
4
5 2
X
6 BGRAY A 9
12A10
GRAY
12A11
GRAY
12 X53 A1 5
12
X4 5 6 78
910
11 12 13 14 1516 C A16 (
4WD)
12
345X7891011
12 13
14 X 16 X 18 19 20 2122
12
XX567X91011 12 13
X15
16 X 18192021222324 25 26B A17 (
2WD)
D A17 (
4W D)
1 212 A21
GRAY
12B 2
GRAY
(
A/T)(
M/T)(
A/T)
(
M/T)
XX
XX
XX X11
XXX
16 X XX X
23 22X D 1
BLACK
(
SEE PAGE 26) F 8
(
SEE PAGE 25) F 7
A A A A A
AAAAAAAJ 1
BL UEJ 5
BLUE
(
HINT : SEE PAGE 7)(
HINT : SEE PAGE 7)
CCC BBBBGRAY J11
AGRAY J10
(
HINT : SEE PAGE 7)(
HINT : SEE PAGE 7) 1234XX
78910X12A A16 (
2WD)
8 X8 X X ABROWN C 9
ABROWN C 9
X 7 BBLUE C10
7X BBLUE C10
DDD1
12S 5
BROW NP 2
BLACK

145
HORN
FROM POW ER SOURCE SYSTEM (
SEE PAGE 54)
15A
HAZ-HORN
SW
. SW ] 15 14
2
6
W
6 66
G-R
G-R
HO RN
REL AY
G-W
HORN H 3
HORN
[C O M B C12 31 2
IB1 12
1
HORN RELAY
(6) 2 - (6) 3 : CLOSED WITH HORN SW ON
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
C1230H 328
: RELAY BLOCKS
CODESEE PAGERELAY BLOCKS (RELAY BLOCK LOCATION)
223R/B NO. 2 (ENGINE COMPARTMENT LEFT)
625R/B NO. 6 (ENGINE COMPARTMENT LEFT)
: CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS
CODESEE PAGEJOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION)
IB136ENGINE ROOM MAIN WIRE AND INSTRUMENT PANEL WIRE (LEFT KICK PANEL)
XX 61 C12
BLACKH 3
BLACK
SERVICE HINTS

146
CRUISE CONTROL
I 7
I 5
I1 1
I 8 A C
B BBBIG 1 2
IG 2 9IG210IG 1 5
IG 1 12
IGIG R-L
R- R-L
(
M/T)
R-L
R-L
R-L
R-L R-L
(
M/T)
(
A/T) R- L
(
A/T) B-W
(
A/T) BR
G-R
L-B
R-Y
V-W
R-L
(
M/T)
R-L
(
A/T)
R-YL-B BR
VEHICLE SPEED SENSOR
(
COMBINATIO N METER)J1 0
P
(
A/T) V-W
V-W
Y-B
(
A/T)
G- R
W-BV-W
W-BB- W
(
A/T)
B-W
(
M/T)
LL
B-W
(
A/T)CRUISE CONTROL
CLUTCH SW C15
FR O M THR O TTLE P O SITIO N
SENSOR
FROM POW ER SOURCE SYSTEM (
SEE PAGE 54)
E
CK]
JUNCTION
CONNECTORB J10 , J11A
B P 1 , A
PARK/NEUTRAL POSITION SW
IG 1 6
I 5
B 6B9B20 A15
SPD DOD1S2
ENGINE CONTROL MODULEB E 4 , E 6A
P
(
A/T) P
(
A/T) P
(
A/T)
TO ELECTRONICALLY
CONTROLLED TRANSMISSION
SOLENOID
B 2(
4W D) A 6(
2W D)
A 8(
2W D)
B 10(
4W D)
B-W
(
A/T)
43
R
-L
10A GAUG
[FUS E B LO F 8
1
CO M BINA TIO N M ETER C 9
CRUISE
SPEED
12 6 11 10 28
21 2
13 7 9 20CRUISE CONTROL ECU C16
22 DIDL
SPDODECT PI GND
213
V 2
A
A
JU NC TIO N
