TOYOTA RAV4 1996 Service Repair Manual

W01262
SST
W01263
SST
Spacer
Lock NutBC
A
W04192
12°
Hexagon Wrench
W01265
SST
− STEERINGPOWER STEERING GEAR
SR−57
1996 RAV4 (RM447U)
12. INSTALL LOCK NUT
(a) Using SST to stop the control valve shaft rotating, torque
a new nut.
SST 09616−00010
Torque: 12 N·m (125 kgf·cm, 9 ft·lbf)
(b) Turn C of SST to obtain dimension A, then set SST, as
shown.
SST 09613−12020
Dimension A: 16.5 − 17.0 mm (0.65 − 0.67 in.)
(c) Stake the nut by turning B of SST until it touches the
spacer of SST.
13. INSTALL RACK HOUSING CAP
(a) Apply sealant to 2 or 3 threads of the cap.
Sealant: Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Torque the cap.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
14. INSTALL RACK GUIDE SEAT, RACK GUIDE, RACK
GUIDE SPRING AND RACK GUIDE SPRING CAP
(a) Install the seat to the guide.
(b) Apply sealant to 2 or 3 threads of the cap.
Sealant: Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Temporarily install the cap.
15. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporarily install the RH and LH rack ends.
(b) Using a hexagon wrench (21 mm), torque the rack guide
spring cap.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Using a hexagon wrench (21 mm), return the cap 12°.
(d) Using SST, turn the control valve shaft right and left 1 or
2 times.
SST 09616−00010
(e) Using a hexagon wrench (21 mm), loosen the cap until the
rack guide spring is not functioning.

W01266
SST
Hexagon Wrench
W01267SSTFulcrum
Length
W01268
Rack Groove
W01269
SSTFulcrum
Length SR−58
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
(f) Using SST, a torque wrench and hexagon wrench (21
mm), tighten the cap until the preload is within the specifi-
cation.
SST 09616−00010
Preload (turning):
0.8 − 1.3 N·m (8 − 13 kgf·cm, 6.9 − 11.3 in.·lbf)
16. INSTALL RACK GUIDE SPRING CAP LOCK NUT
(a) Apply sealant to 2 or 3 threads of the nut.
Sealant: Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a hexagon wrench (21 mm) to stop the rack guide
spring cap rotating, and using SST, torque the nut.
SST 09922−10010
Torque: 32 N·m (330 kgf·cm, 24 ft·lbf)
NOTICE:
Use SST 09922−10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(c) Recheck the total preload.
SST 09616−00010
Preload (turning):
0.8 − 1.3 N·m (8 − 13 kgf·cm, 6.9 − 11.3 in.·lbf)
(d) Remove the RH and LH rack ends.
17. INSTALL RH AND LH CLAW WASHERS AND RACK
ENDS
(a) Install a new washer, and temporarily install the rack end.
HINT:
Align the claws of the washer with the steering rack grooves.
(b) Using a spanner (22 mm) to hold the steering rack steady,
and using SST, torque the rack end.
SST 09922−10010
Torque: 60 N·m (615 kgf·cm, 44 ft·lbf)
NOTICE:
Use SST 09922−10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).

W01270
Brass Bar
W01261
W01271
2 mm
(0.08 in.)
W01272
SST
Fulcrum
Length
− STEERINGPOWER STEERING GEAR
SR−59
1996 RAV4 (RM447U)
(c) Using a brass bar and a hammer, stake the washer.
NOTICE:
Avoid any impact to the rack.
18. INSTALL GROMMET
Install the grommet to the rack housing No.1 bracket.
19. INSTALL RACK HOUSING NO.1 BRACKET
(a) Align the matchmarks on the bracket and housing.
(b) Torque the bolt.
Torque: 61 N·m (620 kgf·cm, 45 ft·lbf)
20. INSTALL RH AND LH RACK BOOTS, CLAMPS AND
CLIPS
(a) Make sure that the steering rack hole is not clogged with
grease.
HINT:
If the hole is clogged, the pressure inside the boot will change
after it is assembled and the steering wheel turned.
(b) Install the boot.
NOTICE:
Be careful not to damage or twist the boot.
(c) Tighten the clamp, as shown in the illustration.
21. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS
(a) Screw the lock nut and tie rod end onto the rack end until
the matchmarks are aligned.
(b) After adjusting toe−in, torque the nut
(See page SA−4).
Torque: 56 N·m (570 kgf·cm, 41 ft·lbf)
22. INSTALL 2 TURN PRESSURE TUBES
(a) Using SST, install the tube.
SST 09633−00020
Torque: 23 N·m (234 kgf·cm, 17 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 250 mm
(9.84 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
(b) Torque the union bolt with a new gasket on each side of
the tube.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

