TOYOTA RAV4 1996 Service Repair Manual

EM0EV−02
A04063
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable part
29 (300, 22)
Hold Down ClampHold Down Clamp
BatteryEngine Hood
Battery Tray
Lower Radiator
HosePS Pump
w/ BracketCharcoal Canister
Battery Tray
IAT Sensor ConnectorAir Cleaner Cap
 Gasket
 Gasket
Fuel Inlet Hose
Fuel Filter
Water Inlet
Upper Radiator
Hose
Heater Hose
PS Pump Drive Belt
Generator Drive
Belt
Accelerator Cable
Generator
Generator Drive Belt
Adjusting Bar
Air Filter
EVAP VSV Connector
Air Cleaner Case
Radiator
Reservoir
Relay Block No. 2
Upper Cover
Relay Block No. 2
Wire Harness
A/C Compressor
Type B Type A
Type B Type A
− ENGINE MECHANICALENGINE UNIT
EM−65
1996 RAV4 (RM447U)
ENGINE UNIT
COMPONENTS

EM−66
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)

S01563
ECM Connector
Floor Carpet
Center CoverConnector on Bracket
Engine Wire
Connector
for Relay Block No. 4
Cowl Side Trim
Scuff Plate
− ENGINE MECHANICALENGINE UNIT
EM−67
1996 RAV4 (RM447U)

EM1BA−02
S01374
Cover
Connector EM−68
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE BATTERY
2. REMOVE ENGINE HOOD
3. REMOVE ENGINE UNDER COVERS
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL
6. DRAIN TRANSAXLE OIL
7. REMOVE AIR CLEANER CAP AND CASE
8. DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY, CABLE BRACKET AND CLAMPS
9. DISCONNECT ENGINE WIRE FROM RELAY BLOCK
NO. 2
(a) Remove the 2 bolts, and disconnect the relay block No.
2 from the body.
(b) Remove the upper cover.
(c) Disconnect the connector.
(d) Remove the 2 nuts and disconnect the engine wire.
10. REMOVE CHARCOAL CANISTER
11. REMOVE GENERATOR (See page CH−7)
12. REMOVE RADIATOR UPPER AND LOWER HOSES
13. REMOVE WATER INLET
Remove the 2 nuts and water inlet.
14. DISCONNECT HEATER HOSES
15. DISCONNECT FUEL INLET HOSE
CAUTION:
Catch leaking fuel in a container.
16. M/T only:
REMOVE STARTER (See page ST−4)
17. DISCONNECT GROUND CABLE
Remove the bolt and disconnect the ground cable on the trans-
axle.

S01351
Buck−up Light
Connector M/T only
S01797
M/T
A/T
S01785
A/T only
− ENGINE MECHANICALENGINE UNIT
EM−69
1996 RAV4 (RM447U)
18. M/T only:
DISCONNECT CLUTCH RELEASE CYLINDER FROM
TRANSAXLE
(a) Disconnect the back−up light switch connector.
(b) Remove the clamp, and disconnect the tube from the
bracket.
(c) Remove the bolt, and disconnect the bracket from the
transaxle.
(d) Remove the clamp bolt, and disconnect the tube from the
transaxle.
(e) Remove the 2 bolts, and disconnect the release cylinder
from the transaxle.
19. DISCONNECT TRANSAXLE CONTROL CABLE(S)
FROM TRANSAXLE
20. A/T only:
DISCONNECT TRANSAXLE CONTROL CABLE FROM
FRONT SUSPENSION CROSSMEMBER AND ENGINE
MOUNTING CENTER MEMBER
Remove the 2 bolts, and disconnect the control cable from the
crossmember and center member.
21. A/T and 4WD w/ M/T:
DISCONNECT TRANSAXLE OIL COOLER HOSES

