1996 TOYOTA RAV4 door lock

BO48D−01
H02975: 4 Clips
H02976
: 9 Clips BO−46
− BODYQUARTER WINDOW GLASS (3−Door)
1996 RAV4 (RM447U)
REMOVAL
HINT:
Tape the screwdriver tip before using to pry parts.
1. REMOVE REAR SEAT
2. REMOVE FRONT DOOR SCUFF PLATE
3. REMOVE REAR FLOOR FINISH PLATE
4. REMOVE FRONT SEAT OUTER BELT SHOULDER AN-
CHOR BOLT
5. REMOVE QUARTER TRIM
(a) Remove the rear seat outer belt floor anchor bolt.
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
(b) Remove the 4 screws.
(c) Using a screwdriver, remove the quarter trim.
6. REMOVE ROOF SIDE INNER GARNISH
(a) Remove the rear seat belt shoulder anchor bolt.
(b) Remove the 3 clips and roof side inner garnish.
7. REMOVE FRONT PILLAR GARNISH
Using a screwdriver, remove the front pillar garnish.
8. REMOVE QUARTER WINDOW GLASS
Remove the 2 nuts and quarter window glass.
9. REMOVE QUARTER WINDOW LOCK
Remove the bolt, 2 screws and quarter window glass.
10. REMOVE HINGE

BO10X−08
H04707
BO5232
H03789
BO−52
− BODYBACK DOOR GLASS
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE STOP LIGHT COVER
2. REMOVE UPPER GARNISHES
3. REMOVE UPPER SIDE GARNISHES
4. REMOVE STOP LIGHT
5. REMOVE WIPER ARM
6. REMOVE BACK DOOR MOULDING
Using a knife, cut off the moulding as shown in the illustration.
NOTICE:
Do not damage the body with the knife.
7. REMOVE BACK DOOR GLASS
(a) Push piano wire through from the interior.
(b) Tie both wire ends to a wooden block or similar object.
HINT:
Apply adhesive tape to the outer surface to keep the surface
from being scratched.
NOTICE:
When scraping the glass, take care not to damage the paint
and interior and exterior ornaments. To prevent scratching
the safety pad when removing the windshield, place a plas-
tic sheet between the piano wire and safety pad.
(c) Cut the adhesive by pulling the piano wire around it.
(d) Remove the glass.
NOTICE:
Leave as much of the adhesive on the body as possible
when cutting off the glass.

BO3D7−01
N11414
− BODYREMOVABLE ROOF
BO−59
1996 RAV4 (RM447U)
REMOVAL
HINT:
Tape a screwdriver tip before using to pry parts.
1. REMOVE REAR SEAT
2. REMOVE FRONT DOOR SCUFF PLATE
3. REMOVE REAR FLOOR FINISH PLATE
4. REMOVE FRONT SEAT BELT SHOULDER ANCHOR
BOLT
5. REMOVE QUARTER TRIM LH AND RH
(a) Quarter trim LH and RH.
(b) Rear seat belt shoulder anchor bolt.
6. REMOVE ROOF SIDE INNER GARNISH
(a) Roof side inner garnish.
(b) Front pillar garnish.
7. REMOVE FRONT AND REAR REMOVABLE ROOF
(a) Disconnect the lock handle from the lock base.
(b) Pull the removable roof rearward to remove it.
8. REMOVE LOCK HANDLE
Remove the 2 screws and lock handle from the removable roof.
9. REMOVE AUXILIARY CATCH

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

HINT: For symbols, capital letters indicate right side of vehicle,
small letters indicate left side of vehicle (Seen from rear).
mm (in.)
(Three-Dimensional Distance)
Hole dia.
6 (0.24) nut
7.5y7.5 (0.295y0.295)
16 (0.63) Name
Back door stopper installation nut-lower
Rear floor finish plate installation hole
Shock absorber installation hole
Roof side rail assembly mark Symbol
c
D, d
E, e
F, f Hole dia.
13 (0.51)
8 (0.31) nut
13 (0.51) Name
Back door opening frame / Roof panel adjoining
portion
Back door hinge installation hole-upper
B
Back door lock striker installation nut-upper
C
Back door hinge installation hole-lower Symbol
A, a
b
BODY OPENING AREAS (REAR View)
BODY DIMENSIONSDIœ6

BE6653
R15784F15319
GL1VGS GL2 (+)
(−)ON
DI−268
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
1996 RAV4 (RM447U)
2 Check voltage between terminals GL1, GL2, VGS of ECU and body ground.
PREPARATION:
(a) Remove the ABS ECU with connectors still connected.
(b) Disconnect the sensor connector.
(c) Turn the ignition switch ON.
4 Door Models:
CHECK:
Measure the voltage between terminals GS1, GS2, VGS of the
ECU and body ground.
OK:
Voltage:
GS1, GL2: 0.5 − 4.5 V
VGS: 4.5 − 5.5 V
NG Check and replace ABS ECU.
OK
Check and replace deceleration sensor.

