engine TOYOTA RAV4 1996 Service User Guide

Q06064
AX129−01
AT0103
D00691
D00692
AX−8
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
VALVE BODY ASSEMBLY
ON−VEHICLE REPAIR
1. REMOVE NO.2 ENGINE UNDER COVER
2. DRAIN ATF
Using a 10 mm hexagon wrench, remove the drain plug, and
drain the ATF into a suitable container.
3. REMOVE OIL PAN AND GASKET
(a) Remove the 17 bolts.
(b) Remove the oil pan by lifting transaxle case.
NOTICE:
Some fluid remain in the oil pan.
4. EXHAUST PARTICLES IN PAN
Remove the magnet and use it to collect any steel chips.
Lock carefully at the chips and particles in the oil pan and on the
magnet to anticipate when type of wear you will find in the trans-
axle.
Steel (magnetic): bearing, gear and plate wear
Brass (non−magnetic): bushing wear
5. REMOVE OIL PIPE BRACKET AND STRAINER
(a) Remove the 2 bolts and oil pipe bracket.
(b) Remove the 3 bolts and strainer.
(c) Remove the gasket from the strainer.
6. REMOVE MANUAL VALVE BODY
(a) Remove the 2 bolts and detent spring.

Z13390A B
Z13391
A
BA
B
Q06019
Q06064
AX−12
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
(d) Place the detent springs on the manual valve body and
hand−tighten the 2 bolts first.
Then, tighten them with a torque wrench.
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
Bolt A: 14 mm (0.55 in.)
Bolt B: 37 mm (1.46 in.)
(e) Check that the manual valve lever is touching the center
of the detent spring tip roller.
18. INSTALL PIPE BRACKET AND OIL STRAINER
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
Bolt A: 22 mm (0.87 in.)
Bolt B: 53 mm (2.09 in.)
19. INSTALL MAGNETS IN PLACE
NOTICE:
Make sure that the magnets do not interfere with the oil
pipes.
20. INSTALL OIL PAN WITH NEW GASKET
(a) Install a new gasket and oil pan.
(b) Install and tighten 17 bolts.
Torque: 7.9 N·m (80 kgf·cm, 70 in.·lbf)
21. FILL ATF AND CHECK FLUID LEVEL
(a) Using a 10 mm hexagon wrench, install a new gasket and
the drain plug.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
(b) Fill the ATF and check the fluid level (See page DI−173).
22. INSTALL NO.2 ENGINE UNDER COVER

Q06113
AX04U−02
Q05857
Z19463
Q05858
− AUTOMATIC TRANSAXLE (A540H)AUTOMATIC TRANSAXLE UNIT
AX−19
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE TRANSAXLE WITH ENGINE (See page
EM−68)
2. REMOVE STARTER
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
3. REMOVE STIFFENER PLATE
Remove the 3 bolts and stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
4. REMOVE REAR END PLATE
Remove the 4 bolts and rear end plate.
Torque:
Bolt A: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
Bolt B: 25 N·m (250 kgf·cm, 18 ft·lbf)
5. REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLTS
Turn the crankshaft to gain access and remove the 6 bolts with
holding the crankshaft pulley nut by a wrench.
Torque: 27 N·m (280 kgf·cm, 20 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Coat the threads of the bolts with sealant.
Sealant: Part No. 08833 − 00070, THREE BONDS 1324
or equivalent
Tighten the bolts evenly.
First install dark green colored bolt and then the 5
bolts.
6. DISCONNECT CONNECTORS AND WIRE HARNESS
FROM TRANSAXLE

BE277−01
BE−68
− BODY ELECTRICALAUDIO SYSTEM
1996 RAV4 (RM447U)
TROUBLESHOOTING
NOTICE:
When replacing the internal mechanism (computer part) of the audio system, be careful that no part
of your body or clothing comes in contact with the terminals of the leads from the IC etc. of the re-
placement part (spare part).
HINT:
This inspection procedure is a simple troubleshooting which should be carried out on the vehicle during sys-
tem operation and was prepared on the assumption of system component troubles (except for the wires and
connectors, etc.).
Always inspect the trouble taking the following items into consideration.
Open or short circuit of the wire harness
Connector or terminal connection fault
ProblemNo.
RadioNo power coming in.1
Power coming in, but radio not operating.2
Noise present, but AM − FM not operating.3
Either speaker does not work.4
Either AM or FM does not work.5
Reception poor (Volume faint).5
Few preset tuning bands.5
Sound quality poor.6
Cannot set station select button.6
Preset memory disappears.7
Tape PlayerCassette tape cannot be inserted.8
Cassette tape inserted, but no power.9
Power coming in, but tape player not operating.10
Either speaker does not work.11
Sound quality poor (Volume faint).12
Tape jammed, malfunction with tape speed or auto−reverse.13
APS, SKIP, RPT buttons not operating.14
Cassette tape will not ejected.15
AntennaAntenna−related.16
NoiseNoise produced by vibration or shock while driving.17
Noise produced when engine starts.18

V08467
18
Noise NOISE PRODUCED WHEN ENGINE STARTS
Whistling noise which becomes high−pitched
when accelerator strongly depressed, disappears
shortly after engine stops.Ye s
Generator noise.
No
Whining noise occurs when A/C is operating.Ye s
A/C noise.
Scratching noise occurs during sudden
acceleration, driving on rough roads or when
ignition switch is turned on.No
Ye s
Fuel gauge noise.
No
Clicking sound heard when horn button is
pressed, then released. Whirring/grating sound
when pushed continuously.Ye s
Horn noise.
No
Murmuring sound stops when engine stops.
NoYe s
Ignition noise.
Tick−tock noise, occurs in co−ordination with
blinking of flasher.Ye s
Turn signal noise.
No
Noise occurs during window washer operation.Ye s
Washer noise.
No
Scratching noise occurs while engine is running,
continues a while even after engine stops.
NoEngine coolant temperature gauge noise. Ye s
Scraping noise in time with wiper beat.
NoYe s
Wiper noise.
Other type of noise.
− BODY ELECTRICALAUDIO SYSTEM
BE−79
1996 RAV4 (RM447U)

