oil temperature TOYOTA RAV4 1996 Service Repair Manual

Component to be alignedSection of repair manual
for relevant model
Front Wheels
Suspension and Axle (SA) section
Rear Wheels
Suspension and Axle (SA) section
1. Never disassemble the steering wheel pad assembly.
2. Do not subject the steering wheel pad to shocks or bring magnets close to it.
3. Do not expose the steering wheel pad to high temperatures or fire.
4. If grease, cleaner, oil or water gets on the steering wheel pad, promptly wipe it off with a dry cloth.
5. Do not drop the steering wheel pad. Never use a steering wheel pad which has been dropped.
6. Never install the steering wheel and pad in another vehicle.
7. When the steering wheel pad is removed, store it on a stable, flat place with the pad surface facing upœ
wards. Never place anything on top of the pad.
8. When work on the vehicle will produce too strong a shock, first loosen the sensor lock release bolt until
it turns freely and perform the work after sensor lock occurs.
9. Even in cases where the vehicle is in a low-impact accident where the airbag is not activated, always
check the pad surface and airbag sensor part. If dents, cracks or deformation is visible, replace the airœ
bag with a new assembly.
10. When disposing of the vehicle or steering wheel, always deploy the airbag first.
11. The deployed inflator inside the steering wheel pad is hot, so dispose of it after it has been cooled by
atmospheric air. Never apply water to cool it down.
2. BRAKE SYSTEM
The brake system is one of the most important safety components. Always follow the directions and
notes given in section BR of the repair manual for the relevant model year when handling brake system
parts.
3. DRIVE TRAIN AND CHASSIS
The drive train and chassis are components that can have great effects on the running performance
and vibration resistance of the vehicle. After installing components in the sections listed in the table
below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate
repair of the body must also be done to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions
given in the repair manual for the relevant model during alignment and section DI of this manual.
INTRODUCTIONINœ7

P00495
Outside
Inside
− DIAGNOSTICSENGINE
DI−9
1996 RAV4 (RM447U)
4 Check air filter.
PREPARATION:
Remove air filter.
CHECK:
Visually check that the air cleaner element is not excessively
dirty or oily.
HINT:
If necessary, clean element with compressed air.
First blow from inside thoroughly,then blow from outside of ele-
ment.
NG Repair or replace.
OK
5 Check idle speed.
PREPARATION:
(a) Warm up engine to normal operating temperature.
(b) Switch off all accessories.
(c) Switch off air conditioning.
(d) Shift transmission into ”N” position.
(e) Connect the OBDII scan tool or TOYOTA hand−held tes-
ter to DLC3 on the vehicle.
CHECK:
Use CURRENT DATA to check the engine idle speed.
OK:
Idling speed: 650 − 750 rpm
NG Proceed to matrix chart of problem symptoms
on page DI−20.
OK

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.

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

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

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


−

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

EM1Q2−01
EM1321
SST
EM7329
Oil Hole
P01038
EM1322
EM−96
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
REPLACEMENT
1. REPLACE CONNECTING ROD BUSHINGS
(a) Using SST and a press, press out the bushing.
SST 09222−30010
(b) Align the oil holes of a new bushing and the connecting
rod.
(c) Using SST and a press, press in the bushing.
SST 09222−30010
(d) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance (See page EM−89) be-
tween the bushing and piston pin.
(e) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, and push it into the connect-
ing rod with your thumb.
2. REPLACE OVERSIZED (O/S) PISTONS FOR CYLIN-
DER BORING
HINT:
Bore all the 4 cylinders for the O/S piston outside diame-
ter.
Replace all the piston rings with ones to match the O/S
pistons.
(a) Keep 4 new O/S pistons.
O/S 0.50 piston diameter:
86.370 − 86.400 mm (3.4004 − 3.4016 in.)

17
E
1. NORMALLY
OPENOpens and
closes circuits,
thereby
stopping (1) or
allowing (2)
current flow.
RESISTOR
An electrical component with a
fixed resistance, placed in a circuit
to reduce voltage to a specific
value.
RESISTOR, TAPPED
A resistor which supplies two or
more different non adjustable
resistance values.
SENSOR (Thermistor)
A resistor which varies its
resistance with temperature.
SHORT PIN
Used to provide an unbroken
connection within a junction
block.
SOLENOID
An electromagnetic coil which
forms a magnetic field when
current flows, to move a plunger,
etc.SWITCH, DOUBLE THROW
A switch which continuously
passes current through one set
of contacts or the other.
SWITCH,
IGNITION
A key operated switch with
several positions which allows
various circuits, particularly the
primary ignition circuit, to
become operational.
Wires are always
drawn as straight lines
on wiring diagrams.
Crossed wires (1)
without a black dot at
the junction are not
joined; crossed wires
(2) with a black dot or
octagonal (
) mark at
the juction as spliced
(joined) connections. RELAY, DOUBLE THROW
A relay which passes current
through one set of contacts or the
other.
SENSOR, SPEED
Uses magnetic impulses to open
and close a switch to create a
signal for activation of other
components.TRANSISTOR
A solid state device typically used
as an electronic relay; stops or
passes current depending on the
voltage applied at base.º SWITCH, WIPER PARK
Automatically returns wipers to
the stop position when the wiper
switch is turned off. SWITCH, MANUAL SPEAKER
An electromechanical device
which creates sound waves from
current flow.
2. NORMALLY
CLOSED
RESISTOR, VARIABLE OR
RHEOSTAT
A controllable resistor with a
variable rate of resistance.
Also called a potentiometer or
rheostat. 2. NORMALLY
OPEN RELAY
1. NORMALLY
CLOSEDBasically, an electrically
operated switch which may
be normally closed (1) or
open (2).
Current flow through a
small coil creates a
magnetic field which either
opens or closes an
attached switch.
(2) SPLICED WIRES
(1) NOT
CONNECTED