TOYOTA RAV4 1996 Service Repair Manual

IG0J8−01
P23836
B11572
IG−12
− IGNITIONDISTRIBUTOR
1996 RAV4 (RM447U)
REASSEMBLY
1. INSTALL ROTOR
(a) Align the hollow of the signal rotor with the protrusion of
the rotor.
(b) Install the rotor with the 2 screws.
2. INSTALL DISTRIBUTOR CAP
(a) Install a new packing to the distributor housing.
(b) Install the distributor cap with the 2 bolts.

IG0J9−01
B11573
B11574
− IGNITIONDISTRIBUTOR
IG−13
1996 RAV4 (RM447U)
INSTALLATION
1. SET NO. 1 CYLINDER TO DTC/COMPRESSION
Turn the crankshaft clockwise, and position the slit of the intake
camshaft as shown in the illustration.
2. INSTALL DISTRIBUTOR
(a) Install a new O−ring to the housing.
(b) Apply a light coat of engine oil on the O−ring.
(c) Align the cutout of the coupling with the line of the hous-
ing.
(d) Insert the distributor, aligning the center of the flange with
that of bolt hole on the cylinder head.
(e) Tighten the hold−down bolt.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
3. CONNECT HIGH−TENSION CORDS TO SPARK
PLUGS
Firing order:
1 − 3 − 4 − 2
4. CONNECT HIGH−TENSION CORD TO IGNITION COIL
5. CONNECT DISTRIBUTOR CONNECTOR
6. INSTALL AIR CLEANER CAP ASSEMBLY

IG06J−03
IG−14
− IGNITIONCRANKSHAFT POSITION SENSOR
1996 RAV4 (RM447U)
CRANKSHAFT POSITION SENSOR
COMPONENTS

IG06K−02
B11571
− IGNITIONCRANKSHAFT POSITION SENSOR
IG−15
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT CRANKSHAFT POSITION SENSOR
CONNECTOR FROM GENERATOR DRIVE BELT AD-
JUSTING BAR
2. REMOVE NO.1 TIMING BELT COVER
(See page EM−15)
3. REMOVE CRANKSHAFT POSITION SENSOR
Remove the bolt and disconnect the crankshaft position sensor.

IG06M−02
IG−16
− IGNITIONCRANKSHAFT POSITION SENSOR
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
Install the crankshaft position sensor with the bolt.
Torque: 9.5 N·m (97 kgf·cm, 84 in.·lbf)
2. INSTALL NO.1 TIMING BELT COVER (See page EM−20)
3. CONNECT CRANKSHAFT POSITION SENSOR CONNECTOR TO GENERATOR DRIVE BELT AD-
JUSTING BAR

LU060−04
S01260
Oil Pressure Gauge
P13638
Adhesive
− LUBRICATIONOIL AND FILTER
LU−1
1996 RAV4 (RM447U)
OIL AND FILTER
INSPECTION
1. CHECK ENGINE OIL QUALITY
Check the oil for deterioration, entry of water, discoloring or thin-
ning.
If the quality is visibly poor, replace the oil.
Oil grade:
API grade SH, Energy − Conserving II multigrade en-
gine oil or ILSAC multigrade engine oil.
Recommended viscosity is as shown in the illustra-
tion.
2. CHECK ENGINE OIL LEVEL
The oil level should be between the ”L” and ”F” marks on the dip-
stick.
If low, check for leakage and add oil up to ”F” mark.
3. REMOVE OIL PRESSURE SWITCH, AND INSTALL OIL
PRESSURE GAUGE
4. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
5. CHECK OIL PRESSURE
Oil pressure:
At idle
29 kPa (0.3 kgf/cm
2, 4.3 psi) or more
At 3,000 rpm
245 − 490 kPa
(2.5 − 5.0 kgf/cm
2, 36 − 71 psi)
6. REMOVE OIL PRESSURE GAUGE AND REINSTALL
OIL PRESSURE SWITCH
(a) Remove the oil pressure gauge.
(b) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Reinstall the oil pressure switch.
7. START ENGINE AND CHECK FOR LEAKS

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.

S01263
SST
3/4
Turn
− LUBRICATIONOIL AND FILTER
LU−3
1996 RAV4 (RM447U)
(e) Using SST, give it an additional 3/4 turn to seat the filter.
SST 09228−06501
3. FILL WITH ENGINE OIL
(a) Clean and install the oil drain plug with a new gasket.
Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
(b) Fill with new engine oil.
Capacity:
Drain and refill
w/ Oil filter change
3.9 liters (4.1 US qts, 3.4 lmp. qts)
w/o Oil filter change
3.7 liters (3.9 US qts, 3.3 lmp. qts)
Dry fill
4.4 liters (4.7 US qts, 3.9 lmp. qts)
(c) Reinstall the oil filler cap.
4. START ENGINE AND CHECK FOR OIL LEAKS
5. RECHECK ENGINE OIL LEVEL

LU062−03
LU−4
− LUBRICATIONOIL PUMP
1996 RAV4 (RM447U)
OIL PUMP
COMPONENTS

− LUBRICATIONOIL PUMP
LU−5
1996 RAV4 (RM447U)