1996 TOYOTA RAV4 length

W01205
1
2
R10746
R10747
SA0028
AB
FrontA B
A: Inside
B: Outside SA−6
− SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
1996 RAV4 (RM447U)
(i) Follow the above mentioned steps again. Between the
step (b) and (c), exchange 1 or 2 selected bolts.
HINT:
When exchanging the 2 bolts, exchange 1 bolt for each time.
6. ADJUST TOE−IN
(a) Remove the boot clamps.
(b) Loosen the tie rod end lock nuts.
(c) Turn the left and right rack ends an equal amount to adjust
the toe−in.
HINT:
Try to adjust the toe−in to the center value.
Make sure that the length of the left and right rack ends
is the same.
Tie rod end length difference:
1.5 mm (0.059 in.) or less
(d) Torque the tie rod end lock nuts.
Torque: 56 N·m (570 kgf·cm, 41 ft·lbf)
(e) Place the boot on the seat and install the clamp.
HINT:
Make sure that the boots are not twisted.
7. INSPECT WHEEL ANGLE
Turn the steering wheel fully, and measure the turning angle.
Inside wheel33°15’ ± 2.0° (33.25° ± 2.0°)
Outside wheel: Reference28°05’ (28.08°)
If the wheel angles differ from the standard specification, adjust
the toe−in.

W01213
RH
LH
R10353
SST
F01439
w/o ABS w/ ABS
SST
SA1453
W00880
SST SA−28
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 RAV4 (RM447U)
(2) Make sure that the 2 boots are not stretched or con-
tracted when the drive shaft is at standard length.
Drive shaft standard length:
RH842.9 ± 5.0 mm (33.185 ± 0.197 in.)
LH542.6 ± 5.0 mm (21.362 ± 0.197 in.)
(3) Place 2 new boot clamps to the inboard joint boot.
(4) Bend the band and lock it with a screwdriver.
(5) Secure the 2 clamps onto the boot.
(6) Place SST onto the clamps.
SST 09521−24010
(7) Tighten the SST so that the clamps.
NOTICE:
Do not overtighten the SST.
(8) Using SST, adjust the clearance of the clamps.
SST 09240−00020
Clearance: 1.9 mm (0.075 in.)
2. 2WD A/T and 4WD:
REASSEMBLE DRIVE SHAFT
(a) Install the No.2 dust deflector.
Using SST and a press, install a new No.2 dust deflector.
SST 09309−36010, 09316−20011
(b) 2WD RH:
Assemble the center drive shaft.
(1) Using a pin punch and hammer, install the straight
pin into the bearing case.
(2) Using SST and a press, install a new bearing into
the bearing case.
SST 09950−60010 (09951−00580),
09950−70010 (09951−07150)
(3) Using a screwdriver, install a new snap ring.

W01214
2WD A/T RH
Others SA−30
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 RAV4 (RM447U)
(1) Place the beveled side of the tripod axial spline to-
ward the outboard joint.
(2) Align the matchmarks placed before removal.
(3) Using a brass bar and hammer, tap in the tripod to
the drive shaft.
NOTICE:
Do not tap the roller.
(4) Using a snap ring expander, install a new snap ring.
(g) Install the boot to outboard joint.
Before assembling the boot, pack the outboard joint and
boot with grease in the boot kit.
HINT:
Use the grease supplied in the boot kit.
Grease capacity (Color = Black):
120 − 130 g (4.2 − 4.6 oz.)
(h) Install the inboard joint tulip or center drive shaft to front
drive shaft.
(1) Pack the inboard joint and boot with grease in the
boot kit.
HINT:
Use the grease supplied in the boot kit.
Grease capacity (Color = Yellow ocher):
180 − 190 g (6.3 − 6.7 oz.)
(2) Align the matchmarks placed before removal, and
install the inboard joint tulip on center drive shaft to
the drive shaft.
(3) Temporarily install the boot to the inboard joint tulip.
(i) Assemble the boot clamps to both boots.
(1) Make sure that the 2 boots are on the shaft groove.
(2) Make sure that the 2 boots are not stretched or con-
tracted when the drive shaft is at standard length.
Drive shaft standard length:
2WD A/T RH844.6 ± 5.0 mm (33.252 ± 0.197 in.)
2WD A/T LH548.5 ± 5.0 mm (21.594 ± 0.197 in.)
4WD RH511.2 ± 5.0 mm (20.126 ± 0.197 in.)
4WD LH508.0 ± 5.0 mm (20.000 ± 0.197 in.)
(3) Place 4 new boot clamps to the 2 boots.
(4) Bend the band and lock it with a screwdriver.

Z13445
SA−66
− SUSPENSION AND AXLEREAR DRIVE SHAFT
1996 RAV4 (RM447U)
(c) Make sure that the 2 boots are not stretched or contracted
when the drive shaft is at standard length.
Standard length:
RH599.4 ± 5.0 mm (23.598 ± 0.197 in.)
LH553.4 ± 5.0 mm (21.787 ± 0.197 in.)
(d) Place 4 new boot clamps to the 2 boots.
(e) Bend the band and lock it with a screwdriver.

S01831
New Gasket
FI1654
Fulcrum Length
30 mm
SST
FI0420
O−Ring
Injector
GrommetDelivery PipeCORRECT
WRONG
P15485
O−Ring
Injector Grommet
O−Ring Insulator
− SFISFI SYSTEM
SF−3
1996 RAV4 (RM447U)
(b) When connecting the flare nut or union bolt on the high
pressure pipe union, observe the following procedures:
(1) Union Bolt Type:
Always use 2 new gaskets.
(2) Union Bolt Type:
Tighten the union bolt by hand.
(3) Union Bolt Type:
Tighten the union bolt to the specified torque.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(4) Flare Nut Type:
Apply a light coat of engine oil to the flare nut, and
tighten the flare nut by hand.
(5) Flare Nut Type:
Using SST, tighten the flare nut to specified torque.
SST 09631−22020
NOTICE:
Do not rotate the fuel pipe, when tightening the flare nut.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
28 N·m (285 kgf·cm, 21 ft·lbf) for SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
(c) Observe the following precautions when removing and
installing the injectors.
(1) Never reuse the O−ring.
(2) When placing a new O−ring on the injector, take
care not to damage it in any way.
(3) Coat a new O−ring with spindle oil or gasoline be-
fore installing−never use engine, gear or brake oil.
(4) Install the injector to the delivery pipe and intake
manifold as shown in the illustration.

SF0QQ−03
S01905
(4) (3)
(2)
(1)
S01907
A
B
Protrusion
(Bolt: Type A)
(Nut: Type B)B A
S01902
(1)
(3)(2) SF−30
− SFITHROTTLE BODY
1996 RAV4 (RM447U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. A/T:
DISCONNECT THROTTLE CABLE FROM THROTTLE
BODY
3. DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
4. REMOVE AIR CLEANER CAP ASSEMBLY (See page
ST−4)
5. REMOVE THROTTLE BODY
(a) Disconnect the throttle position sensor connector.
(b) Disconnect the IAC valve connector.
(c) Disconnect these hoses from the throttle body:
(1) PCV hose from air tube
(2) Vacuum hose from port ”R” of EGR vacuum modu-
lator
(3) Vacuum hose from port ”P” of EGR vacuum modu-
lator
(4) EVAP hose from chacoal canister
(d) Remove the 4 bolts (Type A) or the 2 bolts, 2 nuts (Type
B) and gasket, and diaconnect the throttle body from the
intake manifold.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
HINT:
At the time of installation, plaese refer to the following items.
Place a new gasket on the intake chamber, facing the pro-
trusion downward.
Each bolt is indicated in the illustration (Type A).
Bolt length:
A: 40 mm (1.57 in.)
B: 55 mm (2.17 in.)
(e) Disconnect these hoses from the throttle body:
(1) Water bypass hose from water outlet
(2) Water bypass hose from water bypass pipe
(3) Air hose from intake manifold

SR0FX−03
R10967
R10992
SST
R10968
SR−34
− STEERINGPOWER STEERING VANE PUMP
1996 RAV4 (RM447U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE PS VANE PUMP ROTATING TORQUE
(a) Check that the pump rotates smoothly without abnormal
noise.
(b) Using a torque wrench, check the pump rotating torque.
Rotating torque:
0.3 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less
2. REMOVE PUMP FRONT BRACKET AND PUMP
BRACKET
Remove the 2 bolts.
3. REMOVE VANE PUMP PULLEY
(a) Using SST to stop the pulley rotating, remove the pulley
set nut.
SST 09960−10010 (09962−01000, 09963−01000)
(b) Remove the woodruff key from the vane pump shaft.
4. REMOVE AIR CONTROL VALVE
Remove the union seat.
5. REMOVE PRESSURE FEED NO.2 TUBE
Remove the union bolt and 2 gaskets.
6. REMOVE SUCTION PORT UNION
(a) Remove the union set bolt.
(b) Remove the O−ring from the union.
7. REMOVE PRESSURE PORT UNION
Remove the O−ring from the union.
8. REMOVE FLOW CONTROL VALVE AND SPRING
9. REMOVE FLOW CONTROL SPRING SEAT
(a) Using snap ring pliers, remove the snap ring.
(b) Install the 2 or 3 threads of a bolt (6 mm normal diameter,
1.0 mm pitch, 50 mm length).
Reference
Bolt: 91651−60650
(c) Using pliers, remove the spring seat from the front hous-
ing.
(d) Remove the O−ring from the flow control spring seat.

SR0FY−01
W01200
Micrometer
Caliper
Gauge
Front Housing
Vane Pump Shaft Bushing
N00372
Height
LengthThickness
R10282Feeler Gauge
R13897
Inscribed Mark
SR−36
− STEERINGPOWER STEERING VANE PUMP
1996 RAV4 (RM447U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE OIL CLEARANCE BETWEEN VANE PUMP
SHAFT AND BUSHING
Using a micrometer and a caliper gauge, measure the oil clear-
ance.
Standard clearance:
0.03 − 0.05 mm (0.0012 − 0.0020 in.)
Maximum clearance: 0.07 mm (0.0028 in.)
If it is more than the maximum, replace the front housing and
vane pump shaft.
2. INSPECT VANE PUMP ROTOR AND VANE PLATES
(a) Using a micrometer, measure the height, thickness and
length of the 10 plates.
Minimum height: 8.1 mm (0.319 in.)
Minimum thickness: 1.797 mm (0.0707 in.)
Minimum length: 14.988 mm (0.59008 in.)
(b) Using a feeler gauge, measure the clearance between
the rotor groove and plate.
Maximum clearance: 0.03 mm (0.0012 in.)
If it is more than the maximum, replace the plate and/or rotor
with one having the same mark stamped on the cam ring.
Inscribed mark: 1, 2, 3, 4 or None