1996 TOYOTA RAV4 coolant

EM1BA−02
S01374
Cover
Connector EM−68
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE BATTERY
2. REMOVE ENGINE HOOD
3. REMOVE ENGINE UNDER COVERS
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL
6. DRAIN TRANSAXLE OIL
7. REMOVE AIR CLEANER CAP AND CASE
8. DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY, CABLE BRACKET AND CLAMPS
9. DISCONNECT ENGINE WIRE FROM RELAY BLOCK
NO. 2
(a) Remove the 2 bolts, and disconnect the relay block No.
2 from the body.
(b) Remove the upper cover.
(c) Disconnect the connector.
(d) Remove the 2 nuts and disconnect the engine wire.
10. REMOVE CHARCOAL CANISTER
11. REMOVE GENERATOR (See page CH−7)
12. REMOVE RADIATOR UPPER AND LOWER HOSES
13. REMOVE WATER INLET
Remove the 2 nuts and water inlet.
14. DISCONNECT HEATER HOSES
15. DISCONNECT FUEL INLET HOSE
CAUTION:
Catch leaking fuel in a container.
16. M/T only:
REMOVE STARTER (See page ST−4)
17. DISCONNECT GROUND CABLE
Remove the bolt and disconnect the ground cable on the trans-
axle.

S01374
Cover
Connector
− ENGINE MECHANICALENGINE UNIT
EM−79
1996 RAV4 (RM447U)
25. INSTALL GENERATOR (See page CH−19)
26. INSTALL CHARCOAL CANISTER
27. CONNECT ENGINE WIRE TO RELAY BOX NO. 2
(a) Connect the engine wire to the relay block No.2 with the
2 nuts.
(b) Connect the connector.
(c) Install the upper cover.
(d) Connect the relay block No. 2 to the body with the 2 bolts.
28. INSTALL ACCELERATOR CABLE TO THROTTLE
BODY, CABLE BRACKET AND CLAMPS
29. INSTALL AIR CLEANER CASE AND CAP
30. INSTALL BATTERY
31. FILL WITH TRANSAXLE OIL
32. FILL WITH ENGINE OIL
33. FILL WITH ENGINE COOLANT
34. START ENGINE AND CHECK FOR LEAKS
35. PERFORM ENGINE ADJUSTMENT
36. CHECK FRONT WHEEL ALIGNMENT
37. INSTALL ENGINE UNDER COVERS
38. INSTALL ENGINE HOOD
39. ROAD TEST VEHICLE
Check for abnormal noises, shock slippage, correct shift points
and smooth operation.
40. RECHECK ENGINE COOLANT AND OIL LEVELS

28
G ELECTRICAL WIRING ROUTING
Position of Parts in Engine Compartment
*1 : w/ A/C
*2 : w/o A/C
A 1 A/C Condenser Fan Motor E 1 Electronically Controlled Transmission Solenoid
A 2 A/C Magnetic Clutch and Lock Sensor E 2 Engine Coolant Temp. Sensor
A 3 A/C Triple Pressure SW (A/C Dual and Single
Pressure SW) F 1 Front Side Marker Light LH
A 4 A/C Water Temp. SW F 2 Front Side Marker Light RH
A 5 A/T Fluid Temp. SW F 3 Front Turn Signal Light LH and Front Parking
A 6 ABS Actuator Light LH
A 7 ABS Actuator F 4 Front Turn Signal Light RH and Front Parking
A 8 ABS Relay Light RH
A 9 ABS Relay F 5 Front Washer Motor
A 10 ABS Speed Sensor Front LH F 6 Front Wiper Motor
A 11 ABS Speed Sensor Front RH F 7 Fusible Link Block
B 1 Back-Up Light SW (M/T) G 1 Generator
B 2 Brake Fluid Level Warning SW G 2Generator
C 1 Center Diff. Lock Warning Buzzer SW H 1 Headlight LH
C 2 Crankshaft Position Sensor H 2 Headlight RH
C 3 Cruise Control Actuator H 3 Horn
D 1 Data Link Connector 1

64
ENGINE CONTROL
THE ENGINE CONTROL SYSTEM UTILIZES A MICROCOMPUTER AND MAINTAINS OVERALL CONTROL OF THE ENGINE ETC. AN
OUTLINE OF ENGINE CONTROL IS GIVEN HERE.
