Ignition Switch and Key Unlock Warning Switch Inspection

BE10
BODY ELECTRICAL
IGNITION SWITCH AND KEY UNLOCK WARNING

SWITCH
IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH

LOCATION
1996 RAV4 (RM447U)
BE0J304
BODY ELECTRICAL

SWITCH
BE11
BE0J404
INSPECTION
1.
4
8
3
7
2
6
1
5
N11771
INSPECT IGNITION SWITCH CONTINUITY

Switch position
Tester connection
Specified condition
LOCK
No continuity
ACC
23
Continuity
ON
2 3 4, 6 7
Continuity
START
124, 678
Continuity
If continuity is not as specified, replace the switch.

2.
OFF
2 1
ON
INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY

Switch position
Tester connection
Specified condition
SW OFF
(Key removed)
No continuity
SW ON (Key set)
12
Continuity

Z10028
3.
(a)
(b)
(c)
Key Unlock Warning System:

INSPECT INTEGRATION RELAY OPERATION
Connect the positive (+) lead from the battery to terminal
A1.
Connect the negative () lead from the battery to terminals A5, A6 and A10.
Check the buzzer sounds.
N01923
(d)
(e)
Disconnect the negative () lead from the battery to terminals A6.

Check that the buzzer stops sounding.
N01924
(f)
Connect the negative () lead from the battery to terminals A6.

(g) Disconnect the negative () lead from the battery to terminals A5.
(h) Check that the buzzer stops sounding.
If operation is not as specified, replace the relay.
N01925
1996 RAV4 (RM447U)
BE12
BODY ELECTRICAL
4.
5.
1996 RAV4 (RM447U)

SWITCH
INSPECT INTEGRATION RELAY CIRCUIT (See page

BE37)
INSPECT DOOR COURTESY SWITCH CONTINUITY
(See Page BE22)
BE13
BODY ELECTRICAL
HEADLIGHT AND TAILLIGHT SYSTEM

LOCATION
1996 RAV4 (RM447U)
BE0J506
BE14
BODY ELECTRICAL

BE0J601
COMPONENTS
Wiper and Washer Switch
Light Control Switch
Switch Body
Spiral Cable
N17327
1996 RAV4 (RM447U)
BE15
BODY ELECTRICAL
HEAD
TAI L
OFF

BE1MW01
INSPECTION
Right
1.
Flash
Left
INSPECT LIGHT CONTROL SWITCH CONTINUITY

Switch position
Tester connection
Specified condition
OFF
No continuity
TAIL
14 16
Continuity
HEAD
13 14 16
Continuity

2.
INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY
8
Switch position
Tester connection
Specified condition
Flash
7 8 16
Continuity
Low beam
16 17
Continuity
High beam
7 16
Continuity
17 16
14 13
Z17623
3.
2
INSPECT HEADLIGHT CONTROL RELAY CONTINUITY

Condition
Tester connection
Specified condition
Constant
34
Continuity
Apply B+ between
terminals 3 and 4.
12
Continuity
If continuity is not as specified, replace the relay.

Z13558
4.
3
INSPECT TAILLIGHT CONTROL RELAY CONTINUITY

Condition
Tester connection
Specified condition
Constant
12
Continuity
Apply B+ between
terminals 1 and 2.
35
Continuity
Z05657
5.
Lighton Warning System:

INSPECT INTEGRATION RELAY OPERATION
(a) Connect the positive (+) lead from the battery to terminal
1 and 12, the negative () lead to terminals 10.
(b) Check that the buzzer sounds when the negative () lead
from the battery is connected to terminal 6.
6.
INSPECT DOOR COURTESY SWITCH CONTINUITY(See pageBE22)
1996 RAV4 (RM447U)
BE16
BODY ELECTRICAL
ADJUSTMENT
1.
(a)
Beam Angle Gauge

(Vertical Direction)
OK
Beam is
Downward
BE1MX01
ADJUST HEADLIGHT AIM

Do the following before inspection.
S
Make sure that the body around the headlight is not
deformed.
S
Park the vehicle on a level spot.
S
The driver gets into the drivers seat and puts the
vehicle in a state ready for driving (with a full tank).
S
Bounce the vehicle several times.
(b) Adjust the headlight aim in vertical direction.

If the bubble is outside the acceptable range of the beam angle
gauge, adjust it by using adjusting screw A.
OK
Front
Beam is
Upward
OK
Bubble
N18226
Beam Angle Gauge

(Horizontal Direction)
O Reading
Acceptable Range
Front
1996 RAV4 (RM447U)
Adjusting
Screw B
Z17543
(c) Adjust the headlight aim in horizontal direction.

If 0 mark is not within the acceptable range, adjust the 0
reading to the 0 mark using adjusting screw B.
BE17
BODY ELECTRICAL
Beam Angle Gauge

(Vertical Direction)
Beam is
Downward
OK
OK
Beam is
Upward
Bubble
N18226
Beam Angle Gauge

Acceptable Range
O Reading
2.
(a)
(b)
ADJUST HEADLIGHT AIM

Replace the headlight.
Do the following before inspection.
S
Make sure that the body around the headlight is not
deformed.
S
Park the vehicle on a level spot.
S
The driver gets into the drivers seat and puts the
vehicle in a state ready for driving (with a full tank).
S
Bounce the vehicle several times.
(c)
Adjust the headlight aim in vertical direction.

