engine TOYOTA RAV4 1996 Service Repair Manual

MX05O−02
Q08747
Q08748
A
B
Q08749
Q08750
A B
A
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
MX−3
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR
HOSE
2. REMOVE ENGINE COOLANT RESERVOIR TANK
3. REMOVE ENGINE WIRE CLAMP SET NUT
4. REMOVE STARTER
(a) Disconnect the connector and wire from the starter.
(b) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
5. DISCONNECT CLUTCH RELEASE CYLINDER AND
LINE
(a) Remove the 2 set bolts of the clutch line bracket.
Torque:
Bolt A: 12 N·m (120 kgf·cm, 9 ft·lbf)
Bolt B: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
(b) Remove the 2 bolts, release cylinder and line.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
6. DISCONNECT GROUND CABLE
Remove the set bolt of the ground cable from the transaxle.
7. DISCONNECT VEHICLE SPEED SENSOR AND
BACK−UP LIGHT SWITCH CONNECTORS
8. DISCONNECT CONTROL CABLE
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
9. REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING
BOLTS
Torque:
Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf)
Bolt B: 35 N·m (360 kgf·cm, 26 ft·lbf)

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)

Q08754
A
B A
B D
E
C
Q08755
Q08756DEC C
FG G
F
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
MX−5
1996 RAV4 (RM447U)
(d) Remove the 2 nuts, 6 bolts and front suspension cross-
member assembly with the stabilizer bar.
Torque:
Bolt A: 206 N·m (2,100 kgf·cm, 152 ft·lbf)
Bolt B: 137 N·m (1,400 kgf·cm, 101 ft·lbf)
Nut C: 115 N·m (1,170 kgf·cm, 85 ft·lbf)
20. REMOVE ENGINE MOUNTING CENTER MEMBER
Remove the 4 bolts and center member.
Torque:
Bolt D: 80 N·m (820 kgf·cm, 59 ft·lbf)
Bolt E: 35 N·m (360 kgf·cm, 26 ft·lbf)
21. JACK UP TRANSAXLE SLIGHTLY
Using a trasmission jack, support the transaxle.
22. DISCONNECT ENGINE LEFT MOUNTING BRACKET
FROM ENGINE LEFT MOUNTING INSULATOR
Remove the set bolt of the engine left mounting bracket.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
23. REMOVE STIFFENER PLATE, NO.2 REAR END
PLATE AND TRANSAXLE LOWER SIDE MOUNTING
BOLT
(a) Remove the 2 bolts and stiffener plate.
Torque:
Bolt G: 37 N·m (380 kgf·cm, 27 ft·lbf)
(b) Remove the 7 bolts and No.2 rear end plate.
Torque:
Bolt C: 29 N·m (300 kgf·cm, 22 ft·lbf)
Bolt D: 46 N·m (470 kgf·cm, 34 ft·lbf)
Bolt E: 25 N·m (250 kgf·cm, 18 ft·lbf)
Bolt F: 9.0 N·m (95 kgf·cm, 78 in.·lbf)
24. REMOVE TRANSAXLE
Lower the engine left side and remove the transaxle from the
engine.
HINT:
At the time of installation, please refer to the following items.
Align the input shaft with the clutch disc and install the
transaxle to the engine.
Temporarily tighten the transaxle mounting bolts.

MX05S−01
Q09031
B
A
C
FED A
A
C
Q08759
No.1
No.2 No.0
No.0
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (4WD)
MX−9
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE TRANSAXLE WITH ENGINE
(See page EM−80)
2. REMOVE TRANSAXLE CASE PROTECTOR
Remove the 2 bolts and transaxle case protector.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
3. REMOVE STARTER
(a) Disconnect the connector and wire from the starter.
(b) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
4. DISCONNECT DIFFERENTIAL LOCK INDICATOR
SWITCH, BACK−UP LIGHT SWITCH AND VEHICLE
SPEED SENSOR CONNECTORS
5. REMOVE TRANSFER VACUUM ACTUATOR BRACK-
ET
Remove the 4 bolts and bracket.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
6. REMOVE TRANSFER VACUUM ACTUATOR AS-
SEMBLY
(a) Disconnect the 4 solenoid hoses from the transfer vacu-
um actuator assembly.
NOTICE:
At the time of installation, please refer to the following item.
Check that the hose No.0, No.1 and No.2 are securely
installed to the solenoid.
(b) Remove the 2 bolts and transfer vacuum actuator assem-
bly.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
7. REMOVE RIGHT TRANSFER STIFFENER PLATE
Remove the 5 bolts and right transfer stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
8. REMOVE CENTER TRANSFER STIFFENER PLATE
Remove the 3 bolts and center transfer stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
9. REMOVE STIFFENER PLATE
Remove the 2 bolts and stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
10. REMOVE TRANSAXLE FROM ENGINE
(a) Remove the 9 transaxle mounting bolts from the engine.
Torque:
Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf)
Bolt B: 35 N·m (360 kgf·cm, 26 ft·lbf)
Bolt C: 29 N·m (300 kgf·cm, 22 ft·lbf)
Bolt D: 46 N·m (470 kgf·cm, 34 ft·lbf)
Bolt E: 25 N·m (250 kgf·cm, 18 ft·lbf)
Bolt F: 9.0 N·m (95 kgf·cm, 78 in.·lbf)

Q06187
Q06188
Q06189
MX−10
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (4WD)
1996 RAV4 (RM447U)
(b) Pull straight until there is a gap of about 60−80 mm
(2.4−3.1 in.) between the engine and transaxle case.
(c) Move the transmission case cover in the direction, as
shown in the illustration.
(d) While holding transfer output, gently pull out whole trans-
axle.

