engine TOYOTA RAV4 1996 Service Repair Manual

DI−136
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
9. HYDRAULIC TEST
Measure the line pressure.
NOTICE:
Do the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
The line pressure test should always carried out in pairs. One technician should observe the
conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
Be careful to prevent SST’s hose from interfering with the exhaust pipe.
(1) Warm up the ATF.
(2) Remove the teat plug on the transaxle case left side and connect SST (See page AX−14. for the
location to connect SST).
SST SST 09992−00094 (09992−00230, 09992−00270)
(3) Chock the 4 wheels.
(4) Fully apply the parking brake.
(5) Start the engine and check idling speed.
(6) Keep your left foot pressed firmly on the brake pedal and shift into the D position.
(7) Measure the line pressure when the engine is idling.
(8) Fully depress the accelerator pedal. Quickly read the highest line pressure when engine speed
reaches stall speed.
NOTICE:
Release the accelerator pedal and stop test if the wheels being to rotate before the engine speed
reaches specified stall speed.
(9) In the same way, do the teat in R position.
Specified line pressure:
ConditionD position kPa (kgf/cm2, psi)R position kPa (kgf/cm2, psi)
Idling353 − 422 (3.6 − 4.3, 51 − 61)598 − 804 (6.1 − 8.2, 87 − 117)
Stall824 − 971 (8.4 − 9.9, 119 − 141)1,530 − 1,780 (15.6 − 18.1, 222 − 257)
If the measured pressures are not up to specified values, recheck the throttle cable adjustment and do a
retest.
Evaluation:
ProblemPossible cause
If the measured value in all positions are higher.
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
If the measured values in all positions are lower.
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
Oil pump defective
U/D direct clutch defective
If pressure is low in the D position only.D position circuit fluid leakage
Forward clutch defective
If pressure is low in the R position only.
R position circuit fluid leakage
Direct clutch defective
1st and reverse brake defective

DI40F−02
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−141
1996 RAV4 (RM447U)
PROBLEM SYMPTOMS TABLE
If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the
circuits for each symptom in the order given in the charts on the following pages and proceed to the page
given for troubleshooting.
The Matrix Chart is divided into 3 chapters.
Chapter 1: Electronic Circuit Matrix Chart
Chapter 2: On−Vehicle repair Matrix Chart
Chapter 3: Off−Vehicle repair Matrix Chart
When troubleshooting, check Chapter 1 first. If instructions are given in Chapter 1 to proceed to chapter 2
or 3, proceed as instructed.
(1) If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow
chart for each circuit, proceed to the circuit with the next highest number in the table to continue
the check.
(2) If the trouble still occurs even though there are no abnormalities in any of the other circuits, then
check and replace the ECM.
Chapter 1: Electronic Circuit Matrix Chart
SymptomSuspect AreaSee page
No up−shift (A particular gear, from 1st to 3rd gear, is not up−
shifted)7. ECMDI−140
No up−shift (3rd → O/D)
1. O/D main switch & O/D OFF indicator light circuit
2. O/D cancel signal circuit
3. ECMDI−161
DI−166
DI−140
No down−shift (O/D → 3rd)
1. O/D main switch & O/D OFF indicator light circuit
2. O/D cancel signal circuit
3. ECMDI−161
DI−166
DI−140
No down−shift (A particular gear, from 1st to 3rd gear, is not
down−shifted)1. ECMDI−140
No lock−up1. Stop light switch circuit
2. ECMDI−159
DI−140
No lock−up off1. Pattern select switch circuit
2. ECMDI−168
DI−140
Shift point too high or too low1. ECMDI−140
Up−shift to O/D from 3rd while O/D main switch is OFF1. O/D main switch & O/D OFF indicator light circuit
2. ECMDI−161
DI−140
Up−shift to O/D from 3rd while engine is cold1. ECMDI−140
No kick−down1. ECMDI−140
Engine stalls when starting off or stopping1. ECMDI−140
Chapter 2: On−Vehicle Repair
(: A241E, A244E, A245E, A246E Automatic Transaxle Repair Manual Pub. No. RM390U)
SymptomSuspect AreaSee page
Does not move in any forward position1. Off−vehicle matrix chart−
Does not move in reverse position1. Off−vehicle matrix chart−
Does not move in any position
1. Primary regulator valve
2. Manual valve
3. Throttle valve
4. Off−vehicle matrix chart