(1) Using adjusting screw A, adjustment the headlight
aim to within the specifications.
(2) Make sure that the gauge bubble is within the acceptable range.
OK
Front
HINT:
If the gauge bubble is outside the acceptable range, check that
the vehicle is parked on a level spot.
Readjust the headlight aim after parking the vehicle on a level
spot.
(d) Adjust the headlight aim in horizontal direction.
Using adjusting screw B, adjust the headlight aim to within
the specifications.
Holder Assembly
Front
Adjusting
Screw B
Z17544
Holer Assembly
3.
O Reading
Adjusting Screw B
N18085
Temporary Pawl
Pawl
O Reading
N18086
1996 RAV4 (RM447U)
HOW TO RESET LH AND RH AIMING INDICATORS

(Unlocking method)
HINT:
These operations should be done only when the head adjustment of the headlight aim is necessary, for example in case the
headlight aim 0 mark deviates from the acceptable range
when the headlight is reassembled after repair.
(a) Turn the adjusting screw B to the right, and remove the
holder assembly from the cylindrical part of the housing.
(b)
Unlock the holder assembly.
BE18
BODY ELECTRICAL
(c)
Insert the holder assembly, unlock in step (b), to the screw

and housing again.
HINT:
When the assembly is inserted till the pawl for temporary set is
hooded to the cross slit of the housing as shown in view A, setting is completed.
Temporary
Pawl
O Reading
View A
View A
Temporary Pawl
N18087
Beam Angle Gauge

Acceptable Range
O Reading
(e)
Holder Assembly
Front
Adjusting
Screw B
Z17544
1996 RAV4 (RM447U)
(d)
Turn the adjusting screw B to the left and adjust the LH

and RH headlight aims.
Pull the holder assembly backwards and lock it.
BE19
BODY ELECTRICAL
TURN SIGNAL AND HAZARD WARNING SYSTEM

LOCATION
1996 RAV4 (RM447U)
BE0J905
BE20
BODY ELECTRICAL

BE0JA01
INSPECTION
Right
1.
Left
INSPECT TURN SIGNAL SWITCH CONTINUITY

Switch position
Tester connection
Specified condition
Left turn
12
Continuity
Neutral
No continuity
Right turn
23
Continuity
Z17622
2.
4 3
2 1
10 9 8 7 6 5
INSPECT HAZARD WARNING SWITCH CONTINUITY

Switch position
Tester connection
Specified condition
Switch OFF
7 10
Continuity
Switch ON
4569
78
Continuity
Illumination circuit
23
Continuity

Z07679
3.
(a)
(b)
1
BE1843
1996 RAV4 (RM447U)
INSPECT TURN SIGNAL FLASHER OPERATION

2 and the negative () lead to terminal 3.
Connect the 2 turn signal light bulbs parallel to each other
to terminals 1 and 3, check that the bulbs flash.
HINT:
The turn signal lights should flash 60 or 120 times per minute.
If one of the front or rear turn signal lights has an open circuit,
the number of flashing will be more than 140 per minute.
If operation is not as specified, replace the flasher.
BE24
BODY ELECTRICAL
BACKUP LIGHT SYSTEM
BACKUP LIGHT SYSTEM

LOCATION
1996 RAV4 (RM447U)
BE0JD05
BE25
BODY ELECTRICAL
BACKUP LIGHT SYSTEM

BE0JE02
INSPECTION
1.
Push
Free
BE2682
1996 RAV4 (RM447U)
INSPECT BACKUP LIGHT SWITCH CONTINUITY

Switch position
Tester connection
Specified condition
Free
12
No continuity
Push
12
Continuity

2.
INSPECT PARK/NEUTRAL POSITION SWITCH (See
page DI156, DI218)
BE26
BODY ELECTRICAL
STOP LIGHT SYSTEM
STOP LIGHT SYSTEM

LOCATION
1996 RAV4 (RM447U)
BE0JF06
BE27
BODY ELECTRICAL
STOP LIGHT SYSTEM

BE0JG01
INSPECTION
INSPECT STOP LIGHT SWITCH CONTINUITY
4
2
1996 RAV4 (RM447U)
3
1
4
Z05647
Switch position
Tester connection
Specified condition
Switch pin free

(Pedal depressed)
12
Continuity
Switch pin pushed in

(Pedal released)
34
No continuity
BE28
BODY ELECTRICAL
WIPER AND WASHER SYSTEM

LOCATION
1996 RAV4 (RM447U)
BE0JH06
BE29
BODY ELECTRICAL
Washer
Washer
1.
INSPECT FRONT WIPER SWITCH CONTINUITY

Switch position
Tester connection
Specified condition
OFF
7 16
Continuity
INT
7 16
Continuity
LO
7 17
Continuity
HI
8 17
Continuity
INT
HI
BE27101
INSPECTION
OFF
LO

2.
INSPECT FRONT WASHER SWITCH CONTINUITY
Switch position
Tester connection
Specified condition
OFF
No continuity
ON
2 11
Continuity
17
11
16
N20863
3.
(a)
(b)
7
17
(c)
(d)
16
N17243
INSPECT INTERMITTENT WIPER OPERATION

Turn the wiper switch to the INT position.
Turn the intermittent time control switch to the FAST position.
Connect the positive (+) lead from the voltmeter to terminal 7 and the negative () lead to terminal 16, check that
the meter needle indicates battery positive voltage.
(e)
After connecting terminal 2 to terminal 17, connect to terminal 16.

(f)
Then, check that the voltage rises from 0 V to battery positive voltage within the times, as shown in the table.
If operation is not as specified, replace the switch.
7 2
17
INT time control

switch position
16
N17244
FAST
SLOW
Voltage
Approx. 1 3 sec.
Battery positive voltage
0 volt
Approx. 10 15 sec.
Battery positive voltage
0 volt
V03883
1996 RAV4 (RM447U)
BE30
BODY ELECTRICAL
4.
Washer 1
ON
INT
OFF
Washer 2
INSPECT REAR WIPER AND WASHER SWITCH CONTINUITY

Switch position
Tester connection
Specified condition
Washer 1
2 16
Continuity
Wiper OFF
No continuity
Wiper INT
10 16
Continuity
Wiper ON
1 16
Continuity
Washer 2
1 2 16
Continuity

2 1
10
16
N20864
5.
(a)
INSPECT REAR WIPER RELAY CONTINUITY

Check that no continuity exists between terminals 3 and
4.
(b) Check that continuity exists between terminals 4 and 5.
Relay Side
6 5 4 3
Z09992
6.
(a)
Battery Voltage
4
3
No Voltage 6
5
N05767
2
4
Within 9
to 15
Seconds
3
5
N05768
1996 RAV4 (RM447U)
INSPECT REAR WIPER RELAY OPERATION

(b) Connect the positive (+) lead from the voltmeter to terminal 5 and the negative () lead to terminal 6, check that
the meter needle indicates 0 volts.
(c) Connect the positive (+) lead from the voltmeter to terminal 4 and the negative () lead to terminal 6, check that
the meter needle indicates battery positive voltage.
7.
INSPECT REAR WIPER RELAY INTERMITTENT OPERATION
(a) Connect the positive (+) lead from the battery to terminal
5 and the negative () lead to terminal 2 more than 2 seconds.
(b) Connect the positive (+) lead from the voltmeter to terminal 4 and the negative () lead to terminal 2.
BE31
BODY ELECTRICAL
(c)
After disconnecting the positive (+) lead from terminal 5

connect it to terminal 3, and than, check that the meter
needle rises from 0 volts to battery positive voltage within
9 to 15 seconds.
8.
(a)
INSPECT FRONT WIPER MOTOR OPERATION

Inspect the motor operation at low speed.
3 and the negative () lead from the battery to terminal 1,
check that the motor operates at low speed.
If operation is not as specified, replace the motor.
N05769
(b)
Inspect the motor operation at high speed.

2 and the negative () lead from the battery to terminal 1,
check that the motor operates at high speed.
2
1
N05770
(c)
Inspect the motor operation when stopping it.

(1) Operate the motor at low speed and stop the motor
operation anywhere except at the stop position by
disconnecting the positive (+) lead from terminal 3.
N05771
(2)
(3)
Connect terminals 3 and 5.

Connect the positive (+) lead from the battery to terminal 6 and negative () lead from the battery terminal 1, check that the motor stops running at the stop
position after the motor operates again.
5
6
N05772
1996 RAV4 (RM447U)
BE32
BODY ELECTRICAL
9.
(a)
INSPECT REAR WIPER MOTOR OPERATION

4 and the negative () lead to the motor body, check that
the motor operates.
N11726
(b)
Operate the motor and stop the motor operation anywhere except at the stop position by disconnecting the
positive (+) lead from terminal 4.
N11727
(c)
(d)
Connect terminals 2 and 4.

1 and the negative () lead to the motor body, check that
the motor stops running at the stop position after the motor operates again.
1
N11728
10. INSPECT WASHER MOTOR OPERATION

Connect the positive (+) lead from the battery to terminal 2 and
the negative () lead to terminal 1, check that the motor operates.
NOTICE:
These tests must be performed quickly (within 20 seconds)
to prevent the coil from burning out.
2
1
I01272
1996 RAV4 (RM447U)
BE44
BODY ELECTRICAL
DEFOGGER SYSTEM
DEFOGGER SYSTEM
Repair Point
ONVEHICLE REPAIR
Broken
Wire
Masking Tape
BE0150
IF NECESSARY,REPAIR DEFOGGER WIRE

(a) Clean the broken wire tips with grease, wax and silicone
remover.
(b) Place the masking tape along both sides of the wire to be
repaired.
(c) Thoroughly mix the repair agent (Dupont paste No.
4817).
(d)
(e)
(f)
BE0151
1996 RAV4 (RM447U)
BE27401
Using a fine tip brush, apply a small amount to the wire.

After a few minutes, remove the masking tape.
Do not repair the defogger wire for at least 24 hours.
BE45
BODY ELECTRICAL
LOCATION
1996 RAV4 (RM447U)
DEFOGGER SYSTEM
BE0JM06
BE46
BODY ELECTRICAL
DEFOGGER SYSTEM
BE27501
INSPECTION
1.
Z13284
INSPECT DEFOGGER SWITCH CONTINUITY

Switch position
Tester connection
Specified condition
Switch OFF
No continuity
Switch ON
358
Continuity
Switch ON
35
Continuity
26
Continuity

2.
INSPECT DEFOGGER RELAY CONTINUITY
Condition
Tester connection
Specified condition
Constant
12
Continuity
Apply B + between
terminal 1 and 2.
35
Continuity
Z05657
Tester Probe
Heat Wire
Tin Foil
BE4029
3.
INSPECT DEFOGGER WIRE
NOTICE:
S
When cleaning the glass, use a soft, dry cloth, and
wipe the glass in the direction of the wire. Take care
not to damage the wires.
S
Do not use detergents or glass cleaners with abrasive
ingredients.
S
When measuring voltage, wind a piece of tin foil
around the top of the negative probe and press the foil
against the wire with your finger, as shown.
(a) Turn the ignition switch ON.
(b) Turn the defogger switch ON.
(c) Inspect the voltage at the center of each heat wire, as
shown in the table below.
Voltage
Criteria
Approx. 5V
Okay (No break in wire)
Approx. 10V or 0V
Broken wire
HINT:
If there is approximately 10 V, the wire is broken between the
center of the wire and the positive (+) end. If there is no voltage,
the wire is broken between the center of the wire and ground.
1996 RAV4 (RM447U)
BE47
BODY ELECTRICAL
At Center
DEFOGGER SYSTEM
(d)
Place the voltmeter positive (+) lead against the defogger

positive (+) terminal.
(e)
Place the voltmeter negative () lead with the foil strip

against the heat wire at the positive (+) terminal end and
slide it toward the negative () terminal end.
The point where the voltmeter deflects from zero to several V is the place where the heat wire is broken.
BE0123
Several Volts
0 Volts
(f)
Broken
Wire
V
BE0124
1996 RAV4 (RM447U)
HINT:
If the heat wire is not broken, the voltmeter indicates 0 V at the
positive (+) end of the heat wire but gradually increases to about
12 V as the meter probe moves to the other end.
BE48
BODY ELECTRICAL
POWER WINDOW CONTROL SYSTEM

LOCATION
1996 RAV4 (RM447U)
BE0JP05
BE49
BODY ELECTRICAL
1996 RAV4 (RM447U)
BE50
BODY ELECTRICAL

BE27601
INSPECTION
1.
Z13573
3 Door models:
INSPECT POWER WINDOW MASTER SWITCH CONTINUITY
Drivers Switch:
Switch position
Tester connection
Specified condition
UP
39
46
Continuity
OFF
346
Continuity
DOWN
36
49
Continuity
Passenger s Switch (Window unlock):

Switch position
Tester connection
Specified condition
UP
67
9 10
Continuity
OFF
6 7 10
Continuity
DOWN
79
6 10
Continuity
Passenger s Switch (Window lock):

Switch position
Tester connection
Specified condition
UP
9 10
Continuity
OFF
7 10
Continuity
DOWN
79
Continuity
2.
5 Door models:
INSPECT POWER WINDOW MASTER SWITCH CONTINUITY
Drivers Switch:
Switch position
Tester connection
UP
1 13
67
Continuity
OFF
1 6 13
Continuity
DOWN
16
7 13
Continuity
Z15858
Specified condition
Passenger s Switch (Window unlock):
1996 RAV4 (RM447U)
Switch position
Tester connection
Specified condition
UP
15
7 12
Continuity
OFF
1 5 12
Continuity
DOWN
1 12
57
Continuity
BE51
BODY ELECTRICAL
Passenger s Switch (Window lock):

Switch position
Tester connection
UP
7 12
Continuity
Specified condition
OFF
5 12
Continuity
DOWN
57
Continuity
Rear LH side switch (Window lock):

Switch position
Tester connection
Specified condition
UP
19
7 10
Continuity
OFF
1 9 10
Continuity
DOWN
1 10
79
Continuity
Rear LH side switch (Window lock):

Switch position
Tester connection
Specified condition
UP
7 10
Continuity
OFF
9 10
Continuity
DOWN
79
Continuity
Rear RH side switch (Window lock):

Switch position
Tester connection
Specified condition
UP
1 14
7 11
Continuity
OFF
1 11 14
Continuity
DOWN
1 11
7 14
Continuity
Rear RH side switch (Window lock):

Switch position
Tester connection
Specified condition
UP
7 11
Continuity
OFF
11 14
Continuity
DOWN
7 14
Continuity
3.
3 Door models:
INSPECT SWITCH ILLUMINATION
Connect the positive (+) lead from the battery to terminal 9, and
the negative () lead to terminal 6, and check that all the illuminations light up.
If operation is not as specified, replace the master switch.
1996 RAV4 (RM447U)
BE52
BODY ELECTRICAL
4.
Wire Harness Side

3 4
5 Door models
INSPECT SWITCH ILLUMINATION
Connect the positive (+) lead from the battery to terminal 7 and
the negative () lead to terminal 1 check that all the illuminations
light up.
5.
3 Door models:
INSPECT ONE TOUCH POWER WINDOW SYSTEM
(a) Using an ammeter, inspect the system.
(1) Disconnect the connector from the master switch.
(2) Connect the positive (+) lead from the ammeter to
terminal 3 on the wire harness side connector and
the negative () lead to the negative () terminal of
the battery.
(3) Connect the positive (+) lead from the battery to terminal 4 on the wire harness side connector.
Z10673
Wire Harness Side

3 4
Z10674
(4)
(5)
HINT:
The circuit breaker opens some 4 40 seconds after the window stops going down, so that check must be made before the
circuit breaker operates.
If the operation is not as specified, replace the master switch.
(b) Using an ammeter with a current measurement probe, inspect the system.
(1) Remove the master switch with connector connected.
(2)
(3)
Z10675
1996 RAV4 (RM447U)
As the window goes down, check that the current

flow is approximately 7 amperes.
Check that the current increases up to approximately 14.5 amperes or more when the window
stops going down.
Attach a currentmeasuring probe to terminal 3 of

the wire harness.
Turn the ignition switch ON and set the power window switch in the down position.
BE53
BODY ELECTRICAL
(4)
(5)
Z10676
As the window goes down, check that the current is

approximately 7 amperes.
stops going down.
HINT:
6.
5 Door models:
INSPECT ONE TOUCH POWER WINDOW SYSTEM
(a) Using an ammeter, inspect the system.
(1) Disconnect the connector from the master switch.
(2)
(3)
(4)
(5)
Connect the positive (+) lead from the ammeter to

terminal 6 on the wire harness side connector and
the negative () lead to negative () terminal of the
battery.
Connect the positive (+) lead from the battery to terminal 13 on the wire harness side connector.
As the window goes down, check that the current

flow is approximately 7 amperes.
Check that the current increases up to approximately 14.5 A or more when the window stops going
down.
HINT:
If the operation is not as specified, replace the master switch.
(b) Using an ammeter with a current measurement probe, inspect the system.
(1) Remove the master switch with connector connected.
1996 RAV4 (RM447U)
BE54
BODY ELECTRICAL
(2)
Attach a currentmeasuring probe to terminal 6 of

the wire harness.
Turn the ignition switch ON and set the power window switch in the down position.
(3)
(4)
As the window goes down, check that the current is

approximately 7 amperes.
stops going down.
(5)
HINT:
7.
INSPECT FRONT POWER WINDOW SWITCH CONTINUITY
Switch position
Tester connection
Specified condition
UP
1 2, 3 4
Continuity
OFF
1 2, 3 5
Continuity
DOWN
1 4, 3 5
Continuity

Z10844
8.
UP
DOWN
Z15867
Switch position
Tester connection
Specified condition
UP
1 2, 3 4
Continuity
OFF
1 2, 4 5
Continuity
DOWN
2 3, 4 5
Continuity

9.
(a)
1996 RAV4 (RM447U)
5 Door models:
INSPECT REAR POWER WINDOW SWITCH CONTINUITY
Drivers door of 3 door models:

INSPECT POWER WINDOW MOTOR OPERATION
1 and the negative () lead to terminal 2, check that the
motor turns counterclockwise.
BE55
BODY ELECTRICAL
(b)
Reverse the polarity, check that the motor turns counterclockwise.

10.
(a)
Passenger s door of 3 door models:

motor turns clockwise.
N11404
(b)
2
Revers the polarity, check that the motor turns counterclockwise.

N11405
11.
(a)
Drivers door of 5 door models:

Z15868
Z15869
1996 RAV4 (RM447U)
(b)

BE56
BODY ELECTRICAL
12.
(a)
Passenger s door of 5 door models:

Z15870
(b)

Z15871
13.
(a)
5 Door models:
INSPECT LH REAR POWER WINDOW MOTOR OPERATION
Z15872
(b)

Z15873
14.
(a)
Z15874
1996 RAV4 (RM447U)
5 Door models:
INSPECT RH REAR POWER WINDOW MOTOR OPERATION
BE57
BODY ELECTRICAL
(b)

Z15875
15.
UP
5 Door
(a)
UP
3 Door
within
4 to 40
seconds
Drivers Door:
INSPECT CIRCUIT BREAKER OPERATION
With the window in the fully closed position, hold the power window switch in UP position and check that there is
a circuit breaker operation noise within 4 to 40 seconds.
Z17551
5 Door
(b)
DOWN
DOWN
With the window in the fully closed position, hold the

switch in DOWN position and check that the window begins to descend within 60 seconds.
3 Door
within
60
seconds
Z17552
16.
(a)
UP
Passenger s Door:
within
4 to 40
seconds
Z10682
(b)

DOWN
within
60 seconds
Z10683
1996 RAV4 (RM447U)
BE58
BODY ELECTRICAL
17.
UP
(a)
Rear door of 5 door models:

within
4 to 40
seconds
Z17553
(b)

within
60 seconds
DOWN
Z17554
18.
3
Z05657
1996 RAV4 (RM447U)
INSPECT POWER MAIN RELAY CONTINUITY

Condition
Tester connection
Specified condition
Constant
12
Continuity
Apply B+ between
terminals 1 and 2
35
Continuity
BE64
BODY ELECTRICAL
POWER MIRROR CONTROL SYSTEM

LOCATION
1996 RAV4 (RM447U)
BE0JV06
BE65
BODY ELECTRICAL

BE1N101
INSPECTION
1.
OFF
LEFT SIDE
RIGHT SIDE
UP
LEFT
OFF
RIGHT
Z06854
Tester connection
Specified condition
OFF
No continuity
UP
1 10, 3 4
Continuity
DOWN
1 3, 4 10
Continuity
LEFT
1 9, 3 4
Continuity
RIGHT
1 3, 4 9
Continuity
Switch Position
Tester connection
Specified condition
OFF
No continuity
(b)
2
UP
1 6, 3 4
Continuity
DOWN
1 3, 4 6
Continuity
LEFT
1 2, 3 4
Continuity
RIGHT
1 3, 2 4
Continuity

2.
(a)
Switch Position
Right Side:
DOWN
INSPECT MIRROR CONTROL SWITCH CONTINUITY

Left side:
INSPECT MIRROR MOTOR OPERATION

3 and the negative () lead to terminal 2, and check that
the mirror turns upward.
Reverse the polarity, and check that the mirror turns
downward.
3
N11748
(c)
1

1 and the negative () lead to terminal 2, and check that
the mirror turns left side
(d) Reverse the polarity, and check that the mirror turns right
side.
If operation is not as specified, replace the mirror assembly.
2
N11749
1996 RAV4 (RM447U)
BE66
BODY ELECTRICAL
AUDIO SYSTEM
AUDIO SYSTEM
BE0JX01
DESCRIPTION
1.
RADIO WAVE BAND
The radio wave bands used in radio broadcasting are as follows:

