1996 TOYOTA RAV4 throttle

AT8584
AT8586
Z11664
B A
B
B A
B A
A A CA
AT3327
Q06411
BA AX−6
− AUTOMATIC TRANSAXLE (A241E)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
6. REMOVE MANUAL DETENT SPRING
Remove the bolt and manual detent spring.
7. REMOVE 3 SOLENOID CONNECTORS
8. REMOVE VALVE BODY
(a) Disconnect the throttle cable.
(b) Remove the 11 bolts and wire retainer.
Bolt length:
Bolt A: 20 mm (0.79 in.)
Bolt B: 30 mm (1.18 in.)
Bolt C: 55 mm (2.17 in.)
(c) Disconnect the manual valve connecting rod.
(d) Remove the valve body.
9. REMOVE 3 SOLENOID VALVES
(a) Remove the 3 solenoid valves.
(b) Remove the O−rings from each of the solenoid valves.
10. INSTALL SHIFT SOLENOID VALVE
(a) Coat new O−rings with ATF and install them to the each
of the solenoid valve.
(b) Install the 3 shift solenoid valves with the 2 bolts.
Torque:
Bolt A: 6.4 N·m (65 kgf·cm, 56 in.·lbf)
Bolt B: 10 N·m (100 kgf·cm, 7 ft·lbf)

AT3327
Z11664
B A
B
B A
B A
A A C
AT8586
AT8584
Q06418
− AUTOMATIC TRANSAXLE (A241E)VALVE BODY ASSEMBLY
AX−7
1996 RAV4 (RM447U)
11. INSTALL VALVE BODY
(a) Install the valve body.
(b) Connect the manual valve connecting rod.
(c) Install the 17 bolts and wire retainer.
Bolt length:
Bolt A: 20 mm (0.79 in.)
Bolt B: 30 mm (1.18 in.)
Bolt C: 55 mm (2.17 in.)
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
(d) Connect the throttle cable.
12. CONNECT 3 SOLENOID CONNECTORS
13. INSTALL MANUAL DETENT SPRING
Install the manual detent spring with the bolt.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
HINT:
Check that the manual valve lever is in contact with the center
of the roller at the tip of the detent spring.
14. INSTALL OIL PIPE CLAMP AND OIL PIPES
(a) Install the 5 pipes with a large screwdriver.
(b) Install the oil pump clamp with the bolt.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)

Q06117
AX055−02
AT5641
Q057310.8−1.5 mm (0.031−0.059 in.) 200 mm (7.87 in.)
− AUTOMATIC TRANSAXLE (A241E)THROTTLE CABLE
AX−9
1996 RAV4 (RM447U)
THROTTLE CABLE
ON−VEHICLE REPAIR
1. DISCONNECT THROTTLE CABLE FROM ENGINE
2. REMOVE NO.2 ENGINE UNDER COVER
3. REMOVE PARK/NEUTRAL POSITION SWITCH (See
page AX−4)
4. REMOVE VALVE BODY (See page AX−5)
5. REMOVE THROTTLE CABLE
(a) Remove the retaining bolt and plate.
(b) Pull out the cable from the transaxle case.
6. INSTALL THROTTLE CABLE
If throttle cable is new, do the following operations (a) − (c).
(a) Bend the cable so there is a radius of about 200 mm (7.87
in.).
(b) Pull theinner cable lightly until a slight resistance is felt,
and hold it.
(c) Stake the stopper 0.8 − 1.5 mm (0.031 − 0.059 in.) from
the end of outer cable.
(d) Be sure to push it in all the way.
(e) Install the bolt.
7. INSTALL VALVE BODY (See page AX−5)
8. INSTALL PARK/NEUTRAL POSITION SWITCH (See
page AX−4)
9. INSTALL NO.2 ENGINE UNDER COVER
10. CONNECT THROTTLE CABLE
11. ADJUST THROTTLE CABLE (See page DI−127)
12. FILL ATF AND CHECK ATF (See page DI−127)

D02186
AX127−01
Q08747
Q08761
D02187
Q08763
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
AX−15
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT THROTTLE CABLE
2. REMOVE ENGINE COOLANT RESERVOIR TANK
3. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the connector and ABS relay.
(b) Remove the 3 bolts and air cleaner assembly.
4. REMOVE GROUND CABLE
Remove the bolt from the transaxle.
Torque: 19 N·m (194 kgf·cm, 14 ft·lbf)
5. REMOVE SET NUT OF ENGINE WIRE CLAMP
6. REMOVE STARTER
(a) Disconnect the connector and nut from the starter.
(b) Remove the 2 bolts and disconnect the engine wire.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Remove the starter.
7. REMOVE 3 UPPER SIDE TRANSAXLE MOUNTING
BOLTS
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
8. INSTALL ENGINE SUPPORT FIXTURE

