TOYOTA RAV4 1996 Service Repair Manual

S01775S01237B13839
A/T M/T LU−16
− LUBRICATIONOIL PUMP
1996 RAV4 (RM447U)
9. INSTALL STIFFENER PLATE
Install the stiffener plate with the 2 bolts (M/T) or 3 bolts (A/T).
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
10. INSTALL FRONT EXHAUST PIPE (See page EM−55)
11. FILL WITH ENGINE OIL
12. START ENGINE AND CHECK FOR LEAKS
13. RECHECK ENGINE OIL LEVEL
14. INSTALL RH ENGINE UNDER COVER
15. INSTALL HOOD

LU069−03
− LUBRICATIONOIL COOLER
LU−17
1996 RAV4 (RM447U)
OIL COOLER
COMPONENTS

LU06A−03
S01365
S01359
SST
S01366
LU−18
− LUBRICATIONOIL COOLER
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE FRONT EXHAUST PIPE (See page EM−33)
4. REMOVE GENERATOR (See page CH−7)
5. REMOVE OIL DIPSTICK
6. REMOVE EXHAUST MANIFOLD AND FRONT TWC
ASSEMBLY (See page EM−33)
7. REMOVE WATER BYPASS PIPE HEAT PROTECTOR
Remove the bolt, 2 nuts and heat protector.
8. REMOVE OIL FILTER
Using SST, remove the oil filter.
SST 09228−06501
9. REMOVE OIL COOLER
(a) Disconnect the 2 water bypass hoses from the oil cooler.
(b) Remove the union bolt and plate washer.
(c) Remove the nut and oil cooler.
(d) Remove the O−ring from the oil cooler.

P15377
Push
LU0O6−01
P15378
IN
OUT
− LUBRICATIONOIL COOLER
LU−19
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT RELIEF VALVE
Push the valve with a wooden stick to check if it is stuck.
If stuck, replace the relief valve.
2. INSPECT OIL COOLER
Check the oil cooler for damage or clogging.
If necessary, replace the oil cooler.

LU06C−02
LU−20
− LUBRICATIONOIL COOLER
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL OIL COOLER
(a) Clean the oil cooler contact surface on the oil cooler
mounting.
(b) Install a new O−ring to the oil cooler.
(c) Temporarily install the oil cooler with the nut.
(d) Apply a light coat of engine oil on the threads and under
the head of the relief valve.
(e) Install the plate washer and union bolt.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
(f) Tighten the nut.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(g) Connect the 2 water bypass hoses to the oil cooler.
2. INSTALL OIL FILTER
3. INSTALL WATER BYPASS HOSE HEAT PROTECTOR
Install the heat protector with the bolt and 2 nuts.
4. INSTALL EXHAUST MANIFOLD AND FRONT TWC AS-
SEMBLY (See page EM−55)
5. INSTALL OIL DIPSTICK
6. INSTALL GENERATOR (See page CH−19)
7. INSTALL FRONT EXHAUST PIPE (See page EM−55)
8. FILL WITH ENGINE COOLANT
9. START ENGINE AND CHECK FOR LEAKS
10. CHECK ENGINE OIL LEVEL
11. INSTALL RH ENGINE UNDER COVER

MX01Z−08
− MANUAL TRANSAXLETROUBLESHOOTING
MX−1
1996 RAV4 (RM447U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Noise
14.Oil (Level low) 2WD
4WD
15. Oil (Wrong) 2WD
4WD
16.Gear (Worn or damaged)
17.Bearing (Worn or damaged)MX−3
MX−9
MX−3
MX−9
MX−12
MX−79
MX−12
MX−79
Oil leakage
1. Oil (Level too high) 2WD
4WD
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O−Ring (Worn or damaged)MX−3
MX−9
MX−12
MX−79
MX−12
MX−79
MX−12
MX−78
MX−79
Hard to shift or will not shift
1. Control cable (Faulty)
2. Synchronizer ring (Worn or damaged)
3. Shift key spring (Damaged)MX−77
MX−12
MX−29
MX−36
MX−12
MX−29
MX−36
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MX−12
MX−12
MX−79
MX−12
MX−79
MX−12
MX−79
Tight corner braking1. Differential, Center differential (Faulty)MX−58
MX−72

MX05N−02
Q10400
Air Intake Connector
Engine Coolant
Reservoir Tank Clutch Release Cylinder
and Line
Vehicle Speed
Sensor Connector
Back−Up Light Switch
Connector
Control Cable
Clip
Ground Cable
Transaxle Case Protector
Tie Rod End RH Drive Shaft
Stiffener PlateNo.2 Rear
End Plate
 Snap Ring
 Cotter Pin LH Drive
Shaft
PS Gear Assembly
Engine Mounting
Center Member
RH Engine
Under Cover
LH Engine Under CoverFront Suspension Crossmember
Assembly with Stabilizer BarClipAir Cleaner Case
Assembly
with Air Hose
Snap Ring
Engine
Wire
Clamp
 Cotter Pin
Lock Cap Starter
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 
4.9 (50, 43 in.·lbf)
12 (120, 9)
29 (300, 22)
35 (360, 26)32 (330, 24)46 (470, 34)
64 (650, 47)
35 (360, 26)
64 (650, 47)
12 (120, 9)
64 (650, 47)
25 (250, 18)
25 (250, 18)
9.0 (95, 78 in.·lbf)
37 (380, 27)
39 (400, 29)
9.0 (95, 78 in.·lbf)
29 (300, 22)
37 (380, 27)49 (500, 36)
113 (1,150, 83)
137 (1,400, 101)
206 (2,100, 152)
216 (2,200, 159)
113 (1,150, 83)
64 (650, 47)
48 (490, 35)
80 (820, 59)
115 (1,170, 85)
127 (1,300, 94)
62 (630, 46)
Front Exhaust Pipe
 GasketClip
Washer
MX−2
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
1996 RAV4 (RM447U)
MANUAL TRANSAXLE UNIT (2WD)
COMPONENTS

