1996 TOYOTA RAV4 engine oil

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

Q08751
Q08752
Q10165
Filler Plug
Oil Level
0 − 5 mm
Drain Plug
Q08753
MX−4
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
1996 RAV4 (RM447U)
10. REMOVE ENGINE LEFT MOUNTING INSULATOR SET
BOLT AND 2 NUTS
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
11. INSTALL ENGINE SUPPORT FIXTURE
12. TIE PS GEAR ASSEMBLY TO ENGINE SUPPORT FIX-
TURE BY CORD OR EQUIVALENT
13. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
14. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
15. REMOVE LH AND RH ENGINE UNDER COVERS
16. DRAIN TRANSAXLE OIL
Oil grade: API GL−4 or GL−5
Viscosity: SAE 75W−90
Capacity: 3.9 liters (4.1 US qts, 3.4 Imp. qts)
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
17. REMOVE LH AND RH FRONT DRIVE SHAFTS
(See page SA−18)
18. REMOVE FRONT EXHAUST PIPE
(a) Remove the 3 nuts and gasket from the exhaust manifold.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Remove the 2 bolts, gasket and pipe.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
19. REMOVE FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY WITH STABILIZER BAR
(a) Support the front suspension crossmember with a jack.
(b) Disconnect the ring from the center exhaust pipe.
(c) Remove the 2 set bolts and nuts of the PS gear assembly.
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)

MX066−01
Z17562
Oil Cooler Clamp
Cushion
Oil Cooler Assembly
Oil Cooler Line Clamp
 O−Ring
Union
LH Engine Under Cover
 Non−reusable partOil Cooler No.2 Line
Painted Mark Line Clamp
Oil Cooler No.1 Line
: Specified torque
N·m (kgf·cm, ft·lbf)Bumper Cover RH Engine Under Cover
17 (175, 13)
34 (350, 25)
4.9 (50, 43 in.·lbf)
29 (300, 22)34 (350, 25)
6.4 (65, 56 in.·lbf)
 O−Ring
Elbow
26 (270, 20)
6.4 (65, 56 in.·lbf)
ClampCushion
6.4 (65, 56 in.·lbf)6.4 (65, 56 in.·lbf)CushionClamp
 
Line Clamp
34 (350, 25)
MX−78
− MANUAL TRANSAXLEOIL COOLER (4WD)
1996 RAV4 (RM447U)
OIL COOLER (4WD)
COMPONENTS

R10850
W01204
F01195
Bolt
Set Bolt Adjusting Bolt
1 Dot 2 Dots 3 Dots
30’
45’
1°15’
1°30’
Adjusting
ValueOD=13.9 mmOD=13.3 mm OD=12.4 mm
Original
15’
1°00’
− SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
SA−5
1996 RAV4 (RM447U)
5. ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe−in.
(a) Remove the front wheels.
(b) Remove the 2 nuts on the lower side of the shock absorb-
er.
(c) Coat the threads of the nuts with engine oil.
(d) Temporarily install the 2 nuts.
(e) Adjust the camber by pushing or pulling the lower side of
the shock adjustment is required.
(f) Tighten the 2nuts.
Torque: 158 N·m (1,610 kgf·cm, 117 ft.lbf)
(g) Install the front wheels.
Torque: 103 N·m (1,050 kgf·cm, 76 ft.lbf)
(h) Check the camber.
HINT:
Try to adjust the camber to the center value.
Adjusting value for the set bolts is 6’ − 30’ (0.1° − 0.5°).
If the camber is not within the specification, using the table be-
low, estimate for how much additional camber adjustment will
be required, and select the camber adjusting bolt.

R10678
SST
− SUSPENSION AND AXLEFRONT AXLE HUB
SA−11
1996 RAV4 (RM447U)
(b) Using SST, disconnect the tie rod end from the steering
knuckle.
SST 09610−20012
7. DISCONNECT LOWER BALL JOINT FROM LOWER
ARM
Remove the bolt and 2 nuts.
Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf)
8. REMOVE STEERING KNUCKLE WITH AXLE HUB
HINT:
At the time of installation, please refer to the following item.
Coat the threads of the nut’s with engine oil.
NOTICE:
Be careful not to damage the oil seal, boot and ABS speed
sensor rotor.

SA1YB−02
FA1535
SST
R10849
SA−20
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 RAV4 (RM447U)
REMOVAL
NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the ve-
hicle with the drive shaft bearing removed.
Therefore if it is absolutely necessary to place the ve-
hicle weight on the hub bearing, first support it with
the SST.
SST 09608−16042 (09608−02021, 09608−02041)
w/ ABS:
After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage ABS speed sensor
rotor serrations on the drive shaft.
1. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. REMOVE ENGINE UNDER COVER
3. DRAIN GEAR OIL (M/T) OR ATF (A/T)
4. w/ABS:
REMOVE BOLT AND ABS SPEED SENSOR
Torque: 8 N·m (80 kgf·cm, 69 in.·lbf)
5. REMOVE COTTER PIN, LOCK CAP AND LOCK NUT
(a) Remove the cotter pin and lock cap.
(b) With applying the brakes, remove the nut.
Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf)
6. D I S C O N N E C T T I E R O D E N D F R O M S T E E R I N G
KNUCKLE (See page SA−10)
7. DISCONNECT STABILIZER BAR LINK FROM LOWER
SUSPENSION ARM
HINT:
If the ball joint turns together with the nut, use a 5 mm hexagon
wrench to hold the stud.
Torque:
3 Door vehicle
64 N·m (650 kgf·cm, 47ft·lbf)
5 Door vehicle and all over fender vehicle
113 N·m (1,150 kgf·cm, 83 ft·lbf)
8. DISCONNECT LOWER BALL JOINT FROM LOWER
SUSPENSION ARM (See page SA−12)

SA0TL−03
R10850
R10823
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA−33
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. DISCONNECT FLEXIBLE HOSE AND ABS SPEED
SENSOR WIRE HARNESS (w/ ABS) FROM SHOCK
ABSORBER
Remove the 2 bolts and disconnect the flexible hose and ABS
speed sensor wire harness.
Torque:
Flexible hose: 19 N·m (192 kgf·cm, 14 ft·lbf)
ABS wire harness: 5 N·m (55 kgf·cm, 48 in.·lbf)
3. DISCONNECT SHOCK ABSORBER FROM STEERING
KNUCKLE
Torque: 158 N·m (1,610 kgf·cm, 117 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Coat the nut’s threads with engine oil.
4. REMOVE SHOCK ABSORBER WITH COIL SPRING
Remove the 3 nuts, suspension support No.2 and shock ab-
sorber with the coil spring.
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)

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.