power steering TOYOTA RAV4 1996 Service Repair Manual

Q08774
Q08768
D01757
Q08769
C
D
NutAB C
D
A
B
B
B
Nut
Q08770
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
AX−17
1996 RAV4 (RM447U)
15. DISCONNECT FOLLOWING CONNECTORS
Shift solenoid valve SL connector
Park/neutral position switch connector
Vehicle speed sensor connector
16. DISCONNECT 2 OIL COOLER HOSES
Loosen the 2 clips and disconnect the 2 oil cooler hoses.
17. REMOVE 2 POWER STEERING GEAR MOUNTING
BOLTS AND NUTS
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
NOTICE:
Support the power steering gear housing securely.
18. REMOVE FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY WITH STABILIZER BAR
Remove the 10 bolts, 2 nuts and front suspension crossmem-
ber assembly with stabilizer bar.
Torque:
A bolt: 206 N·m (2,100 kgf·cm, 152 ft·lbf)
B bolt: 137 N·m (1,400 kgf·cm, 101 ft·lbf)
C bolt: 35 N·m (360 kgf·cm, 26 ft·lbf)
D bolt: 72 N·m (730 kgf·cm, 53 ft·lbf)
Nut: 73 N·m (740 kgf·cm, 54 ft·lbf)
19. REMOVE STIFFENER PLATE
Remove the 3 bolts and stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

BR1NN−01
W04219
Power Steering
Fluid Reservoir Actuator Bracket Cushion ABS Actuator Cushion Bolt Cushion
5 (55, 48 in.·lbf)
19 (195, 14)
19 (195, 14)
15 (155, 11)
N·m (kgf·cm, ft·lbf)
: Specified torque
19 (195, 14)
2WD BR−38
− BRAKEABS ACTUATOR
1996 RAV4 (RM447U)
COMPONENTS

BR0MA−03
BR−40
− BRAKEABS ACTUATOR
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT BRAKE LINES
Using SST, disconnect the 6 brake lines from the ABS actuator.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
2. DISCONNECT POWER STEERING FLUID RES-
ERVOIR
(a) Remove the bolt and disconnect the PS hose from the ac-
tuator bracket.
(b) Disconnect the PS fluid reservoir.
3. REMOVE ABS ACTUATOR ASSEMBLY
(a) Disconnect the 2 connectors.
(b) Remove the 3 bolts and ABS actuator assembly.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
4. 2WD
REMOVE ABS ACTUATOR
Remove the 2 nuts and actuator from the actuator bracket.
Torque: 5 N·m (55 kgf·cm, 48 in.·lbf)
5. 4WD
REMOVE ABS ACTUATOR
Remove the 3 nuts and actuator from the actuator bracket.
Torque: 5 N·m (55 kgf·cm, 48 in.·lbf)
6. 2WD
REMOVE 2 CUSHION BOLTS AND 3 CUSHIONS
7. 4WD
REMOVE 3 HOLDERS AND 3 CUSHIONS

Fuse BlockEngine ECU R/B No. 5 J/B No. 1J/B No. 4 ABS ECUDaytime Running
Light Relay (*1) Door Look Control RelayA/C Amplifier J/B No. 3
4. ECU (ELECTRONIC CONTROL UNIT)
Locations of ECUs
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.

Before starting electric welding operations, disconnect the negative (-) terminal cable from the battery.
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all
equipped with memory function, it is not possible to make a record of the memory contents.
So when the operation is finished, it will be necessary to explain this fact to the customer, and request
the customer to adjust the features and reset the memory.

Do not expose the ECUs to ambient temperatures above 80°C (176°F).
NOTICE: If it is possible the ambient temperature may reach 80 °C (176 °F) or more, remove the ECUs
from the vehicle before starting work.

Be careful not to drop the ECUs and not to apply physical shocks to them.
4. COMPONENTS ADJACENT TO THE BODY PANELS
Various types of component parts are mounted directly on or adjacently to the body panels.
Strictly observe the following precautions to prevent damaging these components and the body panels
during handling.

Before repairing the body panels, remove their components or apply protective covers over the comœ
ponents.

Before prying components off using screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components and the body paint.

Before removing components from the outer surface of the body, attach protective tape to the body to
ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.

Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.
INTRODUCTIONINœ8

ABS Antilock Brake System
A/C Air Conditioner
assy assembly
ECT Electronic Controlled Transmission
ECU Electronic Control Unit
e.g. Exempli Gratia (for Example)
Ex. Except
FWD Front Wheel Drive Vehicles
4WD Four Wheel Drive Vehicles
in. inch
LH Left-hand
LHD Left-hand Drive
MIG Metal Inert Gas
M/Y Model Year
PPS Progressive Power Steering
RH Right-hand
RHD Right-hand Drive
SRS Supplemental Restraint System
w/ with
w/o without
ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual.
INTRODUCTIONINœ15

11 5
SRS
NOTICE: When inspecting or repairing the SRS, perform the operation in accordance with the following
precautionary instructions and the procedure and precautions in the Repair Manual for the applicable model
year.

Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble
codes become the most important source of information when troubleshooting.
When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before
disconnecting the battery.

Work must be started after 90 seconds from the time the ignition SW is turned to the LOCKº position and the
negative (-) terminal cable is disconnected from the battery.
(The supplemental restraint system is equipped with a back-up power source so that if work is started within
90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be activated.)
When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio
systems will be canceled. So before starting work, make a record of the contents memorized by each memory
system. When work is finished, reset the clock and audio system as before and adjust the clock.
To avoid erasing the memory of each memory system, never use a back-up power supply from outside the
vehicle.

When removing the steering wheel pad or handling a new steering wheel pad, keep the pad upper surface
facing upward. Also, lock the lock lever of the twin lock type connector at the rear of the pad and take care
not to damage the connector.
(Storing the pad with its metallic surface up may lead to a serious accident if the SRS inflates for some reason.)

Always store a removed or new front passenger airbag assembly with the airbag door facing up. Storing the
airbag assembly with the airbag door facing down could cause a serious accident if the airbag inflates.

Store the steering wheel pad where the ambient temperature remains below 935C (2005F), without high
humidity and away from electrical noise.

Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor
assembly.

Before repairing the body, remove the airbag sensor if during repair shocks are likely to be applied to the
sensors due to vibration of the body or direct tapping with tools or other parts.

Do not reuse a steering wheel pad or front airbag sensors.
After evaluating whether the center airbag sensor assembly is damaged or not, decide whether or not to reuse
it. (See the Repair Manual for the method for evaluating the center airbag sensor assembly.)

When troubleshooting the supplemental restraint system, use a high-impedance (Min. 10kW/V) tester.

The wire harness of the supplemental restraint system is integrated with the instrument panel wire harness
assembly.
The vehicle wiring harness exclusively for the airbag system is distinguished by corrugated yellow tubing, as
are the connectors.

Do not measure the resistance of the airbag squibs.
(It is possible this will deploy the airbag and is very dangerous.)

If the wire harness used in the supplemental restraint system is damaged, replace the whole wire harness
assembly.

INFORMATION LABELS (NOTICES) are attached to the periphery of the SRS components. Follow the
instructions on the notices.

K
1
234
11 RAV4
2AC C
IG 1
IG 2
ST2 AM13
4
6 7AM2
40A AM 1
1D 9
1K 411IG1
7EA1
2
20A
AM2
2 2
2
80A MAIN
100A ALT
20 1
21 2
2 6W
W B- R
W B-R
BATTERY
IE Instrument
panel brace
LHIDLeft kick
panel 1D 8
1E 91F51D 6
1M 31E 1
1M 21E 41E 7
1M 4
3EA1 18 IG2
W-B W-B RLB W
B-OGR
B-OGR
B- OL-RWW-LVVW-L
W-L
W-L W-G W-G B-R
B-R
B
W
W-L
6 543 21B C4 A
11 7 16
910 87B C3 A
15 6 10
12
12 E1 E2 D+ D - P+ P- F 8
FUSE
BLOCK
7. 5A IGN15A CIG
& RAD 7. 5A SRS
C
A20
AIRBAG SQUIB
(
Steering
Wheel Pad)A19
AIRBAG SQUIB
(
Front P assenger` s
Airbag Assembly) IG A CC LA TCA18
AIRBAG SENSOR
ASSEMBLYJ 7
JU NC TIO N
CO N NEC TO R
C11
SRS INDICATOR LIGHT
[COMB. METER]
J 7
JUNCTION
CO N NEC TO R
J 7
JUNCTION
CONNECTOR
T o D ate Link
C onnector 1
<2-3
R-L
Y-B
R- G 4 3
F 8
10A
GAUGE
[FUSE BLOCK]
81B1E 8
, C 10
J 1
JUNCTION
CONNECTOR 2 1
2 113 B 1 810Y- B Y- BW-BY-B
V 5
VSV(
C en ter D iff.
Lock No. 1) V 6
VSV(
C en ter D iff.
Lock No. 2)
C 4
CENTER DIFF.
LOCK CONTROL SWC 1
CENTER DIFF.
LOCK W ARNING
BUZZER SW
C OM BIN A TIO N M ET E R
C. DIFF
LOCK
EA IGRadiator right Right kick
panel A A 10 EA1W-B W-B W-BW-B
W-B W-B B
BUZZER
B
R- L R-L
IH214A C 9 BROW N
B C10 BLUE C OM B INA TIO N M ET E R
IG 21
IG 213
2 7
R-B
Y- B Y- BR-B R- G
Y-B
A 3
2B
A C 9
13 9 8 7 6 5 4 3 2 1 101112
13 9 8 7 6 5 4 3 2 1 101112
A A
J10
JU NC TIO N
CO NN ECTO R C
BC
BBJ10
JU NC TIO N
CONNECTOR
J 3
JUNCTION
CONNECTOR
Center Diff. Lock(
4WD M/T)
F 7
FUSIBLE LINK
BLOCK7
1D1
1F B-YL- RW
W
B-RB-R
I1 0
IGN ITIO N S W
SRS Power Source
SPIRAL
CABLE17 IB1
W-L W-L LOCK UNLOCK

AB0158
Battery
SST
AB0152
SST
AB0158
Battery
SST
H01580
SST
RS−12
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 RAV4 (RM447U)
1. AIRBAG DEPLOYMENT WHEN SCRAPPING VE-
HICLE
HINT:
Have a battery ready as the power source to deploy the airbag.
(a) Check functioning of the SST.
CAUTION:
When deploying the airbag, always use the specified SST:
SRS Airbag Deployment Tool.
SST 09082−00700
(1) Connect the SST to battery.
Connect the red clip of the SST to the battery posi-
tive (+) terminal and the black clip to the battery neg-
ative (−) terminal.
HINT:
Do not connect the yellow connector which will be connected
with the supplemental restraint system.
(2) Check functioning of the SST.
Press the SST activation switch, and confirm the
LED of the SST activation switch lights up.
CAUTION:
If the LED lights up when the activation switch is not being
pressed, SST malfunction is probable, so definitely do not
use the SST.
(b) Install the SST.
CAUTION:
Check that there is no looseness in the steering wheel and
steering wheel pad.
(1) Remove the steering column lower cover.
(2) Disconnect the airbag connector of the spiral cable.

AB0163
Wire Harness
Diameter
Stripped Wire Harness Section
R05748
L
M RS−14
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 RAV4 (RM447U)
2. DEPLOYMENT WHEN DISPOSING OF STEERING
WHEEL PAD ONLY
NOTICE:
When disposing of the steering wheel pad (with air-
bag) only, never use the customers vehicle to deploy
the airbag.
Be sure to follow the procedure given below when de-
ploying the airbag.
HINT:
Have a battery ready as the power source to deploy the airbag.
(a) Remove the steering wheel pad (See page SR−12).
CAUTION:
When storing the steering wheel pad, keep the upper sur-
face of the pad facing upward.
(b) Using a service−purpose wire harness for the vehicle tie
down the steering wheel pad to the disc wheel
Wire harness: Stripped wire harness section
1.25 mm
2 or more (0.0019 in.2 or more).
CAUTION:
If a wire harness which is too thin or some other thing is
used to tie down the steering wheel pad, it may be snapped
by the shock when the airbag is deployed. This is highly
dangerous. Always use a wire harness for vehicle use
which is at least 1.25 mm
2 (0.0019 in.2).
HINT:
To calculate the square of the stripped wire harness section:
Square = 3.14 X (Diameter)
2 divided by 4
(1) .Install the 2 bolts with washer in the 2 bolt holes in
the steering wheel pad.
Bolt:
L: 35.0 mm (1.387 in.)
M: 6.0 mm (0.236 in.)
Pitch: 1.0 mm (0.039 in.)
NOTICE:
Tighten the bolts by hand until the bolts become diffi-
cult to turn.
Do not tighten the bolts too much.

SA0TR−03
Z19330
23 Door vehicle
Stabilizer Bar LinkStabilizer
BarPower Steering Gear Assembly
Bracket
No.1
Bushing
Bushing
Clamp
(A/T Only)
Front Suspension
Crossmember
Center MemberLower Suspension
Arm Bracket
Cushion
Retainer
Lower Suspension Arm
LH Engine Cover
29 (300, 22)
29 (300, 22)
113 (1,150, 83)
8.3 (85, 74 in.·lbf)
112 (1,140, 82)
172 (1,750, 126)
206 (2,100, 152)
127 (1,300, 94)
137 (1,400, 101)
28 (290, 21)

N·m (kgf·cm, ft·lbf)
Non−reusable part: Specified torque
X7
Clamp 137 (1,400, 101)
64 (650, 47)
113 (1,150, 83)5 Door vehicle
− SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
SA−39
1996 RAV4 (RM447U)
FRONT LOWER SUSPENSION ARM
COMPONENTS