engine TOYOTA RAV4 1996 Service Service Manual

CO0BM−02
P13611
Protrusion
Jiggle
Valve5° 5° CO−12
− COOLINGTHERMOSTAT
1996 RAV4 (RM447U)
INSTALLATION
1. PLACE THERMOSTAT IN WATER PUMP
(a) Install a new gasket to the thermostat.
(b) Align the jiggle valve of the thermostat with the protrusion
of the water inlet, and insert the thermostat in the water
inlet.
HINT:
The jiggle valve may be set within 5° of either side of the pre-
scribed position.
2. INSTALL WATER INLET AND THERMOSTAT
Install the water inlet and thermostat with the 2 nuts.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
3. INSTALL OIL FILTER (See page LU−2)
4. FILL WITH ENGINE COOLANT
5. START ENGINE AND CHECK FOR LEAKS
6. CHECK ENGINE OIL LEVEL

CO0BO−02
Z00570
Radiator Cap Tester
Radiator Cap30° or More
S01265
Radiator Cap Tester CO−14
− COOLINGRADIATOR
1996 RAV4 (RM447U)
ON−VEHICLE INSPECTION
1. REMOVE 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.
2. INSPECT RADIATOR CAP
NOTICE:
If the radiator cap has contaminations, always rinse
it with water.
When performing steps (a) and (b) below, keep the ra-
diator cap tester at an angle of over 30°above the hor-
izontal.
(a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed:
1 push/(3 seconds or more)
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(b) Pump the tester and measure the relief valve opening
pressure.
Pump speed:
1 push within 1 second
NOTICE:
This pump speed is for the first pump only (in order to close
the vacuum valve). After this, the pump speed can be re-
duced.
Standard opening pressure:
74 − 103 kPa (0.75 − 1.05 kgf/cm
2, 10.7 − 14.9 psi)
Minimum opening pressure:
59 kPa (0.6 kgf/cm
2, 8.5 psi)
HINT:
Use the tester’s maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 118kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and cylinder head.
4. REINSTALL RADIATOR CAP

CO0BP−02
S01819
Lower Radiator
Hose
No.2 Cooling
Fan Connector
(w/ A/C)
Radiator
Assembly Upper Radiator
Support
ECT Switch
ConnectorRadiator
Upper Radiator
SupportNo.1 Cooling FanNo.2 Cooling Fan
(w/ A/C)
Radiator Cap
Upper Radiator Hose
Engine Wire
Radiator Reservoir Hose
A/T Oil Cooler Hose
 O−Ring
No.1 Cooling
Fan Connector Lower Radiator
Support Cooler Condenser
RH Engine
Under Cover
LH Engine
Under CoverLH Engine
Under Cover
 Non−reusable partM/TA/TDrain Plug
− COOLINGRADIATOR
CO−15
1996 RAV4 (RM447U)
COMPONENTS

CO0BQ−03
S01355
S01278
w/ A/C
S01293
CO−16
− COOLINGRADIATOR
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE ENGINE UNDER COVERS
2. DRAIN ENGINE COOLANT
3. w/ A/C:
REMOVE COOLER CONDENSER (See page AC−47)
4. REMOVE RADIATOR ASSEMBLY
(a) Disconnect the No.1 cooling fan connector.
(b) w/ A/C:
Disconnect the No.2 cooling fan connector.
(c) Disconnect the ECT switch connector for electric cooling
fan.
(d) Disconnect the engine wire clamp from No.1 cooling fan
shroud.
(e) Disconnect the upper radiator hose from radiator.
(f) Disconnect the lower radiator hose from radiator.
(g) Disconnect the radiator reservoir hose from radiator.
(h) Disconnect the 2 A/T oil cooler hoses from oil cooler
pipes.
(i) Remove the 2 bolts and 2 upper radiator supports.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(j) Remove the radiator assembly.
HINT:
At the time of installation, plaese refer to the following items. Af-
ter installation, check that the rubber cushion (A) of the support
is not depressed.
(k) Remove the 2 lower radiator supports.
5. w/ A/C:
REMOVE NO.2 COOLING FAN FROM RADIATOR
Remove the 3 bolts and cooling fan.
Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf)
6. REMOVE NO.1 COOLING FAN FROM RADIATOR
Remove the 4 bolts and cooling fan.
Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf)

S01294
CO0BS−03
S01279
Disconnect
S01277
93°C
S01290
Ammeter
Battery
S01291
Ammeter
Battery CO−18
− COOLINGELECTRIC COOLING FAN
1996 RAV4 (RM447U)
ELECTRIC COOLING FAN
ON−VEHICLE INSPECTION
1. CHECK COOLING FAN OPERATION WITH LOW TEM-
PERATURE (Below 83°C (181°F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and ECT switch, and check
for a separated connector or severed wire between the cooling
fan relay and ECT switch.
(c) Disconnect the ECT switch connector.
(d) Check that the cooling fan rotates.
If not, check the fan main relay, cooling fan relay, cooling fan,
fuses, and check for short circuit between the cooling fan relay
and ECT switch.
(e) Reconnect the ECT switch connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEM-
PERATURE (Above 93°C (199°F))
(a) Start the engine, and raise coolant temperature to above
93°C (199°F).
(b) Check that the cooling fan rotates.
If not, replace the ECT switch.
3. INSPECT NO.1 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connec-
tor.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage: 10.9 − 13.9 A
(d) Reconnect the cooling fan connector.
4. INSPECT NO.2 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connec-
tor.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage: 9.1 − 11.1 A
(d) Reconnect the cooling fan connector.

