1996 TOYOTA RAV4 coolant
[x] Cancel search: coolantPage 904 of 1354
135
E 4 (A), E 5 (B), E 6 (C) ENGINE CONTROL MODULE
BATT -E1 :9.0-14.0 VOLTS (ALWAYS)
+B -E1 :9.0-14.0 VOLTS (IGNITION SW ON)
VTA -E2 :3.2-4.9 VOLTS (IGNITION SW ON AND THROTTLE VALVE OPEN)
PIM -E2 :3.3-3.9 VOLTS (IGNITION SW AT ON POSITION)
VC -E2 :4.5-5.5 VOLTS (IGNITION SW ON)
SPD -E2 :4.5-5.5 VOLTS (IGNITION SW AT ON POSITION)
THW -E2 :0.2-1.0 VOLTS (IGNITION SW ON AND COOLANT TEMP. 80C (176F))
B/K -E1 :9.0-14.0 VOLTS (BRAKE PEDAL DEPRESS)
S1, S2 -E1 :9.0-14.0 VOLTS WITH THE IGNITION SW ON (ENGINE RUNNING)
OD2 -E1 :0-3.0 VOLTS WITH THE O/D MAIN SW TURNED ON
:9.0-14.0 VOLTS WITH THE O/D MAIN SW TURNED OFF
2-E1 :7.5-14.0 VOLTS WITH THE SHIFT LEVER AT 2 POSITION
:0-1.5 VOLTS WITH THE SHIFT LEVER AT EXCEPT 2 POSITION
L-E1 :7.5-14.0 VOLTS WITH THE SHIFT LEVER AT L POSITION
:0.1.5 VOLTS WITH THE SHIFT LEVER AT EXCEPT L POSITION
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
C 9A30F 728M 129
C10B30F 831O 431
D 128I 929P1A29
E1A28I1031P 1B29E 1B28J 131S 129
E 228J 231T 129
E 331J 331V 129
E 4A31J 531V 229
E 5B31J10A31V 329
E 6C31J11B31V 429
: RELAY BLOCKS
CODESEE PAGERELAY BLOCKS (RELAY BLOCK LOCATION)
223R/B NO. 2 (ENGINE COMPARTMENT LEFT)
625R/B NO. 6 (ENGINE COMPARTMENT LEFT)
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
1B20INSTRUMENT PANEL WIRE AND J/B NO 1 (LOWER FINISH PANEL)1D20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1E20FUSE BLOCK ASSY WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1H20INSTRUMENT PANEL WIRE AND J/B NO 1 (LOWER FINISH PANEL)1J20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
: 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)
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 PANEL CENTER)
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
EA34RADIATOR RIGHT
EC34INTAKE MANIFOLD
IG36RIGHT KICK PANEL
: SPLICE POINTS
CODESEE PAGEWIRE HARNESS WITH SPLICE POINTSCODESEE PAGEWIRE HARNESS WITH SPLICE POINTS
E 134ENGINE ROOM MAIN WIREI 538ENGINE WIRE
I 438ENGINE WIRE
SERVICE HINTS
Page 928 of 1354
159
FAN MOTOR OPERATION
WHEN THE IGNITION SW IS TURNED ON, CURRENT FROM THE ECU-IG FUSE FLOWS TO THE FAN NO. 1 RELAY (COIL SIDE) AND
THE FAN NO. 2 RELAY (COIL SIDE) "TERMINAL 2 OF THE A/C SINGLE PRESSURE SW "TERMINAL 3 "TERMINAL 2 OF THE A/C
WATER TEMP. SW "TERMINAL 1 "GROUND, AND THE FAN NO. 1 RELAY AND THE FAN NO. 2 RELAY ARE TURNED ON.
AT THE SAME TIME THAT THIS CURRENT FLOWS, CURRENT FROM THE ECU-IG FUSE FLOWS TO THE E/G MAIN RELAY (COIL
SIDE) "GROUND, AND THE E/G MAIN RELAY IS TURNED ON. AS A RESULT, CURRENT FROM THE ALT FUSE FLOWS TO THE CDS
FA N FUSE AND RDI FAN FUSE.
