shift TOYOTA RAV4 1996 Service Owner's Manual

− DIAGNOSTICSENGINE
DI−19
1996 RAV4 (RM447U) FC (E6−14) − E1 (E4−14)
G−R ↔ BRIG switch ON9 ∼ 14
EGR (E4−23) − E1 (E4−14)B−W ↔ BRIG switch ON0 ∼ 3
ISCC (E4−9) − E1 (E4−14)B−Y ↔ BRIG switch ON
Disconnect E4 of ECM connector9 ∼ 14
ISCO (E4−10) − E1 (E4−14)B−L ↔ BRIG switch ON
Disconnect E4 of ECM connector9 ∼ 14
OX1 (E5−6) − E1 (E4−14)B ↔ BRMaintain engine speed at 2,500 rpm for 2 mins. after
warning up.Pulse generation
OX2 (E5−5) − E1 (E4−14)B ↔ BRMaintain engine speed at 2,500 rpm for 2 mins. after
warning up.Pulse generation
KNK (E5−10) − E1 (E4−14)B ↔ BRIdlingPulse generation
(See page DI−56)
* NSW (E6−22) − E1 (E4−14)B−W ↔ BR
IG switch ON
Other shift position in ”P” , ”N” position9 ∼ 14
IG switch ON
Shift position in ”P” , ”N” position0 ∼ 3.0
SPD (E6−9) − E1 (E4−14)V−W ↔ BRIG switch ON
Rotate driver wheel slowly.Pulse generation
(See page DI−94)
TE1 (E5−15) − E1 (E4−14)L−W ↔ BRIG switch ON9 ∼ 14
W (E6−5) − E1 (E4−14)G−R ↔ BRIdling9 ∼ 14
IG switch ONBelow 3.0
AC (E6−10) − E1 (E4−14)Y−G ↔ BRIdling, A/C switch ONBelow 2.0
Idling, A/C switch OFF9 ∼ 14
ACT (E6−21) − E1 (E4−14)R−Y ↔ BRIdling, A/C switch ON9 ∼ 14
Idling, A/C switch OFFBelow 2.0
* OD2 (E6−7) − E1 (E4−14)LG ↔ BRIG switch ON, O/D main switch pushed out9 ∼ 14
IG switch ON, O/D main switch pushed in0 ∼ 3
* OD1 (E6−20) − E1 (E4−14)Y−B ↔ BRIG switch ON, Cruise control ECU no request O/D cut9 ∼ 14
IG switch ON, Cruise control ECU request O/D cut0 ∼ 3
EVP (E4−22) − E1 (E4−14)P ↔ BRIG switch ON9 ∼ 14
TPC (E5−8) − E1 (E4−14)R−W ↔ BRIG switch ON9 ∼ 14
PTNK (E5−7) − E2 (E5−9)L−Y ↔ BR
IG switch ON, Disconnect vacuum hose from vapor
pressure sensor2.9 ∼ 3.7
Apply vacuum
(4.0 kPa, 30 mmHg, 1.18 in. Hg)
(less than 66.7 kPa, 500 mmHg, 19.7 in. Hg)
Below 0.5
ELS (E6−17) − E1 (E4−14)B ↔ BRDefogger switch and taillight switch ON7.5 ∼ 14
Defogger switch and taillight switch OFF0 ∼ 1.5
SDL (E6−16) − E1 (E4−14)W ↔ BRDuring transmissionPules generation
*: A/T only

A00415
SPD
(+)
ON
AT7809
4.5 − 5.5 V
Turn the wheel
0
DI−96
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
2 Check voltage between terminal SPD of ECM connector and body ground.
PREPARATION:
(a) Remove side trim cover (See page SF−62).
(b) Shift the shift lever to neutral.
(c) Jack up one of the front wheels
(d) Turn ignition switch ON.
CHECK:
Measure voltage between terminal SPD of ECM connector and
body ground when the wheel is turned slowly.
OK:
Voltage is generated intermittently.
NG Check and repair harness and connector be-
tween combination meter and ECM.
OK
Check and replace ECM (See page IN−30).

