oil level TOYOTA RAV4 1996 Service Owner's Manual

LU060−04
S01260
Oil Pressure Gauge
P13638
Adhesive
− LUBRICATIONOIL AND FILTER
LU−1
1996 RAV4 (RM447U)
OIL AND FILTER
INSPECTION
1. CHECK ENGINE OIL QUALITY
Check the oil for deterioration, entry of water, discoloring or thin-
ning.
If the quality is visibly poor, replace the oil.
Oil grade:
API grade SH, Energy − Conserving II multigrade en-
gine oil or ILSAC multigrade engine oil.
Recommended viscosity is as shown in the illustra-
tion.
2. CHECK ENGINE OIL LEVEL
The oil level should be between the ”L” and ”F” marks on the dip-
stick.
If low, check for leakage and add oil up to ”F” mark.
3. REMOVE OIL PRESSURE SWITCH, AND INSTALL OIL
PRESSURE GAUGE
4. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
5. CHECK OIL PRESSURE
Oil pressure:
At idle
29 kPa (0.3 kgf/cm
2, 4.3 psi) or more
At 3,000 rpm
245 − 490 kPa
(2.5 − 5.0 kgf/cm
2, 36 − 71 psi)
6. REMOVE OIL PRESSURE GAUGE AND REINSTALL
OIL PRESSURE SWITCH
(a) Remove the oil pressure gauge.
(b) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Reinstall the oil pressure switch.
7. START ENGINE AND CHECK FOR LEAKS

S01263
SST
3/4
Turn
− LUBRICATIONOIL AND FILTER
LU−3
1996 RAV4 (RM447U)
(e) Using SST, give it an additional 3/4 turn to seat the filter.
SST 09228−06501
3. FILL WITH ENGINE OIL
(a) Clean and install the oil drain plug with a new gasket.
Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
(b) Fill with new engine oil.
Capacity:
Drain and refill
w/ Oil filter change
3.9 liters (4.1 US qts, 3.4 lmp. qts)
w/o Oil filter change
3.7 liters (3.9 US qts, 3.3 lmp. qts)
Dry fill
4.4 liters (4.7 US qts, 3.9 lmp. qts)
(c) Reinstall the oil filler cap.
4. START ENGINE AND CHECK FOR OIL LEAKS
5. RECHECK ENGINE OIL LEVEL

S01775S01237B13839
A/T M/T LU−16
− LUBRICATIONOIL PUMP
1996 RAV4 (RM447U)
9. INSTALL STIFFENER PLATE
Install the stiffener plate with the 2 bolts (M/T) or 3 bolts (A/T).
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
10. INSTALL FRONT EXHAUST PIPE (See page EM−55)
11. FILL WITH ENGINE OIL
12. START ENGINE AND CHECK FOR LEAKS
13. RECHECK ENGINE OIL LEVEL
14. INSTALL RH ENGINE UNDER COVER
15. INSTALL HOOD

LU06C−02
LU−20
− LUBRICATIONOIL COOLER
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL OIL COOLER
(a) Clean the oil cooler contact surface on the oil cooler
mounting.
(b) Install a new O−ring to the oil cooler.
(c) Temporarily install the oil cooler with the nut.
(d) Apply a light coat of engine oil on the threads and under
the head of the relief valve.
(e) Install the plate washer and union bolt.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
(f) Tighten the nut.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(g) Connect the 2 water bypass hoses to the oil cooler.
2. INSTALL OIL FILTER
3. INSTALL WATER BYPASS HOSE HEAT PROTECTOR
Install the heat protector with the bolt and 2 nuts.
4. INSTALL EXHAUST MANIFOLD AND FRONT TWC AS-
SEMBLY (See page EM−55)
5. INSTALL OIL DIPSTICK
6. INSTALL GENERATOR (See page CH−19)
7. INSTALL FRONT EXHAUST PIPE (See page EM−55)
8. FILL WITH ENGINE COOLANT
9. START ENGINE AND CHECK FOR LEAKS
10. CHECK ENGINE OIL LEVEL
11. INSTALL RH ENGINE UNDER COVER

MX01Z−08
− MANUAL TRANSAXLETROUBLESHOOTING
MX−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
Noise
14.Oil (Level low) 2WD
4WD
15. Oil (Wrong) 2WD
4WD
16.Gear (Worn or damaged)
17.Bearing (Worn or damaged)MX−3
MX−9
MX−3
MX−9
MX−12
MX−79
MX−12
MX−79
Oil leakage
1. Oil (Level too high) 2WD
4WD
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O−Ring (Worn or damaged)MX−3
MX−9
MX−12
MX−79
MX−12
MX−79
MX−12
MX−78
MX−79
Hard to shift or will not shift
1. Control cable (Faulty)
2. Synchronizer ring (Worn or damaged)
3. Shift key spring (Damaged)MX−77
MX−12
MX−29
MX−36
MX−12
MX−29
MX−36
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MX−12
MX−12
MX−79
MX−12
MX−79
MX−12
MX−79
Tight corner braking1. Differential, Center differential (Faulty)MX−58
MX−72

