seats TOYOTA RAV4 1996 Service Repair Manual

GENERAL REPAIR INSTRUCTIONS
Work Precautions
VEHICLE PROTECTION
When welding, protect the
painted surfaces, windows,
seats and carpet with heat-
resistant, fire-proof covers. SAFETY
Never stand in direct line
with the chain when using
a puller on the body or
frame, and be sure to
attach a safety cable.SAFETY
1. Before performing repair work, check
for fuel leaks. If a leak is found, be sure
to close the opening totally.
2. If it is necessary to use a frame in the
area of the fuel tank, first remove the
tank and plug the fuel line.
WRONG
Glass Cover
Safety Cable
Seat Cover
WRONG
HAND TOOLS
Keeping your hand tools
in neat order improve
your work efficiency. SAFETY WORK CLOTHES
In addition to the usual mechanic's wear, cap and safety shoes,
the appropriate gloves, head protector, glasses, ear plugs, face
protector, dust-prevention mask, etc. should be worn as the
situation demands.
Dust-
Prevention
MaskWelder's
Glasses
Ear
Plugs
Face
ProtectorBody
Tools
Stand
Head
Protector Eye
Protector
Welder's
Gloves Safety
Shoes
INTRODUCTIONINœ9

EM2534
Overall Length
EM0255
EM3300
45° Carbide
Cutter
Z00055
Width
− ENGINE MECHANICALCYLINDER HEAD
EM−47
1996 RAV4 (RM447U)
(d) Check the valve overall length.
Standard overall length:
Intake97.60 mm (3.8425 in.)
Exhaust98.45 mm (3.8760 in.)
Minimum overall length:
Intake97.1 mm (3.823 in.)
Exhaust98.0 mm (3.858 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than the minimum length.
7. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(c) Check the valve face and seat for the following:
If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
Check that the seat contact is in the middle of the
valve face with the following width:
1.0 − 1.4 mm (0.039 − 0.055 in.)

Z02852
45°
30°
1.0 − 1.4 mm
Z06188
75°
45°
1.0 − 1.4 mm
P03273
EM0988
Deviation
EM0801
EM−48
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.
(2) If the seating is too low on the valve face, use 75°
and 45° cutters to correct the seat.
(d) Hand−lap the valve and valve seat with an abrasive com-
pound.
(e) After hand−lapping, clean the valve and valve seat.
8. INSPECT VALVE SPRINGS
(a) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation: 2.0 mm (0.079 in.)
If the deviation is greater than maximum, replace the valve
spring.
(b) Using a vernier caliper, measure the free length of the
valve spring.
Free length: 41.96 − 41.99 mm (1.6520 − 1.6531 in.)
If the free length is not as specified, replace the valve spring.

MT0693
SST
Q06375
Z17557
Matchmarks
Q01614
Q08124
MX−20
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
23. REMOVE OUTPUT SHAFT REAR TAPER ROLLER
BEARING OUTER RACE
Using SST and a hammer, remove the output shaft rear taper
roller bearing outer race.
SST 09316−60011 (09316−00011)
24. REMOVE TRANSMISSION OIL PIPE
(a) Remove the gasket from the oil pipe.
(b) Remove the 2 bolts and oil pipe.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
25. REMOVE REVERSE SHIFT ARM BRACKET AS-
SEMBLY
Remove the bolt and pull off the reverse shift arm and bracket.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
26. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft, remove the reverse idler gear and thrust
washer.
HINT:
At the time of reassembly, please refer to the following item.
Align the matchmarks, as shown.
27. REMOVE STRAIGHT SCREW PLUG, LOCKING BALL
AND SPRING
(a) Using a hexagon wrench (6 mm), remove the 2 plugs.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Using a magnetic finger, remove the 2 seats, springs and
balls.
28. REMOVE NO.1, NO.2 SHIFT FORKS AND SHIFT HEAD
SET BOLT
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
29. REMOVE NO.1 SHIFT FORK SHAFT
Pull up the No.3 shift fork shaft, remove the No.1 shift fork shaft.
HINT:
At the time of reassembly, please refer to the following item.
When it is difficult to push the fork shaft through the reverse shift
fork, pull up the No.3 shift fork shaft.

N00402SST
Z01716
N00406
SST
W01254
Screw Extractor
Union Seat
− STEERINGPOWER STEERING GEAR
SR−53
1996 RAV4 (RM447U)
(f) Carefully slide the tapered end of SST over the ring to
seat it.
SST 09630−24014 (09631−24031)
NOTICE:
Be careful not to damage the ring.
5. IF NECESSARY, REPLACE TEFLON RINGS
(a) Using a screwdriver, remove the 4 rings from the control
valve assembly.
NOTICE:
Be careful not to damage the grooves for the ring.
(b) Expand 4 new teflon rings with your fingers.
NOTICE:
Be careful not to overexpand the ring.
(c) Coat the rings with power steering fluid.
(d) Install the rings to the control valve assembly, and snug
them down with your fingers.
(e) Carefully slide the tapered end of SST over the rings to
seat them.
SST 09631−20081
NOTICE:
Be careful not to damage the rings.
6. IF NECESSARY, REPLACE 2 UNION SEATS
(a) Using a screw extractor, remove the union seats.

W01255
Union Seat
Extension Bar
W01202
Cylinder
End Stopper
SR−54
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
(b) Using an extension bar and a hammer, tap in 2 new union
seats.
NOTICE:
Before installing the union seat, remove dust sticking to
the rack housing.
7. INSPECT BUSHING
(a) Check for wear and damage on the inside of the bushing
of the cylinder end stopper.
If the bushing is worn or damaged, replace the cylinder end
stopper.
(b) Coat inside of the bushing with molybdenum disulfide lith-
ium base grease.