1996 TOYOTA RAV4 replacement

REAR FLOOR SIDE REAR MEMBER (ASSY)
REMOVAL (With the rear floor pan extension and rear
floor inner crossmember removed.)
Rear Floor Inner Crossmember
1. After removing the rear floor inner crossœ
member, remove the rear floor side rear
member.
BODY PANEL REPLACEMENTREœ28

INSTALLATION
Butt Weld
1. Temporarily install the new parts and meaœ
sure each part in accordance with the body
dimension diagram.2. Install the new parts of rear floor inner crossœ
member shown above.
BODY PANEL REPLACEMENTREœ29

ROOF PANEL (ASSY): Normal Roof
REMOVAL
BODY PANEL REPLACEMENTREœ30

INSTALLATION
Body Sealer
1. Before temporarily installing the new parts,
apply body sealer to the windshield header
panel, roof panel reinforcement and back
door opening frame.HINT:
1) Apply just enough sealer for the new parts to
make contact.
2) For other sealing points, refer to Section AR.
BODY PANEL REPLACEMENTREœ31

ROOF PANEL (ASSY): Moon Roof
REMOVAL
BODY PANEL REPLACEMENTREœ32

INSTALLATION
Body Sealer
1. Before temporarily installing the new parts,
apply body sealer to the windshield header
panel, roof panel reinforcement and back
door opening frame.HINT:
1) Apply just enough sealer for the new parts to
make contact.
2) For other sealing points, refer to Section AR.
BODY PANEL REPLACEMENTREœ33

CO0BE−01
S01292Drain Plug CO−2
− COOLINGCOOLANT
1996 RAV4 (RM447U)
REPLACEMENT
1. DRAIN ENGINE COOLANT
(a) Remove the 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.
(b) Loosen the radiator drain plug (on the left side of the ra-
diator lower tank) and engine drain plug (on the left rear
of the cylinder block), and drain the coolant.
(c) Close the drain plugs.
Torque: Engine drain plug
25 N·m (250 kgf·cm, 18 ft·lbf)
2. FILL ENGINE COOLANT
(a) Slowly fill the system with coolant.
Use a good brand of ethylene−glycol base coolant
and mix it according to the manufacture’s direc-
tions.
Using coolant which includes more than 50 % ethyl-
ene−glycol (but not more than 70 %) is recom-
mended.
NOTICE:
Do not use an alcohol type coolant.
The coolant should be mixed with demineralized wa-
ter or distilled water.
Capacity (w/ Heater):
M/T: 8.0 liters (8.5 US qts, 7.0 lmp. qts)
A/T: 7.7 liters (8.1 US qts, 6.8 lmp. qts)
(b) Install radiator cap.
(c) Start the engine, and bleed the cooling system.
(d) Refill the radiator reservoir with coolant until it reaches the
”FULL” line.
3. CHECK ENGINE COOLANT FOR LEAKS

P25455
Turn
P03443
1
1
2
2
1
13
3
P03442
2 233 44
44
P13927
Upward
Cam Lobe
Spark Plug SideNotch EM−6
− ENGINE MECHANICALVALVE CLEARANCE
1996 RAV4 (RM447U)
3. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley and align its groove with timing
mark ”0” of the No. 1 timing belt cover.
(b) Check that the valve lifters on the No.1 cylinder are loose
and valve lifters on the No.4 are tight.
If not, turn the crankshaft 1 revolution (360°) and align the mark
as above.
4. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
Record the out−of−specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake0.19 − 0.29 mm (0.007 − 0.011 in.)
Exhaust0.28 − 0.38 mm (0.011 − 0.015 in.)
(b) Turn the crankshaft 1 revolution (360°) and align the mark
as above (See procedure in step 3).
(c) Check only the valves indicated as shown. Measure the
valve clearance (See procedure in step (a)).
5. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
Turn the crankshaft so that the cam lobe of the cam-
shaft on the adjusting valve points upward.
Position the notch of the valve lifter facing the spark
plug side.