SR0G6−02
W01119
SST
Fulcrum Length SR−60
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
INSTALLATION
1. CONNECT PRESSURE FEED AND RETURN TUBE
CLAMPS
Torque the bolt.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
2. INSTALL FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY (See page SA−42)
3. TORQUE 2 PS GEAR ASSEMBLY SET BOLTS AND
NUTS
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
4. CONNECT RH AND LH LOWER SUSPENSION ARMS
(See page SA−42)
5. INSTALL STABILIZER BAR WITH LINK
(See page SA−50)
6. INSTALL FRONT EXHAUST PIPE
(a) Torque the 2 bolts with a new gasket.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
(b) Torque 3 new nuts with a new gasket.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
7. CONNECT PRESSURE FEED AND RETURN TUBES
Using SST, connect the tube.
SST 09631−22020
Torque: 36 N·m (365 kgf·cm, 26 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
Securely suspend the steering gear assembly.
8. CONNECT NO.2 INTERMEDIATE SHAFT
(See page SR−19)
9. CONNECT RH AND LH TIE ROD ENDS
(See page SA−16)
10. INSTALL RH AND LH ENGINE UNDER COVERS
Tighten the 13 bolts.
11. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
HINT:
Do it with the front of the vehicle jacked up.

− STEERINGPOWER STEERING GEAR
SR−61
1996 RAV4 (RM447U)
12. CENTER SPIRAL CABLE (See page SR−19)
13. INSTALL STEERING WHEEL
(a) Align the matchmarks on the wheel and steering column
main shaft.
(b) Temporarily tighten the wheel set nut.
(c) Connect the connector.
14. BLEED POWER STEERING SYSTEM
(See page SR−4)
15. CHECK STEERING WHEEL CENTER POINT
16. TORQUE STEERING WHEEL SET NUT
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
17. INSTALL STEERING WHEEL PAD (See page SR−19)
18. CHECK FRONT WHEEL ALIGNMENT
(See page SA−4)

ST05H−01
− STARTINGSTARTING SYSTEM
ST−1
1996 RAV4 (RM447U)
STARTING SYSTEM
ON−VEHICLE INSPECTION
NOTICE:
Before changing the starter, check the following items again:
Connector connection
Accessory installation, e.g.: theft deterrent system

ST05I−03
S01781
PCV Hose
IAT Sensor
Connector
Air Cleaner Case AssemblyStarter
Starter WireAir Cleaner Cap Assembly
VSV Air Hose
Starter Connector
Skid Control
Relay Connectors
Engine Coolant Reservoir ElementHigh−tension Cord ST−2
− STARTINGSTARTER
1996 RAV4 (RM447U)
STARTER
COMPONENTS

B03395
Stop Collar
Compression
Spring
Spring
RetainerStarter Housing
Starter
Clutch
Compression
Spring
Clutch Shaft  Snap Ring
Pinion Gear
Idler Gear
Steel BallBearing
Return Spring Starter Housing and
Clutch Assembly
 Terminal 30 Kit Part Terminal C Kit Part
Terminal Nut
Wave
Washer
Insulator
Packing
O−Ring
Terminal
Outer
Terminal Insulator
InnerContact PlateTerminal Bolt
 Dust Protector Brush Holder  O−Ring Field Frame
Lead Terminal
Plunger
 Gasket
End Cover Terminal
Outer O−Ring
Wave
Washer
Terminal Nut
Terminal
Insulator
Inner
Contact Plate Terminal Bolt
End Cover
 O−Ring  Front Bearing
Armature
 Rear Bearing
 Non−reusable part
− STARTINGSTARTER
ST−3
1996 RAV4 (RM447U)

ST05J−03
S01596(1) (2)
(3)(5)
(4)
S01642
Disconnect
S01783
ST−4
− STARTINGSTARTER
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE ENGINE COOLANT RESERVOIR
2. REMOVE AIR CLEANER CAP ASSEMBLY
(a) Disconnect these hoses, cord and connectors:
(1) Skid control relay connectors
(2) High−tension cord from the air cleaner hose and
resonator
(3) IAT sensor connector
(4) PCV hose from the air cleaner hose
(5) Air hose from the air cleaner cap assembly
(b) Disconnect the 4 clamps and air cleaner cap assembly
from the air cleaner case assembly.
(c) Loosen the hose clamp, and disconnect the air cleaner
hose from the throttle body.
(d) Remove the air cleaner cap assembly.
3. REMOVE AIR CLEANER CASE ASSEMBLY
(a) Disconnect the VSV from the air cleaner case assembly.
(b) Remove the 3 bolts and air cleaner case assembly.
4. REMOVE STARTER
(a) Disconnect the starter connector.
(b) Remove the nut, and disconnect the starter wire.
(c) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

ST0N5−01
S02332
P13717
S02331
P13464
− STARTINGSTARTER
ST−5
1996 RAV4 (RM447U)
DISASSEMBLY
HINT:
At the time of installation, please refer to the following item.
Use high−temperature grease to lubricate the bearings,
springs, steel ball, and gears when assembling the starter.
1. REMOVE DUST PROTECTOR
2. REMOVE FIELD FRAME AND ARMATURE
(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
(b) Remove the 2 through bolts.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
(c) Pull out the field frame together with the armature.
NOTICE:
At the time of installation, please refer to the following item.
Align the protrusion of the field frame with the groove of the
magnetic switch.
(d) Remove the O−ring from the field frame.
HINT:
At the time of installation, please refer to the following item.
Use a new O−ring.
3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY
AND GEAR
(a) Remove the 2 screws.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)