check engine light TOYOTA RAV4 1996 Service Service Manual

LU061−02
S01264
SST
LU0555
S01266
LU−2
− LUBRICATIONOIL AND FILTER
1996 RAV4 (RM447U)
REPLACEMENT
CAUTION:
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In addi-
tion, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Care should be taken, therefore, when changing en-
gine oil to minimize the frequency and length of time
your skin is exposed to used engine oil. Protective
clothing and gloves that cannot be penetrated by oil
should be worn. The skin should be thoroughly
washed with soap and water, or use water−less hand
cleaner, to remove any used engine oil. Do not use
gasoline, thinners, or solvents.
In order to preserve the environment, used oil and
used oil filters must be disposed of only at desig-
nated disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug, and drain the oil into a contain-
er.
2. REPLACE OIL FILTER
(a) Using SST, remove the oil filter.
SST 09228−06501
(b) Check and clean the oil filter installation surface.
(c) Lubricate the filter rubber gasket with clean engine oil.
(d) Lightly tighten the oil filter by hand until the rubber gasket
contacts the seat of the filter mounting.

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

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)

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.

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.

R06184
SR0FI−02
R09732
− STEERINGSTEERING WHEEL
SR−9
1996 RAV4 (RM447U)
STEERING WHEEL
INSPECTION
1. CHECK STEERING WHEEL FREEPLAY
With the vehicle stopped and tires facing straight ahead, rock
the steering wheel gently back and forth with light finger pres-
sure.
Freeplay should not exceed the maximum.
Maximum freeplay: 30 mm (1.18 in.)
2. CHECK STEERING EFFORT
(a) Center the steering wheel.
(b) Remove the steering wheel pad (See page SR−12).
(c) Start the engine and run it at idle.
(d) Measure the steering effort in both directions.
Reference: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
HINT:
Be sure to consider the tire type, pressure and contact surface
before making your diagnosis.
(e) Torque the steering wheel set nut.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
(f) Install the steering wheel pad (See page SR−19).