Engine TOYOTA RAV4 1996 Service Manual PDF

BRAKE PEDAL FREE PLAY
1. Brake pedal free play is distance brake pedal travels before feeling resistance with engine stopped. To
check pedal free play, depress brake pedal several times to exhaust vacuum from booster.
2. Depress pedal and measure travel until initial resistance is felt. See BRAKE PEDAL
SPECIFICATIONS table. If free play is not within specification, adjust by turning push rod. See Fig. 1.
BRAKE PEDAL RESERVE DISTANCE
1. Pedal reserve distance is measured from face of pedal pad to asphalt sheet under carpet with brakes
applied. Measure reserve distance with engine running and weight of 110 lbs. (50 kg) applied against
pedal.
2. If measured reserve distance is less than specification, inspect brake system. See BRAKE PEDAL
MINIMUM RESERVE DISTANCE SPECIFICATIONS table.
BRAKE PEDAL MINIMUM RESERVE DISTANCE SPECIFICATIONS
LOAD-SENSING PROPORTIONING VALVE (LSPV) & BY-PASS VALVE (BPV)
PARKING BRAKE
Lever Stroke Adjustment
1. To check parking brake adjustment, pull on parking brake lever with weight of 66 lbs. (27 kg) on Sienna
and 44 lbs. (20 k
g) on all other models. Count number of notches (clicks) until parking brake is fully
RAV4.04-.24 (1-6)6.19-6.58 (157-167)
Sienna.04-.24 (1-6)6.28-6.67 (160-170)
Tacoma.12-.24 (3-6)6.09-6.48 (155-165)
Tundra.04-.24 (1-6)6.46-6.85 (164-174)
4Runner.12-.24 (3-6)6.34-6.74 (161-171)
ApplicationIn. (mm)
Land Cruiser4.57 (116)
RAV42.95 (75)
Sienna3.78 (96)
Tacoma2.83 (72)
Tundra3.74 (95)
4Runner2.83 (72)
NOTE: See LOAD
-SENSING PROPORTIONING VALVE (LSPV) & BY-PASS VALVE (BPV)
under TESTING.
NOTE: Rear brakes must be correctly adjusted before adjusting parking brake. See
REAR BRAKE DRUM
under REMOVAL & INSTALLATION.

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1999-2000 BRAKES Disc & Drum - Trucks & Vans
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Fig. 2: Adjusting Brake Booster Push Rod
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REAR DRUM BRAKE SHOES
To set initial lining-to-drum clearance, raise and support rear of vehicle. Release parking brake. Remove rear
wheels and brake drums. Measure brake drum inside diameter and brake lining diameter. Measured clearance
between linings and braking surface of drum should be .024" (.60 mm) on RAV4 and Tacoma, or .020" (.50
mm) on all other models. Turn brake adjuster to obtain specified clearance. Install brake drum and wheel and
adjust brakes (if necessary).
STOPLIGHT SWITCH
Remove lower instrument panel and air duct (if necessary). Loosen lock nuts. Turn switch until clearance
between threaded end of switch and pedal stop is .02-.09" (.5-2.3 mm), on all models except Land Cruiser.
Clearance should be .039" (1.0 mm) on Land Cruiser. See Fig. 1
. Check brake pedal height and brakelight
operation.
TESTING
POWER BRAKE UNIT (EXCEPT LAND CRUISER)
Operational Check
Depress brake pedal several times with engine off. There should be no change in pedal reserve distance.
NOTE: All rear drum brakes have a self-adjuster which is activated when brake pedal is
applied with vehicle traveling in reverse.

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1999-2000 BRAKES Disc & Drum - Trucks & Vans
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Depress brake pedal and start engine. If pedal goes down slightly, operation is normal.
Air Tightness Check
1. Start engine and run for 1-2 minutes, then turn engine off. Depress brake pedal several times slowly. If
pedal goes down farthest on first time, but gradually rises after second or third time, power brake unit is
airtight.
2. With engine stopped, depress brake pedal several times using normal pressure. Pedal should be low when
first depressed. On consecutive applications, pedal height should gradually rise. If pedal height does not
increase, check for air leaks.
LOAD-SENSING PROPORTIONING VALVE (LSPV) & BY-PASS VALVE (BPV)
Tacoma & Tundra
1. For testing purposes, rear axle is loaded to a specified weight. Set total rear axle weight to specified
amount. See LSPV REAR AXLE TEST WEIGHT
table.
2. Attach pressure gauge set to front caliper and rear wheel cylinder or caliper. Bleed air from system. See
BLEEDING BRAKE SYSTEM
. Depress brake pedal until front pressure is as specified. See LSPV
PRESSURE SPECIFICATIONS table. Wait 2 seconds and record rear pressure reading.
LSPV REAR AXLE TEST WEIGHT
LSPV PRESSURE SPECIFICATIONS NOTE: DO NOT depress brake pedal more than once or release pedal while
setting pressure on front gauge.
ApplicationLbs. (kg)
Tacoma
2WD1543 (700)
4WD1874 (850)
Tundra
V6
Engine
(5UZ-
FE)2205 (1000)
V8
Engine
(2UZ-
FE)2315 (1050)
4Runner2033 (922)
Application
Front Pressure - psi
(kg/cm
2 )
Rear Pressure - psi
(kg/cm
2 )
Tacoma

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See MASTER CYLINDER .
2. Remove ABS actuator assembly. Disconnect vacuum hose from power brake unit. Remove lower
instrument panel finish panels to access brake pedal arm. Remove Cruise Control Engine Control Unit
(ECU). Remove pedal return spring, clip and clevis pin.
3. Remove 4 nuts and clevis, and remove power brake unit.
4. Install power brake unit. Attach clevis pin, clip and return spring. Install Cruise Control Engine Control
Unit (ECU). Adjust push rod length. See POWER BRAKE UNIT PUSH ROD
under ADJUSTMENTS.
5. Install master cylinder with NEW gasket. Connect vacuum hose. Fill master cylinder. Bleed system and
check for leads. Adjust brake pedal, if necessary. Install cowl panel and vent louvers.

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1999-2000 BRAKES Disc & Drum - Trucks & Vans
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Fig. 2: Center Differential Lock System Schematic
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
TROUBLE SHOOTING
CENTER DIFFERENTIAL LOCK SYSTEM
1. Raise vehicle off ground so all 4 wheels can rotate. Apply parking brake and start engine. Turn center
differential lock system on.
2. Depress clutch pedal and shift into 2nd gear. With engine idling, gradually engage the clutch and ensure
engine stalls.
3. With parking brake and engine on, turn center differential lock system off. Depress clutch pedal and shift
into 2nd gear. With engine idling, gradually engage the clutch and ensure front wheels rotate.
CENTER DIFFERENTIAL LOCK INDICATOR LIGHT
Turn ignition on. Ensure indicator light is off with center differential lock system off, and on with system on.
WARNING BUZZER
1. Start en
gine and ensure warning buzzer does not sound when center differential lock switch is turned on.
NOTE: If the buzzer continues to sound, point the wheels straight ahead, accelerate or
decelerate, or drive the vehicle in reverse to stop the buzzer.

