TOYOTA RAV4 1996 Service Repair Manual

W04167
Sensor Rotor
Front Speed Sensor
N·m (kgf·cm, ft·lbf): Specified torque
8 (80, 69 in.·lbf)
5 (55, 48 in.·lbf)
BR03V−08
BR−42
− BRAKEFRONT SPEED SENSOR
1996 RAV4 (RM447U)
FRONT SPEED SENSOR
COMPONENTS

BR03W−04
R10728
R10703
− BRAKEFRONT SPEED SENSOR
BR−43
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT SPEED SENSOR CONNECTOR
(a) Remove the fender liner.
(b) Disconnect the speed sensor connector.
2. REMOVE SPEED SENSOR
(a) Remove the 4 clamp bolts holding the sensor harness to
the body, shock absorber and steering knuckle.
Torque: 5 N·m (55 kgf·cm, 48 in.·lbf)
(b) Remove the speed sensor from the steering knuckle.
Torque: 8 N·m (80 kgf·cm, 69 in.·lbf)

BR03X−02
BR−44
− BRAKEFRONT SPEED SENSOR
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page BR−43).
AFTER INSTALLATION, CHECK SPEED SENSOR SIGNAL (See page DI−234)

BR03Y−07
W04168
Rear Speed Sensor Rotor
Rear Speed Sensor
N·m (kgf·cm, ft·lbf) : Specified torque
5 (55, 48 in.·lbf)
13 (130, 9)
8 (80, 69 in.·lbf)
− BRAKEREAR SPEED SENSOR
BR−45
1996 RAV4 (RM447U)
REAR SPEED SENSOR
COMPONENTS

BR03Z−02
R10729
R10704
BR−46
− BRAKEREAR SPEED SENSOR
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT SPEED SENSOR CONNECTOR
(a) Remove the seat cushion and rear side trim.
(b) Disconnect the speed sensor connector, and pull out the
sensor wire harness with grommet.
(c) Disconnect the parking brake cable from the suspension
arm.
(d) Remove the 3 clamp bolts holding the sensor wire har-
ness to the body and suspension arm.
Torque:
To body: 5.0 N·m (55 kgf·cm, 49 in.·lbf)
To suspension arm: 13 N·m (130 kgf·cm, 9 ft·lbf)
2. 2WD:
REMOVE SPEED SENSOR WITH AXLE HUB
(See page SA−52)
3. 4WD:
REMOVE SPEED SENSOR
Remove the speed sensor from the axle carrier.
Torque: 8.0 N·m (80 kgf·cm, 69 in.·lbf)

BR040−02
− BRAKEREAR SPEED SENSOR
BR−47
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page BR−46).
AFTER INSTALLATION, CHECK SPEED SENSOR SIGNAL (See page DI−234)

Manual NamePub. No.

3S-FE Engine Repair Manual

TOYOTA RAV4 Chassis and Body Repair
Manual

TOYOTA RAV4 Chassis and Body Repair
Manual Supplement

TOYOTA RAV4 Electrical Wiring
Diagram

TOYOTA RAV4 Electrical Wiring
Diagram Supplement

TOYOTA RAV4 New Car Features

TOYOTA RAV4 Repair Manual
For Collision Damage

Fundamental Painting Procedures

Fundamental Body Repair ProceduresBRM024E
BRM002E NCF108E
BRM045E EWD234F EWD206Y RM454E RM395E
FOREWORD
This repair manual has been prepared to provide essential
information on body panel repair methods (including cutting
and welding operations, but excluding painting) for the
TOYOTA RAV4 5-DOOR.
Applicable models: SXA11 series
This manual consists of body repair methods, exploded diaœ
grams and illustrations of the body components and other
information relating to body panel replacement such as hanœ
dling precautions, etc. However, it should be noted that the
front fenders of the TOYOTA model is bolted on and require
no welding.
When repairing, don't cut and join areas that are not shown in
this manual. Only work on the specified contents to maintain
body strength.
Body construction will sometimes differ depending on specifiœ
cations and country of destination. Therefore, please keep in
mind that the information contained herein is based on veœ
hicles for general destinations.
For the repair procedures and specifications other than colliœ
sion-damaged body components of the TOYOTA RAV 4
5-DOOR refer to the following repair manuals.
If you require the above manuals, please contact your TOœ
YOTA Dealer.
All information contained in this manual is the most up-to-
date at the time of publication. However, specifications and
procedures are subject to change without prior notice.
TOYOTA MOTOR CORPORATION
RM401E

mm in.
150
2505.91
9.84
QUARTER PANEL (CUT)
QUARTER PANEL
RH:
LH:
1. Cut and join the parts at the location shown above.
HOW TO USE THIS MANUAL
Each repair method description provided in Section RE of this manual comprises two pages, divided into 2
blocks (REMOVAL AND INSTALLATION) and includes illustrations to facilitate body repair.
RE-10
BODY PANEL REPLACEMENT
REMOVAL
[Cut and Join Location]
250 mm
Cut and Join Location
Cut and Join Location
(Cut Location for
Supply Parts)
Cut and Join Location
(Cut and Join Location )
Braze
REPLACEMENT PARTS AND METHOD
(CUT)
Replacement method
(ASSY) Assembly replacement. . . . .
(CUT) Major cutting (less than 1/2 of parts used). . . . . .
(CUT-H) Half cutting (about 1/2 of parts used). . . .
(CUT-P) Partial cutting (most of parts used). . . .
Replacement Parts
PARTS LOCATION
REMOVAL DIAGRAM
Describes in detail removal of the damaged parts involving repair by cutting.
REMOVAL GUIDE
Provides additional information to more efficiently help you perform the removal.
INTRODUCTIONINœ2

mm in.
5
0.20
1. Before temporarily installing the new parts, apply
body sealer to the wheel arch.
HINT:
1) Apply body sealer about 5 mm (0.20in.) from the
flange, avoiding any oozing.
2) Apply sealer evenly, about 3 - 4 mm (0. 12 -
0.16in.) in diameter.
3) For other sealing points, refer to section AR.
SYMBOLS
See page IN-4.
RH:
LH: BODY PANEL REPLACEMENT
RE-11
INSTALLATION
Butt Weld
Body Sealer
Butt Weld
Butt weld
Body sealer
Braze
about 5 mm
RH:
LH:
2. Temporarily install the new parts and check the fit
of the rear door, back door and rear combination
light.
INSTALLATION DIAGRAM
Describes in detail installation of the new parts involving repair by welding and/or cutting, but exœ
cluding painting.
INSTALLATION GUIDE
Provides additional information to more efficiently help you perform the installation.
ILLUSTRATION OF WELD POINTS
Weld method and panel position symbols.
See page IN-5.
INTRODUCTIONINœ3

SYMBOLSMEANINGILLUSTRATION
SAW CUT OR
ROUGH CUT
REMOVE BRAZE
(See page IN-5) SPOT WELD OR
MIG PLUG WELD WELD POINTS
BRAZE CONTINUOUS MIG
WELD (BUTT WELD
OR TACK WELD)
BODY SEALER
SYMBOLS
The following symbols are used in the Welding Diagrams in Section RE of this manual to indicate cutting
areas and the types of weld required.
INTRODUCTIONINœ4