CONNECTORL
1E 8
1B 8

147
IB 2 7
ID11
BFROM POWER SOURCE SYSTEM(
SEE PAGE 54)
L
Y
Y
W L-B R-B R-GL-RLG L-O
R-Y
G-WG-Y W-L
CRUISE CONTROL SW
[CO M B . SW ]
W-B
18 12 15
W
13 DATA LINK CONNECTOR 1 D 1
2 TC1918 7. 5A
ECU-IG
[FUSE BLOCK] F 8
10A
STOP
[FUSE
BLOCK] F 8
15A
DO ME
EA1 3
IB 1 17
B
JUNCTION
CO NNECTOR J 7
W- W-L V
L- L-Y
B- B-Y
R- R-W
1I 9
1H 7
IB2 16 IB 2 5 IB 2 6 IB2 17 IB 2 18 IB 2 19
2 3 4 5
3
1 4R-W L-B R-B R-GL- RLG L- O
G-B
R-Y
G-WC12 CRUISE
CANCEL
SET/
COAST
RESUME/
ACCEL W-B
B-B
JU NC TIO N
CONNECTOR J10
1F 2 1E 6 1J 5
1I 11 1A 6 1G 7
V
14 15 8
10 26 11 12 25 24 23 16 18 19CRUISE CONTROL ECU C16
CMS CCS STP- VR1 VR2 VR3 MO M C L- LB BATT TC
CRUISE CONTROL ACTUATOR
4 7 6 3 2 1
5 C 3M
STOP LIGHT SW S 5
B

148
CRUISE CONTROL
CURRENT IS APPLIED AT ALL TIMES THROUGH THE STOP FUSE TO TERMINAL 2 OF THE STOP LIGHT SW, AND ALSO THROUGH
THE DOME FUSE TO TERMINAL 15 OF THE CRUISE CONTROL ECU.
WITH THE IGNITION SW TURNED TO ON, CURRENT FLOWS THROUGH THE GAUGE FUSE TO TERMINAL 8 OF THE COMBINATION
METER AND THE CURRENT THROUGH THE DOME FUSE FLOWS TO TERMINAL 15 OF THE CRUISE CONTROL ECU.
WHEN THE IGNITION SW IS ON AND THE CRUISE CONTROL MAIN SW IS TURNED ON, A SIGNAL IS INPUT FROM TERMINAL 5 OF THE
CRUISE CONTROL SW TO TERMINAL 19 OF THE CRUISE CONTROL ECU. AS A RESULT, THE CRUISE CONTROL ECU FUNCTIONS
AND THE CURRENT FLOWS FROM THE ECU-IG FUSE TO TERMINAL 14 OF THE CRUISE CONTROL ECU TO TERMINAL 13 OF THE
CRUISE CONTROL ECU " GROUND, AND THE CRUISE CONTROL SYSTEM IS IN A CONDITION READY FOR OPERATION.
AT THE SAME TIME, THE CURRENT THROUGH THE GAUGE FUSE FLOWS TO TERMINAL 8 OF THE CRUISE CONTROL INDICATOR
LIGHT "TERMINAL 6 "TERMINAL 7 OF THE CRUISE CONTROL ECU "TERMINAL 13 "GROUND, CAUSING THE CRUISE
CONTROL INDICATOR LIGHT TO LIGHT UP, INDICATING THAT THE CRUISE CONTROL IS READY FOR OPERATION.
1. SET OPERATION
WHEN THE CRUISE CONTROL MAIN SW IS TURNED ON AND THE SET SW IS PUSHED WITH THE VEHICLE SPEED WITHIN THE SET
LIMIT (APPROX. 40 KM/H, 25 MPH TO 200 KM/H, 124 MPH), A SIGNAL IS INPUT TO TERMINAL 18 OF THE CRUISE CONTROL ECU AND
THE VEHICLE SPEED AT THE TIME THE SET SW IS RELEASED IS MEMORIZED IN THE ECU AS THE SET SPEED.
