engine TOYOTA RAV4 1996 Service Repair Manual

SA1YB−02
FA1535
SST
R10849
SA−20
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 RAV4 (RM447U)
REMOVAL
NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the ve-
hicle with the drive shaft bearing removed.
Therefore if it is absolutely necessary to place the ve-
hicle weight on the hub bearing, first support it with
the SST.
SST 09608−16042 (09608−02021, 09608−02041)
w/ ABS:
After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage ABS speed sensor
rotor serrations on the drive shaft.
1. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. REMOVE ENGINE UNDER COVER
3. DRAIN GEAR OIL (M/T) OR ATF (A/T)
4. w/ABS:
REMOVE BOLT AND ABS SPEED SENSOR
Torque: 8 N·m (80 kgf·cm, 69 in.·lbf)
5. REMOVE COTTER PIN, LOCK CAP AND LOCK NUT
(a) Remove the cotter pin and lock cap.
(b) With applying the brakes, remove the nut.
Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf)
6. D I S C O N N E C T T I E R O D E N D F R O M S T E E R I N G
KNUCKLE (See page SA−10)
7. DISCONNECT STABILIZER BAR LINK FROM LOWER
SUSPENSION ARM
HINT:
If the ball joint turns together with the nut, use a 5 mm hexagon
wrench to hold the stud.
Torque:
3 Door vehicle
64 N·m (650 kgf·cm, 47ft·lbf)
5 Door vehicle and all over fender vehicle
113 N·m (1,150 kgf·cm, 83 ft·lbf)
8. DISCONNECT LOWER BALL JOINT FROM LOWER
SUSPENSION ARM (See page SA−12)

SA0TL−03
R10850
R10823
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA−33
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. DISCONNECT FLEXIBLE HOSE AND ABS SPEED
SENSOR WIRE HARNESS (w/ ABS) FROM SHOCK
ABSORBER
Remove the 2 bolts and disconnect the flexible hose and ABS
speed sensor wire harness.
Torque:
Flexible hose: 19 N·m (192 kgf·cm, 14 ft·lbf)
ABS wire harness: 5 N·m (55 kgf·cm, 48 in.·lbf)
3. DISCONNECT SHOCK ABSORBER FROM STEERING
KNUCKLE
Torque: 158 N·m (1,610 kgf·cm, 117 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Coat the nut’s threads with engine oil.
4. REMOVE SHOCK ABSORBER WITH COIL SPRING
Remove the 3 nuts, suspension support No.2 and shock ab-
sorber with the coil spring.
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)

SA0TR−03
Z19330
23 Door vehicle
Stabilizer Bar LinkStabilizer
BarPower Steering Gear Assembly
Bracket
No.1
Bushing
Bushing
Clamp
(A/T Only)
Front Suspension
Crossmember
Center MemberLower Suspension
Arm Bracket
Cushion
Retainer
Lower Suspension Arm
LH Engine Cover
29 (300, 22)
29 (300, 22)
113 (1,150, 83)
8.3 (85, 74 in.·lbf)
112 (1,140, 82)
172 (1,750, 126)
206 (2,100, 152)
127 (1,300, 94)
137 (1,400, 101)
28 (290, 21)

N·m (kgf·cm, ft·lbf)
Non−reusable part: Specified torque
X7
Clamp 137 (1,400, 101)
64 (650, 47)
113 (1,150, 83)5 Door vehicle
− SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
SA−39
1996 RAV4 (RM447U)
FRONT LOWER SUSPENSION ARM
COMPONENTS

SA0TS−03
R10828
A
A B
R10829
W01708
SA−40
− SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. A/T LH:
REMOVE LH ENGINE UNDER COVER
3. EXCEPT A/T LH:
DISCONNECT STABILIZER BAR LINK FROM LOWER
SUSPENSION ARM (See page SA−48)
4. A/T LH:
REMOVE STABILIZER BAR (See page SA−48)
5. DISCONNECT LOWER SUSPENSION ARM FROM
LOWER BALL JOINT
Remove the bolt and 2 nuts.
Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf)
6. DISCONNECT LOWER SUSPENSION ARM BRACKET
Remove the nut and 2 bolts.
Torque:
Bolt A: 137 N·m (1,400 kgf·cm, 101 ft·lbf)
Nut B: 28 N·m (290 kgf·cm, 21 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
After stabilizing the suspension, torque the bolts and nut.
7. EXCEPT A/T LH:
REMOVE LOWER SUSPENSION ARM
Remove the bolt and lower suspension arm.
Torque: 172 N·m (1,750 kgf·cm, 126 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
After stabilizing the suspension, torque the bolt.
8. A/T LH:
REMOVE LOWER SUSPENSION ARM
(a) Remove the 2 center member set nuts and disconnect the
center member.
Torque: 112 N·m (1,140 kgf·cm, 82 ft·lbf)