D00694
OR0038
Z13387A B CDC
C
D00696
AX−10
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
11. REMOVE VALVE BODY
(a) Remove the 10 bolts.
(b) Disconnect the throttle cable from the cam and remove
the valve body.
12. INSTALL VALVE BODY TO TRANSAXLE CASE
(a) While holding the cam down with your hand, slip the cable
end into the slot.
(b) Raise up the valve body into place.
NOTICE:
Do not entangle the solenoid wire.
(c) Install and tighten the 10 bolts.
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Hand−tighten the 10 bolts first, then torque with a torque
wrench.
Bolt length:
Bolt A: 22 mm (0.87 in.)
Bolt B: 32 mm (1.26 in.)
Bolt C: 43 mm (1.69 in.)
Bolt D: 55 mm (2.17 in.)
13. INSTALL B
3 APPLY PIPE
NOTICE:
Be careful not to bend or damage the pipe.

Q06117
AX04R−02
Q06068
Q057310.8 − 1.5 mm (0.031 − 0.059 in.) 200 mm
(7.87 in.)
− AUTOMATIC TRANSAXLE (A540H)THROTTLE CABLE
AX−13
1996 RAV4 (RM447U)
THROTTLE CABLE
ON−VEHICLE REPAIR
1. DISCONNECT THROTTLE CABLE FROM LINKAGE
2. REMOVE PARK/NEUTRAL POSITION SWITCH
(See page AX−6)
3. REMOVE VALVE BODY
(See page AX−8)
4. REMOVE THROTTLE CABLE
(a) Remove the bolt and pull the cable out of the transaxle
case.
(b) Remove the O−ring from the throttle cable.
5. INSTALL THROTTLE CABLE INTO TRANSAXLE
CASE
If the throttle cable is new do the following operations (a) − (c).
(a) Bend the cable so there is a radius of about 200 mm (7.87
in.).
(b) Pull the inner cable lightly until a slight resistance is felt,
and hold it.
(c) Stake the stopper 0.8 − 1.5 mm (0.031 − 0.059 in.) from
the end of outer cable.
(d) Install a new O−ring to the throttle cable.
(e) Make sure to push it in all the way.
(f) Install and torque the bolt.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
6. INSTALL VALVE BODY
(See page AX−8)
7. CONNECT THROTTLE CABLE TO LINKAGE
8. ADJUST THROTTLE CABLE
(See page DI−173)
9. INSTALL PARK/NEUTRAL POSITION SWITCH
(See page AX−6)
10. TEST DRIVE VEHICLE

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.

− DIAGNOSTICSENGINE
DI−7
1996 RAV4 (RM447U)
(10) After checking the DTC, inspect the applicable cir-
cuit.
(b) Clear the DTC.
The following actions will erase the DTC and freezed
frame data.
(1) Operating the OBDII scan tool (complying with SAE
J1978) or TOYOTA hand−held tester to erase the
codes.
(See the OBDII scan tool’s instruction book for oper-
ating instructions.)
(2) Disconnecting the battery terminals or EFI fuse.
NOTICE:
If the TOYOTA hand−held tester switches the ECM from
normal mode to check mode or vice−versa, or it the ignition
switch is turned from ON to ACC or OFF during check
mode, the DTC and freezed frame data will be erased.
4. FAIL−SAFE CHART
If any of the following codes is recorded, the ECM enters fail−sate mode.
DTC No.Fail−Safe OperationFail−Safe Deactivation Conditions
P0105Ignition timing fixed at 5° BTDCReturned to normal condition
P0110Intake air temp. is fixed at 68°F (20°C)Returned to normal condition
P0115Engine coolant temp. is fixed at 176°F (80°C)Returned to normal condition
P0120VTA is fixed at 0°
The following condition must be repeated at least
2 times consecutively
When closed throttle position switch is ON:
0.1 V  VTA  0.95 V
P0325Max. timing retardationIgnition switch OFF
P1300Fuel cutIGF signal is detected for 1 ignition
5. CHECK FOR INTERMITTENT PROBLEMS
TOYOTA hand−held tester only:
By putting the vehicle’s ECM in check mode, 1 trip detection logic possible instead of 2 trip detection logic
and sensitivity to detect open circuit is increased. This makes it easier to detect intermittent problems.
(1) Clear the diagnostic trouble codes (See page DI−3)
(2) Set the check mode (See page DI−3)
(3) Perform a simulation test (See page IN−20)
(4) Check the connector and terminal inspection (See page IN−30)
(5) Visual check and contact pressure (See page IN−30)
(6) Handle the connector (See page IN−30)