1996 TOYOTA RAV4 torque

BO10W−01
H03772
Back Door Glass Back Door Moulding
Wiper Arm
Stop Light
Stop Light
Cover
Upper GarnishUpper Side
Garnish
Back Door Upper Cover
Upper Side Garnish
5.4 (55, 48 in.·lbf)
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable part
− BODYBACK DOOR GLASS
BO−51
1996 RAV4 (RM447U)
BACK DOOR GLASS
COMPONENTS

R10851
Pedal Height Push RodStop Light
Switch
BR1DV−01
BR4980
R00935
Pedal Freeplay BR−6
− BRAKEBRAKE PEDAL
1996 RAV4 (RM447U)
BRAKE PEDAL
ON−VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
157.1 − 167.1 mm (6.185 − 6.579 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop
light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(f) Install the stop light switch and turn it until it lightly con-
tacts with the pedal stopper.
(g) Turn the stop light switch back one turn.
(h) Check the clearance (A) between stop light switch and
pedal.
Clearance: 0.5 − 2.4 mm (0.020 − 0.094 in.)
(i) Tighten the stop light switch lock nut.
(j) Connect the connector to the stop light switch.
(k) Check that the stop lights come on when the brake pedal
is depressed, and go off when the brake pedal is re-
leased.
(l) After adjusting the pedal height, check the pedal freeplay.
HINT:
If clearance (A) between the stop light switch and the brake
pedal stopper has been adjusted correctly, the pedal freeplay
will meet the specifications.
3. CHECK PEDAL FREEPLAY
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the resistance begins to
be felt, then measure the distance, as shown.
Pedal freeplay: 1 − 6 mm (0.04 − 0.24 in.)

R10698
BR02J−10
R10730
Lock Nut
Adjusting
Nut BR−8
− BRAKEPARKING BRAKE LEVER
1996 RAV4 (RM447U)
PARKING BRAKE LEVER
ON−VEHICLE INSPECTION
1. CHECK PARKING BRAKE LEVER TRAVEL
Pull the parking brake lever all the way up, and count the num-
ber of clicks.
Parking brake lever travel at 196 N (20 kgf, 44 lbf):
5 − 8 clicks
If incorrect, adjust the parking brake.
2. IF NECESSARY, ADJUST PARKING BRAKE
HINT:
Before adjusting the parking brake, make sure that the rear
brake shoe clearance has been adjusted. For shoe clearance
adjustment, see page BR−33.
(a) Remove the rear console box.
(b) Loosen the lock nut and turn the adjusting nut until the le-
ver travel is correct.
(c) Tighten the lock nut.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(d) Install the rear console box.

BR02L−02
W01806
SST
W01807
− BRAKEBRAKE MASTER CYLINDER
BR−11
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT LEVEL WARNING SWITCH CONNEC-
TOR
2. DRAW OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
3. DISCONNECT R/B NO.2
Remove the 2 bolts and disconnect R/B No.2.
4. REMOVE AIR CLEANER CAP WITH AIR CLEANER
HOSE
5. w/o ABS:
DISCONNECT BRAKE LINES
Using SST, disconnect the 5 brake lines from the master cylin-
der and 3−way.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
6. w/ ABS:
DISCONNECT BRAKE LINES
Using SST, disconnect the 2 brake lines from the master cylin-
der.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
7. M/T:
DISCONNECT CLUTCH RESERVOIR HOSE
8. w/o ABS:
REMOVE MASTER CYLINDER
Remove the 2 nuts and pull out the master cylinder, 3−way and
gasket.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
9. w/ ABS:
REMOVE MASTER CYLINDER
Remove the 2 nuts, and pull out the master cylinder and gasket.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

BR02M−02
R09358
R09359
R12236
A BR−12
− BRAKEBRAKE MASTER CYLINDER
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque:
1.8 N·m (18 kgf·cm, 16 in.·lbf)
(b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. PLACE CYLINDER IN VISE
4. REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove
the piston stopper bolt and gasket.
HINT:
Tape the screwdriver tip before use.
Torque:
10 N·m (100 kgf·cm, 7 ft·lbf)
5. REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
HINT:
Tape the screwdriver tip before use.
(b) Remove the No.1 piston and spring by hand, pulling
straight out, not at an angle.
NOTICE:
If pulled out and installed at an angle, there is a possi-
bility that the cylinder bore could be damaged.
At the time of reassembly, be careful not to damage
the rubber lips on the pistons.
(c) Place a rag and 2 wooden blocks on the work table and
lightly tap the cylinder flange against the block edges until
the piston drops out of the cylinder.
HINT:
Make sure the distance (A) from the rag to the top of the blocks
is at least 100 mm (3.94 in.).

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)

R10629
BR−22
− BRAKEFRONT BRAKE PAD
1996 RAV4 (RM447U)
7. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti−squeal shims must be
replaced together with the pads.
(a) Apply disc brake grease to both side of the inner anti−
squeal shims (See page BR−20).
(b) Install the anti−squeal shim to the inner pad.
(c) Install the inner pad with pad wear indicator plate facing
upward.
(d) Install the outer pad.
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or the disc.
8. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or an equiva-
lent.
HINT:
If the piston is difficult to push in, loosen the bleeder plug and
push in the piston while letting some brake fluid escape.
(c) Install the caliper.
(d) Hold the sliding pin and torque the installation bolt.
Torque: 26 N·m (270 kgf·cm, 20 ft·lbf)
(e) Install the flexible hose bracket.
Torque: 33 N·m (340 kgf·cm, 25 ft·lbf)
9. INSTALL FRONT WHEEL
10. CHECK THAT FLUID LEVEL IS AT MAX LINE

BR0M5−01
R10630
BR−24
− BRAKEFRONT BRAKE CALIPER
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Install the flexible hose lock securely in the lock hole in the cali-
per.
(b) Use a container to catch the brake fluid as it drains out.
2. REMOVE CALIPER
(a) Hold the sliding pin and loosen the 2 installation bolts.
Torque: 26 N·m (270 kgf·cm, 20 ft·lbf)
(b) Remove the 2 installation bolts.
(c) Remove the caliper from the torque plate.
3. REMOVE THESE PARTS:
2 brake pads with anti−squeal shims
4 pad support plates