1996 TOYOTA RAV4 Sensor

IG06K−02
B11571
− IGNITIONCRANKSHAFT POSITION SENSOR
IG−15
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT CRANKSHAFT POSITION SENSOR
CONNECTOR FROM GENERATOR DRIVE BELT AD-
JUSTING BAR
2. REMOVE NO.1 TIMING BELT COVER
(See page EM−15)
3. REMOVE CRANKSHAFT POSITION SENSOR
Remove the bolt and disconnect the crankshaft position sensor.

IG06M−02
IG−16
− IGNITIONCRANKSHAFT POSITION SENSOR
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
Install the crankshaft position sensor with the bolt.
Torque: 9.5 N·m (97 kgf·cm, 84 in.·lbf)
2. INSTALL NO.1 TIMING BELT COVER (See page EM−20)
3. CONNECT CRANKSHAFT POSITION SENSOR CONNECTOR TO GENERATOR DRIVE BELT AD-
JUSTING BAR

P04349
S02326
Engine
Hanger
No.1
S01635
SST
S01599
S01581
LU−8
− LUBRICATIONOIL PUMP
1996 RAV4 (RM447U)
7. REMOVE OIL PAN BAFFLE PLATE AND OIL STRAIN-
ER
Remove the 2 bolts, 2 nuts, oil strainer, baffle plate and gasket.
8. SUSPEND ENGINE WITH ENGINE SLING DEVICE
Install a engine hanger No. 1 in the correct direction.
Part No. :
Engine hanger No. 1 12281−74060
Bolt 91611−B1020
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
9. REMOVE TIMING BELT (See page EM−15)
10. REMOVE NO.2 IDLER PULLEY AND CRANKSHAFT
TIMING PULLEY (See page EM−81)
11. REMOVE OIL PUMP PULLEY
Using SST, remove the nut and pulley.
SST 09960−10010 (09962−01000, 09963−00600)
12. REMOVE CRANKSHAFT POSITION SENSOR
(a) Disconnect the connector from the generator drive belt
adjusting bar.
(b) Remove the bolt and crankshaft position sensor.
13. REMOVE OIL PUMP
(a) Remove the 12 bolts.

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.

MX05N−02
Q10400
Air Intake Connector
Engine Coolant
Reservoir Tank Clutch Release Cylinder
and Line
Vehicle Speed
Sensor Connector
Back−Up Light Switch
Connector
Control Cable
Clip
Ground Cable
Transaxle Case Protector
Tie Rod End RH Drive Shaft
Stiffener PlateNo.2 Rear
End Plate
 Snap Ring
 Cotter Pin LH Drive
Shaft
PS Gear Assembly
Engine Mounting
Center Member
RH Engine
Under Cover
LH Engine Under CoverFront Suspension Crossmember
Assembly with Stabilizer BarClipAir Cleaner Case
Assembly
with Air Hose
Snap Ring
Engine
Wire
Clamp
 Cotter Pin
Lock Cap Starter
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 
4.9 (50, 43 in.·lbf)
12 (120, 9)
29 (300, 22)
35 (360, 26)32 (330, 24)46 (470, 34)
64 (650, 47)
35 (360, 26)
64 (650, 47)
12 (120, 9)
64 (650, 47)
25 (250, 18)
25 (250, 18)
9.0 (95, 78 in.·lbf)
37 (380, 27)
39 (400, 29)
9.0 (95, 78 in.·lbf)
29 (300, 22)
37 (380, 27)49 (500, 36)
113 (1,150, 83)
137 (1,400, 101)
206 (2,100, 152)
216 (2,200, 159)
113 (1,150, 83)
64 (650, 47)
48 (490, 35)
80 (820, 59)
115 (1,170, 85)
127 (1,300, 94)
62 (630, 46)
Front Exhaust Pipe
 GasketClip
Washer
MX−2
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
1996 RAV4 (RM447U)
MANUAL TRANSAXLE UNIT (2WD)
COMPONENTS

