ad blue TOYOTA RAV4 1996 Service Repair Manual

3. Check ABS control relay. See SOLENOID RELAY SECTION under ABS CONTROL RELAY under
COMPONENT TESTS. Replace as necessary. If ABS control relay is okay, go to next step.
4. Check for open or short circuit in wiring harness between ABS control relay and ABS ECU. Repair as
necessary. See WIRING DIAGRAMS
. If circuit is okay, go to next step.
5. Clear DTCs and then recheck for DTCs. See RETRIEVING DTCS
under DIAGNOSIS & TESTING. If
same DTC is output after DTC is cleared, check contact condition of each connection. Repair as
necessary. If connections are okay, replace ABS ECU. See ABS ECU
under REMOVAL &
INSTALLATION.
Fig. 4: Testing ABS Control (Solenoid) Relay Power/Ground Circuits

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
DTC 13 & DTC 14: ABS CONTROL (MOTOR) RELAY CIRCUIT
Circuit Description
ABS control relay supplies power to ABS pump motor. While ABS is activated, ABS ECU switches ABS
control relay on and operates ABS pump motor. If malfunction occurs in ABS control relay circuit, ABS ECU
cuts off current to ABS control rela
y and prohibits ABS control.
SRLRA17-14Brown/Red
SRLHA17-15Brown/White
SRRRA16-12Green/Yellow
SRRHA16-11Green/Black
SFLRA16-6Blue/White
SFLHA16-5Blue/Red
SFRRA17-1Red/Green
SFRHA17-2Red/White

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1999-2000 BRAKES Anti-Lock - RAV4
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DTC Detecting Condition
Detection of any of the following conditions may set DTC 13 or DTC 14 if condition occurs for .2 seconds or
more:
If voltage at ABS control relay connector terminal A8-4 is less than 1.5 volts, and voltage at connector
terminal A8-2 is zero volts, DTC 13 may set.
If voltage at ABS control relay connector terminal A8-4 is 10-14 volts, and voltage at connector terminal
A8-2 is 10-14 volts, DTC 14 may set.
Diagnostic Procedure
1. Disconnect ABS control relay connector A8, located in engine compartment at front of vehicle. See Fig.
1 . Measure voltage between ground and motor relay connector terminal A8-1. See Fig. 5 . If voltage is
10-14 volts, go to next step. If voltage is not 10-14 volts, repair wiring harness between battery and motor
relay. See WIRING DIAGRAMS
.
2. Disconnect 2 ABS actuator connectors. Check for continuity on Blue/Red wire between ABS actuator
connector terminal A7-2 and ABS control relay connector terminal A8-2. Also check for continuity on
Blue/Red wire between ABS actuator connector terminal A7-3 and ABS ECU connector terminal A16-
10. See Fig. 5
. Continuity should exist. If continuity is not present on either wire, repair open circuit on
affected wire between ABS control relay and ABS ECU. If continuity is present on both wires, go to next
step.
3. Check resistance between ABS actuator terminals A7-2 and A7-3. Resistance should be 26-40 ohms. If
resistance is as specified, go to next step. If resistance is not as specified, replace ABS actuator.
4. Check ABS control relay. See MOTOR RELAY SECTION
under ABS CONTROL RELAY under
COMPONENT TESTS. Replace relay as necessary. If relay tests okay, go to next step.
5. Check for open or short circuit in wiring harness between ABS control relay and ABS ECU. Repair as
necessary. See WIRING DIAGRAMS
. If circuit is okay, go to next step.
6. Clear DTCs and then recheck for DTCs. See RETRIEVING DTCS
under DIAGNOSIS & TESTING. If
same DTC is output after DTC is cleared, check contact condition of each connection. Repair as
necessar
y. If connections are okay, replace ABS ECU.

