engine TOYOTA RAV4 1996 Service Repair Manual

LOW OIL PRESSURE WARNING LIGHT
RAV4, Sienna, Tacoma, Tundra Without Tachometer & 4Runner
Disconnect low oil pressure switch connector. See OIL PRESSURE SWITCH LOCATION table. Using a
jumper wire, connect low oil pressure switch connector terminal to ground. Turn ignition switch to ON position.
Low oil pressure warning light should turn on. If low oil pressure warning light is off, check bulb or inspect
wiring harness.
OCCUPANT DETECTION SENSOR
Land Cruiser & Tundra
Disconnect occupant detection sensor connector, located under passenger seat. Check continuity between sensor
connector terminals. Continuity should exist only when pressing on sensor. If continuity is not as specified,
replace occupant detection sensor.
OIL PRESSURE GAUGE & SENDER
Oil Pressure Gauge & Harness Operational Test (Land Cruiser & Tundra With Tachometer)
1. Disconnect oil pressure sender connector. See OIL PRESSURE SENDER LOCATION table. Turn
ignition switch to ON position. Oil gauge should indicate LOW. Turn ignition switch to OFF position.
Connect a 12-volt, 3.4-watt test light between oil sending unit harness connector terminal and ground.
2. Turn ignition switch to ON position. Test light should be on and oil pressure gauge should slowly move
to HIGH. If gauge functions as specified, perform OIL PRESSURE SENDER OPERATIONAL
TEST . If gauge does not function as specified, perform OIL PRESSURE GAUGE RESISTANCE
TEST .
Oil Pressure Sender Operational Test (Land Cruiser & Tundra With Tachometer)
Disconnect oil pressure sender connector. See OIL PRESSURE SENDER LOCATION table. Using 12-volt
source, connect an LED tester between positive battery terminal and oil pressure sender terminal. With engine
off, LED should be off. With engine running, LED should flash. LED flashes will vary with engine speed and
oil pressure. Replace oil pressure sender if LED does not operate as specified.
OIL PRESSURE SENDER LOCATION
Oil Pressure Gauge Resistance Test (Land Cruiser & Tundra With Tachometer)
Remove instrument cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Using
an ohmmeter, check resistance between oil gauge terminals on rear of instrument cluster. See Fig. 16
or Fig.
17 . See OIL PRESSURE GAUGE RESISTANCE SPECIFICATIONS table. If resistance is not as
specified, replace oil pressure
gauge.
ApplicationLocation
Land Cruiser & TundraOn Oil Filter Housing

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Ensure tires are correct size and inflated properly. Place vehicle on standard speedometer tester. Compare tester
with speedometer readings. See SPEEDOMETER TEST
table. If vehicle speedometer readings are not within
allowable range, replace speedometer. If speedometer does not operate at all, check speedometer resistance. If
speedometer resistance is okay, check vehicle speed sensor. See appropriate SYSTEM & COMPONENT
TESTING article in ENGINE PERFORMANCE.
Speedometer Operational Test (Except Land Cruiser)
Ensure tires are correct size and inflated properly. Place vehicle on standard speedometer tester. Compare tester
with speedometer readings. See SPEEDOMETER TEST
table. If vehicle speedometer readings are not within
allowable range, replace speedometer. If speedometer does not operate at all, check vehicle speed sensor. See
SYSTEM & COMPONENT TESTING article in ENGINE PERFORMANCE.
SPEEDOMETER TEST
Speedometer Resistance (Land Cruiser & Tundra)
Remove instrument cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Using
an ohmmeter, check resistance between speedometer terminals on rear of instrument cluster. See Fig. 6
and Fig.
20 . See SPEEDOMETER RESISTANCE table. If resistance is not as specified, replace speedometer.
SPEEDOMETER RESISTANCE
Standard Indication (MPH)Allowable Range (MPH)
2018-24
4038-44
6056-66
8078-88
10098-110
120118-132
ApplicationOhms
Land Cruiser & Tundra
Terminals "A" & "B"160
Terminals "C" & "D"160

