TOYOTA RAV4 1996 Service Repair Manual

CL04Q−02
CL−14
− CLUTCHCLUTCH RELEASE CYLINDER
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal. (See page CL−11)
HINT:
After installation, bleed the clutch system.

CL04R−02
Q08882
Flywheel
N·m (kgf·cm, ft·lbf): Specified torqueClutch Cover
Release Fork
BootRelease Fork Support Release Bearing with Hub x6 Clutch Disc
19 (195, 14)
47 (480, 35)88 (900, 65)
− CLUTCHCLUTCH UNIT
CL−15
1996 RAV4 (RM447U)
CLUTCH UNIT
COMPONENTS

CL04S−02
Q06030
Matchmarks
Q06031
CL−16
− CLUTCHCLUTCH UNIT
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE TRANSAXLE FROM ENGINE
(2WD: See page MX−2)
(4WD: See page MX−8)
2. REMOVE CLUTCH COVER AND DISC
(a) Place matchmarks on the flywheel and clutch cover.
(b) Loosen each set bolt one turn at a time until spring tension
is released.
(c) Remove the set bolts, and pull off the clutch cover with the
clutch disc.
NOTICE:
Do not drop the clutch disc.
3. REMOVE RELEASE BEARING AND FORK FROM
TRANSAXLE
(a) Remove the release bearing together with the fork and
then separate them.
(b) Remove the boot.

CL04T−01
Q06032
Q06033
Q06034
Q06035
AB
Q06036
− CLUTCHCLUTCH UNIT
CL−17
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.
Minimum rivet depth: 0.3 mm (0.012in.)
If a problem is found, replace the clutch disc.
2. INSPECT CLUTCH DISC RUNOUT
Using a dial indicator, check the disc runout.
Maximum runout: 0.8 mm (0.031 in.)
If runout is excessive, replace the clutch disc.
3. INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout.
Maximum runout: 0.1 mm (0.004 in.)
If runout is excessive, replace the flywheel.
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
4. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and
width of wear.
Maximum:
A (Depth): 0.5 mm (0.020 in.)
B (Width): 6.0 mm (0.236 in.)
If necessary, replace the clutch cover.
5. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direc-
tion.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
If a problem is found, replace the bearing.

CL04U−02
Q06037
Flywheel
Side
SST
Q06038
Matchmarks8 2, 5
6
SST
3
7 1, 4
Q06039SST
Q06245
CL−18
− CLUTCHCLUTCH UNIT
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON
FLYWHEEL
(a) Insert SST in the clutch disc, and then set them and the
clutch cover in position.
SST 09301−00220
(b) Align the matchmarks on the clutch cover and flywheel.
(c) Temporarily tighten the topmost bolt from the 3 near the
knock pins.
HINT:
Temporarily tighten the No.3 bolt.
(d) Torque the bolts on the clutch cover in the order shown.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non−alignment: 0.5 mm (0.020 in.)
If alignment is not as specified, using SST, adjust the dia-
phragm spring tip alignment.
SST 09333−00013
3. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE
GREASE (NLGI NO.2)
(a) Apply release hub grease to the following parts.
Release fork and hub contact point
Release fork and push rod contact point
Release fork pivot point
(b) Apply clutch spline grease.
Clutch disc spline
HINT:
Recommended grease part number 08887−01706 (100g).
4. INSTALL RELEASE BEARING AND FORK TO TRANS-
AXLE
Install the bearing to the release fork, and then install them to
the transaxle.
5. INSTALL TRANSAXLE TO ENGINE
(2WD: See page MX−2)
(4WD: See page MX−8)

CO0BD−01
− COOLINGCOOLANT
CO−1
1996 RAV4 (RM447U)
COOLANT
INSPECTION
1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR
The engine coolant level should be between the ”LOW” and ”FULL” lines, when engine is cold.
If low, check for leaks and add engine coolant up to the ”FULL” line.
2. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot, as fluid and steam can be blown out under pressure.
(b) There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler
hole, and the coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.

CO0BE−01
S01292Drain Plug CO−2
− COOLINGCOOLANT
1996 RAV4 (RM447U)
REPLACEMENT
1. DRAIN ENGINE COOLANT
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
(b) Loosen the radiator drain plug (on the left side of the ra-
diator lower tank) and engine drain plug (on the left rear
of the cylinder block), and drain the coolant.
(c) Close the drain plugs.
Torque: Engine drain plug
25 N·m (250 kgf·cm, 18 ft·lbf)
2. FILL ENGINE COOLANT
(a) Slowly fill the system with coolant.
Use a good brand of ethylene−glycol base coolant
and mix it according to the manufacture’s direc-
tions.
Using coolant which includes more than 50 % ethyl-
ene−glycol (but not more than 70 %) is recom-
mended.
NOTICE:
Do not use an alcohol type coolant.
The coolant should be mixed with demineralized wa-
ter or distilled water.
Capacity (w/ Heater):
M/T: 8.0 liters (8.5 US qts, 7.0 lmp. qts)
A/T: 7.7 liters (8.1 US qts, 6.8 lmp. qts)
(b) Install radiator cap.
(c) Start the engine, and bleed the cooling system.
(d) Refill the radiator reservoir with coolant until it reaches the
”FULL” line.
3. CHECK ENGINE COOLANT FOR LEAKS

CO0BF−03
S06209
No.3 ABS Actuator Bracket
Engine Wire
Generator
Generator
Drive Belt
PS Pump
Drive BeltGround Strap
Connector
Generator
BracketPS Reservoir Bracket
PS Reservoir
RH Engine Mounting Insulator
RH Engine Mounting Bracket
RH Engine
Under Cover
N·m (kgf·cm, ft·lbf): Specified Torque
37 (380, 27)
52 (530, 38)
52 (530, 38)
52 (530, 38)
52 (530, 38)
52 (530, 38)52 (530, 38)
− COOLINGWATER PUMP
CO−3
1996 RAV4 (RM447U)
WATER PUMP
COMPONENTS

CO−4
− COOLINGWATER PUMP
1996 RAV4 (RM447U)

CO0BG−02
S01613
P15462
P15546
1
3
2
P15463
Disconnect
− COOLINGWATER PUMP
CO−5
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE TIMING BELT (See page EM−15)
4. DISCONNECT LOWER RADIATOR HOSE FROM
WATER INLET
5. REMOVE TIMING BELT TENSION SPRING AND NO.2
IDLER PULLEY
6. REMOVE GENERATOR DRIVE BELT ADJUSTING
BAR
(a) Disconnect the crankshaft position sensor connector
clamp.
(b) Remove the bolt and adjusting bar.
7. REMOVE WATER PUMP AND WATER PUMP COVER
ASSEMBLY
(a) Remove the 2 nuts holding the water pump to the water
bypass pipe.
(b) Remove the 3 bolts in the sequence shown.
(c) Disconnect the water pump cover from the water bypass
pipe, and remove the water pump and water pump cover
assembly.
(d) Remove the gasket and 2 O−ring from the water pump
and water bypass pipe.