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1999-2000 BRAKES Anti-Lock - RAV4
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UPPER VALVE BODY VALVE SPRING SPECIFICATIONS
UPPER VALVE BODY VALVE SPRING SPECIFICATIONS (A-540E)
UPPER VALVE BODY VALVE SPRING SPECIFICATIONS (A-540H)
UPPER VALVE BODY VALVE SPRING SPECIFICATIONS (A-541E)
Disassembly & Reassembly (Lower Valve Body A-540E, A-540H & A-541E)
1. When disassembling lower valve body, maintain parts in order for reassembly reference. Ensure each
valve is kept with corresponding spring. Inspect valve springs for damage, squareness, rust and collapsed
coils.
2. Measure lower valve bod
y valve spring free height. Replace any spring if specification is exceeded. See
ApplicationColorFree Height - In. (mm)
2nd Coast Modulator ValveBrown1.083 (27.50)
2nd Coast Brake Orifice Control ValveWhite.976 (24.80)
Downshift PlugYellow1.012 (25.70)
Throttle ValvePurple1.209 (30.70)
Throttle Modulator ValveOrange.854 (21.70)
Cut-Back ValveRed.858 (21.80)
No. 1 Accumulator Control ValveYellow1.106 (28.10)
Lock-Up Relay ValveGreen1.047 (26.60)
ApplicationColorFree Height - In. (mm)
2nd Coast Modulator ValveLight Blue1.126 (28.60)
2nd Coast Brake Orifice Control ValveWhite.976 (24.80)
Downshift PlugYellow1.173 (29.80)
Throttle ValvePurple1.209 (30.70)
Throttle Modulator ValveOrange.854 (21.70)
Cut-Back ValveRed.858 (21.80)
No. 1 Accumulator Control ValveBlue.992 (25.20)
Lock-Up Relay ValveGreen1.047 (26.60)
ApplicationColorFree Height - In. (mm)
Lock-Up Relay ValveYellow1.055 (26.80)
2nd Coast Brake Orifice Control ValveWhite.976 (24.80)
Throttle ValveGreen1.240 (31.50)
Downshift PlugNone.591 (15.00)
Low Coast Modulator ValvePurple.795 (20.20)
NOTE: On A-540H transaxle, line pressure changes according to part of plunger sleeve
which comes into contact with retainer. When reassembling lower valve body,
align retainer in same position.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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ACCUMULATOR SPRING SPECIFICATIONS
21. Install 2nd brake apply gasket. Install throttle cable and solenoid wire. Place valve body on transaxle.
While holding cam down with hand, slip cable end in slot. Lower valve body into position. DO NOT
entangle solenoid wiring. Install valve body bolts. Ensure proper length and location of bolts. See Fig. 1
.
Finger tighten all bolts. Tighten bolts in crisscross pattern to specification. See TORQUE
SPECIFICATIONS .
22. Install 1st and reverse brake apply tube. Install connector clamp and tube retainer. Connect solenoid
connectors. Using a plastic hammer, install oil tubes. DO NOT bend or damage tubes. Place manual valve
body on transmission. Align manual lever with pin of manual shaft lever. Lower manual valve body into
position. Ensure proper length and location of bolts. See Fig. 3
. Finger tighten bolts. Evenly tighten bolts
in crisscross pattern.
23. Install detent spring. Ensure proper length and location of each bolt. Finger tighten bolts. Check for
correct operation of manual valve lever. Ensure lever is touching center of detent spring tip roller.
24. Install tube bracket and oil strainer. Install magnets in oil pan. Ensure magnets do not interfere with oil
tubes. Install oil pan with NEW gasket. Install vehicle speed sensor with "O" ring (as applicable). Install
speed sensor connector. Install throttle cable retaining plate. Install solenoid wire.
25. Install transaxle case upper cover. Install direct clutch speed (T/M revolution) sensor (if equipped). Install
park/neutral position switch to manual valve shaft. Install NEW locking plate. Tighten nut and stake with
locking plate. Adjust switch by aligning groove and neutral basic line. Tighten bolts. Install manual shift
lever.
26. On A-540H transaxle, install NEW snap ring to shaft groove and install differential side gear intermediate
shaft. See Fig. 63
. Keeping intermediate shaft on pinion shaft of differential, measure shaft protrusion
length from transaxle case surface to end of shaft. Protrusion length should be 10.059" (255.50 mm).
27. Install NEW apply gasket on differential carrier cover. Install transfer case assembly to transaxle. Apply
seal packing Three Bond (1281) or Loctite (518) to contacting surface of transaxle case. Coat threads of
ApplicationColorFree Length - In. (mm)
A-540E
Direct ClutchYellow/Purple2.173 (55.20)
2nd BrakeBlue/White2.701 (68.60)
Forward ClutchBlue/Green2.803 (71.20)
A-540H
Direct ClutchRed2.008 (51.00)
2nd BrakeBlue/White2.701 (68.60)
Forward ClutchPink2.433 (61.80)
A-541E
Direct ClutchYellow/Purple2.039 (51.08)
2nd Brake
1997Brown/Pink3.035 (77.10)
1998
InnerNone3.472 (88.20)
OuterNone2.768 (70.30)
Forward ClutchNone2.898 (73.60)

