oil dipstick TOYOTA RAV4 1996 Service Repair Manual

Q06070
AT3417
OK if hot
Add if hot DI−132
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
(b) 2 position test.
Shift into the 2 position and, while drive with the accelerator pedal held constantly at the full throttle
valve opening position, check on the following points:
(1) Check up−shift operation.
Check that the 1 → 2 up−shift takes place and that the shift point conforms to the automatic shift
schedule (See page SS−32).
HINT:
There is no O/D up−shift and lock−up in the 2 position.
(2) Check engine braking.
While running in the 2nd gear of the 2 position, release the accelerator pedal and check the en-
gine braking effect.
(3) Check for abnormal noises during acceleration and deceleration, and for shock at up−shift and
down−shift.
(c) L position test.
Shift into the L position and while driving with the accelerator pedal held constantly at the full throttle
valve opening position, check the following points:
(1) Check no up−shift.
While running in the L position, check that there in no up−shift to 2nd gear.
(2) Check engine braking.
While running in the L position, release the accelerator pedal and check the engine braking ef-
fect.
(3) Check for abnormal noises during acceleration and deceleration.
(d) R position test.
Shift into the R position and while starting at full throttle, check for slipping.
CAUTION:
Before conducting this test ensure that the test area is free from personnel and obstructions.
(e) P position test.
Stop the vehicle on a gradient (more than 5°) and after shifting into the P position, release the parking
brake. Then check that the parking lock pawl holds the vehicle in place.
7. BASIC INSPECTION
(a) Check the fluid level.
HINT:
Drive the vehicle so that the engine and transaxle are at
normal operating temperature.
Fluid temperature: 70 − 80°C (158 − 176°F)
Only use the COOL range on the dipstick as a rough refer-
ence when the fluid is replaced or the engine does not
run.
(1) Park the vehicle on a level surface and set the park-
ing brake.
(2) With the engine idling and the brake pedal de-
pressed, shift the shift lever into all positions from
the P to L position and return to the P position.
(3) Pull out the oil level gauge and wipe it clean.
(4) Push it back fully into the pipe.
(5) Pull it out and check that the fluid level is in the HOT
range.
If the level is at the low side, add new fluid.

OR0028
Q06076
AT3417
OK if hot
Add if hot
AT4252
0 − 1 mm
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−133
1996 RAV4 (RM447U)
Fluid type: ATF DEXRON ®II
NOTICE:
Do not overfill.
(b) Check the fluid condition.
If the fluid smells burnt or is black, replace it.
(c) Replace the fluid.
(1) Remove the drain plug and drain the fluid.
(2) Reinstall the drain plug securely.
(3) With the engine OFF, add new fluid through the oil
filler pipe.
Fluid type: ATF DEXRON ®II
Capacity:
Drain and refill: 3.3 liters (3.5 US qts, 2.9 lmp. qts)
(4) Start the engine and shift the shift lever into all posi-
tions from P to L position and then shift into P posi-
tion.
(5) With the engine idling, check the fluid level. Add
fluid up to the COOL level on the dipstick.
(6) Check the fluid level at the normal operating tem-
perature 70 − 80°C (158 − 176°F) and add as nec-
essary.
NOTICE:
Do not overfill.
(d) Check the fluid leaks.
Check for leaks in the transaxle.
If there are leaks, it is necessary to replace O−rings, gaskets,
oil seals, plugs or other parts.
(e) Inspect and adjust throttle cable.
(1) Check that the throttle valve is fully closed.
(2) Check that the inner cable is not slack.
(3) Measure the distance between the outer cable end
and stopper on the cable.
Standard distance: 0 − 1 mm (0 − 0.04 in.)
If the distance is not within the standard, adjust the cable by the
adjusting nuts.

Q06070
D02315
OK if hot
Add if hot
D00697
Ok if hot
Add if hot
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−179
1996 RAV4 (RM447U)
7. BASIC INSPECTION
(a) Check the ATF level.
HINT:
The vehicle must have been driven so that the engine and
transaxle are at normal operating temperature.
ATF temperature: 70 − 80°C (158 − 176°F)
(1) Park the vehicle on a level surface, set the parking
brake.
(2) With the engine idling and the brake pedal de-
pressed, shift the shift lever into each gear from the
P position to L position smoothly and return to the
P position.
(3) Pull out the transaxle dipstick and wipe it clean.
(4) Push it back fully into the pipe.
(5) Pull it out and check that the fluid level is in the HOT
range.
If the level is at the low side of the hot range, add fluid.
Fluid type: ATF type T or equivalent
NOTICE:
Do not overfill.
(b) Check the transfer oil level.
(1) Park the vehicle on a level surface, set the parking
brake.
(2) Pull out the transfer dipstick and wipe it clean.
(3) Push it back fully into the pipe.
(4) Pull it out and check the oil level, as shown in the il-
lustration.
Oil grade: API GL−5
Oil viscosity: SAE 75W−90

Q06065
Q06076
D02315
OK if hot
Add if hot
D00699
D00700
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−181
1996 RAV4 (RM447U)
(d) Replace the ATF.
NOTICE:
Do not overfill.
(1) Using a 10 mm hexagon wrench, remove the drain
plug, gasket and drain the fluid.
(2) Install a new gasket and the drain plug securely.
(3) Add new fluid through the filler pipe.
Fluid type: ATF type T or equivalent
Drain and refill: 3.3 liters (3.5 US qts, 2.9 lmp. qts)
(4) Start the engine and shift the selector into all the
positions from P through L and then shift into the P
position.
(5) With the engine idling, check the fluid level. Add
fluid up to the COOL level on the dipstick.
(6) Check the fluid level with the normal fluid tempera-
ture 70 − 80°C (158 − 176°F) and add as neces-
sary.
NOTICE:
Do not overfill.
(e) Replace the transfer oil.
(1) Using a 10 mm hexagon wrench, remove the drain
plug and drain the oil.
(2) Install the drain plug.
(3) Add new oil through the filler pipe.
Recommended oil:
Oil grade API GL−5
Viscosity SAE 75W−90
Capacity: 0.7 liters (0.7 US qts, 0.6 lmp. qts)
(4) Check the oil level and add as necessary.
NOTICE:
Do not overfill.

LU0O4−01
S01775S01237B13839
M/T
A/T
S01375
P04282
SST
SST
− LUBRICATIONOIL PUMP
LU−7
1996 RAV4 (RM447U)
REMOVAL
HINT:
When repairing the oil pump, the oil pan and strainer should be
removed and cleaned.
1. REMOVE HOOD
2. REMOVE RH ENGINE UNDER COVER
3. DRAIN ENGINE OIL
4. REMOVE FRONT EXHAUST PIPE (See page EM−33)
5. REMOVE STIFFENER PLATE
Remove the 2 bolts (M/T) or 3 bolts (A/T) and stiffener plate.
6. REMOVE OIL PAN
(a) Remove the dipstick.
(b) Remove the 17 bolts and the 2 nuts.
(c) Insert the blade of SST between the cylinder block and oil
pan, and cut off applied sealer and remove the oil pan.
SST 09032−00100
NOTICE:
Do not use SST for the oil pump body side and rear oil
seal retainer.
Be careful not to damage the oil pan flange.

P04349
LU0420
Seal Width
ABC
A
B
C
5mm (0.20 in.)
S01375
− LUBRICATIONOIL PUMP
LU−15
1996 RAV4 (RM447U)
7. INSTALL OIL PAN BAFFLE PLATE AND OIL STRAIN-
ER
Install a new gasket, the oil strainer and baffle plate with the 2
bolts and 2 nuts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
8. INSTALL OIL PAN
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil pan
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non−residue solvent, clean both sealing
surfaces.
NOTICE:
Do not use a solvent which will affect the painted surfaces.
(b) Apply seal packing to the oil pan as shown in the illustra-
tion.
Seal packing:
Part No.08826−00080 or equivalent
Install a nozzle that has been cut to a 3−5 mm (0.12
− 0.20 in.) opening.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the oil pan with 17 bolts and 2 nuts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(d) Install the dipstick.

LU06A−03
S01365
S01359
SST
S01366
LU−18
− LUBRICATIONOIL COOLER
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE FRONT EXHAUST PIPE (See page EM−33)
4. REMOVE GENERATOR (See page CH−7)
5. REMOVE OIL DIPSTICK
6. REMOVE EXHAUST MANIFOLD AND FRONT TWC
ASSEMBLY (See page EM−33)
7. REMOVE WATER BYPASS PIPE HEAT PROTECTOR
Remove the bolt, 2 nuts and heat protector.
8. REMOVE OIL FILTER
Using SST, remove the oil filter.
SST 09228−06501
9. REMOVE OIL COOLER
(a) Disconnect the 2 water bypass hoses from the oil cooler.
(b) Remove the union bolt and plate washer.
(c) Remove the nut and oil cooler.
(d) Remove the O−ring from the oil cooler.

LU06C−02
LU−20
− LUBRICATIONOIL COOLER
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL OIL COOLER
(a) Clean the oil cooler contact surface on the oil cooler
mounting.
(b) Install a new O−ring to the oil cooler.
(c) Temporarily install the oil cooler with the nut.
(d) Apply a light coat of engine oil on the threads and under
the head of the relief valve.
(e) Install the plate washer and union bolt.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
(f) Tighten the nut.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(g) Connect the 2 water bypass hoses to the oil cooler.
2. INSTALL OIL FILTER
3. INSTALL WATER BYPASS HOSE HEAT PROTECTOR
Install the heat protector with the bolt and 2 nuts.
4. INSTALL EXHAUST MANIFOLD AND FRONT TWC AS-
SEMBLY (See page EM−55)
5. INSTALL OIL DIPSTICK
6. INSTALL GENERATOR (See page CH−19)
7. INSTALL FRONT EXHAUST PIPE (See page EM−55)
8. FILL WITH ENGINE COOLANT
9. START ENGINE AND CHECK FOR LEAKS
10. CHECK ENGINE OIL LEVEL
11. INSTALL RH ENGINE UNDER COVER

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.