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1999-2000 DRIVE AXLES Center Differential Lock
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1999-2000 STARTING & CHARGING SYSTEMS
Generators & Regulators
DESCRIPTION & OPERATION
The generator is a small, high RPM, high performance type with an internal Integrated Circuit (IC) voltage
regulator which controls charging system voltage. A transistor inside IC regulator controls generator voltage
output to maintain a constant voltage. Charging system voltage is maintained within an operating range of 13.2-
15.1 volts. See GENERATOR REGULATED OUTPUT SPECIFICATIONS
table under NO-LOAD TEST
under ON-VEHICLE TESTING for specific model operating ranges. For generator rated ampere output, see
GENERATOR RATED AMPERE OUTPUT SPECIFICATIONS
table.
When ignition is turned on, battery voltage flows from generator terminal "L" through IC regulator to ground,
causing discharge warning light to come on. When engine starts, generator RPM increases, which increases
generator output voltage. When generator output voltage is greater than battery voltage, voltage to recharge
battery flows from terminal "B". At the same time, voltage at terminal "L" increases and the potential difference
between battery and terminal "L" ceases, causing discharge warning light to go off.
GENERATOR RATED AMPERE OUTPUT SPECIFICATIONS
ADJUSTMENTS
NOTE: This article also applies to Lexus LX470. For Lexus LX470, refer to Land
Cruiser, unless otherwise indicated.
ApplicationAmperes
Avalon, Camry, Camry Solara & Corolla80
Celica
A/T80
M/T70
Land Cruiser80 Or 100
RAV490
Sienna100
Tacoma
4-Cylinder70
V690 Or 100
Tundra
V670 Or 80
V870 Or 100
4Runner
4-Cylinder70
V660

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
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BELT TENSION
4-Cylinder
Check belt tension using Burroughs Tension Gauge (BT-33-73F) at longest belt run. Adjust belt tension if
necessary. See BELT TENSION SPECIFICATIONS (4
-CYLINDER) table.
BELT TENSION SPECIFICATIONS (4-CYLINDER)
(1)
V6
Check belt tension using Burroughs Tension Gauge (BT-33-73F) at longest belt run. Adjust belt tension if
necessary. See BELT TENSION SPECIFICATIONS (V6) table.
BELT TENSION SPECIFICATIONS (V6)
(1) NOTE: New belt refers to a belt which has been used 5 minutes or less on a running
engine. Used belt refers to a belt which has been used more than 5 minutes on
a running engine. After installing new belt(s), run engine for at least 5 minutes
and recheck tension.
NOTE: Corolla uses an automatic belt tensioner. Adjustment is not required.
ApplicationNew Belt Lbs. (kg)Used Belt Lbs. (kg)
Camry, Camry Solara & RAV4
Generator
With A/C140-190 (64-86)100-120 (45-54)
Without A/C100-150 (45-68)75-115 (34-52)
Power Steering95-145 (43-66)60-100 (27-45)
Celica
Generator
With A/C170-180 (77-82)95-135 (43-61)
Without A/C100-150 (45-68)75-115 (34-52)
Power Steering99-121 (45-55)44-77 (20-35)
Corolla(2) (2)
Tacoma & 4Runner
A/C135-185 (61-84)80-100 (36-45)
Generator116-169 (53-77)66-88 (30-40)
Power Steering135-180 (61-82)85-120 (39-54)
(1)Measure belt tension with Burroughs (BT-33-73F) tension gauge.
(2)Automatic belt tensioner is used. Adjustment is not required.
ApplicationNew Belt Lbs. (kg)Used Belt Lbs. (kg)
Avalon, Camry, Camry Solara & Sienna

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Check all fuses, fusible links, ignition switch and appropriate relays (if equipped). Check generator output. See
NO
-LOAD TEST under ON-VEHICLE TESTING.
ON-VEHICLE TESTING
NO-LOAD TEST
1. Disconnect battery-to-generator terminal "B" wire. See Fig. 2
. Using an ammeter and voltmeter, connect
negative ammeter lead to disconnected generator terminal "B" wire end, and connect positive ammeter
lead to generator terminal "B".
2. Connect voltmeter positive lead to generator terminal "B" and negative lead to ground. See Fig. 2
. Start
engine and increase engine speed to 2000 RPM. Both meters should read within specification. See
GENERATOR REGULATED OUTPUT SPECIFICATIONS
table. If voltage is more than specified,
replace IC regulator. If voltage is less than specified, go to next step.
3. Locate small hole in back of generator. See Fig. 3
. It may be necessary to remove generator end cover to
access hole. Using a probe, ground generator terminal "F" (full field) to generator case. See Fig. 3
. If
voltage is more than specified range, replace IC regulator. If voltage is less than specified range, repair or
replace generator.
GENERATOR REGULATED OUTPUT SPECIFICATIONS
(1) NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION.
ApplicationAmpsVolts
Avalon10 Or Less13.2-14.8
Camry, Camry Solara & Corolla10 Or Less13.5-15.1
Celica & RAV4
With Temperature At 77°F (25°C)10 Or Less14.0-15.1
With Temperature At 239°F (115°C)10 Or Less13.5-14.3
Land Cruiser & Sienna10 Or Less13.2-14.8
Tacoma
With Temperature At 77°F (25°C)10 Or Less13.7-14.7
With Temperature At 239°F (115°C)10 Or Less13.2-14.0
Tundra
V610 Or Less13.2-14.8
V8
With Temperature At 77°F (25°C)10 Or Less13.7-14.7
With Temperature At 239°F (115°C)10 Or Less13.2-14.0
4Runner
With Temperature At 77°F (25°C)10 Or Less13.7-14.7
With Temperature At 239°F (115°C)10 Or Less13.2-14.0
(1)Specification given is with engine speed at 2000 RPM.

