check engine TOYOTA RAV4 1996 Service User Guide

Q08873
Push Rod Play
Adjust Point
Pedal Height
Adjust Point
Push Rod
Play
Pedal HeightCL04G−02
CL0042
Pedal Freeplay
CL0512
25 mm (0.98 in.) or more
Release Point
Full Stroke
End Position CL−2
− CLUTCHCLUTCH PEDAL
1996 RAV4 (RM447U)
CLUTCH PEDAL
INSPECTION
1. CHECK PEDAL HEIGHT IS CORRECT
Pedal height from asphalt sheet:
157.6 − 167.6 mm (6.205 − 6.598 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and turn the stopper bolt until the height is
correct. Tighten the lock nut.
3. CHECK PEDAL FREEPLAY AND PUSH ROD PLAY
(a) Push in on the pedal until the beginning of clutch resis-
tance is felt.
Pedal freeplay: 5.0−15.0 mm (0.197−0.591 in.)
(b) Gently push on the pedal until the resistance begins to in-
crease a little.
Push rod play at pedal top:
1.0−5.0 mm (0.039−0.197 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
(d) Connect the air duct and install the lower finish panel.
5. INSPECT CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start the engine and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into the reverse position until the gears contact.
(d) Gradually depress the clutch pedal and measure the
stroke distance from the point the gear noise stops (re-
lease point) up to the full stroke end position.
Standard distance:
25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified.
Inspect pedal height.
Inspect push rod play and pedal freeplay.
Bleed the clutch line.
Inspect the clutch cover and disc.

Q08874
Clutch Start Switch
Q08667
8 ± 0.5 mm
(0.31 ± 0.020 in.)
Q08677
No continuity
321
Q08678
No continuity
321
− CLUTCHCLUTCH PEDAL
CL−3
1996 RAV4 (RM447U)
6. CHECK CLUTCH START SYSTEM
(a) Check that the engine does not start when the clutch ped-
al is released.
(b) Check that the engine starts when the clutch pedal is fully
depressed.
If necessary, replace the clutch start switch.
7. CHECK CONTINUITY OF CLUTCH START SWITCH
Check the continuity between terminals when the switch is ON
and OFF.
Switch positionCondition
ON (pushed)Continuity
OFF (free)No Continuity
If continuity is not as specified, replace the switch.
8. CHECK CONTINUITY OF CLUTCH START CANCEL
SWITCH
(a) Check that there is no continuity when connecting the
positive (+) lead from the ohmmeter to terminal 2 and the
negative (−) lead to terminal 1.
(b) Check that there is no continuity when connecting the
positive (+) lead from the ohmmeter to terminal 3 and the
negative (−) lead to terminal 1 and 2.
If continuity is not as specified, replace the clutch start cancel
switch.

CL04U−02
Q06037
Flywheel
Side
SST
Q06038
Matchmarks8 2, 5
6
SST
3
7 1, 4
Q06039SST
Q06245
CL−18
− CLUTCHCLUTCH UNIT
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON
FLYWHEEL
(a) Insert SST in the clutch disc, and then set them and the
clutch cover in position.
SST 09301−00220
(b) Align the matchmarks on the clutch cover and flywheel.
(c) Temporarily tighten the topmost bolt from the 3 near the
knock pins.
HINT:
Temporarily tighten the No.3 bolt.
(d) Torque the bolts on the clutch cover in the order shown.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non−alignment: 0.5 mm (0.020 in.)
If alignment is not as specified, using SST, adjust the dia-
phragm spring tip alignment.
SST 09333−00013
3. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE
GREASE (NLGI NO.2)
(a) Apply release hub grease to the following parts.
Release fork and hub contact point
Release fork and push rod contact point
Release fork pivot point
(b) Apply clutch spline grease.
Clutch disc spline
HINT:
Recommended grease part number 08887−01706 (100g).
4. INSTALL RELEASE BEARING AND FORK TO TRANS-
AXLE
Install the bearing to the release fork, and then install them to
the transaxle.
5. INSTALL TRANSAXLE TO ENGINE
(2WD: See page MX−2)
(4WD: See page MX−8)

CO0BD−01
− COOLINGCOOLANT
CO−1
1996 RAV4 (RM447U)
COOLANT
INSPECTION
1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR
The engine coolant level should be between the ”LOW” and ”FULL” lines, when engine is cold.
If low, check for leaks and add engine coolant up to the ”FULL” line.
2. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot, as fluid and steam can be blown out under pressure.
(b) There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler
hole, and the coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.

CO0BE−01
S01292Drain Plug CO−2
− COOLINGCOOLANT
1996 RAV4 (RM447U)
REPLACEMENT
1. DRAIN ENGINE COOLANT
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
(b) Loosen the radiator drain plug (on the left side of the ra-
diator lower tank) and engine drain plug (on the left rear
of the cylinder block), and drain the coolant.
(c) Close the drain plugs.
Torque: Engine drain plug
25 N·m (250 kgf·cm, 18 ft·lbf)
2. FILL ENGINE COOLANT
(a) Slowly fill the system with coolant.
Use a good brand of ethylene−glycol base coolant
and mix it according to the manufacture’s direc-
tions.
Using coolant which includes more than 50 % ethyl-
ene−glycol (but not more than 70 %) is recom-
mended.
NOTICE:
Do not use an alcohol type coolant.
The coolant should be mixed with demineralized wa-
ter or distilled water.
Capacity (w/ Heater):
M/T: 8.0 liters (8.5 US qts, 7.0 lmp. qts)
A/T: 7.7 liters (8.1 US qts, 6.8 lmp. qts)
(b) Install radiator cap.
(c) Start the engine, and bleed the cooling system.
(d) Refill the radiator reservoir with coolant until it reaches the
”FULL” line.
3. CHECK ENGINE COOLANT FOR LEAKS

CO0BH−02
CO0877
− COOLINGWATER PUMP
CO−7
1996 RAV4 (RM447U)
INSPECTION
INSPECT WATER PUMP
(a) Visually check the drain hole for coolant leakage.
If leakage is found, replace the water pump.
If engine coolant has leaked onto the timing belt, replace the
timing belt.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and quietly.
If necessary, replace the water pump.