MX0C0−02
Q06152
− MANUAL TRANSAXLEDIFFERENTIAL LOCKING SYSTEM (4WD)
MX−73
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT CENTER DIFFERENTIAL LOCK SYSTEM
(a) Inspect the differential lock operation.
(1) Use a lift or jack stand to lift up the vehicle so that
all 4 tires can rotate.
(2) Apply the parking brake and start the engine.
(3) Set the center differential lock switch to ON.
(4) Depress the clutch pedal and shift into the 2nd gear.
(5) With the engine idling, gradually engage the clutch
and check that the engine stops.
(6) With the parking brake and engine ON, turn the cen-
ter differential lock switch OFF.
(7) Depress the clutch pedal and shift into the 2nd gear.
(8) With the engine idling, gradually engage the clutch
and check that the front wheels rotate.
HINT:
This inspection must be done when the engine is idling.
(b) Inspect the center differential lock indicator operation.
(1) Turn the ignition switch ON.
(2) Check that when the differential lock switch is
turned ON and OFF, the differential lock indicator
lamp lights up and goes off, respectively.
(c) Inspect the center differential lock warning buzzer opera-
tion.
(1) Start the engine and check that the differential lock
warning buzzer does not sound when the center dif-
ferential lock switch is turned ON.
(2) Interchange the solenoid hose No.1 and solenoid
hose No.2 between the differential lock control sole-
noid No.1 and No.2 and the differential lock actua-
tor. And check that the differential lock warning
buzzer sounds when the differential lock switch is
turned OFF.
(3) Return the solenoid hose No.1 and solenoid hose
No.2 to their original location, and check that the dif-
ferential lock warning buzzer stops.
HINT:
Do the inspection with the vehicle stopped.
After finishing the inspection, inspect the differential lock
control solenoid hoses.

MX066−01
Z17562
Oil Cooler Clamp
Cushion
Oil Cooler Assembly
Oil Cooler Line Clamp
 O−Ring
Union
LH Engine Under Cover
 Non−reusable partOil Cooler No.2 Line
Painted Mark Line Clamp
Oil Cooler No.1 Line
: Specified torque
N·m (kgf·cm, ft·lbf)Bumper Cover RH Engine Under Cover
17 (175, 13)
34 (350, 25)
4.9 (50, 43 in.·lbf)
29 (300, 22)34 (350, 25)
6.4 (65, 56 in.·lbf)
 O−Ring
Elbow
26 (270, 20)
6.4 (65, 56 in.·lbf)
ClampCushion
6.4 (65, 56 in.·lbf)6.4 (65, 56 in.·lbf)CushionClamp
 
Line Clamp
34 (350, 25)
MX−78
− MANUAL TRANSAXLEOIL COOLER (4WD)
1996 RAV4 (RM447U)
OIL COOLER (4WD)
COMPONENTS

R10850
W01204
F01195
Bolt
Set Bolt Adjusting Bolt
1 Dot 2 Dots 3 Dots
30’
45’
1°15’
1°30’
Adjusting
ValueOD=13.9 mmOD=13.3 mm OD=12.4 mm
Original
15’
1°00’
− SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
SA−5
1996 RAV4 (RM447U)
5. ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe−in.
(a) Remove the front wheels.
(b) Remove the 2 nuts on the lower side of the shock absorb-
er.
(c) Coat the threads of the nuts with engine oil.
(d) Temporarily install the 2 nuts.
(e) Adjust the camber by pushing or pulling the lower side of
the shock adjustment is required.
(f) Tighten the 2nuts.
Torque: 158 N·m (1,610 kgf·cm, 117 ft.lbf)
(g) Install the front wheels.
Torque: 103 N·m (1,050 kgf·cm, 76 ft.lbf)
(h) Check the camber.
HINT:
Try to adjust the camber to the center value.
Adjusting value for the set bolts is 6’ − 30’ (0.1° − 0.5°).
If the camber is not within the specification, using the table be-
low, estimate for how much additional camber adjustment will
be required, and select the camber adjusting bolt.

R10678
SST
− SUSPENSION AND AXLEFRONT AXLE HUB
SA−11
1996 RAV4 (RM447U)
(b) Using SST, disconnect the tie rod end from the steering
knuckle.
SST 09610−20012
7. DISCONNECT LOWER BALL JOINT FROM LOWER
ARM
Remove the bolt and 2 nuts.
Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf)
8. REMOVE STEERING KNUCKLE WITH AXLE HUB
HINT:
At the time of installation, please refer to the following item.
Coat the threads of the nut’s with engine oil.
NOTICE:
Be careful not to damage the oil seal, boot and ABS speed
sensor rotor.

SA0TF−06
W04172
2WD M/T
Snap RingCenter Bearing Bracket
RH Drive Shaft
Snap RingABS Speed Sensor
Tie Rod End
Cotter Pin
Lock Cap LH Drive Shaft
Boot Clamp
Engine
Under
Cover
3 Door vehicle
64 (650, 47)
5 Door vehicle,
All over fender
vehicle
113 (1,150, 83)


32 (330, 24)
64 (650, 47)
8 (80, 69 in.·lbf)
49 (500, 36)
216 (2,200, 159)
127 (1,300, 94)
Lower Suspension Arm X6
X7
Center Drive Shaft Inner Race Ball Cage Stabilizer Bar Link
Snap Ring
Snap Ring
Dust Cover
Center Bearing Dust Cover
Inboard Joint Tulip Outboard Joint
Shaft No.2 Dust
DeflectorBoot




 
N·m (kgf·cm, ft·lbf)
: Specified torque
Non−reusable part
LH SA−18
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 RAV4 (RM447U)
FRONT DRIVE SHAFT
COMPONENTS