oil TOYOTA RAV4 1996 Service User Guide

Q06041
SST
AX04S−01
Q06072
Q06040SST
Q06042
SST AX−14
− AUTOMATIC TRANSAXLE (A540H)SIDE GEAR SHAFT OIL SEAL
1996 RAV4 (RM447U)
SIDE GEAR SHAFT OIL SEAL
ON−VEHICLE REPAIR
1. REMOVE BOTH DRIVE SHAFTS
(See page SA−20)
2. REMOVE LH SIDE GEAR SHAFT OIL SEAL
Using SST, pull out the oil seal.
SST 09308−00010
3. REMOVE RH SIDE GEAR SHAFT OIL SEAL
Using a screwdriver, remove the oil seal.
4. INSTALL LH SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a hammer, driver in a new oil seal.
SST 09608−32010, 09950−70010 (09951−07100)
Oil seal depth: 0 ± 0.5 mm (0 ± 0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
5. INSTALL RH SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09608−32010, 09950−70010 (09951−07100)
Oil seal depth: 0 ± 0.5 mm (0 ± 0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
6. INSTALL BOTH DRIVE SHAFTS (See page SA−31)
7. CHECK FLUID LEVEL (See page DI−173)

N11726
4
N117274
N11728
1 42
I01272
2
1
BE−32
− BODY ELECTRICALWIPER AND WASHER SYSTEM
1996 RAV4 (RM447U)
9. INSPECT REAR WIPER MOTOR OPERATION
(a) Connect the positive (+) lead from the battery to terminal
4 and the negative (−) lead to the motor body, check that
the motor operates.
If operation is not as specified, replace the motor.
(b) Operate the motor and stop the motor operation any-
where except at the stop position by disconnecting the
positive (+) lead from terminal 4.
(c) Connect terminals 2 and 4.
(d) Connect the positive (+) lead from the battery to terminal
1 and the negative (−) lead to the motor body, check that
the motor stops running at the stop position after the mo-
tor operates again.
If operation is not as specified, replace the motor.
10. INSPECT WASHER MOTOR OPERATION
Connect the positive (+) lead from the battery to terminal 2 and
the negative (−) lead to terminal 1, check that the motor oper-
ates.
NOTICE:
These tests must be performed quickly (within 20 seconds)
to prevent the coil from burning out.
If operation is not as specified, replace the motor.

BE275−01
Z13284
Z05657
5
2 31
2
51
3
BE4029
Tester Probe
Heat Wire
Tin Foil
BE−46
− BODY ELECTRICALDEFOGGER SYSTEM
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT DEFOGGER SWITCH CONTINUITY
Switch positionTester connectionSpecified condition
Switch OFF−No continuity
Switch ON3 − 5 − 8Continuity
Switch ON
Illumination circuit3 − 5Continuity
Illumination circuit2 − 6Continuity
If continuity is not as specified, replace the switch.
2. INSPECT DEFOGGER RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant1 − 2Continuity
Apply B + between
terminal 1 and 2.3 − 5Continuity
If continuity is not as specified, replace the relay.
3. INSPECT DEFOGGER WIRE
NOTICE:
When cleaning the glass, use a soft, dry cloth, and
wipe the glass in the direction of the wire. Take care
not to damage the wires.
Do not use detergents or glass cleaners with abrasive
ingredients.
When measuring voltage, wind a piece of tin foil
around the top of the negative probe and press the foil
against the wire with your finger, as shown.
(a) Turn the ignition switch ON.
(b) Turn the defogger switch ON.
(c) Inspect the voltage at the center of each heat wire, as
shown in the table below.
VoltageCriteria
Approx. 5VOkay (No break in wire)
Approx. 10V or 0VBroken wire
HINT:
If there is approximately 10 V, the wire is broken between the
center of the wire and the positive (+) end. If there is no voltage,
the wire is broken between the center of the wire and ground.

