1996 TOYOTA RAV4 ECU

BR0M5−01
R10630
BR−24
− BRAKEFRONT BRAKE CALIPER
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Install the flexible hose lock securely in the lock hole in the cali-
per.
(b) Use a container to catch the brake fluid as it drains out.
2. REMOVE CALIPER
(a) Hold the sliding pin and loosen the 2 installation bolts.
Torque: 26 N·m (270 kgf·cm, 20 ft·lbf)
(b) Remove the 2 installation bolts.
(c) Remove the caliper from the torque plate.
3. REMOVE THESE PARTS:
2 brake pads with anti−squeal shims
4 pad support plates

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

New Spot
Locations
POST-WELDING
REFINISHING
1. Always check the welded
spots to insure they are
secure.
2. When smoothing out the
weld spots with a disc
grinder, be careful not to
grind off too much as this
would weaken the weld.
INSTALLATION
PRE-WELDING MEASUREMENTS
Always take measurements
before installing underbody or
engine components to insure
correct assembly. After installation,
confirm proper fit.WELDING PRECAUTIONS
1. The number of welding spots
should be as follows.
Spot weld: 1.3 y No. of
manufacturer`s spots.
Plug weld: More than No.
of manufacturer's plugs.
WRONG
WRONG OKAY
2. Plug welding should be done
with a MIG (Metal Inert Gas)
welder. Do not gas weld or
braze panels at areas other
than specified.
Safety Glass
Body
Measurement
Diagrams
SPOT WELDING PRECAUTIONS
1. The shape of the welding tip
point has an effect on the
strength of the weld.
2. Always insure that the
seams and welding tip are
free of paint. SPOT WELD LOCATIONS
Try to avoid welding over
previous spots.
Old
Spot
Locations
Tip Cutter
INTRODUCTIONINœ12

ABS Antilock Brake System
A/C Air Conditioner
assy assembly
ECT Electronic Controlled Transmission
ECU Electronic Control Unit
e.g. Exempli Gratia (for Example)
Ex. Except
FWD Front Wheel Drive Vehicles
4WD Four Wheel Drive Vehicles
in. inch
LH Left-hand
LHD Left-hand Drive
MIG Metal Inert Gas
M/Y Model Year
PPS Progressive Power Steering
RH Right-hand
RHD Right-hand Drive
SRS Supplemental Restraint System
w/ with
w/o without
ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual.
INTRODUCTIONINœ15

GENERAL INFORMATION
1. BASIC DIMENSIONS
(a) There are two types of dimensions in the diagram.
(Three-dimensional distance)

Straight-line distance between the centers of two
measuring points.
(Two-dimensional distance)

Horizontal distance in forward/rearward between
the centers of two measuring points.

The height from an imaginary standard line.
(b) In cases in which only one dimension is given, left
and right are symmetrical.
(c) The dimensions in the following drawing indicate
actual distance. Therefore, please use the dimenœ
sions as a reference.
2. MEASURING
(a) Basically, all measurements are to be done with a
tracking gauge. For portions where it is not possible
to use a tracking gauge, a tape measure should be
used.
(b) Use only a tracking gauge that has no looseness in
the body, measuring plate, or pointers.
HINT:
1. The height of the left and right pointers must be equal.
2. Always calibrate the tracking gauge before measuring or
after adjusting the pointer height.
3. Take care not to drop the tracking gauge or otherwise
shock it.
4. Confirm that the pointers are securely in the holes.
(c) When using a tape measure, avoid twists and
bends in the tape.
(d) When tracking a diagonal measurement from the
front spring support inner hole to the suspension
member upper rear installation hole, measure
along the front spring support panel surface.
Center-to-center
straight-line
distance Three-dimensional
distance
Front Spring Support Inner Hole
Tape Measure
Along Body
Surface
Front Suspension Member Rear Side
Upper Installation HoleMaster Gauge PointerPointer LoosenessBody LoosenessPlate Looseness Two-dimensional
distanceCenter-to-center
Horizontal distance in
forward/rearward
Vertical distance
in lower surface Vertical distance
in center
Imaginary Standard Line
WrongCorrect
Pointer
BODY DIMENSIONSDIœ2

DI3Z7−01
FI0534
S01354
TOYOTA
Hand−Held Tester
− DIAGNOSTICSENGINE
DI−3
1996 RAV4 (RM447U)
PRE−CHECK
1. DIAGNOSIS SYSTEM
(a) Description
When troubleshooting OBDII vehicles, the only dif-
ference from the usual troubleshooting procedure
is that you connect to the vehicle the OBDII scan
tool complying with SAE J1978 or TOYOTA hand−
held tester, and read off various data output from
the vehicle’s ECM.
OBDII regulations require that the vehicle’s on−
board computer lights up the Malfunction Indicator
Light (MIL) on the instrument panel when the com-
puter detects a malfunction in the computer itself on
in drive system components which affect vehicle
emissions. In addition to the MIL lighting up when
a malfunction is detected, the applicable Diagnostic
Trouble Code (DTC) prescribed by SAE J2012 are
recorded in the ECM memory (See page DI−14).
If the malfunction does not recur in 3 trips, the MIL
goes off but the DTC remain recorded in the ECM
memory.
To check the DTC, connect the OBDII scan tool or
TOYOTA hand−held tester to Data Link Connector
3 (DLC3) on the vehicle. The OBDII scan tool or
TOYOTA hand−held tester also enables you to
erase the DTC and check freezed frame data and
various forms of engine data. (For operating instruc-
tions, see the OBDII scan tool’s instruction book.)
DTC include SAE controlled codes and Manufac-
ture controlled codes.
SAE controlled codes must be set as prescribed by
the SAE, while Manufacturer controlled codes can
be set freely by the manufacturer within the pre-
scribed limits (See DTC chart on page DI−14).
The diagnosis system operates in normal mode
during normal vehicle use. It also has a check mode
for technicians to simulate malfunction symptoms
and troubleshoot. Most DTC use 2 trip detection
logic* to prevent erroneous detection and ensure
thorough malfunction detection.

