1996 TOYOTA RAV4 Service Repair Manual

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.

CO0BL−03
P13560
P00436
CO1233
Valve Lift
− COOLINGTHERMOSTAT
CO−11
1996 RAV4 (RM447U)
INSPECTION
INSPECT THERMOSTAT
HINT:
The thermostat is numbered with the valve operating tempera-
ture.
(a) Immerse the thermostat in water and gradually heat the
water.
(b) Check the valve opening temperature.
Valve opening temperature:
80 − 84°C (176 − 183°F)
If the valve opening temperature is not as specified, replace the
thermostat.
(c) Check the valve lift.
Valve lift:
At 95°C (203°F): 8 mm (0.31 in.) or more
If the valve lift is not as specified, replace the thermostat.
(d) Check that the valve is fully closed when the thermostat
is at low temperatures (below 40°C (104°F)).
If not closed, replace the thermostat.

CO0BM−02
P13611
Protrusion
Jiggle
Valve5° 5° CO−12
− COOLINGTHERMOSTAT
1996 RAV4 (RM447U)
INSTALLATION
1. PLACE THERMOSTAT IN WATER PUMP
(a) Install a new gasket to the thermostat.
(b) Align the jiggle valve of the thermostat with the protrusion
of the water inlet, and insert the thermostat in the water
inlet.
HINT:
The jiggle valve may be set within 5° of either side of the pre-
scribed position.
2. INSTALL WATER INLET AND THERMOSTAT
Install the water inlet and thermostat with the 2 nuts.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
3. INSTALL OIL FILTER (See page LU−2)
4. FILL WITH ENGINE COOLANT
5. START ENGINE AND CHECK FOR LEAKS
6. CHECK ENGINE OIL LEVEL

CO0BN−01
− COOLINGRADIATOR
CO−13
1996 RAV4 (RM447U)
RADIATOR
ON−VEHICLE CLEANING
Using water or a steam cleaner, remove any mud or dirt from the radiator core.
NOTICE:
If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Main-
tain a distance between the cleaner nozzle and radiator core.)

CO0BO−02
Z00570
Radiator Cap Tester
Radiator Cap30° or More
S01265
Radiator Cap Tester CO−14
− COOLINGRADIATOR
1996 RAV4 (RM447U)
ON−VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
2. INSPECT RADIATOR CAP
NOTICE:
If the radiator cap has contaminations, always rinse
it with water.
When performing steps (a) and (b) below, keep the ra-
diator cap tester at an angle of over 30°above the hor-
izontal.
(a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed:
1 push/(3 seconds or more)
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(b) Pump the tester and measure the relief valve opening
pressure.
Pump speed:
1 push within 1 second
NOTICE:
This pump speed is for the first pump only (in order to close
the vacuum valve). After this, the pump speed can be re-
duced.
Standard opening pressure:
74 − 103 kPa (0.75 − 1.05 kgf/cm
2, 10.7 − 14.9 psi)
Minimum opening pressure:
59 kPa (0.6 kgf/cm
2, 8.5 psi)
HINT:
Use the tester’s maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 118kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and cylinder head.
4. REINSTALL RADIATOR CAP

CO0BP−02
S01819
Lower Radiator
Hose
No.2 Cooling
Fan Connector
(w/ A/C)
Radiator
Assembly Upper Radiator
Support
ECT Switch
ConnectorRadiator
Upper Radiator
SupportNo.1 Cooling FanNo.2 Cooling Fan
(w/ A/C)
Radiator Cap
Upper Radiator Hose
Engine Wire
Radiator Reservoir Hose
A/T Oil Cooler Hose
 O−Ring
No.1 Cooling
Fan Connector Lower Radiator
Support Cooler Condenser
RH Engine
Under Cover
LH Engine
Under CoverLH Engine
Under Cover
 Non−reusable partM/TA/TDrain Plug
− COOLINGRADIATOR
CO−15
1996 RAV4 (RM447U)
COMPONENTS

CO0BQ−03
S01355
S01278
w/ A/C
S01293
CO−16
− COOLINGRADIATOR
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE ENGINE UNDER COVERS
2. DRAIN ENGINE COOLANT
3. w/ A/C:
REMOVE COOLER CONDENSER (See page AC−47)
4. REMOVE RADIATOR ASSEMBLY
(a) Disconnect the No.1 cooling fan connector.
(b) w/ A/C:
Disconnect the No.2 cooling fan connector.
(c) Disconnect the ECT switch connector for electric cooling
fan.
(d) Disconnect the engine wire clamp from No.1 cooling fan
shroud.
(e) Disconnect the upper radiator hose from radiator.
(f) Disconnect the lower radiator hose from radiator.
(g) Disconnect the radiator reservoir hose from radiator.
(h) Disconnect the 2 A/T oil cooler hoses from oil cooler
pipes.
(i) Remove the 2 bolts and 2 upper radiator supports.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(j) Remove the radiator assembly.
HINT:
At the time of installation, plaese refer to the following items. Af-
ter installation, check that the rubber cushion (A) of the support
is not depressed.
(k) Remove the 2 lower radiator supports.
5. w/ A/C:
REMOVE NO.2 COOLING FAN FROM RADIATOR
Remove the 3 bolts and cooling fan.
Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf)
6. REMOVE NO.1 COOLING FAN FROM RADIATOR
Remove the 4 bolts and cooling fan.
Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf)

CO18K−01
− COOLINGRADIATOR
CO−17
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page CO−16).