engine TOYOTA RAV4 1996 Service Repair Manual

Q06070
D02315
OK if hot
Add if hot
D00697
Ok if hot
Add if hot
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−179
1996 RAV4 (RM447U)
7. BASIC INSPECTION
(a) Check the ATF level.
HINT:
The vehicle must have been driven so that the engine and
transaxle are at normal operating temperature.
ATF temperature: 70 − 80°C (158 − 176°F)
(1) Park the vehicle on a level surface, set the parking
brake.
(2) With the engine idling and the brake pedal de-
pressed, shift the shift lever into each gear from the
P position to L position smoothly and return to the
P position.
(3) Pull out the transaxle dipstick and wipe it clean.
(4) Push it back fully into the pipe.
(5) Pull it out and check that the fluid level is in the HOT
range.
If the level is at the low side of the hot range, add fluid.
Fluid type: ATF type T or equivalent
NOTICE:
Do not overfill.
(b) Check the transfer oil level.
(1) Park the vehicle on a level surface, set the parking
brake.
(2) Pull out the transfer dipstick and wipe it clean.
(3) Push it back fully into the pipe.
(4) Pull it out and check the oil level, as shown in the il-
lustration.
Oil grade: API GL−5
Oil viscosity: SAE 75W−90

Q06065
Q06076
D02315
OK if hot
Add if hot
D00699
D00700
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−181
1996 RAV4 (RM447U)
(d) Replace the ATF.
NOTICE:
Do not overfill.
(1) Using a 10 mm hexagon wrench, remove the drain
plug, gasket and drain the fluid.
(2) Install a new gasket and the drain plug securely.
(3) Add new fluid through the filler pipe.
Fluid type: ATF type T or equivalent
Drain and refill: 3.3 liters (3.5 US qts, 2.9 lmp. qts)
(4) Start the engine and shift the selector into all the
positions from P through L and then shift into the P
position.
(5) With the engine idling, check the fluid level. Add
fluid up to the COOL level on the dipstick.
(6) Check the fluid level with the normal fluid tempera-
ture 70 − 80°C (158 − 176°F) and add as neces-
sary.
NOTICE:
Do not overfill.
(e) Replace the transfer oil.
(1) Using a 10 mm hexagon wrench, remove the drain
plug and drain the oil.
(2) Install the drain plug.
(3) Add new oil through the filler pipe.
Recommended oil:
Oil grade API GL−5
Viscosity SAE 75W−90
Capacity: 0.7 liters (0.7 US qts, 0.6 lmp. qts)
(4) Check the oil level and add as necessary.
NOTICE:
Do not overfill.

Q06077NRP
Q06078
Neutral
Basic
Line
Groove
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−183
1996 RAV4 (RM447U)
(3) Return the lever 2 notches to the NEUTRAL posi-
tion.
(4) Set the shift lever in the N position.
(5) While holding the lever lightly toward the ”R” posi-
tion side, tighten the shift lever nut.
(i) Adjust the park/neutral position switch.
If the engine will start with the shift selector in any position other
than the N or P position, adjustment is required.
(1) Loosen the park/neutral position switch bolts and
set the shift selector to the N position.
(2) Align the groove and neutral basic line.
(3) Hold in position and tighten the bolts.
Torque: 5.4 N·m(55 kgf·cm,48 in·lbf)
(j) Inspect the idle speed.
Idle speed: 750 ± 50 rpm (In N position and A/C OFF)
8. MECHANICAL SYSTEM TESTS
(a) Measure the stall speed.
The object of this test is to check the overall performance of the transaxle and engine by measuring
the stall speeds in the D and R positions.
NOTICE:
Do the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear, level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Connect OBD II scan tool or TOYOTA hand−held tester to the DLC3.
(3) Fully apply the parking brake.
(4) Keep your left foot pressed firmly on the brake pedal.
(5) Start the engine.
(6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot.
Quickly read the stall speed at this time.
Stall speed: 2,400 ± 150 rpm
(7) Do the same test in R position.
Stall speed: 2,400 ± 150 rpm
Evaluation:
ProblemPossible cause
Stall speed low in D and R positions
Engine output may be insufficient
Stator one−way clutch is operating properly
HINT:
If more than 600 rpm below the specified value, the torque converter clutch could
be faulty

