1996 TOYOTA RAV4 Service Repair Manual

SA0UT−03
W04028
Retainer Suspension Cap
Retainer Retainer Cushion
Rear
Shock
Absorber
Bushing
Brake Drum
25 (250, 18)
Cushion Retainer
Retainer
7.8 (80, 69 in.·lbf)
13 (130, 9)
18 (185, 13)
19 (195, 14)
19 (195, 14)
4WD
Lock cap
Cotter Pin
216 (2,200, 59)
80 (820, 59)

 Parking Brake Cable
113 (1,150, 83)
113 (1,150, 83)Upper Suspension Arm
113 (1,150, 83)Camber
Adjust
Cam
Lower Suspension Arm103 (1,050, 76)
Clip 
103 (1,050, 76)
132 (1,350, 98)
To e−adjust Cam
Attachment
Bushing
Rear No.1 Suspension Arm
Attachment Spring Bumper
Upper Insulator
Coil Spring
Shock Absorber
Lower Pivot pin
13 (130, 9)
140 (1,430, 103)
N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part

56 (570, 41)
37 (380, 27)
Rear Drive Shaft4WD: Rear Differential
13 (130, 9)
2WD
Rear Axle Shaft
− SUSPENSION AND AXLEREAR SUSPENSION ARM AND COIL SPRING
SA−95
1996 RAV4 (RM447U)
REAR SUSPENSION ARM AND COIL SPRING
COMPONENTS

SA0UU−03
R10779
R10764
SST
R10765
SST SA−96
− SUSPENSION AND AXLEREAR SUSPENSION ARM AND COIL SPRING
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE REAR WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. 2WD:
REMOVE AXLE SHAFT (See page SA−52)
3. 4WD:
REMOVE REAR DRIVE SHAFT (See page SA−62)
4. REMOVE BRAKE DRUM
5. REMOVE 2 BRAKE LINE CLAMP BOLTS
Torque:
Bracket: 18 N·m (185 kgf·cm, 13 ft·lbf)
Clamp: 13 N·m (130 kgf·cm, 9 ft·lbf)
6. REMOVE PARKING BRAKE CABLE CLAMP BOLT
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
7. w/ ABS:
REMOVE ABS SPEED SENSOR AND WIRE HARNESS
Torque:
ABS speed sensor: 8 N·m (80 kgf·cm, 69 in.·lbf)
Wire harness: 13 N·m (130 kgf·cm, 9 ft·lbf)
8. REMOVE REAR AXLE HUB WITH BRAKE
(a) Remove the 4 bolts and rear axle hub with brake.
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)
(b) Support it securely.
9. DISCONNECT LOWER SIDE OF SHOCK ABSORBER
(See page SA−91)
10. REMOVE UPPER AND LOWER SUSPENSION ARMS
(a) Remove the 2 clips and 2 nuts.
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
(b) Using SST, disconnect the upper suspension arm.
SST 09628−62011
(c) Using SST, disconnect the lower suspension arm.
SST 09628−62011

W01762Matchmarks
W01764
Matchmarks
− SUSPENSION AND AXLEREAR SUSPENSION ARM AND COIL SPRING
SA−97
1996 RAV4 (RM447U)
(d) Place matchmarks on the camber adjust cam and sus-
pension member.
(e) Remove the bolt, camber adjust cam, nut and lower sus-
pension arm.
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
After stabilizing the suspension, torque the bolt.
(f) Remove the bolt, nut and upper suspension arm.
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
HINT:
At the time of installaion, please refer to the following item.
After stabilizing the suspension, torque the bolt.
11. REMOVE COIL SPRING AND REAR NO.1 SUSPEN-
SION ARM
(a) Place matchmarks on the toe−adjust cam and body.
(b) Loosen the bolt and remove the coil spring and upper in-
sulator.
HINT:
At the time of installation, please refer to the following item.
Fit the lower end of the coil spring into the gap of the No.1 sus-
pension arm.
(c) Remove the bolt, toe−adjust cam, 2 attachments, nut and
lower suspension arm.
Torque: 132 N·m (1,350 kgf·cm, 98 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
After stabilizing the suspension, torque the bolt.
12. REMOVE SPRING BUMPER
Remove the bolt and spring bumper.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