Q
R
S
T
U
V
W
X
6
B HOW TO USE THIS MANUAL
WITH THE IGNITION SW TURNED ON, THE CURRENT FLOWS TO TERMINAL 3 OF THE POWER WINDOW MASTER SW, TERMINAL 2 OF THE POWER WINDOW CONTROL
RELAY AND TERMINAL 8 OF THE POWER WINDOW SW THROUGH THE DOOR FUSE.
1.DRIVER'S WINDOW MANUAL UPº OPERATION BY MASTER SW
HOLDING MANUAL SW (DRIVER'S) ON UPº POSITION LOCATED IN POWER WINDOW MASTER SW, THE CURRENT FLOWS TO TERMINAL 5 OF THE POWER WINDOW
CONTROL RELAY THROUGH TERMINAL 3 OF THE MASTER SW TERMINAL 2 TO OPERATE A POWER WINDOW CONTROL RELAY. THUS THE CURRENT INSIDE THE RELAY
FLOWS FROM TERMINAL 2 OF THE RELAY TERMINAL 1 TERMINAL 2 OF THE POWER WINDOW MOTOR TERMINAL 1 TERMINAL 4 OF THE RELAY TERMINAL
3 TO GROUND. THE MOTOR TURNS TO ASCENT THE WINDOW. RELEASING THIS SW, THE ROTATION OF MOTOR IS STOPPED AND THE WINDOWS CAN STOP AT WILL
POINT.
(FOR THE MANUAL DOWNº OPERATION, CURRENT FLOWS IN THE REVERSE DIRECTION BECAUSE THE TERMINALS WHERE IT FLOW ARE CHANGED).
2.DRIVER'S WINDOW AUTO DOWNº OPERATION BY MASTER SW
ONCE THE AUTO DOWNº BUTTON OF THE MASTER SW IS PUSHED, THE CURRENT FLOW TERMINAL 9 OF THE POWER WINDOW CONTROL RELAY THROUGH TERMINAL
3 OF THE MASTER SW TERMINALS 8 AND 9 TO OPERATE THE RELAY. THUS THE CURRENT INSIDE THE POWER WINDOW CONTROL RELAY FLOWS FROM TERMINAL
2 OF THE RELAY TERMINAL 4 TERMINAL 1 OF THE POWER WINDOW MOTOR TERMINAL 2 TERMINAL 1 OF THE RELAY TERMINAL 3 TO GROUND.
THE MOTOR CONTINUES THE ROTATION ENABLING TO DESCENT THE WINDOW.
THE WINDOW DESCENDS TO THE END POSITION. THE CURRENT WILL BE CUT OFF TO RELEASE THE AUTO DOWN FUNCTION BASED ON THE INCREASING CURRENT
BETWEEN TERMINAL 2 OF THE RELAY AND TERMINAL 1 IN RELAY.
3.DRIVER'S WINDOW AUTO DOWN RELEASE OPERATION BY MASTER SW
HOLDING THE MANUAL SW (DRIVER'S) ON UPº POSITION IN OPERATING AUTO DOWN. THE CURRENT FROM TERMINAL 3 OF THE MASTER SW PASSING TERMINAL 2
FLOWS TERMINAL 5 OF THE RELAY AND RELEASES THE AUTO DOWN FUNCTION IN THE POWER WINDOW CONTROL RELAY. RELEASING THE HAND FROM SW, WINDOW
STOPS AND CONTINUING ON TOUCHING SW, THE FUNCTION SWITCHES TO MANUAL UP OPERATION.
4.PASSENGER'S WINDOW UP OPERATION (MASTER SW) AND WINDOW LOCK SW OPERATION
HOLDING PASSENGER'S WINDOW SW (MASTER SW) ON UPº, THE CURRENT FLOWS FROM TERMINAL 3 OF THE MASTER SW PASSING TERMINAL 6 TO TERMINAL 3 OF
THE POWER WINDOW SW (PASSENGER'S) TERMINAL 4 TERMINAL 2 OF THE MOTOR TERMINAL 1 TERMINAL 9 OF THE POWER WINDOW SW TERMINAL
7 TERMINAL 1 OF THE MASTER SW TERMINAL 4 TO GROUND. THE MOTOR RUNS TO ASCENT THE WINDOW. RELEASING THIS SW, THE ROTATION OF MOTOR
IS STOPPED AND WINDOW CAN STOP AT WILL PLACE.
SWITCHING THE WINDOW LOCK SW IN LOCKº POSITION, THE CIRCUIT IS OPENED AND STOPPED THE MOTOR ROTATION.
(FOR THE DOWN OPERATION, CURRENT FLOWS IN THE REVERSE DIRECTION BECAUSE THE TERMINALS WHERE IT FLOWS ARE CHANGED).
P 2 POWER WINDOW CONTROL RELAY
3-GROUND: ALWAYS CONTINUITY
2-GROUND: APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION
5-GROUND: APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION AND THE MASTER SW AT UP POSITION
8-GROUND: APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION AND THE MASTER SW AT AUTO DOWN POSITION
9-GROUND: APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION AND THE MASTER SW AT DOWN OR AUTO DOWN POSITION
P 4 POWER WINDOW MASTER SW
4-GROUND: ALWAYS CONTINUITY
3-GROUND: APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION
WINDOW LOCK SW
OPEN WITH THE WINDOW LOCK SW AT LOCK POSITION
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
P 221P 421P 621
P 321P 521
: RELAY BLOCKS
CODESEE PAGERELAY BLOCK (RELAY BLOCK LOCATION)
116R/B NO. 1 (INSTRUMENT PANEL LEFT)
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
3B14J/B NO. 3 AND COWL WIRE (INSTRUMENT PANEL LEFT SIDE)
: CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS
CODESEE PAGEJOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION)
ID126FRONT DOOR RH WIRE AND COWL WIRE (RIGHT KICK PANEL)
IH126FRONT DOOR LH WIRE AND COWL WIRE (LEFT KICK PANEL)
: GROUND POINTS
CODESEE PAGEGROUND POINT LOCATION
IC24COWL LEFT
: SPLICE POINTS
CODESEE PAGEWIRE HARNESS WITH SPLICE POINTSCODESEE PAGEWIRE HARNESS WITH SPLICE POINTS
I 524COWL WIRE
SYSTEM OUTLINE
SERVICE HINTS

