1996 TOYOTA RAV4 Sensor

S01653
1 2
S01646
S01647
S01645
S01432
EM−36
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(c) Disconnect the engine wire protector from the 2 mounting
bolts of the No. 2 timing belt cover in the sequence shown.
(d) Remove the 4 nuts, grommets, head cover and gasket.
HINT:
Arrange the grommets in the correct order, so that they can be
reinstalled into their original positions. This minimizes any pos-
sibility of oil leakage due to reuse of the grommets in different
positions.
27. DISCONNECT ENGINE WIRE
(a) Remove the 2 bolts, and disconnect the engine wire pro-
tector from the LH side of the intake manifold.
(b) Disconnect the 4 injector connectors.
(c) w/ A/C:
Disconnect the A/C compressor connector.
(d) Disconnect the crankshaft position sensor connector.
(e) Disconnect the 3 clamps from the No. 2 timing bet cover
and generator drive belt adjusting bar.
(f) Disconnect the engine wire protector from the 2 brackets
on the front side of the intake manifold.
(g) Remove the RH scuff plate, RH cowl side trim and RH
floor carpet center cover.
(h) Disconnect the 2 ECM connectors.
(i) Disconnect the 2 connectors from the connectors on the
bracket.
(j) Disconnect the Connector from the J/B No. 4.
(k) Disconnect the wire clamp from the bracket.
(l) Pull out the engine wire from the cabin.
(m) Take out the engine wire between the cylinder head and
intake manifold.
28. DISCONNECT TIMING BELT FROM CAMSHAFT TIM-
ING PULLEY (See page EM−15)
29. REMOVE CAMSHAFT TIMING PULLEY (See page
EM−15)
30. REMOVE NO. 1 IDLER PULLEY AND TENSION
SPRING

S01647
S01432
P03283
: Seal Packing
S01658Marking 15°
15°
Z17351
12 EM−60
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(c) Install the engine wire protector to the LH side of the in-
take manifold with the 2 bolts.
(d) Push in the engine wire through the cowl panel.
(e) Install the wire clamp to the bracket.
(f) Connect the 2 ECM connectors.
(g) Connect the 2 connectors to the connectors on the brack-
et.
(h) Connect the connector to the J/B No. 4.
(i) Install the RH floor carpet center cover.
(j) Install the RH cowl side trim.
(k) Install the RH scuff plate.
16. INST ALL CYLINDER HEAD COVER
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as shown in the
illustration.
Seal packing: Part No. 08826−00080 or equivalent
(c) Install the gasket to the head cover.
(d) Install the head cover with the 4 grommets and nuts. Uni-
formly tighten the nuts in several passes.
Torque: 23 N·m (230 kgf·cm, 17 ft·lbf)
HINT:
Install the grommets so that their markings are as shown in the
illustration.
(e) Install the engine wire protector to the 2 mounting bolts of
the No. 2 timing belt cover in the sequence shown.
(f) Connect the 3 clamps to the No. 2 timing belt cover and
generator drive belt adjusting bar.
(g) Connect the crankshaft position sensor connector.
(h) w/ A/C:
Connect the A/C compressor connector.

S01791
S01644
S01806
− ENGINE MECHANICALCYLINDER HEAD
EM−61
1996 RAV4 (RM447U)
(i) Connect the PCV hose to the intake manifold.
(j) Install the accelerator cable bracket with the 2 bolts.
17. INSTALL VSV FOR EGR (See page SF−42)
18. CONNECT GROUND CABLE
Connect the ground cable to the intake manifold with the bolt.
19. CONNECT KNOCK SENSOR CONNECTOR
20. CONNECT PS IDLE−UP AIR HOSES TO AIR TUBE
21. A/T only:
CONNECT A/T THROTTLE CONTROL CABLE TO IN-
TAKE MANIFOLD
Connect the control cable to the clamp on the rear side of the
intake manifold.
22. INSTALL INTAKE MANIFOLD STAY
Install the intake manifold stay with the 2 bolts.
Torque: 42 N·m (425 kgf·cm, 31 ft·lbf)
23. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket and the EGR valve with the union nut
and 2 nuts.
Torque:
13 N·m (130 kgf·cm, 9 ft·lbf) for nut
59 N·m (600 kgf·cm, 43 ft·lbf) for union nut
(b) Install the vacuum modulator to the clamp on the intake
manifold.
(c) Connect the 2 vacuum hoses to the VSV for the EGR.
24. CONNECT FUEL INLET HOSE TO FUEL FILTER
Connect the inlet hose with 2 new gaskets and the union bolt.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