R10851
Pedal Height Push RodStop Light
Switch
BR1DV−01
BR4980
R00935
Pedal Freeplay BR−6
− BRAKEBRAKE PEDAL
1996 RAV4 (RM447U)
BRAKE PEDAL
ON−VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
157.1 − 167.1 mm (6.185 − 6.579 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop
light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(f) Install the stop light switch and turn it until it lightly con-
tacts with the pedal stopper.
(g) Turn the stop light switch back one turn.
(h) Check the clearance (A) between stop light switch and
pedal.
Clearance: 0.5 − 2.4 mm (0.020 − 0.094 in.)
(i) Tighten the stop light switch lock nut.
(j) Connect the connector to the stop light switch.
(k) Check that the stop lights come on when the brake pedal
is depressed, and go off when the brake pedal is re-
leased.
(l) After adjusting the pedal height, check the pedal freeplay.
HINT:
If clearance (A) between the stop light switch and the brake
pedal stopper has been adjusted correctly, the pedal freeplay
will meet the specifications.
3. CHECK PEDAL FREEPLAY
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the resistance begins to
be felt, then measure the distance, as shown.
Pedal freeplay: 1 − 6 mm (0.04 − 0.24 in.)

R00934
Pedal Reverse
Distance
− BRAKEBRAKE PEDAL
BR−7
1996 RAV4 (RM447U)
HINT:
The freeplay to the 1st point of resistance is due to the play be-
tween the clevis and pin. It is 1 − 3 mm (0.04 − 0.12 in.) on the
pedal.
If incorrect, check the stop light switch clearance. If the clear-
ance is OK, then troubleshoot the brake system.
4. CHECK PEDAL RESERVE DISTANCE
(a) Release the parking brake.
(b) With the engine running, depress the pedal and measure
the pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf): More than 75 mm (2.95 in.)
If the reserve distance is incorrect, troubleshoot the brake sys-
tem.

BR2237
BR02Q−02
BR2238
GOOD
1st2nd3rdNO GOOD BR−16
− BRAKEBRAKE BOOSTER ASSEMBLY
1996 RAV4 (RM447U)
BRAKE BOOSTER ASSEMBLY
ON−VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine
OFF and check that there is no change in the pedal re-
serve distance.
(b) Depress the brake pedal and start the engine.
If the pedal goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down farthest at the 1st time, but gradually
rises after at the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed.
If there is no change in the pedal reserve travel after holding the
pedal for 30 seconds, the booster is air−tight.

BR1811
R00326
R00324
R00325
BR1813
BR−36
− BRAKEABS ACTUATOR
1996 RAV4 (RM447U)
(c) Place the ”SHEET A” (SST) on the actuator checker.
SST 09990−00163
4. INSPECT BRAKE ACTUATOR OPERATION OF
FRONT RH WHEEL
(a) Start the engine, and run it at idle.
(b) Turn the selector switch of the actuator checker to
”FRONT RH” position.
(c) Push and hold in the MOTOR switch for a few seconds.
Make sure that you can hear the motor running.
(d) Depress the brake pedal and hold it for about 15 seconds,
and check that the brake pedal does not go down.
(e) With your foot still applying onto the brake pedal, push
MOTOR switch and check that the pedal does not pul-
sate.
(f) Depress the brake pedal and hold it. As you hold the ped-
al down, push and hold in the POWER SWITCH for a few
seconds. Check that the pedal does not go down.
NOTICE:
Do not keep the POWER SWITCH pushed for more than 10
seconds.
(g) With your foot still applying onto the brake pedal, release
the POWER SWITCH and check that the pedal goes
down.
(h) With your foot still applying onto the brake pedal, push the
MOTOR switch and check that the brake pedal returns.
(i) Release the brake pedal.
5. INSPECT FRONT LH WHEEL
(a) Turn the selector switch to ”REAR RH” position.
(b) Repeating (c) to (i) in the step 4, check the actuator oper-
ating similarly.
6. INSPECT REAR RH WHEEL
(a) Turn the selector switch to ”FRONT LH” position.
(b) Repeating (c) to (i) in the step 4, check the actuator opera-
tion similarly.

BR1811
− BRAKEABS ACTUATOR
BR−37
1996 RAV4 (RM447U)
7. INSPECT REAR LH WHEEL
Repeating (c) to (i) in the step 4, check the actuator operation
similarly.
HINT:
When inspecting the ”REAR LH” position, push the REAR LH
switch instead of the POWER SWITCH. This makes it possible
to inspect wherever the selector switch position indicates.
8. PUSH MOTOR SWITCH
(a) Push and hold in the MOTOR switch for a few seconds.
(b) Stop the engine.
9. DISCONNECT ACTUATOR CHECKER (SST) FROM
ACTUATOR
Remove the ”SHEET A” (SST) and disconnect the actuator
checker (SST) and sub−wire harness (SST) from the actuator,
control relay and body side wire harness.
SST 09990−00150, 09990−00163, 09990−00200,
09990−00300
10. CONNECT CONNECTORS
(a) Connect the connector to the actuator.
(b) Connect the 2 connectors to the control relay.
11. CLEAR DTC (See page DI−234)