CO0BI−03
P13480
New O−Ring
New Gasket
P15547
New O−Ring
P15464
Connect
Z16489
3
1
2 CO−8
− COOLINGWATER PUMP
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL WATER PUMP TO WATER PUMP COVER
Install a new gasket and the water pump with the 3 bolts.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
2. INSTALL WATER PUMP AND WATER PUMP COVER
ASSEMBLY
(a) Install new O−ring and gasket to water pump cover.
(b) Install a new O−ring to the water bypass pipe.
(c) Apply soapy water to the O−ring on the water bypass
pipe.
(d) Connect the water pump cover to the water bypass pipe.
Do not install the nuts yet.
(e) Install the water pump with the 3 bolts. Tighten the bolts
in the sequence shown.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(f) Install the 2 nuts holding the water pump cover to the wa-
ter bypass pipe.
Torque: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
3. INSTALL GENERATOR DRIVE BELT ADJUSTING BAR
(a) Install the adjusting bar with the bolt.
Torque: 27 N·m (275 kgf·cm, 20 ft·lbf)
(b) Connect the crankshaft position sensor connector clamp.
4. INSTALL NO.2 IDLER PULLEY AND TIMING BELT
TENSION SPRING
5. CONNECT LOWER RADIATOR HOSE
6. INSTALL TIMING BELT (See page EM−20)
7. FILL WITH ENGINE COOLANT
8. START ENGINE AND CHECK FOR COOLANT LEAKS
9. INSTALL RH ENGINE UNDER COVER

CO0BM−02
P13611
Protrusion
Jiggle
Valve5° 5° CO−12
− COOLINGTHERMOSTAT
1996 RAV4 (RM447U)
INSTALLATION
1. PLACE THERMOSTAT IN WATER PUMP
(a) Install a new gasket to the thermostat.
(b) Align the jiggle valve of the thermostat with the protrusion
of the water inlet, and insert the thermostat in the water
inlet.
HINT:
The jiggle valve may be set within 5° of either side of the pre-
scribed position.
2. INSTALL WATER INLET AND THERMOSTAT
Install the water inlet and thermostat with the 2 nuts.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
3. INSTALL OIL FILTER (See page LU−2)
4. FILL WITH ENGINE COOLANT
5. START ENGINE AND CHECK FOR LEAKS
6. CHECK ENGINE OIL LEVEL

CO0BO−02
Z00570
Radiator Cap Tester
Radiator Cap30° or More
S01265
Radiator Cap Tester CO−14
− COOLINGRADIATOR
1996 RAV4 (RM447U)
ON−VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
2. INSPECT RADIATOR CAP
NOTICE:
If the radiator cap has contaminations, always rinse
it with water.
When performing steps (a) and (b) below, keep the ra-
diator cap tester at an angle of over 30°above the hor-
izontal.
(a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed:
1 push/(3 seconds or more)
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(b) Pump the tester and measure the relief valve opening
pressure.
Pump speed:
1 push within 1 second
NOTICE:
This pump speed is for the first pump only (in order to close
the vacuum valve). After this, the pump speed can be re-
duced.
Standard opening pressure:
74 − 103 kPa (0.75 − 1.05 kgf/cm
2, 10.7 − 14.9 psi)
Minimum opening pressure:
59 kPa (0.6 kgf/cm
2, 8.5 psi)
HINT:
Use the tester’s maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 118kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and cylinder head.
4. REINSTALL RADIATOR CAP

CO0BQ−03
S01355
S01278
w/ A/C
S01293
CO−16
− COOLINGRADIATOR
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE ENGINE UNDER COVERS
2. DRAIN ENGINE COOLANT
3. w/ A/C:
REMOVE COOLER CONDENSER (See page AC−47)
4. REMOVE RADIATOR ASSEMBLY
(a) Disconnect the No.1 cooling fan connector.
(b) w/ A/C:
Disconnect the No.2 cooling fan connector.
(c) Disconnect the ECT switch connector for electric cooling
fan.
(d) Disconnect the engine wire clamp from No.1 cooling fan
shroud.
(e) Disconnect the upper radiator hose from radiator.
(f) Disconnect the lower radiator hose from radiator.
(g) Disconnect the radiator reservoir hose from radiator.
(h) Disconnect the 2 A/T oil cooler hoses from oil cooler
pipes.
(i) Remove the 2 bolts and 2 upper radiator supports.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(j) Remove the radiator assembly.
HINT:
At the time of installation, plaese refer to the following items. Af-
ter installation, check that the rubber cushion (A) of the support
is not depressed.
(k) Remove the 2 lower radiator supports.
5. w/ A/C:
REMOVE NO.2 COOLING FAN FROM RADIATOR
Remove the 3 bolts and cooling fan.
Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf)
6. REMOVE NO.1 COOLING FAN FROM RADIATOR
Remove the 4 bolts and cooling fan.
Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf)