1996 TOYOTA RAV4 Engine

R06184
SR0FI−02
R09732
− STEERINGSTEERING WHEEL
SR−9
1996 RAV4 (RM447U)
STEERING WHEEL
INSPECTION
1. CHECK STEERING WHEEL FREEPLAY
With the vehicle stopped and tires facing straight ahead, rock
the steering wheel gently back and forth with light finger pres-
sure.
Freeplay should not exceed the maximum.
Maximum freeplay: 30 mm (1.18 in.)
2. CHECK STEERING EFFORT
(a) Center the steering wheel.
(b) Remove the steering wheel pad (See page SR−12).
(c) Start the engine and run it at idle.
(d) Measure the steering effort in both directions.
Reference: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
HINT:
Be sure to consider the tire type, pressure and contact surface
before making your diagnosis.
(e) Torque the steering wheel set nut.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
(f) Install the steering wheel pad (See page SR−19).

SR0FV−02
Z19806
Union Bolt
PS Gear Assembly
Tube ClampPressure Feed Tube
Return Hose
Vacuum Hose
13 (130, 9)
44 (450, 32)
*36 (365, 26)
52 (525, 38)
29 (300, 22)
3 Door vehicle 64 (650, 47)
5 Door vehicle 113 (1,150, 83)
43 (440, 32)
113 (1, 150, 83)
x7
x6
13 (130, 9)
 Gasket
N·m (kgf·cm, ft·lbf)Bracket
BushingDrive Belt
PS Vane Pump Assembly
with Pump Bracket
62 (630, 46)
29 (300, 22)
BushingBracket
 Gasket
Clamp
(A/T)
Front Exhaust Pipe
 Gasket Stabilizer Bar
with Link
Front Suspension
Crossmember Assembly
137 (1, 400, 101)
206 (2, 100, 152)
127 (1, 300, 94)
Engine Under
Cover
127 (1, 300, 94)
137 (1, 400, 101)
112 (1, 140, 82)
8.3 (84, 73 in.·lbf)
48 (490, 35)

206 (2, 100, 152)
: Specified torque
* For use with SST  Non−reusable part
W02019
3 Door vehicle 64 (650, 47)
5 Door vehicle 113 (1,150, 83)
− STEERINGPOWER STEERING VANE PUMP
SR−31
1996 RAV4 (RM447U)
POWER STEERING VANE PUMP
COMPONENTS

SR0FW−02
R10965
Z13365
Pressure
Feed Tube
SST
R10984
R10966
− STEERINGPOWER STEERING VANE PUMP
SR−33
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE RH AND LH ENGINE UNDER COVERS
Remove the 13 bolts.
2. REMOVE FRONT EXHAUST PIPE
Remove the 2 bolts, 3 nuts and 2 gaskets.
3. REMOVE STABILIZER BAR WITH LINK
(See page SA−48)
4. DISCONNECT RH AND LH LOWER SUSPENSION
ARMS (See page SA−40)
5. REMOVE 2 PS GEAR ASSEMBLY SET BOLTS AND
NUTS
6. REMOVE FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY (See page SA−40)
7. DISCONNECT 2 TUBE CLAMPS
Remove the bolt.
8. DISCONNECT 2 VACUUM HOSES
9. DISCONNECT RETURN HOSE
NOTICE:
Take care not to spill fluid on the drive belt.
10. REMOVE DRIVE BELT
Loosen the 2 bolts.
11. DISCONNECT PRESSURE FEED TUBE
Using SST, disconnect the tube.
SST 09631−22020
12. REMOVE PS VANE PUMP ASSEMBLY WITH PUMP
BRACKET
Remove the 3 bolts.
13. REMOVE PRESSURE FEED TUBE
Remove the union bolt, gasket and tube from the PS vane
pump assembly.

− STEERINGPOWER STEERING VANE PUMP
SR−43
1996 RAV4 (RM447U)
12. INSTALL FRONT EXHAUST PIPE
(a) Torque the 2 bolts with a new gasket.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
(b) Torque 3 new nuts with a new gasket.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
13. INSTALL RH AND LH ENGINE UNDER COVERS
Tighten the 13 bolts.
14. BLEED POWER STEERING SYSTEM
(See page SR−4)

SR0G1−03
Z19807
3 Door vehicle 64 (650, 47)
5 Door vehicle 113 (1,150, 83)
 GasketTube ClampReturn Tube
No.2 Intermediate
Shaft Pressure Feed Tube
Stabilizer Bar with Link
Front Suspension
Crossmember
Assembly
Front Exhaust Pipe
13 (130, 9)
13 (130, 9)
113 (1, 150, 83)
29 (300, 22)
29 (300, 22)
44 (450, 32)
*36 (365, 26)
62 (630, 46)

62 (630, 46)
 Gasket
Clamp
(A/T)
48 (490, 35)
PS Gear Assembly
Bracket
Bushing
Bracket
Bushing
49 (500, 36)
35 (360, 26)
113 (1, 150, 83)

 Cotter Pin
127 (1, 300, 94)
206 (2, 100, 152)
137 (1, 400, 101)
8.3 (84, 73 in.·lbf)
112 (1, 140, 82)
127 (1, 300, 94)
206 (2, 100, 152)x7 Engine Under CoverN·m (kgf·cm, ft·lbf) : Specified torque
* For use with SST  Non−reusable partx6
127 (1, 300, 94)
137 (1, 400, 101)
137 (1, 400, 101)
W01195
49 (500, 36)
3 Door vehicle 64 (650, 47)
5 Door vehicle 113 (1,150, 83)
SR−44
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
POWER STEERING GEAR
COMPONENTS

SR0G2−03
R10984
SST
− STEERINGPOWER STEERING GEAR
SR−47
1996 RAV4 (RM447U)
REMOVAL
NOTICE:
Remove the steering wheel assembly before the steering
gear removal, because there is possibility of breaking of
the spiral cable.
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE STEERING WHEEL PAD (See page SR−12)
3. REMOVE STEERING WHEEL (See page SR−12)
4. REMOVE RH AND LH ENGINE UNDER COVERS
Remove the 13 bolts.
5. DISCONNECT RH AND LH TIE ROD ENDS
(See page SA−10)
6. REMOVE FRONT EXHAUST PIPE
Remove the 2 bolts, 3 nuts and 2 gaskets.
7. REMOVE STABILIZER BAR WITH LINK
(See page SA−48)
8. DISCONNECT NO.2 INTERMEDIATE SHAFT
(See page SR−12)
9. DISCONNECT PRESSURE FEED AND RETURN
TUBES
Using SST, disconnect the tube.
SST 09631−22020
10. DISCONNECT PRESSURE FEED AND RETURN TUBE
CLAMPS
Remove the bolt.
11. DISCONNECT RH AND LH LOWER SUSPENSION
ARMS (See page SA−40)
12. REMOVE 2 PS GEAR ASSEMBLY SET BOLTS AND
NUTS
HINT:
Securely suspend the steering gear assembly.
13. REMOVE FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY (See page SA−40)

SR0G6−02
W01119
SST
Fulcrum Length SR−60
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
INSTALLATION
1. CONNECT PRESSURE FEED AND RETURN TUBE
CLAMPS
Torque the bolt.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
2. INSTALL FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY (See page SA−42)
3. TORQUE 2 PS GEAR ASSEMBLY SET BOLTS AND
NUTS
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
4. CONNECT RH AND LH LOWER SUSPENSION ARMS
(See page SA−42)
5. INSTALL STABILIZER BAR WITH LINK
(See page SA−50)
6. INSTALL FRONT EXHAUST PIPE
(a) Torque the 2 bolts with a new gasket.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
(b) Torque 3 new nuts with a new gasket.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
7. CONNECT PRESSURE FEED AND RETURN TUBES
Using SST, connect the tube.
SST 09631−22020
Torque: 36 N·m (365 kgf·cm, 26 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
Securely suspend the steering gear assembly.
8. CONNECT NO.2 INTERMEDIATE SHAFT
(See page SR−19)
9. CONNECT RH AND LH TIE ROD ENDS
(See page SA−16)
10. INSTALL RH AND LH ENGINE UNDER COVERS
Tighten the 13 bolts.
11. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
HINT:
Do it with the front of the vehicle jacked up.

ST05I−03
S01781
PCV Hose
IAT Sensor
Connector
Air Cleaner Case AssemblyStarter
Starter WireAir Cleaner Cap Assembly
VSV Air Hose
Starter Connector
Skid Control
Relay Connectors
Engine Coolant Reservoir ElementHigh−tension Cord ST−2
− STARTINGSTARTER
1996 RAV4 (RM447U)
STARTER
COMPONENTS