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Tachometer Operational Test
Connect a tune-up test tachometer and start engine. Compare vehicle tachometer RPM reading against test
tachometer. If vehicle tachometer reading is outside allowable range, replace tachometer. See TACHOMETER
TEST table.
TACHOMETER TEST
Tachometer Resistance (Land Cruiser & Tundra)
Remove instrument cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Using
an ohmmeter, check resistance between tachometer terminals on rear of instrument cluster. See Fig. 6
and Fig.
20 . See TACHOMETER RESISTANCE table. If resistance is not as specified, replace tachometer.
TACHOMETER RESISTANCE
VOLTMETER
Land Cruiser & Tundra
Remove instrument cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Using
an ohmmeter, measure resistance between tachometer terminals on rear of instrument cluster. See Fig. 6
and
Vehicle RPM ReadingAllowable Range (RPM)
Land Cruiser, Sienna, RAV4, Tundra & 4Runner
700630-770
1000900-1100
20001850-2150
30002800-3200
40003800-4200
50004800-5200
60005750-6250
70006700-7300
Tacoma
700630-770
30002850-3150
50004850-5150
70006790-7210
Application & TerminalsOhms
Land Cruiser
"A" & "B"160
"C" & "D"160
Tundra
"A" & "B"140-185
"C"& "D"130-175

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Fig. 21 . Resistance should be 347 ohms. If resistance is not as specified, replace tachometer.
Fig. 21: Identifying Voltmeter Terminals (Land Cruiser)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
VEHICLE SPEED SENSOR
For vehicle speed sensor testing procedures, see SYSTEM & COMPONENT TESTING article in ENGINE
PERFORMANCE.
WASHER LEVEL WARNING LIGHT
Sienna, RAV4, Tacoma, Tundra & 4Runner
Disconnect washer level switch connector. Connect a jumper wire between washer level switch wiring harness
connector terminals. Turn ignition switch to ON position. Washer level warning light should be on. If washer
level warning light is off, check bulb and wiring harness. Repair as necessary.
WASHER LEVEL WARNING SWITCH
Sienna, RAV4, Tacoma, Tundra & 4Runner

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Fig. 1: VIN Code ID Explanation
MAINTENANCE SERVICE INFORMATION
SEVERE & NORMAL SERVICE DEFINITIONS
Service is recommended at mileage intervals based on vehicle operation and engine type. Service schedules are
based on the following primary operating conditions:
Light Service
Light, non-commercial duty for distances greater than 5 miles in temperate climates above freezing and
below 90°F (32°C).

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Normal Service
Driven More Than 10 Miles Daily
No Operating Conditions From Severe Service Schedule
Severe Service (Unique Driving Conditions)
CAMSHAFT TIMING BELT
Inspect timing belt at 60,000 miles or 48 months and thereafter inspect timing belt every 15,000 miles, or 12
months. Replace belt as necessary.
The condition of camshaft drive belts should always be checked on vehicles which have more than 50,000
miles. Although some manufacturers do not recommend belt replacement at a specified mileage, others require
it at 60,000-100,000 miles. A camshaft drive belt failure may cause extensive damage to internal engine
components on most engines, although some designs do not allow piston-to-valve contact. These designs are
often called Free Wheeling.
Many manufacturers changed their maintenance and warranty schedules in the mid-1980's to reflect timing belt
inspection and/or replacement at 50,000-60,000 miles. Most service interval schedules in this manual reflect
these changes.
Belts or components should be inspected and replaced if any of the following conditions exist:
Cracks Or Tears In Belt Surface
Missing, Damaged, Cracked Or Rounded Teeth
Oil Contamination
Damaged Or Faulty Tensioners
Incorrect Tension Adjustment NOTE: Use the Severe Service schedule if the vehicle to be serviced is operated under
ANY (one or more) of these conditions:
Towing a trailer or using a camper or car-top carrier.
Repeated short trips of less than 5 miles in temperatures below freezing.
Extensive idling or low-speed driving for long distances as in heavy
commercial use such as delivery, taxi or patrol car.
Operating on rough, muddy or salt covered roads.
Operating on unpaved or dusty roads.
CAUTION: Failure to replace a faulty camshaft timing belt may result in serious
engine damage.

