TOYOTA RAV4 1996 Service Repair Manual

INSTALLATION
Body Sealer
1. Before temporarily installing the new parts,
apply body sealer to the windshield header
panel, roof panel reinforcement and back
door opening frame.HINT:
1) Apply just enough sealer for the new parts to
make contact.
2) For other sealing points, refer to Section AR.
BODY PANEL REPLACEMENTREœ33

CodeMaterial
nameHeat*
resistant
temperature
limit °C (°F)Resistance to
alcohol or gasolineNotes
AASAcrylonitrile
Acrylic Styrene80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease.)Avoid gasoline and
organic or aromatic
solvents.
ABSAcrylonitrile
Butadiene Styrene80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease.)Avoid gasoline and
organic or aromatic
solvents.
AESAcrylonitrile
Ethylene Styrene80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).Avoid gasoline and
organic or aromatic
solvents.
BMCBulk
Moulding
Compound150
(302)Alcohol and gasoline are
harmless.Most solvents are
harmless.
CABCellulose
Acetate80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).Avoid gasoline and
organic or aromatic
solvents.
EPDM100
(212) Ethylene
PropyleneAlcohol is harmless.
Gasoline is harmless if applied
only for short time in small
amounts.Most solvents are
harmless but avoid
dipping in gasoline,
solvents, etc.
PAPolyamide
(Nylon)80
(176)Alcohol and gasoline are
harmless.Avoid battery acid.
PBTPolybutylene
Terephthalate160
(320)Alcohol and gasoline are
harmless.Most solvents are
harmless.
PC
Polycarbonate120
(248)Alcohol is harmless.Avoid gasoline brake
fluid, wax, wax removers
and organic solvents.
Avoid alkali.
PE
Polyethylene80
(176)Alcohol and gasoline are harmless.Most solvents are
harmless.
PETPolyethylene
Terephthalate75
(167)Alcohol and gasoline are
harmless.Avoid dipping in water.
HANDLING PRECAUTIONS
1. The repair procedure for plastic body parts must conform with the type of plastic material.
2. Plastic body parts are identified by the codes in the following chart.
3. When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding,
painting etc.), consideration must given to the property of the plastic.
*Temperatures higher than those listed here may result in material deformation during repair.
PLASTIC BODY PARTSPPœ2

CodeMaterial
nameHeat*
resistant
temperature
limit °C (°F)Resistance to
alcohol or gasolineNotes
PMMAPolymethyl
Methacrylate80
(176)Alcohol is harmless if applied
only for short time in small
amounts.Avoid dipping or immersœ
ing in alcohol, gasoline,
solvents, etc.
POMPolyoxymethylene
(Polyacetal)100
(212)Alcohol and gasoline are
harmless.Most solvents are
harmless.
PP
Polypropylene80
(176)Alcohol and gasoline are
harmless.Most solvents are
harmless.
PPOModified
Polyphenylene
Oxide100
(212)Alcohol is harmless.Gasoline is harmless if
applied only for quick
wiping to remove
grease.
PS
Polystyrene60
(140)Alcohol and gasoline are harmœ
less if applied only for short time
in small amounts.Avoid dipping or immersœ
ing in alcohol, gasoline,
solvents, etc.
PUR
Polyurethane80
(176)Alcohol is harmless if applied only
for very short time in small amounts
(e.g., quick wiping to remove
grease.)Avoid dipping or immersœ
ing in alcohol, gasoline,
solvents, etc.
PVCPolyvinylchloride
(Vinyl)80
(176)Alcohol and gasoline are harmless if
applied only for short time in small
amounts (e.g., quick wiping to remove
grease).Avoid dipping or immersœ
ing in alcohol, gasoline,
solvents, etc.
SANStyrene
Acrylonitrile80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease.)Avoid dipping or immersœ
ing in alcohol, gasoline,
solvents etc.
SMCSheet
Moulding
Compound180
(356)Alcohol and gasoline are
harmless.Avoid alkali.
TPOThermoplastic
Olefine80
(176)Alcohol is harmless.
Gasoline is harmless if applied
only for short time in small
amounts.Most solvents are harmœ
less but avoid dipping in
gasoline, solvents,
etc.
TPUThermoplastic
Polyurethane80
(176)Alcohol is harmless if applied
only for very short time in small
amounts (e.g., quick wiping to
remove grease).Avoid dipping or immersœ
ing in alcohol, gasoline,
solvents, etc.
TSOPTOYOTA
Super
Olefine Polymer80
(176)Alcohol and gasoline are
harmless.Most solvents are
harmless.
UPUnsaturated
Polyester11 0
(233)Alcohol and gasoline are
harmless.Avoid alkali.
*Temperatures higher than those listed here may result in material deformation during repair.
PLASTIC BODY PARTSPPœ3

