TOYOTA RAV4 1996 Service Repair Manual

BR0M8−01
BR1542
BR0046
BR1543
BR−32
− BRAKEREAR DRUM BRAKE
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.
2. MEASURE BRAKE SHOE LINING THICKNESS
Using a ruler, measure the shoe lining thickness.
Standard thickness: 5.0 mm (0.197 in.)
Minimum thickness: 1.0 mm (0.039 in.)
If the shoe lining is less than the minimum or shows signs of un-
even wear, replace the brake shoes.
HINT:
If a brake shoe needs replacing, the brake shoes must be re-
placed as a set.
3. MEASURE BRAKE DRUM INSIDE DIAMETER
Using a vernier calipers, measure the inside diameter of the
drum.
Standard inside diameter: 228.6 mm (9.000 in.)
Maximum inside diameter: 230.6 mm (9.079 in.)
If the drum is scored or worn, the brake drum may be lathed to
the maximum inside diameter.
4. INSPECT REAR BRAKE LINING AND DRUM FOR
PROPER CONTACT
If the contact between the brake lining and drum is improper, re-
pair the lining with a brake shoe grinder, or replace the brake
shoe assembly.

BR0M9−01
Z13455
− BRAKEREAR DRUM BRAKE
BR−33
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page
BR−30).
1. AFTER INSTALLATION, FILL BRAKE RESERVOIR
WITH BRAKE FLUID, BLEED BRAKE SYSTEM (See
page BR−4) AND CHECK FOR LEAKS
NOTICE:
Apply lithium soap base glycol grease and high tempera-
ture grease to the parts indicated by the arrows (See page
BR−29).
2. CHECK OPERATION OF AUTOMATIC ADJUSTING
MECHANISM
(a) Move the parking brake lever of the rear shoe back and
forth. Check that the adjuster turns.
If the adjuster does not turn, check incorrect installation of the
rear brake.
(b) Adjust the adjuster length to the shortest possible
amount.
(c) Install the brake drum.
(d) Pull the parking brake lever all the way up until a clicking
sound can no longer be heard.
3. CHECK CLEARANCE BETWEEN BRAKE SHOES AND
DRUM
(a) Remove the brake drum.
(b) Measure the brake drum inside diameter and diameter of
the brake shoes. Check that the difference between the
diameters is the correct shoe clearance.
Shoe clearance: 0.6 mm (0.024 in.)
If incorrect, check the parking brake system.

F04193
SST
SST
BR03I−02
BR−34
− BRAKEPROPORTIONING VALVE (P VALVE)
1996 RAV4 (RM447U)
PROPORTIONING VALVE (P VALVE)
ON−VEHICLE INSPECTION
1. INSTALL LSPV GAUGE (SST) AND BLEED AIR
SST 09709−29018
2. RAISE MASTER CYLINDER PRESSURE AND CHECK REAR WHEEL CYLINDER PRESSURE
Master cylinder pressureRear wheel cylinder pressure
2,452 kPa (25 kgf/cm2, 356 psi)2,452 kPa (25 kgf/cm2, 356 psi)
7,845 kPa (80 kgf/cm2, 1,138 psi)3,800 kPa (38.75 kgf/cm2, 551 psi)
When inspecting the fluid pressure, inspect the left front and right rear together, and the right front and left
rear together.
If the rear wheel cylinder pressure is incorrect, replace the P valve assembly.
3. BLEED BRAKE SYSTEM (See page BR−4)
4. CHECK FOR LEAKS

BR03N−04
R04103
Sub−Wire Harness C (SST)
Sub−Wire Harness I (SST) ABS
Actuator(SST)
To Body
To Body Control Relay
− BRAKEABS ACTUATOR
BR−35
1996 RAV4 (RM447U)
ABS ACTUATOR
ON−VEHICLE INSPECTION
1. INSPECT BATTERY POSITIVE VOLTAGE
Battery positive voltage: 10 −14 V
2. DISCONNECT CONNECTORS
(a) Disconnect the 2 connectors from the control relay.
(b) Disconnect the connector from, the actuator.
3. CONNECT ACTUATOR CHECKER (SST) TO ACTUA-
TOR
(a) Connect the actuator checker (SST) to the actuator, con-
trol relay and body side wire harness through the sub−
wire harness C and I (SST) as shown.
SST 09990−00150, 09990−00200, 09990−00300
(b) Connect the red cable of the checker to the battery posi-
tive (+) terminal and black cable to the negative (−) termi-
nal. Connect the black cable of the sub−wire harness to
the battery negative (−) terminal or body ground.

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)

BR1NN−01
W04219
Power Steering
Fluid Reservoir Actuator Bracket Cushion ABS Actuator Cushion Bolt Cushion
5 (55, 48 in.·lbf)
19 (195, 14)
19 (195, 14)
15 (155, 11)
N·m (kgf·cm, ft·lbf)
: Specified torque
19 (195, 14)
2WD BR−38
− BRAKEABS ACTUATOR
1996 RAV4 (RM447U)
COMPONENTS

4WD
− BRAKEABS ACTUATOR
BR−39
1996 RAV4 (RM447U)

BR0MA−03
BR−40
− BRAKEABS ACTUATOR
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT BRAKE LINES
Using SST, disconnect the 6 brake lines from the ABS actuator.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
2. DISCONNECT POWER STEERING FLUID RES-
ERVOIR
(a) Remove the bolt and disconnect the PS hose from the ac-
tuator bracket.
(b) Disconnect the PS fluid reservoir.
3. REMOVE ABS ACTUATOR ASSEMBLY
(a) Disconnect the 2 connectors.
(b) Remove the 3 bolts and ABS actuator assembly.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
4. 2WD
REMOVE ABS ACTUATOR
Remove the 2 nuts and actuator from the actuator bracket.
Torque: 5 N·m (55 kgf·cm, 48 in.·lbf)
5. 4WD
REMOVE ABS ACTUATOR
Remove the 3 nuts and actuator from the actuator bracket.
Torque: 5 N·m (55 kgf·cm, 48 in.·lbf)
6. 2WD
REMOVE 2 CUSHION BOLTS AND 3 CUSHIONS
7. 4WD
REMOVE 3 HOLDERS AND 3 CUSHIONS

BR03Q−02
− BRAKEABS ACTUATOR
BR−41
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page BR−41).
AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID, BLEED BRAKE SYSTEM
(See page BR−4) AND CHECK FOR LEAKS