TOYOTA RAV4 1996 Service Repair Manual

SR0F9−02
− STEERINGTILT STEERING COLUMN
SR−27
1996 RAV4 (RM447U)
INSPECTION
(See page SR−16)

SR0FA−04
W01127
9.0 mm
(0.354 in.)
W01128
PawlNo.2 Shaft
Mark
MColor
W01129No.2 Tilt Steering Shaft
W00595
SR−28
− STEERINGTILT STEERING COLUMN
1996 RAV4 (RM447U)
REASSEMBLY
NOTICE:
When using a vise, do not overtightened it.
1. COAT WITH MOLYBDENUM DISULFIDE LITHIUM
BASE GREASE (See page SR−22)
2. INSTALL TILT STEERING PAWL
(a) Using a plastic hammer, tap in a new pin until the projec-
tion is 9.0 mm (0.354 in.)
(b) Select a new tilt steering No.2 shaft according to the fol-
lowing table.
Pawl MarkNo.2 Shaft ColorNo.2 Shaft Part No.
1White45856−42010
2Yellow45856−42020
3Black45856−42030
(c) Using a plastic hammer, tap in the selected No.2 shaft and
install the pawl.
NOTICE:
Tap the shaft completely into the steering column upper
tube.
3. INSTALL STEERING MAIN SHAFT
(a) Using an offset wrench and a hammer, drive in a new col-
lar to the shaft.
NOTICE:
Be careful not to damage the collar.
(b) Install the bearing thrust collar and compression spring to
the shaft.
(c) Install the shaft to the steering column upper tube.

W01124
SST
W01117
− STEERINGTILT STEERING COLUMN
SR−29
1996 RAV4 (RM447U)
(d) Using SST, compress the compression spring.
SST 09950−40010 (09958−04010)
NOTICE:
Do not bend the universal joint of the shaft more than 20°.
(e) Using a snap ring expander, install a new snap ring to the
shaft.
4. INSTALL TILT LEVER RETAINER
NOTICE:
Make sure to install the retainer facing the correct direction
(See page SR−22).
5. INSTALL STEERING COLUMN UPPER TUBE WITH
STEERING MAIN SHAFT
(a) Install the upper tube with the shaft to the steering column
tube.
(b) Using a hexagon wrench, torque the 2 tilt steering bolts.
Torque: 20 N·m (204 kgf·cm, 15 ft·lbf)
(c) Check that the upper tube turns smoothly.
6. INSTALL COMBINATION SWITCH BRACKET
Torque the 2 bracket set bolts.
Torque: 6.0 N·m (58 kgf·cm, 53 in.·lbf)
7. INSTALL 3 TENSION SPRINGS
HINT:
Install the springs with the tilt function at maximum tilt up.
8. INSTALL STEERING COLUMN UPPER BRACKET
AND STEERING COLUMN UPPER CLAMP
(See page SR−18)
9. CHECK TILT STEERING OPERATION

SR0FB−02
SR−30
− STEERINGTILT STEERING COLUMN
1996 RAV4 (RM447U)
INSTALLATION
(See page SR−19)

SR0FV−02
Z19806
Union Bolt
PS Gear Assembly
Tube ClampPressure Feed Tube
Return Hose
Vacuum Hose
13 (130, 9)
44 (450, 32)
*36 (365, 26)
52 (525, 38)
29 (300, 22)
3 Door vehicle 64 (650, 47)
5 Door vehicle 113 (1,150, 83)
43 (440, 32)
113 (1, 150, 83)
x7
x6
13 (130, 9)
 Gasket
N·m (kgf·cm, ft·lbf)Bracket
BushingDrive Belt
PS Vane Pump Assembly
with Pump Bracket
62 (630, 46)
29 (300, 22)
BushingBracket
 Gasket
Clamp
(A/T)
Front Exhaust Pipe
 Gasket Stabilizer Bar
with Link
Front Suspension
Crossmember Assembly
137 (1, 400, 101)
206 (2, 100, 152)
127 (1, 300, 94)
Engine Under
Cover
127 (1, 300, 94)
137 (1, 400, 101)
112 (1, 140, 82)
8.3 (84, 73 in.·lbf)
48 (490, 35)

206 (2, 100, 152)
: Specified torque
* For use with SST  Non−reusable part
W02019
3 Door vehicle 64 (650, 47)
5 Door vehicle 113 (1,150, 83)
− STEERINGPOWER STEERING VANE PUMP
SR−31
1996 RAV4 (RM447U)
POWER STEERING VANE PUMP
COMPONENTS

W01194
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable partUnion Bolt
Spring Pressure Feed No.2 Tube
Side Front PlatePressure Port Union
Flow Control
Valve
Pump Front Bracket
Flow Control
Spring Seat Gasket
 Shorter Staright Pin
Air Control Valve  O−Ring
 Snap Ring O−Ring
 Union Seat Longer Straight Pin
Vane Pump Shaft
Suction Port
UnionFront Housing
 O−Ring
 Oil Seal
 O−Ring
 O−Ring
Woodruff Key Vane Pump PulleyPump Bracket
 Snap Ring
Cam Ring Side Rear PlateVane Plate Wave Washer
Vane Pump Rotorx10
Power steering fluidRear Housing
 O−Ring  O−Ring  Snap Ring
69 (700, 51)
13 (130, 9)43 (440, 32)
36 (370, 27)
43 (440, 32)
SR−32
− STEERINGPOWER STEERING VANE PUMP
1996 RAV4 (RM447U)

SR0FW−02
R10965
Z13365
Pressure
Feed Tube
SST
R10984
R10966
− STEERINGPOWER STEERING VANE PUMP
SR−33
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE RH AND LH ENGINE UNDER COVERS
Remove the 13 bolts.
2. REMOVE FRONT EXHAUST PIPE
Remove the 2 bolts, 3 nuts and 2 gaskets.
3. REMOVE STABILIZER BAR WITH LINK
(See page SA−48)
4. DISCONNECT RH AND LH LOWER SUSPENSION
ARMS (See page SA−40)
5. REMOVE 2 PS GEAR ASSEMBLY SET BOLTS AND
NUTS
6. REMOVE FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY (See page SA−40)
7. DISCONNECT 2 TUBE CLAMPS
Remove the bolt.
8. DISCONNECT 2 VACUUM HOSES
9. DISCONNECT RETURN HOSE
NOTICE:
Take care not to spill fluid on the drive belt.
10. REMOVE DRIVE BELT
Loosen the 2 bolts.
11. DISCONNECT PRESSURE FEED TUBE
Using SST, disconnect the tube.
SST 09631−22020
12. REMOVE PS VANE PUMP ASSEMBLY WITH PUMP
BRACKET
Remove the 3 bolts.
13. REMOVE PRESSURE FEED TUBE
Remove the union bolt, gasket and tube from the PS vane
pump assembly.

SR0FX−03
R10967
R10992
SST
R10968
SR−34
− STEERINGPOWER STEERING VANE PUMP
1996 RAV4 (RM447U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE PS VANE PUMP ROTATING TORQUE
(a) Check that the pump rotates smoothly without abnormal
noise.
(b) Using a torque wrench, check the pump rotating torque.
Rotating torque:
0.3 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less
2. REMOVE PUMP FRONT BRACKET AND PUMP
BRACKET
Remove the 2 bolts.
3. REMOVE VANE PUMP PULLEY
(a) Using SST to stop the pulley rotating, remove the pulley
set nut.
SST 09960−10010 (09962−01000, 09963−01000)
(b) Remove the woodruff key from the vane pump shaft.
4. REMOVE AIR CONTROL VALVE
Remove the union seat.
5. REMOVE PRESSURE FEED NO.2 TUBE
Remove the union bolt and 2 gaskets.
6. REMOVE SUCTION PORT UNION
(a) Remove the union set bolt.
(b) Remove the O−ring from the union.
7. REMOVE PRESSURE PORT UNION
Remove the O−ring from the union.
8. REMOVE FLOW CONTROL VALVE AND SPRING
9. REMOVE FLOW CONTROL SPRING SEAT
(a) Using snap ring pliers, remove the snap ring.
(b) Install the 2 or 3 threads of a bolt (6 mm normal diameter,
1.0 mm pitch, 50 mm length).
Reference
Bolt: 91651−60650
(c) Using pliers, remove the spring seat from the front hous-
ing.
(d) Remove the O−ring from the flow control spring seat.

W01800
W01803
Vinyl Tape
− STEERINGPOWER STEERING VANE PUMP
SR−35
1996 RAV4 (RM447U)
10. REMOVE REAR HOUSING, WAVE WASHER AND SIDE
REAR PLATE
(a) Using 2 screwdrivers, remove the snap ring.
(b) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the vane pump shaft.
(c) Using a plastic hammer, tap out the housing, washer and
plate.
(d) Remove the O−ring from the housing.
(e) Remove the O−ring from the plate.
11. REMOVE CAM RING AND 10 VANE PLATES
12. REMOVE VANE PUMP SHAFT WITH VANE PUMP RO-
TOR AND SIDE FRONT PLATE
13. REMOVE VANE PUMP ROTOR AND SIDE FRONT
PLATE
(a) Using a screwdriver, remove the snap ring from the vane
pump shaft.
(b) Remove the 2 O−rings from the plate.
14. REMOVE SHORTER STRAIGHT PIN
Using pliers, remove the pin from the side front plate.
15. REMOVE LONGER STRAIGHT PIN
Using pliers, remove the pin from the front housing.

SR0FY−01
W01200
Micrometer
Caliper
Gauge
Front Housing
Vane Pump Shaft Bushing
N00372
Height
LengthThickness
R10282Feeler Gauge
R13897
Inscribed Mark
SR−36
− STEERINGPOWER STEERING VANE PUMP
1996 RAV4 (RM447U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE OIL CLEARANCE BETWEEN VANE PUMP
SHAFT AND BUSHING
Using a micrometer and a caliper gauge, measure the oil clear-
ance.
Standard clearance:
0.03 − 0.05 mm (0.0012 − 0.0020 in.)
Maximum clearance: 0.07 mm (0.0028 in.)
If it is more than the maximum, replace the front housing and
vane pump shaft.
2. INSPECT VANE PUMP ROTOR AND VANE PLATES
(a) Using a micrometer, measure the height, thickness and
length of the 10 plates.
Minimum height: 8.1 mm (0.319 in.)
Minimum thickness: 1.797 mm (0.0707 in.)
Minimum length: 14.988 mm (0.59008 in.)
(b) Using a feeler gauge, measure the clearance between
the rotor groove and plate.
Maximum clearance: 0.03 mm (0.0012 in.)
If it is more than the maximum, replace the plate and/or rotor
with one having the same mark stamped on the cam ring.
Inscribed mark: 1, 2, 3, 4 or None