1996 TOYOTA RAV4 oil

R10629
BR−22
− BRAKEFRONT BRAKE PAD
1996 RAV4 (RM447U)
7. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti−squeal shims must be
replaced together with the pads.
(a) Apply disc brake grease to both side of the inner anti−
squeal shims (See page BR−20).
(b) Install the anti−squeal shim to the inner pad.
(c) Install the inner pad with pad wear indicator plate facing
upward.
(d) Install the outer pad.
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or the disc.
8. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or an equiva-
lent.
HINT:
If the piston is difficult to push in, loosen the bleeder plug and
push in the piston while letting some brake fluid escape.
(c) Install the caliper.
(d) Hold the sliding pin and torque the installation bolt.
Torque: 26 N·m (270 kgf·cm, 20 ft·lbf)
(e) Install the flexible hose bracket.
Torque: 33 N·m (340 kgf·cm, 25 ft·lbf)
9. INSTALL FRONT WHEEL
10. CHECK THAT FLUID LEVEL IS AT MAX LINE

Component to be alignedSection of repair manual
for relevant model
Front Wheels
Suspension and Axle (SA) section
Rear Wheels
Suspension and Axle (SA) section
1. Never disassemble the steering wheel pad assembly.
2. Do not subject the steering wheel pad to shocks or bring magnets close to it.
3. Do not expose the steering wheel pad to high temperatures or fire.
4. If grease, cleaner, oil or water gets on the steering wheel pad, promptly wipe it off with a dry cloth.
5. Do not drop the steering wheel pad. Never use a steering wheel pad which has been dropped.
6. Never install the steering wheel and pad in another vehicle.
7. When the steering wheel pad is removed, store it on a stable, flat place with the pad surface facing upœ
wards. Never place anything on top of the pad.
8. When work on the vehicle will produce too strong a shock, first loosen the sensor lock release bolt until
it turns freely and perform the work after sensor lock occurs.
9. Even in cases where the vehicle is in a low-impact accident where the airbag is not activated, always
check the pad surface and airbag sensor part. If dents, cracks or deformation is visible, replace the airœ
bag with a new assembly.
10. When disposing of the vehicle or steering wheel, always deploy the airbag first.
11. The deployed inflator inside the steering wheel pad is hot, so dispose of it after it has been cooled by
atmospheric air. Never apply water to cool it down.
2. BRAKE SYSTEM
The brake system is one of the most important safety components. Always follow the directions and
notes given in section BR of the repair manual for the relevant model year when handling brake system
parts.
3. DRIVE TRAIN AND CHASSIS
The drive train and chassis are components that can have great effects on the running performance
and vibration resistance of the vehicle. After installing components in the sections listed in the table
below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate
repair of the body must also be done to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions
given in the repair manual for the relevant model during alignment and section DI of this manual.
INTRODUCTIONINœ7

ANTI-RUST TREATMENT
When replacing body panels, always apply body sealer, anti-rust agent or undercoat according to the reœ
quirements of your country.
HINT: For further details, see the description given in Section AR of this manual.
BODY SEALER
Apply body sealer to the
required areas.ANTI-RUST AGENT (WAX)
Apply anti-rust agent to
following sections.

Inside of the hems of the
doors and hood.

Around the hinges of the
doors and hood.

Inside of the welded parts
with boxed cross-section.
Cartridge Type Tube Type
UNDERCOAT
Apply undercoat to the underbody and
wheel housings.
Spray Gun
Undercoating
(Oil base)Undercoating
(Water base)
INTRODUCTIONINœ13

BODY PANEL UNDERCOATING AREAS
HINT:
1. First wipe off any dirt, grease or oil with a rag soaked in a grease, wax and silicone remover.
2. Cover the surrounding areas with masking paper to avoid coating unnecessary areas. If other areas are
accidently coated, wipe off the coating immediately.
3. Apply the first coating of undercoat to all welded areas and panel joints, then apply a second coat over
the entire area.
4. Do not coat parts which become hot, such as the tailpipe, or moving parts, such as the propeller shaft.
5. Besides the locations described below, apply undercoating to all weld points under the body to insure
corrosion prevention.
6. Be sure to seal the edge of the flange of the member and bracket with undercoating.
7. If undercoat is damaged by peeling, cracks, etc., be sure to repair as necessary.
8. Before the undercoat apply sealer allowing rust prevention to be attained.
[Left Side]
[Right Side]
REFERENCE: Referring to the notes above, undercoating should be applied according to the specifications
for your country.
ANTI-RUST TREATMENTARœ8

CL04F−03
− CLUTCHTROUBLESHOOTING
CL−1
1996 RAV4 (RM447U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Clutch grabs/chatters
3. Engine mounting (Loosen)
4. Clutch disc (Runout is excessive)
5. Clutch disc (Oily)
6. Clutch disc (Worn out)
7. Clutch disc torsion rubber (Damaged)
8. Clutch disc (Glazed)
9. Diaphragm spring (Out of tip alignment)−
CL−15
CL−15
CL−15
CL−15
CL−15
CL−15
Clutch pedal spongy
1. Clutch line (Air in line)
2. Master cylinder cup (Damaged)
3. Release cylinder cup (Damaged)−
CL−5
CL−10
Clutch noisy1. Release bearing (Worn, dirty, or damaged)
2. Clutch disc torsion rubber (Damaged)CL−15
CL−15
Clutch slips
1. Clutch pedal (Free play out of adjustment)
2. Clutch disc (Oily)
3. Clutch disc (Worn out)
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion)
6. Flywheel (Distortion)CL−2
CL−15
CL−15
CL−15
CL−15
−
Clutch does not disengage
1. Clutch pedal (Free play out of adjustment)
2. Clutch line (Air in line)
3. Master cylinder cup (Damaged)
4. Release cylinder cup (Damaged)
5. Clutch disc (Out of true)
6. Clutch disc (Runout is excessive)
7. Clutch disc (Lining broken)
8. Clutch disc (Dirty or burned)
9. Clutch disc (Oily)
10.Clutch disc (Lack of spline grease)
11. Diaphragm spring (Damaged)
12.Diaphragm spring (Out of tip alignment)
13.Pressure plate (Distortion)CL−2
−
CL−5
CL−10
CL−15
CL−15
CL−15
CL−15
CL−15
CL−18
CL−15
CL−18
CL−15

CO0BD−01
− COOLINGCOOLANT
CO−1
1996 RAV4 (RM447U)
COOLANT
INSPECTION
1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR
The engine coolant level should be between the ”LOW” and ”FULL” lines, when engine is cold.
If low, check for leaks and add engine coolant up to the ”FULL” line.
2. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot, as fluid and steam can be blown out under pressure.
(b) There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler
hole, and the coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.

CO0BJ−01
S01641
Thermostat
 Gasket
Water InletOil Filter
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
8.8 (90, 78 in.·lbf)
− COOLINGTHERMOSTAT
CO−9
1996 RAV4 (RM447U)
THERMOSTAT
COMPONENTS

CO0BK−01
S01348
CO−10
− COOLINGTHERMOSTAT
1996 RAV4 (RM447U)
REMOVAL
HINT:
Removal of the thermostat would have an adverse effect, caus-
ing a lowering of cooling efficiency. Do not remove the thermo-
stat, even if the engine tends to overheat.
1. DRAIN ENGINE COOLANT
2. REMOVE OIL FILTER (See page LU−2)
3. REMOVE WATER INLET AND THERMOSTAT
(a) Remove the 2 nuts, and disconnect the water inlet from
the water pump cover.
(b) Remove the thermostat.
(c) Remove the gasket from the thermostat.