Jack TOYOTA RAV4 1996 Service Repair Manual

Z18887
A
A
A
B
Q08772
Q08773
A
B AX−18
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
1996 RAV4 (RM447U)
20. REMOVE REAR END PLATE
Remove the 4 bolts and rear end plate.
Torque:
A bolt: 9.0 N·m (95 kgf·cm, 78 in.·lbf)
B bolt: 19 N·m (195 kgf·cm, 14 ft·lbf)
21. REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLT
Turn the crankshaft to gain access and remove the 6 bolts with
holding the crankshaft pulley set bolt by a wrench.
Torque: 27 N·m (280 kgf·cm, 20 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
First install the gray bolt. Then install 5 black bolts while turning
the crankshaft to grain access.
22. SUPPORT TRANSAXLE WITH A TRANSMISSION
JACK
23. REMOVE TRANSAXLE
Remove the rear side transaxle mouting 2 bolts and transaxle.
Torque:
A bolt: 25 N·m (250 kgf·cm, 18 ft·lbf)
B bolt: 46 N·m (470 kgf·cm, 34 ft·lbf)

SUPPORT POSITIONPANTOGRAPH JACK POSITION
CAUTION: Before jacking-up the rear and front, make sure the car is
not carrying any extra weight.
Front Front crossmember. . . . . . . .
Rear Rear axle beam. . . . . . . .
JACK POSITION
Front
VEHICLE LIFT AND SUPPORT LOCATIONS
Safety stand and swing arm type lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTIONINœ14

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).

Q08860
Solenoid
Connector
S2
S1
S1
S2
D02257
S1S2
Shift Solenoid Valve No. 1 and No. 2
DI−200
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
2 Check harness and connector between ECM and automatic transaxle solenoid
connector.
PREPARATION:
(a) Disconnect the connector from the ECM.
(b) Disconnect the solenoid connector from the automatic
transaxle.
CHECK:
Check the harness and connector between terminal S1 or S2
of the ECM and terminal S1 or S2 of the solenoid connector.
OK:
There is no open and no short circuit.
NG Repair or replace harness or connector.
OK
3 Check shift solenoid valve No. 1 or No. 2.
PREPARATION:
(a) Jack up the vehicle.
(b) Remove the oil pan.
(c) Disconnect the solenoid connector.
(d) Remove the shift solenoid valve No. 1 or No. 2.
CHECK:
Measure resistance between solenoid connector and solenoid
body.
OK:
Resistance: 11 − 15 Ω
CHECK:
Connect positive  lead to terminal of the solenoid connector,
negative  lead to the solenoid body.
OK:
The solenoid makes an operating noise.
NG Replace shift solenoid valve No. 1 or No. 2.
OK
Repair or replace solenoid wire.

D02262
(+)
(−)
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−205
1996 RAV4 (RM447U)
3 Check shift solenoid valve SL.
PREPARATION:
(a) Jack up the vehicle.
(b) Remove the oil pan.
(c) Disconnect the shift solenoid valve SL connector.
(d) Remove the shift solenoid valve SL.
CHECK:
Measure the resistance between the solenoid connector and
solenoid body.
OK:
Resistance: 11 − 15 Ω
CHECK:
Connect positive  lead to terminal of the solenoid connector,
negative  lead to the solenoid body.
OK:
The shift solenoid valve SL makes operations noise.
NG Replace shift solenoid valve SL.
OK
Check and replace or repair solenoid wire.

D02274
(+)
(−)
DI−214
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
3 Check shift solenoid valve ST.
PREPARATION:
(a) Jack−up the vehicle.
(b) Remove the oil pan.
(c) Disconnect the shift solenoid valve ST connector.
(d) Remove the shift solenoid valve ST.
CHECK:
Measure the resistance between solenoid connector and sole-
noid body.
OK:
Resistance: 11 − 15 Ω
CHECK:
Connect positive  lead to terminal of the solenoid connector,
negative  lead to the solenoid body.
OK:
The shift solenoid valve ST makes operations noise.
NG Replace shift solenoid valve ST.
OK
Check and replace or repair solenoid wire.

D02276
S1 3
S1 1Shift Solenoid
Valve SLD
BR−B
IG214 IG213
L−B
L−B
E6
E62
SLD−
SLD+
B+ ECM
BR−B3
D02277
2
1
2
1
DI−216
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
WIRING DIAGRAM
INSPECTION PROCEDURE
1 Check shift solenoid valve SLD.
Check solenoid resistance:
PREPARATION:
(a) Jack up the vehicle.
(b) Remove the oil pan.
(c) Disconnect the connector.
CHECK:
Measure the resistance between terminals 1 and 2 of the sole-
noid connector.
OK:
Resistance: 5.1 − 5.5 Ω
Check solenoid operation:
CHECK:
Connect positive  lead with an 8 − 10 W bulb to terminal 1 of
the solenoid connector and nagative  lead to terminal 2, then
check the movement of the valve.
OK:
When battery positive voltage is appliedValve moves in → direction in illumina-
tion (on the left)
When battery positive voltage is cut offValve moves in ← direction in illumina-
tion (on the right)