CO0BT−02
S01818
Radiator
No.1 Cooling Fan Lower Radiator Hose
No.2 Cooling
Fan Connector
(w/ A/C)
Upper Radiator
Support
Radiator Cap
Upper Radiator Hose
Engine Wire
Radiator Reservoir Hose
A/T Oil Cooler Hose
Drain Plug
 O−Ring
LH Engine
Under Cover ECT Switch
Connector
Radiator
Assembly
Cooler Condenser
Lower Radiator
Support
No.1 Cooling
Fan Connector
RH Engine
Under Cover
 Non−reusable PartA/T
M/TUpper Radiator
Support
LH Engine
Under Cover NO.1 COOLING FAN
− COOLINGELECTRIC COOLING FAN
CO−19
1996 RAV4 (RM447U)
COMPONENTS

S01820
Upper Radiator Support
No.2 Cooling Fan Connector
No.2 Cooling Fan
Cooler Condenser
RH Engine
Under Cover NO.2 COOLING FAN
x 6 CO−20
− COOLINGELECTRIC COOLING FAN
1996 RAV4 (RM447U)

CO18L−01
S01356
(A)
S01433
− COOLINGELECTRIC COOLING FAN
CO−21
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE NO.1 COOLING FAN (See page CO−16)
2. REMOVE NO.2 COOLING FAN
(a) Remove the RH engine under cover.
(b) w/ A/C:
Remove the cooler condenser (See page AC−47).
(c) Remove the upper radiator supports.
Torque:13 N·m (130kgf·cm, 9 ft·lbf)
HINT:
At the time of installation, plaese refer to the following items. Af-
ter installation, check that the rubber cushion (A) of the support
is not depressed.
(d) Remove the No.2 cooling fan.
(1) Disconnect the cooling fan connector.
(2) Push the radiator toward the front bumper.
(3) Remove the 3 bolts.
(4) Push the No.2 cooling fan toward radiator and pull
it upward.

S01280ECT Switch
CO0BY−01
P05962
Ohmmeter
− COOLINGENGINE COOLANT TEMPERATURE (ECT) SWITCH
CO−25
1996 RAV4 (RM447U)
ENGINE COOLANT
TEMPERATURE (ECT) SWITCH
INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE ECT SWITCH
3. INSPECT ECT SWITCH
(a) Using an ohmmeter, check that there is no continuity be-
tween the terminals when the coolant temperature is
above 93°C (199°F).
(b) Using an ohmmeter, check that there is continuity be-
tween the terminals when the coolant temperature is be-
low 83°C (181°F).
If continuity is not as specified, replace the switch.
4. REINSTALL ECT SWITCH
5. REFILL WITH ENGINE COOLANT
6. START ENGINE AND CHECK FOR COOLANT LEAKS

DI3Z5−01
Vehicle Brought to Workshop
Customer Problem Analysis P. DI−2
Problem Symptom Confirmation
If the engine does not start perform steps 10 and 12 firstConnect the OBD II scan tool or TOYOTA hand−held tester to DLC3 P. DI−3
If the display indicates a communication fault in the tool, inspect DLC3 P. DI−3
Check DTC and Freeze Frame Data (Pre−check)
Record or Print DTC and Freeze Frame Data P. DI−3
Clear DTC and Freeze Frame Data P. DI−3
Visual Inspection
Setting the Check Mode Diagnosis P. DI−3
Symptom Simulation P.IN−20
Basic Inspection P. DI−3DTC Chart P. DI−14
Matrix Chart of Problems Symptoms P. DI−20
Circuit Inspection P. DI−21
Adjustment, Repair
DTC Check P. DI−3
Titles insideare titles of pages in
in the bottom portion. See the indicated
pages for detailes explanations.this manual, with the page number indicated
Malfunction
occurs.Malfunction does not occur.
Parts Inspection
Check for Intermittent Problems P. DI−3
Identification of Problem
Confirmation Test
End 1
2
3
4
5
6
7
108
9
11
12
13
15 14
16
Normal Malfunction code.
17
− DIAGNOSTICSENGINE
DI−1
1996 RAV4 (RM447U)
ENGINE
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshoot in accordance with the procedure on the following pages.