SA0TY−03
Z19330
23 Door vehicle
Stabilizer Bar LinkStabilizer
BarPower Steering Gear Assembly
Bracket
No.1
Bushing
Bushing
Clamp
(A/T Only)
Front Suspension
Crossmember
Center MemberLower Suspension
Arm Bracket
Cushion
Retainer
Lower Suspension Arm
LH Engine Cover
29 (300, 22)
29 (300, 22)
113 (1,150, 83)
8.3 (85, 74 in.·lbf)
112 (1,140, 82)
172 (1,750, 126)
206 (2,100, 152)
127 (1,300, 94)
137 (1,400, 101)
28 (290, 21)

N·m (kgf·cm, ft·lbf)
Non−reusable part: Specified torque
X7
Clamp 137 (1,400, 101)
64 (650, 47)
113 (1,150, 83)5 Door vehicle
− SUSPENSION AND AXLEFRONT STABILIZER BAR
SA−47
1996 RAV4 (RM447U)
FRONT STABILIZER BAR
COMPONENTS

SF0Q4−03
− SFISFI SYSTEM
SF−1
1996 RAV4 (RM447U)
SFI SYSTEM
PRECAUTION
1. BEFORE WORKING ON THE FUEL SYSTEM, DISCON-
NECT THE NEGATIVE (−) TERMINAL CABLE FROM
THE BATTERY
HINT:
Any diagnostic trouble code retained by the computer will be
erased when the negative (−) terminal cable is removed.
Therefore, if necessary, read the diagnosis before removing the
terminal.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME
WHEN WORKING ON THE FUEL SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATH-
ER PARTS
4. MAINTENANCE PRECAUTIONS
(a) In event of engine misfire, these precautions should be
taken.
(1) Check proper connection to battery terminals, etc.
(2) After repair work, check that the ignition coil termi-
nals and all other ignition system lines are recon-
nected securely.
(3) When cleaning the engine compartment, be espe-
cially careful to protect the electrical system from
water.
(b) Precautions when handling oxygen sensor.
(1) Do not allow oxygen sensor to drop or hit against an
object.
(2) Do not allow the sensor to come into contact with
water.
5. IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYS-
TEM (HAM, CB, ETC.)
If the vehicle is equipped with a mobile communication system,
refer to the precaution in the IN section.
6. AIR INDUCTION SYSTEM
(a) Separation of the engine oil dipstick, oil filler cap, PCV
hose, etc. may cause the engine to run out of tune.
(b) Disconnection, looseness or cracks in the parts of the air
induction system between the throttle body and cylinder
head will allow air suction and cause the engine to run out
of tune.
7. ELECTRONIC CONTROL SYSTEM
(a) Before removing SFI wiring connectors, terminals, etc.,
first disconnect the power by either turning the ignition
switch to LOCK or disconnecting the negative (−) terminal
cable from the battery.
HINT:
Always check the diagnostic trouble code before disconnecting
the negative (−) terminal cable from the battery.

FI2553
SST
S01837
Fuel
Pump
Connector
S01832
Plug SF−2
− SFISFI SYSTEM
1996 RAV4 (RM447U)
(b) When installing the battery, be especially careful not to in-
correctly connect the positive (+) and negative (−) cables.
(c) Do not permit parts to receive a severe impact during re-
moval or installation. Handle all SFI parts carefully, espe-
cially the ECM.
(d) Do not be careless during troubleshooting as there are
numerous transistor circuits and even slight terminal con-
tact can cause further troubles.
(e) Do not open the ECM cover.
(f) When inspecting during rainy weather, take care to pre-
vent entry of water. Also, when washing the engine
compartment, prevent water from getting on the SFI parts
and wiring connectors.
(g) Parts should be replaced as an assembly.
(h) Care is required when pulling out and inserting wiring con-
nectors.
(i) Release the lock and pull out the connector, pulling on the
connectors.
(j) Fully insert the connector and check that it is locked.
(k) Use SST for inspection or test of the injector or its wiring
connector.
SST 09842−30070
8. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out, so observe the following
procedures:
(1) Disconnect the fuel pump connector.
(2) Start the engine. After the engine has stopped on
its own, turn the ignition switch to LOCK.
(3) Put a container under the connection.
(4) Slowly loosen the connection.
(5) Disconnect the connection.
(6) Plug the connection with a rubber plug.