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Perform ELECTRONICALLY CONTROLLED TRANSMISSION (ECT) CIRCUIT test under
SYSTEM TESTS.
Replace cruise control ECU with a known-good ECU and retest. If symptom is no longer present, replace
ECU.
DTC Memory Is Erased
Replace cruise control ECU with a known-good ECU and retest. If symptom is no longer present, replace ECU.
DTC Not Output, Or DTC Output When It Should Not Be
Check the following components and/or circuits:
Perform DIAGNOSTIC CIRCUIT test under SYSTEM TESTS.
Replace cruise control ECU with a known-good ECU and retest. If symptom is no longer present, replace
ECU.
CRUISE Control Indicator Light Stays On Or Fails To Turn On
Check the following components and/or circuits:
Perform CRUISE CONTROL INDICATOR LIGHT CIRCUIT test under SYSTEM TESTS.
Replace cruise control ECU with a known-good ECU and retest. If symptom is no longer present, replace
ECU.
COMPONENT TESTS
VEHICLE SPEED SENSOR
1. Remove vehicle speed sensor from transaxle. See Fig. 1
. Using jumper wires, connect positive battery
terminal to vehicle speed sensor terminal No. 1 (Red/Blue wire) and negative battery terminal to terminal
No. 2 (Blue/Black wire).
2. Connect voltmeter positive lead to terminal No. 3 (Red/Yellow wire) and negative lead to terminal No. 2
(Blue/Black wire). See Fig. 5
. Rotate vehicle speed sensor shaft and ensure voltage changes from 0-11
volts or more 4 times per shaft revolution. Replace vehicle speed sensor as necessary.
SYSTEM TESTS
CRUISE CONTROL SWITCH CIRCUIT
1. Perform SET/COAST, RES/ACC, and CANCEL SWITCHES tests under CRUISE CONTROL
NOTE: To identify cruise control ECU connector terminals, see Fig. 6 . To help identify
all other cruise control related connector terminals and wire colors, see WIRING
DIAGRAMS .

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1999 ACCESSORIES & EQUIPMENT Cruise Control Systems - RAV4
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1. Check stoplight operation. If stoplight operation is okay, go to next step. If stoplights DO NOT operate
correctly, check and repair stoplight system as necessary. See WIRING DIAGRAMS
.
2. Perform CANCEL SWITCHES test under CRUISE CONTROL FUNCTION TEST
under TROUBLE
SHOOTING. If stoplight input signal is not as specified, go to next step. If stoplight input signal is as
specified, no problem is indicated at this time. Fault may be intermittent. If sent here from SYMPTOM
DIAGNOSIS, perform next test listed.
3. Remove cruise control ECU with connector attached. See Fig. 1
. Turn ignition switch to ON position.
Backprobing cruise control ECU connector, measure voltage between ground and cruise control ECU
connector terminal No. 2 (Green/White wire). With brake pedal depressed, battery voltage should exist.
With brake pedal released, voltage should be less than one volt. If voltage is not as specified, go to next
step. If voltage is as specified, no problem is indicated at this time. Fault may be intermittent. If sent here
from SYMPTOM DIAGNOSIS, perform next test listed.
4. Check for open circuit in wiring harness and connectors between cruise control ECU and stoplight switch.
Repair as necessary and retest system. If wiring harness and connectors are okay, replace cruise control
ECU and retest system.
IDLE SIGNAL CIRCUIT
1. Remove cruise control ECU with connector attached. Disconnect Engine Control Module (ECM) 16-pin
connector. ECM is located behind bottom center of instrument panel, in front of console. Turn ignition
switch to ON position. Backprobing connector, measure voltage between ground and cruise control ECU
connector terminal No. 13 (Blue wire).
2. With throttle valve fully open, battery voltage should exist. With throttle valve fully closed, voltage
should be less than 2 volts. If voltage is not as specified, go to next step. If voltage is as specified, no
problem is indicated at this time. Fault may be intermittent. If sent here from SYMPTOM DIAGNOSIS,
perform next test listed.
3. Check wiring harness and connectors between ECM and TP sensor. Repair as necessary and retest
system. If wiring harness and connectors are okay, go to next step.
4. Disconnect TP sensor 3-pin Black connector. Measure resistance between TP sensor connector terminals
No. 2 (Brown wire) and No. 3 (Blue/Red wire). Resistance should be 2000-10,200 ohms with throttle
valve fully opened, and 200-6300 ohms with throttle valve fully closed. If resistance is as specified, go to
next step. If resistance is not as specified, replace TP sensor and retest system.
5. Check wiring harness and connectors between cruise control ECU and TP sensor, and between TP sensor
and ground. Repair as necessary and retest system. If wiring harness and connectors are okay, replace
cruise control ECU and retest system.
ELECTRONICALLY CONTROLLED TRANSMISSION (ECT) CIRCUIT
1. Start engine and bring to operating temperature. Drive vehicle and ensure overdrive operation is turned on
and off when overdrive ON-OFF switch is operated. If overdrive switch is okay, go to next step. If
overdrive switch is not okay, see appropriate ELECTRONIC CONTROLS article in AUTOMATIC NOTE: Ensure Throttle Position (TP) sensor circuit is operating as designed, and no
fault codes are present for TP sensor circuit. See appropriate ON-VEHICLE
ADJUSTMENTS article in ENGINE PERFORMANCE.

1999 Toyota RAV4
1999 ACCESSORIES & EQUIPMENT Cruise Control Systems - RAV4
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TRANSMISSIONS article.
2. Turn ignition switch to OFF position. Remove cruise control ECU and disconnect connector. See Fig. 1
.
Turn ignition switch to ON position. Using voltmeter positive lead, backprobe cruise control ECU
harness connector terminal No. 14 (Yellow/Black wire) with negative lead to ground. If battery voltage is
present, go to next step. If battery voltage is not present, go to step 5 .
3. Turn ignition switch to OFF position. Reconnect cruise control ECU connector. Using voltmeter positive
lead, backprobe cruise control ECU connector terminal No. 6 (Pink wire) with negative lead to ground.
Bring engine to operating temperature and test drive vehicle with overdrive switch moved from ON to
OFF position. With overdrive in OFF position, voltage should be less than .5 volt. With overdrive in ON
position, battery voltage should be present. If voltage is not as specified, go to next step. If voltage is as
specified, no problem is indicated at this time. Fault may be intermittent. If sent here from SYMPTOM
DIAGNOSIS, perform next test listed.
4. Check wiring harness and connectors between cruise control ECU terminal No. 6 (Pink wire) and
electronically controlled transmission solenoid. Repair as necessary. If wiring harness and connectors are
okay, replace cruise control ECU and retest system.
5. Check wiring harness and connectors between cruise control ECU connector terminal No. 14
(Yellow/Black wire) and Engine Control Module (ECM) 22-pin connector terminal No. 20
(Yellow/Black wire). Repair as necessary. If wiring harness and connectors are okay, replace cruise
control ECU and retest system.
PARK/NEUTRAL POSITION SWITCH CIRCUIT
1. Ensure starting system is operating normally. Check for starting system problems and repair as necessary.
See STARTERS article in STARTING & CHARGING SYSTEMS. If starting system is okay, go to next
step.
2. Perform park/neutral position switch test. See CANCEL SWITCHES test in CRUISE CONTROL
FUNCTION TEST under TROUBLE SHOOTING. If park/neutral position switch input signal is not as
specified, go to next step. If park/neutral position switch input signal is as specified, no problem is
indicated at this time. Fault may be intermittent. If sent here from SYMPTOM DIAGNOSIS, perform
next test listed.
3. Remove cruise control ECU with connector attached. See Fig. 1
. Turn ignition switch to ON position.
Backprobing connector, measure voltage between ground and terminal No. 3 (Blue/Black wire) at cruise
control ECU connector. With shift lever in Drive, battery voltage should be present. With shift lever in
any other position, voltage should be less than one volt. If voltage is not as specified, go to next step. If
voltage is as specified, no problem is indicated at this time. Fault may be intermittent. If sent here from
SYMPTOM DIAGNOSIS, perform next test listed.
4. Check wiring harness and connectors between cruise control ECU and park/neutral position switch.
Repair as necessary. If wiring harness and connectors are okay, replace cruise control ECU and retest
system.
CLUTCH SWITCH CIRCUIT
1. Ensure starting system is operating normally. Check for starting system problems and repair as necessary.
If starting system is okay, go to next step.
2. Perform clutch switch position test. See CANCEL SWITCHES test in CRUISE CONTROL