MX05O−02
Q08747
Q08748
A
B
Q08749
Q08750
A B
A
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
MX−3
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR
HOSE
2. REMOVE ENGINE COOLANT RESERVOIR TANK
3. REMOVE ENGINE WIRE CLAMP SET NUT
4. REMOVE STARTER
(a) Disconnect the connector and wire from the starter.
(b) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
5. DISCONNECT CLUTCH RELEASE CYLINDER AND
LINE
(a) Remove the 2 set bolts of the clutch line bracket.
Torque:
Bolt A: 12 N·m (120 kgf·cm, 9 ft·lbf)
Bolt B: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
(b) Remove the 2 bolts, release cylinder and line.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
6. DISCONNECT GROUND CABLE
Remove the set bolt of the ground cable from the transaxle.
7. DISCONNECT VEHICLE SPEED SENSOR AND
BACK−UP LIGHT SWITCH CONNECTORS
8. DISCONNECT CONTROL CABLE
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
9. REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING
BOLTS
Torque:
Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf)
Bolt B: 35 N·m (360 kgf·cm, 26 ft·lbf)

Q08751
Q08752
Q10165
Filler Plug
Oil Level
0 − 5 mm
Drain Plug
Q08753
MX−4
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
1996 RAV4 (RM447U)
10. REMOVE ENGINE LEFT MOUNTING INSULATOR SET
BOLT AND 2 NUTS
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
11. INSTALL ENGINE SUPPORT FIXTURE
12. TIE PS GEAR ASSEMBLY TO ENGINE SUPPORT FIX-
TURE BY CORD OR EQUIVALENT
13. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
14. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
15. REMOVE LH AND RH ENGINE UNDER COVERS
16. DRAIN TRANSAXLE OIL
Oil grade: API GL−4 or GL−5
Viscosity: SAE 75W−90
Capacity: 3.9 liters (4.1 US qts, 3.4 Imp. qts)
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
17. REMOVE LH AND RH FRONT DRIVE SHAFTS
(See page SA−18)
18. REMOVE FRONT EXHAUST PIPE
(a) Remove the 3 nuts and gasket from the exhaust manifold.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Remove the 2 bolts, gasket and pipe.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
19. REMOVE FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY WITH STABILIZER BAR
(a) Support the front suspension crossmember with a jack.
(b) Disconnect the ring from the center exhaust pipe.
(c) Remove the 2 set bolts and nuts of the PS gear assembly.
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)

Q08754
A
B A
B D
E
C
Q08755
Q08756DEC C
FG G
F
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
MX−5
1996 RAV4 (RM447U)
(d) Remove the 2 nuts, 6 bolts and front suspension cross-
member assembly with the stabilizer bar.
Torque:
Bolt A: 206 N·m (2,100 kgf·cm, 152 ft·lbf)
Bolt B: 137 N·m (1,400 kgf·cm, 101 ft·lbf)
Nut C: 115 N·m (1,170 kgf·cm, 85 ft·lbf)
20. REMOVE ENGINE MOUNTING CENTER MEMBER
Remove the 4 bolts and center member.
Torque:
Bolt D: 80 N·m (820 kgf·cm, 59 ft·lbf)
Bolt E: 35 N·m (360 kgf·cm, 26 ft·lbf)
21. JACK UP TRANSAXLE SLIGHTLY
Using a trasmission jack, support the transaxle.
22. DISCONNECT ENGINE LEFT MOUNTING BRACKET
FROM ENGINE LEFT MOUNTING INSULATOR
Remove the set bolt of the engine left mounting bracket.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
23. REMOVE STIFFENER PLATE, NO.2 REAR END
PLATE AND TRANSAXLE LOWER SIDE MOUNTING
BOLT
(a) Remove the 2 bolts and stiffener plate.
Torque:
Bolt G: 37 N·m (380 kgf·cm, 27 ft·lbf)
(b) Remove the 7 bolts and No.2 rear end plate.
Torque:
Bolt C: 29 N·m (300 kgf·cm, 22 ft·lbf)
Bolt D: 46 N·m (470 kgf·cm, 34 ft·lbf)
Bolt E: 25 N·m (250 kgf·cm, 18 ft·lbf)
Bolt F: 9.0 N·m (95 kgf·cm, 78 in.·lbf)
24. REMOVE TRANSAXLE
Lower the engine left side and remove the transaxle from the
engine.
HINT:
At the time of installation, please refer to the following items.
Align the input shaft with the clutch disc and install the
transaxle to the engine.
Temporarily tighten the transaxle mounting bolts.