low oil pressure TOYOTA RAV4 1996 Service Repair Manual

CL04F−03
− CLUTCHTROUBLESHOOTING
CL−1
1996 RAV4 (RM447U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Clutch grabs/chatters
3. Engine mounting (Loosen)
4. Clutch disc (Runout is excessive)
5. Clutch disc (Oily)
6. Clutch disc (Worn out)
7. Clutch disc torsion rubber (Damaged)
8. Clutch disc (Glazed)
9. Diaphragm spring (Out of tip alignment)−
CL−15
CL−15
CL−15
CL−15
CL−15
CL−15
Clutch pedal spongy
1. Clutch line (Air in line)
2. Master cylinder cup (Damaged)
3. Release cylinder cup (Damaged)−
CL−5
CL−10
Clutch noisy1. Release bearing (Worn, dirty, or damaged)
2. Clutch disc torsion rubber (Damaged)CL−15
CL−15
Clutch slips
1. Clutch pedal (Free play out of adjustment)
2. Clutch disc (Oily)
3. Clutch disc (Worn out)
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion)
6. Flywheel (Distortion)CL−2
CL−15
CL−15
CL−15
CL−15
−
Clutch does not disengage
1. Clutch pedal (Free play out of adjustment)
2. Clutch line (Air in line)
3. Master cylinder cup (Damaged)
4. Release cylinder cup (Damaged)
5. Clutch disc (Out of true)
6. Clutch disc (Runout is excessive)
7. Clutch disc (Lining broken)
8. Clutch disc (Dirty or burned)
9. Clutch disc (Oily)
10.Clutch disc (Lack of spline grease)
11. Diaphragm spring (Damaged)
12.Diaphragm spring (Out of tip alignment)
13.Pressure plate (Distortion)CL−2
−
CL−5
CL−10
CL−15
CL−15
CL−15
CL−15
CL−15
CL−18
CL−15
CL−18
CL−15

CO0BD−01
− COOLINGCOOLANT
CO−1
1996 RAV4 (RM447U)
COOLANT
INSPECTION
1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR
The engine coolant level should be between the ”LOW” and ”FULL” lines, when engine is cold.
If low, check for leaks and add engine coolant up to the ”FULL” line.
2. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot, as fluid and steam can be blown out under pressure.
(b) There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler
hole, and the coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.

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

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

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

D02250
2 − 3 m
(6.6 − 9.8 ft)
Battery
Adaptor SST 1
90980−10629 90980−111433
24 W
or
Q05128
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−187
1996 RAV4 (RM447U)
Clear the DTC’s after the test.
Evaluation:
ProblemPossible cause
If the measured values at all conditions are higher than the
specificationDifferential control valve defective
Solenoid modulator valve defective
If the measured values at all conditions are lower than the
specificationOil pump defective
Differential control valve defective
Solenoid modulator valve defective
If the pressure is low in the stall test
(Shift solenoid valve SLD ON only)Shift solenoid valve SLD defective
If the measured values are lower than the specification,
when sub−harness is connectedSolenoid modulator valve defective
Differential control valve defective
If the measured values are higher than the specification,
when sub−harness is connectedSolenoid modulator valve defective
Differential control valve defective
11. MANUAL SHIFTING TEST
HINT:
With this test, it can be determined whether the trouble is within
the electrical circuit or is a mechanical problem in the transaxle.
(a) Disconnect the solenoid wire.
(b) Inspect the manual driving operation.
Check that the shift and gear positions correspond with
the table below.

− 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
−

D02275
Current flow to solenoid Center
Differential
Control
Pressure
ON
OFF
1 cycleDuty Ratio =
A + B
A
x 100 (%)
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−215
1996 RAV4 (RM447U)
DTC P1770 Differential Lock Solenoid No. 1 Circuit
Malfunction (Shift Solenoid Valve SLD)
CIRCUIT DESCRIPTION
Shift solenoid valve SLD controls the oil pressure applied to the
center differential clutch and maintains the limited slip differen-
tial effects at most appropriate level.
The ECM determines optimum control pressure according to
the signals from the throttle position sensor, front and rear
transaxle revolution sensor and control volume of current flow
to the shift solenoid valve.
The amount of current flow to the solenoid valve is controlled
by the duty ratio* of the ECM output signal. The higher the duty
ratio becomes, the higher the center differential control pres-
sure becomes during the center differential control operation.
*: Duty Ratio
The duty ratio is the ratio of the period of continuity in one cycle.
For example, if A is the period of continuity in one cycle, and B
is the period of non−continuity, then
DTC No.DTC Detection ConditionTrouble Area
P1770
All conditions below are detected 1 sec. or more
(2 trip detection logic)
(a) SLD output signal’s duty ON of 3.3 msecs. or more with
duty ratio of at least 5 % lasts
(b) B
+ voltage: 11 V or more
Open or short in shift solenoid valve SLD circuit
Shift solenoid valve SLD
ECM
DI417−01

EM0EH−03
S01361
Compression
Gauge
− ENGINE MECHANICALCOMPRESSION
EM−3
1996 RAV4 (RM447U)
COMPRESSION
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. DISCONNECT DISTRIBUTOR CONNECTOR
3. DISCONNECT HIGH−TENSION CORDS FROM SPARK
PLUGS AND IGNITION COIL
4. REMOVE SPARK PLUGS
5. CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine speed of
250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
1,275 kPa (13.0 kgf/cm
2, 185 psi) or more
Minimum pressure: 932 kPa (9.5 kgf/cm
2, 135 psi)
Difference between each cylinder:
98 kPa (1.0 kgf/cm
2, 14 psi) or less
(e) If the cylinder compression in one or more cylinders is low,
pour a small amount of engine oil into the cylinder through
the spark plug hole and repeat steps (a) through (c) for
cylinders with low compression.
If adding oil helps the compression, it is likely that
the piston rings and/or cylinder bore are worn or
damaged.
If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.
6. REINSTALL SPARK PLUGS
7. RECONNECT HIGH−TENSION CORDS TO SPARK
PLUGS AND IGNITION COIL

S01823
Oxygen Sensor
(Bank 1 Sensor 1)
Oxygen Sensor (Bank 1 Sensor 2)
P03152
S01368
S01365
S01594
EM−34
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
10. REMOVE OXYGEN SENSOR (BANK 1 SENSOR 1)
FROM EXHAUST MANIFOLD
11. REMOVE OXYGEN SENSOR (BANK 1 SENSOR 2)
FROM FRONT TWC
12. SEPARATE EXHAUST MANIFORD AND FRON TWC
(a) Remove the 5 bolts and lower manifold heat insulator.
(b) Remove the 8 bolts and 2 TWC heat insulators.
(c) Remove the 3 bolts, 2 nuts, TWC, gasket retainer and
cushion.
13. DISCONNECT OIL PRESSURE SWITCH CONNECTOR
14. REMOVE WATER OUTLET
(a) Disconnect the ECT sensor connector.
(b) Disconnect the ECT sender gauge connector.
(c) Disconnect the radiator hose from the water outlet.
(d) Disconnect the water bypass pipe hose from the water
outlet.
(e) Disconnect the heater water hose from the water outlet.
(f) Remove the 2 nuts, water outlet and gasket.
15. REMOVE WATER BYPASS PIPE
(a) Remove the bolt, 2 nuts and oil cooler heat protector.
(b) Disconnect the IAC valve water bypass hose from the wa-
ter bypass pipe.
(c) Disconnect the heater water hose from the water bypass
pipe.
(d) Disconnect the 2 oil cooler water bypass hoses from the
oil cooler.
(e) Remove the nut and disconnect the wire protector.
(f) Remove the 2 bolts and 2 nuts.
(g) Disconnect the water bypass pipe from the water pump
cover, and remove the water bypass pipe.
(h) Remove the gasket and O−ring.
16. REMOVE THROTTLE BODY (See page SF−30)