check engine TOYOTA RAV4 1996 Service Repair Manual

Q06117
AX055−02
AT5641
Q057310.8−1.5 mm (0.031−0.059 in.) 200 mm (7.87 in.)
− AUTOMATIC TRANSAXLE (A241E)THROTTLE CABLE
AX−9
1996 RAV4 (RM447U)
THROTTLE CABLE
ON−VEHICLE REPAIR
1. DISCONNECT THROTTLE CABLE FROM ENGINE
2. REMOVE NO.2 ENGINE UNDER COVER
3. REMOVE PARK/NEUTRAL POSITION SWITCH (See
page AX−4)
4. REMOVE VALVE BODY (See page AX−5)
5. REMOVE THROTTLE CABLE
(a) Remove the retaining bolt and plate.
(b) Pull out the cable from the transaxle case.
6. INSTALL THROTTLE CABLE
If throttle cable is new, do the following operations (a) − (c).
(a) Bend the cable so there is a radius of about 200 mm (7.87
in.).
(b) Pull theinner cable lightly until a slight resistance is felt,
and hold it.
(c) Stake the stopper 0.8 − 1.5 mm (0.031 − 0.059 in.) from
the end of outer cable.
(d) Be sure to push it in all the way.
(e) Install the bolt.
7. INSTALL VALVE BODY (See page AX−5)
8. INSTALL PARK/NEUTRAL POSITION SWITCH (See
page AX−4)
9. INSTALL NO.2 ENGINE UNDER COVER
10. CONNECT THROTTLE CABLE
11. ADJUST THROTTLE CABLE (See page DI−127)
12. FILL ATF AND CHECK ATF (See page DI−127)

AX056−03
Z02840
SST
Z02841
SST LH Side
Z02842
SST
AX−10
− AUTOMATIC TRANSAXLE (A241E)DIFFERENTIAL OIL SEAL
1996 RAV4 (RM447U)
DIFFERENTIAL OIL SEAL
ON−VEHICLE REPAIR
1. DRAIN ATF
2. REMOVE ENGINE UNDER COVER
3. REMOVE LH AND RH DRIVE SHAFTS
(See page SA−20)
4. REMOVE LH AND RH SIDE OIL SEALS
Using SST, drive out the both side oil seals.
SST 09308−00010
5. INSTALL LH AND RH SIDE OIL SEALS
(a) Using SST and a hammer, drive in a new oil seal until its
surface is flush until the case surface.
SST LH side
09350−32014 (09351−32111, 09351−32130)
RH side
09350−32014 (09351−32130, 09351−32150)
Oil seal drive in depth:
LH side: 5.2 ± 0.5 mm (0.205 ± 0.020 in.)
RH side: 0 ± 0.5 mm (0 ± 0.020 in.)
(b) Coat the oil seal lip with MP grease.
6. INSTALL LH AND RH DRIVE SHAFTS
(See page SA−31)
7. FILL ATF AND CHECK ATF LEVEL (See page DI−127)
8. INSTALL ENGINE UNDER COVER

Z13390A B
Z13391
A
BA
B
Q06019
Q06064
AX−12
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
(d) Place the detent springs on the manual valve body and
hand−tighten the 2 bolts first.
Then, tighten them with a torque wrench.
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
Bolt A: 14 mm (0.55 in.)
Bolt B: 37 mm (1.46 in.)
(e) Check that the manual valve lever is touching the center
of the detent spring tip roller.
18. INSTALL PIPE BRACKET AND OIL STRAINER
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
Bolt A: 22 mm (0.87 in.)
Bolt B: 53 mm (2.09 in.)
19. INSTALL MAGNETS IN PLACE
NOTICE:
Make sure that the magnets do not interfere with the oil
pipes.
20. INSTALL OIL PAN WITH NEW GASKET
(a) Install a new gasket and oil pan.
(b) Install and tighten 17 bolts.
Torque: 7.9 N·m (80 kgf·cm, 70 in.·lbf)
21. FILL ATF AND CHECK FLUID LEVEL
(a) Using a 10 mm hexagon wrench, install a new gasket and
the drain plug.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
(b) Fill the ATF and check the fluid level (See page DI−173).
22. INSTALL NO.2 ENGINE UNDER COVER

R10851
Pedal Height Push RodStop Light
Switch
BR1DV−01
BR4980
R00935
Pedal Freeplay BR−6
− BRAKEBRAKE PEDAL
1996 RAV4 (RM447U)
BRAKE PEDAL
ON−VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
157.1 − 167.1 mm (6.185 − 6.579 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop
light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(f) Install the stop light switch and turn it until it lightly con-
tacts with the pedal stopper.
(g) Turn the stop light switch back one turn.
(h) Check the clearance (A) between stop light switch and
pedal.
Clearance: 0.5 − 2.4 mm (0.020 − 0.094 in.)
(i) Tighten the stop light switch lock nut.
(j) Connect the connector to the stop light switch.
(k) Check that the stop lights come on when the brake pedal
is depressed, and go off when the brake pedal is re-
leased.
(l) After adjusting the pedal height, check the pedal freeplay.
HINT:
If clearance (A) between the stop light switch and the brake
pedal stopper has been adjusted correctly, the pedal freeplay
will meet the specifications.
3. CHECK PEDAL FREEPLAY
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the resistance begins to
be felt, then measure the distance, as shown.
Pedal freeplay: 1 − 6 mm (0.04 − 0.24 in.)

R00934
Pedal Reverse
Distance
− BRAKEBRAKE PEDAL
BR−7
1996 RAV4 (RM447U)
HINT:
The freeplay to the 1st point of resistance is due to the play be-
tween the clevis and pin. It is 1 − 3 mm (0.04 − 0.12 in.) on the
pedal.
If incorrect, check the stop light switch clearance. If the clear-
ance is OK, then troubleshoot the brake system.
4. CHECK PEDAL RESERVE DISTANCE
(a) Release the parking brake.
(b) With the engine running, depress the pedal and measure
the pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf): More than 75 mm (2.95 in.)
If the reserve distance is incorrect, troubleshoot the brake sys-
tem.

BR2237
BR02Q−02
BR2238
GOOD
1st2nd3rdNO GOOD BR−16
− BRAKEBRAKE BOOSTER ASSEMBLY
1996 RAV4 (RM447U)
BRAKE BOOSTER ASSEMBLY
ON−VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine
OFF and check that there is no change in the pedal re-
serve distance.
(b) Depress the brake pedal and start the engine.
If the pedal goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down farthest at the 1st time, but gradually
rises after at the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed.
If there is no change in the pedal reserve travel after holding the
pedal for 30 seconds, the booster is air−tight.

BR1811
R00326
R00324
R00325
BR1813
BR−36
− BRAKEABS ACTUATOR
1996 RAV4 (RM447U)
(c) Place the ”SHEET A” (SST) on the actuator checker.
SST 09990−00163
4. INSPECT BRAKE ACTUATOR OPERATION OF
FRONT RH WHEEL
(a) Start the engine, and run it at idle.
(b) Turn the selector switch of the actuator checker to
”FRONT RH” position.
(c) Push and hold in the MOTOR switch for a few seconds.
Make sure that you can hear the motor running.
(d) Depress the brake pedal and hold it for about 15 seconds,
and check that the brake pedal does not go down.
(e) With your foot still applying onto the brake pedal, push
MOTOR switch and check that the pedal does not pul-
sate.
(f) Depress the brake pedal and hold it. As you hold the ped-
al down, push and hold in the POWER SWITCH for a few
seconds. Check that the pedal does not go down.
NOTICE:
Do not keep the POWER SWITCH pushed for more than 10
seconds.
(g) With your foot still applying onto the brake pedal, release
the POWER SWITCH and check that the pedal goes
down.
(h) With your foot still applying onto the brake pedal, push the
MOTOR switch and check that the brake pedal returns.
(i) Release the brake pedal.
5. INSPECT FRONT LH WHEEL
(a) Turn the selector switch to ”REAR RH” position.
(b) Repeating (c) to (i) in the step 4, check the actuator oper-
ating similarly.
6. INSPECT REAR RH WHEEL
(a) Turn the selector switch to ”FRONT LH” position.
(b) Repeating (c) to (i) in the step 4, check the actuator opera-
tion similarly.

BR1811
− BRAKEABS ACTUATOR
BR−37
1996 RAV4 (RM447U)
7. INSPECT REAR LH WHEEL
Repeating (c) to (i) in the step 4, check the actuator operation
similarly.
HINT:
When inspecting the ”REAR LH” position, push the REAR LH
switch instead of the POWER SWITCH. This makes it possible
to inspect wherever the selector switch position indicates.
8. PUSH MOTOR SWITCH
(a) Push and hold in the MOTOR switch for a few seconds.
(b) Stop the engine.
9. DISCONNECT ACTUATOR CHECKER (SST) FROM
ACTUATOR
Remove the ”SHEET A” (SST) and disconnect the actuator
checker (SST) and sub−wire harness (SST) from the actuator,
control relay and body side wire harness.
SST 09990−00150, 09990−00163, 09990−00200,
09990−00300
10. CONNECT CONNECTORS
(a) Connect the connector to the actuator.
(b) Connect the 2 connectors to the control relay.
11. CLEAR DTC (See page DI−234)

New Spot
Locations
POST-WELDING
REFINISHING
1. Always check the welded
spots to insure they are
secure.
2. When smoothing out the
weld spots with a disc
grinder, be careful not to
grind off too much as this
would weaken the weld.
INSTALLATION
PRE-WELDING MEASUREMENTS
Always take measurements
before installing underbody or
engine components to insure
correct assembly. After installation,
confirm proper fit.WELDING PRECAUTIONS
1. The number of welding spots
should be as follows.
Spot weld: 1.3 y No. of
manufacturer`s spots.
Plug weld: More than No.
of manufacturer's plugs.
WRONG
WRONG OKAY
2. Plug welding should be done
with a MIG (Metal Inert Gas)
welder. Do not gas weld or
braze panels at areas other
than specified.
Safety Glass
Body
Measurement
Diagrams
SPOT WELDING PRECAUTIONS
1. The shape of the welding tip
point has an effect on the
strength of the weld.
2. Always insure that the
seams and welding tip are
free of paint. SPOT WELD LOCATIONS
Try to avoid welding over
previous spots.
Old
Spot
Locations
Tip Cutter
INTRODUCTIONINœ12

CL04F−03
− CLUTCHTROUBLESHOOTING
CL−1
1996 RAV4 (RM447U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Clutch grabs/chatters
3. Engine mounting (Loosen)
4. Clutch disc (Runout is excessive)
5. Clutch disc (Oily)
6. Clutch disc (Worn out)
7. Clutch disc torsion rubber (Damaged)
8. Clutch disc (Glazed)
9. Diaphragm spring (Out of tip alignment)−
CL−15
CL−15
CL−15
CL−15
CL−15
CL−15
Clutch pedal spongy
1. Clutch line (Air in line)
2. Master cylinder cup (Damaged)
3. Release cylinder cup (Damaged)−
CL−5
CL−10
Clutch noisy1. Release bearing (Worn, dirty, or damaged)
2. Clutch disc torsion rubber (Damaged)CL−15
CL−15
Clutch slips
1. Clutch pedal (Free play out of adjustment)
2. Clutch disc (Oily)
3. Clutch disc (Worn out)
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion)
6. Flywheel (Distortion)CL−2
CL−15
CL−15
CL−15
CL−15
−
Clutch does not disengage
1. Clutch pedal (Free play out of adjustment)
2. Clutch line (Air in line)
3. Master cylinder cup (Damaged)
4. Release cylinder cup (Damaged)
5. Clutch disc (Out of true)
6. Clutch disc (Runout is excessive)
7. Clutch disc (Lining broken)
8. Clutch disc (Dirty or burned)
9. Clutch disc (Oily)
10.Clutch disc (Lack of spline grease)
11. Diaphragm spring (Damaged)
12.Diaphragm spring (Out of tip alignment)
13.Pressure plate (Distortion)CL−2
−
CL−5
CL−10
CL−15
CL−15
CL−15
CL−15
CL−15
CL−18
CL−15
CL−18
CL−15