1996 TOYOTA RAV4 drain bolt

EM1B8−02
S01285
S01557
− ENGINE MECHANICALCYLINDER HEAD
EM−33
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. A/T only:
DISCONNECT THROTTLE CABLE FROM THROTTLE
BODY
4. DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
5. REMOVE AIR CLEANER CAP AND CASE
6. REMOVE GENERATOR (See page CH−7)
7. REMOVE DISTRIBUTOR
8. REMOVE FRONT EXHAUST PIPE
(a) Using a 14 mm deep socket wrench, remove the 3 nuts
holding the front exhaust pipe to the front TWC.
(b) Remove the 2 bolts holding the front exhaust pipe to the
TWC w/ pipe.
(c) Remove the front exhaust pipe and 2 gaskets.
9. REMOVE EXHAUST MANIFOLD AND HEAT INSULA-
TOR ASSEMBLY
(a) Disconnect the oxygen sensor (bank 1 sensor 1) connec-
tor.
(b) Disconnect the oxygen sensor (bank 1 sensor 2) connec-
tor.
(c) Remove the 6 bolts and manifold upper heat insulator.
(d) Remove the 2 bolts holding the RH exhaust manifold stay
to the cylinder block.
(e) Remove the 6 nuts, the exhaust manifold and heat insula-
tor assembly.

EM1BA−02
S01374
Cover
Connector EM−68
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE BATTERY
2. REMOVE ENGINE HOOD
3. REMOVE ENGINE UNDER COVERS
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL
6. DRAIN TRANSAXLE OIL
7. REMOVE AIR CLEANER CAP AND CASE
8. DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY, CABLE BRACKET AND CLAMPS
9. DISCONNECT ENGINE WIRE FROM RELAY BLOCK
NO. 2
(a) Remove the 2 bolts, and disconnect the relay block No.
2 from the body.
(b) Remove the upper cover.
(c) Disconnect the connector.
(d) Remove the 2 nuts and disconnect the engine wire.
10. REMOVE CHARCOAL CANISTER
11. REMOVE GENERATOR (See page CH−7)
12. REMOVE RADIATOR UPPER AND LOWER HOSES
13. REMOVE WATER INLET
Remove the 2 nuts and water inlet.
14. DISCONNECT HEATER HOSES
15. DISCONNECT FUEL INLET HOSE
CAUTION:
Catch leaking fuel in a container.
16. M/T only:
REMOVE STARTER (See page ST−4)
17. DISCONNECT GROUND CABLE
Remove the bolt and disconnect the ground cable on the trans-
axle.

LU0O4−01
S01775S01237B13839
M/T
A/T
S01375
P04282
SST
SST
− LUBRICATIONOIL PUMP
LU−7
1996 RAV4 (RM447U)
REMOVAL
HINT:
When repairing the oil pump, the oil pan and strainer should be
removed and cleaned.
1. REMOVE HOOD
2. REMOVE RH ENGINE UNDER COVER
3. DRAIN ENGINE OIL
4. REMOVE FRONT EXHAUST PIPE (See page EM−33)
5. REMOVE STIFFENER PLATE
Remove the 2 bolts (M/T) or 3 bolts (A/T) and stiffener plate.
6. REMOVE OIL PAN
(a) Remove the dipstick.
(b) Remove the 17 bolts and the 2 nuts.
(c) Insert the blade of SST between the cylinder block and oil
pan, and cut off applied sealer and remove the oil pan.
SST 09032−00100
NOTICE:
Do not use SST for the oil pump body side and rear oil
seal retainer.
Be careful not to damage the oil pan flange.

LU06A−03
S01365
S01359
SST
S01366
LU−18
− LUBRICATIONOIL COOLER
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE FRONT EXHAUST PIPE (See page EM−33)
4. REMOVE GENERATOR (See page CH−7)
5. REMOVE OIL DIPSTICK
6. REMOVE EXHAUST MANIFOLD AND FRONT TWC
ASSEMBLY (See page EM−33)
7. REMOVE WATER BYPASS PIPE HEAT PROTECTOR
Remove the bolt, 2 nuts and heat protector.
8. REMOVE OIL FILTER
Using SST, remove the oil filter.
SST 09228−06501
9. REMOVE OIL COOLER
(a) Disconnect the 2 water bypass hoses from the oil cooler.
(b) Remove the union bolt and plate washer.
(c) Remove the nut and oil cooler.
(d) Remove the O−ring from the oil cooler.

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)

Q09034

N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 Precoated partTransmission Case Cover Transmission CaseNo.2 Selecting Bellcrank with
Selecting Bellcrank Support Shift and Select Lever
Shaft Assembly
No.1 Oil Receiver Pipe Reverse Restrict
Pin Straight Screw PlugBack−Up Light SwitchNo.3 Shift Fork No.3 Shift Fork ShaftInterlock Roller
Snap RingShift Head
Shift and Select Lever
Shaft Lock BoltNo.2 Shift Fork Shaft Straight Screw Plug Reverse Shift Arm Bracket Assembly
Snap Ring
Reverse Shift Fork
No.1 Shift Fork
No.1 Shift Fork Shaft Seat
Spring
Ball
Slotted Spring
PinSnap RingSnap Ring
No.2 Shift Fork
No.2 Oil Receiver Pipe
Drain Plug Filler Plug
x10 x17


24 (240, 17)
25 (250, 18)
25 (250, 18)
24 (240, 17)
24 (240, 17)
25 (250, 18)
17 (175, 13)
40 (410, 30)
13 (130, 9)49 (500, 36)20 (200, 14)
17 (175, 13)
29 (300, 22)
49 (500, 36)
20 (200, 14)
49 (500, 36)
49 (500, 36)
29 (300, 22)
Breather Plug Gasket  Gasket
 Gasket  Gasket Gasket
 Gasket MX−14
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)

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)

SA0UJ−01
W04156
R10756
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−73
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE DRIVE SHAFTS (See page SA−62)
HINT:
Support the drive shafts securely.
2. REMOVAL PROPELLER SHAFT (See page PR−2)
HINT:
Support the propeller shaft securely.
3. DRAIN DIFFERENTIAL OIL
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
4. REMOVE DIFFERENTIAL
(a) Support the differential with a jack.
(b) Remove the 2 rear mounting bolts.
Torque: 65 N·m (660 kgf·cm, 48 ft·lbf)
(c) Remove the 2 front mounting bolts and differential.
Torque: 132 N·m (1,350 kgf·cm, 98 ft·lbf)
(d) Remove the 2 bolts and differential rear mount cushion
from the differential.
Torque: 137 N·m (1,400 kgf·cm, 101 ft·lbf)