BE6443
(1)
(2)
(1)
No.Operation MethodCRUISE MAIN Indicator Light
Blinking PatternDiagnosis
1 Turn SET/COAST switch ON
2Turn RES/ACC switch ON
3Turn CANCEL switch ON
Turn stop light switch ON
Depress brake pedal
Turn PNP switch OFF
(Shift to except D position)
4Drive at about 40 km/h
(25 mph)or higher
Drive at about 40 km/h
(25 mph) or below
LightON
OFF
LightON
OFF
LightON
OFFSwitch ON
Switch OFF
LightON
OFFSwitch OFF
Switch ONSET/COAST switch circuit
is normal
RES/ACC switch circuit
is normal
CANCEL switch circuit
is normal
Stop light switch circuit
is normal
PNP switch circuit is
normal
Vehicle Speed Sensor is
normal
LightON
OFF LightON
OFF
1sec.
0.25 sec.0.25 sec.
Turn clutch switch OFF
(Depress clutch pedal)Clutch switch circuit
is normal
− DIAGNOSTICSCRUISE CONTROL SYSTEM
DI−331
1996 RAV4 (RM447U)
4. INPUT SIGNAL CHECK
HINT:
(1) For check No.1 − No.2.
Turn the ignition switch ON.
(2) For check No.3.
Turn ignition switch ON.
Shift to D position. (A/T Vehicle)
(3) For check No.4.
Jack up the vehicle.
Start the engine.
Shift to D position. (A/T Vehicle)
(a) Press the control switch to the SET/COAST or RES/ACC
position and hold it down or hold it up (1).
(b) Push the main switch ON (2).
(c) Check that the CRUISE MAIN indicator light blinks twice
or 3 times repeatedly after 3 seconds.
(d) Turn the SET/COAST or RES/ACC switch OFF.
(e) Operate each switch as listed in the table below.
(f) Read the blinking pattern of the CRUISE MAIN indicator
light.
(g) After performing the check, turn the main switch OFF.
HINT:
When 2 or more signals are input to the ECU, the lowest num-
bered code will be displayed first.

EM0EM−03
S01283
B
SST
A
S01358
Oil Pump
S01630
SST
SST
− ENGINE MECHANICALTIMING BELT
EM−15
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT PS RESERVOIR AND REMOVE RES-
ERVOIR BRACKET
2. DISCONNECT WIRE HARNESS BRACKET FOR DLC1
3. REMOVE GENERATOR (See page CH−7)
4. REMOVE GENERATOR BRACKET
5. w/ ABS:
REMOVE NO. 3 ABS ACTUATOR BRACKET (See page
BR−40)
6. REMOVE RH FRONT WHEEL
7. REMOVE RH ENGINE UNDER COVER
8. REMOVE PS PUMP DRIVE BELT
(a) Loosen the bolt A.
(b) Using SST and a deep socket wrench, loosen the bolt B.
SST SST09249−63010
(c) Remove the drive belt.
9. SLIGHTLY JACK UP ENGINE
Attach the jack to the oil pan, and raise the engine enough to
remove the weight from the engine mounting on the right side.
10. REMOVE RH ENGINE MOUNTING INSULATOR
11. REMOVE SPARK PLUGS
12. REMOVE CRANKSHAFT PULLEY
(a) Using SST (and bolt), remove the pulley bolt.
SST 09213−54015 (91651−60855 for type A),
09330−00021
Bolt: Part No. 91121−40665 for type B
HINT:
Either of 2 types of pulley may be used, each with its own
bolt size, type A and type B.
When using bolt type B, a plate washer must be inserted
between the bolt and SST.

S01434
S01364
S01362
S01363
S01283
B
SST
A
− ENGINE MECHANICALENGINE UNIT
EM−71
1996 RAV4 (RM447U)
29. REMOVE FRONT SUSPENSION CROSSMEMBER
(a) Remove the 2 bolts and 2 nuts holding the PS gear as-
sembly to the front suspension crossmember.
(b) Remove the 2 nuts, and disconnect the engine mounting
center member.
(c) Disconnect the TWC w/ pipe from the ring.
(d) Support the front suspension crossmember with a jack.
(e) Remove the 6 bolts and front suspension crossmember.
30. REMOVE ENGINE MOUNTING CENTER MEMBER
(a) Remove the 2 bolts holding the center member to the
front engine mounting insulator.
(b) Remove the 2 bolts holding the center member to the
body, and remove the center member.
31. DISCONNECT PS PUMP FROM ENGINE
(a) Disconnect the 2 air hoses.
(b) Remove the bolt A.
(c) Using SST and a deep socket wrench, loosen the bolt B.
SST 09249−63010
(d) Remove the drive belt.