−
No up−shift (1st → 2nd)1. 1−2 shift valve
2. Off−vehicle matrix chart
−

DI−142
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U) No up−shift (2nd → 3rd)
1. 2−3 shift valve
2. Off−vehicle matrix chart
−
No up−shift (3rd → O/D)1. 3−4 shift valve
2. Off−vehicle matrix chart
−
No down−shift (O/D → 3rd)1. 3−4 shift valve
2. Off−vehicle matrix chart
−
No down−shift (3rd → 2nd)1. 2−3 shift valve
2. Off−vehicle matrix chart
−
No down−shift (2nd → 1st)1. 1−2 shift valve
2. Off−vehicle matrix chart
−
Harsh engagement (N → R)1. C2 accumulator
2. Off−vehicle matrix chart
−
Harsh engagement (N → D)1. C1 accumulator
2. Off−vehicle matrix chart
−
Harsh engagement (N → L)
1. 1. C1 accumulator
2. Low coast modulator valve
3. Off−vehicle matrix chart

−
Harsh engagement (1st → 2nd (D position) )
1. Accumulator control valve
2. B
2 Accumulator
3. Off−vehicle matrix chart


−
Harsh engagement (1st → 2nd (2 position) )
1. B2 accumulator
2. Accumulator control valve
3. 2nd coast modulator valve
4. Off−vehicle matrix chart


−
Harsh engagement (1st → 2nd → 3rd → O/D)1. Throttle valve
2. Primary regulator valve

Harsh engagement (2nd → 3rd)
1. C2 accumulator
2. Accumulator control valve
3. Off−vehicle matrix chart

−
Harsh engagement (3rd → O/D)
1. B2 accumulator
2. C
3 accumulator
3. Off−vehicle matrix chart


−
Harsh engagement (O/D → 3rd)1. B4 accumulator
2. Off−vehicle matrix chart
−
Harsh engagement (3rd → 2nd)1. C2 Accumulator
2. Off−vehicle matrix chart
−
Slip (Forward & Reverse)1. Primary regulator valve
2. Off−vehicle matrix chart
−
Slip (R position)1. Off−vehicle matrix chart−
Slip (1st)1. Off−vehicle matrix chart−
Slip (2nd)1. Off−vehicle matrix chart−
Slip (3rd)1. Off−vehicle matrix chart−
Slip (O/D)1. Off−vehicle matrix chart−
No engine braking (1st (L position))1. Low coast modulator valve
2. Off−vehicle matrix chart
−
No engine braking (2nd (2 position))1. 2nd coast modulator valve
2. Off−vehicle matrix chart
−
No kick−down
1. 1−2 shift valve
2. 2−3 shift valve
3. 3−4 shift valve



DI−144
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U) Harsh engagement (O/D → 3rd)
1. U/D brake (B4)
2. On−vehicle matrix chart
−
Harsh engagement (3rd → 2nd)1. Direct clutch (C2)
2. On−vehicle matrix chart
−
Harsh engagement (Lock−up)1. Torque converter clutchAX−20
Slip (Forward & reverse)
1. Torque converter clutch
2. Oil pump
3. On−vehicle matrix chartAX−20

−
Slip (R position)1. Direct clutch (C2)
2. 1st and reverse brake (B
3)


Slip (1st)
1. Forward clutch (C1)
2. No. 2 one−way clutch (F
2)
3. U/D one−way clutch (F
3)



Slip (2nd)
1. Forward clutch (C1)
2. 2nd brake (B
2)
3. No. 1 one−way clutch (F
1)
4. U/D one−way clutch (F
3)

Slip (3rd)
1. Forward clutch (C1)
2. Direct clutch (C
2)
3. U/D one−way clutch (F
3)



Slip (O/D)
1. Forward clutch (C1)
2. Direct clutch (C
2)
3. U/D clutch (C
3)



No engine braking (1st (L position))1. 1st and reverse brake (B3)
2. On−vehicle matrix chart
−
No engine braking (2nd (2 position))1. 2nd coast brake (B1)
2. On−vehicle matrix chart
−
No kick−down1. On−vehicle matrix chart−
Poor acceleration
1. Torque converter clutch
2. Forward clutch (C
1)
3. On−vehicle matrix chart
AX−20

−
No lock−up1. Torque converter clutch
2. On−vehicle matrix chartAX−20
−
Engine stalls when staring off or stopping1. Torque converter clutchAX−20