BE0123
At Center
BE0124
0 VoltsSeveral Volts
Broken
Wire
V
− BODY ELECTRICALDEFOGGER SYSTEM
BE−47
1996 RAV4 (RM447U)
(d) Place the voltmeter positive (+) lead against the defogger
positive (+) terminal.
(e) Place the voltmeter negative (−) lead with the foil strip
against the heat wire at the positive (+) terminal end and
slide it toward the negative (−) terminal end.
(f) The point where the voltmeter deflects from zero to sever-
al V is the place where the heat wire is broken.
HINT:
If the heat wire is not broken, the voltmeter indicates 0 V at the
positive (+) end of the heat wire but gradually increases to about
12 V as the meter probe moves to the other end.

BR02G−04
BR−2
− BRAKETROUBLESHOOTING
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
Lower pedal or spongy pedal
1. Brake system (Fluid leaks)
2. Brake system (Air in)
3. Piston seals (Worn or damaged)
4. Rear Brake shoe clearance (Out of adjustment)
5. Master cylinder (Faulty)
6. Booster push rod (Out of adjustment)DI−282
−
BR−23
BR−33
BR−9
BR−19
Brake drag
1. Brake pedal freeplay (Minimal)
2. Parking brake lever travel (Out of adjustment)
3. Parking brake wire (Sticking)
4. Rear brake shoe clearance (Out of adjustment)
5. Pad or lining (Cracked or distorted)
6. Piston (Stuck)
7. Piston (Frozen)
8. Anchor or return spring (Faulty)
9. Booster push rod (Out of adjustment)
10. Booster system (Vacuum leaks)
11. Master cylinder (Faulty)BR−6
BR−8
−
BR−33
BR−20
BR−29
BR−23
BR−23
BR−29
BR−29
BR−19
BR−16
BR−9
Brake pull
1. Piston (Stuck)
2. Pad or lining (Oily)
3. Piston (Frozen)
4. Disc (Scored)
5. Pad or lining (Cracked or distorted)BR−23
BR−20
BR−29
BR−23
BR−29
BR−20
BR−20
BR−29

− BRAKETROUBLESHOOTING
BR−3
1996 RAV4 (RM447U) Hard pedal but brake inefficient
1. Brake system (Fluid leaks)
2. Brake system (Air in)
3. Pad or lining (Worn)
4. Pad or lining (Cracked or distorted)
5. Rear brake shoe clearance (Out of adjustment)
6. Pad or lining (Oily)
7. Pad or lining (Glazed)
8. Disc (Scored)
9. Booster push rod (Out of adjustment)
10. Booster system (Vacuum leaks)DI−282
−
BR−20
BR−29
BR−20
BR−29
BR−33
BR−20
BR−29
BR−20
BR−29
BR−23
BR−19
BR−16
Noise from brake
1. Pad or lining (Cracked or distorted)
2. Installation bolt (Loose)
3. Disc (Scored)
4. Pad support plate (Loose)
5. Sliding pin (Worn)
6. Pad or lining (Dirty)
7. Pad or lining (Glazed)
8. Anchor or return spring (Faulty)
9. Anti−squeal shim (Damage)
10. Hold−down spring (Damage)BR−20
BR−29
BR−23
BR−23
BR−23
BR−23
BR−20
BR−29
BR−20
BR−29
BR−29
BR−20
BR−29

R10629
BR−22
− BRAKEFRONT BRAKE PAD
1996 RAV4 (RM447U)
7. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti−squeal shims must be
replaced together with the pads.
(a) Apply disc brake grease to both side of the inner anti−
squeal shims (See page BR−20).
(b) Install the anti−squeal shim to the inner pad.
(c) Install the inner pad with pad wear indicator plate facing
upward.
(d) Install the outer pad.
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or the disc.
8. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or an equiva-
lent.
HINT:
If the piston is difficult to push in, loosen the bleeder plug and
push in the piston while letting some brake fluid escape.
(c) Install the caliper.
(d) Hold the sliding pin and torque the installation bolt.
Torque: 26 N·m (270 kgf·cm, 20 ft·lbf)
(e) Install the flexible hose bracket.
Torque: 33 N·m (340 kgf·cm, 25 ft·lbf)
9. INSTALL FRONT WHEEL
10. CHECK THAT FLUID LEVEL IS AT MAX LINE