MX05O−02
Q08747
Q08748
A
B
Q08749
Q08750
A B
A
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
MX−3
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR
HOSE
2. REMOVE ENGINE COOLANT RESERVOIR TANK
3. REMOVE ENGINE WIRE CLAMP SET NUT
4. REMOVE STARTER
(a) Disconnect the connector and wire from the starter.
(b) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
5. DISCONNECT CLUTCH RELEASE CYLINDER AND
LINE
(a) Remove the 2 set bolts of the clutch line bracket.
Torque:
Bolt A: 12 N·m (120 kgf·cm, 9 ft·lbf)
Bolt B: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
(b) Remove the 2 bolts, release cylinder and line.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
6. DISCONNECT GROUND CABLE
Remove the set bolt of the ground cable from the transaxle.
7. DISCONNECT VEHICLE SPEED SENSOR AND
BACK−UP LIGHT SWITCH CONNECTORS
8. DISCONNECT CONTROL CABLE
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
9. REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING
BOLTS
Torque:
Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf)
Bolt B: 35 N·m (360 kgf·cm, 26 ft·lbf)

MX05R−02
Q09030
Solenoid Hose No.1
Transfer Vacuum Actuator
Bracket
Transfer Vacuum Actuator Assembly
Right Transfer Stiffener Plate
Center Transfer Stiffener Plate
Differential Lock Indicator Switch Connector
Back−Up Light
Switch Connector
Vehicle Speed
Sensor Connector
Transaxle Case Protector
Starter Stiffener Plate
N·m (kgf·cm, ft·lbf): Specified torque
25 (250, 18)
37 (380, 27)
9.0 (95, 78 in.·lbf)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
46 (470, 34)
29 (300, 22)
25 (250, 18)
64 (650, 47)
39 (400, 29)
64 (650, 47)
35 (360, 26)
29 (300, 22)
Solenoid Hose No.0
Solenoid Hose No.2
Solenoid Hose No.0 MX−8
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (4WD)
1996 RAV4 (RM447U)
MANUAL TRANSAXLE UNIT (4WD)
COMPONENTS

MX05S−01
Q09031
B
A
C
FED A
A
C
Q08759
No.1
No.2 No.0
No.0
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (4WD)
MX−9
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE TRANSAXLE WITH ENGINE
(See page EM−80)
2. REMOVE TRANSAXLE CASE PROTECTOR
Remove the 2 bolts and transaxle case protector.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
3. REMOVE STARTER
(a) Disconnect the connector and wire from the starter.
(b) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
4. DISCONNECT DIFFERENTIAL LOCK INDICATOR
SWITCH, BACK−UP LIGHT SWITCH AND VEHICLE
SPEED SENSOR CONNECTORS
5. REMOVE TRANSFER VACUUM ACTUATOR BRACK-
ET
Remove the 4 bolts and bracket.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
6. REMOVE TRANSFER VACUUM ACTUATOR AS-
SEMBLY
(a) Disconnect the 4 solenoid hoses from the transfer vacu-
um actuator assembly.
NOTICE:
At the time of installation, please refer to the following item.
Check that the hose No.0, No.1 and No.2 are securely
installed to the solenoid.
(b) Remove the 2 bolts and transfer vacuum actuator assem-
bly.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
7. REMOVE RIGHT TRANSFER STIFFENER PLATE
Remove the 5 bolts and right transfer stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
8. REMOVE CENTER TRANSFER STIFFENER PLATE
Remove the 3 bolts and center transfer stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
9. REMOVE STIFFENER PLATE
Remove the 2 bolts and stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
10. REMOVE TRANSAXLE FROM ENGINE
(a) Remove the 9 transaxle mounting bolts from the engine.
Torque:
Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf)
Bolt B: 35 N·m (360 kgf·cm, 26 ft·lbf)
Bolt C: 29 N·m (300 kgf·cm, 22 ft·lbf)
Bolt D: 46 N·m (470 kgf·cm, 34 ft·lbf)
Bolt E: 25 N·m (250 kgf·cm, 18 ft·lbf)
Bolt F: 9.0 N·m (95 kgf·cm, 78 in.·lbf)