1. INPUT SIGNALS
(1) ENGINE COOLANT TEMP. SENSOR SIGNAL SYSTEM
THE ENGINE COOLANT TEMP. SENSOR DETECTS THE ENGINE COOLANT TEMP. AND HAS A BUILT-IN THERMISTOR WITH A
RESISTANCE WHICH VARIES ACCORDING TO THE ENGINE COOLANT TEMP. THUS THE ENGINE COOLANT TEMP. IS INPUT IN
THE FORM OF A CONTROL SIGNAL TO TERMINAL THW OF THE ENGINE CONTROL MODULE.
(2) INTAKE AIR TEMP. SIGNAL SYSTEM
THE INTAKE AIR TEMP. SENSOR DETECTS THE INTAKE AIR TEMP. , WHICH IS INPUT AS A CONTROL SIGNAL TO TERMINAL THA
OF THE ENGINE CONTROL MODULE.
(3) OXYGEN SENSOR SIGNAL SYSTEM
THE OXYGEN SENSOR DETECTS THE OXYGEN DENSITY IN THE EXHAUST EMISSION WHICH IS INPUT AS A CONTROL SIGNAL
TO TERMINALS OX1 AND OX2 OF THE ENGINE CONTROL MODULE.
(4) THROTTLE SIGNAL SYSTEM
THE THROTTLE POSITION SENSOR DETECTS THE THROTTLE VALVE OPENING ANGLE, WHICH IS INPUT AS A CONTROL
SIGNAL TO TERMINAL VTA OF THE ENGINE CONTROL MODULE, OR WHEN THE VALVE IS FULLY CLOSED.
(5) VEHICLE SPEED CIRCUIT
THE VEHICLE SPEED IS DETECTED BY VEHICLE SPEED SENSOR INSTALLED IN THE TRANSMISSION AND THE SIGNAL IS INPUT
TO TERMINAL SPD OF THE ENGINE CONTROL MODULE VIA THE COMBINATION METER.
(6) PARK/NEUTRAL POSITION SW SIGNAL SYSTEM
THE PARK/NEUTRAL POSITION SW DETECTS WHETHER THE SHIFT POSITION IS IN NEUTRAL OR NOT, AND INPUTS A CONTROL
SIGNAL TO TERMINAL NSW OF THE ENGINE CONTROL MODULE.
(7) A/C SW SIGNAL SYSTEM
THE OPERATING VOLTAGE OF THE A/C MAGNETIC CLUTCH IS DETECTED AND INPUT IN THE FORM OF A CONTROL SIGNAL TO
TERMINAL ACI OF THE ENGINE CONTROL MODULE.
(8) BATTERY SIGNAL SYSTEM
VOLTAGE IS CONSTANTLY APPLIED TO TERMINAL BATT OF THE ENGINE CONTROL MODULE. WHEN THE IGNITION SW IS
TURNED TO ON, VOLTAGE FOR THE ENGINE CONTROL MODULE OPERATION IS APPLIED VIA THE EFI MAIN RELAY TO
TERMINAL +B OF THE ENGINE CONTROL MODULE.
(9) INTAKE AIR VOLUME SIGNAL SYSTEM
INTAKE AIR VOLUME IS DETECTED BY THE MANIFOLD ABSOLUTE PRESSURE SENSOR AND IS INPUT AS A CONTROL SIGNAL
TO TERMINAL PIN OF THE ENGINE CONTROL MODULE.
(10) STARTER SIGNAL SYSTEM
TO CONFIRM THAT THE ENGINE IS CRANKING, THE VOLTAGE APPLIED TO THE STARTER MOTOR DURING CRANKING IS
DETECTED AND IS INPUT AS A CONTROL SIGNAL TO TERMINAL STA OF THE ENGINE CONTROL MODULE.
(11) ELECTRICAL LOAD SIGNAL SYSTEM
THE SIGNAL WHEN SYSTEMS SUCH AS THE REAR WINDOW DEFOGGER, HEADLIGHT, ETC. WHICH CAUSE A HIGH ELECTRICAL
BURDEN ARE ON IS INPUT TO TERMINAL ELS AS A CONTROL SIGNAL.