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Fig. 3: Testing Generator Full Field Output (Typical)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
LOAD TEST
1. Connect an ammeter as described in NO
-LOAD TEST , step 1) . See Fig. 2 . Start engine. Turn on high
beam headlights and place heater blower control on HI. Increase engine speed to 2000 RPM.
2. Check ammeter reading. Ammeter should read 30 amps or more. If amperage is less than specified, repair
or replace generator.
BENCH TESTING
BRUSHES
1. Brushes should slide smoothly in holders. Replace brushes if damaged or worn. On Tundra and 4Runner,
new brush exposed length should be .374-.453" (9.5-11.5 mm). On all other models, new brush exposed
length should be .413" (10.5 mm).
2. On all models, minimum exposed length should be more than .059" (1.5 mm). There are 2 different brush
holders used. One brush holder is replaced as an assembl
y, and the other has replaceable brushes. If
NOTE: If battery is fully charged, disable ignition system. Crank engine for about 15
seconds to partially discharge battery.
NOTE: If battery is fully charged, generator load test results may be less than 30 amps.

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1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
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exposed brush length is less than minimum, replace brushes or brush holder assembly. Install new brush
springs when replacing brushes.
ROTOR
1. Check rotor for open field windings by using an ohmmeter across slip rings. Rotor resistance should be
within specification. See ROTOR RESISTANCE SPECIFICATIONS
table.
2. Check rotor for shorts to ground by connecting ohmmeter between slip ring and rotor shaft. Ohmmeter
should indicate no continuity. Check slip rings for wear or pitting. Standard slip ring diameter is .559-
.567" (14.2-14.4 mm). Turn slip rings on lathe if necessary. Minimum slip ring diameter is .504" (12.8
mm).
ROTOR RESISTANCE SPECIFICATIONS
STATOR
Connect ohmmeter between 2 stator leads. Continuity should exist between all stator leads. Connect ohmmeter
between each stator lead and metal core. Continuity should not exist. If stator does not test as indicated, replace
stator.
DIODES
1. With diode/rectifier assembly removed and on bench, contact positive diode plate terminal with one
ohmmeter probe. Using other ohmmeter probe, contact each diode lead in same plate. Note ohmmeter
reading. Reverse ohmmeter probes, and repeat tests for all diodes.
2. All diodes should show continuity in one direction and no continuity in opposite direction. If any diode is
defective, replace diode/rectifier assembly.
REMOVAL & INSTALLATION
GENERATOR
Removal & Installation (Land Cruiser)
1. Disconnect negative battery cable. Drain engine coolant. Rotate belt tensioner counterclockwise to release
tension on belt and remove drive belt. Remove splash shield from underneath en
gine. Remove radiator
Application(1) Ohms
Avalon2.1-2.5
Camry & Camry Solara
4-Cyl.2.7-3.1
V62.1-2.5
Land Cruiser, Sienna, Tacoma, Tundra & 4Runner2.1-2.5
All Other Models2.7-3.1
(1)Specification given is with temperature at 68°F (20°C).

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1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
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