*LOW SPEED OPERATION
WHEN THE IGNITION SW IS TURNED ON AND THE A/C IS ACTIVATED, CURRENT FLOWS FROM THE MG/C RELAY (POINT SIDE) "
THE FAN NO. 3 RELAY (COIL SIDE) "GROUND, AND THE FAN NO. 3 RELAY IS TURNED ON. AS A RESULT, CURRENT FROM THE
CDS FAN FUSE FLOWS TO TERMINAL 2 OF THE A/C CONDENSER FAN MOTOR "TERMINAL 1 "THE FAN NO. 2 RELAY (POINT
SIDE) "THE FAN NO. 3 RELAY (POINT SIDE) "TERMINAL 2 OF THE RADIATOR FAN MOTOR "TERMINAL 1 "GROUND, AND
BOTH OF THE FAN MOTORS, WITH THE RESULT THAT THE FANS ARE ACTIVATED AT LOW SPEED.
IF THE ENGINE COOLANT TEMPERATURE IS APPROX. 90C (194F) OR LESS, AND THE REFRIGERANT PRESSURE IS APPROX.
15.5 KG/CM
2 (1323 KPA, 191.7 PSI) OR LESS, BOTH THE A/C WATER TEMP. SW AND THE A/C SINGLE PRESSURE SW ARE CLOSED,
SO THAT THE FAN NO. 1 RELAY AND THE FAN NO. 2 RELAY ARE TURNED ON. AS A RESULT, BOTH OF THE FAN MOTOR OPERATE
AT LOW SPEED.
*HIGH SPEED OPERATION
WHEN, DURING A/C OPERATION, THE REFRIGERANT PRESSURE BECOMES HIGHER THAN ORDINARY LEVEL (APPROX. 15.5
KG/CM
2 (1323 PSI. 191.7 KPA)), THE A/C SINGLE PRESSURE SW IS TURNED OFF. AS A RESULT, THE FAN NO. 1 RELAY AND THE
FAN NO. 2 RELAY ARE TURNED OFF, AND THE CURRENT FLOWS FROM THE RDI FAN FUSE TO FAN NO. 1 RELAY (POINT SIDE) "
TERMINAL 2 OF THE RADIATOR FAN MOTOR "TERMINAL 1 "GROUND, AND CURRENT FROM THE CDS FAN FUSE FLOWS TO
TERMINAL 2 OF THE A/C CONDENSER FAN MOTOR "TERMINAL 1 "THE FAN NO. 2 RELAY (POINT SIDE) "GROUND, AND TO
BOTH OF THE FAN MOTORS IN PARALLEL, THUS CAUSING THE FAN MOTORS TO OPERATE AT HIGH SPEED.
NOTE THAT, BECAUSE THE CURRENT FLOWS IN THE SAME MANNER EVEN IF THE COOLANT TEMPERATURE IS APPROX. 90C
(194F) OR HIGHER, THE FAN MOTORS STILL OPERATE AT HIGH SPEED.