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1999 ACCESSORIES & EQUIPMENT Cruise Control Systems - RAV4
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FUNCTION TEST under TROUBLE SHOOTING. If clutch switch input signal is not as specified, go to
next step. If clutch switch input signal is as specified, no problem is indicated at this time. Fault may be
intermittent. If sent here from SYMPTOM DIAGNOSIS, perform next test listed.
3. Remove cruise control ECU with connector attached. See Fig. 1
. Turn ignition switch to ON position.
Using voltmeter positive lead, backprobe cruise control ECU connector terminal No. 3 (Blue/Black wire)
with negative lead to ground. With clutch pedal depressed, battery voltage should exist. With clutch pedal
released, voltage should be less than one volt. If voltage is not as specified, go to next step. If voltage is
as specified, no problem is indicated at this time. Fault may be intermittent. If sent here from SYMPTOM
DIAGNOSIS, perform next test listed.
4. Check wiring harness and connectors between cruise control ECU and TURN & GAUGE fuses in
instrument panel junction block. Repair as necessary. If wiring harness and connectors are okay, replace
cruise control ECU and retest system.
CRUISE CONTROL ECU POWER SOURCE CIRCUIT
1. Locate ECU-IG (10-amp) fuse in instrument panel junction block. See Fig. 1
. Remove ECU-IG fuse and
ensure fuse continuity. If fuse is okay, go to next step. If fuse is not okay, check for short between cruise
control ECU connector terminal No. 9 (Black/Yellow wire) and ECU-IG fuse.
2. Remove cruise control ECU with connector attached. See Fig. 1
. Turn ignition switch to ON position.
Using voltmeter, backprobe between cruise control ECU connector terminals No. 9 (Black/Yellow wire)
and No. 16 (White/Black wire). If battery voltage is not present, go to next step. If battery voltage is
present, no problem is indicated at this time. Fault may be intermittent. If sent here from SYMPTOM
DIAGNOSIS, perform next test listed.
3. Turn ignition switch to OFF position. Backprobing connector, measure resistance between ground and
terminal No. 16 (White/Black wire) at cruise control ECU connector. If resistance is less than one ohm,
check wiring harness or connector between cruise control ECU connector and battery. Repair as
necessary and retest system. If resistance is one ohm or more, repair wiring harness or connector between
cruise control ECU connector terminal No. 16 (White/Black wire) and ground. Retest system.
CRUISE CONTROL INDICATOR LIGHT CIRCUIT
1. Turn ignition switch to ON position. Backprobing connector, measure voltage between ground and
terminal No. 4 (Green/Red wire) at cruise control ECU connector. With cruise control switch in OFF
position, battery voltage should be present. With cruise control switch in ON position, voltage should be
less than 1.2 volts.
2. If voltage is as specified, no problem is indicated at this time. Fault may be intermittent. If sent here from
SYMPTOM DIAGNOSIS, perform next test listed. If voltage is not as specified, check instrument
cluster. See appropriate INSTRUMENT PANELS article. Repair as necessary. If instrument cluster is
okay, replace cruise control ECU and retest system.
DIAGNOSTIC CIRCUIT
1. Locate Data Link Connector (DLC) No. 1 in right side of engine compartment, near shock tower.
Connect voltmeter positive lead to terminal Tc and negative lead to terminal E1. See Fig. 2
. Turn
ignition switch to ON position. If battery voltage is not present, go to next step. If battery voltage is
present, no problem is indicated at this time. Fault ma
y be intermittent. If sent here from SYMPTOM

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1999 ACCESSORIES & EQUIPMENT Cruise Control Systems - RAV4
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Sunday, November 22, 2009 10:52:01 AMPage 13 © 2005 Mitchell Repair Information Company, LLC.

1. Perform VEHICLE SPEED SENSOR test under CRUISE CONTROL FUNCTION TEST under
TROUBLE SHOOTING. If speed sensor input signals are not as specified, go to next step. If speed
sensor input signals are as specified, replace cruise control ECU and retest system.
2. Check speedometer circuit. See appropriate INSTRUMENT PANELS article. If speedometer circuit is
okay, go to next step. If speedometer circuit is not okay, repair wiring harness, connector or instrument
cluster as necessary. Retest system.
3. Check wiring harness and connectors between cruise control ECU, vehicle speed sensor and instrument
cluster. Repair as necessary and retest system. If wiring harness and connectors are okay, go to next step.
4. Remove vehicle speed sensor from transaxle. See Fig. 1
. Using jumper wires, connect positive battery
terminal to vehicle speed sensor terminal No. 1 (Red/Blue wire) and negative battery terminal to terminal
No. 2 (Blue/Black wire). Connect voltmeter positive lead to terminal No. 3 (Red/Yellow wire) and
negative lead to terminal No. 2 (Blue/Black wire). See Fig. 5
. Rotate vehicle speed sensor shaft and
ensure voltage changes from 0-11 volts or more 4 times per shaft revolution. Replace vehicle speed
sensor as necessary. If vehicle speed sensor is okay, replace cruise control ECU and retest system.
Fig. 5: Testing Vehicle Speed Sensor

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
DTC 23: VEHICLE SPEED SENSOR SIGNAL FAULT
Check vehicle speed sensor. See COMPONENT TESTS
. Replace vehicle speed sensor as necessary. If

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1999 ACCESSORIES & EQUIPMENT Cruise Control Systems - RAV4
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Fig. 2: Identifying Defogger Switch Harness Connector Terminals (2000 Celica)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
MR2
1. Disconnect defogger switch 14-pin connector. Check continuity between ground and defogger switch
harness connector terminal No. 4 (White/Black wire). See Fig. 3
. If continuity exists, go to next step. If
continuity does not exist, repair ground circuit as necessary. See WIRING DIAGRAMS
.
2. Turn ignition on. Measure voltage between ground and defogger switch harness connector terminal No.
12 (Pink/Blue wire). Battery voltage should exist. With ignition switch in LOCK or ACC position, no
voltage should exist. If voltage is as specified, go to next step. If voltage is not as specified, repair
appropriate circuit as necessary. See WIRING DIAGRAMS
.
3. Connect defogger switch harness connector. Turn ignition on. Measure voltage between ground and
defogger switch connector (backprobe) terminal No. 12 (Pink/Blue wire). Battery voltage should exist.
Turn defogger switch to ON position. No voltage should exist. If voltage is not as specified, replace
defo
gger switch and retest system.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Rear Window & Mirror Defoggers
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