DI−11 0
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
DTC P1780 Park/Neutral Position Switch Malfunction
CIRCUIT DESCRIPTION
The park / neutral position switch goes on when the shift lever is in the N or P shift position. When it goes
on terminal NSW of the ECM is grounded to body ground via the starter relay thus the terminal NSW voltage
becomes 0 V. When the shift lever is in the D, 2, L or R position, the park / neutral position switch goes off,
so the voltage of ECM terminal NSW becomes battery positive voltage, the voltage of the ECM internal pow-
er source.
If the shift lever is moved from the N position to the D position, this signal is used for air−fuel ratio correction
and for idle speed control (estimated control), etc.
DTC No.DTC Detecting ConditionTrouble Area
P1780
Two or more switches are ON simultaneously for ”N”, ”2”, ”L”
and ”R” position
(2 trip detection logic)
Short in park / neutral position switch circuit
Park / neutral position switch
ECMWhen driving under conditions (a) and (b) 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
HINT:
After confirming DTC P1780 use the TOYOTA hand−held tester to confirm the PNP switch signal from ”CUR-
RENT DATA”.
DI404−01

S07292
1K1D 49
EA1IG1
1211
22
2 225
23
1
22
6
5 21
20
AA
BR 1D1F1E
1B
1H
1D3718
8
13 34 Fuse Block
B
R−L
R−LECM
E6
E6
E6
E6 19 188 22
IG17
16
IG2
IG2 15 3B 5
53A
IG2 2 IG1 10 EA17
EA113S3 1 B
B
*1: 2WD
*2: 4WD
J1
Junction
Connector Fusible
Link
BlockMAIN
Battery
To Terminal STA of ECMEAB
StarterPark/Neutral
Position
Switch
R−B5 B−W W
B−R
J/B No.1
B−RB−R
724
8B−W B−Y IG Switch
W
ST Relay
ALT
AM2
MAIN No.1
B
R−L
B−W J/B No.1
LG−R
LG
LG R−B
LG−R
W−BW−BB+
R
2
LE1
E1
E1 NSW
8
9
3
4
4
6 3 5 2 6
R
AM1
1
2
GAUGE
R/B No.2
W
W2 6*
1
*2
*12 *1
*1
*2
*1
*2
*1
*2
*2
*1
R−L
S02502S02496A07403
2WD:
4WD:4
6
2
10
− DIAGNOSTICSENGINE
DI−111
1996 RAV4 (RM447U)
WIRING DIAGRAM
INSPECTION PROCEDURE
1 Check park / neutral position switch.
PREPARATION:
Disconnect park / neutral position switch connector.
CHECK:
Check continuity between each terminal shown below when the
shift lever is positioned to each range.
OK:
Shift PositionTerminal No. to continuity
P6 − 1 *1 : 2 − 7 *22 − 3 *1 : 5 − 6 *2
R6 − 5 *1 : 2 − 8 *2
N6 − 7 *1 : 2 − 9 *22 − 3 *1 : 5 − 6 *2
D6 − 8 *1 : 2 − 10 *2
26 − 9 *1 : 2 − 3 *2
L6 − 4 *1 : 2 − 4 *2
*1: 2WD
*
2: 4WD
NG Replace park / neutral position switch.

BE6653P23734A07404
ON
NSW
(+)
DI−11 2
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
OK
2 Check voltage between terminal NSW of ECM connector and body ground.
PREPARATION:
(a) Remove side trim cover (See page SF−61).
(b) Turn ignition switch ON.
CHECK:
Measure voltage between terminal NSW of ECM connector and
body ground after the shift lever is moved to the following posi-
tions.
OK:
Shift lever positionP or NL, 2, D or R
Voltage0 − 3 V9 − 14 V
OK Check and replace ECM (See page IN−30).
NG
Check for open and short in harness and con-
nector between ECM and park / neutral posi-
tion switch (See page IN−30).