DI−184
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U) Stall speed high in D position
Line pressure too low
Forward clutch slipping
No. 2 one−way clutch not operating properly
O/D one−way clutch not operating properly
Stall speed high in R position
Line pressure too low
Direct clutch slipping
1st and reverse brake slipping
O/D clutch slipping
Stall speed high in D and R positions
Line pressure too low
Improper fluid level
O/D one−way clutch not operating properly
(b) Measure the time lag.
When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before
the shock can be felt. This is used for checking the condition of the O/D direct clutch, forward clutch,
direct clutch, and 1st and reverse brake.
NOTICE:
Do the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
Be sure to allow 1 minute interval between tests.
Take 3 measurements and take the average value.
(1) Fully apply the parking brake.
(2) Start the engine and check idle speed.
Idle speed: 750 ± 50 rpm (In N position and A/C OFF)
(3) Shift the shift lever from the N to D position. Using a stop watch, measure the time it takes from
shifting the lever until the shock is felt.
Time lag: N → D Less than 1.2 seconds
In the same way, measure the time lag for N → R.
Time lag: N → R Less than 1.5 seconds
If N → D or N → R time lag is longer than specified:
Evaluation:
ProblemPossible cause
N → D time lag is longer
Line pressure too low
Forward clutch worn
O/D one−way clutch not operating properly
N → R time lag is longer
Line pressure too low
Direct clutch worn
1st and reverse brake worn
O/D one−way clutch not operating properly
9. Line Pressure:
HYDRAULIC TEST
(a) Preparation.
(1) Warm up the ATF.
(2) Remove the test plug on the transaxle case and connect SST (See page AX−18 for the location
to connect SST).
SST 09992−00094 (09992−00230)

D02249
1
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−185
1996 RAV4 (RM447U)
CAUTION:
Perform the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
The line pressure test should always be carried out in parts. One should observe the conditions
of wheels or wheel stopper outside the vehicle while the other is performing the test.
(b) Measure the line pressure.
(1) Fully apply the parking brake and chock the 4 wheels.
(2) Start the engine and check idling speed.
(3) Step down strongly on the brake pedal with your left foot and shift into the D position.
(4) Measure the line pressure when the engine is idling speed.
(5) Press the accelerator pedal all the way down. Quickly read the highest line pressure when engine
speed reaches stall speed.
(6) Only when the shift solenoid valve ST is opened:
Apply battery positive voltage between terminal of the solenoid connector and body ground.
(7) In the same way, perform the test in the R position.
Automatic Transaxle Idling kPa (kgf/cm2, psi) Stall kPa (kgf/cm2, psi)
* D position (Shift solenoid valve ST open)530 − 706 (5.4 − 7.2, 76 − 102)1,324 − 1,549 (13.5 − 15.8, 192 − 225)
D position (Shift solenoid valve ST close)363 − 442 (3.7 − 4.3, 53 − 61)736 − 863 (7.5 − 8.8, 106 − 125)
R position530 − 706 (5.4 − 7.2, 76 − 102)1,324 − 1,549 (13.5 − 15.8, 192 − 225)
*: When battery voltage is supplied to terminal 4 of the solenoid connector and body ground, the shift sole-
noid valve ST valve is open.
If the measured pressures are not with in the specification, recheck the throttle cable adjustment and perform
a retest.
(8) Clear the DTC’s after the test.
Evaluation:
ProblemPossible cause
If the measured values at all positions are higher than speci-
fiedThrottle cable out of adjustment
Throttle valve defective
Regulator valve defective
If the measured value in all positions are lower than speci-
fied
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
Oil pump defective
O/D direct clutch defective