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LUBRICATION SPECIFICATIONS
LUBRICATION SPECIFICATIONS
FLUID CAPACITIES
FLUID CAPACITIES
BATTERY SPECIFICATIONS
MaterialConditionSpecification
Engine OilAmbient Temperature Less Than
50°F (10°C) to -20°F (-29°C)SAE 5W-30 API SH
Engine OilAmbient Temperature Above 0°F
(-18°C) to Over 100°F (38°C)SAE 10W-30 API SH
Automatic Transaxle Fluid2WD: AllATF DEXRON II
Automatic Transaxle Fluid4WD: AllATF Type T or Equiv.
Manual Transaxle FluidAllAPI GL-4 or GL-5 SAE 75W-90
Clutch FluidAllDOT 3
Transfer Case FluidAllMultipurpose Gear Oil API GL-5,
SAE 75W-90
Rear Differential FluidAllHypoid Gear Oil API GL-5, SAE
90
Engine CoolantAllEthylene-Glycol Based
Power Steering FluidAllATF DEXRON II
Brake FluidAllDOT 3
ItemConditionSpecification (1)
Engine OilDrained, With Filter4.3 Qts. (4.1L)
Engine OilDrained, Without Filter4.1 Qts. (3.9L)
Engine CoolantM/T: Drained8.5 Qts. (8.0L)
Engine CoolantA/T: Drained8.1 Qts. (7.7L)
Transfer Case Oil (2) Drained0.7 Qts. (0.7L)
Automatic Transaxle Fluid2WD: Drained3.5 Qts. (3.3L)
Automatic Transaxle Fluid4WD: Drained7.4 Qts. (7.0L)
Manual Transaxle Oil2WD: Drained4.1 Qts. (3.9L)
Manual Transaxle Oil4WD: Drained5.3 Qts. (5.0L)
Rear Differential Oil (3) Drained1.0 Qts. (0.9L)
Fuel TankCapacity15.3 Gals. (58.0L)
(1)Capacities are recommended or calculated levels. Always use dipstick (if available) to measure level.
(2)4WD models with an automatic transaxle.
(3)4WD models, includes LSD.

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On models equipped with anti-lock brake systems, ALWAYS observe the following cautions:
DO NOT attempt to bleed hydraulic system without first referring to the appropriate ANTI-LOCK
BRAKE SYSTEM article in the BRAKES Section.
DO NOT mix tire sizes. As long as tires remain close to the original diameter, increasing the width is
acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the
same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.
Use ONLY recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.
BATTERY WARNING
REPLACING BLOWN FUSES
BRAKE PAD WEAR INDICATOR
Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.
CATALYTIC CONVERTER CAUTION: The anti-lock brake system contains electronic equipment that can be
susceptible to interference caused by improperly installed or high output
radio transmitting equipment. Since this interference could cause the
possible loss of the anti-lock braking capability, such equipment should
be installed by qualified professionals.
WARNING:When battery is disconnected, vehicles equipped with computers may
lose memory data. When battery power is restored, driveability problems
may exist on some vehicles. These vehicles may require a relearn
procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL
INFORMATION section.
CAUTION: Before replacing a blown fuse, remove ignition key, turn off all lights and
accessories to avoid damaging the electrical system. Be sure to use fuse
with the correct indicated amperage rating. The use of an incorrect
amperage rating fuse may result in a dangerous electrical system
overload.
CAUTION: Continued operation of vehicle with a severe malfunction could cause
converter to overheat, resulting in possible damage to converter and
vehicle.
CAUTION: Any modification to the exhaust system on turbo models, which reduces
exhaust backpressure, will lead to lean fuel mixtures and excessive spark
advance. This could cause serious engine damage.