DI409−02
Vehicle Brought to Workshop
P.DI−126
Connect the OBD ll Scan Tool or TOYOTA Hand−Held Tester to DLC3
If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have
connected the scan tool/TOYOTA hand−held tester, inspect DLC3 P. DI−127
Check DTC and Freeze Frame Data (Pre−check)
Record or Print DTC and Freeze Frame Data P. DI−127
Clear DTC and Freeze Frame Data P. DI−127 Customer Problem Analysis
Visual Inspection
DTC CheckSymptom Simulation Setting the Check Mode Diagnosis P. DI−127
Problem Symptom Confirmation
P. IN−20 Symptom does
not occur
OK Codethe page number indicated in the bottom portion. See the
indicated pages for detailed explanations.
Preliminary Checkare titles of pages in the manual, with Item inside
Mechanical System Tests DTC Chart
Chapter 1
(Electronic)Manual Shifting Test
Matrix Chart of Symptoms Problems − P. DI−140
(On−vehicle)
 Pattern Select Signal Check  O/D Signal Check
InspectionCircuit(Off−vehicle) Chapter 2 Chapter 3
END Repair
Confirmation Test
Identification of ProblemParts Inspection P. DI−127
P. DI−127P. DI−127
P. DI−127
P. DI−127
P. DI−145 − DI−168 P. DI−141 1
2
P. DI−141P. DI−141 3
4
5
6
78
9
1011
12
13
14
16
18 15
17
Symptom occurs
OKNG
OKNG
NG
OK
OK OK
NG
NGNG
Step 2, 3, 4, 6, 9, 15, 18:
Diagnostic steps permitting the use of the TOYOTA
hand−held tester or TOYOTA brake−out−box.
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−125
1996 RAV4 (RM447U)
AUTOMATIC TRANSAXLE (A241E)
HOW TO PROCEED WITH TROUBLESHOOTING
Trobleshoot in accordance with the procedure on the follwoing pages.

Brought InInspector ’s
System Check Sheet
Name
Customer ’s NameTransaxle Control
Registration No.
Frame No.
Date VehicleRegistration Year:
Date Problem
Frequency
Problem Occurs Occurred/ /
Odometer Reading
SymptomsIntermittent ( times a day)
Vehicle does not move Any positionContinuous
Particular position) / /km
mile
/ /
Shift point too high or too low No up−shift 1st → 2nd
Lock−up malfunction
Harsh engagement No down−shift
(
3rd → O/D) (
N → D (
2nd → 1st) 2nd → 3rd
3rd → 2nd O/D → 3rd
Slip or shudder
No kick−down
Malfunction code (Code )Any drive position) Lock−up
Others
1st Time
2nd Time(
Indicator LampRemains ON Check ItemMalfunction
Normal
DTC Check
Normal
NormalMalfunction code (Code )
DI40A−01
DI−126
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
CUSTOMER PROBLEM ANALYSIS CHECK

− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−131
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 simulation test (See page IN−20).
(4) Check the connector connection and terminal (See page IN−30).
(5) Visual check and contact pressure (See page IN−20).
(6) Handle the connector (See page IN−20).
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, 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 symp-
toms.
6. ROAD TEST
NOTICE:
Do the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
(a) D position test.
Shift into the D position, keep the accelerator pedal constant at the full throttle valve opening position
and check the following points:
(1) Check up− shift operation.
Check that 1 → 2, 2 → 3 and 3 → O/D up−shift takes place, at the shift point shown in the automat-
ic shift schedule (See page SS−32).
HINT:
O/D Gear Up−shift Prohibition Control:
Engine coolant temperature is 50°C (122°F) or less.
If there is a 10km/h (6 mph) difference between the set cruise control speed and vehicle speed.
O/D main switch is pushed ON (During the O/D OFF indicator light lights up.).
O/D Gear Lock−up Prohibition Control:
Brake pedal is depressed.
Engine coolant temperature is 50°C (122°F) or less.
(2) Check for shift shock and slip.
Check for shock and slip at the 1 → 2, 2 → 3 and 3 → O/D up−shifts.
(3) Check for abnormal noise and vibration.
Run at the D position lock−up or O/D gear and check for abnormal noise and vibration.
HINT:
The check for the cause of abnormal noise and vibration must be performed very thoroughly as it could also
be due to loss of balance in the torque converter clutch, etc.
(4) Check kick−down operation.
While running in the D position, 2nd, 3rd and O/D gears, check that the possible kick−down ve-
hicle 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−32).
(5) Check abnormal shock and slip at kick−down.
(6) Check 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 RPM does not change abruptly.
If there is a big jump in RPM, there is no lock−up.