− DIAGNOSTICSENGINE
DI−7
1996 RAV4 (RM447U)
(10) After checking the DTC, inspect the applicable cir-
cuit.
(b) Clear the DTC.
The following actions will erase the DTC and freezed
frame data.
(1) Operating the OBDII scan tool (complying with SAE
J1978) or TOYOTA hand−held tester to erase the
codes.
(See the OBDII scan tool’s instruction book for oper-
ating instructions.)
(2) Disconnecting the battery terminals or EFI fuse.
NOTICE:
If the TOYOTA hand−held tester switches the ECM from
normal mode to check mode or vice−versa, or it the ignition
switch is turned from ON to ACC or OFF during check
mode, the DTC and freezed frame data will be erased.
4. FAIL−SAFE CHART
If any of the following codes is recorded, the ECM enters fail−sate mode.
DTC No.Fail−Safe OperationFail−Safe Deactivation Conditions
P0105Ignition timing fixed at 5° BTDCReturned to normal condition
P0110Intake air temp. is fixed at 68°F (20°C)Returned to normal condition
P0115Engine coolant temp. is fixed at 176°F (80°C)Returned to normal condition
P0120VTA is fixed at 0°
The following condition must be repeated at least
2 times consecutively
When closed throttle position switch is ON:
0.1 V  VTA  0.95 V
P0325Max. timing retardationIgnition switch OFF
P1300Fuel cutIGF signal is detected for 1 ignition
5. CHECK FOR INTERMITTENT PROBLEMS
TOYOTA hand−held tester only:
By putting the vehicle’s ECM in check mode, 1 trip detection logic possible instead of 2 trip detection logic
and sensitivity to detect open circuit is increased. This makes it easier to detect intermittent problems.
(1) Clear the diagnostic trouble codes (See page DI−3)
(2) Set the check mode (See page DI−3)
(3) Perform a simulation test (See page IN−20)
(4) Check the connector and terminal inspection (See page IN−30)
(5) Visual check and contact pressure (See page IN−30)
(6) Handle the connector (See page IN−30)

− DIAGNOSTICSENGINE
DI−19
1996 RAV4 (RM447U) FC (E6−14) − E1 (E4−14)
G−R ↔ BRIG switch ON9 ∼ 14
EGR (E4−23) − E1 (E4−14)B−W ↔ BRIG switch ON0 ∼ 3
ISCC (E4−9) − E1 (E4−14)B−Y ↔ BRIG switch ON
Disconnect E4 of ECM connector9 ∼ 14
ISCO (E4−10) − E1 (E4−14)B−L ↔ BRIG switch ON
Disconnect E4 of ECM connector9 ∼ 14
OX1 (E5−6) − E1 (E4−14)B ↔ BRMaintain engine speed at 2,500 rpm for 2 mins. after
warning up.Pulse generation
OX2 (E5−5) − E1 (E4−14)B ↔ BRMaintain engine speed at 2,500 rpm for 2 mins. after
warning up.Pulse generation
KNK (E5−10) − E1 (E4−14)B ↔ BRIdlingPulse generation
(See page DI−56)
* NSW (E6−22) − E1 (E4−14)B−W ↔ BR
IG switch ON
Other shift position in ”P” , ”N” position9 ∼ 14
IG switch ON
Shift position in ”P” , ”N” position0 ∼ 3.0
SPD (E6−9) − E1 (E4−14)V−W ↔ BRIG switch ON
Rotate driver wheel slowly.Pulse generation
(See page DI−94)
TE1 (E5−15) − E1 (E4−14)L−W ↔ BRIG switch ON9 ∼ 14
W (E6−5) − E1 (E4−14)G−R ↔ BRIdling9 ∼ 14
IG switch ONBelow 3.0
AC (E6−10) − E1 (E4−14)Y−G ↔ BRIdling, A/C switch ONBelow 2.0
Idling, A/C switch OFF9 ∼ 14
ACT (E6−21) − E1 (E4−14)R−Y ↔ BRIdling, A/C switch ON9 ∼ 14
Idling, A/C switch OFFBelow 2.0
* OD2 (E6−7) − E1 (E4−14)LG ↔ BRIG switch ON, O/D main switch pushed out9 ∼ 14
IG switch ON, O/D main switch pushed in0 ∼ 3
* OD1 (E6−20) − E1 (E4−14)Y−B ↔ BRIG switch ON, Cruise control ECU no request O/D cut9 ∼ 14
IG switch ON, Cruise control ECU request O/D cut0 ∼ 3
EVP (E4−22) − E1 (E4−14)P ↔ BRIG switch ON9 ∼ 14
TPC (E5−8) − E1 (E4−14)R−W ↔ BRIG switch ON9 ∼ 14
PTNK (E5−7) − E2 (E5−9)L−Y ↔ BR
IG switch ON, Disconnect vacuum hose from vapor
pressure sensor2.9 ∼ 3.7
Apply vacuum
(4.0 kPa, 30 mmHg, 1.18 in. Hg)
(less than 66.7 kPa, 500 mmHg, 19.7 in. Hg)
Below 0.5
ELS (E6−17) − E1 (E4−14)B ↔ BRDefogger switch and taillight switch ON7.5 ∼ 14
Defogger switch and taillight switch OFF0 ∼ 1.5
SDL (E6−16) − E1 (E4−14)W ↔ BRDuring transmissionPules generation
*: A/T only