S01432
S01285
S01347
EM−70
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
22. DISCONNECT CONNECTORS, CORD, STRAP AND
HOSES
(a) Disconnect the vapor pressure sensor connector.
(b) Disconnect the igniter connector.
(c) Disconnect the ignition coil connector.
(d) Disconnect the noise filter connector.
(e) Disconnect the high−tension cord from the ignition coil.
(f) Disconnect the MAP sensor connector.
(g) Disconnect the MAP sensor vacuum hose from the gas
filter on the intake manifold.
(h) Disconnect the brake booster hose from the intake man-
ifold.
(i) 4WD M/T:
Disconnect the differential lock control solenoid connec-
tor.
(j) Disconnect the ground strap from the cowl.
23. DISCONNECT ENGINE WIRE FROM CABIN
(a) Remove the RH scuff plate.
(b) Remove the RH cowl side trim.
(c) Remove the RH floor carpet center cover.
(d) Disconnect the 2 ECM connectors.
(e) Disconnect the 2 connectors from the connectors on the
bracket.
(f) Disconnect the connector from the J/B No. 4.
(g) Disconnect the wire clamp from the bracket.
(h) Pull out the engine wire from the cabin.
24. REMOVE FRONT EXHAUST PIPE
(a) Using a 14 mm deep socket wrench, remove the 2 bolts
holding the front exhaust pipe to the front TWC.
(b) Remove the 2 bolts and 2 nuts holding the front exhaust
pipe to the TWC w/ pipe.
(c) Remove the front exhaust pipe and 2 gaskets.
25. DISCONNECT A/C COMPRESSOR FROM ENGINE
(a) Disconnect the A/C compressor connector.
(b) Remove the 2 bolts, nut and stud bolt, and disconnect the
A/C compressor from the engine.
HINT:
Suspend the A/C compressor securely.
26. 4WD only:
REMOVE PROPELLER SHAFT (See page PR−3)
27. REMOVE FRONT DRIVE SHAFT (See page SA−20)
28. REMOVE STABILIZER (See page SA−40)

S01434
S01364
S01362
S01363
S01283
B
SST
A
− ENGINE MECHANICALENGINE UNIT
EM−71
1996 RAV4 (RM447U)
29. REMOVE FRONT SUSPENSION CROSSMEMBER
(a) Remove the 2 bolts and 2 nuts holding the PS gear as-
sembly to the front suspension crossmember.
(b) Remove the 2 nuts, and disconnect the engine mounting
center member.
(c) Disconnect the TWC w/ pipe from the ring.
(d) Support the front suspension crossmember with a jack.
(e) Remove the 6 bolts and front suspension crossmember.
30. REMOVE ENGINE MOUNTING CENTER MEMBER
(a) Remove the 2 bolts holding the center member to the
front engine mounting insulator.
(b) Remove the 2 bolts holding the center member to the
body, and remove the center member.
31. DISCONNECT PS PUMP FROM ENGINE
(a) Disconnect the 2 air hoses.
(b) Remove the bolt A.
(c) Using SST and a deep socket wrench, loosen the bolt B.
SST 09249−63010
(d) Remove the drive belt.

R10966
S01357
Engine
Hanger
No. 1
S01296
S01350
S01559
Ground Strap
Connector EM−72
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
(e) Remove the 3 bolts, and disconnect the PS pump from
the engine.
HINT:
Suspend the PS pump securely.
32. REMOVE ENGINE AND TRANSAXLE ASSEMBLY
FROM VEHICLE
(a) Install a engine hange No. 1 in the correct direction.
Part No. 1:
Engine hanger No. 1 12281−74060
Bolt 91611−B1020
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Attach the engine sling device to the engine hangers.
(c) Remove the 2 nuts and 2 bolts, and disconnect the LH en-
gine mounting bracket from the mounting insulator.
(d) Disconnect the ground strap connector.
(e) Remove the bolt and 2 nuts, and disconnect the RH en-
gine mounting bracket from the mounting insulator.

S01326
− ENGINE MECHANICALENGINE UNIT
EM−73
1996 RAV4 (RM447U)
(f) Lower the engine out of the vehicle slowly and carefully,
and raise the vehicle.
HINT:
Make sure the engine is clear of all wiring, hoses and cables.
(g) Place the engine and transaxle assembly onto the stand.
33. 2WD:
REMOVE DRIVE SHAFT BEARING BRACKET
34. SEPARATE ENGINE AND TRANSAXLE
(M/T (2WD): See page MX−3)
(M/T (4WD): See page MX−9)
(A/T/A241E (2WD): See page AX−15)
(A/T/A540H (2WD): See page AX−19)
35. M/T only:
REMOVE CLUTCH COVER AND DISC

EM0EX−03
S01296
S01431
S01350
EM−74
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
INSTALLATION
1. M/T only:
INSTALL CLUTCH DISC AND COVER (See page
CL−18)
2. ASSEMBLE ENGINE AND TRANSAXLE
(M/T (2WD): See page MX−7)
(M/T (4WD): See page MX−11)
(A/T/A241E (2WD): See page AX−19)
(A/T/A540H (2WD): See page AX−21)
3. 2WD:
INSTALL DRIVE SHAFT BEARING BRACKET
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
4. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN
VEHICLE
(a) Attach the engine sling device to the engine hangers.
(b) Slowly lower the vehicle, and raise the engine into the en-
gine compartment.
(c) Keep the engine level, and align RH and LH mountings
with the body mountings.
(d) Attach the RH engine mounting bracket to the mounting
insulator, and temporarily install the bolt and 2 nuts.
(e) Attach the LH engine mounting bracket to the mounting
insulator, and install the 2 nuts and 2 bolts.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)