Q
R
S
T
U
V
W
X
7
B
:Explains the system outline.
:Indicates values or explains the function for reference during troubleshooting.
:Indicates the reference page showing the position on the vehicle of the parts in the system circuit.
Example: Part P 4º (Power Window Master SW) is on page 21 of the manual.
* The letter in the code is from the first letter of the part, and the number indicates its order
in parts starting with the letter.
Part is 4th in order
Power Window Master SW Example: P
4
:Indicates the reference page showing the position on the vehicle of Relay Block Connectors in the
system circuit.
Example: Connector 1º is described on page 16 of this manual and is installed on the left side of the
instrument panel.
:Indicates the reference page showing the position on the vehicle of J/B and Wire Harness in the system
circuit.
Example: Connector 3Bºconnects the Cowl Wire and J/B No. 3. It is described on page 14 of this
manual, and is installed on the instrument panel left side.
:Indicates the reference page describing the wiring harness and wiring harness connector (the female
wiring harness is shown first, followed by the male wiring harness).
Example: Connector ID1ºconnects the front door RH wire (female) and cowl wire (male). It is described
on page 26 of this manual, and is installed on the right side kick panel.
:Indicates the reference page showing the position of the ground points on the vehicle.
Example: Ground point ICº is described on page 24 of this manual and is installed on the cowl left side.
:Indicates the reference page showing the position of the splice points on the vehicle.
Example: Splice point I 5º is on the Cowl Wire Harness and is described on page 24 of this manual.
HINT:
Junction connector (code: J1, J2, J3, J4, J5, J6, J7, J8,
J9) in this manual include a short terminal which is
connected to a number of wire harnesses. Always
perform inspection with the short terminal installed.
(When installing the wire harnesses, the harnesses
can be connected to any position within the short
terminal grouping. Accordingly, in other vehicles, the
same position in the short terminal may be connected
to a wire harness from a different part.)
Wire harness sharing the same short terminal
grouping have the same color.