A 3 A/C SINGLE PRESSURE SW
2-3 : OPEN ABOVE APPROX. 15.5 KG/CM2 (191.7 PSI, 1323 KPA)
CLOSE BELOW APPROX. 12.5 KG/CM2 (142 PSI, 980 KPA)A 4 A/C WATER TEMP. SW
1-2 : OPEN ABOVE APPROX. 90C (194F)
CLOSED BELOW APPROX. 83C (181.4F)
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
A 128F 728R 129
A 328F 831
A 428J 131
: RELAY BLOCKS
CODESEE PAGERELAY BLOCKS (RELAY BLOCK LOCATION)
223R/B NO. 2 (ENGINE COMPARTMENT LEFT)
625R/B NO. 6 (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)
1E20FUSE BLOCK ASSY WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
: CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS
CODESEE PAGEJOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION)
IB236ENGINE ROOM MAIN WIRE AND INSTRUMENT PANEL WIRE (RIGHT KICK PANEL)
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
EA34RADIATOR RIGHT
EB34RADIATOR LEFT
SYSTEM OUTLINE
SERVICE HINTS
Page 941 of 1354
K OVERALL ELECTRICAL WIRING DIAGRAM
1
234
2 RAV4
ACC
IG1
IG2
ST2 AM1
6 7AM2
1H 14
21E 2
5566 21I 171B 1 8IG1
11 IB 1
2 1
5 3
2 1
5 31 2
1 2
1 2
1 2 3IG1
20 IB2 7EA1 11 IG1
1C 12A 11A 10A12 C A 8 B 22 A 23 A 6 B
2B 7B C C C C
14C13 21
1 2
1 2
B
B-R
R- W LG
B-OB R- Y Y- GL
L-Y
B-O
B-R B-RB-R B-R B-R
B-R
B-L B- Y R- WP B-W
B- R B- R
B- O B-Y
B-Y
B-R
B-R B-O B-O
B-Y
B-R
B-Y
B- RB-OB-R B-Y
B-R B-R B-R B-R
B- O
FC ELS ACT AC1 OD1 PTNK PIM17 15
21
20
2
80A MAIN
5566
4ID1
EA BH
L-B B-R
11 2
A A53
5 BB4A 17A C
L-WRG R
C
14 A A
16B A4BE1 EO2 EO3 IG F TH W
B 1BVTA VC
B
B
L- Y
B WL
L- R
Y
11 12 2
LG-RBR
BR BR
BR BR BR
BR
BR BR BRY
432 323
E2 E2
R-W
2EA1 I10
IG NIT IO N SW
I 5
IN JE C TO R NO . 1 I 7
IN JE C TO R NO . 3 I 6
IN JE C TO R NO . 2 I 8
IN JE C TO R NO . 4
R- W
9
5
11
I 1
IDLE AIR CONTROL VALVEV 9
VSV(
Vapor Pressure Sensor) V 8
VSV(
EVAP) V 7
VSV(
EG R) O 3
OXYGEN SENSOR(
Bank 1 Sensor 2)
2
BR
BATT # 10 # 20 +B ISCO ISCC TPC EVP EGR OX1 OX2
20A A M2E F I M A IN R EL AY
CIRCUIT OPENING RELAYF11
FUEL PU M P
Under the center
p illar L HR adiator right
From D iode(
Engine Idle-Up)
< 8- 2 <12-4
E 4 A , E 6 C
J 1
JUNCTION
CONNECTOR From A/C A mplifier
<20-4 To A/C Amplifier
<20-4 To Cruise Control ECU
<13-4
PTN K VCC PIM VCV 1
VAPOR PRESSURE SENSOR M 1
MANIFOLD ABSOLUTE PRESSURE SENSOR
16
F rom M alfunction Indicator
Lamp[Comb. M eter]< 18-2
From Igniter
<5-4
26 3
T 1
THROTTLE POSITION SENSOR
E 2
ENG INE COOLANT TEMP. SENSORI 9
INTAKE AIR TEM P. SENSOR
TE1 W N E+ N E- SD LE1
AB D 1
DATA LINK
CONNECTOR
1
ENGINE CONTROL MODULE
Power
SourceEngine Control
BATTERY
G-R
B-R G-R
, E 5 B
B- O
17
M 54
W-B
L-BW-B W-B
20 10 21C
G-W(
A/T)B/KFrom Stop Light SW
<9-34 22C
B-W(
A/T)NSWTo P ark /N eutral
Position SW<1-3C