DI−186
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U) 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
10. Center Differential Control Clutch:
HYDRAULIC TEST
(a) Preparation.
(1) Warm up the ATF.
(2) Remove the test plug and connect SST (See page AX−18 for the location to connect SST).
SST SST 09992−00094 (09992−00111)
CAUTION:
Perform the test at normal operating ATF temperature 50 − 80°C (122 − 176°F)
The line pressure test should always be carried out in pairs. One should observe the conditions
of wheels or wheel stoppers outside the vehicle while the other is performing the test.
(b) Measure the center differential clutch control pressure.
(1) Start the vehicle and open the accelerator open 50 % or more and check that the center differen-
tial clutch control pressure is in the range from more than 294 kPa (3.0 kgf/cm
2, 42 psi).
(2) Fully close the accelerator and check that the SST registers 9.8 kPa (0.1 kgf/cm
2, 1.4 psi) or less.
CAUTION:
Confirm safety of the road before checking.
Take care to avoid slip when you start the vehicle on a paved road.
Check the pressure at normal driving ATF temperature 50 − 80°C (122 − 176°F).
Reference:
To measure center differential control pressure to be measured with the solenoid opened by applying voltage
to it, refer to the following:
Prepare a sub−assembly for checking as follows:
Prepare a supply connector (Part No. 90980−10629, or 90980−11143)
Connect a harness of 2 − 3 m (6.6 − 9.8 ft) to terminal 1 of the connector.
Place a bulb of 24W in between the harness.
Connect a harness of 2 − 3 m (6.6 − 9.8 ft) to terminal 3 of the connector.
Connect the inspection’s sub−harness assembly to the solenoid connector of the transfer.
Connect terminal 1 of the sub−harness to the battery’s positive (+) terminal, and terminal 3 of the sub−
harness to the battery’s negative (−) terminal.
Measure the center differential control pressure at idling and when performing the stall test (When 1st
gear).
Engine speedSub−harnessLine pressure kPa (kgf/cm2, psi)
IdlingConnected363 − 422 (3.7 − 4.3, 53 − 61)
Stall (Shift solenoid valve SLD OFF)Connected735 − 863 (7.5 − 8.8, 107 − 125)
Stall (Shift solenoid valve SLD ON)Connected1,324 − 1,549 (13.5 − 15.8, 192 − 225)
All rpmNot connected9.8 (0.1, 1.4) or less

DI40X−02
DI−192
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
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)2. ECMDI−191
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−223
DI−221
DI−191
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−223
DI−221
DI−191
No down−shift (A particular gear, from 1st to 3rd gear, is not
down−shifted)1. ECMDI−191
No lock−up1. Stop light switch circuit
2. ECMDI−227
DI−191
No lock−up off1. ECMDI−191
Shift point too high or too low1. Pattern select switch circuit
2. ECMDI−229
DI−191
Up−shifts to O/D from 3rd while O/D main switch is OFF1. O/D main switch & O/D OFF indicator light circuit
2. ECMDI−223
DI−191
Up−shifts to O/D from 3rd while engine is cold1. ECMDI−191
No kick−down1. ECMDI−191
Engine stalls when starting off or stopping1. ECMDI−191
”A/T OIL” indicator light does not light up or does not goes off1. A/T temperature switchDI−191
Chapter 2: On−Vehicle Repair
(: A540H Automatic Transaxle Repair Manual Pub. No. RM488U)
SymptomSuspect AreaSee page
Vehicle does not move in R position
1. 1−2 shift valve
2. 2−3 shift valve
3. Throttle valve
4. Off−vehicle repair matrix chart


−
Vehicle does not move in any forward position or reverse position
1. Manual valve
2. Primary regulator valve
3. Secondary regulator valve
4. Off−vehicle repair matrix chart


−

− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−193
1996 RAV4 (RM447U) No lock−up
1. Lock−up relay valve
2. Off−vehicle repair matrix chart
−
No lock− up OFF1. Lock−up relay valve
2. Off−vehicle repair matrix chart
−
No kick−down
1. Throttle cable
2. 1−2 shift valve
3. 2−3 shift valve
4. 3−4 shift valve
5. Down shift plug




No engine braking (1st (L position))
1. Low coast modulator valve
2. Low coast modulator valve
3. Off−vehicle repair matrix chart

