belt TOYOTA RAV4 1996 Service Repair Manual

BO483−01
BO0020
N11412
N11473
N17924
BO−10
− BODYFRONT DOOR
1996 RAV4 (RM447U)
DISASSEMBLY
HINT:
Tape the screwdriver tip before using to pry parts.
1. w/o Power Window:
REMOVE REGULATOR HANDLE
Pull off the snap ring with a shop rag and remove the regulator
handle and plate.
2. REMOVE INSIDE HANDLE BEZEL
(a) Remove the screw.
(b) Using a screwdriver, pry out the bezel.
3. REMOVE OUTSIDE REAR VIEW MIRROR COVER
4. REMOVE DOOR PULL HANDLE
5. w/ Power window:
REMOVE POWER WINDOW SWITCH
6. REMOVE DOOR TRIM
(a) Remove the 3 screws.
(b) Insert a screwdriver between the door and door trim to pry
out the door trim.
(c) Pull the trim upwards to remove it.
7. REMOVE DOOR INSIDE HANDLE
(a) Disconnect the link and door lock cable.
(b) Remove the 2 screws and inside handle.
8. REMOVE SERVICE HOLE COVER
HINT:
At the time of reassembly, bring out the links through the service
hole cover.
9. REMOVE OUTSIDE REAR VIEW MIRROR
10. REMOVE DOOR GLASS RUN
11. REMOVE DOOR BELT MOULDING
12. REMOVE DOOR SPEAKER

H03784: 5 Clips
H03785
N14554
− BODYREAR DOOR
BO−17
1996 RAV4 (RM447U)
8. REMOVE DOOR BELT MOULDING
9. REMOVE DOOR GLASS RUN
10. REMOVE DIVISION BAR
11. REMOVE REAR DOOR QUARTER WINDOW WEATH-
ERSTRIP
12. REMOVE REAR DOOR QUARTER WINDOW GLASS
13. REMOVE DOOR GLASS AND WINDOW REGULATOR
ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 3 bolts and nut from the window regulator.
(c) w/o Power Window:
Remove the 3 bolts from the window regulator.
(d) Remove the 2 nuts and glass channel from the window
regulator lift arm bracket, then remove the door glass.
(e) Remove the window regulator through the service hole.
HINT:
At the time of reassembly, apply MP grease to the window regu-
lator rollers.
14. REMOVE DOOR LOCK ASSEMBLY
(a) w/ Power door Lock:
Disconnect the connector.
(b) Disconnect the 2 links from the outside handle.
(c) Remove the 3 screws and door lock assembly.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
HINT:
At the time of reassembly, refer to following procedure.
Apply adhesive to the 3 screws.

BO48D−01
H02975: 4 Clips
H02976
: 9 Clips BO−46
− BODYQUARTER WINDOW GLASS (3−Door)
1996 RAV4 (RM447U)
REMOVAL
HINT:
Tape the screwdriver tip before using to pry parts.
1. REMOVE REAR SEAT
2. REMOVE FRONT DOOR SCUFF PLATE
3. REMOVE REAR FLOOR FINISH PLATE
4. REMOVE FRONT SEAT OUTER BELT SHOULDER AN-
CHOR BOLT
5. REMOVE QUARTER TRIM
(a) Remove the rear seat outer belt floor anchor bolt.
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
(b) Remove the 4 screws.
(c) Using a screwdriver, remove the quarter trim.
6. REMOVE ROOF SIDE INNER GARNISH
(a) Remove the rear seat belt shoulder anchor bolt.
(b) Remove the 3 clips and roof side inner garnish.
7. REMOVE FRONT PILLAR GARNISH
Using a screwdriver, remove the front pillar garnish.
8. REMOVE QUARTER WINDOW GLASS
Remove the 2 nuts and quarter window glass.
9. REMOVE QUARTER WINDOW LOCK
Remove the bolt, 2 screws and quarter window glass.
10. REMOVE HINGE

N14553
BO48G−01
H02978
4 Clips
H02979
: Clip
H02980
: 4 Clips
H02981
− BODYQUARTER WINDOW GLASS (5−Door)
BO−49
1996 RAV4 (RM447U)
REMOVAL
HINT:
Tape the screwdriver tip before using to pry parts.
1. REMOVE REAR DOOR SCUFF PLATE
2. REMOVE REAR FLOOR FINISH PLATE
3. REMOVE REAR SIDE TRIM
(a) Remove the rear seat outer belt floor anchor bolt.
(b) Using a screwdriver, pull the garnish upwards to remove
it.
4. REMOVE DECK SIDE TRIM
(a) Remove the side trim tool bag cover.
(b) Remove the 8 screws.
(c) Using a screwdriver, remove the deck side trim.
5. REMOVE ROOF SIDE INNER GARNISH
(a) Remove the rear seat outer belt shoulder anchor bolt.
(b) Remove the screw and 3 clips.
(c) Using a screwdriver, remove the roof side inner garnish.
6. REMOVE QUARTER WINDOW GLASS
Remove the 3 clips and glass.

BO3D7−01
N11414
− BODYREMOVABLE ROOF
BO−59
1996 RAV4 (RM447U)
REMOVAL
HINT:
Tape a screwdriver tip before using to pry parts.
1. REMOVE REAR SEAT
2. REMOVE FRONT DOOR SCUFF PLATE
3. REMOVE REAR FLOOR FINISH PLATE
4. REMOVE FRONT SEAT BELT SHOULDER ANCHOR
BOLT
5. REMOVE QUARTER TRIM LH AND RH
(a) Quarter trim LH and RH.
(b) Rear seat belt shoulder anchor bolt.
6. REMOVE ROOF SIDE INNER GARNISH
(a) Roof side inner garnish.
(b) Front pillar garnish.
7. REMOVE FRONT AND REAR REMOVABLE ROOF
(a) Disconnect the lock handle from the lock base.
(b) Pull the removable roof rearward to remove it.
8. REMOVE LOCK HANDLE
Remove the 2 screws and lock handle from the removable roof.
9. REMOVE AUXILIARY CATCH

CO0BF−03
S06209
No.3 ABS Actuator Bracket
Engine Wire
Generator
Generator
Drive Belt
PS Pump
Drive BeltGround Strap
Connector
Generator
BracketPS Reservoir Bracket
PS Reservoir
RH Engine Mounting Insulator
RH Engine Mounting Bracket
RH Engine
Under Cover
N·m (kgf·cm, ft·lbf): Specified Torque
37 (380, 27)
52 (530, 38)
52 (530, 38)
52 (530, 38)
52 (530, 38)
52 (530, 38)52 (530, 38)
− COOLINGWATER PUMP
CO−3
1996 RAV4 (RM447U)
WATER PUMP
COMPONENTS

CO0BG−02
S01613
P15462
P15546
1
3
2
P15463
Disconnect
− COOLINGWATER PUMP
CO−5
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE TIMING BELT (See page EM−15)
4. DISCONNECT LOWER RADIATOR HOSE FROM
WATER INLET
5. REMOVE TIMING BELT TENSION SPRING AND NO.2
IDLER PULLEY
6. REMOVE GENERATOR DRIVE BELT ADJUSTING
BAR
(a) Disconnect the crankshaft position sensor connector
clamp.
(b) Remove the bolt and adjusting bar.
7. REMOVE WATER PUMP AND WATER PUMP COVER
ASSEMBLY
(a) Remove the 2 nuts holding the water pump to the water
bypass pipe.
(b) Remove the 3 bolts in the sequence shown.
(c) Disconnect the water pump cover from the water bypass
pipe, and remove the water pump and water pump cover
assembly.
(d) Remove the gasket and 2 O−ring from the water pump
and water bypass pipe.

CO0BH−02
CO0877
− COOLINGWATER PUMP
CO−7
1996 RAV4 (RM447U)
INSPECTION
INSPECT WATER PUMP
(a) Visually check the drain hole for coolant leakage.
If leakage is found, replace the water pump.
If engine coolant has leaked onto the timing belt, replace the
timing belt.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and quietly.
If necessary, replace the water pump.

CO0BI−03
P13480
New O−Ring
New Gasket
P15547
New O−Ring
P15464
Connect
Z16489
3
1
2 CO−8
− COOLINGWATER PUMP
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL WATER PUMP TO WATER PUMP COVER
Install a new gasket and the water pump with the 3 bolts.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
2. INSTALL WATER PUMP AND WATER PUMP COVER
ASSEMBLY
(a) Install new O−ring and gasket to water pump cover.
(b) Install a new O−ring to the water bypass pipe.
(c) Apply soapy water to the O−ring on the water bypass
pipe.
(d) Connect the water pump cover to the water bypass pipe.
Do not install the nuts yet.
(e) Install the water pump with the 3 bolts. Tighten the bolts
in the sequence shown.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(f) Install the 2 nuts holding the water pump cover to the wa-
ter bypass pipe.
Torque: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
3. INSTALL GENERATOR DRIVE BELT ADJUSTING BAR
(a) Install the adjusting bar with the bolt.
Torque: 27 N·m (275 kgf·cm, 20 ft·lbf)
(b) Connect the crankshaft position sensor connector clamp.
4. INSTALL NO.2 IDLER PULLEY AND TIMING BELT
TENSION SPRING
5. CONNECT LOWER RADIATOR HOSE
6. INSTALL TIMING BELT (See page EM−20)
7. FILL WITH ENGINE COOLANT
8. START ENGINE AND CHECK FOR COOLANT LEAKS
9. INSTALL RH ENGINE UNDER COVER

EM0EI−02
S01653
21
S01367
− ENGINE MECHANICALVALVE CLEARANCE
EM−5
1996 RAV4 (RM447U)
VALVE CLEARANCE
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. DISCONNECT PS RESERVOIR
2. REMOVE CYLINDER HEAD COVER
(a) Disconnect the accelerator cable from the throttle body.
(b) Disconnect the accelerator cable from the clamp on the
intake manifold.
(c) Disconnect the accelerator cable from the clamp on the
generator bracket.
(d) Disconnect the A/T throttle control cable from the throttle
body.
(e) Disconnect the PCV hose from the air cleaner hose.
(f) Disconnect the PCV hose from the intake manifold.
(g) Disconnect the high−tension cords from the spark plugs.
(h) Remove the 2 bolts, and disconnect the accelerator cable
bracket from the intake manifold.
(i) Disconnect the engine wire protector from the 2 mounting
bolts of the No. 2 timing belt cover in the sequence shown.
(j) Remove the 4 nuts, grommets, cylinder head cover and
gasket.
HINT:
Arrange the grommets in the correct order, so that they can be
reinstalled into their original positions. This minimizes any pos-
sibility of oil leakage due to reuse of the grommets in different
positions.