Q08751
Q08752
Q10165
Filler Plug
Oil Level
0 − 5 mm
Drain Plug
Q08753
MX−4
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
1996 RAV4 (RM447U)
10. REMOVE ENGINE LEFT MOUNTING INSULATOR SET
BOLT AND 2 NUTS
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
11. INSTALL ENGINE SUPPORT FIXTURE
12. TIE PS GEAR ASSEMBLY TO ENGINE SUPPORT FIX-
TURE BY CORD OR EQUIVALENT
13. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
14. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
15. REMOVE LH AND RH ENGINE UNDER COVERS
16. DRAIN TRANSAXLE OIL
Oil grade: API GL−4 or GL−5
Viscosity: SAE 75W−90
Capacity: 3.9 liters (4.1 US qts, 3.4 Imp. qts)
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
17. REMOVE LH AND RH FRONT DRIVE SHAFTS
(See page SA−18)
18. REMOVE FRONT EXHAUST PIPE
(a) Remove the 3 nuts and gasket from the exhaust manifold.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Remove the 2 bolts, gasket and pipe.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
19. REMOVE FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY WITH STABILIZER BAR
(a) Support the front suspension crossmember with a jack.
(b) Disconnect the ring from the center exhaust pipe.
(c) Remove the 2 set bolts and nuts of the PS gear assembly.
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)

SA0T5−01
− SUSPENSION AND AXLETROUBLESHOOTING
SA−1
1996 RAV4 (RM447U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below th 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
Wander/pulls
1. Tires (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Steering linkage (Loosen or worn)
4. Hub bearings (Loosen or worn)
5. Steering gear (Out of adjustment or broken)
6. Suspension parts (Worn out)SA−2
SA−4
−
SA−10
SA−52
SA−56
−
−
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn out)−
SA−32
SA−95
SA−35
SA−92
Sways/pitches
1. Tires (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn out)SA−2
SA−49
SA−35
SA−92
Front wheel shimmy
1. Tires (Worn or improperly inflated)
2. Wheels (Out of balance)
3. Shock absorber (Worn out)
4. Wheel alignment (Incorrect)
5. Ball joints (Worn)
6. Hub bearings (Loosen or worn)
7. Steering linkage (Loosen or worn)
8. Steering gear (Out of adjustment or broken)SA−2
SA−2
SA−35
SA−2
SA−45
SA−10
−
−
Abnormal tire wear
1. Tires (Improperly inflated)
2. Wheel alignment (Incorrect)
3. Suspension parts (Worn out)
4. Shock absorber (Worn out)SA−2
SA−4
−
SA−35
SA−92
Noise in rear differential
1. Oil level (Low or wrong grade)
2. Excessive backlash between pinion and ring gear
3. Ring, pinion or side gears (Worn or chipped)
4. Pinion shaft bearing (Worn)
5. Side bearing (Worn)
6. Differential bearing (Loosen or worn)SA−69
SA−79
SA−79
SA−79
SA−79
SA−79
Oil leak from rear differential
1. Oil level (Too high or wrong grade)
2. Drive pinion oil seal (Worn or damaged)
3. Side gear oil seal (Worn or damaged)
4. Companion flange (Loose or damaged)
5. Side gear shaft (Damaged)SA−69
SA−79
SA−79
SA−74
SA−79

SR0FG−01
R00427
R11229
Normal
Abnormal
R11562Engine Idling
Engine Stopped 5 mm (0.2 in.)
or less
− STEERINGPOWER STEERING FLUID
SR−5
1996 RAV4 (RM447U)
INSPECTION
1. CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON® II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the
reservoir. If the fluid is cold, check that it is within the COLD
LEVEL range.
(c) Start the engine and run it at idle.
(d) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80°C (176°F)
(e) Check for foaming or emulsification.
If there is foaming or emulsification, bleed power steering
system (See page SR−4).
(f) With the engine idling, measure the fluid level in the oil
reservoir.
(g) Stop the engine.
(h) Wait a few minutes and remeasure the fluid level in the oil
reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed power steering system
(See page SR−4)
(i) Check the fluid level.