S01560
(1)
(2)
(3)
P15451
ConnectNew
New
Gasket
O−Ring
S01594
S01368
EM−62
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
25. INSTALL HOSES AND GROUND STRAP
(a) Connect the vacuum sensor hose to the gas filter on the
intake manifold.
(b) Connect the brake booster vacuum hose to the intake
manifold.
(c) Connect the ground strap to the intake manifold.
26. INSTALL THROTTLE BODY (See page SF−33)
27. INSTALL WATER BYPASS PIPE
(a) Install a new gasket to the water pump cover.
(b) Install a new O−ring to the bypass pipe.
(c) Apply soapy water on the O−ring.
(d) Connect the water bypass pipe to the water pump cover.
(e) Install the bypass pipe with the 2 nuts and 2 bolts.
Torque:
9.3 N·m (95 kgf·cm, 82 in.·lbf) fot nut
19 N·m (195 kgf·cm, 14 ft·lbf) fot bolt
(f) Connect the engine wire protector with the nut.
(g) Connect the IAC valve water bypass hose to the water by-
pass pipe.
(h) Connect the heater water hose to the water bypass pipe.
(i) Connect the 2 oil cooler water bypass hoses to the oil
cooler.
(j) Install the oil cooler heat protector with the 2 nuts and bolt.
28. INSTALL WATER OUTLET
(a) Install a new gasket and the water outlet with the 2 nuts.
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
(b) Connect the radiator hose to the water outlet.
(c) Connect the water bypass pipe hose to the water outlet.
(d) Connect the heater water hose to the water outlet.
(e) Connect the IAC valve water bypass hose to the water
outlet.
(f) Connect the ECT sensor connector.
(g) Connect the ECT sender gauge connector.

P03469
Retainer
Cushion
New Gasket
S01823
Oxygen Sensor
(Bank 1 Sensor 1)
Oxygen Sensor (Bank 1 Sensor 2)
S01557
− ENGINE MECHANICALCYLINDER HEAD
EM−63
1996 RAV4 (RM447U)
29. CONNECT OIL PRESSURE SWITCH CONNECTOR
30. ASSEMBLE EXHAUST MANIFOLD AND FRONT TWC
(a) Place the cushion, retainer and a new gasket on the
TWC.
(b) Install the TWC to the exhaust manifold with the 3 bolts
and 2 nuts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(c) Install the lower manifold heat insulator with the 5 bolts.
(d) Install the 2 TWC heat insulators with the 8 bolts.
31. INSTALL OXYGEN SENSOR (BANK 1 SENSOR 1) TO
EXHAUST MANIFOLD
Install a new gasket and the oxygen sensor with 2 new nuts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
32. INSTALL OXYGEN SENSOR (BANK 1 SENSOR 2) TO
FRONT TWC
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
33. INSTALL EXHAUST MANIFOLD AND FRONT TWC AS-
SEMBLY
(a) Install a new gasket, the exhaust manifold and TWC as-
sembly with the 6 nuts. Uniformly tighten the nuts in sev-
eral passes.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
(b) Install the RH exhaust manifold stay with the 2 bolts and
2 new nuts.
Torque: 42 N·m (452 kgf·cm, 31 ft·lbf)
(c) Install the upper manifold heat insulator with the 6 bolts.
(d) Connect the oxygen sensor (bank 1 sensor 1) connector.
(e) Connect the oxygen sensor (bank 1 sensor 2) connector.
34. INSTALL FRONT EXHAUST PIPE (See page EM−74)
35. INSTALL GENERATOR (See page CH−19)
36. INSTALL AIR CLEANER CASE AND CAP
37. CONNECT ACCELERATOR CABLE TO THROTTLE
BODY AND CABLE BRACKET
38. A/T only:
CONNECT THROTTLE CABLE TO THROTTLE BODY
AND CABLE BRACKET

