transmission 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)

ABS Antilock Brake System
A/C Air Conditioner
assy assembly
ECT Electronic Controlled Transmission
ECU Electronic Control Unit
e.g. Exempli Gratia (for Example)
Ex. Except
FWD Front Wheel Drive Vehicles
4WD Four Wheel Drive Vehicles
in. inch
LH Left-hand
LHD Left-hand Drive
MIG Metal Inert Gas
M/Y Model Year
PPS Progressive Power Steering
RH Right-hand
RHD Right-hand Drive
SRS Supplemental Restraint System
w/ with
w/o without
ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual.
INTRODUCTIONINœ15

S02459
− DIAGNOSTICSENGINE
DI−5
1996 RAV4 (RM447U) Terminal No.
Connection / Voltage or ResistanceCondition
2Bus  Line / Pulse generationDuring transmission
4Chassis Ground / ↔ Body Ground 1 Ω or lessAlways
5Signal Ground / ↔ Body Ground 1 Ω or lessAlways
16Battery Positive / ↔ Body Ground 9 ∼ 14VAlways
HINT:
If your display shows ”UNABLE TO CONNECT TO VEHICLE”
when you have connected the cable of the OBDII scan tool or
TOYOTA hand−held tester to DLC3, turned the ignition switch
ON and operated the scan tool, there is a problem on the ve-
hicle side or tool side.
If communication is normal when the tool is connected to
another vehicle, inspect DLC3 on the original vehicle.
If communication is still not possible when the tool is con-
nected to another vehicle, the problem is probably in the
tool itself, so consult the Service Department listed in the
tool’s instruction manual.
2. INSPECT DIAGNOSIS (Normal Mode)
(a) Check the MIL.
(1) The MIL comes on when the ignition switch is turned
ON and the engine is not running.
HINT:
If the MIL does not light up, troubleshoot the combination meter.
(2) When the engine is started, the MIL should go off.
If the lamp remains on,the diagnosis system has
detected a malfunction or abnormality in the sys-
tem.
(b) Check the DTC.
NOTICE:
TOYOTA hand−held tester only:
When the diagnosis system is switched from normal mode
to check mode, it erases all DTC and freezed frame data re-
corded in normal mode. So before switching modes, al-
ways check the DTC and freezed frame data, and note them
down.
(1) Prepare the OBDII scan tool (complying with SAE
J1978) or TOYOTA hand−held tester.
(2) Connect the OBDII scan tool or TOYOTA hand−
held tester to DLC3 at the lower of the instrument
panel.
(3) Turn the ignition switch ON and turn the OBDII scan
tool or TOYOTA hand−held tester switch ON.
(4) Use the OBDII scan tool or TOYOTA hand−held tes-
ter to check the DTC and freezed frame data, note
them down.
(5) See page DI−14 to confirm the details of the
DTC.

FI3605
ONFlashing
0.13 Seconds OFF
DI−6
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
NOTICE:
When simulating symptoms with an OBDII scan tool (Ex-
cluding TOYOTA hand−held tester) to check the DTC, use
normal mode. For codes on the DTC chart subject to ”2 trip
detection logic”, turn the ignition switch OFF after the
symptom is simulated the first time. Then repeat the simu-
lation process again. When the problem has been simu-
lated twice, the MIL lights up and the DTC are recorded in
the ECM.
3. INSPECT DIAGNOSIS (Check Mode)
HINT:
TOYOTA Hand−Held Tester only:
Compared to the normal mode, the check mode has an in-
creased sensitivity 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.
Transmission in park or neutral position.
Air conditioning switched OFF.
(2) Turn ignition switch OFF.
(3) Prepare the TOYOTA hand−held tester.
(4) Connect the TOYOTA hand−held tester to DLC3 at
the lower of the instrument panel.
(5) Turn the ignition switch ON and push the TOYOTA
hand−held tester main switch ON.
(6) Switch the TOYOTA hand−held tester normal mode
to check mode. (Check that the MIL flashes.)
(7) Start the engine. (The MIL goes out after the engine
starts.)
(8) Simulate the conditions of the malfunction de-
scribed by the customer.
NOTICE:
Leave the ignition switch ON until you have checked the
DTC, etc.
(9) After simulating the malfunction conditions, use the
TOYOTA hand−held tester diagnosis selector to
check the DTC 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 diagnostic codes, etc. are erased.

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

S01261S01272A04480
DLC1
TE1
SST
E1
DI−10
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
6 Check ignition timing.
PREPARATION:
(a) Warm up engine to normal operating temperature.
(b) Shift transmission into ”N” position.
(c) Keep the engine speed at idle.
(d) Using SST, connect terminals TE1 and E1 of DLC1.
SST 09843−18020
(e) Using a timing light, connect the tester to No.1 high−ten-
sion cord.
CHECK:
Check ignition timing.
OK:
Ignition timing: 10° BTDC at idle
NG Proceed to IGNITION and continue to trouble-
shoot.
OK
Proceed to matrix chart of problem symp-
toms on page DI−20.

− 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

Q00515
4−pulse 4−pluse
ECM Combination
Meter No.1 Vehicle
Speed Sensor
Transaxle DI−94
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
DTC P0500 Vehicle Speed Sensor Malfunction
CIRCUIT DESCRIPTION
The No.1 vehicle speed sensor outputs a 4−pulse signal for every revolution of the rotor shaft, which is ro-
tated by the transmission output shaft via the driven gear. After this signal is converted into a more precise
rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted
to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals.
DTC No.DTC Detecting ConditionTrouble Area
P0500
No vehicle speed sensor signal to ECM under the following
conditions:
(2 trip detection logic)
For A/T:
(a) Park / neutral position switch is OFF
(b) Vehicle is being driven
For M/T:
(a) Engine speed is between 2,000 rpm and 5,000 rpm
(b) Vehicle is being driven at 88 km/h (54 mph) or more
Open or short in vehicle speed sensor circuit
Vehicle speed sensor
Combination meter
ECM
DI3ZZ−01

Q08867
Junction Connector
Fuse Block
FL Block
DI−168
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
Pattern Select Switch Circuit
CIRCUIT DESCRIPTION
The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, and L posi-
tion and the lock−up patterns. Following the programs corresponding to the signals from the pattern select
switch, the park/neutral position switch and other various sensors, the ECM switches the solenoid valves
ON and OFF, and control the transmission gear change and the lock−up clutch operation.
WIRING DIAGRAM
INSPECTION PROCEDURE
1 Check operation of PWR indicator light.
CHECK:
Check if the PWR indicator light normally when the pattern select switch is set to NORM and PWR position.
OK:
Pattern select switchPWR indicator light
PWRLight up
NORMGoes off
NG Check and repair PWR indicator light (See page
BE−2).
OK
DI40P−02

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.