1996 TOYOTA RAV4 belt

S01559
Ground
Strap
Connector
R10966
S01283
B
SST
A
S01363
− ENGINE MECHANICALENGINE UNIT
EM−75
1996 RAV4 (RM447U)
(f) Tighten the bolt and 2 nuts holding the RH engine mount-
ing bracket to the mounting insulator.
Torque:
37 N·m (380 kgf·cm, 27 ft·lbf) for bolt
52 N·m (530 kgf·cm, 38 ft·lbf) for nut:
(g) Connect the ground strap connector.
(h) Remove the engine sling device from the engine.
(i) Remove the engine hanger No. 1.
5. INSTALL PS PUMP
(a) Install the PS pump with the 3 bolts.
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
(b) Install the belt.
(c) Tighten the bolt A.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(d) Using SST and a deep socket wrench, tighten the bolt B.
SST 09249−63010
Torque:
43 N·m (440 kgf·cm, 32 ft·lbf)
30 N·m (300 kgf·cm, 22 ft·lbf) for SST
HINT:
Use a torque wrench with a fulcrum length of 340 mm (13.39
in.).
(e) Connect the 2 air hoses.
6. INSTALL ENGINE MOUNTING CENTER MEMBER
(a) Attach the center member to the body.
(b) Temporarily install the 2 bolts holding the center member
to the body.
(c) Temporarily install the 2 bolts holding the center member
to the front engine mounting insulator.

P15297
M/T
EM1BB−02
P15299
A/T
P13432
P15304
RH Engine
Mounting
Bracket
PS Pump
Bracket
S01580
1
3
2
− ENGINE MECHANICALCYLINDER BLOCK
EM−81
1996 RAV4 (RM447U)
DISASSEMBLY
1. M/T:
REMOVE FLYWHEEL
Remove the 8 bolts and flywheel.
2. A/T:
REMOVE DRIVE PLATE
Remove the 8 bolts, front plate, drive plate and rear spacer.
3. REMOVE REAR END PLATE
Remove the bolt and end plate.
4. INSTALL ENGINE TO ENGINE STAND FOR DIS-
ASSEMBLY
5. REMOVE RH ENGINE MOUNTING BRACKET
Remove the 3 bolts and mounting bracket.
6. REMOVE PS PUMP BRACKET
Remove the 3 bolts and PS pump bracket.
7. REMOVE TIMING BELT AND PULLEYS (See page
EM−15)
8. REMOVE CYLINDER HEAD (See page EM−33)
9. REMOVE OIL PAN AND OIL PUMP (See page LU−7)
10. REMOVE GENERATOR DRIVE BELT ADJUSTING
BAR, WATER PUMP AND WATER PUMP COVER AS-
SEMBLY
(a) Remove the bolt and adjusting bar.
(b) Remove the 3 bolts in the sequence shown, remove the
water pump, water pump cover assembly and O−ring.
11. REMOVE OIL COOLER (See page LU−18)

P13453
Painted Mark
90°90°
P05527
S01632
SST
P15371
New O−Ring EM−102
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
If any one of the cap nuts does not meet the torque specifica-
tion, replace the connecting rod bolt and cap nut as a set.
(3) Mark the front of the cap nut with the paint.
(4) Retighten the cap nuts 90° as shown.
(5) Check that the painted mark is now at a 90° angle
to the front.
(c) Check that the crankshaft turns smoothly.
(d) Check the connecting rod thrust clearance (See page
EM−81).
10. INSTALL REAR OIL SEAL RETAINER
Install a new gasket and the retainer with the 6 bolts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
11. INSTALL KNOCK SENSOR
Using SST, install the knock sensor.
SST 09816−30010
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
12. INSTALL OIL COOLER AND OIL FILTER (See page
LU−20)
13. INSTALL WATER PUMP, WATER PUMP COVER AS-
SEMBLY AND GENERATOR DRIVE BELT ADJUSTING
BAR
(a) Install a new O−ring to the water pump cover.

