1996 TOYOTA RAV4 Vacuum

DI3ZA−02
A07400
E4E5E6 DI−18
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
TERMINALS OF ECM
Symbols (Terminals No.)Wiring ColorConditionSTD Voltage (V)
BATT (E6−1) − E1 (E4−14)R−W ↔ BRAlways9 ∼ 14
+B (E6−12) − E1 (E4−14)B−R ↔ BRIG switch ON9 ∼ 14
VC (E5−1) − E2 (E5−9)Y ↔ BRIG switch ON4.5 ∼ 5.5
VTA (E5−11) − E2 (E5−9)L−R ↔ BR
IG switch ON
Throttle valve fully closed.0.3 ∼ 0.8
IG switch ON
Throttle valve fully open.3.2 ∼ 4.9
PIM (E5−2) − E2 (E5−9)LG−R ↔ BR
IG switch ON3.3 ∼ 3.9
Apply vacuum 26.7 kpa
(200 mmHg, 7.9 in. Hg)2.5 ∼ 3.1
THA (E5−3) − E2 (E5−9)Y−B ↔ BRIdling, Intake air temp. 20°C (68°F)0.5 ∼ 3.4
THW (E5−4) − E2 (E5−9)W ↔ BRIdling, Engine coolant temp. 80°C (176°F)0.2 ∼ 1.0
STA (E6−11) − E1 (E4−14)B−W (M/T) ↔ BRCranking6.0 or more
STA (E6−11) − E1 (E4−14)B (A/T) ↔ BRCranking6.0 or more
#10 (E4−12) − E01 (E4−13)B−R ↔ BR
IG switch ON9 ∼ 14
IdlingPulse generation
(See page DI−51)
#20 (E4−11) − E01 (E4−13)B−Y ↔ BR
IG switch ON9 ∼ 14
IdlingPulse generation
(See page DI−51)
#30 (E4−25) − E01 (E4−13)B−R ↔ BR
IG switch ON9 ∼ 14
IdlingPulse generation
(See page DI−51)
#40 (E4−24) − E01 (E4−13)B−Y ↔ BR
IG switch ON9 ∼ 14
IdlingPulse generation
(See page DI−51)
IGT (E4−20) − E1 (E4−14)B ↔ BRIdlingPulse generation
(See page DI−100)
IGF (E4−3) − E1 (E4−14)L−Y ↔ BR
IG switch ON
Disconnect igniter connector4.5 ∼ 5.5
IdlingPulse generation
(See page DI−100)
G (E4−5) − NE (E4−14)B ↔ GIdlingPulse generation
(See page DI−59)
NE (E4−4) − NE (E4−17)R ↔ GIdlingPulse generation
(See page DI−59)

− 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

DI3ZC−01
P01242
(V)
(3.96)
3.6
2.4
1.2
150 450 750 (840)mmHg
20
60
100(112)
Manifold Absolute PressurekPa
Output Voltage
− DIAGNOSTICSENGINE
DI−21
1996 RAV4 (RM447U)
CIRCUIT INSPECTION
DTC P0105 Manifold Absolute Pressure / Barometric
Pressure Circuit Malfunction
CIRCUIT DESCRIPTION
By a built−in sensor unit, the manifold absolute pressure sensor
detects the intake manifold pressure as a voltage. The ECM
then determines the basic injection duration and basic injection
advance angle based on this voltage. Since the manifold abso-
lute pressure sensor does not use the atmospheric pressure as
a criterion, but senses the absolute pressure inside the intake
manifold (the pressure in proportion to the present absolute
vacuum 0) , it is not influenced by fluctuations in the atmospher-
ic pressure due to high altitude and other factors. This permits
it to control the air−fuel ratio at the proper lever under all condi-
tions.
DTC No.DTC Detecting ConditionTrouble Area
P0105Open or short manifold absolute pressure sensor circuit
Open or short in manifold absolute pressure sensor circuit
Manifold absolute pressure sensor
ECM
If the ECM detects DTC ”P0105” it operates the fail safe function, keeping the ignition timing and injection
volume constant and making it possible to drive the vehicle.
HINT:
After confirming DTC P0105 use the OBDII scan tool or TOYOTA hand−held tester to confirm the manifold
absolute pressure from ”CURRENT DATA”.
Manifold Absolute PressureMalfunction
0 kpaPIM circuit short
130 kpa or more
VC circuit open or short
PIM circuit open
E2 circuit open