LOCATION OF PLASTIC BODY PARTS
Quarter Vent Duct (PP)
Rear Door Outside Handle (PC)
Front Door Outside Handle (PC)
Outer Rear View Mirror (AAS)
Instrument Panel Safety Pad (PP)
Cowl TopVentilator Louver (PP)
Radiator Grill (ABS)
Quarter Outside Moulding
(TSOP)
Rear Door Outside Moulding (TSOP) Front Bumper Cover (TSOP)
Front Turn Signal Light (PMMA/PP)
Front Door Outside Moulding (TSOP)
Front Fender Moulding (TSOP)
HINT:
wResin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPPœ4

Center Pillar Lower Garnish (PP/PE)
Center Pillar Garnish (PP)
Back Door Trim Board (PP)
Front Pillar Garnish (PP)
Front Fender Liner (PE)
Quater Panel Mudguard (TPU)
Side Turn Signal Light (SAN/ABS)
Washer Jar (PP)
Front Fender Mudguard (TPU)
Radiator Reserve Tank (PP)
Engine Under Cover (PE)
HINT:
wResin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPPœ5

Rear Combination Light (PMMA/PP)
Roof Side Inner Garnish (TSOP)
Air Conditioner Unit (PP)
Heater Blower (PP)
Rear Bumper Side Seal (PE)
Cowl Side Trim Board (PP)
Deck Trim Side Panel (TSOP) Front Door Outside Scuff Plate (PP/PE)
Back Door Outside Handle (PC) Rear Door Outside Scuff Plate (PP/PE)
Rear Bumper Piece (TSOP)
Licence Plate Light (PC)
Reflex Reflector (PMMA/ABS)
HINT:
wResin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPPœ6

mm in.
10
11.5
13
140.39
0.453
0.51
0.55 Assembly Mark 14y11.5
10f
13f 10f
10f
10f Assembly Mark10f 10f
STANDARD BODY MARKS
Center Mark
Center Mark
Assembly Mark
Assembly Mark
Assembly Mark
BODY PANEL CONSTRUCTIONCNœ2

CL04F−03
− CLUTCHTROUBLESHOOTING
CL−1
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
Clutch grabs/chatters
3. Engine mounting (Loosen)
4. Clutch disc (Runout is excessive)
5. Clutch disc (Oily)
6. Clutch disc (Worn out)
7. Clutch disc torsion rubber (Damaged)
8. Clutch disc (Glazed)
9. Diaphragm spring (Out of tip alignment)−
CL−15
CL−15
CL−15
CL−15
CL−15
CL−15
Clutch pedal spongy
1. Clutch line (Air in line)
2. Master cylinder cup (Damaged)
3. Release cylinder cup (Damaged)−
CL−5
CL−10
Clutch noisy1. Release bearing (Worn, dirty, or damaged)
2. Clutch disc torsion rubber (Damaged)CL−15
CL−15
Clutch slips
1. Clutch pedal (Free play out of adjustment)
2. Clutch disc (Oily)
3. Clutch disc (Worn out)
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion)
6. Flywheel (Distortion)CL−2
CL−15
CL−15
CL−15
CL−15
−
Clutch does not disengage
1. Clutch pedal (Free play out of adjustment)
2. Clutch line (Air in line)
3. Master cylinder cup (Damaged)
4. Release cylinder cup (Damaged)
5. Clutch disc (Out of true)
6. Clutch disc (Runout is excessive)
7. Clutch disc (Lining broken)
8. Clutch disc (Dirty or burned)
9. Clutch disc (Oily)
10.Clutch disc (Lack of spline grease)
11. Diaphragm spring (Damaged)
12.Diaphragm spring (Out of tip alignment)
13.Pressure plate (Distortion)CL−2
−
CL−5
CL−10
CL−15
CL−15
CL−15
CL−15
CL−15
CL−18
CL−15
CL−18
CL−15

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.