EM0EV−02
A04063
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable part
29 (300, 22)
Hold Down ClampHold Down Clamp
BatteryEngine Hood
Battery Tray
Lower Radiator
HosePS Pump
w/ BracketCharcoal Canister
Battery Tray
IAT Sensor ConnectorAir Cleaner Cap
 Gasket
 Gasket
Fuel Inlet Hose
Fuel Filter
Water Inlet
Upper Radiator
Hose
Heater Hose
PS Pump Drive Belt
Generator Drive
Belt
Accelerator Cable
Generator
Generator Drive Belt
Adjusting Bar
Air Filter
EVAP VSV Connector
Air Cleaner Case
Radiator
Reservoir
Relay Block No. 2
Upper Cover
Relay Block No. 2
Wire Harness
A/C Compressor
Type B Type A
Type B Type A
− ENGINE MECHANICALENGINE UNIT
EM−65
1996 RAV4 (RM447U)
ENGINE UNIT
COMPONENTS

S01432
S01285
S01347
EM−70
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
22. DISCONNECT CONNECTORS, CORD, STRAP AND
HOSES
(a) Disconnect the vapor pressure sensor connector.
(b) Disconnect the igniter connector.
(c) Disconnect the ignition coil connector.
(d) Disconnect the noise filter connector.
(e) Disconnect the high−tension cord from the ignition coil.
(f) Disconnect the MAP sensor connector.
(g) Disconnect the MAP sensor vacuum hose from the gas
filter on the intake manifold.
(h) Disconnect the brake booster hose from the intake man-
ifold.
(i) 4WD M/T:
Disconnect the differential lock control solenoid connec-
tor.
(j) Disconnect the ground strap from the cowl.
23. DISCONNECT ENGINE WIRE FROM CABIN
(a) Remove the RH scuff plate.
(b) Remove the RH cowl side trim.
(c) Remove the RH floor carpet center cover.
(d) Disconnect the 2 ECM connectors.
(e) Disconnect the 2 connectors from the connectors on the
bracket.
(f) Disconnect the connector from the J/B No. 4.
(g) Disconnect the wire clamp from the bracket.
(h) Pull out the engine wire from the cabin.
24. REMOVE FRONT EXHAUST PIPE
(a) Using a 14 mm deep socket wrench, remove the 2 bolts
holding the front exhaust pipe to the front TWC.
(b) Remove the 2 bolts and 2 nuts holding the front exhaust
pipe to the TWC w/ pipe.
(c) Remove the front exhaust pipe and 2 gaskets.
25. DISCONNECT A/C COMPRESSOR FROM ENGINE
(a) Disconnect the A/C compressor connector.
(b) Remove the 2 bolts, nut and stud bolt, and disconnect the
A/C compressor from the engine.
HINT:
Suspend the A/C compressor securely.
26. 4WD only:
REMOVE PROPELLER SHAFT (See page PR−3)
27. REMOVE FRONT DRIVE SHAFT (See page SA−20)
28. REMOVE STABILIZER (See page SA−40)

S01797
M/T
A/T
S01785
A/T Only
S01351
M/T Only
Back−up Light
Connector EM−78
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
14. CONNECT CONNECTORS, CORD, STRAP AND
HOSES
(a) Connect the vapor pressure sensor connector.
(b) Connect the igniter connector.
(c) Connect the ignition coil connector.
(d) Connect the noise filter connector.
(e) Connect the high−tension cord to the ignition coil.
(f) Connect the MAP sensor connector.
(g) Connect the MAP sensor vacuum hose to the gas filter on
intake manifold.
(h) Connect the brake booster hose to the intake manifold.
(i) 4WD M/T:
Connect the differential lock control solenoid connector.
(j) Connect the ground strap to the cowl.
15. A/T and 4WD w/ M/T:
CONNECT TRANSAXLE OIL COOLER HOSES
16. CONNECT TRANSAXLE CONTROL CABLE(S) TO
TRANSAXLE
17. A/T only:
INSTALL TRANSAXLE CONTROL CABLE TO FRONT
SUSPENSION CROSSMEMBER AND ENGINE
MOUNTING CENTER MEMBER
18. M/T only:
INSTALL CLUTCH RELEASE CYLINDER
(a) Install the release cylinder with the 2 bolts.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
(b) Install the bracket with the bolt, and install the tube to the
bracket with the clamp.
(c) Install the tube with the clamp and bolt.
(d) Connect the back−up light switch connector.
19. CONNECT GROUND CABLE
Connect the ground cable onto the transaxle.
20. M/T only:
INSTALL STARTER (See page ST−19)
21. CONNECT FUEL INLET HOSE TO FUEL FILTER
Connect the inlet hose with 2 new gaskets and the union bolt.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
22. CONNECT HEATER HOSES
23. INSTALL WATER INLET
Install the water inlet with the 2 nuts.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
24. INSTALL RADIATOR UPPER AND LOWER HOSES