SA0UV−01
R10753
SA−98
− SUSPENSION AND AXLEREAR SUSPENSION ARM AND COIL SPRING
1996 RAV4 (RM447U)
INSPECTION
INSPECT BALL JOINT FOR ROTATION CONDITION
(a) As shown in the illustration, flip the ball joint stud back and
forth 5 times, before installing the nut.
(b) Using a torque wrench, turn the nut continuously one turn
each 2 − 4 seconds and take the torque reading on the 5th
turn.
Turning Torque:
Upper suspension arm:
0.5 − 3.5 N·m (5 − 35 kgf·cm, 7 − 30 in.·lbf)
Lower suspension arm:
0.5 − 3.5 N·m (5 − 35 kgf·cm, 7 − 30 in.·lbf)

SA0UW−01
W01228
R11091
SST
R11092
5°
5°SST
Horizontal Line
Press Line
Position Mark
− SUSPENSION AND AXLEREAR SUSPENSION ARM AND COIL SPRING
SA−99
1996 RAV4 (RM447U)
REPLACEMENT
1. REMOVE SHOCK ABSORBER LOWER PIVOT PIN
(a) Mount No.1 suspension arm in a vise.
(b) Remove the nut.
(c) Using a plastic hammer, remove the pivot pin.
2. INSTALL SHOCK ABSORBER LOWER PIVOT PIN
(a) Install the pivot pin.
(b) Install the nut.
Torque: 140 N·m (1,430 kgf·cm, 103 ft·lbf)
3. REMOVE REAR NO.1 SUSPENSION ARM BUSHING
Using SST and a press, remove the bushing.
SST 09649−17010, 09710−30050
4. INSTALL NEW BUSHING
(a) Place position mark on to a new bushing, as shown.
(b) Using SST and a press, install the bushing.
SST 09710−30050
HINT:
At the time of installation, please refer to the following items.
Before installing the bushing, align the position mark and
press line.
When assembling the bushing, assemble it so that its pro-
jections are horizontal.
Do not let grease or oil get on the bushing.

SA0UX−04
SA−100
− SUSPENSION AND AXLEREAR SUSPENSION ARM AND COIL SPRING
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−96).
AFTER INSTALLATION, CHECK ABS SPEED SENSOR SIGNAL (See page DI−257) AND REAR WHEEL
ALIGNMENT (See page SA−7)

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.

FI2553
SST
S01837
Fuel
Pump
Connector
S01832
Plug SF−2
− SFISFI SYSTEM
1996 RAV4 (RM447U)
(b) When installing the battery, be especially careful not to in-
correctly connect the positive (+) and negative (−) cables.
(c) Do not permit parts to receive a severe impact during re-
moval or installation. Handle all SFI parts carefully, espe-
cially the ECM.
(d) Do not be careless during troubleshooting as there are
numerous transistor circuits and even slight terminal con-
tact can cause further troubles.
(e) Do not open the ECM cover.
(f) When inspecting during rainy weather, take care to pre-
vent entry of water. Also, when washing the engine
compartment, prevent water from getting on the SFI parts
and wiring connectors.
(g) Parts should be replaced as an assembly.
(h) Care is required when pulling out and inserting wiring con-
nectors.
(i) Release the lock and pull out the connector, pulling on the
connectors.
(j) Fully insert the connector and check that it is locked.
(k) Use SST for inspection or test of the injector or its wiring
connector.
SST 09842−30070
8. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out, so observe the following
procedures:
(1) Disconnect the fuel pump connector.
(2) Start the engine. After the engine has stopped on
its own, turn the ignition switch to LOCK.
(3) Put a container under the connection.
(4) Slowly loosen the connection.
(5) Disconnect the connection.
(6) Plug the connection with a rubber plug.