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ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
ENGINE OIL
FUEL SYSTEM SERVICE
HALOGEN BULBS
RADIATOR CAP
RADIATOR FAN
WARRANTY INFORMATION
NEW VEHICLE LIMITED WARRANTY WARNING:Many solid state electrical components can be damaged by static
electricity (ESD). Some will display a warning label, but many will not.
Discharge personal static electricity by touching a metal ground point on
the vehicle prior to servicing any ESD sensitive component.
CAUTION: Never use non-detergent or straight mineral oil.
WARNING:Relieve fuel system pressure prior to servicing any fuel system
component (fuel injection models).
WARNING:Halogen bulbs contain pressurized gas which may explode if overheated.
DO NOT touch glass portion of bulb with bare hands. Eye protection
should be worn when handling or working around halogen bulbs.
CAUTION: Always disconnect the fan motor when working near the radiator fan. The
fan is temperature controlled and could start at any time even when the
ignition key is in the OFF position. DO NOT loosen or remove radiator cap
when cooling system is hot.
WARNING:Keep hands away from radiator fan. Fan is controlled by a thermostatic
switch which may come on or run for up to 15 minutes even after engine
is turned off.
CAUTION: Due to the different warranties offered in various regions and the variety of
after-market extended warranties available, please refer to the warranty
package that came with the vehicle to verify all warranty options.

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Covers any repair or replacement of parts which becomes necessary due to defects in materials or workmanship
under normal use for 36 months or 36,000 miles from in-service date.
The items specified below are covered for a period different from the basic coverage:
Air Conditioner
The air conditioner refrigerant charge is covered for the first 12 months, regardless of mileage, unless done as
part of a warranty repair.
Adjustments
Service adjustment (minor repairs not usually associated with the replacement of parts) are covered for the first
12 months or 12,500 miles, whichever occurs first.
POWERTRAIN WARRANTY
Engine, transmission, front wheel drive, rear wheel drive and restraint system are warranted against defects in
materials or workmanship under normal use for 5 years or 60,000 miles, whichever occurs first. See copy of
warranty for specific components covered.
CORROSION PERFORATION WARRANTY
Covers any repair or replacement to body sheet metal which develops corrosion perforation (hole through
panel), in normal use, due to defects in material or workmanship for a period of 5 years, regardless of mileage.
BATTERY WARRANTY
Covers replacement of defective original battery for first 12 months or 12,000 miles. After the first 12 months
or 12,000 miles, warranty covers a pro-rated amount based on months in service, up to a maximum of 36
months.
EMISSION SYSTEM DEFECT WARRANTY (EXCEPT CALIFORNIA)
Warrants to the retail purchaser, and subsequent purchaser that vehicle was designed, built, and equipped so as
to conform at the time of sale with applicable emission regulations and that it is free from defects in materials or
workmanship which may cause the vehicle to fail to conform with applicable regulations for 5 years or 50,000
miles, whichever occurs first.
EMISSION SYSTEM PERFORMANCE WARRANTY (EXCEPT CALIFORNIA)
Covers all repairs, adjustments, or replacements if vehicle fails to conform to applicable emission standards and
such failure results in the vehicle owner having to bear a penalty or other sanction under local, state or federal
law for 5 years or 50,000 miles, whichever comes first. If the vehicle has been in use for more than 24 months
or 24,000 miles, the manufacturer will make the necessary adjustments, repairs or replacements at no cost to the
owner only when noncompliance is caused by failure of components which have been installed in the vehicle
for the sole or primary purpose of reducing vehicle emissions. See copy of warranty for specific components

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