height TOYOTA RAV4 1996 Service Repair Manual

BO4421
H02865
Primer MPrimer M
Adhesive
Primer M
N08473
Primer G
H03970
A BO−42
− BODYWINDSHIELD
1996 RAV4 (RM447U)
6. CLEAN CONTACT SURFACE OF GLASS
Using a cleaner, clean the contact surface which is black−col-
ored area around the entire glass rim.
NOTICE:
Do not touch the glass face after cleaning it.
7. COAT CONTACT SURFACE OF BODY WITH PRIMER
”M”
Using a brush, coat Primer M to the exposed part of body on the
vehicle side.
NOTICE:
Let the primer coating dry for 3 minutes or more.
Do not coat Primer M to the adhesive.
Do not keep any of the opened primer M for later use.
8. COAT CONTACT SURFACE OF GLASS WITH PRIMER
”G”
(a) Using a brush or sponge, coat the edge of the glass and
the contact surface with Primer G.
(b) Before the Primer dries, wipe it off with a clean shop rag.
NOTICE:
Let the primer coating dry for 3 minutes or more.
Do not keep any of the opened Primer G for later use.
9. APPLY ADHESIVE
(a) Cut off the tip of the cartridge nozzle.
Part No. 08850−00801 or equivalent.
HINT:
After cutting off the tip, use all adhesive within the described
time in the chart below.
TemperatureTackfree time
35°C (95°F)15 minutes
20°C (68°F)100 minutes
5°C (41°F)8 hours
(b) Load the cartridge into the sealer gun.
(c) Coat the glass with adhesive as shown.
Adhesive height:
A: 10 mm (0.39 in.)

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.)

GENERAL INFORMATION
1. BASIC DIMENSIONS
(a) There are two types of dimensions in the diagram.
(Three-dimensional distance)

Straight-line distance between the centers of two
measuring points.
(Two-dimensional distance)

Horizontal distance in forward/rearward between
the centers of two measuring points.

The height from an imaginary standard line.
(b) In cases in which only one dimension is given, left
and right are symmetrical.
(c) The dimensions in the following drawing indicate
actual distance. Therefore, please use the dimenœ
sions as a reference.
2. MEASURING
(a) Basically, all measurements are to be done with a
tracking gauge. For portions where it is not possible
to use a tracking gauge, a tape measure should be
used.
(b) Use only a tracking gauge that has no looseness in
the body, measuring plate, or pointers.
HINT:
1. The height of the left and right pointers must be equal.
2. Always calibrate the tracking gauge before measuring or
after adjusting the pointer height.
3. Take care not to drop the tracking gauge or otherwise
shock it.
4. Confirm that the pointers are securely in the holes.
(c) When using a tape measure, avoid twists and
bends in the tape.
(d) When tracking a diagonal measurement from the
front spring support inner hole to the suspension
member upper rear installation hole, measure
along the front spring support panel surface.
Center-to-center
straight-line
distance Three-dimensional
distance
Front Spring Support Inner Hole
Tape Measure
Along Body
Surface
Front Suspension Member Rear Side
Upper Installation HoleMaster Gauge PointerPointer LoosenessBody LoosenessPlate Looseness Two-dimensional
distanceCenter-to-center
Horizontal distance in
forward/rearward
Vertical distance
in lower surface Vertical distance
in center
Imaginary Standard Line
WrongCorrect
Pointer
BODY DIMENSIONSDIœ2

Q08873
Push Rod Play
Adjust Point
Pedal Height
Adjust Point
Push Rod
Play
Pedal HeightCL04G−02
CL0042
Pedal Freeplay
CL0512
25 mm (0.98 in.) or more
Release Point
Full Stroke
End Position CL−2
− CLUTCHCLUTCH PEDAL
1996 RAV4 (RM447U)
CLUTCH PEDAL
INSPECTION
1. CHECK PEDAL HEIGHT IS CORRECT
Pedal height from asphalt sheet:
157.6 − 167.6 mm (6.205 − 6.598 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and turn the stopper bolt until the height is
correct. Tighten the lock nut.
3. CHECK PEDAL FREEPLAY AND PUSH ROD PLAY
(a) Push in on the pedal until the beginning of clutch resis-
tance is felt.
Pedal freeplay: 5.0−15.0 mm (0.197−0.591 in.)
(b) Gently push on the pedal until the resistance begins to in-
crease a little.
Push rod play at pedal top:
1.0−5.0 mm (0.039−0.197 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
(d) Connect the air duct and install the lower finish panel.
5. INSPECT CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start the engine and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into the reverse position until the gears contact.
(d) Gradually depress the clutch pedal and measure the
stroke distance from the point the gear noise stops (re-
lease point) up to the full stroke end position.
Standard distance:
25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified.
Inspect pedal height.
Inspect push rod play and pedal freeplay.
Bleed the clutch line.
Inspect the clutch cover and disc.

EM0281
EM1628
EM2011
EM2538
EM3322
Free Distance
− ENGINE MECHANICALCYLINDER HEAD
EM−49
1996 RAV4 (RM447U)
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
164 − 189 N (16.7 − 19.3 kgf, 36.8 − 42.5 lbf)
at 34.7 mm (1.366 in.)
If the installed tension is not as specified, replace the valve
spring.
9. INSPECT CAMSHAFTS
(a) Inspect the circle runout.
(1) Place the camshaft on V−blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.04 mm (0.0016 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake42.01 − 42.11 mm (1.6539 − 1.6579 in.)
Exhaust40.06 − 40.16 mm (1.5772 − 1.5811 in.)
Minimum cam lobe height:
Intake41.90 mm (1.6496 in.)
Exhaust39.95 mm (1.5728 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
(c) Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 − 26.975 mm (1.0614 − 1.0620 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
(d) Using vernier calipers, measure the free distance be-
tween the gear spring ends.
Free distance: 22.5 − 22.9 mm (0.886 − 0.902 in.)
If the free distance is not as specified, replace the gear spring.

MX0DX−01
Q06209
A
B
Case No.1 Differential
Case No.2 Differential
Q06210
A B
Z12920
MX−62
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
INSPECTION
1. MEASURE NO.1 AND NO.2 DIFFERENTIAL CASES
Using a cylinder gauge, measure the inner diameter of the No.1
and No.2 differential cases bushing.
Standard diameter:
A: 104.000−104.035 mm (4.0945−4.0959 in.)
B: 97.000−97.035 mm (3.8189−3.8203 in.)
Maximum diameter:
A: 104.060 mm (4.0969 in.)
B: 97.060 mm (3.8213 in.)
2. MEASURE FRONT DIFFERENTIAL CASE
Using a micrometer, measure the outer diameter of the front dif-
ferential case.
Standard diameter:
A: 103.929−103.964 mm (4.0917−4.0931 in.)
B: 96.929−96.964 mm (3.8161−3.8175 in.)
Minimum diameter:
A: 103.850 mm (4.0887 in.)
B: 96.850 mm (3.8130 in.)
3. MEASURE CONICAL SPRING WASHER
Using calipers, measure the height of the conical spring wash-
er.
Standard height:
No.2 differential case side
2.60−2.80 mm (0.102−0.110 in.)
No.1 differential case side
1.70−1.90 mm (0.067−0.075 in.)
Minimum height:
No.2 differential case side
2.50 mm (0.098 in.)
No.1 differential case side
1.60 mm (0.063 in.)

R10734R10735
F02020
Front:
Rear:SA0T7−05
Z03382
SA3213
A
CB
FrontD SA−4
− SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
1996 RAV4 (RM447U)
FRONT WHEEL ALIGNMENT
INSPECTION
1. MEASURE VEHICLE HEIGHT
Tire sizeFront*1
mm (in.)Rear*2
mm (in.)
215/70R16 (2WD)227 (8.94)353 (13.90)
215/70R16 (4WD)227 (8.94)360 (14.17)
*1: Front measuring point:
Measure from the ground to the center of the lower suspension
arm front mounting bolt.
*
2: Rear measuring point:
Measure from the ground to the center of the body side No.1
suspension arm mounting bolt.
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to the specification.
If the vehicle height is not to specification, try to adjust it by
pushing down on or lifting the body.
2. INSTALL CAMBER−CASTER−KINGPIN GAUGE
ONTO VEHICLE OR POSITION VEHICLE ON WHEEL
ALIGNMENT TESTER
Follow the specific instructions of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
Tire size: 215/70R16
2WD4WD
Camber
Left−right error−0°20’ ± 45’
(−0.33°± 0.75°)
45’ (0.75°) or less−0°15’± 45’
(−0.25° ± 0.75°)
45’ (0.75°) or less
Caster
Left−right error1°25’ ± 45’
(1.42° ± 0.75°)
45’ (0.75°) or less1°20 ± 45’
(1.33° ± 0.75°)
45’ (0.75°) or less
Steering axis inclination
Left−right error11°00’ ± 45’
(11° ± 0.75°)
45’ (0.75°) or less10°45’ ± 45’
(10.75° ± 0.75°)
45’ (0.75°) or less
If the caster and steering axis inclination are not within the spec-
ification, after the camber has correctly adjusted, recheck the
suspension parts for damaged and/or worn out parts.
4. INSPECT TOE−IN
To e−in
(total)A + B: 0° ± 0’10’ (0° ± 0.17°)
C D: 0 ± 2 mm (0 ± 0.08 in.)
If the toe−in is not within the specification, adjust it by the tie rod
end.

SA0T8−05
SA3213
AB
D
Front
C
W01763
− SUSPENSION AND AXLEREAR WHEEL ALIGNMENT
SA−7
1996 RAV4 (RM447U)
REAR WHEEL ALIGNMENT
INSPECTION
1. MEASURE VEHICLE HEIGHT (See page SA−4)
NOTICE:
Before inspect the wheel alignment, adjust the vehicle
height to specification.
2. INSTALL CAMBER−CASTER−KINGPIN GAUGE OR
ONTO WHEEL ALIGNMENT TESTER
Follow the specifications of the equipment manufacturer.
3. INSPECT CAMBER
2WD4WD
Camber
Left−right error−1°20’ ± 45’
(1.33° ± 0.75°)
45’ (0.75°) or less−1°05’ ± 45’
(1.08° ± 0.75°)
45’ (0.75°) or less
If the camber is not within the specification, adjust it by the cam-
ber adjust cam.
4. INSPECT TOE−IN
2WD
To e−in
(total)A + B: 0°20’ ± 0’10’ (0.33° ± 0.17°)
C − D: 4 ± 2 mm (0.16 ± 0.08 in.)
4WD
To e−in
(total)A + B: 0°15’ ± 0’10’ (0.25° ± 0.17°)
C − D: 3 ± 2 mm (0.12 ± 0.08 in.)
If the toe−in is not within the specification, adjust it by the toe−
adjust cam.
If the toe−in is not within the specification, adjust it by the toe−
adjust cam.
5. ADJUST CAMBER
(a) Loosen the camber adjust cam lock bolt.
(b) Turn the camber adjust cam to adjust camber.
HINT:
Try to adjust the camber to the center value.
The camber will change about 16’ (0.27°) with each grad-
uation of the cam.
(c) Torque the lock bolt.
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)

SR0FY−01
W01200
Micrometer
Caliper
Gauge
Front Housing
Vane Pump Shaft Bushing
N00372
Height
LengthThickness
R10282Feeler Gauge
R13897
Inscribed Mark
SR−36
− STEERINGPOWER STEERING VANE PUMP
1996 RAV4 (RM447U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE OIL CLEARANCE BETWEEN VANE PUMP
SHAFT AND BUSHING
Using a micrometer and a caliper gauge, measure the oil clear-
ance.
Standard clearance:
0.03 − 0.05 mm (0.0012 − 0.0020 in.)
Maximum clearance: 0.07 mm (0.0028 in.)
If it is more than the maximum, replace the front housing and
vane pump shaft.
2. INSPECT VANE PUMP ROTOR AND VANE PLATES
(a) Using a micrometer, measure the height, thickness and
length of the 10 plates.
Minimum height: 8.1 mm (0.319 in.)
Minimum thickness: 1.797 mm (0.0707 in.)
Minimum length: 14.988 mm (0.59008 in.)
(b) Using a feeler gauge, measure the clearance between
the rotor groove and plate.
Maximum clearance: 0.03 mm (0.0012 in.)
If it is more than the maximum, replace the plate and/or rotor
with one having the same mark stamped on the cam ring.
Inscribed mark: 1, 2, 3, 4 or None