S01831
New Gasket
FI1654
Fulcrum Length
30 mm
SST
FI0420
O−Ring
Injector
GrommetDelivery PipeCORRECT
WRONG
P15485
O−Ring
Injector Grommet
O−Ring Insulator
− SFISFI SYSTEM
SF−3
1996 RAV4 (RM447U)
(b) When connecting the flare nut or union bolt on the high
pressure pipe union, observe the following procedures:
(1) Union Bolt Type:
Always use 2 new gaskets.
(2) Union Bolt Type:
Tighten the union bolt by hand.
(3) Union Bolt Type:
Tighten the union bolt to the specified torque.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(4) Flare Nut Type:
Apply a light coat of engine oil to the flare nut, and
tighten the flare nut by hand.
(5) Flare Nut Type:
Using SST, tighten the flare nut to specified torque.
SST 09631−22020
NOTICE:
Do not rotate the fuel pipe, when tightening the flare nut.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
28 N·m (285 kgf·cm, 21 ft·lbf) for SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
(c) Observe the following precautions when removing and
installing the injectors.
(1) Never reuse the O−ring.
(2) When placing a new O−ring on the injector, take
care not to damage it in any way.
(3) Coat a new O−ring with spindle oil or gasoline be-
fore installing−never use engine, gear or brake oil.
(4) Install the injector to the delivery pipe and intake
manifold as shown in the illustration.

S01354
TOYOTA
Hand−Held Tester
S01830
Fuel Inlet Hose SF−4
− SFISFI SYSTEM
1996 RAV4 (RM447U)
(d) Check that there are no fuel leaks after performing main-
tenance anywhere on the fuel system.
(1) Connect the TOYOTA hand−held tester to the
DLC3.
(2) Turn the ignition switch ON and TOYOTA hand−
held tester main switch ON.
NOTICE:
Do not start the engine.
(3) Select the active test mode on the TOYOTA hand−
held tester.
(4) Please refer to the TOYOTA hand−held tester oper-
ator ’s manual for further details.
(5) If you have no TOYOTA hand−held tester, connect
the positive (+) and negative (−) leads from the bat-
tery to the fuel pump connector (See page
SF−5).
(6) Pinch the fuel inlet hose.
The pressure in the high pressure line will rise to
approx. 400 kPa (4 kgf/cm
2, 57 psi). In this state,
check that there are no leaks from any part of the
fuel system.
NOTICE:
Always pinch the hose. Avoid bending as it may cause the
hose to crack.
(7) Turn the ignition switch to LOCK.
(8) Disconnect the TOYOTA hand−held tester from the
DLC3.
(9) Start the engine.
NOTICE:
Keep cranking the engine until the air is removed from the
fuel line.
(10) After the engine starts, check again that there are
no fuel leaks.

S01354
TOYOTA
Hand−Held Tester
SF0Q5−03
S01830
Fuel Inlet Hose
S01827
− SFIFUEL PUMP
SF−5
1996 RAV4 (RM447U)
FUEL PUMP
ON−VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION
(a) Connect the TOYOTA hand−held tester to the DLC3.
(b) Turn the ignition switch ON and TOYOTA hand−held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(c) Select the active test mode on the TOYOTA hand−held
tester.
(d) Please refer to the TOYOTA hand−held tester operator’s
manual for further details.
(e) If you have no TOYOTA hand−held tester, connect the
positive (+) and negative (−) leads from the battery to the
fuel pump connector (See page SF−5).
(f) Check that there is pressure in the fuel inlet hose from the
fuel filter.
HINT:
If there is fuel pressure, you will hear the sound of fuel flowing.
If there is no pressure, check the H−fuse, fuses, EFI main relay,
circuit opening relay, fuel pump, ECM and wiring connections.
(g) Turn the ignition switch to LOCK.
(h) Disconnect the TOYOTA hand−held tester from the
DLC3.
2. CHECK FUEL PRESSURE
(a) Check the battery positive voltage is above 12 V.
(b) Disconnect the negative (−) terminal cable from the bat-
tery.
(c) Remove the air cleaner assembly (See page ST−4).
(d) Remove the 2 bolts, and disconnect the engine comport-
ment R/B No.2 from the bracket on the body.
(e) Remove the union bolt and 2 gaskets, and disconnect the
fuel inlet hose from the fuel filter outlet.
CAUTION:
Put a shop towel under the fuel filter. Slowly loosen the
union bolt.