1996 TOYOTA RAV4 light

BR0M3−01
F03521
SST
Gasket
N00744
SST
− BRAKEBRAKE BOOSTER ASSEMBLY
BR−19
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque:
13 N·m (130 kgf·cm, 9 ft·lbf)
(d) Insert the clevis pin into clevis, brake pedal, and install the
clip to the clevis pin.
(e) Install the pedal return spring.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install a new gasket on the master cylinder.
(b) Set the SST on the gasket, and lower the pin until its tip
slightly touches the piston.
SST 09737−00010
(c) Turn the SST upside down, and set it on the booster.
SST 09737−00010
(d) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod
slightly touches the pin head.
3. INSTALL CHARCOAL CANISTER TO ORIGINAL POSI-
TION
4. INSTALL MASTER CYLINDER
5. CONNECT VACUUM HOSE TO BRAKE BOOSTER
6. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR−4)
7. M/T:
BLEED CLUTCH SYSTEM
8. CHECK FOR LEAKS
9. CHECK AND ADJUST BRAKE PEDAL
(See page BR−6)
Check and adjust the brake pedal, then tighten the clevis lock
nut.
Torque:
25 N·m (260 kgf·cm, 19 ft·lbf)
10. DO OPERATIONAL CHECK (See page BR−16)

mm in.
5
0.20
1. Before temporarily installing the new parts, apply
body sealer to the wheel arch.
HINT:
1) Apply body sealer about 5 mm (0.20in.) from the
flange, avoiding any oozing.
2) Apply sealer evenly, about 3 - 4 mm (0. 12 -
0.16in.) in diameter.
3) For other sealing points, refer to section AR.
SYMBOLS
See page IN-4.
RH:
LH: BODY PANEL REPLACEMENT
RE-11
INSTALLATION
Butt Weld
Body Sealer
Butt Weld
Butt weld
Body sealer
Braze
about 5 mm
RH:
LH:
2. Temporarily install the new parts and check the fit
of the rear door, back door and rear combination
light.
INSTALLATION DIAGRAM
Describes in detail installation of the new parts involving repair by welding and/or cutting, but exœ
cluding painting.
INSTALLATION GUIDE
Provides additional information to more efficiently help you perform the installation.
ILLUSTRATION OF WELD POINTS
Weld method and panel position symbols.
See page IN-5.
INTRODUCTIONINœ3

Fuse BlockEngine ECU R/B No. 5 J/B No. 1J/B No. 4 ABS ECUDaytime Running
Light Relay (*1) Door Look Control RelayA/C Amplifier J/B No. 3
4. ECU (ELECTRONIC CONTROL UNIT)
Locations of ECUs
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.

Before starting electric welding operations, disconnect the negative (-) terminal cable from the battery.
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all
equipped with memory function, it is not possible to make a record of the memory contents.
So when the operation is finished, it will be necessary to explain this fact to the customer, and request
the customer to adjust the features and reset the memory.

Do not expose the ECUs to ambient temperatures above 80°C (176°F).
NOTICE: If it is possible the ambient temperature may reach 80 °C (176 °F) or more, remove the ECUs
from the vehicle before starting work.

Be careful not to drop the ECUs and not to apply physical shocks to them.
4. COMPONENTS ADJACENT TO THE BODY PANELS
Various types of component parts are mounted directly on or adjacently to the body panels.
Strictly observe the following precautions to prevent damaging these components and the body panels
during handling.

Before repairing the body panels, remove their components or apply protective covers over the comœ
ponents.

Before prying components off using screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components and the body paint.

Before removing components from the outer surface of the body, attach protective tape to the body to
ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.

Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.
INTRODUCTIONINœ8

mm in.
5
0.20
INSTALLATION
Butt Weld
Body Sealer
Butt Weld
RH:
LH:
Butt weld
Body sealer
Braze
about 5 mm
RH:
LH:
2. Temporarily install the new parts and check
the fit of the rear door, back door and rear
combination light. 1. Before temporarily installing the new parts,
apply body sealer to the wheel arch.
HINT:
1) Apply body sealer about 5 mm (0.20in.) from
the flange, avoiding any oozing.
2) Apply sealer evenly, about 3 - 4 mm (0.12 -
0.16in.) in diameter.
3) For other sealing points, refer to section AR.
BODY PANEL REPLACEMENTREœ11

mmin.
5
0.20Braze
INSTALLATION
Butt Weld
Body Sealer
RH:
LH:
Body Sealer
about 5 mm
RH:
LH:
1. Before temporarily installing the new parts,
apply body sealer to the wheel arch.
HINT:
1) Apply body sealer about 5 mm (0.20 in.) from
the flange, avoiding any oozing.
2) Apply sealer evenly, about 3 - 4 mm (0.12 -
0.16 in.) diameter.
3) For other sealing points, refer to section AR.
2. Temporarily install the new parts and check the
fit of the rear door, back door and rear combinaœ
tion light.
3. Before welding, cut the lining away from the
weld seams a little.
BODY PANEL REPLACEMENTREœ13

LOCATION OF PLASTIC BODY PARTS
Quarter Vent Duct (PP)
Rear Door Outside Handle (PC)
Front Door Outside Handle (PC)
Outer Rear View Mirror (AAS)
Instrument Panel Safety Pad (PP)
Cowl TopVentilator Louver (PP)
Radiator Grill (ABS)
Quarter Outside Moulding
(TSOP)
Rear Door Outside Moulding (TSOP) Front Bumper Cover (TSOP)
Front Turn Signal Light (PMMA/PP)
Front Door Outside Moulding (TSOP)
Front Fender Moulding (TSOP)
HINT:
wResin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPPœ4

Center Pillar Lower Garnish (PP/PE)
Center Pillar Garnish (PP)
Back Door Trim Board (PP)
Front Pillar Garnish (PP)
Front Fender Liner (PE)
Quater Panel Mudguard (TPU)
Side Turn Signal Light (SAN/ABS)
Washer Jar (PP)
Front Fender Mudguard (TPU)
Radiator Reserve Tank (PP)
Engine Under Cover (PE)
HINT:
wResin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPPœ5

Rear Combination Light (PMMA/PP)
Roof Side Inner Garnish (TSOP)
Air Conditioner Unit (PP)
Heater Blower (PP)
Rear Bumper Side Seal (PE)
Cowl Side Trim Board (PP)
Deck Trim Side Panel (TSOP) Front Door Outside Scuff Plate (PP/PE)
Back Door Outside Handle (PC) Rear Door Outside Scuff Plate (PP/PE)
Rear Bumper Piece (TSOP)
Licence Plate Light (PC)
Reflex Reflector (PMMA/ABS)
HINT:
wResin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPPœ6