engine TOYOTA RAV4 1996 Service Service Manual

SUPRA
TORQUE SPECIFICATIONS (SUPRA)
Drive Plate-To-Crankshaft Bolt61 (83)
Front Exhaust Pipe Support Bracket Bolt15 (20)
Front Exhaust Pipe-To-Exhaust Manifold Nut46 (62)
Front Exhaust Pipe-To-Rear Exhaust Pipe Bolt/Nut41 (56)
Front (Radiator Side) Engine Mount Shock Absorber-To-Lower Frame Bolt35 (47)
Front (Radiator Side) Engine Mount-To-Lower Frame Bolt/Nut
Green Bolt49 (66)
Silver Bolt32 (44)
Lower Frame Assembly Bracket-To-Body Bolt/Nut
Front Bolt134 (182)
Front Nut27 (37)
Rear Large Bolt134 (182)
Rear Small Bolt24 (33)
Rear Nut27 (37)
Rear (Firewall Side) Engine Mount-To-Lower Frame Bolt/Nut49 (66)
Stabilizer Bar Mount Bracket-To-Lower Frame Assembly Bolt14 (19)
Starter Bolt29 (39)
Steering Gear Assembly-To-Lower Frame Assembly Bolt/Nut134 (182)
Torque Converter Bolt30 (41)
Torque Converter Bracket & Hole Cover
Bolts(1)
Nuts15 (20)
Transaxle Mount-To-Frame Nut59 (80)
Transaxle-To-Cylinder Block Bolt
Upper Bolts (5)49 (66)
Lower Bolts (3)
Bolt At 9-O'Clock Position36 (48)
Except Bolt At 9-O'Clock Position27 (37)
Wheel Lug Nut76 (103)
Wiper Arm Nut15 (20)
(1)Tighten bolts to 71 INCH Lbs. (8.0 N.m).
ApplicationFt. Lbs. (N.m)
Drive Plate-To-Crankshaft Bolt61 (83)
Drive Shaft Center Bearing Assembly-To-Body Bolt36 (49)
Drive Shaft Flange Bolt/Nut
Non-Turbo58 (77)

1998 Toyota Avalon XLS
TRANSMISSION SERVICING - A/T 1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal &
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TACOMA
TORQUE SPECIFICATIONS (TACOMA)
TERCEL
TORQUE SPECIFICATIONS (TERCEL)
Turbo41 (56)
Starter Bolt27 (37)
Torque Converter Bolt
Non-Turbo30 (41)
Turbo40 (54)
Transmission Crossmember Bolt18 (24)
Transmission-To-Cylinder Block Bolt
14-mm (4 Bottom Bolts)27 (37)
17-mm53 (72)
INCH Lbs. (N.m)
Floor Crossmember Brace Bolt115 (13.0)
ApplicationFt. Lbs. (N.m)
Drive Plate-To-Crankshaft Bolt
2.4L 4-Cyl. & 2.7L 4-Cyl.54 (73)
3.4L V661 (83)
Drive Shaft Center Bearing Assembly-To-Crossmember Bolt27 (37)
Drive Shaft Flange Bolt/Nut54 (73)
Front Differential Assembly Rear Mount Bolt (4WD)80 (109)
Front Differential Assembly Rear Mount To-Crossmember Nut (4WD)64 (87)
Stabilizer Bar Link-To-Lower Control Arm Nut (4WD)51 (69)
Stabilizer Bar Mounting Bracket-To-Frame Bolt (4WD)19 (26)
Starter Bolt29 (39)
Stiffener Plate Bolt (2WD 2.4L 4-Cyl)27 (37)
Transmission Crossmember Bolt/Nut (4WD)48 (65)
Transmission-To-Cylinder Block Bolt53 (72)
Transmission Mount-To-Transmission Crossmember Bolt (4WD)14 (19)
Torque Converter Bolt30 (41)
ApplicationFt. Lbs. (N.m)
Drive Plate-To-Crankshaft Bolt65 (88)
Exhaust Pipe Bolt46 (62)
Front (Radiator Side) Transaxle Mount Bolt36 (49)
Rear (Firewall) Engine Mount Assembly-To-Body Bolt
Outside Small Bolts (2)59 (80)

1998 Toyota Avalon XLS
TRANSMISSION SERVICING - A/T 1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal &
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T100
TORQUE SPECIFICATIONS (T100)
4RUNNER
TORQUE SPECIFICATIONS (4RUNNER)
Center Large Bolts (3)68 (92)
Rear (Firewall) Engine Mount Through-Bolt48 (65)
Starter Bolt29 (39)
Torque Converter Bolt20 (27)
Transaxle-To-Cylinder Block Bolt
Upper Bolt47 (64)
Lower Bolt(1)
Wheel Lug Nut76 (103)
(1)For bolt tightening specifications, see Fig. 9 and Fig. 10 .
ApplicationFt. Lbs. (N.m)
Drive Plate-To-Crankshaft Bolt61 (83)
Drive Shaft Center Bearing Assembly-To-Crossmember Bolt (4WD)27 (37)
Drive Shaft Flange Bolt/Nut (4WD)
Front Drive Shaft54 (73)
Rear Drive Shaft56 (76)
Stabilizer Bar-To-Lower Control Bolt/Nut (4WD)18 (25)
Stabilizer Bar Mounting Bracket-To-Frame Bolt (4WD)22 (30)
Starter Bolt29 (39)
Stiffener Plate Bolt27 (37)
Transmission Crossmember Bolt (4WD)70 (95)
Transmission-To-Cylinder Block Bolt53 (72)
Transmission Mount-To-Transmission Crossmember Bolt 4WD13 (18)
Torque Converter Bolt30 (41)
ApplicationFt. Lbs. (N.m)
Drive Plate-To-Crankshaft Bolt
2.7L 4-Cyl.55 (74)
3.4L V661 (83)
Drive Shaft Flange Bolt/Nut55 (74)
Front Exhaust Pipe-To-Exhaust Manifold Nut46 (62)
Front Exhaust Pipe-To-Rear Exhaust Pipe Bolt/Nut36 (48)
Rear Transmission Mount-To-Transmission Bolt48 (65)
Rear Transmission Mount-To-Transmission Crossmember Bolt
2WD14 (19)

1998 Toyota Avalon XLS
TRANSMISSION SERVICING - A/T 1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal &
Installation

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November-03-08 10:30:29 AMPage 41 © 2005 Mitchell Repair Information Company, LLC.

ON-VEHICLE SERVICE
PARK/NEUTRAL POSITION (PNP) SWITCH
Removal & Installation
1. Disconnect park/neutral position (PNP) switch connector. Remove nut and disconnect shift control cable.
Remove nut, washer and manual shaft lever. Pry back locking tab on manual shaft washer and remove
nut. Remove 2 bolts and remove park/neutral position (PNP) switch.
2. Install PNP switch to manual shaft. Install 2 bolts finger tight. Install NEW locking plate. Install nut and
tighten to 61 INCH lbs. (6.9 N.m). Stake nut with locking plate. Install manual shaft lever, washer and
nut. Tighten nut to 115 INCH lbs. (13 N.m). Install shift control cable and nut. Tighten nut to 11 ft. lbs.
(15 N.m). Adjust switch by aligning groove and neutral basic line. Tighten 2 bolts to 48 INCH lbs. (5.4
N.m). Ensure engine starts in Park and Neutral.
THROTTLE CABLE
See appropriate AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING.
VALVE BODY ASSEMBLY
Removal
1. Clean exterior of transaxle. Remove oil pan plug. Drain transaxle. Remove oil pan and gasket. Discard
gasket. Remove oil strainer. Note location of magnets in oil pan. Remove magnets. Examine particles in
pan. Steel (magnetic) particles indicate bearing, gear, or plate wear. Brass (non-magnetic) particles
indicate bushing wear.
2. Remove tube bracket. Note location of oil tubes, and remove oil tubes. Disconnect solenoid wiring
harness connector(s). Remove manual detent spring. Remove manual valve. Disconnect throttle cable
from cam. Remove valve body assembly. Remove 2nd brake apply gasket.
Installation
1. Install NEW 2nd brake apply gasket. While holding cam down, slip cable end into slot. DO NOT tangle
RAV4
Drain & Refill3.5 (3.3)
Dry Refill7.4 (7.0)
Sienna
Drain & Refill3.7 (3.5)
Dry Refill6.9 (6.5)
CAUTION: Note bolt length and location during disassembly. Proper length bolts
must be installed to prevent case damage.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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clutch.
Vehicle Does Not Move In Reverse ("R")
Check 1-2 shift valve, 2-3 shift valve, 2nd coast brake, front planetary gear, rear planetary gear, direct clutch,
OD direct clutch and 1st and reverse brake.
No 1-2 &/Or 2-3 Upshift
Check Throttle Position (TP) sensor circuit, No. 1 and No. 2 shift solenoid circuit, Vehicle Speed Sensor (VSS)
circuit, Electronic Control Transmission Electronic Control Module (ECT ECM), 1-2 shift valve, 2-3 shift
valve, 2nd brake, direct clutch and No. 1 one-way clutch.
No 3-O/D Upshift
Check OD switch and OD OFF indicator switch circuit, OD cancel signal circuit, No. 1 and No. 2 shift solenoid
circuit, VSS, Engine Coolant Temperature (ECT) circuit, ECT ECM, 3-4 shift valve and OD brake.
No O/D-3 Downshift
Check No. 1 and No. 2 shift solenoid valve, VSS circuit, OD cancel signal circuit, ECT ECM and 3-4 shift
valve.
No 3-2 &/Or 2-1 Downshift
Check No. 1 and No. 2 shift solenoid valve, VSS circuit, TP sensor circuit, ECT ECM, 2-3 shift valve, 1-2 shift
valve and 2nd coast brake.
No Torque Converter Lock-Up
Check shift solenoid valve SL circuit, TP sensor circuit, VSS circuit, OD cancel circuit, brakelight circuit, ECT
circuit, ECT ECM, lock-up relay valve and torque converter clutch.
Torque Converter Lock-Up Will Not Release
Check shift solenoid valve SL circuit, TP sensor circuit, brakelight circuit, ECT ECM circuit, lock-up relay
valve and torque converter clutch.
Shift Speeds Too High Or Too Low
Check TP sensor circuit, VSS circuit, shift solenoid valve SL circuit, OD cancel signal circuit, pattern select
switch circuit and ECT ECM.
Harsh Engagement Neutral To Reverse
Check direct clutch accumulator, direct clutch, throttle valve and 1st and reverse brake.
Harsh Engagement Neutral To Drive

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1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Check forward clutch accumulator, throttle valve and forward clutch.
No Engine Braking In Low
Check low coast modulator valve and 1st and reverse brake.
No Engine Braking In 2nd
Check 2nd coast modulator valve and 2nd coast brake.
CLUTCH & BRAKE APPLICATION
Selector Lever
Position
Elements In Use
"D" (Drive)
1st GearForward Clutch, OD Direct Clutch, OD One-Way Clutch & No. 2 One-Way
Clutch
2nd GearForward Clutch, OD Direct Clutch, OD One-Way Clutch, No. 1 One-Way
Clutch & 2nd Brake
3rd GearForward Clutch, Direct Clutch, OD Direct Clutch, OD One-Way Clutch & 2nd
Brake
OverdriveDirect Clutch, Forward Clutch, OD Brake & 2nd Brake
"2" (Second)
1st GearForward Clutch, OD One-Way Clutch, OD Direct Clutch & No. 2 One-Way
Clutch
2nd GearForward Clutch, OD Direct Clutch, OD One-Way Clutch, 2nd Brake, 2nd Coast
Brake & No. 1 One-Way Clutch
3rd Gear (1)Forward Clutch, Direct Clutch, Direct Clutch, OD One-Way Clutch & 2nd
Brake
"L" (Low)
1st GearForward Clutch, OD Direct Clutch, OD One-Way Clutch, & 1st & Reverse
Brake & No. 2 One-Way Clutch
2nd Gear (2)Forward Clutch, OD Direct Clutch, OD One-Way Clutch, No. 1 One-Way
Clutch, 2nd Brake & 2nd Coast Brake
"R" (Reverse)Direct Clutch, OD Direct Clutch & 1st & Reverse Brake
"N" (Neutral)OD Direct Clutch
"P" (Park)OD Direct Clutch
(1)Downshift only in 3rd gear for "2" position.
(2)Downshift only in 2nd gear for "L" position. Upshift does not occur.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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1. If shift lever is actuated with engine idling, a time lag will be noted before shock can be felt. This test is
used for checking condition of OD direct clutch, forward clutch, direct clutch, and 1st and reverse brake.
2. Apply parking brake. Start engine. On RAV4, ensure idle speed is 700-800 RPM. On all other models,
ensure idle speed is 650-750 RPM. Shift transaxle from "N" into "D" range. Use a stop watch to measure
elapsed time between shifting of lever until shock is felt. Standard time lag is less than 1.2 seconds.
3. Repeat procedure outlined in step 2) to measure time lag for "N" to "R". Standard lag time is less than 1.5
seconds.
4. If "N" to "D" time lag is longer than specification, line pressure is too low, forward clutch may be worn,
or OD one-way clutch is not operating properly.
5. If "N" to "R" time lag is longer than specified, direct clutch may be worn, 1st and reverse brake may be
worn, line pressure is too low or OD one-way clutch is not operating properly.
ROAD TEST
"D" Range Test In NORM & PWR Pattern Ranges
1. Shift into "D" range. Hold accelerator pedal constant at full throttle. Place shift mode button in NORM or
PWR position. Check 1-2, 2-3, and 3-OD lock-up and upshift points. See appropriate table under SHIFT
SPEED SPECIFICATIONS .
zIf no 1-2 upshift occurs, check 1-2 shift valve or solenoid.
zIf no 2-3 upshift occurs, check 2-3 shift valve or solenoid.
zIf no 3-OD upshift occurs, check 3-OD shift valve.
zIf all shift points are incorrect, check throttle valve, 1-2 shift valve, 2-3 shift valve and 3-OD shift
valve.
zIf all lock-up points are incorrect, check lock-up relay valve or shift solenoid valve SL.
2. Use procedure outlined in step 1) to check for shock and slip between 1-2, 2-3, and 3-OD upshifts. If
shock is harsh, line pressure may be too high. Check accumulator or check ball.
3. Run vehicle in "D" range lock-up or overdrive gear. Check for abnormal noise and vibration.
4. While running in "D" range, confirm correct kickdown vehicle speed limits for 2-1, 3-2, OD-3 shift
points. Check for abnormal shock and slip at kickdown.
5. Check loc
k-up function. Drive vehicle in OD gear of "D" range with lock-up on. Hold vehicle speed NOTE: Perform test at normal operating fluid temperature of 122-176°F (50-80°C).
NOTE: There is no overdrive upshift when coolant temperature is below 140°F
(60°C). There is no lock-up when vehicle speed is 6 MPH less than the set
cruise control speed.
NOTE: Check for cause of abnormal noise and vibration must be made with
extreme care as problem could be due to an unbalanced drive shaft,
differential, tire, torque converter, etc.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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steady at 43 MPH for 1997 Avalon, 47 MPH for RAV4 and 37 MPH for all other models. Lightly depress
accelerator pedal. Ensure engine RPM does not change abruptly. Large increase in engine RPM indicates
lock-up function is faulty.
"2" Range Test
1. Shift into "2" range and fully depress accelerator pedal to full throttle. Ensure 1-2 upshift takes place and
shift point conforms to specifications. See appropriate table under SHIFT SPEED SPECIFICATIONS
.
2. While driving in "2" range, 2nd gear, release accelerator pedal and check engine braking effect. If there is
no engine braking effect, 2nd coast brake is faulty. Check for abnormal noise and shock at acceleration
and deceleration.
"L" Range Test
While running in "L" range, ensure there is no upshift to 2nd gear. While running in "L" range, release
accelerator pedal. If there is no engine braking effect, 1st and reverse brake is faulty. Check for abnormal noise
at acceleration and deceleration.
"R" Range Test
Shift into "R" range. Accelerate vehicle from a stop at full throttle. Ensure slipping does not occur.
"P" Range Test
Stop vehicle on 5 degree or more gradient. Shift transaxle into "P" range. Release parking brake. Ensure parking
pawl holds vehicle.
SHIFT SPEED SPECIFICATIONS
AVALON A-541E SHIFT SPEED SPECIFICATIONS
Application (1)MPH
"D" Range (NORM or PWR)
1st-2nd41-44
2nd-3rd76-81
3rd-OD117-123
3rd-OD (2)24-27
OD-3rd (2)12-15
OD-3rd113-118
3rd-2nd70-75
2nd-1st34-37
"2" Range (NORM or PWR)
1st-2nd41-44
3rd-2nd83-88
2nd-1st34-37

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1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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STALL SPEED TEST
1. Object of test is to check overall performance of transaxle and engine by measuring maximum stall
speeds in "D" and "R" ranges.
2. Block front and rear wheels. Connect scan tool to DLC3, located under instrument panel. Apply parking
and service brakes. Start engine. Position transmission in "D" range. Fully depress accelerator pedal.
Immediately note highest engine RPM. DO NOT perform test longer than 5 seconds. Repeat test in "R"
range. See STALL SPEED SPECIFICATIONS
table.
STALL SPEED SPECIFICATIONS
3. If stall speed is same for both ranges, but lower than specified RPM, engine output may be insufficient or
stator one-way clutch is not operating properly.
4. If stall speed in "D" range is higher than specifications, forward clutch may be slipping, No. 2 one-way
clutch and OD one-way clutch are not operating properly, or line pressure is too low.
5. If stall speed in "R" range is higher than specifications, direct clutch is slipping, 1st and reverse brake is
slipping, OD direct clutch is slipping or line pressure is too low.
6. If stall speed in "R" and "D" ranges is higher than specifications, line pressure is too low, fluid level is
incorrect or OD one-wa
y clutch is not operating properly.
Lock-Up ON In 3rd (3)36-40
Lock-Up OFF In 3rd (3)32-36
Lock-Up ON In OD36-40
Lock-Up OFF In OD32-36
(1)Throttle valve opening 5 percent.
(2)There is no lock-up in "L" or "2" ranges.
(3)With OD switch off.
CAUTION: Perform test at normal operating fluid temperature of 122-176°F (50-80°C).
DO NOT maintain stall speed RPM for more than 5 seconds. Allow vehicle
to idle in Neutral or Park for at least 5 minutes before performing next test.
ApplicationsRPM
A-540E2300-2750
A-540H2250-2550
A-541E
1998-99 Avalon2250-2550
Except 1998-99 Avalon2450-2750
NOTE: If stall speed RPM is more than 600 RPM below specified value, torque
converter may be faulty.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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HYDRAULIC PRESSURE TEST
Line Pressure Test
1. Ensure transmission fluid is at operating temperature. Raise and support vehicle. Remove transaxle case
test plug and install pressure gauge. See Fig. 5
. Lower vehicle and block all wheels.
2. Fully apply parking brake. Start engine. Apply brakes. Shift into "D" range. On A-540H transaxle, apply
battery voltage between ground and terminal No. 1 of shift solenoid valve ST connector. See Fig. 6
. On
all transaxles, measure line pressure at idle. Accelerate to full throttle. Measure line pressure at stall
speed. See appropriate LINE PRESSURE SPECIFICATIONS table.
3. On all models, repeat test in "R" range. DO NOT ground shift solenoid valve ST in "R" range.
4. If pressures exceed specifications in all ranges, regulator valve or throttle valve is faulty or throttle cable
is out of adjustment.
5. If pressures in all ranges are lower than specifications, oil pump, regulator valve, throttle valve or OD
direct clutch is faulty or throttle cable is out of adjustment.
6. If pressure is lower than specifications in "D" range only, forward clutch is faulty or "D" range circuit has
a fluid leak.
7. If pressure is lower than specifications in "R" range only, direct clutch is faulty, 1st and reverse brake is
faulty or "R" range circuit has a fluid leak.
LINE PRESSURE SPECIFICATIONS (A-540E)
LINE PRESSURE SPECIFICATIONS (A-540H) 1997
(1)
CAUTION: Hydraulic pressure test should be performed with transmission fluid
temperature of 122-176°F (50-80°C).
Selector PositionPressure - psi (kg/cm2 )
"D" Position
Idle Speed51-60 (3.6-4.2)
Stall Speed127-148 (8.9-10.4)
"R" Position
Idle Speed93-108 (6.5-7.6)
Stall Speed230-268 (16.1-18.8)
Selector PositionPressure - psi (kg/cm2 )
"D" Position
Idle Speed
With Solenoid Valve ST On76-102 (5.4-7.2)
With Solenoid Valve ST Off53-61 (3.7-4.3)
Stall Speed
With Solenoid Valve ST On192-225 (13.5-15.8)
With Solenoid Valve ST Off106-125 (7.5-8.8)

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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