2. SET SPEED CONTROL
DURNING CRUISE CONTROL DRIVING, THE ECU COMPARES THE SET SPEED MEMORIZED IN THE ECU WITH THE ACTUAL VEHICLE
SPEED INPUT INTO TERMINAL 20 OF THE CRUISE CONTROL ECU FROM THE SPEED SENSOR, AND CONTROLS THE CRUISE
CONTROL ACTUATOR TO MAINTAIN THE SET SPEED.
WHEN THE ACTUAL SPEED IS LOWER THAN THE SET SPEED, THE ECU CAUSES THE CURRENT TO THE CRUISE CONTROL
ACTUATOR TO FLOW FROM TERMINAL 12 OF THE CRUISE CONTROL ECU "TERMINAL 6 OF THE CRUISE CONTROL ACTUATOR "
TERMINAL 7 "TERMINAL 11 OF THE CRUISE CONTROL ECU. AS A RESULT, THE MOTOR IN THE CRUISE CONTROL ACTUATOR IS
ROTATED TO OPEN THE THROTTLE VALVE AND THE THROTTLE CABLE IS PULLED TO INCREASE THE VEHICLE SPEED. WHEN THE
ACTUAL DRIVING SPEED IS HIGHER THAN THE SET SPEED, THE CURRENT TO THE CRUISE CONTROL ACTUATOR FLOWS FROM
TERMINAL 11 OF THE ECU "TERMINAL 7 OF THE CRUISE CONTROL ACTUATOR "TERMINAL 6 "TERMINAL 12 OF THE CRUISE
CONTROL ECU.
THIS CAUSES THE MOTOR IN THE CRUISE CONTROL ACTUATOR TO ROTATE TO CLOSE THE THROTTLE VALVE AND RETURN THE
THROTTLE CABLE TO DECREASE THE VEHICLE SPEED.
3. COAST CONTROL
DURING THE CRUISE CONTROL DRIVING, WHILE THE COAST SW IS ON, THE CRUISE CONTROL ACTUATOR RETURNS THE
THROTTLE CABLE TO CLOSE THE THROTTLE VALVE AND DECREASE THE DRIVING SPEED. THE VEHICLE SPEED WHEN THE COAST
SW IS TURNED OFF IS MEMORIZED AND THE VEHICLE CONTINUES AT THE NEW SET SPEED.
4. ACCEL CONTROL
DURING CRUISE CONTROL DRIVING, WHILE THE ACCEL SW IS TURNED ON, THE CRUISE CONTROL ACTUATOR PULLS THE
THROTTLE CABLE TO OPEN THE THROTTLE VALVE AND INCREASE THE DRIVING SPEED.
THE VEHICLE SPEED WHEN THE ACCEL SW IS TURNED OFF IS MEMORIZED AND THE VEHICLE CONTINUES AT THE NEW SET
SPEED.
5. RESUME CONTROL
UNLESS THE VEHICLE SPEED FALLS BELOW THE MINIMUM SPEED LIMIT (APPROX. 40 KM/H, 25 MPH) AFTER CANCELING THE SET
SPEED BY THE CANCEL SW, PUSHING THE RESUME SW WILL CAUSE THE VEHICLE TO RESUME THE SPEED SET BEFORE
CANCELLATION.
6. MANUAL CANCEL MECHANISM
IF ANY OF THE FOLLOWING OPERATIONS OCCURS DURING CRUISE CONTROL OPERATION, THE MAGNETIC CLUTCH OF THE
ACTUATOR TURNS OFF AND THE MOTOR ROTATES TO CLOSE THE THROTTLE VALVE AND THE CRUISE CONTROL IS RELEASED.