Component to be alignedSection of repair manual
for relevant model
Front Wheels
Suspension and Axle (SA) section
Rear Wheels
Suspension and Axle (SA) section
1. Never disassemble the steering wheel pad assembly.
2. Do not subject the steering wheel pad to shocks or bring magnets close to it.
3. Do not expose the steering wheel pad to high temperatures or fire.
4. If grease, cleaner, oil or water gets on the steering wheel pad, promptly wipe it off with a dry cloth.
5. Do not drop the steering wheel pad. Never use a steering wheel pad which has been dropped.
6. Never install the steering wheel and pad in another vehicle.
7. When the steering wheel pad is removed, store it on a stable, flat place with the pad surface facing upœ
wards. Never place anything on top of the pad.
8. When work on the vehicle will produce too strong a shock, first loosen the sensor lock release bolt until
it turns freely and perform the work after sensor lock occurs.
9. Even in cases where the vehicle is in a low-impact accident where the airbag is not activated, always
check the pad surface and airbag sensor part. If dents, cracks or deformation is visible, replace the airœ
bag with a new assembly.
10. When disposing of the vehicle or steering wheel, always deploy the airbag first.
11. The deployed inflator inside the steering wheel pad is hot, so dispose of it after it has been cooled by
atmospheric air. Never apply water to cool it down.
2. BRAKE SYSTEM
The brake system is one of the most important safety components. Always follow the directions and
notes given in section BR of the repair manual for the relevant model year when handling brake system
parts.
3. DRIVE TRAIN AND CHASSIS
The drive train and chassis are components that can have great effects on the running performance
and vibration resistance of the vehicle. After installing components in the sections listed in the table
below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate
repair of the body must also be done to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions
given in the repair manual for the relevant model during alignment and section DI of this manual.
INTRODUCTIONINœ7

ANTI-RUST TREATMENT
When replacing body panels, always apply body sealer, anti-rust agent or undercoat according to the reœ
quirements of your country.
HINT: For further details, see the description given in Section AR of this manual.
BODY SEALER
Apply body sealer to the
required areas.ANTI-RUST AGENT (WAX)
Apply anti-rust agent to
following sections.

Inside of the hems of the
doors and hood.

Around the hinges of the
doors and hood.

Inside of the welded parts
with boxed cross-section.
Cartridge Type Tube Type
UNDERCOAT
Apply undercoat to the underbody and
wheel housings.
Spray Gun
Undercoating
(Oil base)Undercoating
(Water base)
INTRODUCTIONINœ13

BODY PANEL UNDERCOATING AREAS
HINT:
1. First wipe off any dirt, grease or oil with a rag soaked in a grease, wax and silicone remover.
2. Cover the surrounding areas with masking paper to avoid coating unnecessary areas. If other areas are
accidently coated, wipe off the coating immediately.
3. Apply the first coating of undercoat to all welded areas and panel joints, then apply a second coat over
the entire area.
4. Do not coat parts which become hot, such as the tailpipe, or moving parts, such as the propeller shaft.
5. Besides the locations described below, apply undercoating to all weld points under the body to insure
corrosion prevention.
6. Be sure to seal the edge of the flange of the member and bracket with undercoating.
7. If undercoat is damaged by peeling, cracks, etc., be sure to repair as necessary.
8. Before the undercoat apply sealer allowing rust prevention to be attained.
[Left Side]
[Right Side]
REFERENCE: Referring to the notes above, undercoating should be applied according to the specifications
for your country.
ANTI-RUST TREATMENTARœ8