Q08868
To ST Relay DI−156
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
DTC P1780 Park/Neutral Position Switch Malfunction
CIRCUIT DESCRIPTION
The park/neutral position switch detects the shift lever position and sends signals to the ECM.
The ECM receives signals (NSW, R, 2 and L) from the park/neutral position switch. When the signal is not
sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in the D position.
DTC No.DTC Detecting ConditionTrouble Area
P1780
2 or more switches are ON simultaneously for N, R, 2 or L
position (2 trip detection logic)
Short in park/neutral position switch circuit
Park/neutral position switch
ECMWhen driving under conditions (a), (b) and (c) for 30 sec. or
more, the park / neutral position switch is ON (N position)
(2 trip detection logic)
(a) Vehicle speed: 80 km/h (50 mph) or more
(b) Engine speed: 1,500 − 3,000 rpm
(c) Manifold absolute pressure: 450 mmHg or more
WIRING DIAGRAM
DI40M−02

Q08870
Fuse Block
Junction Connector
FL Block
Stop Light RH Stop Light LHTo ABS ECU
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−159
1996 RAV4 (RM447U)
Stop Light Switch Circuit
CIRCUIT DESCRIPTION
The purpose of this circuit is to prevent the engine from stalling, while driving in lock−up condition, when
brakes are suddenly applied.
When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels of the lock−up
clutch while braking is in progress.
WIRING DIAGRAM
INSPECTION PROCEDURE
1 Check operation of stop light.
CHECK:
Check if the stop lights go on and off normally when the brake pedal is operated and released.
NG Check and repair stop light circuit.
OK
DI98Q−03

Q08848
DI−174
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
The diagnosis system operates in normal mode
during normal vehicle use, and also has a check
mode for technicians to simulate malfunction symp-
toms and perform troubleshooting. Most DTCs use
2 trip detection logic (*) to prevent erroneous detec-
tion. By switching the ECM to check mode when
troubleshooting, the technician can cause the MIL
to light up for a malfunction that is only detected
once or momentarily (TOYOTA hand−held tester)
(See step 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 test
drive, this second detection causes the MIL to light up.
2. Normal Mode:
INSPECT DIAGNOSIS
(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
(See page BE−2).
(2) When the engine starts, the MIL should go off. If the
lamp remains on, the diagnosis system has a mal-
function or abnormality in the system.
(b) Check the DTC.
NOTICE:
TOYOTA hand−held tester only:
When the diagnostic system is switched from the normal
mode to the check mode, it erases all DTCs and freezed
frame data recorded in the normal mode. So before switch-
ing modes, always check the DTCs and freezed frame data,
and note them down.
(1) Prepare the OBD II scan tool (complying with SAE
J1978) or TOYOTA hand−held tester.
(2) Connect the OBD II scan tool or TOYOTA hand−
held tester to the DLC3.
(3) Turn the ignition switch ON and turn the OBD II scan
tool or TOYOTA hand−held tester switch ON.
(4) Use the OBD II scan tool or TOYOTA hand−held
tester to check the DTCs and freezed frame data.
Note them down (For operating instructions, see
the OBDII scan tool’s instruction book.).

FI3605
ON
OFF
0.13 sec.
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−175
1996 RAV4 (RM447U)
(5) See page DI−189 to confirm the details of the
DTCs.
NOTICE:
When simulating symptoms with an OBD II scan tool (ex-
cluding TOYOTA hand−held tester) to check the DTCs, use
the normal mode. For codes on the DTC chart subject to ”2
trip detection logic”, turn the ignition switch off after the
symptoms have been simulated for the first time. Then re-
peat the simulation process again. When the program has
been simulated twice, the MIL lights up and the DTCs are
recorded in the ECM.
3. Check Mode:
INSPECT DIAGNOSIS
HINT:
TOYOTA hand−held tester only:
Compared to the normal mode, the check mode has high sens-
ing ability to detect malfunctions.
Furthermore, the same diagnostic items which are detected in
the normal mode can also be detected in the check mode.
(a) Check the DTC.
(1) Initial conditions.
Battery positive voltage 11 V or more.
Throttle valve fully closed
Transaxle in the PARK position
Air conditioning switched off
(2) Prepare the TOYOTA hand−held tester.
(3) Connect the TOYOTA hand−held tester to the
DLC3.
(4) Turn the ignition switch ON and switch the TOYOTA
hand−held tester ON.
(5) Switch the TOYOTA hand−held tester from the nor-
mal mode to the check mode (Check that the MIL
flashes.).
(6) Start the engine (The MIL goes off after the engine
start.).
(7) Simulate the conditions of the malfunction de-
scribed by the customer.
NOTICE:
Leave the ignition switch ON until you have checked the
DTCs, etc.
(8) After simulating the malfunction conditions, use the
TOYOTA hand−held tester diagnosis selector to
check the DTCs and freezed frame data, etc.
HINT:
Take care not to turn the ignition switch OFF. Turning the ignition
switch off switches the diagnosis system from check mode to
normal mode, so all DTCs, etc. are erased.
(9) After checking the DTC, inspect the applicable cir-
cuit.

− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−177
1996 RAV4 (RM447U)
4. CHECK FOR INTERMITTENT PROBLEMS
TOYOTA hand−held tester only:
By putting the vehicle’s ECM in check mode, 1 trip detection logic is possible instead of 2 trip detection logic
and sensitivity to detect open circuits is increased. This makes it easier to detect intermittent problems.
(1) Clear the DTCs (See step 3).
(2) Set the check mode (See step 3).
(3) Do a simulation test (See page IN−30).
(4) Check the connector connection and terminal (See page IN−30).
(5) Visual check and contact pressure (See page IN−30).
(6) Handle the connector (See page IN−30).
5. PROBLEM SYMPTOM CONFIRMATION
Taking into consideration the results of the customer problem analysis, try to reproduce the symptoms of the
trouble. If the problem is that the transaxle does not up−shift, does down−shift, or the shift point is too high
or too low, conduct the following road test to confirm the automatic shift schedule and simulate the problem
symptoms.
6. ROAD TEST
NOTICE:
Perform the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
(a) D position test in NORM and PWR pattern ranges.
Shift into the D position and hold the accelerator pedal constant at the full throttle valve opening posi-
tion and check the following:
(1) 1 → 2, 2 → 3 and 3 → O/D up−shift should take place, and shift points should conform to those
shown in the automatic shift schedule (See page SS−34).
HINT:
There is not O/D up−shift and lock−up when the engine coolant temperature is below 60°C (140°F).
There is not lock−up when the vehicle speed is 10 km/h (6 mph) less than the set cruise control speed.
ProblemPossible cause
If there is no 1 → 2 up−shiftShift solenoid valve No. 2 stuck
1−2 shift valve is stuck
If there is no 2 → 3 up−shiftShift solenoid valve No. 1 is stuck
2−3 shift valve is stuck
If there is no 3 → O/D up−shift3−4 shift valve is stuck
If the shift point is defectiveThrottle valve, 1−2 shift valve, 2−3 shift valve, 3−4 shift valve etc., are defective
If the lock−up is defectiveShift solenoid valve SL is stuck
Lock−up relay valve is stuck
(2) In the same way, check the shock and slip at the 1 → 2, 2 → 3 and 3 → O/D up−shifts.
Evaluation:
ProblemPossible cause
If the shock is excessive
Line pressure is too high
Accumulator is defective
Check ball is defective
(3) Run at the D position lock−up or O/D gear and check for abnormal noises and vibration.
HINT:
The check for the cause of any abnormal noise and vibration must be made with extreme care as it could
also be due to loss of balance in the drive shaft, tire, torque converter clutch, etc.
(4) While running the D position, 2nd, 3rd and O/D gears, check to see that the possible kick−down
vehicle speed limits for 2 → 1, 3 → 2 and O/D → 3 kick−downs conform to those indicated on
the automatic shift schedule (See page SS−34).
(5) Check for abnormal shock and slip at kick−down.

DI−178
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
(6) Check for the lock−up mechanism.
Drive in the D position, O/D gear, at a steady speed (lock−up ON) of about 75 km/h (47
mph).
Lightly depress the accelerator pedal and check that the engine speed does not change
abruptly.
If there is a big jump in engine speed, there is no lock−up.
(b) 2 position test.
Shift into the 2 position and, while driving with the accelerator pedal held constantly at the full throttle
valve opening position, push in one of the pattern selectors and check on the following points.
(1) Check to see that the 1 → 2 up−shift takes place and that the shift point conforms to that shown
on the automatic shift schedule (See page SS−35).
(2) While running in the 2 points and 2nd gear, release the accelerator pedal and check the engine
braking effect.
Evaluation:
ProblemPossible cause
If these is no engine braking effect2nd coast brake is defective
(3) Check for abnormal noises during acceleration and deceleration, and for shock at up−shift and
down−shift.
(c) L position test.
(1) While running in the L position, check to see that there in no up−shift to 2nd gear.
(2) While running in the L position, release the accelerator pedal and check the engine braking ef-
fect.
Evaluation:
ProblemPossible cause
If these is no engine braking effect1st and reverse brake defective
(3) Check for abnormal noises during acceleration and deceleration.
(d) R position test.
Shift into the R position and, while starting at full throttle, check for slipping.
CAUTION:
Before conducting this test ensure that the test area is free from personnel an obstructions.
(e) P position test.
Stop the vehicle on a gradient (more than 5°) and after shifting into the P position, release the parking
brake. Then check to see that the parking lock pawl holds the vehicle in place.