throttle TOYOTA RAV4 1996 Service Owner's Guide

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



Q08599
Line
Pressure
Drain
Q08590
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−151
1996 RAV4 (RM447U)
DTC P0770 Shift Solenoid E Malfunction
(Shift Solenoid Valve SL)
SYSTEM DESCRIPTION
The ECM uses signals from the throttle position sensor, air−flow
meter and crankshaft position sensor to monitor the engage-
ment condition of the lock−up clutch.
Then the ECM compares the engagement condition of the
lock−up clutch with the lock−up schedule in the ECM memory
to detect mechanical trouble of the shift solenoid valve SL,
valve body and torque converter clutch.
DTC No.DTC Detecting ConditionTrouble Area
P0770
Lock−up does not occur when driving in the lock−up range
(normal driving at 80 km/h (50 mph)) lock−up remains ON in
the lock−up OFF range (2 trip detection logic)Shift solenoid valve SL is stuck open or closed
Valve body is blocked up or stuck
Lock−up clutch
INSPECTION PROCEDURE
1 Check shift solenoid valve SL operation.
PREPARATION:
(a) Remove the oil pan.
(b) Remove the shift solenoid valve SL.
CHECK:
(a) Applying 490 kPa (5 kgf/cm2, 71 psi) of compressed air,
check that the solenoid valve leak air.
(b) When battery positive voltage is supplied to the solenoid
valve, check it close.
NG Replace shift solenoid valve SL.
OK
DI40J−01

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.

D00697
Ok if hot
Add if hot
AT4252
0 − 1 mm
D02248
DI−182
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
(f) Check the fluid leaks.
Check for leaks in the transmission and transfer.
If there are leaks, it is necessary to repair or replace O − rings,
FIPG’s, oil seals or other parts.
(g) Inspect and adjust the throttle cable.
(1) Check that the throttle valve is fully closed.
(2) Check that the inner cable is not slack.
(3) Loosen the adjustment nuts.
(4) Adjust the outer cable so that the distance between
the end of the boot and stopper on the cable is as
standard.
Standard boot and cable stopper distance:
0 − 1 mm (0 − 0.04 in.)
(5) Tighten the adjusting nuts.
(6) Recheck the adjustments.
(h) Adjust the shift control cable.
(1) Loosen the nut on the lever.
(2) Push the manual lever fully toward the right side of
the vehicle.

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

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
−

D02258
Drain
Drain Line
Pressure
Q08777
(+)
(+)
(−) (−)
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−201
1996 RAV4 (RM447U)
DTC P0770 Shift Solenoid E Malfunction
(Shift Solenoid Valve SL)
SYSTEM DESCRIPTION
The ECM uses the signals from the throttle position sensor and
air flow meter to monitor the engagement condition of the lock−
up clutch
Then the ECM compares the engagement condition of the
lock−up clutch with the lock−up schedule in the ECM memory
to detect mechanical trouble of the shift solenoid valve SL,
valve body and torque converter clutch.
DTC No.DTC Detecting ConditionTrouble Area
P0770
Lock−up does not occur when driving in the lock−up range
(normal driving at 80 km/h (50 mph)), or lock−up remains ON
in the lock−up OFF range (2 trip detection logic)Shift solenoid valve SL is stuck open or closed
Valve body blocked up or stuck
Lock−up clutch
INSPECTION PROCEDURE
1 Check shift solenoid valve SL operation.
PREPARATION:
Remove the shift solenoid valve SL from the valve body.
CHECK:
(a) Applying 490 kPa (5 kgf/cm2, 71 psi) of compressed air,
check that the solenoid valve open.
(b) When battery positive voltage is supplied to the solenoid
valve, check that solenoid valve does not leak air.
NG Replace shift solenoid valve SL.
OK
DI411−01