1996 TOYOTA RAV4 torque

CO18L−01
S01356
(A)
S01433
− COOLINGELECTRIC COOLING FAN
CO−21
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE NO.1 COOLING FAN (See page CO−16)
2. REMOVE NO.2 COOLING FAN
(a) Remove the RH engine under cover.
(b) w/ A/C:
Remove the cooler condenser (See page AC−47).
(c) Remove the upper radiator supports.
Torque:13 N·m (130kgf·cm, 9 ft·lbf)
HINT:
At the time of installation, plaese refer to the following items. Af-
ter installation, check that the rubber cushion (A) of the support
is not depressed.
(d) Remove the No.2 cooling fan.
(1) Disconnect the cooling fan connector.
(2) Push the radiator toward the front bumper.
(3) Remove the 3 bolts.
(4) Push the No.2 cooling fan toward radiator and pull
it upward.

− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−131
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 simulation test (See page IN−20).
(4) Check the connector connection and terminal (See page IN−30).
(5) Visual check and contact pressure (See page IN−20).
(6) Handle the connector (See page IN−20).
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, 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 symp-
toms.
6. ROAD TEST
NOTICE:
Do the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
(a) D position test.
Shift into the D position, keep the accelerator pedal constant at the full throttle valve opening position
and check the following points:
(1) Check up− shift operation.
Check that 1 → 2, 2 → 3 and 3 → O/D up−shift takes place, at the shift point shown in the automat-
ic shift schedule (See page SS−32).
HINT:
O/D Gear Up−shift Prohibition Control:
Engine coolant temperature is 50°C (122°F) or less.
If there is a 10km/h (6 mph) difference between the set cruise control speed and vehicle speed.
O/D main switch is pushed ON (During the O/D OFF indicator light lights up.).
O/D Gear Lock−up Prohibition Control:
Brake pedal is depressed.
Engine coolant temperature is 50°C (122°F) or less.
(2) Check for shift shock and slip.
Check for shock and slip at the 1 → 2, 2 → 3 and 3 → O/D up−shifts.
(3) Check for abnormal noise and vibration.
Run at the D position lock−up or O/D gear and check for abnormal noise and vibration.
HINT:
The check for the cause of abnormal noise and vibration must be performed very thoroughly as it could also
be due to loss of balance in the torque converter clutch, etc.
(4) Check kick−down operation.
While running in the D position, 2nd, 3rd and O/D gears, check that the possible kick−down ve-
hicle 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−32).
(5) Check abnormal shock and slip at kick−down.
(6) Check 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 RPM does not change abruptly.
If there is a big jump in RPM, there is no lock−up.

Q08832
Q08831N
RP
Q07907
Neutral
Basic
Line
Groove
DI−134
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
(f) Inspect and adjust shift lever position.
When shifting the shift lever from the N position to other
positions, check that the lever can be shifted smoothly
and accurately to each position and that the position indi-
cator correctly indicates the position.
If the indicator is not aligned with the correct position, carry out
the following adjustment procedures:
(1) Loosen the nut on the control shaft lever.
(2) Push the control shaft lever fully downward.
(3) Return the control shaft lever 2 notches to the N
position.
(4) Set the shift lever to the N position.
(5) While holding the shift lever lightly toward the R
position side, tighten the shift lever nut.
Torque: 6.9 N·m (70 kgf·cm, 61 in·lbf)
(6) Start the engine and make sure that the vehicle
moves forward when shifting the lever from the N to
D position and reverses when shifting it to the R
position.
(g) Inspect and adjust park/neutral position switch.
Check that the engine can be started with the shift lever
only in the N or P position, but not in other positions.
If not as stated above, carry out the following adjustment proce-
dure:
(1) Loosen the park/neutral position switch bolt and set
the shift lever to the N position.
(2) Align the groove and neutral basic line.
(3) Hold in position and tighten the bolt.
Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf)
HINT:
For continuity inspection of the park/neutral position switch, see
page DI−156.
(h) Inspect the idle speed.
Idle speed: 700 ± 50 rpm (In N position and A/C OFF)
8. MECHANICAL SYSTEM TESTS
(a) Measure the stall test
The object of this test is to check the overall performance of the transaxle and engine by measuring
the stall speeds in the D and R positions.
NOTICE:
Do the test at normal operation ATF temperature 50 − 80°C (122 − 176°F).
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear, level area which provides good traction.
The stall test should be always carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Fully apply the parking brake.
(3) Connect OBD II scan tool or TOYOTA hand−held tester to the DLC3.

− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−135
1996 RAV4 (RM447U)
(4) Start the engine and check idle speed.
(5) Keep your left foot pressed firmly on the brake pedal.
(6) Shift into the D position. Fully depress the accelerator pedal. Quickly read the stall speed at this
time.
Stall speed: 2,370 ± 150 rpm
(7) Do the same test in R position.
Stall speed: 2,370 ± 150 rpm
Evaluation:
ProblemPossible cause
Stall speed low in D and R positions
Engine output may be insufficient
Stator one−way clutch is operating properly
HINT:
If more than 600 rpm below the specified value, the torque converter clutch could
be faulty
Stall speed high in D position
Line pressure too low
Forward clutch slipping
No. 2 one−way clutch not operating properly
U/D one−way clutch not operating properly
Stall speed high in R position
Line pressure too low
Direct clutch slipping
1st and reverse brake slipping
U/D brake slipping
Stall speed high in D and R positions
Line pressure too low
Improper fluid level
U/D one−way clutch not operating properly
(b) Measure the time lag.
When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before
the shock can be felt. This is used for checking the condition of the U/D direct clutch, forward clutch,
direct clutch, and 1st and reverse brake.
NOTICE:
Do the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
Make sure to allow 1 minute interval between tests.
Take 3 measurements and take the average value.
(1) Fully apply the parking brake
(2) Start the engine and check idle speed.
Idle speed: 700 ± 50 rpm (In N position and A/C OFF)
(3) Shift the shift lever from the N to D position. Using a stop watch, measure the time it takes from
shifting the lever until the shock is felt.
Time lag: N → D Less than 1.2 seconds
In the same way, measure the time lag for N → R.
Time lag: N → R Less than 1.5 seconds
Evaluation:
ProblemPossible cause
N → D time lag is longer
Line pressure too low
Forward clutch worn
U/D one−way clutch not operating properly
N → R time lag is longer
Line pressure too low
Direct clutch worn
1st and reverse brake worn
U/D brake worn

− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−143
1996 RAV4 (RM447U) Poor acceleration
1. Primary regulator valve
2. Off−vehicle matrix chart
−
No lock−up1. Look−up relay valve
2. Off−vehicle matrix chart
−
Chapter 3: Off−Vehicle Repair
(: A241E, A244E, A245E, A246E Automatic Transaxle Repair Manual Pub. No. RM390U)
SymptomSuspect AreaSee page
Does not move in any forward position1. Forward clutch (C1)
Does not move in reverse position
1. Direct clutch (C2)
2. 1st and reverse brake (B
3)
3. U/D brake (B
4)



Does not move in any position
1. Torque converter clutch
2. Oil pump
3. U/D one−way clutch (F
3)
4. Front planetary gear
5. Rear planetary gear
6. On−vehicle matrix chart
AX−20




−
No up−shift (1st → 2nd)
1. 2nd brake (B2)
2. No. 1 one−way clutch (F
1)
3. On−vehicle matrix chart


−
No up−shift (2nd → 3rd)1. Direct clutch (C2)
2. On−vehicle matrix chart
−
No up−shift (3rd → O/D)1. U/D brake (C3)
2. On−vehicle matrix chart
−
No down−shift (O/D → 3rd)
1. U/D brake (B4)
2. U/D one−way clutch (F
3)
3. On−vehicle matrix chart


−
No down−shift (3rd → 2nd)1. No. 1 one−way clutch (F1)
2. On−vehicle matrix chart
−
No down−shift (2nd → 1st)1. No. 2 one−way clutch (F2)
2. On−vehicle matrix chart
−
Harsh engagement (N → R)
1. Direct clutch (C2)
2. 1st and reverse brake (B
3)
3. On−vehicle matrix chart


−
Harsh engagement (N → D)1. Forward clutch (C1)
2. On−vehicle matrix chart
−
Harsh engagement (N → L)
1. Forward clutch (C1)
2. 1st and reverse brake (B
3)
3. On−vehicle matrix chart


−
Harsh engagement (1st → 2nd (D position))
1. 2nd brake (B2)
2. No. 1 one−way clutch (F
1)
3. On−vehicle matrix chart


−
Harsh engagement (1st → 2nd (2 position))
1. 2nd coast brake (B1)
2. 2nd brake (B
2)
3. No. 1 one−way clutch (F
1)
4. On−vehicle matrix chart



−
Harsh engagement (1st → 2nd → 3rd → O/D)1. On−vehicle matrix chart−
Harsh engagement (2nd → 3rd)1. Direct clutch (C2)
2. On−vehicle matrix chart
−
Harsh engagement (3rd → O/D)1. U/D clutch (C3)
2. On−vehicle matrix chart
−

DI−144
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U) Harsh engagement (O/D → 3rd)
1. U/D brake (B4)
2. On−vehicle matrix chart
−
Harsh engagement (3rd → 2nd)1. Direct clutch (C2)
2. On−vehicle matrix chart
−
Harsh engagement (Lock−up)1. Torque converter clutchAX−20
Slip (Forward & reverse)
1. Torque converter clutch
2. Oil pump
3. On−vehicle matrix chartAX−20

−
Slip (R position)1. Direct clutch (C2)
2. 1st and reverse brake (B
3)


Slip (1st)
1. Forward clutch (C1)
2. No. 2 one−way clutch (F
2)
3. U/D one−way clutch (F
3)



Slip (2nd)
1. Forward clutch (C1)
2. 2nd brake (B
2)
3. No. 1 one−way clutch (F
1)
4. U/D one−way clutch (F
3)

Slip (3rd)
1. Forward clutch (C1)
2. Direct clutch (C
2)
3. U/D one−way clutch (F
3)



Slip (O/D)
1. Forward clutch (C1)
2. Direct clutch (C
2)
3. U/D clutch (C
3)



No engine braking (1st (L position))1. 1st and reverse brake (B3)
2. On−vehicle matrix chart
−
No engine braking (2nd (2 position))1. 2nd coast brake (B1)
2. On−vehicle matrix chart
−
No kick−down1. On−vehicle matrix chart−
Poor acceleration
1. Torque converter clutch
2. Forward clutch (C
1)
3. On−vehicle matrix chart
AX−20

−
No lock−up1. Torque converter clutch
2. On−vehicle matrix chartAX−20
−
Engine stalls when staring off or stopping1. Torque converter clutchAX−20

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

DI−152
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
2 Check valve body (See page DI−141).
NG Repair or replace valve body.
OK
Replace torque converter clutch (See page
AX−14).