*PLACING THE SHIFT LEVER EXCEPT Dº POSITION (PARK/NEUTRAL POSITION SW EXCEPT Dº POSITION). SIGNAL IS NOT INPUT
TO TERMINAL 2 OF THE ECUº
*DEPRESSING THE BRAKE PEDAL (STOP LIGHT SW ON). SIGNAL INPUT TO TERMINAL 16 OF THE ECUº
*PUSHING THE CANCEL SW (CANCEL SW ON). SIGNAL INPUT TO TERMINAL 18 OF THE ECUº
SYSTEM OUTLINE

149
7. AUTO CANCEL FUNCTION
A) IF ANY OF THE FOLLOWING OPERATING CONDITIONS OCCURS DURING CRUISE CONTROL OPERATION, THE SET SPEED IS
ERASED, CURRENT FLOW TO THE MAGNETIC CLUTCH IS STOPPED AND THE CRUISE CONTROL IS RELEASED. (MAIN SW TURNS
OFF).
WHEN THIS OCCURS, THE IGNITION SW MUST BE TURNED OFF ONCE BEFORE THE MAIN SW WILL TURN ON.
*WHEN CURRENT CONTINUED TO FLOW TO THE MOTOR INSIDE THE ACTUATOR IN THE THROTTLE VALVE OPENº DIRECTION.
*THE MOTOR DOES NOT OPERATE DESPITE THE MOTOR DRIVE SIGNAL BEING OUTPUT.
B) IF ANY OF THE FOLLOWING OPERATING CONDITIONS OCCURS DURING CRUISE CONTROL OPERATION, THE SET SPEED IS
ERASED, CURRENT FLOW TO THE MAGNETIC CLUTCH IS STOPPED AND THE CRUISE CONTROL IS RELEASED. (MAIN SW TURN
OFF).
WHEN THIS OCCURS, THE CANCEL STATE IS CLEARED AS THE MAIN SW WILL TURN ON AGAIN.
*OVER CURRENT TO TRANSISTOR DRIVING THE MOTOR AND/OR THE MAGNETIC CLUTCH.
*OPEN CIRCUIT IN THE MAGNETIC CLUTCH.
*MOMENTARY INTERRUPTION OF VEHICLE SPEED SIGNAL.
*SHORT CIRCUIT IN THE CRUISE CONTROL SW.
*WHEN THE VEHICLE SPEED FALLS MORE THAN 16 KM/H (10 MPH) BELOW THE SET SPEED, E.G. ON AN UPWARD SLOPE.
C) IF ANY OF THE FOLLOWING CONDITIONS OCCURS DURING CRUISE CONTROL OPERATION, THE SET SPEED IS ERASED AND
THE CRUISE CONTROL IS RELEASED. (THE POWER TO THE MAGNETIC CLUTCH IS CUT OFF UNTIL THE SET SW IS ONº AGAIN.)
*WHEN THE VEHICLE SPEED FALLS BELOW THE MINIMUM SPEED LIMIT, APPROX. 40 KM/H (25 MPH)
*WHEN POWER TO THE CRUISE CONTROL SYSTEM IS MOMENTARILY CUT OFF.
D) IF ANY OF THE FOLLOWING CONDITIONS OCCURS DURING CRUISE CONTROL OPERATION, THE CRUISE CONTROL IS
RELEASED.
*OPEN THE CIRCUIT FOR TERMINAL 2 OF THE STOP LIGHT SW.
8. AUTOMATIC TRANSMISSION CONTROL FUNCTION
*IN OVERDRIVE, IF THE VEHICLE SPEED BECOMES LOWER THAN THE OVERDRIVE CUT SPEED (SET SPEED MINUS APPROX. 4
KM/H, 2.5 MPH) DURING CRUISE CONTROL OPERATION, SUCH AS DRIVING UP A HILL, THE OVERDRIVE IS RELEASED AND THE
POWER INCREASED TO PREVENT A REDUCTION IN VEHICLE SPEED.
*AFTER RELEASING THE OVERDRIVE, VEHICLE SPEED BECOMES HIGHER THAN THE OVERDRIVE RETURN SPEED (SET SPEED
MINUS APPROX. 2 KM/H, 1.2 MPH) AND THE ECU JUDGES BY THE SIGNALS FROM THE ACTUATOR'S POTENTIOMETER THAT THE
UPWARD SLOPE HAS FINISHED, THE OVERDRIVE IS RESUMED AFTER APPROXIMATELY 2 SECONDS.