To ST Relay< 1-3 B-W(
M/T)
STA
11
R-W F 8
7. 5A O B D
[FUSE BLOCK]
F 7
FUSIBLE LINK BLOCK G-R
IG 1 9
15
B-R
9BR
20B BKNK E2
B
A IG T
10
15A EFI16 2
171D 8
1E 9
100A ALT62 2
W
W
1F 8
1K 1
R-W
#30 25 A
#40 24 A2 1
1 2
5IG1
Y-B(
A/T)To Cruise C ontrol
E CU < 13- 3
BR
EC Intake manifold 11
TC
O 2
OXYGEN SENSOR(
Bank 1 Sensor 1)
Y
Y
1 THA
B 3
Y-BK 1
KNOCK SENSOR
EO1
13ABRBR BR
5A
G+ 10
F 8
7. 5A IG N
[FUSE BLOCK]B-O11
1E 1
1J 2B-O
W
IG Right kick panel
(
SH IE LD E D)
A A
AA
A
A
A
A
A
A
(SHIELDED)
(
SHIELDED)
AAB
AA
(
SHIELDED)54 216
IG 211
BR
BR
BR
BR
(
SHIELDED)
12
34567891011 12 13
14 15
16 17 18 19 20 21 22 2324 25 2612345678
9 1011121314151612
34567891011
12 13
14 15 16 17 18 19 20 2122
J10 A , J11 B
JUNCTIO N CONNECTOR
AAAAAA
BBBCCC B E 5 D AR K G RAY CE 6 DARK GRAY
B J11A J10
GRAY A E 4 DARK GRAY
ENGINE CONTROL MODULEJUNCTION CONNECTOR
J 2
JU NC T IO N
CONNECTOR
BR BR BR BRW-BW-B
SG CG SD L BAT
(
SHIELDED)
W WW-LBR BRL
W
D 2
DATA LINK CONNECTOR 3
GRAY
C SPD
To S peedometer[C omb. M eter]
<18-19V- W
B(
A/T)
To ST Relay< 1-3 C 2
CRANKSHAFT POSITION SEN SORFrom Ignition Coil
and D istributor< 5-3
2
1
G WW From C ruise C ontrol
ECU< 13-4
From Airbag Sensor
Assembly< 11-2
+B 12
B-R8TE1
From
Airbag
Sensor
Assembly
<11-2
W-L
Page 993 of 1354
LU06A−03
S01365
S01359
SST
S01366
LU−18
− LUBRICATIONOIL COOLER
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE FRONT EXHAUST PIPE (See page EM−33)
4. REMOVE GENERATOR (See page CH−7)
5. REMOVE OIL DIPSTICK
6. REMOVE EXHAUST MANIFOLD AND FRONT TWC
ASSEMBLY (See page EM−33)
7. REMOVE WATER BYPASS PIPE HEAT PROTECTOR
Remove the bolt, 2 nuts and heat protector.
8. REMOVE OIL FILTER
Using SST, remove the oil filter.
SST 09228−06501
9. REMOVE OIL COOLER
(a) Disconnect the 2 water bypass hoses from the oil cooler.
(b) Remove the union bolt and plate washer.
(c) Remove the nut and oil cooler.
(d) Remove the O−ring from the oil cooler.
Page 995 of 1354
LU06C−02
LU−20
− LUBRICATIONOIL COOLER
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL OIL COOLER
(a) Clean the oil cooler contact surface on the oil cooler
mounting.
(b) Install a new O−ring to the oil cooler.
(c) Temporarily install the oil cooler with the nut.
(d) Apply a light coat of engine oil on the threads and under
the head of the relief valve.
(e) Install the plate washer and union bolt.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
(f) Tighten the nut.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(g) Connect the 2 water bypass hoses to the oil cooler.
2. INSTALL OIL FILTER
3. INSTALL WATER BYPASS HOSE HEAT PROTECTOR
Install the heat protector with the bolt and 2 nuts.