30 kHz
Frequency
Designation
3 MHz
300 kHz
LF
MF
AM
Radio wave
Modulation method
30 MHz
300 MHz
VHF
HF
FM
Amplitude modulation
Frequency modulation
LF: Low frequency MF: Medium Frequency HF: High Frequency VHF: Very High Frequency
FM (Stereo)
FM(Monaural)
AM
BE2818
Fading
(1)
lonosphere
BE2819
1996 RAV4 (RM447U)
2.
SERVICE AREA
There are great differences in the size of the service area for
AM, FM monaural, and FM stereo broadcasts cannot be received even though AM comes in very clearly.
Not only does FM stereo have the smallest service area, but it
also picks up static and other types of interference (noise)
easily.
3.
RECEPTION PROBLEMS
Besides the problem of static, there are also the problems
called fading, multipath and fade out. These problems are
caused not by electrical noise but by the nature of the radio
waves themselves.
Fading:
Besides electrical interference, AM broadcasts are
also susceptible to other types of interference, especially at night. This is because AM radio waves
bounce off the ionosphere at night. These radio
waves then interfere with the signals from the same
transmitter that reach the vehicles antenna directly.
This type of interference is called fading.
BE67
BODY ELECTRICAL
Multipath
AUDIO SYSTEM
(2)
Multipath:
One type of interference caused by the bouncing of
radio waves off of obstructions is called multipath.
Multipath occurs when a signal from the broadcast
transmitter antenna bounces off buildings and
mountains and interferes with the signal that is received directly.
(3)
Fade Out:
Because FM radio waves are of higher frequencies
than AM radio waves, they bounce off buildings,
mountains, and other obstructions. For this reason,
FM signals often seem to gradually disappear or
fade away as the vehicle goes behind a building or
other obstruction. This is called fade out.
BE2820
Fade Out
BE2821
4.
Example
Head
Capstan
(a)
(b)
Pinch Roller
1996 RAV4 (RM447U)
N17398
Tape Player/Head Cleaning:

MAINTENANCE
Raise the cassette door with your finger.
Then, using a pencil or like object, push in the guide.
Using a cleaning pen or cotton applicator soaked in cleaner, clean the head surface, punch rollers and capstans.
BE68
BODY ELECTRICAL
AUDIO SYSTEM
BE27701
TROUBLESHOOTING
NOTICE:
When replacing the internal mechanism (computer part) of the audio system, be careful that no part
of your body or clothing comes in contact with the terminals of the leads from the IC etc. of the replacement part (spare part).
HINT:
This inspection procedure is a simple troubleshooting which should be carried out on the vehicle during system operation and was prepared on the assumption of system component troubles (except for the wires and
connectors, etc.).
Always inspect the trouble taking the following items into consideration.
S
Open or short circuit of the wire harness
S
Connector or terminal connection fault
Radio
Tape Player
Problem
No.
No power coming in.
Power coming in, but radio not operating.
Noise present, but AM FM not operating.
Either speaker does not work.
Either AM or FM does not work.
Reception poor (Volume faint).
Few preset tuning bands.
Sound quality poor.
Cannot set station select button.
Preset memory disappears.
Cassette tape cannot be inserted.
Cassette tape inserted, but no power.
Power coming in, but tape player not operating.
10
Either speaker does not work.
11
Sound quality poor (Volume faint).
12
Tape jammed, malfunction with tape speed or autoreverse.
13
APS, SKIP, RPT buttons not operating.
14
Cassette tape will not ejected.
15
Antenna
Antennarelated.
16
Noise
Noise produced by vibration or shock while driving.
17
Noise produced when engine starts.
18
1996 RAV4 (RM447U)
BE69
BODY ELECTRICAL
1996 RAV4 (RM447U)
AUDIO SYSTEM
BE70
BODY ELECTRICAL
Radio
AUDIO SYSTEM
NO POWER COMING IN
Yes
Is tape player operating normally?
Radio assembly faulty.
No
NG
Check CIG & RAD fuse is OK?
Replace fuse.
OK
No
Is ACC applied to radio?
ACC wire harness faulty.
Yes
NG
Check if GND (wire harness side) to radio is OK?
GND wire harness faulty.
OK
Radio
POWER COMING ON, BUT RADIO NOT OPERATING
Antenna w/o Motor

A
Go to No.23.
Do speakers pop when the volume switch is turned

to maximum and then the power is switch ON?
If radio side
faulty
Radio faulty.
No
Yes

No
Is power for the antenna

being output from the radio
or radio assembly?
Yes
Does continuity exist in speaker wire harness?
No
Speaker wire harness faulty.
Yes
Temporarily install another speaker
Function OK?
Yes
Speaker faulty.
No
Radio assembly
faulty.
Go to No.23.
If radio side
faulty
Radio assembly
faulty.
No
V07430
1996 RAV4 (RM447U)
BE71
BODY ELECTRICAL
AUDIO SYSTEM
NOISE PRESENT, BUT AMFM NOT OPERATING
Radio
No
Is power for the antenna being output from the

radio or radio assembly?
Yes
Go to No.17.
If radio side faulty

Yes
No
Hiss noise from speaker?
No
Power amplifier faulty. Recheck system after repair.
Yes
Radio asembly faulty. Recheck system after repair.
Radio
EITHER SPEAKER DOES NOT WORK
Yes
No
Is hiss noise produced by nonfunctioning speaker?
Yes
No
No
Yes
Temporarily install another speaker.
Function OK?
Yes
Speaker faulty.
No
V07431
1996 RAV4 (RM447U)
BE72
BODY ELECTRICAL
AUDIO SYSTEM
EITHER AM OR FM DOES NOT WORK, RECEPTION