*DURING CRUISE CONTROL DRIVING, THE CRUISE CONTROL OPERATION SIGNAL IS OUTPUT FROM THE CRUISE CONTROL
ECU TO THE ENGINE CONTROL MODULE. UPON RECEIVING THIS SIGNAL, THE ENGINE CONTROL MODULE CHANGES THE SHIFT
PATTERN TO NORMAL.
TO MAINTAIN SMOOTH CRUISE CONTROL OPERATION (ON A DOWNWARD SLOPE ETC.), THE LOCK-UP RELEASE OF THE
TRANSMISSION WHEN THE IDLING POINT OF THE THROTTLE POSITION IS ONº IS FORBIDDEN.
C 3 CRUISE CONTROL ACTUATOR
1-3 : APPROX. 2 KW
5-4 : APPROX. 38 W
C12 CRUISE CONTROL SW [COMB. SW]
5-3 : CONTINUITY WITH THE CRUISE MAIN SW ON
4-3 : APPROX. 418 W WITH THE CANCEL SW ON
APPROX. 68 W WITH THE SET/COAST SW ON
APPROX. 198W WITH THE RESUME/ACCEL SW ON
C16 CRUISE CONTROL ECU
14-GROUND : APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION
15-GROUND : ALWAYS APPROX. 12 VOLTS
20-GROUND :4 PULSES WITH 1 ROTATION OF THE ROTOR SHAFT
18-GROUND : APPROX. 418 W WITH THE CANCEL SW ON IN THE CONTROL SW
APPROX. 198 W WITH THE SET/COAST SW ON IN THE CONTROL SW
APPROX. 68 W WITH THE RESUME/ACCEL SW ON IN THE CONTROL SW
13-GROUND : ALWAYS CONTINUITY
SERVICE HINTS

150
CRUISE CONTROL
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
C 328E 4A31P1A29
C 930E 6B31P 1B29
C1230F 831S 531
C1530J 731V 229
C1630J10A31
D 128J11B31
: RELAY BLOCKS
CODESEE PAGERELAY BLOCKS (RELAY BLOCK LOCATION)
223R/B NO. 2 (ENGINE COMPARTMENT LEFT)
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
1A20INSTRUMENT PANEL WIRE AND J/B NO 1 (LOWER FINISH PANEL)1B20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1E20FUSE BLOCK ASSY WIRE AND J/B NO 1 (LOWER FINISH PANEL)1F20FUSE BLOCK ASSY WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1G
1H20INSTRUMENT PANEL WIRE AND J/B NO 1 (LOWER FINISH PANEL)1I20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1J
: CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS
CODESEE PAGEJOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION)
EA134ENGINE WIRE AND ENGINE ROOM MAIN WIRE (INSIDE OF R/B NO. 2)
IB136ENGINE ROOM MAIN WIRE AND INSTRUMENT PANEL WIRE (LEFT KICK PANEL)
IB236ENGINE ROOM MAIN WIRE AND INSTRUMENT PANEL WIRE (RIGHT KICK PANEL)
IG138ENGINE WIRE AND INSTRUMENT PANEL WIRE (UNDER THE INSTRUMENT PANEL CENTER)IG238ENGINE WIRE AND INSTRUMENT PANEL WIRE (UNDER THE INSTRUMENT PA N E L CENTER)
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
ID36LEFT KICK PANEL
IG36RIGHT KICK PANEL
: SPLICE POINTS
CODESEE PAGEWIRE HARNESS WITH SPLICE POINTSCODESEE PAGEWIRE HARNESS WITH SPLICE POINTS
I538ENGINE WIREI 838INSTRUMENT PANEL WIRE
I738INSTRUMENT PANEL WIREI1138INSTRUMENT PANEL WIRE

151