1996 TOYOTA RAV4 check engine light

Q06117
AX055−02
AT5641
Q057310.8−1.5 mm (0.031−0.059 in.) 200 mm (7.87 in.)
− AUTOMATIC TRANSAXLE (A241E)THROTTLE CABLE
AX−9
1996 RAV4 (RM447U)
THROTTLE CABLE
ON−VEHICLE REPAIR
1. DISCONNECT THROTTLE CABLE FROM ENGINE
2. REMOVE NO.2 ENGINE UNDER COVER
3. REMOVE PARK/NEUTRAL POSITION SWITCH (See
page AX−4)
4. REMOVE VALVE BODY (See page AX−5)
5. REMOVE THROTTLE CABLE
(a) Remove the retaining bolt and plate.
(b) Pull out the cable from the transaxle case.
6. INSTALL THROTTLE CABLE
If throttle cable is new, do the following operations (a) − (c).
(a) Bend the cable so there is a radius of about 200 mm (7.87
in.).
(b) Pull theinner cable lightly until a slight resistance is felt,
and hold it.
(c) Stake the stopper 0.8 − 1.5 mm (0.031 − 0.059 in.) from
the end of outer cable.
(d) Be sure to push it in all the way.
(e) Install the bolt.
7. INSTALL VALVE BODY (See page AX−5)
8. INSTALL PARK/NEUTRAL POSITION SWITCH (See
page AX−4)
9. INSTALL NO.2 ENGINE UNDER COVER
10. CONNECT THROTTLE CABLE
11. ADJUST THROTTLE CABLE (See page DI−127)
12. FILL ATF AND CHECK ATF (See page DI−127)

R10851
Pedal Height Push RodStop Light
Switch
BR1DV−01
BR4980
R00935
Pedal Freeplay BR−6
− BRAKEBRAKE PEDAL
1996 RAV4 (RM447U)
BRAKE PEDAL
ON−VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
157.1 − 167.1 mm (6.185 − 6.579 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop
light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(f) Install the stop light switch and turn it until it lightly con-
tacts with the pedal stopper.
(g) Turn the stop light switch back one turn.
(h) Check the clearance (A) between stop light switch and
pedal.
Clearance: 0.5 − 2.4 mm (0.020 − 0.094 in.)
(i) Tighten the stop light switch lock nut.
(j) Connect the connector to the stop light switch.
(k) Check that the stop lights come on when the brake pedal
is depressed, and go off when the brake pedal is re-
leased.
(l) After adjusting the pedal height, check the pedal freeplay.
HINT:
If clearance (A) between the stop light switch and the brake
pedal stopper has been adjusted correctly, the pedal freeplay
will meet the specifications.
3. CHECK PEDAL FREEPLAY
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the resistance begins to
be felt, then measure the distance, as shown.
Pedal freeplay: 1 − 6 mm (0.04 − 0.24 in.)

R00934
Pedal Reverse
Distance
− BRAKEBRAKE PEDAL
BR−7
1996 RAV4 (RM447U)
HINT:
The freeplay to the 1st point of resistance is due to the play be-
tween the clevis and pin. It is 1 − 3 mm (0.04 − 0.12 in.) on the
pedal.
If incorrect, check the stop light switch clearance. If the clear-
ance is OK, then troubleshoot the brake system.
4. CHECK PEDAL RESERVE DISTANCE
(a) Release the parking brake.
(b) With the engine running, depress the pedal and measure
the pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf): More than 75 mm (2.95 in.)
If the reserve distance is incorrect, troubleshoot the brake sys-
tem.

BR2237
BR02Q−02
BR2238
GOOD
1st2nd3rdNO GOOD BR−16
− BRAKEBRAKE BOOSTER ASSEMBLY
1996 RAV4 (RM447U)
BRAKE BOOSTER ASSEMBLY
ON−VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine
OFF and check that there is no change in the pedal re-
serve distance.
(b) Depress the brake pedal and start the engine.
If the pedal goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down farthest at the 1st time, but gradually
rises after at the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed.
If there is no change in the pedal reserve travel after holding the
pedal for 30 seconds, the booster is air−tight.

DI3Z6−01
ENGINE CONTROL SYSTEM Check Sheet
Customer’s Name
Driver’s Name
Data Vehicle
Brought in
License No.
Model and Model
Year
Frame No.
Engine Model
Odometer Reading
km
miles
Problem Symptoms
Engine does
not Start
Difficult to
Start
Poor Idling
Poor
Driveaability
Engine Stall
Others
Engine does not crankNo initial combustionNo complete combustion
Engine cranks slowly
Other
Incorrect first idleIdling rpm is abnormalHigh ( rpm)Low ( rpm)
Rough idling
Other
HesitationBack fireMuffler explosion (after−fire)Surging
Knocking
Other
Soon after startingAfter accelerator pedal depressed
After accelerator pedal released
During A/C operation
Shifting from N to D
Other
Datas Problem
Occurred
Problem Frequency
Condition When
Problem Occurs
Weather
Engine Operation
Engine Temp. Place Outdoor
TemperatureConstant
Sometimes ( times per day/month)Once only
Other
Fine
CloudyRainySnowyVarious/Other
Hot
Warm CoolCold (approx. °F/ °C)
Highway
SuburbsInner CityUphillDownhill
Rough road
Other
Cold
Warming upAfter Warming upAny temp.Other
Starting
Just after starting ( min.)IdlingRacing
Driving
Constant speedAccelerationDeceleration
A/C switch ON/OFF
Other
Condition of MILRemains on Sometimes light up Does not light up
NormalMalfunction code(s) (code )
Freeze frame data ( )
NormalMalfunction code(s) (code )
Freeze frame data ( )
Normal mode
(Precheck)
Check Mode DTC InspectionInspector’s
Name
DI−2
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
CUSTOMER PROBLEM ANALYSIS CHECK