P25430
Throttle Body
Exhaust GasEGR Valve
Diagram ECM
VSV
Throttle
Valve
Intake Air
Chamber
EGR
Vacuum
Modulator
S02387
From
Battery6
1J2
1
1E J/B No.1EFI Main Relay
Fuse Block
11
10E423
EA12 R/B No.6ECM
J1
Junction Connector
AA
W−B B−W VSV (for EGR)
2
1
B−O
IGNEGR
E01
EAFrom
IG Switch
B−O 666 3
125
R−W
B−RB−R
W−B
− DIAGNOSTICSENGINE
DI−65
1996 RAV4 (RM447U)
DTC P0401 Exhaust Gas Recirculation Flow Insufficient
Detected
CIRCUIT DESCRIPTION
The EGR system recirculates exhaust gas, which is controlled to the proper quantity to suit the driving condi-
tions, into the intake air mixture to slow down combustion, reduce the combustion temperature and reduce
NOx emissions. The amount of EGR is regulated by the EGR vacuum modulator according to the engine
load.
If even one the following conditions is fulfilled, the VSV is turned
ON by a signal from ECM. This results in atmospheric air acting
on the EGR valve, closing the EGR valve and shutting off the
exhaust gas (EGR cut−off).
Before the engine is warmed up
During deceleration (throttle valve closed) .
Light engine load (amount of intake air very small).
Engine idling.
Engine speed over 4,400 rpm.
High engine load (amount of intake air very large)
.
DTC No.DTC Detecting ConditionTrouble Area
P0401
After the engine is warmed up, the intake manifold absolute
pressure is lager than the valve calculated by the ECM while
the EGR system is ON
(2 trip detected logic)
EGR valve stuck closed
Open or short in VSV circuit for EGR
Vacuum or EGR hose disconnected
Manifold absolute pressure sensor
EGR VSV open or close malfunction
ECM
WIRING DIAGRAM
DI3ZT−01

A00407
System: (OFF) System: (ON)Air
GGAir
EE
Air Filter
− DIAGNOSTICSENGINE
DI−67
1996 RAV4 (RM447U)
TOYOTA hand−held tester
1 Check the connection of the vacuum hose, EGR hose (See page EC−5).
NG Repair or replace.
OK
2 Check the VSV for EGR.
PREPARATION:
Select the ACTIVE TEST mode on the TOYOTA hand−held tes-
ter.
CHECK:
Check operation of VSV, when it is operated by the TOYOTA
hand−held tester.
OK:
EGR system is OFF:
Air from pipe E is flowing out through the air filter.
EGR system is ON:
Air from pipe E is flowing out pipe G.
OK Go to step 4.
NG
3 Check operation of the VSV for EGR (See page SF−43).
NG Replace VSV for EGR.
OK
Check for open and short in harness and con-
nector between R/B No.6 and ECM
(See page IN−30).

DI−68
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
4 Check EGR vacuum modulator (See page EC−8).
NG Repair or replace.
OK
5 Check EGR valve (See page EC−8).
NG Repair or replace.
OK
6 Check manifold absolute pressure sensor (See page DI−21).
NG Repair or replace.
OK
Check and replace ECM (Se page IN−30).
OBDII scan tool (excluding TOYOTA hand−held tester)
1 Check the connection of vacuum hose, EGR hose (See page EC−5).
NG Repair or replace.
OK

DI−70
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
4 Check EGR vacuum modulator (See page EC−8).
NG Repair or replace.
OK
5 Check EGR valve (See page EC−8).
NG Repair or replace.
OK
6 Check manifold absolute pressure sensor (See page DI−21).
NG Repair or replace.
OK
Check and replace ECM
(See page IN−30).

− DIAGNOSTICSENGINE
DI−71
1996 RAV4 (RM447U)
DTC P0402 Exhaust Gas Recirculation Flow Excessive
Detected
CIRCUIT DESCRIPTION
Refer to Exhaust Gas Recirculation Flow Insufficient Detected on page DI−65.
DTC No.DTC Detecting ConditionTrouble Area
P0402
After the engine is warmed up, conditions (a) and (b) continue
(a) The intake manifold absolute pressure is larger than the
value calculated by the ECM while the EGR system is ON.
(b) Misfiring is detected during idling
(2 trip detection logic)EGR valve stuck open
Vacuum or EGR hose is connected to wrong post
Manifold absolute pressure sensor
ECM
See DTC P0140 for System Check Driving Pattern and Wiring Diagram.
INSPECTION PROCEDURE
HINT:
If DTC ”P0105” and / or ”P0106” and ”P0402” are output simultaneously, perform troubleshooting of
DTC ”P0105” first.
If DTC ”P0401” and ”P0402” are output simultaneously, perform troubleshooting of DTC ”P0402” first.
1 Check the connection of the vacuum hose, EGR hose (See page EC−5).
NG Repair or replace.
OK
2 Check EGR valve (See page EC−8).
NG Repair or replace.
OK
3 Check the VSV for EGR * .
* If you have TOYOTA hand−held tester, see page DI−65, step 2.
If you have no TOYOTA hand−held tester, see page DI−65, step 2.
OK Go to step 5.
NG
DI3ZU−01