POOR (VOLUME FAINT), FEW PRESET TUNING BANDS
Radio
Problem with radio wave signals or location?
Yes
Poor signals or poor location.
No
Are both AM and FM defective?
No
Yes
Is power for the antenna being output from
the radio assembly?
No
Yes
Go to No.17.
If radio side faulty.
Is tape player operating normaly?
Yes
No

Functions OK?
Yes
Speaker faulty.
No
V07432
1996 RAV4 (RM447U)
BE73
BODY ELECTRICAL
AUDIO SYSTEM
SOUND QUALITY POOR
Radio
No
Is sound quality always bad?
Yes
Is sound quality bad in

certain areas only?
Poor signals or poor

location.
Yes
No
Yes
Is tape player operating normaly?
Go to No.23.
No
No
Is speaker properly installed?
Install properly.
Yes
Yes

Function OK?
Speaker faulty.
No
Go to No.17.
CANNOT SET STATION SELECT BUTTON, PRESET

MEMORY DISAPPEARS
Radio
Can cassette tape be inserted in tape player?
Yes
No
Check if DOME fuse is OK?
NG
Replace fuse.
OK
Is +B applied to radio or radio assembly?
No
+B wire harness faulty.
Yes
Check if GND (wire harness side) to
radio assembly is OK?
NG
GND faulty.
OK
V07433
1996 RAV4 (RM447U)
BE74
BODY ELECTRICAL
Tape Player
AUDIO SYSTEM
CASSETTE TAPE CANNOT BE INSERTED
Is there a foreign object inside tape player?
Yes
Remove foreign object.
No
Yes
Is radio operating normally?
No
NG
Replace fuse.
OK
No
Is +B applied to radio assembly?
+B wire harness faulty.
Yes
Check if GND (wire harness side) to radio assembly
is OK?
NG
GND faulty.
OK
Tape Player
CASSETTE TAPE INSERTED, BUT NO POWER

Yes
No
Check if CIG & RAD fuse is OK?
NG
Replace fuse.
OK
Is ACC applied to radio assembly?
No
ACC wire harness faulty.
Yes
V07434
1996 RAV4 (RM447U)
BE75
BODY ELECTRICAL
10
Tape Player
AUDIO SYSTEM
POWER COMING IN, BUT TAPE PLAYER NOT

OPERATING
Functions OK if different cassette tape inserted?
Yes
Cassette tape faulty.
No
Yes
No
No
Yes
Yes

Functions OK?
Speaker faulty.
No
11
Tape Player
EITHER SPEAKER DOES NOT WORK
Yes
No
Is hiss noise produced by nonfunctioning speaker?
Yes
No
No
Yes
Functions OK?
OK
Speaker faulty.
NG
V07435
1996 RAV4 (RM447U)
BE76
BODY ELECTRICAL
12
Tape player
AUDIO SYSTEM
SOUND QUALITY POOR (VOLUME FAINT)
Yes
No
Operates normally after cleaning the heads?
Yes
Head dirty.
No
Yes
No
No
Install properly.
Yes
Temporarily install another speaker. Functions OK?
Yes
Speaker faulty.
No
13
Tape Player
TAPE JAMMED, MALFUNCTION WITH TAPE SPEED OR

AUTOREVERSE
Functions OK if different tape (less than 120 mins.) is inserted?
Yes
No
Is there a foreign object inside tape player?
Yes
Remove foreign object.
No
Operates normally after cleaning the heads?
Yes
Head dirty.
No
V04922
1996 RAV4 (RM447U)
BE77
BODY ELECTRICAL
14
Tape Player
AUDIO SYSTEM
APS, SKIP, RPT BUTTONS NOT OPERATING
No
Yes
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

No
Cassette tape jammed.
Yes
Yes
No
NG
Replace fuse.
OK
Is B+ applied to radio assembly?
No
B+ wire haness faulty.
Yes
V07436
1996 RAV4 (RM447U)
BE78
BODY ELECTRICAL
16
Antenna
AUDIO SYSTEM
ANTENNARELATED
No
Is antenna extended.
Extend fully.
Yes
Yes
Temporarily install another antenna.

Functions OK?
Antenna faulty.
No
Radio side faulty.
17
NOISE PRODUCED BY VIBRATION OR SHOCK WHILE