SYSTEM OUTLINE

68
ENGINE CONTROL
I 4 IG 1 9
C 12
+BB 6
OX1B 5
OX2B 15
TE 1
B 2PIM
B 1VC
B 11VTA
B 3TH A
B 4TH W
B 7PTNK
B 9E2 B- R B- R B-O
BR
BR
Y
BR BR BR
B-R B-R
L-W B- R
BR LG-R
YY
L-R
Y-B
W
L- Y
BR BR
BR
B
B
BR
BR(
SHIELDED) (
SHIELDED)
A 5
G+ A 4
NE+A 17
NE -A 3
IG F
C 17ELS
B 10KNK
2
B B
(
SHIELDED)
(
SHIELDED)
MANIFOLD
ABSO LUTE
PRESSURE
SENSORTHROTTLE
POSITION
SENSOR
FROM TAI
RELAY (
L)
FR O M D EF
RELAY (
L)
CK
SO R ENGINE CONTROL MODULEB E 4 , E 5
AC, E 6
ENSOR
A 2 G-
A 1 G+ IGNITION COIL AND DISTRIBUTOR
I I 2 B1
B2
DISTRIBUTOR
B-O
BB-O
IG N ITIO N
COIL
A 20
IG T
R
G
R
B
L-Y (
SHIELDED)
BRB-O
1 2
1 2
OXYGEN SENSOR
(
BANK 1 SENSO R1)
OXYGEN SENSOR
(
BANK 1 SENSO R2) O 2
O 3
L
TO CRUISE
CONTROL ECU
V V
BR
B BBR
BR (
SHIELDED) (
SHIELDED)
I 5 I 5 I 5 I 4
DATA LINK CO NNECTOR 1 D 1
(
SHIELDED) (
SHIELDED)
B
TO A/C
AM PLIFIER
B-W
I 4W
G
I 5
B I 3 , I 4
A
IG2 8
1 2
CRANKSHAFT POSITION
SENSOR C 2
G
1 2
1 2
1 3 232
E2
Y
R
R
Y
L-Y
VCC PTNK1
G
BL-R
L Y
INTAKE AIR TEM P. SENSOR I 9
DIO
(
EN D 4
LLIG H T
OGGER
KNO
SEN K 1
ENGINE COOLANT TEMP. S E 2
IG 1 5
APOR PRESSURE SENSOR 1
I 5
8 12 3
TE 1+B E1
534
-C B TAC
IG T IG F
21 GNITER
3 1DE
GINE IDLE-UP)
1E2 VC PIM
M 11 432
T 1

71
E 4 (A), E 5 (B), E 6 (C) ENGINE CONTROL MODULE
BATT -E1 : ALWAYS 9.0-14.0 VOLTS
+B -E1 :9.0-14.0 VOLTS (IGNITION SW AT ON POSITION)
VC -E2 :4-5-5.5 VOLTS (IGNITION SW AT ON POSITION)
VTA -E2 :0.3-0.8 VOLTS (IGNITION SW ON AND THROTTLE VALVE FULLY CLOSED)
:3.2-4.9 VOLTS (IGNITION SW ON AND THROTTLE VALVE OPEN)
PIM -E2 :3.3-3.9 VOLTS (IGNITION SW AT ON POSITION)
#10,#20, #30, #40-E01, E02 : 9.0-14.0 VOLTS (IGNITION SW AT ON POSITION)
THA -E2 :0.5-3.4 VOLTS (IGNITION SW ON AND THE INTAKE AIR TEMP 20
C, 68
F)
THW -E2 :0.2-1.0 VOLTS (IGNITION SW ON AND THE COOLANT TEMP 80
C, 176
F)
STA -E1 :6.0-14.0 VOLTS (ENGINE CRANKING)
IGT -E1 :0.8-1.2 VOLTS (ENGINE CRANKING OR IDLING)
W -E1 :9.0-14.0 VOLTS (NO TROUBLE AND ENGINE RUNNING)
ACT -E1 :4.5-5.5 VOLTS (IGNITION SW ON AND AIR CONDITIONING ON)
AC1 -E1 :0-3.0 VOLTS (IGNITION SW ON AND AIR CONDITIONING ON)
ISCO, ISCC-E1 :9.0-14.0 VOLTS (IGNITION SW AT ON POSITION)
TE1 -E1 :9.0-14.0 VOLTS (IGNITION SW ON AND DATA LINK CONNECTOR 1 TE1-E1 NOT CONNECTED)
:0-3.0 VOLTS (IGNITION SW ON AND DATA LINK CONNECTOR 1 TE1-E1 CONNECTED)
NSW -E1 :0-3.0 VOLTS (IGNITION SW ON AND PARK/NEUTRAL POSITION SW P OR N RANGE)
:9.0-14.0 VOLTS (IGNITION SW ON AND PARK/NEUTRAL POSITION SW EXCEPT POSITION P AND N RANGE)
RESISTANCE OF ENGINE CONTROL MODULE WIRING CONNECTOR
(DISCONNECT WIRING CONNECTOR)
VTA -E2 :3.3-10.0 KW (THROTTLE VALVE FULLY OPEN)
:0.2-0.8 KW (THROTTLE VALVE FULLY CLOSED)
VC -E2 :3.0-7.0 KW
THA -E2 :2.0-3.0 KW (INTAKE AIR TEMP 20
C, 68
F)
THW -E2 :0.2-0.4 KW (COOLANT TEMP 80
C, 176
F)
G+ -G- :0.17-0.21 KW
ISCO, ISCC-+B :19.3-22.3 W
(5) CIRCUIT OPENING RELAY
(5) 3 -(5) 5 : CLOSED WITH THE IGNITION SW ON OR ST POSITION
(6) EFI MAIN RELAY
(6) 3-(6) 5 : CLOSED WITH THE IGNITION SW ON OR ST POSITION
E 2 ENGINE COOLANT TEMP. SENSOR
1-2 :14.6-17.8 KW (-20
C, -4
F)
5.88 KW (0
C, 32
F)
2.21-2.69 KW (20
C, 68
F)
1.14 KW (40
C, 104
F)
0.584 KW (60
C, 140
F)
0.29-0.354 KW (80
C, 176
F)
I 5, I 6, I 7, I 8 INJECTOR
1-2 : APPROX. 13.8 W
T 1 THROTTLE POSITION SENSOR
3-1 :0.2-5.7 KW WITH CLEARANCE BETWEEN LEVER AND THE STOP SCREW 0 MM (0 IN.)
3-1 :2.0-10.2 KW WITH THROTTLE VALVE FULLY OPEN
2-1 : LESS THAN 2.3 KW WITH CLEARANCE BETWEEN THE LEVER AND THE STOP SCREW 0.5 MM (0.02 IN.)
WITH CLEARANCE BETWEEN LEVER AND THE STOP SCREW 0.7 MM (0.028 IN.)
SERVICE HINTS

130
ELECTRONICALLY CONTROLLED TRANSMISSION
THIS SYSTEM ELECTRONICALLY CONTROLS THE GEAR SHIFT TIMING, LOCK-UP TIMING, THE CLUTCH AND BRAKE HYDRAULIC
PRESSURE, AND THE ENGINE TORQUE DURING SHIFTING TO ACHIEVE OPTIMUM SHIFT FEELING.
IN ACCORDING TO THE VEHICLE DRIVING CONDITIONS AND ENGINE OPERATING CONDITIONS AS DETECTED BY VARIOUS
SENSORS.
1. GEAR SHIFT OPERATION
DURING DRIVING, THE ENGINE CONTROL MODULE SELECTS THE SHIFT FOR EACH GEAR WHICH IS MOST APPROPRIATE TO THE
DRIVING CONDITIONS, BASED ON INPUT SIGNALS FROM THE ENGINE COOLANT TEMP. SENSOR TO TERMINAL THW OF THE
ENGINE CONTROL MODULE, AND ALSO THE INPUT SIGNALS TO TERMINAL SPD OF THE ENGINE CONTROL MODULE FROM THE
SPEEDOMETER DEVOTED TO THE ELECTRONICALLY CONTROLLED TRANSMISSION. CURRENT IS THEN OUTPUT TO THE
ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID. WHEN SHIFTING TO 1ST SPEED, CURRENT FLOWS FROM TERMINAL
S1 OF THE ENGINE CONTROL MODULE "TERMINAL
(A) 3 (2WD) OR (B) 3 (4WD) OF THE ELECTRONICALLY CONTROLLED
TRANSMISSION SOLENOID "GROUND, AND CONTINUES TO THE NO. 1 SOLENOID CAUSES THE SHIFT.
FOR 2ND SPEED, CURRENT FLOWS FROM TERMINAL S1 OF THE ENGINE CONTROL MODULE "TERMINAL 3 OF THE
ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID "GROUND, AND FROM TERMINAL S2 OF THE ENGINE CONTROL
MODULE "TERMINAL
(A) 1 (2WD) OR (B) 6 (4WD) OF THE ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID "
GROUND, AND CONTINUES TO SOLENOIDS NO. 1 AND NO. 2 CAUSES THE SHIFT.
FOR 3RD SPEED, THERE IS NO CONTINUOUS TO NO. 1 SOLENOID, ONLY TO NO. 2 CAUSING THE SHIFT.
SHIFTING INTO 4TH SPEED (OVERDRIVE) TAKES PLACE WHEN THERE IS NO CONTINUOUS TO EITHER NO. 1 OR NO. 2 SOLENOID.
2. LOCK-UP OPERATION
WHEN THE ENGINE CONTROL MODULE JUDGES FROM EACH SIGNAL THAT LOCK-UP OPERATION CONDITIONS HAVE BEEN MET,
CURRENT FLOWS FROM TERMINAL SL OF THE ENGINE CONTROL MODULE "TERMINAL
(A) 2 (2WD) OR (B) 5 (4WD) OF THE
ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID "GROUND, CONTINUES TO THE LOCK-UP SOLENOID AND CAUSING
LOCK-UP OPERATION.
3. STOP LIGHT SW CIRCUIT
IF THE BRAKE PEDAL IS DEPRESSED (STOP LIGHT SW ON) WHEN DRIVING IN LOCK-UP CONDITION, A SIGNAL IS INPUT TO
TERMINAL B/K OF THE ENGINE CONTROL MODULE, THE ENGINE CONTROL MODULE OPERATES AND CURRENT TO THE LOCK-UP
SOLENOID IS CUT.
4. OVERDRIVE CIRCUIT
*O/D MAIN SW ON
WHEN THE O/D MAIN SW IS TURNED ON (SW POINT IS OPEN), A SIGNAL IS INPUT TO TERMINAL OD2 OF THE ENGINE CONTROL
MODULE AND ENGINE CONTROL MODULE OPERATION CAUSES GEAR SHIFT WHEN THE CONDITIONS FOR OVERDRIVE ARE MET.
*O/D MAIN SW OFF
WHEN THE O/D MAIN SW IS TURNED OFF (SW POINT IS CLOSED), THE CURRENT FLOWING THROUGH THE O/D OFF INDICATOR
LIGHT FLOWS THROUGH THE O/D MAIN SW TO GROUND. CAUSING THE INDICATOR LIGHT TO LIGHT UP. AT THE SAME TIME, A
SIGNAL IS INPUT TO TERMINAL OD2 OF THE ENGINE CONTROL MODULE AND ENGINE CONTROL MODULE OPERATION
PREVENTS SHIFT INTO OVERDRIVE.
SYSTEM OUTLINE

133
I 4 I 4 B 2PIM
B 1VC
B 11VTA
B 3TH A
B 4THW
B 7PTN K
B 9E2
Y
BR BR BR
LG-R
YY
L-R
Y-B
W
BR BR
BR
BR
BR SENSOR
OR
ENGINE CONTROL M ODULEB E 4 , E 5AC, E 6
B 15
L-W
A 2
A 15 A1C13 C3C2A8A7B14 B13
TE1S1
S2 SL ST SLD+ SLD- FR+ FR- RR+ RR-
P-B
P
Y-B
LG
L- B
BR-B
Y-R
W-R
L- Y
R-L
I 5 I 5 I 5 TO CRUISE
CONTROL ECUIG 2 14 IG 2 13
IG 2 12 A 3
B 3A 1A2(
2W D)
B 1(
4W D)
B 5 B 6
(
4W D)
(
4W D)(
4WD)
(
4WD)
(
4W D)
(
4W D)
(
4W D)
(
4W D)L-B
BR - B LG
B E 1 , A
ELECTRO NICALLY
CONTROLLED
TRANSM ISSION SOLENOID
(
4W D)(
4W D)
I 5 P
PFROM CRUISE CONTROL ECU
1 31212 SOLENOID VALVE
SLD S 1
VEHICLE SPEED
SENSOR (
FRO N T) V 3
VEHICLE SPEED
SENSOR (
REAR) V 4
1 2
1 2
11 1 3 2432
32
E2
L Y
BR
BR
Y
L- Y
VCC PTNK
L-R
L Y M 1
MANIFOLD ABSOLUTE
PRESSURE SENSOR
THRO TTLE
POSITION T 1
INTAKE AIR TEMP. SENS I 9
ENGINE COOLANT
TEM P
. SE
NSOR E 2
VAPOR PRESSURE
SENSOR V 1 8
B-RDATA LINK
CONNECTOR 1 D 1
12I 5
IG 1 5
E2 VC PIM
+B TE1