Q06070
AT3417
OK if hot
Add if hot DI−132
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
(b) 2 position test.
Shift into the 2 position and, while drive with the accelerator pedal held constantly at the full throttle
valve opening position, check on the following points:
(1) Check up−shift operation.
Check that the 1 → 2 up−shift takes place and that the shift point conforms to the automatic shift
schedule (See page SS−32).
HINT:
There is no O/D up−shift and lock−up in the 2 position.
(2) Check engine braking.
While running in the 2nd gear of the 2 position, release the accelerator pedal and check the en-
gine braking effect.
(3) Check for abnormal noises during acceleration and deceleration, and for shock at up−shift and
down−shift.
(c) L position test.
Shift into the L position and while driving with the accelerator pedal held constantly at the full throttle
valve opening position, check the following points:
(1) Check no up−shift.
While running in the L position, check that there in no up−shift to 2nd gear.
(2) Check engine braking.
While running in the L position, release the accelerator pedal and check the engine braking ef-
fect.
(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 and 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 that the parking lock pawl holds the vehicle in place.
7. BASIC INSPECTION
(a) Check the fluid level.
HINT:
Drive the vehicle so that the engine and transaxle are at
normal operating temperature.
Fluid temperature: 70 − 80°C (158 − 176°F)
Only use the COOL range on the dipstick as a rough refer-
ence when the fluid is replaced or the engine does not
run.
(1) Park the vehicle on a level surface and set the park-
ing brake.
(2) With the engine idling and the brake pedal de-
pressed, shift the shift lever into all positions from
the P to L position and return to the P position.
(3) Pull out the oil level gauge 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, add new fluid.

OR0028
Q06076
AT3417
OK if hot
Add if hot
AT4252
0 − 1 mm
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−133
1996 RAV4 (RM447U)
Fluid type: ATF DEXRON ®II
NOTICE:
Do not overfill.
(b) Check the fluid condition.
If the fluid smells burnt or is black, replace it.
(c) Replace the fluid.
(1) Remove the drain plug and drain the fluid.
(2) Reinstall the drain plug securely.
(3) With the engine OFF, add new fluid through the oil
filler pipe.
Fluid type: ATF DEXRON ®II
Capacity:
Drain and refill: 3.3 liters (3.5 US qts, 2.9 lmp. qts)
(4) Start the engine and shift the shift lever into all posi-
tions from P to L position and then shift into P posi-
tion.
(5) With the engine idling, check the fluid level. Add
fluid up to the COOL level on the dipstick.
(6) Check the fluid level at the normal operating tem-
perature 70 − 80°C (158 − 176°F) and add as nec-
essary.
NOTICE:
Do not overfill.
(d) Check the fluid leaks.
Check for leaks in the transaxle.
If there are leaks, it is necessary to replace O−rings, gaskets,
oil seals, plugs or other parts.
(e) Inspect and adjust throttle cable.
(1) Check that the throttle valve is fully closed.
(2) Check that the inner cable is not slack.
(3) Measure the distance between the outer cable end
and stopper on the cable.
Standard distance: 0 − 1 mm (0 − 0.04 in.)
If the distance is not within the standard, adjust the cable by the
adjusting nuts.