−
No engine braking (2nd (2 position))
1. 2nd coast modulator valve
2. 2nd lock valve
3. Off−vehicle repair matrix chart

−
No up−shift (1st → 2nd)1. 1−2 shift valve
2. Off−vehicle repair matrix chart
−
No up−shift (2nd → 3rd)1. 2−3 shift valve
2. Off−vehicle repair matrix chart
−
No up−shift (3rd → O/D)1. 3−4 shift valve
2. Off−vehicle repair matrix chart
−
No down−shift (O/D → 3rd)1. 3−4 shift valve
2. Off−vehicle repair matrix chart
−
No down shift (3rd → 2nd)1. 2−3 shift valve
2. Off−vehicle repair matrix chart
−
No down shift (2nd → 1st)1. 1−2 shift valve
2. Off−vehicle repair matrix chart
−
Harsh engagement (N → R)1. No. 1 and No. 2 accumulator control valve
2. Off−vehicle repair matrix chart
−
Harsh engagement (N → D)1. C1 accumulator
2. Off−vehicle repair matrix chart
−
Harsh engagement (N → L)1. Low coast modulator valve
Harsh engagement (1st → 2nd (D position))1. B2 accumulator
2. Off−vehicle repair matrix chart
−
Harsh engagement (1st → 2nd (2 position))1. 2nd coast modulator valve
Harsh engagement (1st → 2nd → 3rd)1. Throttle modulator valve
2. No. 1 and No. 2 accumulator control valve

Harsh engagement (1st → 2nd → 3rd → O/D)1. No. 1 and No. 2 accumulator control valve
Harsh engagement (2nd → 3rd)1. C2 accumulator
Harsh engagement (3rd → O/D)1. B0 accumulator
2. Off−vehicle repair matrix chart
−
Harsh engagement (O/D → 3rd)1. C0 accumulator
2. B
0 accumulator


Harsh engagement (3rd → 2nd)
1. B2 accumulator
2. C
0 accumulator
3. B
0 accumulator
4. 2nd coast modulator valve
5. Off−vehicle repair matrix chart




−
Sliper shudder in forward and reverse (Directry after E/G start)
1. Pressure relief valve
2. Oil starter
3. Off−vehicle repair matrix chart
AX−8
−

− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−195
1996 RAV4 (RM447U) Slip on shudder (R range)
1. Direct clutch (C2)
2. O/D direct clutch (C
0)
3. O/D one−way clutch (F
0)



Slip on shudder (1st)1. Forward Clutch (C1)
2. No. 2 one−way Clutch (F
2)


Slip on shudder (2nd)1. 2nd brake (B2)
2. No. 1 one−way clutch (F
1)


Slip on shudder (2nd → 3rd (Up−shift))1. Direct clutch (C2)
Slip on shudder (3rd)1. Direct clutch (C2)
Slip on shudder (O/D)1. O/D brake (B0)
No engine braking (1st − 3rd)1. O/D direct clutch (C0)
No engine braking (1st (L position))1. 1st and reverse brake (B3)
No engine braking (2nd (2 position))2. 2nd coast brake (B1)
Poor acceleration (All positions)1. Torque converter clutch
2. Oil pumpAX−22

Poor acceleration (O/D)1. O/D direct clutch (C0)
2. O/D planetary gear

Poor acceleration (Other than O/D)1. O/D brake (B0)
2. O/D planetary gear

Poor acceleration (Other than 2nd)1. 2nd coast brake (B1)
2. 2nd brake (B
2)


Poor acceleration (1st and 2nd)1. O/D brake (B0)
Poor acceleration (1st and R position)1. 1st and reverse brake (B3)
Poor acceleration (R position)1. Forward clutch (C1)
Front or rear wheel is slipping1. Center differential clutch

Q08868
To ST Relay DI−218
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
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 the N, R, 2 and
L positions (2 trip detection logic)
When 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
Short in park/neutral position switch circuit.
Park/neutral position switch
ECM
WIRING DIAGRAM
DI418−02