Z17349
3
1
2
P15304
RH Engine
Mounting
Bracket
PS Pump
Bracket
P13432
EM7333
P15298
3
1
2 M/T
5
8 7
6
4
− ENGINE MECHANICALCYLINDER BLOCK
EM−103
1996 RAV4 (RM447U)
(b) Install the water pump with the 3 bolts. Tighten the bolts
in the sequence shown.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(c) Install the adjusting bar with the bolt.
Torque: 22 N·m (220 kgf·cm, 16 ft·lbf)
14. INSTALL OIL PUMP AND OIL PAN (See page LU−14)
15. INSTALL CYLINDER HEAD (See page EM−55)
16. INSTALL TIMING BELT AND PULLEYS (See page
EM−20)
17. INSTALL RH ENGINE MOUNTING BRACKET
Install the mounting bracket with the 3 bolts.
Torque: 52 N·m (530 kgf·cm, 38 ft·lbf)
18. INSTALL PS PUMP BRACKET
Install the PS pump bracket with the 3 bolts.
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
19. DISCONNECT ENGINE FROM ENGINE STAND
20. INSTALL REAR END PLATE
Install the rear end plate with the bolt.
Torque: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
21. M/T:
INSTALL FLYWHEEL
(a) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive:
Part No. 08833−00070, THREE BOND 1324 or equiva-
lent
(b) Install the flywheel on the crankshaft.
(c) Install and uniformly tighten the 8 bolts, in several passes,
in the sequence shown.
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)

11 2
UNLOCK AND SEAT BELT WARNING
2
1 215A
DOM E AUGE
BLOCK]
L-Y L-B W-
R-W
UNLOCK
W ARNING
SW
OURTESY SW
S SIDE) U 1FROM POW ER SOURCE SYSTEM (
SEE PAGE 54)
W-
W-B
ID
R- L
41918
W-B
A 8
B 5B B
2 1
R-
BUCKLE SW
LH B 6
W-B
B C
A B
W-B
W-
JUNCTION
CONNECTORB J10 , J11
A
SEAT BELT
WARNING LIGHT
[C O M B . M E T E R ]B C 9 , C11
A
JUNCTION CONNECTORB J10 , J11A
R-L
A C
-B
R-L
10A G
[FUSE 3
F 8
1H 71D11L 51J 5
BUZZER INTE G R ATIO N R EL AY
B
71
10
56
1I 9
B
1E 8 1B 8 1H 12
9
1D 51H1
Y
8
BY
1
DOOR C
(
DRIVER' D 6

11 3
CURRENT ALWAYS FLOWS TO TERMINAL 1 OF THE INTEGRATION RELAY THROUGH THE DOME FUSE.
1. SEAT BELT WARNING SYSTEM
WHEN THE IGNITION SW IS TURNED ON, CURRENT FLOWS FROM THE GAUGE FUSE TO TERMINAL 7 OF THE INTEGRATION RELAY.
AT THE SAME TIME, CURRENT FLOWS TO TERMINAL 9 OF THE RELAY FROM THE GAUGE FUSE THROUGH THE SEAT BELT
WARNING LIGHT. THIS CURRENT ACTIVATES THE INTEGRATION RELAY AND THE CURRENT FLOWING THROUGH THE WARNING
LIGHT FLOWS FROM TERMINAL 9 OF THE RELAY " TERMINAL 10 " GROUND, CAUSING THE WARNING LIGHT TO LIGHT UP. A
BUCKLE SW OFF SIGNAL IS INPUT TO TERMINAL 8 OF THE RELAY, THE CURRENT FLOWING TO TERMINAL 7 OF THE RELAY FLOWS
FROM TERMINAL 10 " GROUND AND THE SEAT BELT WARNING BUZZER SOUNDS FOR APPROX. 4-8 SECONDS. HOWEVER, IF THE
SEAT BELT IS PUT ON DURING THIS PERIOD (WHILE THE BUZZER IS SOUNDING), SIGNAL INPUT TO TERMINAL 8 OF RELAY STOPS
AND THE CURRENT FLOW FROM TERMINAL 7 OF THE RELAY " TERMINAL 10 " GROUND IS CUT, CAUSING THE BUZZER TO STOP.
2. UNLOCK WARNING SYSTEM
WITH THE IGNITION KEY INSERTED IN THE KEY CYLINDER (UNLOCK SW ON), THE IGNITION SW STILL OFF AND DRIVER'S DOOR
OPEN (DOOR COURTESY SW ON), WHEN A SIGNAL IS INPUT TO TERMINAL 6 OF THE RELAY, THE INTEGRATION RELAY OPERATES,
CURRENT FLOWS FROM TERMINAL 7 OF THE RELAY " TERMINAL 10 " GROUND AND UNLOCK WARNING BUZZER SOUNDS.
B 6 BUCKLE SW LH
1-2 : CLOSED WITH DRIVER'S SEAT BELT IN USE
D 6 DOOR COURTESY SW (DRIVER'S SIDE)
1-GROUND : CLOSED WITH LH DOOR OPEN
U 1 UNLOCK WARNING SW
10-9 : CLOSED WITH IGNITION KEY IN CYLINDER
INTEGRATION RELAY
10-GROUND : ALWAYS CONTINUITY
6-GROUND : CONTINUITY WITH THE DRIVER'S DOOR OPEN
5-GROUND : CONTINUITY WITH IGNITION KEY IN CYLINDER
8-GROUND : CONTINUITY WITH THE DRIVER'S SEAT BELT IN USE
9-GROUND :0 VOLTS WITH THE IGNITION SW ON AND THE BUCKLE SW LH OFF
1-GROUND : ALWAYS APPROX. 12 VOLTS
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
B 630D 632 (2-DOOR), 33 (4-DOOR)J11B31
C 9A30F 831U 131
C11B30J10A31
: RELAY BLOCKS
CODESEE PAGERELAY BLOCKS (RELAY BLOCK LOCATION)
223R/B NO. 2 (ENGINE COMPARTMENT LEFT)
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
1B20INSTRUMENT PANEL WIRE AND J/B NO 1 (LOWER FINISH PANEL)1D20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1E20FUSE BLOCK ASSY WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1H
1I20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1J
20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
1L20FLOOR WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
ID36LEFT KICK PANEL
SYSTEM OUTLINE
SERVICE HINTS

