1996 TOYOTA RAV4 fuse

V07430
1 Radio NO POWER COMING IN
Is tape player operating normally?Radio assembly faulty. Ye s
No
Check CIG & RAD fuse is OK?
OKNG
Replace fuse.
Is ACC applied to radio?No
ACC wire harness faulty.
Ye s
Check if GND (wire harness side) to radio is OK?NG
GND wire harness faulty.
OK
Radio assembly faulty.
2Radio POWER COMING ON, BUT RADIO NOT OPERATING
A Antenna w/o Motor
Do speakers pop when the volume switch is turned
to maximum and then the power is switch ON?A
Go to No.23.If radio side
faulty
Radio faulty.
No
Is tape player operating normally?
NoYe s
Is power for the antenna
being output from the radio
or radio assembly?No
Radio assembly
faulty.
Does continuity exist in speaker wire harness?
Ye sNo
Speaker wire harness faulty.Ye s
Go to No.23.
If radio side
faulty
Temporarily install another speaker
Function OK?Ye s
Speaker faulty.Radio assembly
faulty.
Radio assembly faulty.No
BE−70
− BODY ELECTRICALAUDIO SYSTEM
1996 RAV4 (RM447U)

V07433
6
RadioSOUND QUALITY POOR
Is sound quality always bad?
Is sound quality bad in
certain areas only? No Yes
Poor signals or poor
location.
No
Go to No.23.
If radio side faulty
Radio assembly faulty.
Is speaker properly installed?No
Install properly.
Ye s
Temporarily install another speaker.
Function OK?Ye s
Speaker faulty.
No
Go to No.17.If radio side faulty
7
RadioCANNOT SET STATION SELECT BUTTON, PRESET
MEMORY DISAPPEARS
Can cassette tape be inserted in tape player?Ye s
Radio assembly faulty.
No
Check if DOME fuse is OK?NG
Replace fuse.
OK
Is +B applied to radio or radio assembly?No
+B wire harness faulty.
Ye s
Check if GND (wire harness side) to
radio assembly is OK?
OKNG
GND faulty.
Radio assembly faulty.Radio assembly faulty.
Radio assembly faulty. Is tape player operating normaly?Ye s
Ye s
No
− BODY ELECTRICALAUDIO SYSTEM
BE−73
1996 RAV4 (RM447U)

V07434
8 Tape Player CASSETTE TAPE CANNOT BE INSERTED
Is there a foreign object inside tape player?Remove foreign object. Ye s
No
Is radio operating normally?Ye s
Radio assembly faulty.
No
Check if DOME fuse is OK?NG
Replace fuse.
OK
No
Is +B applied to radio assembly?+B wire harness faulty.
Ye s
Check if GND (wire harness side) to radio assembly
is OK?
OKNG
GND faulty.
Radio assembly faulty.
9 Tape PlayerCASSETTE TAPE INSERTED, BUT NO POWER
Is radio operating normally?Ye s
Radio assembly faulty.
No
Check if CIG & RAD fuse is OK?NG
Replace fuse.
OK
Is ACC applied to radio assembly?No
ACC wire harness faulty.
Ye s
Radio assembly faulty.
BE−74
− BODY ELECTRICALAUDIO SYSTEM
1996 RAV4 (RM447U)

V07436
14
Tape PlayerAPS, SKIP, RPT BUTTONS NOT OPERATING
Functions OK if different cassette tape inserted?Radio assembly faulty. No
Ye s
Cassette tape faulty. {Less than 3 secs. of silence between songs (APS, RPT).
Less than 15 secs. of silence (SKIP).}
15
Tape Player
CASSETTE TAPE WILL NOT BE EJECTED
Is tape player operating normally?No
Cassette tape jammed.
Is radio operating normally?Ye s
NoYe s
Radio assembly faulty.
Check if DOME fuse is OK?
OKNG
Replace fuse.
Is B+ applied to radio assembly?
Ye s
Radio assembly faulty.No
B+ wire haness faulty.
− BODY ELECTRICALAUDIO SYSTEM
BE−77
1996 RAV4 (RM447U)

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

S01294
CO0BS−03
S01279
Disconnect
S01277
93°C
S01290
Ammeter
Battery
S01291
Ammeter
Battery CO−18
− COOLINGELECTRIC COOLING FAN
1996 RAV4 (RM447U)
ELECTRIC COOLING FAN
ON−VEHICLE INSPECTION
1. CHECK COOLING FAN OPERATION WITH LOW TEM-
PERATURE (Below 83°C (181°F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and ECT switch, and check
for a separated connector or severed wire between the cooling
fan relay and ECT switch.
(c) Disconnect the ECT switch connector.
(d) Check that the cooling fan rotates.
If not, check the fan main relay, cooling fan relay, cooling fan,
fuses, and check for short circuit between the cooling fan relay
and ECT switch.
(e) Reconnect the ECT switch connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEM-
PERATURE (Above 93°C (199°F))
(a) Start the engine, and raise coolant temperature to above
93°C (199°F).
(b) Check that the cooling fan rotates.
If not, replace the ECT switch.
3. INSPECT NO.1 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connec-
tor.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage: 10.9 − 13.9 A
(d) Reconnect the cooling fan connector.
4. INSPECT NO.2 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connec-
tor.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage: 9.1 − 11.1 A
(d) Reconnect the cooling fan connector.

− DIAGNOSTICSENGINE
DI−7
1996 RAV4 (RM447U)
(10) After checking the DTC, inspect the applicable cir-
cuit.
(b) Clear the DTC.
The following actions will erase the DTC and freezed
frame data.
(1) Operating the OBDII scan tool (complying with SAE
J1978) or TOYOTA hand−held tester to erase the
codes.
(See the OBDII scan tool’s instruction book for oper-
ating instructions.)
(2) Disconnecting the battery terminals or EFI fuse.
NOTICE:
If the TOYOTA hand−held tester switches the ECM from
normal mode to check mode or vice−versa, or it the ignition
switch is turned from ON to ACC or OFF during check
mode, the DTC and freezed frame data will be erased.
4. FAIL−SAFE CHART
If any of the following codes is recorded, the ECM enters fail−sate mode.
DTC No.Fail−Safe OperationFail−Safe Deactivation Conditions
P0105Ignition timing fixed at 5° BTDCReturned to normal condition
P0110Intake air temp. is fixed at 68°F (20°C)Returned to normal condition
P0115Engine coolant temp. is fixed at 176°F (80°C)Returned to normal condition
P0120VTA is fixed at 0°
The following condition must be repeated at least
2 times consecutively
When closed throttle position switch is ON:
0.1 V  VTA  0.95 V
P0325Max. timing retardationIgnition switch OFF
P1300Fuel cutIGF signal is detected for 1 ignition
5. CHECK FOR INTERMITTENT PROBLEMS
TOYOTA hand−held tester only:
By putting the vehicle’s ECM in check mode, 1 trip detection logic possible instead of 2 trip detection logic
and sensitivity to detect open circuit is increased. This makes it easier to detect intermittent problems.
(1) Clear the diagnostic trouble codes (See page DI−3)
(2) Set the check mode (See page DI−3)
(3) Perform a simulation test (See page IN−20)
(4) Check the connector and terminal inspection (See page IN−30)
(5) Visual check and contact pressure (See page IN−30)
(6) Handle the connector (See page IN−30)

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