cable TOYOTA RAV4 1996 Service Manual Online

SA0U5−02
F03767
ABS Speed
SensorRear Drive Shaft Rear Differential
Rear Brake Hub Bolt
Brake DrumCotter pin Lock Cap Parking Brake Cable
Bearing
Axle Hub
Pin
56 (570, 41)
15 (155, 11)
80, (820, 59)
206 (2,100, 152)

7.8 (80, 69 in.·lbf)
Backing Plate
N·m (kgf·cm, ft·lbf)
: Specified torque
Non−reusable part

8 (80, 69 in.·lbf)
Brake Line
− SUSPENSION AND AXLEREAR AXLE HUB (4WD)
SA−55
1996 RAV4 (RM447U)
REAR AXLE HUB (4WD)
COMPONENTS

SA0U6−02
R10700
SST
R10750
SA−56
− SUSPENSION AND AXLEREAR AXLE HUB (4WD)
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE REAR WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. REMOVE BRAKE DRUM
3. CHECK BEARING BACKLASH AND AXLE HUB DEVI-
ATION (See page SA−52)
4. REMOVE BOLT AND ABS SPEED SENSOR
Torque: 8 N·m (80 kgf·cm, 69 in.·lbf)
5. REMOVE REAR DRIVE SHAFT (See page SA−62)
6. DISASSEMBLE REAR BRAKE (See page BR−30)
7. DISCONNECT BRAKE LINE
Using SST, disconnect the brake line from the wheel cylinder.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
8. REMOVE REAR AXLE HUB WITH BACKING PLATE
(a) Remove the 2 bolts and disconnect the parking brake
cable.
Torque: 8 N·m (80 kgf·cm, 69 in.·lbf)
(b) Remove the 4 bolts and rear axle hub.
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)

SA0UO−04
W04028
Retainer Suspension Cap
Retainer Retainer Cushion
Rear
Shock
Absorber
Bushing
Brake Drum
25 (250, 18)
Cushion Retainer
Retainer
7.8 (80, 69 in.·lbf)
13 (130, 9)
18 (185, 13)
19 (195, 14)
19 (195, 14)
4WD
Lock cap
Cotter Pin
216 (2,200, 59)
80 (820, 59)

 Parking Brake Cable
113 (1,150, 83)
113 (1,150, 83)Upper Suspension Arm
113 (1,150, 83)Camber
Adjust
Cam
Lower Suspension Arm103 (1,050, 76)
Clip 
103 (1,050, 76)
132 (1,350, 98)
To e−adjust Cam
Attachment
Bushing
Rear No.1 Suspension Arm
Attachment Spring Bumper
Upper Insulator
Coil Spring
Shock Absorber
Lower Pivot pin
13 (130, 9)
140 (1,430, 103)
N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part

56 (570, 41)
37 (380, 27)
Rear Drive Shaft4WD: Rear Differential
13 (130, 9)
2WD
Rear Axle Shaft SA−90
− SUSPENSION AND AXLEREAR SHOCK ABSORBER
1996 RAV4 (RM447U)
REAR SHOCK ABSORBER
COMPONENTS

SA0UT−03
W04028
Retainer Suspension Cap
Retainer Retainer Cushion
Rear
Shock
Absorber
Bushing
Brake Drum
25 (250, 18)
Cushion Retainer
Retainer
7.8 (80, 69 in.·lbf)
13 (130, 9)
18 (185, 13)
19 (195, 14)
19 (195, 14)
4WD
Lock cap
Cotter Pin
216 (2,200, 59)
80 (820, 59)

 Parking Brake Cable
113 (1,150, 83)
113 (1,150, 83)Upper Suspension Arm
113 (1,150, 83)Camber
Adjust
Cam
Lower Suspension Arm103 (1,050, 76)
Clip 
103 (1,050, 76)
132 (1,350, 98)
To e−adjust Cam
Attachment
Bushing
Rear No.1 Suspension Arm
Attachment Spring Bumper
Upper Insulator
Coil Spring
Shock Absorber
Lower Pivot pin
13 (130, 9)
140 (1,430, 103)
N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part

56 (570, 41)
37 (380, 27)
Rear Drive Shaft4WD: Rear Differential
13 (130, 9)
2WD
Rear Axle Shaft
− SUSPENSION AND AXLEREAR SUSPENSION ARM AND COIL SPRING
SA−95
1996 RAV4 (RM447U)
REAR SUSPENSION ARM AND COIL SPRING
COMPONENTS

