TOYOTA RAV4 1996 Service Repair Manual

Q08679No continuity
32
1
Q08680Continuity
32
1
Q08681No continuity
32
1
CL−4
− CLUTCHCLUTCH PEDAL
1996 RAV4 (RM447U)
9. CHECK OPERATION OF CLUTCH START CANCEL
SWITCH
(a) Connect positive (+) lead from the battery to terminal 3
and negative (−) lead to terminal 1.
(b) Check that there is no continuity when connecting the
positive (+) lead from the ohmmeter to terminal 2 and the
negative (−) lead to terminal 1.
(c) When push the switch, check that the indicator light
comes on and there is continuity between terminal 1 and
2.
(d) Check that there is no continuity between terminals 1 and
2 when disconnect the battery lead.
If continuity is not as specified, replace the clutch start cancel
switch.

CL04H−02
Q11030
Cruise Control Actuator Cover
N·m (kgf·cm, ft·lbf) : Specified torqueMaster Cylinder Body Reservoir Hose
Slotted
Spring PinInlet Union
 Grommet
Clutch Line
BracketBootClip
Clevis
Lock Nut
 Gasket Clip
 Snap Ring  Stop Plate
Piston
 Non−reusable part
6 (60, 52 in.·lbf)
12 (120, 9)
15 (155, 11)
12 (120, 9)
Cruise Control Actuator
Pin
Push Rod
12 (120, 9)
− CLUTCHCLUTCH MASTER CYLINDER
CL−5
1996 RAV4 (RM447U)
CLUTCH MASTER CYLINDER
COMPONENTS

CL04I−02
Q08876
Q08877SST CL−6
− CLUTCHCLUTCH MASTER CYLINDER
1996 RAV4 (RM447U)
REMOVAL
1. w/ Cruise Control System:
REMOVE CRUISE CONTROL ACTUATOR COVER
2. w/ Cruise Control System:
REMOVE CRUISE CONTROL ACTUATOR
Remove the 3 bolts.
Torque: 6 N·m (60 kgf·cm, 52 in.·lbf)
3. DRAW OUT FLUID WITH SYRINGE
4. DISCONNECT CLUTCH LINE
Using SST, disconnect the clutch line. Use a container to catch
the fluid.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
5. DISCONNECT RESERVOIR HOSE FROM MASTER
CYLINDER
Using pliers, disconnect the clip and reservoir hose.
6. REMOVE CLIP AND PIN
7. REMOVE 2 MOUNTING NUTS AND PULL OUT MAS-
TER CYLINDER
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

CL04J−01
Q08878
Q08879
− CLUTCHCLUTCH MASTER CYLINDER
CL−7
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE INLET UNION
(a) Using a pin punch and a hammer, drive out the slotted
spring pin.
(b) Remove the inlet union and grommet.
2. REMOVE PUSH ROD
Pull back the boot, and using snap ring pliers, remove the snap
ring.
3. REMOVE PISTON

CL04K−01
CL0528
Lithium Soap Base Glycol Grease
Q08880
Protrusion
1.5 − 3.5 mm
(0.059 − 0.138 mm) CL−8
− CLUTCHCLUTCH MASTER CYLINDER
1996 RAV4 (RM447U)
REASSEMBLY
1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSERT PISTON INTO CYLINDER
3. INSTALL PUSH ROD ASSEMBLY WITH SNAP RING
4. INSTALL RESERVOIR TANK
(a) Install the reservoir tank and a new grommet.
(b) Using a pin punch and hammer, drive in the slotted spring
pin.

CL04L−02
− CLUTCHCLUTCH MASTER CYLINDER
CL−9
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal. (See page CL−6)
HINT:
After installation, bleed the system and adjust the clutch pedal.

CL04M−01
Q08881
Clutch Line
Release Cylinder Body
Piston
Boot
Push Rod Spring Bleeder Plug
N·m (kgf·cm, ft·lbf): Specified torque
15 (155, 11)
12 (120, 9)
8.4 (85, 57 in.·lbf)
CL−10
− CLUTCHCLUTCH RELEASE CYLINDER
1996 RAV4 (RM447U)
CLUTCH RELEASE CYLINDER
COMPONENTS

CL04N−01
Q10347
SST
− CLUTCHCLUTCH RELEASE CYLINDER
CL−11
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT CLUTCH LINE
Using SST, disconnect the clutch line. Use a container to catch
the fluid.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
2. REMOVE 2 BOLTS AND PULL OUT RELEASE CYL-
INDER
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

CL04O−01
Q05878
CL−12
− CLUTCHCLUTCH RELEASE CYLINDER
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE BLEEDER PLUG
Torque: 8.4 N·m (85 kgf·cm, 57 in.·lbf)
2. PULL OUT BOOT WITH PUSH ROD
3. REMOVE PISTON
Blow compressed air into the release cylinder and remove the
piston with spring.

CL04P−01
CL0672
Lithium Soap Base Glycol Grease
− CLUTCHCLUTCH RELEASE CYLINDER
CL−13
1996 RAV4 (RM447U)
REASSEMBLY
1. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSTALL PISTON WITH SPRING INTO CYLINDER
3. INSTALL BOOT WITH PUSH ROD TO CYLINDER