DRIVING
Noise
No
Install properly.
Yes
Is each system correctly installed?
No
Yes
With vehicle stopped, lightly tap each system.
Is noise produced?
Yes
Each system faulty.
No
Noise produced by static electricity accumulating
in the vehicle body.
V04924
1996 RAV4 (RM447U)
BE79
BODY ELECTRICAL
18
Noise
AUDIO SYSTEM
NOISE PRODUCED WHEN ENGINE STARTS
Whistling noise which becomes highpitched

when accelerator strongly depressed, disappears
shortly after engine stops.
Yes
Generator noise.
No
Whining noise occurs when A/C is operating.
Yes
A/C noise.
No
Scratching noise occurs during sudden
acceleration, driving on rough roads or when
ignition switch is turned on.
Yes
Fuel gauge noise.
No
Clicking sound heard when horn button is
pressed, then released. Whirring/grating sound
when pushed continuously.
Yes
Horn noise.
No
Murmuring sound stops when engine stops.
Yes
Ignition noise.
No
Ticktock noise, occurs in coordination with
blinking of flasher.
Yes
Turn signal noise.
No
Noise occurs during window washer operation.
Yes
Washer noise.
No
Scratching noise occurs while engine is running,
continues a while even after engine stops.
Yes
Engine coolant temperature gauge noise.
No
Scraping noise in time with wiper beat.
Yes
Wiper noise.
No
Other type of noise.
V08467
1996 RAV4 (RM447U)
BE80
BODY ELECTRICAL
LOCATION
1996 RAV4 (RM447U)
AUDIO SYSTEM
BE0JZ06
BE81
BODY ELECTRICAL
AUDIO SYSTEM
REMOVAL
Antenna Nut
BE27801
REMOVE ANTENNA ROD

HINT:
Perform this operation with the negative () terminal cable connected to the battery.
(a) Turn the ignition switch to the LOCK position.
(b) Remove the antenna nut.
BE4671
(c)
Press the AM buttons on the radio receiver, and simultaneously turn the ignition switch to the ACC position.
HINT:
The rod will extend fully and be released from the motor
antenna.
S
After removing the antenna rod, leave the ignition switch
at ACC.
NOTICE:
TO prevent body damage when the antenna rod is released,
hold the rod while it comes out.
S
BE5781
1996 RAV4 (RM447U)
BE82
BODY ELECTRICAL
AUDIO SYSTEM
INSTALLATION
BE27901
INSTALL ANTENNA ROD

(a) Insert the cable of the rod until it reaches the bottom.
HINT:
S
When inserting the cable, the teeth on the cable must face
toward the front of the vehicle.
S
Insert the antenna approx. 300 mm (11.8 in.)
BE5780
(b)
Wind the cable to retract the rod by turning the ignition

switch to the LOCK position.
HINT:
S
S
BE4674
(c)
1996 RAV4 (RM447U)
If the ignition switch is already in the LOCK position, perform step 1 (c) first, then turn the ignition switch to the
ACC position.
In case the cable is not wound, twist it as shown in the illustration.
Even if the rod has not retracted fully, install the antenna
nut and inspect the antenna rod operation. It will finally retract fully.
Inspect the antenna rod operation by pushing the radio
wave band select buttons.

Ignition Switch and Key Unlock Warning Switch Inspection

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Ignition Switch and Key Unlock Warning Switch Inspection

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BE10

IGNITION SWITCH AND KEY UNLOCK WARNING

IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH

1996 RAV4 (RM447U)

IGNITION SWITCH AND KEY UNLOCK WARNING

INSPECT IGNITION SWITCH CONTINUITY

If continuity is not as specified, replace the switch.

INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY

If continuity is not as specified, replace the switch.

Key Unlock Warning System:

Disconnect the negative () lead from the battery to terminals A6.

Connect the negative () lead from the battery to terminals A6.

1996 RAV4 (RM447U)

1996 RAV4 (RM447U)

IGNITION SWITCH AND KEY UNLOCK WARNING

INSPECT INTEGRATION RELAY CIRCUIT (See page

HEADLIGHT AND TAILLIGHT SYSTEM

HEADLIGHT AND TAILLIGHT SYSTEM

1996 RAV4 (RM447U)

HEADLIGHT AND TAILLIGHT SYSTEM

1996 RAV4 (RM447U)

HEADLIGHT AND TAILLIGHT SYSTEM

INSPECT LIGHT CONTROL SWITCH CONTINUITY

If continuity is not as specified, replace the switch.

If continuity is not as specified, replace the switch.

INSPECT HEADLIGHT CONTROL RELAY CONTINUITY

If continuity is not as specified, replace the relay.

INSPECT TAILLIGHT CONTROL RELAY CONTINUITY

If continuity is not as specified, replace the relay.

Lighton Warning System:

HEADLIGHT AND TAILLIGHT SYSTEM

Beam Angle Gauge

ADJUST HEADLIGHT AIM

(b) Adjust the headlight aim in vertical direction.

Beam Angle Gauge

1996 RAV4 (RM447U)

(c) Adjust the headlight aim in horizontal direction.

Beam Angle Gauge

Beam Angle Gauge

HEADLIGHT AND TAILLIGHT SYSTEM

ADJUST HEADLIGHT AIM

Adjust the headlight aim in vertical direction.

1996 RAV4 (RM447U)

HOW TO RESET LH AND RH AIMING INDICATORS

Unlock the holder assembly.

HEADLIGHT AND TAILLIGHT SYSTEM

Insert the holder assembly, unlock in step (b), to the screw

Beam Angle Gauge

1996 RAV4 (RM447U)

Turn the adjusting screw B to the left and adjust the LH

TURN SIGNAL AND HAZARD WARNING SYSTEM

TURN SIGNAL AND HAZARD WARNING SYSTEM

1996 RAV4 (RM447U)

TURN SIGNAL AND HAZARD WARNING SYSTEM

INSPECT TURN SIGNAL SWITCH CONTINUITY

If continuity is not as specified, replace the switch.

INSPECT HAZARD WARNING SWITCH CONTINUITY

If continuity is not as specified, replace the switch.

1996 RAV4 (RM447U)

INSPECT TURN SIGNAL FLASHER OPERATION

BACKUP LIGHT SYSTEM

BACKUP LIGHT SYSTEM