SA0UU−03
R10779
R10764
SST
R10765
SST SA−96
− SUSPENSION AND AXLEREAR SUSPENSION ARM AND COIL SPRING
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE REAR WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. 2WD:
REMOVE AXLE SHAFT (See page SA−52)
3. 4WD:
REMOVE REAR DRIVE SHAFT (See page SA−62)
4. REMOVE BRAKE DRUM
5. REMOVE 2 BRAKE LINE CLAMP BOLTS
Torque:
Bracket: 18 N·m (185 kgf·cm, 13 ft·lbf)
Clamp: 13 N·m (130 kgf·cm, 9 ft·lbf)
6. REMOVE PARKING BRAKE CABLE CLAMP BOLT
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
7. w/ ABS:
REMOVE ABS SPEED SENSOR AND WIRE HARNESS
Torque:
ABS speed sensor: 8 N·m (80 kgf·cm, 69 in.·lbf)
Wire harness: 13 N·m (130 kgf·cm, 9 ft·lbf)
8. REMOVE REAR AXLE HUB WITH BRAKE
(a) Remove the 4 bolts and rear axle hub with brake.
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)
(b) Support it securely.
9. DISCONNECT LOWER SIDE OF SHOCK ABSORBER
(See page SA−91)
10. REMOVE UPPER AND LOWER SUSPENSION ARMS
(a) Remove the 2 clips and 2 nuts.
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
(b) Using SST, disconnect the upper suspension arm.
SST 09628−62011
(c) Using SST, disconnect the lower suspension arm.
SST 09628−62011

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.

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.

S01834
Gasket
SST (Union)
SST
Fuel Inlet Hose Gasket
SST (Union)
S01835
301 − 347 kPa
S01836
For 5 Minutes After Engine has Stopped
147 kPa
or More SF−6
− SFIFUEL PUMP
1996 RAV4 (RM447U)
(f) Install the fuel inlet hose and SST (pressure gauge) to the
fuel filter outlet with the 3 gaskets and SST (union bolt).
SST 09268−45012
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(g) Wipe off any splattered gasoline.
(h) Connect the TOYOTA hand−held tester to the DLC3.
(i) Reconnect the negative (−) terminal cable to the battery.
(j) Turn the ignition switch ON.
(k) Measure the fuel pressure.
Fuel pressure:
301 − 347 kPa (3.1 − 3.5 kgf/cm
2, 44 − 50 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check these parts:
Fuel hoses and connections
Fuel pump
Fuel filter
Fuel pressure regulator
(l) Remove the TOYOTA hand−held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle.
Fuel pressure:
301 − 347 kPa (3.1 − 3.5 kgf/cm
2, 44 − 50 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5
minutes after the engine has stopped.
Fuel pressure:
147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, pressure
regulator and/or injectors.
(q) After checking fuel pressure, disconnect the negative (−)
terminal cable from the battery and carefully remove the
SST to prevent gasoline from splashing.
SST 09268−45012
(r) Reconnect the fuel inlet hose with 2 new gaskets and the
union bolt.
Torque: 29 N·m (300 kgf·cm, 21 ft·lbf)
(s) Reconnect the negative (−) terminal cable to the battery.
(t) Check for fuel leakage (See page SF−1).
(u) Reinstall the engine comportment R/B No.2 and air clean-
er assembly.
3. CHECK FUEL PUMP
(a) Remove the LH rear seat assembly.
(b) Remove the floor service hole cover.

P25497
SST
(Wire)
Connect
P10811
SF−22
− SFIINJECTOR
1996 RAV4 (RM447U)
(j) Connect SST (wire) to the injector and battery for 15 se-
conds, and measure the injection volume with a gra-
duated cylinder. Test each injector 2 or 3 times.
SST 09842−30070
Volume:
54 − 69 cm
3 (3.1 − 4.2 cu in.) per 15 sec.
Difference between each injector:
5 cm
3 (0.8 cu in.) or less
If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE
(a) In the condition above, disconnect the test probes of SST
(wire) from the battery and check the fuel leakage from
the injector.
SST 09842−30070
Fuel drop:
One drop or less per minute
(b) Turn the ignition switch to LOCK.
(c) Disconnect the negative (−) terminal cable from the bat-
tery.
(d) Remove the SST.
SST 09268−41046, 09842−30070
(e) Disconnect the TOYOTA hand−held tester from the
DLC3.