11 4
UNLOCK AND SEAT BELT WARNING

11 9
THE SRS IS A DRIVER AND PASSENGER PROTECTION DEVICE WHICH HAS A SUPPLEMENTAL ROLE TO THE SEAT BELTS.
WHEN THE IGNITION SW IS TURNED TO ACC OR ON, CURRENT FROM THE CIG & RAD FUSE FLOWS TO TERMINAL 10 OF THE
AIRBAG SENSOR ASSEMBLY. ONLY WHEN THE IGNITION SW IS ON DOES THE CURRENT FROM THE IGN FUSE TO TERMINAL 9.
IF AN ACCIDENT OCCURS WHILE DRIVING, WHEN THE FRONTAL IMPACT EXCEEDS A SET LEVEL, CURRENT FROM THE CIG & RAD
OR IGN FUSE FLOWS TO TERMINALS 4 AND 2 OF THE AIRBAG SENSOR ASSEMBLY " TERMINAL 1 OF THE AIRBAG SQUIB "
TERMINAL 2 " TERMINALS 3 AND 1 OF THE AIRBAG SENSOR ASSEMBLY " TERMINAL 5 OR TERMINAL 6 OR BODY GROUND "
GROUND, SO THAT CURRENT FLOWS TO THE AIRBAG SQUIBS AND CAUSES IT TO OPERATE.
THE AIRBAG STORED INSIDE THE STEERING WHEEL PAD IS INSTANTANEOUSLY EXPANDED TO SOFTEN THE SHOCK TO THE
DRIVER.
THE AIRBAG STORED INSIDE THE PASSENGER'S INSTRUMENT PANEL IS INSTANTANEOUSLY EXPANDED TO SOFTEN THE SHOCK
TO THE PASSENGER.
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
A1830C1130J 231
A1930D 128J 731
A2030F 831
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
IE20FUSE BLOCK ASSY WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
IM20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
: CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS
CODESEE PAGEJOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION)
EA134ENGINE WIRE AND ENGINE ROOM MAIN WIRE (INSIDE OF R/B NO. 2)
IB136ENGINE ROOM MAIN WIRE AND INSTRUMENT PANEL WIRE (LEFT KICK PANEL)
IG238ENGINE WIRE AND INSTRUMENT PANEL WIRE (UNDER THE INSTRUMENT PANEL CENTER)
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
EC34INTAKE MANIFOLD
ID36LEFT KICK PANEL
IE36INSTRUMENT PANEL BRACE LH
AB 12
34
5678910A18
YELLOW
12A19
YELLOW
12A20
YELLOW
4 3 XC11
GRAY
XX3
X5X
XX X11
XXX
XXX
X
X D 1
BL ACKF 8
(
SEE PAGE 26)A A A A A
AAAAAAAJ 2
BLUE
(
HINT : SEE PAGE 7)C C A A
AA CCJ 7
GRAY
(
HINT : SEE PAGE 7) B
BBB
SYSTEM OUTLINE