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.

N09214
DLC 3 DI−4
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
By switching the ECM to check mode when trouble-
shooting, the technician can cause the MIL to light
up for a malfunction that is only detected once or
momentarily (TOYOTA hand−held tester only) (See
page DI−3).
*2 trip detection logic:
When a logic malfunction is first detected, the mal-
function is temporarily stored in the ECM memory.
If the same malfunction is detected again during the
second drive test, this second detection causes the
MIL to light up.
The 2 trip repeats the same mode a 2nd time. (How-
ever, the IG switch must be turned OFF between the
1st trip and 2nd trip).
Freeze frame data:
Freeze frame data records the engine condition
when a misfire (DTC P0300 − P0304) or fuel trim
malfunction (DTC P0171, P0172), or other malfunc-
tion (first malfunction only), is detected.
Because freeze frame data records the engine
conditions (fuel system, calculator load, engine
coolant temperature, fuel trim, engine speed, ve-
hicle speed, etc.) when the malfunction is detected,
when troubleshooting it is useful for determining
whether the vehicle was running or stopped, the en-
gine warmed up or not, the air−fuel ratio lean or rich,
etc. at the time of the malfunction.
Priorities for Troubleshooting:
If troubleshooting priorities for multiple diagnostic
codes are given in the applicable diagnostic chart,
these should be followed.
If no instructions are given, troubleshoot DTC according to the
following priorities.
(1) DTC other than fuel trim malfunction (DTC P0171,
P0172), EGR (DTC P0401, P0402), and misfire
(DTC P0300 − P0304).
(2) Fuel trim malfunction (DTC P0171, P0172) and
EGR (DTC P0401, P0402).
(3) Misfire (DTC P0300 − P0304).
(b) Check the DLC3.
The vehicle’s ECM uses V.P.W. (Variable Pulse Width) for
communication to comply with SAE J1850. The terminal
arrangement of DLC3 complies with SAE J1962 and
matches the V.P.W. format.

S02459
− DIAGNOSTICSENGINE
DI−5
1996 RAV4 (RM447U) Terminal No.
Connection / Voltage or ResistanceCondition
2Bus  Line / Pulse generationDuring transmission
4Chassis Ground / ↔ Body Ground 1 Ω or lessAlways
5Signal Ground / ↔ Body Ground 1 Ω or lessAlways
16Battery Positive / ↔ Body Ground 9 ∼ 14VAlways
HINT:
If your display shows ”UNABLE TO CONNECT TO VEHICLE”
when you have connected the cable of the OBDII scan tool or
TOYOTA hand−held tester to DLC3, turned the ignition switch
ON and operated the scan tool, there is a problem on the ve-
hicle side or tool side.
If communication is normal when the tool is connected to
another vehicle, inspect DLC3 on the original vehicle.
If communication is still not possible when the tool is con-
nected to another vehicle, the problem is probably in the
tool itself, so consult the Service Department listed in the
tool’s instruction manual.
2. INSPECT DIAGNOSIS (Normal Mode)
(a) Check the MIL.
(1) The MIL comes on when the ignition switch is turned
ON and the engine is not running.
HINT:
If the MIL does not light up, troubleshoot the combination meter.
(2) When the engine is started, the MIL should go off.
If the lamp remains on,the diagnosis system has
detected a malfunction or abnormality in the sys-
tem.
(b) Check the DTC.
NOTICE:
TOYOTA hand−held tester only:
When the diagnosis system is switched from normal mode
to check mode, it erases all DTC and freezed frame data re-
corded in normal mode. So before switching modes, al-
ways check the DTC and freezed frame data, and note them
down.
(1) Prepare the OBDII scan tool (complying with SAE
J1978) or TOYOTA hand−held tester.
(2) Connect the OBDII scan tool or TOYOTA hand−
held tester to DLC3 at the lower of the instrument
panel.
(3) Turn the ignition switch ON and turn the OBDII scan
tool or TOYOTA hand−held tester switch ON.
(4) Use the OBDII scan tool or TOYOTA hand−held tes-
ter to check the DTC and freezed frame data, note
them down.
(5) See page DI−14 to confirm the details of the
DTC.