4. INSTALL EXHAUST MANIFOLD AND FRONT TWC AS-
SEMBLY (See page EM−55)
5. INSTALL OIL DIPSTICK
6. INSTALL GENERATOR (See page CH−19)
7. INSTALL FRONT EXHAUST PIPE (See page EM−55)
8. FILL WITH ENGINE COOLANT
9. START ENGINE AND CHECK FOR LEAKS
10. CHECK ENGINE OIL LEVEL
11. INSTALL RH ENGINE UNDER COVER
Page 997 of 1354
MX05N−02
Q10400
Air Intake Connector
Engine Coolant
Reservoir Tank Clutch Release Cylinder
and Line
Vehicle Speed
Sensor Connector
Back−Up Light Switch
Connector
Control Cable
Clip
Ground Cable
Transaxle Case Protector
Tie Rod End RH Drive Shaft
Stiffener PlateNo.2 Rear
End Plate
Snap Ring
Cotter Pin LH Drive
Shaft
PS Gear Assembly
Engine Mounting
Center Member
RH Engine
Under Cover
LH Engine Under CoverFront Suspension Crossmember
Assembly with Stabilizer BarClipAir Cleaner Case
Assembly
with Air Hose
Snap Ring
Engine
Wire
Clamp
Cotter Pin
Lock Cap Starter
N·m (kgf·cm, ft·lbf): Specified torque
Non−reusable part
4.9 (50, 43 in.·lbf)
12 (120, 9)
29 (300, 22)
35 (360, 26)32 (330, 24)46 (470, 34)
64 (650, 47)
35 (360, 26)
64 (650, 47)
12 (120, 9)
64 (650, 47)
25 (250, 18)
25 (250, 18)
9.0 (95, 78 in.·lbf)
37 (380, 27)
39 (400, 29)
9.0 (95, 78 in.·lbf)
29 (300, 22)
37 (380, 27)49 (500, 36)
113 (1,150, 83)
137 (1,400, 101)
206 (2,100, 152)
216 (2,200, 159)
113 (1,150, 83)
64 (650, 47)
48 (490, 35)
80 (820, 59)
115 (1,170, 85)
127 (1,300, 94)
62 (630, 46)
Front Exhaust Pipe
GasketClip
Washer
MX−2
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
1996 RAV4 (RM447U)
MANUAL TRANSAXLE UNIT (2WD)
COMPONENTS
Page 998 of 1354
MX05O−02
Q08747
Q08748
A
B
Q08749
Q08750
A B
A
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
MX−3
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR
HOSE
2. REMOVE ENGINE COOLANT RESERVOIR TANK
3. REMOVE ENGINE WIRE CLAMP SET NUT
4. REMOVE STARTER
(a) Disconnect the connector and wire from the starter.
(b) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
5. DISCONNECT CLUTCH RELEASE CYLINDER AND
LINE
(a) Remove the 2 set bolts of the clutch line bracket.
Torque:
Bolt A: 12 N·m (120 kgf·cm, 9 ft·lbf)
Bolt B: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
(b) Remove the 2 bolts, release cylinder and line.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
6. DISCONNECT GROUND CABLE
Remove the set bolt of the ground cable from the transaxle.
7. DISCONNECT VEHICLE SPEED SENSOR AND
BACK−UP LIGHT SWITCH CONNECTORS
8. DISCONNECT CONTROL CABLE
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
9. REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING
BOLTS
Torque:
Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf)
Bolt B: 35 N·m (360 kgf·cm, 26 ft·lbf)
Page 1244 of 1354
SF0QQ−03
S01905
(4) (3)
(2)
(1)
S01907
A
B
Protrusion
(Bolt: Type A)
(Nut: Type B)B A
S01902
(1)
(3)(2) SF−30
− SFITHROTTLE BODY
1996 RAV4 (RM447U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. A/T:
DISCONNECT THROTTLE CABLE FROM THROTTLE
BODY
3. DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
4. REMOVE AIR CLEANER CAP ASSEMBLY (See page
ST−4)
5. REMOVE THROTTLE BODY
(a) Disconnect the throttle position sensor connector.
(b) Disconnect the IAC valve connector.
(c) Disconnect these hoses from the throttle body:
(1) PCV hose from air tube
(2) Vacuum hose from port ”R” of EGR vacuum modu-
lator
(3) Vacuum hose from port ”P” of EGR vacuum modu-
lator
(4) EVAP hose from chacoal canister
(d) Remove the 4 bolts (Type A) or the 2 bolts, 2 nuts (Type
B) and gasket, and diaconnect the throttle body from the
intake manifold.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
HINT:
At the time of installation, plaese refer to the following items.
Place a new gasket on the intake chamber, facing the pro-
trusion downward.
Each bolt is indicated in the illustration (Type A).
Bolt length:
A: 40 mm (1.57 in.)
B: 55 mm (2.17 in.)
(e) Disconnect these hoses from the throttle body:
(1) Water bypass hose from water outlet
(2) Water bypass hose from water bypass pipe
(3) Air hose from intake manifold