1996 TOYOTA RAV4 Service Repair Manual

LU0LF−01
P05146
P25468
LU−10
− LUBRICATIONOIL PUMP
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE RELIEF VALVE
(a) Using snap ring pliers, remove the snap ring.
(b) Remove the retainer, spring and relief valve.
2. REMOVE DRIVE AND DRIVEN ROTORS
Remove the 2 bolts, pump body cover, O−ring, the drive and
driven rotors.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
HINT:
At the time of reassembly, please refer to the following items.
Place the drive and driven rotors into pump body with the
marks facing the pump body side.
Use a new O−ring.

LU065−02
P04232
P04350
P04233
− LUBRICATIONOIL PUMP
LU−11
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT RELIEF VALVE
Coat the valve with engine oil and check that it falls smoothly
into the valve hole by its own weight.
If it doesn’t, replace the relief valve. If necessary, replace the oil
pump assembly.
2. INSPECT DRIVE AND DRIVEN ROTORS
3. INSPECT ROTOR BODY CLEARANCE
Using a feeler gauge, measure the clearance between the driv-
en rotor and body.
Standard body clearance:
0.10 − 0.16 mm (0.0039 − 0.0063 in.)
Maximum body clearance:
0.20 mm (0.0079 in.)
If the body clearance is greater than maximum, replace the ro-
tors as a set. If necessary, replace the oil pump assembly.
4. INSPECT ROTOR TIP CLEARANCE
Using a feeler gauge, measure the clearance between the drive
and driven rotor tips.
Standard tip clearance:
0.04 − 0.16 mm (0.0016 − 0.0063 in.)
Maximum tip clearance:
0.20 mm (0.0079 in.)
If the tip clearance is greater than maximum, replace the rotors
as a set.

LU066−02
P05373
P25628
SST LU−12
− LUBRICATIONOIL PUMP
1996 RAV4 (RM447U)
REPLACEMENT
1. REMOVE OIL SEAL
Using a screwdriver, pry out the oil seal.
2. INSTALL OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the oil pump cover edge.
SST 09950−60010 (09951−00310),
09950−70010 (09951−07100)
(b) Apply MP grease to the oil seal lip.
3. REPLACE CRANKSHAFT FRONT OIL SEAL (See
page EM−96)

LU067−01
− LUBRICATIONOIL PUMP
LU−13
1996 RAV4 (RM447U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page LU−10).

LU0O5−01
Z17341
A
B AA A
A A
A
AAA
B
S01599
S01633
SST LU−14
− LUBRICATIONOIL PUMP
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL OIL PUMP
Install a new gasket and the oil pump with the 12 bolts. Uniform-
ly tighten the bolts is several passes.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
HINT:
Each bolt length is indicated in the illustration.
Bolt length:
A: 25 mm (0.98 in.)
B: 35 mm (1.38 in.)
2. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the crankshaft position sensor with the bolt.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(b) Connect the connector to the generator drive belt adjust-
ing bar.
3. INSTALL OIL PUMP PULLEY
(a) Align the cutouts of the pulley and shaft, and slide on the
pulley.
(b) Using SST, install the pulley nut.
SST 09960−10010 (09962−01000, 09963−00600)
Torque: 24 N·m (245 kgf·cm, 18 ft·lbf)
4. INSTALL CRANKSHAFT TIMING PULLEY AND NO.2
IDLER PULLEY (See page EM−20)
5. INSTALL TIMING BELT (See page EM−20)
6. REMOVE ENGINE SLING DEVICE
Remove the engine hanger No.1.

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.

S01775S01237B13839
A/T M/T LU−16
− LUBRICATIONOIL PUMP
1996 RAV4 (RM447U)
9. INSTALL STIFFENER PLATE
Install the stiffener plate with the 2 bolts (M/T) or 3 bolts (A/T).
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
10. INSTALL FRONT EXHAUST PIPE (See page EM−55)
11. FILL WITH ENGINE OIL
12. START ENGINE AND CHECK FOR LEAKS
13. RECHECK ENGINE OIL LEVEL
14. INSTALL RH ENGINE UNDER COVER
15. INSTALL HOOD

LU069−03
− LUBRICATIONOIL COOLER
LU−17
1996 RAV4 (RM447U)
OIL COOLER
COMPONENTS