tow TOYOTA RAV4 1996 Service Repair Manual

AX04X−02
Q08861
Key Interlock SolenoidStop Light Switch
Shift Lock Override Button Cover
Shift Lock Solenoid
Shift Lock Control Switch
Shift Lock Control ECU HINT:
 The shift indicator housing ordered as
supply parts does not include the cover
of the shift−lock override button.
So, if you replace the shift indicator
housing, install cover from the old
housing into the new housing.
 Install the cover with its cutout facing
toward the rear of the vehicle.
− AUTOMATIC TRANSAXLE (A241E)SHIFT LOCK SYSTEM
AX−11
1996 RAV4 (RM447U)
SHIFT LOCK SYSTEM
LOCATION

AX04X−03
Q08861
Key Interlock SolenoidStop Light Switch
Shift Lock Override Button Cover
Shift Lock Solenoid
Shift Lock Control Switch
Shift Lock Control ECU HINT:
 The shift indicator housing ordered as
supply parts does not include the cover
of the shift−lock override button.
So, if you replace the shift indicator
housing, install cover from the old
housing into the new housing.
 Install the cover with its cutout facing
toward the rear of the vehicle.
− AUTOMATIC TRANSAXLE (A540H)SHIFT LOCK SYSTEM
AX−15
1996 RAV4 (RM447U)
SHIFT LOCK SYSTEM
LOCATION

BE0123
At Center
BE0124
0 VoltsSeveral Volts
Broken
Wire
V
− BODY ELECTRICALDEFOGGER SYSTEM
BE−47
1996 RAV4 (RM447U)
(d) Place the voltmeter positive (+) lead against the defogger
positive (+) terminal.
(e) Place the voltmeter negative (−) lead with the foil strip
against the heat wire at the positive (+) terminal end and
slide it toward the negative (−) terminal end.
(f) The point where the voltmeter deflects from zero to sever-
al V is the place where the heat wire is broken.
HINT:
If the heat wire is not broken, the voltmeter indicates 0 V at the
positive (+) end of the heat wire but gradually increases to about
12 V as the meter probe moves to the other end.

BE279−01
BE5780
BE4674
BE−82
− BODY ELECTRICALAUDIO SYSTEM
1996 RAV4 (RM447U)
INSTALLATION
INSTALL ANTENNA ROD
(a) Insert the cable of the rod until it reaches the bottom.
HINT:
When inserting the cable, the teeth on the cable must face
toward the front of the vehicle.
Insert the antenna approx. 300 mm (11.8 in.)
(b) Wind the cable to retract the rod by turning the ignition
switch to the ”LOCK” position.
HINT:
If the ignition switch is already in the ”LOCK” position, per-
form step 1 (c) first, then turn the ignition switch to the
”ACC” position.
In case the cable is not wound, twist it as shown in the il-
lustration.
Even if the rod has not retracted fully, install the antenna
nut and inspect the antenna rod operation. It will finally re-
tract fully.
(c) Inspect the antenna rod operation by pushing the radio
wave band select buttons.

CO18L−01
S01356
(A)
S01433
− COOLINGELECTRIC COOLING FAN
CO−21
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE NO.1 COOLING FAN (See page CO−16)
2. REMOVE NO.2 COOLING FAN
(a) Remove the RH engine under cover.
(b) w/ A/C:
Remove the cooler condenser (See page AC−47).
(c) Remove the upper radiator supports.
Torque:13 N·m (130kgf·cm, 9 ft·lbf)
HINT:
At the time of installation, plaese refer to the following items. Af-
ter installation, check that the rubber cushion (A) of the support
is not depressed.
(d) Remove the No.2 cooling fan.
(1) Disconnect the cooling fan connector.
(2) Push the radiator toward the front bumper.
(3) Remove the 3 bolts.
(4) Push the No.2 cooling fan toward radiator and pull
it upward.

Q08832
Q08831N
RP
Q07907
Neutral
Basic
Line
Groove
DI−134
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
(f) Inspect and adjust shift lever position.
When shifting the shift lever from the N position to other
positions, check that the lever can be shifted smoothly
and accurately to each position and that the position indi-
cator correctly indicates the position.
If the indicator is not aligned with the correct position, carry out
the following adjustment procedures:
(1) Loosen the nut on the control shaft lever.
(2) Push the control shaft lever fully downward.
(3) Return the control shaft lever 2 notches to the N
position.
(4) Set the shift lever to the N position.
(5) While holding the shift lever lightly toward the R
position side, tighten the shift lever nut.
Torque: 6.9 N·m (70 kgf·cm, 61 in·lbf)
(6) Start the engine and make sure that the vehicle
moves forward when shifting the lever from the N to
D position and reverses when shifting it to the R
position.
(g) Inspect and adjust park/neutral position switch.
Check that the engine can be started with the shift lever
only in the N or P position, but not in other positions.
If not as stated above, carry out the following adjustment proce-
dure:
(1) Loosen the park/neutral position switch bolt and set
the shift lever to the N position.
(2) Align the groove and neutral basic line.
(3) Hold in position and tighten the bolt.
Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf)
HINT:
For continuity inspection of the park/neutral position switch, see
page DI−156.
(h) Inspect the idle speed.
Idle speed: 700 ± 50 rpm (In N position and A/C OFF)
8. MECHANICAL SYSTEM TESTS
(a) Measure the stall test
The object of this test is to check the overall performance of the transaxle and engine by measuring
the stall speeds in the D and R positions.
NOTICE:
Do the test at normal operation ATF temperature 50 − 80°C (122 − 176°F).
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear, level area which provides good traction.
The stall test should be always carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Fully apply the parking brake.
(3) Connect OBD II scan tool or TOYOTA hand−held tester to the DLC3.

D00697
Ok if hot
Add if hot
AT4252
0 − 1 mm
D02248
DI−182
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
(f) Check the fluid leaks.
Check for leaks in the transmission and transfer.
If there are leaks, it is necessary to repair or replace O − rings,
FIPG’s, oil seals or other parts.
(g) Inspect and adjust the throttle cable.
(1) Check that the throttle valve is fully closed.
(2) Check that the inner cable is not slack.
(3) Loosen the adjustment nuts.
(4) Adjust the outer cable so that the distance between
the end of the boot and stopper on the cable is as
standard.
Standard boot and cable stopper distance:
0 − 1 mm (0 − 0.04 in.)
(5) Tighten the adjusting nuts.
(6) Recheck the adjustments.
(h) Adjust the shift control cable.
(1) Loosen the nut on the lever.
(2) Push the manual lever fully toward the right side of
the vehicle.

Q06077NRP
Q06078
Neutral
Basic
Line
Groove
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−183
1996 RAV4 (RM447U)
(3) Return the lever 2 notches to the NEUTRAL posi-
tion.
(4) Set the shift lever in the N position.
(5) While holding the lever lightly toward the ”R” posi-
tion side, tighten the shift lever nut.
(i) Adjust the park/neutral position switch.
If the engine will start with the shift selector in any position other
than the N or P position, adjustment is required.
(1) Loosen the park/neutral position switch bolts and
set the shift selector to the N position.
(2) Align the groove and neutral basic line.
(3) Hold in position and tighten the bolts.
Torque: 5.4 N·m(55 kgf·cm,48 in·lbf)
(j) Inspect the idle speed.
Idle speed: 750 ± 50 rpm (In N position and A/C OFF)
8. MECHANICAL SYSTEM TESTS
(a) Measure the stall speed.
The object of this test is to check the overall performance of the transaxle and engine by measuring
the stall speeds in the D and R positions.
NOTICE:
Do the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear, level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Connect OBD II scan tool or TOYOTA hand−held tester to the DLC3.
(3) Fully apply the parking brake.
(4) Keep your left foot pressed firmly on the brake pedal.
(5) Start the engine.
(6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot.
Quickly read the stall speed at this time.
Stall speed: 2,400 ± 150 rpm
(7) Do the same test in R position.
Stall speed: 2,400 ± 150 rpm
Evaluation:
ProblemPossible cause
Stall speed low in D and R positions
Engine output may be insufficient
Stator one−way clutch is operating properly
HINT:
If more than 600 rpm below the specified value, the torque converter clutch could
be faulty

S01650
S01656
SST
SST
S01620
P25458
S01614
SST
− ENGINE MECHANICALTIMING BELT
EM−17
1996 RAV4 (RM447U)
(a) Loosen the mounting bolt of the No. 1 idler pulley and shift
the pulley toward the left as far as it will go, and temporari-
ly tighten it.
(b) Remove the timing belt from the camshaft timing pulley.
18. REMOVE CAMSHAFT TIMING PULLEY
Using SST, remove the pulley bolt and timing pulley.
SST 09249−63010, 09960−10010 (09962−01000,
09963−01000)
19. REMOVE CRANKSHAFT PULLEY
HINT:
When re−using timing belt:
Remove the pulley without turning it.
20. REMOVE NO. 1 TIMING BELT COVER
(a) Disconnect the engine wire from the timing belt cover.
(b) Remove the 4 bolts and timing belt cover.
21. REMOVE TIMING BELT GUIDE
22. REMOVE TIMING BELT
HINT:
(When re−using timing belt): Draw a direction arrow on the tim-
ing belt (in the direction of engine revolution), and place match-
marks on the timing belt and crankshaft timing pulley.
23. REMOVE NO. 1 IDLER PULLEY AND TENSION
SPRING
24. REMOVE NO. 2 IDLER PULLEY
25. REMOVE CRANKSHAFT TIMING PULLEY
If the pulley cannot be removed by hand, use SST to remove
the timing pulley.
SST 09950−50010 (09951−05010, 09952−05010,
09953−05010, 09953−05020, 09954−05010)
NOTICE:
Do not scratch the angle sensor of the timing pulley.

EM0EO−03
S01634
SST
S01637
Inward
Sensor
S01625
35 mm
S01654
42 mm
S01657
Pry
Move EM−20
− ENGINE MECHANICALTIMING BELT
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL OIL PUMP PULLEY
(a) Align the cutouts of the pulley and shaft, and slide on the
pulley.
(b) Using SST, install the nut.
SST 09960−10010 (09962−01000, 09963−00600)
Torque: 24 N·m (245 kgf·cm, 18 ft·lbf)
2. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the timing pulley set key with the key groove of the
pulley.
(b) Install the timing pulley, facing the sensor side inward.
NOTICE:
Do not scratch the sensor part of the crankshaft timing
pulley.
3. INSTALL NO. 2 IDLER PULLEY
(a) Install the pulley with the bolt.
Torque: 42 N·m (425 kgf·cm, 31 ft·lbf)
HINT:
Use a bolt 35 mm (1.38 in.) in length.
(b) Check that the idler pulley moves smoothly.
4. TEMPORARILY INSTALL NO. 1 IDLER PULLEY AND
TENSION SPRING
(a) Align the bracket pin hole with the pivot pin.
(b) Install the pulley with the bolt. Do not tighten the bolt yet.
HINT:
Use a bolt 42 mm (1.65 in.) in length.
(c) Install the tension spring.
(d) Pry the pulley toward the left as far as it will go and tighten
the bolt.
(e) Check that the idler pulley moves smoothly.